Frequently Asked Questions

Industrial thermography uses infrared cameras and scanners to detect temperature variations on the surface of a rotary kiln. By capturing this thermal data, systems like Kilnscan allow you to visualize hot or cold spots, identify anomalies such as overheating or heat leaks, and predict issues before they become critical. This technology provides real-time monitoring, helping ensure the safety and efficiency of the equipment.

Kilnscan is designed to provide 24/7 non-contact thermal monitoring of your rotary kilns. Benefits include:

• Real-time, detailed temperature mapping with resolution down to a single brick
• Early detection of hot spots to prevent potential damage
• Tracks refractory wear to help extend its service life
• Supports accurate and timely preventive maintenance planning
• Flexible solution suitable for complex setups (e.g., multiple shadow areas, long kilns, limited space)
• Seamless integration with the plant’s control system for efficient data use

Pyroscan provides advanced thermal monitoring for industrial furnaces, offering a range of benefits to improve efficiency and control. Some of the key advantages include:

• Accurate Temperature Measurement: Measures temperatures from 700 °C to 1800 °C, even in dusty and smoky environments.
• High-Resolution Imagery: Provides 1.2 megapixel HDR images for clear visualization of combustion zones.
• Flame Pattern Monitoring: Tracks changes in flame shape, including length, width, and black root.
• Burner Adjustment Tool: Helps optimize burner settings, especially for alternative fuels.
• Real-Time Monitoring: Continuous temperature measurements and real-time video streaming over IP.
• Clinker Area Visualization: Monitors clinker fall and temperature variations in the burning zone.
• Enhanced Dust Filtering: Operates reliably in challenging environments with robust dust filter algorithms.
• Comprehensive Data: Maintains a historical database for video and temperature measurements.
• Customizable Measurements: Allows unlimited user-defined temperature measurement zones for detailed analysis.

Thermography plays a crucial role in predictive maintenance for coolers by monitoring clinker chute, red rivers and thermal variations that could indicate issues like blockages, fan malfunctions, or component degradation. This allows for maintenance interventions to be planned before a costly failure occurs, ensuring continuous operation and extending the equipment’s lifespan.

The data collected by our thermal monitoring systems, such as Kilnscan and Pyroscan, is processed by specialized software that transforms thermal information into clear and easy-to-analyze thermal maps. These software tools help quickly identify problem areas, analyze thermal trends over time, and generate automated reports that assist engineers in making informed maintenance and optimization decisions.

The Kilnscan and Pyroscan are almost maintenance-free equipments.

• The Kilnscan only requires a check and cleaning of its Infrared window, while the Pyroscan will require a regular check of the air filters or the water chiller.
• The very light maintenance required makes operation of the systems very easy and stable.

Yes, our Kilnscan and Pyroscan systems are designed to operate in harsh industrial environments. They are resistant to high temperatures, dust, vibration, and other extreme conditions. The infrared cameras are equipped with protective features to ensure reliability and durability, even in the most demanding environments.

Continuous thermal monitoring allows for the early detection of hot spots or thermal anomalies that could lead to fire risks or equipment failures. By identifying these issues before they become critical, thermal monitoring systems like Kilnscan and Pyroscan help improve the safety of industrial installations by preventing accidents and ensuring proactive risk management.

Thermal Warp, also known as “Thermal crank” refers to the bending of the kiln shell caused by thermal irregularities along its surface. Kilnscan scanners provide real-time tracking of this phenomenon, helping to improve equipment lifespan and production efficiency.
As the kiln rotates and carries its load, any trend for the shell to bend creates cyclical flexions and stresses, which can negatively impact the kiln’s long-term reliability. This leads to load fluctuations on the tyres and rollers, potentially warping the tyres. Even small, periodic flexions can cause local oval distortions, which stress the lining and reduce its durability. Additionally, the kiln’s drive system may experience excessive fatigue due to these cyclical stresses.

Thermal Warp Monitoring tracks the medium and long-term evolution of Thermal Warp data, providing valuable insights into the process development inside the kiln. This includes monitoring the development of coatings, kiln push of unburnt material, and flame adjustment. It also serves as an indicator of mechanical and thermal stresses on the shell and tires, as well as load fluctuations supported by each pier.

When combined with Tire Slip monitoring—measuring the clearance between the kiln shell and its supporting tires—Thermal Warp monitoring helps assess the shell’s geometry, degree of deviation (such as ovality), eccentricity, and misalignment. This comprehensive monitoring supports optimal kiln performance and enhances equipment longevity.

The “Rhino Horn” refers to the build-up of clinker dust at the burner tip inside the kiln. This accumulation can lead to operational inefficiencies, reduced burner performance, and potential damage if not addressed promptly.

Early detection is essential to prevent it from becoming a serious issue. The Pyroscan camera provides high-temperature visual monitoring, enabling close surveillance of the burner area. With Pyroscan, operators can identify early signs of “Rhino Horn” formation and take corrective action before it impacts production.

The “Snowman” phenomenon refers to the sudden and rapid build-up of material—often at the fixed grate area—in clinker coolers. This accumulation can severely disrupt airflow and cooling efficiency, leading to major process issues if not addressed quickly.

The Pyroscan camera enables continuous visual and thermal monitoring of the cooler area, allowing operators to closely track temperature changes. It can be configured to trigger alarms when temperatures drop—an early indicator of Snowman formation.

With timely alerts, operators can take quick corrective actions, such as adjusting air blaster sequences or other parameters, to prevent escalation and minimize the impact on operations.

The Kilnscan Polar View is a feature of the HGH shell scanner software that provides a unique visualization of the rotary kiln. It allows operators to view a cross-sectional “polar” representation of the kiln shell, offering insights into coating thickness and temperature distribution along the entire kiln length. Using a simple cursor, operators can virtually “travel” inside the kiln, observing changes in coating and thermal behavior in real time. This helps in identifying potential issues early and supports better maintenance and process control decisions.