How steam flow measurement in autoclaving processes improves efficiency and quality in the cement industry
Within production processes with high demands on quality and efficiency, the precise regulation of steam flows plays a crucial role. In collaboration with Metra Energie-Messtechnik, KLINGER Belgium realized a project in which a robust measurement system accurately monitors and regulates the steam flow during the autoclaving process. This collaboration contributes to constant process optimization and guarantees product quality.
Accuracy and stability in the autoclaving process
During the autoclaving process, the steam supply determines the quality of the final product. Small variations in the steam flow can affect product properties, leading to unstable product quality. It was essential to implement a system that measures with extreme precision while remaining resistant to industrial environments.
Modular measurement system with
differential pressure technology
To address these challenges, a modular measurement system based on differential pressure technology was installed in the autoclave’s steam injection line. This system provides reliable and consistent measurements essential for the accurate regulation of the steam flow. Thanks to the modular design, the measurement system is flexible in use and easy to adapt to future process requirements. In summary, the connections directly on the storage tank up to the pump must be FIRE-SAFE. For other connections in the piping, it is a recommendation, but not a requirement.
Technical specifications
Type: EDZ 120.1 with compact orifice and integrated PABS transmitter
Feature: very short response times due to integrated pressure transmitter, small inlet distances, minimal pressure losses
Design: up to 350°C and PN40
Measuring range: 30:1 relative to mass flow
Uncertainty: <1% relative to a range of 15:1
Supervision system for continuous insight and analysis
The measurement system is integrated with a supervision system, which collects and analyzes real-time data. This provides operators with continuous insight into the progress of the steam flow, power, and energy, allowing them to monitor the process at a glance and make immediate adjustments where necessary. The process trend graph, with the steam flow rate indicated by the purple line, provides a clear picture of stability throughout the cycle.
Results and impact
Thanks to the new measurement and supervision system, the autoclaving process is now more manageable and predictable. Some of the benefits include:
- Consistent product quality through stable and accurate steam flow control.
- Real-time control of the process with the possibility of immediate adjustments.
- More efficient energy use through optimized steam supply, contributing to a more sustainable process.
“This project with Metra Energie-Messtechnik emphasizes the importance of reliable technologies in industrial processes. KLINGER Belgium remains committed to collaboration and innovative measurement solutions for process optimization and quality control.”
Ronny De Graeve, Product Specialist – KLINGER Belgium