Uptime is critical for rotary kilns. If a kiln stalls or slows, it may be damaged, and the cement in process will be lost. Motors driving kilns can be affected by sags and swells. Motors may stall, slow, accelerate, or overheat due to poor power quality. Rotary kiln motors operate outdoors next to a hot kiln, so minimizing heat dissipation is critical for long motor life. Motors have a lagging power factor that is subject to utility surcharges.
Cycloconverter drives are often employed to power rotary kiln motors from a medium voltage supply. Cycloconverters draw harmonic currents like most motor drives.
Harmonic currents increase heat losses in transformers. AC waveform distortion due to harmonic currents can damage electronic devices. Cycloconverters also draw interharmonic currents. Interharmonics are especially pernicious. Effects of interharmonics include flickering lights, high bills, and poor energy efficiency.
Release 3.0 will feature predictive analytics to estimate remaining motor lifetime. Such prediction is especially useful for rotary kilns. A failing motor can be replaced after a controlled shutdown before a full failure damages the kiln.
Denison Technologies' hardware can monitor medium voltage applications like cycloconverters. Our software provides an easy-to-understand readout of power conditions, and our professional services are available to find solutions. Correcting and proactively monitoring power quality ensures uptime and protects the cement industry's valuable assets.
