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On-line quality controlInstrumentation
For the cement industry
By
Sylvie VALEROITECA - France
CENTRALISED LABORATORY
Additives Blending Silos
Precalciner
AdditivesCement
SiloQuarry
Crusher
Preblending Raw Mill
Kiln Cooler
CementMill
ClinkerSilo
Quarry
S
Air cooling
Sampling tower
Homogenisation hopper
Screw samplerChute
Piston sampler
Sendingstation
Diverter
Electrical cabinet
Hot Meal sampling
Quarry samplingTo the lab
Raw Mix sampling
Cement sampling
CENTRALISED LABORATORY
Loss of Ignition analyser
Receiving stationCO2/SO3
analyser
Raw Mix
Rotative distributing
arm
Manual sample introduction
Raw Mix
CementSupervision
Composite samples storage
Automatic conveyor
MillPress
XRFXRDDedusting Automation cabinet
ON LINE PROCESS CONTROL
Additives Blending Silos
Precalciner
AdditivesCement
SiloQuarry
Crusher
Preblending Raw Mill
Kiln Cooler
CementMill
ClinkerSilo
Q y
Free LimeFree Lime Particle SizeParticle SizeFX 3000FX 3000 Ignition LossIgnition LossAl - Fe - Ca - Si – S - P – K - Cl
COCO22 -- SOSO33
CLINKER5/h
HOT MEAL2/h
RAW MIX10/h
CEMENT4/h Continuous
ON LINE PROCESS CONTROLON LINE PROCESS CONTROL
Advantages over centralised automatic laboratory
Analysis at a higher frequencyenergy savings and more stable quality
Cheaper systems
Simpler to operate
Independent systemsno risk of having no analysis at all in g y
the whole plant
PROBLEM : RAW MIX IS UNSTABLEPROBLEM : RAW MIX IS UNSTABLE
SOLUTION : ON LINE RAW MIX CONTROLSOLUTION : ON LINE RAW MIX CONTROL
RAW MIX CONTROLRAW MIX CONTROL
RAW MIX ANALYSER FX 3000
RAW MIX CONTROL
R i t f ffi i tRequirements for an efficient raw mix control system
Representative & reliable sampling systemp p g y
High quality sample preparation g q y p p p
Repeatable & reliable analysisp y
High frequency controlg y
Representative and reliable sampling systemRAW MIX CONTROL
Representative and reliable sampling systemScrew sampler with variable pitch & speed PREC 100
Homogenisation hopper
Rotating Spoon sampler PGR
Piston sampler P11Homogenisationhopper
Piston sampler P11
To the analyser or transport system
V lValves
RAW MIX CONTROL
Automatic raw mix sampling systemLAFARGE Tetouan (Morocco)
High quality sample preparationRAW MIX CONTROL
g q y p p p
Patented grinding systemPatented grinding system
High density Tungsten Carbide
No grinding aid required
Short grinding time: 90sGrinding
l Short grinding time: 90s vessel
Results
Average particle size: 3μ
90 % of particles < 16μ90 % of particles < 16μ
RAW MIX CONTROL
Raw Mix Analyser FX3000
Raw Mix Analyser FX3000RAW MIX CONTROL
Volumetric dosing system
y
Volumetric dosing system
Puck and mill grinderPuck and mill grinder
Variable frequency drive
Raw Mix Analyser FX3000RAW MIX CONTROL
y
5 drops of alcohol are added directly into the grinder
The ground material is thenThe ground material is then prepared and analysed using a
Labx3500 from Oxford Instruments
Integrated XRF from Oxford InstrumentRAW MIX CONTROL
Integrated XRF from Oxford Instrument
Labx3500
RAW MIX CONTROL
Results obtained by Italcementi for theResults obtained by Italcementi for the Borgo San Dalmazzo plant raw mix
Unground Fused bead Mill and press FX3000 On line analyzerR Std Err R Std Err R Std Err R Std Err
SiO2 0,957 0,688 0,999 0,091 0,998 0,136 0,998 0,129Al2O3 0,927 0,142 0,997 0,032 0,986 0,063 0,975 0,084Fe2O3 0,962 0,085 0,996 0,029 0,996 0,027 0,994 0,035CaO 0,988 0,257 0,998 0,099 0,998 0,097 0,997 0,119
Regression on the analysis of 20 different samples
Raw Mix Analyser FX3000RAW MIX CONTROL
y
12 analysis per hourStandard deviation on main elements :
Ca : 0.1Si : 0.1
Al : 0.03Fe : 0.01
PROBLEM : CALCINATION STABILZATIONSOLUTION : ON LINE HOT MEAL CONTROL
HOT MEAL CONTROL
IGNITION LOSS ANALYSER PF1KIGNITION LOSS ANALYSER PF1K
HOT MEAL CONTROL
Hot Meal Sampler
Ignition loss AnalyserHOT MEAL CONTROL
g y
High T° sampling (± 950 °C)
