The Design And Implementation Of Surface Temperature Monitoring Software For Cement Rotary Kiln

Rotary kiln is the core equipment in the clinker cement manufacturing process. If the internal combustion temperature is too high or thermal swing is too excessive, the kiln lining may be destroyed. Seriously, the red kiln faults will happen or even collapse, causing significant economic losses and threatening worker's life safety. In the manufacturing process, it is very difficult to directly monitor the internal temperature and wall thickness of kiln, but the surface temperature of rotary kiln is easy to be obtained. The temperature field on the surface of rotary kiln is formed under the combined action of various factors, which reflects the change state of the kiln. Therefore, real-time monitoring the surface temperature changes of the rotary kiln, and then process and analyze it, can reflect the operating status of rotary kiln.This thesis developed a surface temperature monitoring software for cement rotary kiln, which converts the thermal radiation intensity information collected from temperature measuring device to temperature information, then process, analysis and display the temperature data. This software consists of data acquisition subsystem, infrared temperature measurement algorithm library, graphical user interface, data analysis subsystem and data storage subsystem, using buffer technology and multithreading technology to ensure the real-time data processing, and through adding the axial temperature compensation algorithm based on traditional algorithm of infrared temperature measurement to ensure the accuracy of the temperature measurement. According to the distribution characteristics of monitoring points, design reasonable horizontal and vertical positioning method to achieve accurate positioning. According to the temperature distribution characteristics of rotary kiln, design 3 kinds of pseudo color mapping algorithm, rendering 2D and 3D thermal image using Open GL. As for the red kiln fault may occur in highest temperature position, designed high temperature real-time tracking function. Based on the characteristics of data, designed reasonable storage mode for the configuration data, temperature data and log data, and the historical data playback function is realized.Using this software, the operator can comprehensively understand the distribution of surface temperature of the rotary kiln, and then determine whether ring forming, faults of brick, red kiln faults, and so on exists in the rotary kiln. That can effectively improve the kiln operation and develop plans to stop the kiln, improving equipment operation rate. At present, this software has been used in Chongqing, Sichuan, Guizhou, Shanxi and other provinces' rotary kiln production site, which has greatly improved the output and quality of clinker cement and reduced the operation cost of the labor intensity and the rotary kiln running cost and brought huge economic benefits for the enterprise.