Cementera Andina Case: Temperature Transmitter in Cement Rotary Kiln and Clinker Cooler Monitoring
Published On: August 27, 2026
1. Client Profile
Cementera Andina S.A.C. runs a 5,000 t/day dry-process rotary kiln line on the northern Peruvian coast. The plant's process control team prioritized reliable temperature measurement at the preheater cyclones, calciner, kiln inlet and clinker cooler to prevent blockages and protect grate equipment from thermal damage.
2. Application Background
In cement production, temperature measurement supports both process control and equipment protection: preheater and kiln inlet temperatures help prevent cyclone blockages, cooler temperatures protect grate equipment, and reliable sensors reduce costly production stops. This case describes the temperature transmitter configuration for a typical dry-process rotary kiln line and the specification points buyers should verify.
3. Real Operating Conditions
| Measurement Point | Typical Temperature | Environment |
|---|---|---|
| Preheater cyclones | 800-900°C | Raw meal dust, alkali-laden gas |
| Calciner | 850-900°C | High dust, turbulent flow |
| Kiln inlet gas | 900-1100°C | Alkali dust, back-spilling hot meal |
| Clinker cooler (grate) | Up to 1300°C at inlet | Extreme abrasion, clinker impact |
4. Customer Pain Points
- Abrasive clinker destroys ordinary thermocouples in the cooler within weeks; replacement is dangerous and causes downtime.
- Alkali attack and dust build-up on preheater sensors cause drift and false alarms, leading to unnecessary process corrections.
- Kiln inlet blockage can go undetected if the gas temperature reading is unreliable, risking a full kiln stop.
- Sensors are hard to reach, so maintenance must be planned around production stops.
5. Engineering Selection
- Clinker cooler: K-type thermocouple with a tungsten-carbide tipped or ceramic-armored protection tube for maximum abrasion resistance.
- Preheater and calciner: K-type or S-type thermocouple with a high-alumina or SiC tube to resist alkali and dust erosion.
- Kiln inlet: robust assembly with a heavy ceramic tube and appropriate insertion to survive back-spilling hot meal.
- Intelligent integrated transmitter (QW-SLS65) with self-diagnosis; QW-SLS67 with local display for field verification.
6. Recommended Qinwei Instruments for This Application
| Model | Description | Applied At |
|---|---|---|
| QW-SLS62 | IP60 armored thermocouple, corrosion-resistant sheathed | Preheater cyclones and calciner with high-alumina tube |
| QW-SLS61 | Durable high-temperature thermocouple, fast response | Kiln inlet gas with heavy ceramic tube assembly |
| QW-SLS72 | Isolated temperature transmitter, high-voltage and strong-interference immune | Clinker cooler with tungsten-carbide tipped sensor |
| QW-SLS65 | Intelligent integrated transmitter with self-diagnosis | All loop conversions with remote diagnostics |
7. Installation Logic
- Mount preheater sensors through the wall at an angle that sheds material and avoids dead zones where meal accumulates.
- For the cooler, position sensors in the refractory with the tip protected from direct clinker impact; use a design that allows hot replacement with a protective sleeve.
- Seal all penetrations to prevent false air ingress, which distorts both temperature and process readings.
- Schedule sensor rotation and cleaning during planned stops and keep calibrated spares ready.
8. Application Results
- Reliable preheater and kiln inlet temperatures help operators detect and prevent cyclone and kiln blockages before they stop production.
- Abrasion-resistant cooler sensors survive longer, cutting replacement cost and maintenance risk.
- Stable temperature signals reduce false alarms and unnecessary process corrections, supporting steady kiln operation and consistent clinker quality.
9. Why Choose Qinwei Instruments
Xi'an Qinwei Instrument Factory (brand QINWEIYB) is a manufacturer established in 2010 with 500-800 employees and 50%-60% export share, focused on industrial automation instruments. For cement plants, Qinwei provides abrasion-resistant assemblies with tungsten-carbide tips, alkali-resistant SiC and high-alumina protection tubes, and isolated transmitters that reject electrical interference from kiln drives. Factory calibration, MOQ from 1 set, 5-8 working days delivery and OEM support help cement producers cut replacement frequency and maintenance risk.
10. Purchase Decision Guide
Specify: maximum service temperature, protection tube material (SiC, high-alumina or tungsten-carbide options), mounting length and connection, response time, and abrasion-resistance rating for cooler service. Confirm that the supplier can provide spare assemblies with matching calibration to minimize downtime.
