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KilnCooler Hot Spot

Control your kiln shell temperature on hot spots.
Infrared controlled water cooling of kiln shell.

Due to the increasing usage of secondary fuels, there are more fluctuations in  the burning process. This leads to increased burden for the refractory and the kiln shell—hot spots may occur.

In order to reduce this burden, large cooling fans, which are blowing ambient air, are widely used.

Unfortunately, fan based cooling shows some disadvantages:

Ineffective—low heat capacity of air; selective cooling is impossible; loud—fans emit a substantial amount of noise; high energy consumption.

Benefits of KilnCooler Hot Spot:

  • Expansion of Kiln‘s Operation Time
  • Reduced Mechanical Tension
  • Almost No Noise Emission
  • Fast, but Carefully Cooling Down
  • Very Low Energy Consumption (2–50w)
  • Energy Savings


Efficiency by Water Cooling

To overcome fan based cooling disadvantages KIMA’s KilnCooler uses waterspray nozzles and precise dosing valves, which are controlled by an infrared temperature sensor. The waterspray of an individual nozzle is switched on only, while its infrared sensor detects a hot spot.


Flexibility Due to Modular Set-up

The KilnCooler Hot Spot is developed as a stand-alone mobile unit especially for hot spots.

Basic set-up

  • Temperature SensorContinuous temperature monitoring by infrared pyrometers.
  • Control PanelChange of temperature settings. Mode selection and trends.
  • ControllerDue to sophisticated control scheme the kiln’s shell temperature is kept at the desired set point.
  • Water NozzleAdjustable fan nozzles for optimised surface coverage at minimised water consumption.


The waterspray is controlled by a FUZZY-controller which uses infrared sensors to precisely locate hot spots on a circumference. The “hot spot temperature” can be set individually for every nozzle.

Cooling down a hot spot

A hot spot can be cooled down rapidly but careful, avoiding any shrinkage of the kiln shell. The cooling rate is up to 2 Kelvin/min. After cooling down, the shell temperature is kept on its nominal value, thus eliminating mechanical tensions.


Is your grinding process efficient enough?
Optimised control of your grinding processes.

Benefits at a glance

  • More Energy Efficiency
  • Increase in Production
  • Improved Product Fineness
  • Less Wear
  • Higher Facility Availability
  • Reduced Maintenance Costs


Predictive Control of Grinding Facilities

MillMaster controls closed grinding circuits—fully automated. If required, without operator. One system is able to operate up to four mills at the same time, thus increasing your facility’s availability by preventing overfilling and similar failures.

The consequent constant and optimal fill level ensures smooth and stable operation, leading to significantly less wear and a more homogenous product. Additionally, the output increases and the power consumption drops.

The new “auto adaptive” mechanism automatically and independently determines and adjusts the ideal filling level to always ensure optimal mill operation.

MillMaster can be integrated into every automation system—it is simply plugged in via a standard OPC interface. With your previous control system on standby you can switch to it at any time.

Benefits from MillMaster:

  • Unattended Operation
  • Auto Adjustment
  • Ready-to-use Modules
  • Fully Automatic
  • Up to 6 Mills (Per System)
  • Fast Commissioning
  • Return of Investment in Less Than 1 Year
  • Low Investment Costs


The modular concept allows you to choose the functions you need. MillMaster offers modules for the following control groups:

Benefits from MillMaster:

  • Unattended Operation
  • Auto Adjustment
  • Ready-to-use Modules
  • Fully Automatic
  • Up to 6 Mills (Per System)
  • Fast Commissioning
  • Return of Investment in Less Than 1 Year
  • Low Investment Costs


If desired—thanks to our flexible system—additional modules can be developed and easily integrated at any time.

More Than 100 Installed Millmaster Control Systems Are in Operation Every Day – Worldwide.



Do you already have enough information on your grinding process?
Fill-level & temperature measurement for ball mills.

In order to optimise grinding processes, it is necessary to measure the most important parameter—the fill level—as precisely as possible. This key parameter cannot be measured directly, it needs to be determined by acoustic or vibration measurement. Because of the obvious disadvantages previous measuring methods (like microphones) are quite useless for nowadays needs. Due to measuring the sound directly where it occurs (on the mill shell), all these disadvantages can be avoided. The solution is SmartFill—a fail-safe, high-precision fill level and temperature measurement system for ball mills.

High-precision Measurement of Fill Levels:

  • Easy Installation
  • Zero Crosstalk
  • Free Frequency Band
  • Almost No Maintenance
  • Process Interface (4—20 Ma)
  • Up to 3 Sensors of Free Choice
  • Up to 16 Product Types
  • Industrial Proved: Ip65 / Atex
  • Mill Mounted (Self-powered)


Predictive Control of Grinding Facilities

Using a high-level control achieves a return of investment in less than a single year.


How does SmartFill improve your production process?

Incorporating the precise results into your grinding process is directly improving your production process. In order to achieve this improvement you permanently need to adjust the mill‘s feed. While keeping the fill level at the optimum, the grinding process becomes stable.

A good operator, for example, takes care of the fill level and manually changes the fresh feed.

Using an automatic controller provides you with even more advantages and convenience. Automatic control reliably compensates disturbances like strong differences in raw material quality and prevents overfilling. These advantages are based on a fact. The automatic controller is reacting fast and precise on concurrent events, taking the correct decision at any time.

SmartFill‘s range of application:All kinds of industrial ball mills or grinding of

  • Cement
  • Limestone
  • Coal
  • Gold Ore
  • Iron Ore
  • Aluminium Oxyde


In addition you achieve a high product homogeneity, ensuring an increased product quality.