Precise temperature control in the thermal chamber of rotary kilns is the key to efficient and stable production of activated carbon, among other things. However, high temperatures and constant movement mean that traditional hard-wired sensors fail - cables wear out, break and lead to failures. Lack of reliable monitoring means not only loss of raw material, but also excessive gas consumption and higher production costs. Our client, a producer of activated carbon, was looking for a solution to precisely control temperature, optimise burner operation and avoid costly downtime. In this case study, we will show how the JUMO Wtrans B wireless measuring system eliminated cable problems, improved process stability and reduced energy consumption. Read on to find out how to effectively monitor temperatures in rotary kilns and avoid breakdowns!
Rotary kilns (including bakery rotary ovens, metallurgical rotary ovens, cement rotary ovens and activated carbon ovens) operate under extreme conditions, and any degree of difference can affect the quality of the final product. Too low a temperature weakens the adsorption properties of the coal, while too high a temperature leads to excessive combustion, which reduces efficiency and generates raw material losses.
The problem is that monitoring the temperature in a rotary furnace is not straightforward. Traditional hard-wired sensors fail - the movement of the furnace causes twisting and rubbing of the cables, leading to failures and the need for frequent repairs. Each downtime means additional costs and loss of valuable time.
Lack of precise temperature control also means excessive gas consumption. Burners have to work longer and more intensively to compensate for irregularities in heat distribution. This translates into higher operating costs and higher energy consumption.
Activated carbon production requires continuous and precise temperature monitoring, as even slight deviations can negatively affect product quality and efficiency. Maintaining precise temperature control throughout the process is critical—not just for ensuring high product standards but also to avoid unnecessary gas consumption. The customer needed a robust monitoring system capable of operating reliably under demanding conditions inside constantly rotating, high-temperature furnaces.
However, the rotating design of the furnace posed a significant technical challenge. Traditional wired temperature measurement systems frequently failed due to cable twisting, friction, and mechanical stress caused by constant movement. Each failure led to costly downtime, repairs, and reduced operational efficiency.
In addition, the customer aimed to reduce gas consumption without negatively impacting production performance. Without accurate temperature data, burners operated inefficiently, often running longer or hotter than necessary, increasing fuel consumption and costs.
Furthermore, the customer required advanced analytical capabilities: temperature measurements needed to be continuously collected, analyzed in real-time, and made easily accessible for operators. A centralized system that would quickly provide actionable insights and allow operators to promptly adjust process parameters was essential.
To ensure continuous temperature monitoring in the rotate furnace and eliminate cable-related issues, the customer implemented the JUMO Wtrans B wireless measurement system. Temperature probes were installed at key measurement points within the furnace, from where they transmit data wirelessly in real-time. This solution guarantees uninterrupted monitoring and smooth furnace operation, regardless of its continuous rotation.
The measured data is transmitted directly to a central JUMO variTRON controller, specifically adapted for this application. The controller receives temperature values, enabling operators to instantly view process conditions and adjust parameters as needed.
Additionally, the customer implemented software for data evaluation and visualization—JUMO smartWARE Evaluation—allowing measurement trends to be recorded, analyzed, and further processed. This provided deeper insight into the furnace operation, helping optimize the overall process.
As a result, eliminating cables by using wireless sensors simplified installation, reduced maintenance downtime, and significantly improved reliability and efficiency of the rotate furnace.
Wireless temperature measurement in rotary furnaces using temperature sensors wTRANS B (707060)
With the new wireless measurement system, the customer no longer needs to worry about sensor failures. The wireless probes reliably deliver continuous temperature readings, even as the furnace rotates constantly. Problems with intermittent measurements and cable damage have become a thing of the past, eliminating costly downtime and frequent repairs.
Precise and stable temperature monitoring allows for accurate control of burner settings, directly optimising gas consumption. The burners now operate more efficiently, only consuming as much fuel as necessary, without wasteful fluctuations or overheating.
As a result, the activated carbon produced has significantly improved in quality and consistency, while the overall production process is now much more stable and predictable. The customer experiences fewer failures, lower operational costs, and a higher-quality end product—exactly the outcome they aimed to achieve.
My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
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