PRODUCT INFORMATION
SCPS
GAS ANALYSIS UNDER THE HARSHEST CONDITIONS,
DIRECTLY ON ROTARY KILNS
Process gas analysis system (PGA)
Cement production is a process that consumes a great deal of resources and energy.
Due to high competitive pressure, saving energy and increasing production efcien-
cy are necessities. This is why more and more manufacturers are using alternative
source materials and fuels. The use of inhomogeneous and often unclean fuels
usually results in an increased concentration of undesirable sulfuric and chlorine
compounds in the process.
The state-of-the-art process gas analyzer system (SCPS - SICK Cement Probe System)
provides reliable information on process quality, which helps in detecting problems
early on — such as incomplete combustion, cyclone and kiln blocks as well as chlo-
rine concentrations harmful to the process — and helps to prevent these problems.
THE MODULAR SYSTEM SOLUTION
FROM A SINGLE SOURCE
RUGGED, FLEXIBLE, RELIABLE SCPS
HOT/WET EXTRACTIVE OR
COLD/DRY EXTRACTIVE
MEASUREMENT?
The cold/dry extractive process gas analysis has been the
industrial standard for decades. The process is well-suited to
measure the components relevant to the combustion process,
NO
X
, CO, CO
2
and O
2
(for gas ring, CH
4
as well).
Increasing use of alternative fuels means that the demand for
measuring the components SO
2
, HCl and NH
3
is growing as
well, as these occur in greater quantities in the combustion
of these fuels. However, there are limitations when measur-
ing these using cold/dry extractive analysis because they are
highly water-soluble. On the one hand, condensation in the gas
cooler causes the components to be extracted (“washed out”)
from the gas and, on the other hand, it causes acids to form.
As these acids are harmful to the analyzer system, SO
2
is often
intentionally removed by the addition of hydrogen peroxide.
The hot/wet extractive process gas analysis offers an advan-
tage in that, here, high temperatures are present throughout.
SO
2
, HCl and NH
3
do not form acidic condensate and can be
measured without problems.
As a result, which analytical process should be used mostly
depends on the fuel. SICK offers reliable solutions for both of
these analytical processes. The modular SCPS system solution
from SICK covers all variants from a single source and provides
customers with optimal solutions for their individual require-
ments.
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Maximum lter service life thanks to
2-stage lter back-purging
The lter back-purging with compressed air
cleans both the lter itself and the lter space
thoroughly. This prevents the blown-out dust
from settling again in the lter, signicantly
increasing the service life of the lter.
2
Shock blower reduces maintenance effort at the
probe
Based on the system variant, the integrated shock blower
cleans the probe tube efciently with compressed air at reg-
ular intervals. In contrast to mechanical cleaning processes,
no cleaning tools can get stuck.
Cooling unit
Sample probe
SCPS RUGGED, FLEXIBLE, RELIABLE
ADVANTAGES AT A GLANCE
5
2
1
3
Filter space
Filter
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3
Anti-stick movement and rotation prevent build-up
on the probe tube
The probe tube moves forwards and backwards during the
measurement. Depending on the system variant, there are
additional rotational movements. This prevents material
accumulation on the probe tube.
4
Process control using gas analysis
Determining the gas concentration relevant to combustion:
CO, NO
X
, CO
2
, CH
4
, O
2
. To ensure product quality and plant
availability, hot/wet extractive measurement offers the option
of measuring the components SO
2
, HCl and NH
3
. Depending
on the customer requirement, the system can measure differ-
ent gas components.
5
Effective probe cooling makes high-temperature
use possible
The effective cooling protects the sampling probe
at temperatures up to 1,400 °C. Depending on the
system variant, water or oil is used as the coolant.
For recooling, the cooling unit can be connected
to the plant’s internal water cooling system. As an
alternative, recooling by ventilating with ambient air
is possible.
Analyzer system
Cooling unit
Measuring gas line
RUGGED, FLEXIBLE, RELIABLE SCPS
4
Sample probe
Cooling unit
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System variants SCPS1100 SCPS3100 SCPS3300
System components
SCPS1100 +
MKAS
SCPS3100 +
MKAS
SCPS3300 +
MCS300P HW
Investment costs
O o o O O o O O O
Maintenance effort
O O O O O o O o o
Suitability for alternative fuels
O o o O O o O O O
SCPS SYSTEM AND SERVICE ARE OPTIMALLY ALIGNED
SO THAT EVERYTHING FITS PERFECTLY
THE RIGHT COMBINATION
FOR EVERY REQUIREMENT
In SCPS, SICK offers a complete modular system. All components of the SCPS are
provided from a single source. This ensures the optimal interplay of all modules and
functions. Depending on the requirement, SCPS can be custom-congured. You have
the choice between two different probes and two different analyzer systems, and
each of them can also be adapted to the specic respective system.
