Ceramics Kiln Multizone Temperature Control Retrofit
Engineered a 24-zone digital temperature control retrofit with SCR thyristor power packs and SCADA telemetry, reducing tile firing defect rates by 14% and cutting natural gas waste.
Operational Bottlenecks & Failure Modes
A high-volume ceramic tile plant running a 120-meter continuous roller kiln experienced thermal fluctuations of up to ±12°C in the critical firing zone. The analog thermal loop controllers suffered from thermocouple drift and could not automatically compensate for seasonal ambient gas pressure drops. Consequently, finished porcelain tiles exhibited curved warpage, color variation, and glaze micro-cracking.
System Retrofit & Modernization
IASBD implemented a multizone closed-loop architecture. We installed 24 Omron digital process controllers paired with SCR thyristor power regulators for modulating gas burner servo valves. All 24 zones were networked via RS-485 Modbus RTU into a centralized SCADA industrial PC providing continuous firing curve logging, burner flameout interlocks, and automated thermal profile adjustment.
Technical Architecture & Subsystems
Engineered fieldbus integration, high-speed loop cycles, and localized safety interlocks.
24 independent closed loops with platinum-rhodium Type S thermocouples and digital PID auto-tuning.
Fast-cycle zero-cross thyristor modules driving burner proportioning valves without mechanical contact wear.
Real-time thermal curve visualization, gas consumption tracking, and SMS alarm notification on thermal deviation.
Hardware & Modules Deployed
- Omron Digital Process Controllers
- Solid State SCR Power Regulators
- Platinum-Rhodium Type S Thermocouple Assemblies
- Yaskawa Heavy-Duty Inverters for Ball Mill & Drive Train
- Isolated RS-485 Modbus Gateways
Featured Catalog Components
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