Metal 3D Printing Improves Gas Analysis Systems in Cement Production

The Danish company FLO2R, in collaboration with the Danish Technological Institute (DTI), has developed a metal 3D-printed component that plays a key role in gas analytics for cement kilns. Through additive manufacturing, the company was able to realize a patented cleaning technology that significantly reduces maintenance requirements and enhances efficiency in the energy-intensive cement production process.

FLO2R supplies analytical equipment for cement plants and works in a strategic partnership with the German technology group ABB. While ABB provides the analytical software, FLO2R develops the hardware components. The goal of these systems is to optimize fuel consumption and process safety in rotary kiln operations. Since cement production accounts for around eight percent of global CO₂ emissions, even small efficiency gains can have a significant impact. According to FLO2R, a single analysis probe can reduce a cement kiln’s emissions by about three percent.

“When you insert a water-cooled tube into such an active mineral process, as we do with our analysis probe, it’s actually the coldest point in the entire kiln. So, to prevent dust and 1,200-degree-hot condensed gases from forming stony deposits on the probe, we have to blow it clean from time to time. Otherwise, it would require a hammer and chisel to remove these deposits”, explains Karsten Brink Floor, CEO of FLO2R.

“The nozzle is 3D printed in stainless steel here at the Danish Technological Institute, and it features a complex internal geometry with various channels that ensure optimal air distribution for the powerful cleaning that FLO2R’s system can deliver”, says Morten Lisberg Jørgensen, senior consultant and 3D printing specialist at the Danish Technological Institute.

FLO2R’s measurement system operates under extreme conditions: temperatures of up to 1,400 degrees Celsius, high dust concentrations, and aggressive chemical reactions that stress the components. The critical part of the system is the water-cooled analysis probe, which must be cleaned regularly to prevent buildup. This is achieved using a 3D-printed nozzle located at the tip of the probe, ensuring precise air distribution.

“With 3D printing, we eliminate the risk of misalignments that could arise from welding, and FLO2R gets consistent quality in the printed components” says Morten Lisberg Jørgensen.

“3D printing has made it possible for us to flow-optimize the internal geometry in ways not possible with traditional manufacturing methods, and that has improved the effectiveness of our patented cleaning solution”, said Karsten Brink Floor, FLO2R.

The process results in a more robust and durable solution that delivers reliable measurement results under the extreme conditions of a cement kiln while substantially reducing maintenance requirements.