KIMA GasTemp Hot Gas Flow & Temperature Analyzer
| Brand | KIMA |
|---|---|
| Origin | Germany |
| Model | GasTemp |
| Application | In-situ high-temperature gas flow and temperature measurement in cement, power, and industrial kiln processes |
| Compliance | Designed for continuous emission monitoring (CEM) support and process optimization in harsh thermal environments |
Overview
The KIMA GasTemp is a robust, in-situ hot gas flow and temperature analyzer engineered for real-time, non-intrusive measurement of velocity and temperature in high-temperature industrial gas streams—typically ranging from 100 °C to over 1,200 °C. Unlike conventional thermocouple-based point sensors or cooled pitot tubes, the GasTemp employs a patented dual-sensor probe architecture combining high-temperature thermocouples with calibrated differential pressure sensing, operating on the principle of thermal anemometry augmented by dynamic pressure correlation. This hybrid methodology enables simultaneous, time-synchronized acquisition of volumetric flow rate (Nm³/h or ft³/min) and static/total gas temperature—critical parameters for mass balance calculation, combustion efficiency analysis, and thermal energy recovery optimization. The system is specifically designed for deployment in cement production lines, waste-to-energy plants, lime kilns, and other high-dust, high-temperature process ducts where traditional flow meters fail due to fouling, erosion, or thermal drift.
Key Features
- High-temperature probe assembly rated up to 1,300 °C continuous service, fabricated from Inconel 600 and ceramic-insulated thermocouples (Type S or K, configurable)
- Dual-channel analog and digital output (4–20 mA, HART, Modbus RTU/TCP) for integration into DCS, SCADA, or PLC systems
- Self-compensating design for gas composition variations (N₂, O₂, CO₂, H₂O content), with optional built-in oxygen sensor interface for stoichiometric correction
- Integrated dust-tolerant purge air management system with adjustable flow control and pressure monitoring
- Field-replaceable sensor modules with traceable calibration certificates (ISO/IEC 17025 accredited laboratories)
- IP66-rated local display unit with real-time trend logging, alarm thresholds, and diagnostic status indicators
Sample Compatibility & Compliance
The GasTemp is validated for use in dusty, corrosive, and turbulent gas flows typical of cement preheater exit ducts, calciner outlets, tertiary air ducts, clinker cooler exhausts, and waste heat recovery boiler bypass lines. It meets mechanical and environmental requirements per EN 61000-6-2 (EMC immunity) and EN 61000-6-4 (EMC emissions). While not a certified CEMS device per EPA Method 2 or ISO 16911, its measurement data supports compliance reporting under EU Industrial Emissions Directive (IED) and U.S. EPA 40 CFR Part 60 Subpart FFFF (Portland Cement NESHAP) when used in conjunction with reference-grade analyzers for cross-validation. Calibration traceability follows DIN EN ISO/IEC 17025, and documentation includes full uncertainty budgets per GUM (Guide to the Expression of Uncertainty in Measurement).
Software & Data Management
The GasTemp operates with KIMA’s ProcessLink™ configuration and diagnostics software, compatible with Windows 10/11 and accessible via Ethernet or USB. Software functions include probe alignment verification, zero/span drift trending, multi-point velocity profile mapping, and automatic compensation for gas density changes due to temperature and composition shifts. All configuration changes, calibration events, and alarm triggers are timestamped and logged with user ID attribution—supporting audit readiness under GLP and GMP frameworks. Optional cloud-enabled firmware updates and remote diagnostics comply with IEC 62443-3-3 security requirements for industrial automation systems.
Applications
- Mass flow monitoring at preheater cyclone downcomers to optimize raw meal suspension and reduce thermal losses
- Decomposer furnace outlet gas profiling for NOₓ formation modeling and SNCR reagent dosing control
- Tertiary air flow quantification to maintain optimal kiln flame shape and clinker nodulization
- Flue gas velocity and temperature measurement upstream of ESP or baghouse filters for differential pressure prediction
- Bypass duct flow balancing in AQC (Air Quenching Cooler) and SP (Steam Power) boilers to maximize steam generation efficiency
- Kiln hood gas characterization for secondary fuel injection control and refractory wear assessment
- Mill outlet gas monitoring in vertical roller mills and ball mills to prevent condensation, dust explosion hazards, and separator efficiency degradation
FAQ
Is the GasTemp suitable for wet or corrosive flue gases?
Yes—the probe housing and sensor sheaths are available in Hastelloy C-276 or ceramic-coated variants upon request, and the purge air system prevents condensate ingress and acid dew point corrosion.
Does it require periodic recalibration during operation?
No field recalibration is required between scheduled maintenance intervals (typically 6–12 months); however, drift verification using portable reference probes is recommended prior to major process shutdowns.
Can it be installed without process shutdown?
Yes—hot-tap installation kits with isolation valves and sealing sleeves enable retrofitting under operational conditions, minimizing production downtime.
What is the typical measurement uncertainty for flow and temperature?
At 500 °C and 15 m/s nominal velocity, combined expanded uncertainty (k=2) is ±3.5% of reading for flow and ±1.5 °C for temperature, as verified per ISO 5167 and ASTM D5467 protocols.
Is FDA 21 CFR Part 11 compliance supported?
Electronic records and signatures functionality—including audit trail, electronic signature capture, and role-based access control—is available in the enterprise version of ProcessLink™ software, supporting regulated pharmaceutical or food-grade thermal process validation.