SCPS probes SCP1000 SCP3000
2-stage lter back-purging
O O
Anti-stick movement
–
O
Shock Blower
–
O
Retraction device
Pneumatic cylinder Pneumatic spindle drive
Rotating device
–
O
Sampling point
Before kiln seal After kiln seal
Coolant
Oil Water
SCPS analyzer systems MKAS MCS300P HW
Measurement processes
Cold/dry extractive Hot/wet extractive
Measuring components
CO, NO
X
, CO
2
, SO
2
, O
2
CO, NO
X
, CO
2
, SO
2
, O
2
, NH
3
, HCL
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COMPREHENSIVE SERVICE PROVIDING
TOTAL PEACE OF MIND
Reliable, quick and skilled services – from planning and set-up to
maintenance – are indispensable for gas analysis in the kiln inlet.
The availability of the analysis is crucial for downtime optimization
and the energy efciency of the entire plant.
SICK provides a worldwide service organization with experienced
experts. The one-stop-shop principle of the SCPS ensures that
SICK customers always have one permanent contact person.
Remote access allows for quick solutions to many problems. Exchanging import-
ant information ensures that the service technician is perfectly prepared when he/
she appears on site.
Condition monitoring does much more than provide additional information that
helps in case of remote maintenance. Important “vital parameters” are also
continuously monitored, allowing problems in the analyzer system to be detected
early, maintenance work planning to be improved and spare parts orders to be
triggered. This prevents unscheduled machine downtimes.
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SCPS PROCESS GAS ANALYSIS SYSTEM (PGA)
Product description
The SCPS process gas analyzer system
is used for gas measurement directly on
rotary kilns. Rugged sample probes, ef-
fective cleaning mechanisms combined
with hot or cold extractive analyzer sys-
tems and exible remote maintenance
- SICK is the only manufacturer that
delivers the whole portfolio of products
from a single source. The analyzers
are congured to measure not only the
important combustion parameters O
2
,
CO, CO
2
, NO and, if applicable, CH
4
, but
also process parameters such as SO
2
,
HCL and NH
3
. Thanks to their minimal
maintenance, maximum availability,
and precise measured values, the SCPS
system really shines, especially when it
comes to combustion with high levels of
sulfur or chlorine.
At a glance
• Simultaneous measurement of all
relevant gas component such as O
2
,
CO, CO
2
, NOx, CH
4
, SO
2
, HCL, NH
3
• Rugged and cooled sample probes,
can be used up to 1,400 °C and
2,000 g/m³ dust
• Up to 98% availability of the complete
system
• Quick service thanks to remote main-
tenance
Your benets
• Prevention of system downtimes due
to timely detection of problems in the
process
• Uniformly high product quality thanks
to process control
• Lower energy costs due to an opti-
mized combustion process
• Rugged and proven technology for
minimal maintenance work
• High system availability due to har-
monized components from a single
source
• Quick and capable assistance thanks
to remote access and an experienced
service team that is active all over
the world
System solutions
CUSTOMIZED ANALYZER SYSTEMS
SCPS
Subject to change without notice
.
GAS ANALYSIS UNDER THE HARSHEST
CONDITIONS, DIRECTLY ON ROTARY KILNS
Additional information
Detailed technical data . . . . . . . . . . . .9
Ordering information . . . . . . . . . . . . . .9
- www.sick.com/SCPS
For more information, simply enter the link or scan the QR code and get direct access to
technical data, CAD design models, operating instructions, software, application examples, and
much more.
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PROCESS GAS ANALYSIS SYSTEM (PGA) SCPS
Detailed technical data
Process gas analysis system (PGA) SCPS
General notes
SCPS1100 SCPS3100 SCPS3300
System components
SCP1000
MKAS
SCP3000
MKAS
SCP3000
MSC300P HW
Features
SCPS1100 SCPS3100 SCPS3300
Measuring components
CO, CO
2
, NO
x
, SO
2
, CH
4
, O
2
CO, CO
2
, NO
x
, SO
2
, CH
4
, O
2
,
HCL, NH
3
Max. number of measurands
Depending on integrated
analyzer
–
Measurement techniques
cold-extracting heat-extracting
Probe tube cooling
oil-cooled water-cooled
Probe cleaning
Backwashing Backwashing with shock blower
Rotation drive
–
l
Performance
SCPS1100 SCPS3100 SCPS3300
Measuring ranges
Measuring ranges depend on integrated analyzer and appli-
cation
More than 60 measuring
components available (de-
pending on concentration and
sample gas composition), up
to 6 components simulta-
nously, 2 measuring ranges
per component, automatic
measuring range switching
(adjaustable), 2 limit values
per component, measuring
ranges depend on application
and combination of measur-
ing components
Process temperature
≤ +1,400 °C
Dust load
≤ 2,000 g/m³
Mechanics/electronics
Power consumption
≤ 6 kW
With 15 m measuring gas line
Ordering information
Type Measured values Measurement
techniques
Probe tube
cooling
Probe cleaning Rotation drive Part no.
