24 X 7 Kiln Surveillance & Monitoring System
Detect hotspots early with 2D and 3D thermal imaging of kiln shells
24 X 7 Kiln Surveillance & Monitoring System
Detect fire early, save lives and safeguard assets with Hi-Tech’s EFD Solutions
Real-time radiometric mapping of kiln shells to prevent refractory failure and optimize energy efficiency
Rotary kilns are the workhorses of heavy industry—essential for cement and lime production, iron ore pelletization, and waste incineration. However, operating at internal temperatures exceeding 1,000°C while continuously rotating under massive loads places immense strain on these critical assets. Managing this strain is paramount to maintaining plant safety, operational continuity, and profitability.
Get In Touch With Our Sales Expert
The Hidden Threat: Refractory Degradation
Inside the kiln, a specialized refractory lining acts as the primary barrier between the intense internal inferno and the structural outer steel shell. This lining faces a relentless combination of destructive forces:
- Extreme Thermal Shock: Constant exposure to massive temperature differentials.
- Chemical Attack: Corrosive reactions from the processed materials.
- Mechanical Stress: Torsional and bending forces generated by the continuous rotation of the massive furnace tube.
Because of these extreme conditions, the refractory lining has a finite lifespan. As bricks wear thin, crack, or fall away, the protective thermal barrier is compromised. If the temperature of the outer steel shell exceeds its critical threshold of approximately 350°C, the steel can warp, yield, or rupture. A failure at this stage is catastrophic—resulting in hazardous accidents, severe risk to personnel, and millions of dollars in unplanned downtime and repair costs.
The Solution: Continuous, Full-Area Thermal Imaging
Relying on periodic visual inspections or spot-checking with handheld scanners leaves dangerous blind spots. To secure these vital assets, modern industrial facilities are turning to continuous, automated thermal monitoring.
Utilizing high-sensitivity thermal imaging cameras from FLIR, plant operators can monitor the entire rotating surface of the kiln in real-time. This non-contact technology generates a complete, live temperature map of the shell, providing actionable insights including early warnings of “hotspots” which manual inspections cannot match.
Make real‐time scan and historical trends of your Kiln available to Operators and Engineers wherever they may be, within the network.
Meeting Industry Needs
The online Kiln Monitoring System developed by Hi-Tech makes use of two or three FLIR A-series cameras each scanning one third of the 60 – 80m long rotary kilns. These thermal video streams are distributed to a visualization system inside the central control room, and provides operators with a 24/7, real-time view of the kiln operation and performance. The kiln has a rotation time of around 30 seconds and the monitoring system is synchronized to the rotation time to build up a thermal image. Whenever the kiln shell reaches an undesired temperature, operators receive dedicated software alerts which allow them to take the appropriate remedial actions.
To give control room operators the best possible view of the situation, the software generates several different viewing modes based on the information received from the FLIR thermal imaging cameras.
The system is remotely accessible, providing real-time data, pre-alarming, and alarming to operators throughout the plant.
Hi-Tech’s Kiln Monitoring System Can:
Our Product Offerings