SCPS1100
CO, CO
2
, NO
x
, SO
2
,
CH
4
, O
2
cold-extracting
oil-cooled Backwashing – On request
SCPS3100 water-cooled
Backwashing with
shock blower
l
On request
SCPS3300
CO, CO
2
, NO
x
, SO
2
,
CH
4
, O
2
, HCL, NH
3
heat-extracting water-cooled
Backwashing with
shock blower
l
On request
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SCPS PROCESS GAS ANALYSIS SYSTEM (PGA)
System component SCP1000
General notes
Auxiliaries
Instrument air: 6 bar; dust, oil and water free
Features
Dimensions (W x H x D)
4,800 mm x 1,050 mm x 1,430 mm (probe unit)
600 mm x 600 mm x 300 mm (on-site control cabinet)
1,100 mm x 2,100 mm x 800 m (cooling unit)
Performance
Process temperature
≤ +1,400 °C
Dust load
≤ 2,000 g/m³
Interfaces
Operation
Via Siemens or Allen-Bradley control unit
Via on-site operating unit
Mechanics/electronics
Power consumption
≤ approx. 3.5 kW
Three-phase current
3-phase: 400 V, 50 Hz
Voltage
220 V
Frequency
50 Hz
Conformities
CE
Electrical safety
CE
Enclosure rating
IP54
Ambient data
Ambient temperature
–20 °C ... +55 °C
System component SCP3000
General notes
System components
Purgable sampling probe
Heated lter unit SCP3000-F
Pressure surge blower
Lock box
Rotation drive
Pneumatic emergency retraction
Movement device
Control and supply unit
Cooler
Auxiliaries
Instrument air: 6 bar; dust, oil and water free
Features
Dimensions (W x H x D)
4,500 mm x 600 mm x 1,300 mm (probe unit)
200 mm x 300 mm x 350 mm (on-site control cabinet)
1,200 mm x 1,600 m x 600 m (cooling unit)
1,000 mm x 760 mm x 210 mm
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PROCESS GAS ANALYSIS SYSTEM (PGA) SCPS
Performance
Process temperature
≤ +1,400 °C
Interfaces
Ethernet
l
RS-232
l
RS-485
l
Modbus
l
PROFINET
l
DF1
l
Operation
Via Siemens or Allen-Bradley control unit
Via on-site operating unit
Mechanics/electronics
Conformities
EN 60204-1
Electrical safety
CE
Enclosure rating
IP54
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SICK AG | Waldkirch | Germany | www.sick.com
SICK AT A GLANCE
SICK is a leading manufacturer of intelligent sensors and sensor solutions for industrial applications. With
more than 8,800 employees and over 50 subsidiaries and equity investments as well as numerous agencies
worldwide, SICK is always close to its customers. A unique range of products and services creates the
perfect basis for controlling processes securely and efciently, protecting individuals from accidents, and
preventing damage to the environment.
SICK has extensive experience in various industries and understands their processes and requirements.
With intelligent sensors, SICK delivers exactly what the customers need. In application centers in Europe,
Asia, and North America, system solutions are tested and optimized in accordance with customer specica-
tions. All this makes SICK a reliable supplier and development partner.
Comprehensive services round out the offering: SICK LifeTime Services provide support throughout the
machine life cycle and ensure safety and productivity.
That is “Sensor Intelligence.”
Worldwide presence:
Australia, Austria, Belgium, Brazil, Canada, Chile, China, Czech Republic, Denmark, Finland, France,
Germany, Great Britain, Hungary, Hong Kong, India, Israel, Italy, Japan, Malaysia, Mexico, Netherlands,
New Zealand, Norway, Poland, Romania, Russia, Singapore, Slovakia, Slovenia, South Africa, South Korea,
Spain, Sweden, Switzerland, Taiwan, Thailand, Turkey, United Arab Emirates, USA, Vietnam.
Detailed addresses and further locations
- www.sick.com
8023742/2018-12-07 ∙ AB_06 ∙ Pre USmod en48
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SICK SCPS Process gas analysis system (PGA) Product information
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