Air cooling to stop decarbonation
Measurement of rate of decarbonationdecarbonation
2 analysis/h
PROBLEM : CLINKER IS OVERBURNT OR FREE LIME IS UNSTABLE
SOLUTION : ON LINE FREE LIME ANALYSER
CLINKER CONTROLCLINKER CONTROL
FREE LIME ANALYSER KLC3
CLINKER CONTROL
Representative and reliable sampling system
Directly at kiln discharge:
High THigh T°° sampler PHT 100sampler PHT 100High THigh T sampler PHT 100sampler PHT 100
In the 3rd or 4th compartment of a grate cooler:
Under grUnder grateate sampler PT 103sampler PT 103
At the cooler discharge:
After clinker crusher PP 101After clinker crusher PP 101
R t ti d li bl li t
CLINKER CONTROL
Representative and reliable sampling system
Kiln Discharge Sampler
2 pneumatic cylinders
Air cooling
Bulk pneumatic transport
Representative and reliable sampling systemCLINKER CONTROL
Representative and reliable sampling system
Kiln Discharge SamplerCooling nozzle
Sampling p gslots
S l ft 15
Discharge jack
Sampler after 15 years of operation
CLINKER CONTROL
Representative and reliable sampling system
Under Grate SamplerUnder Grate Sampler
Cooler
Residues300 cm3
valvesExcess Clinker
Representative and reliable sampling systemCLINKER CONTROL
Representative and reliable sampling system
Under Grate Sampler
CenteringCentering spout under drilleddrilled grates
FineFine particles
elimination
CLINKER CONTROL
Bulk pneumatic transport
Maximum distance: 200 m
Diverter
Sending stationReceiving cyclone Sending stationReceiving cyclone
Bulk Pneumatic transportCLINKER CONTROL
Bulk Pneumatic transport
F Li A l KLC3
CLINKER CONTROL
Free Lime Analyser KLC3
Grinding Analysis Automation
Free Lime Analyser KLC3CLINKER CONTROL
Free Lime Analyser KLC3
5 analysis/h
Analysis cellAnalysis cell
Mill
Weighing of clinker and glycolHeatingHeating
Mixing clinker + glycolConductivity measurement
CLINKER CONTROL
Free Lime and Kiln Data
Tokuyama Soda Japan
CLINKER CONTROL
Free Lime and Kiln DataFree Lime and Kiln Data
A high frequency free lime measurement is required (< 20 mn)
Free Lime / Burning Zone T°/ Kiln Amps and NOx are closelyFree Lime / Burning Zone T / Kiln Amps and NOx are closely correlated over the short term
Over the long term the relation between Free Lime / BZT/ Kiln Amps and NOx changesand NOx changes
CLINKER CONTROL
Operational experienceLafarge Ravena NY USA % free lime
0 80,9
1
0 40,50,60,70,8
Free
lim
e
K-1
00,10,20,30,4%
K-2
1 2 30
Date
2
1 : Analysis not used to control the kiln (over burnt clinker)2 M l t l f kil i f li (hi h f li t b t t bl )2 : Manual control of kiln using free lime (higher free lime rate but unstable)3 : LinkMan connected to the analyser (stable and higher free lime rate)
CLINKER CONTROL
Direct SavingsDirect Savings
A 0,5 % increase in free lime results in :
15 Kcal / Kg CK of fuel savings15 Kcal / Kg CK of fuel savings
1 KWh / Ton CK of electricity savings
Manual analysis labour cost
Indirect SavingsIndirect Savings
Manual analysis labour cost
Cost of handling production rejects
Post production incident costs
CLINKER CONTROL
O Li XRD A l iOn Line XRD Analysis
Solid state detectorSolid state detector
CLINKER CONTROL
O Li XRD A l iOn Line XRD Analysis
It is possible with this analyser to determine all the phases of clinker
determine the real clinker quality, not the one calculated by Bogue
increase the use of alternative fuels, and determine their effects on clinker, real time.
CEMENT CONTROL
CARBON SULPHUR PARTICLE SIZECARBON SULPHUR ANALYSER
PARTICLE SIZE ANALYSER
PROBLEM : GYPSUM / LIMESTONE ADDITIONSPROBLEM : GYPSUM / LIMESTONE ADDITIONS ARE UNSTABLE AND NOT OPTIMZED
SOLUTION : ON LINE C/S CONTROL
CEMENT CONTROL
Representative and reliable sampling system
Screw sampler PREC 100Screw sampler PREC 100
CEMENT CONTROL
Carbon Sulphur Analyser
Measurement of limestone and gypsum additives
CEMENT CONTROL
C b S l h A lCarbon Sulphur Analyser
200 crucible storage system
C b S l h A l
CEMENT CONTROL
Carbon Sulphur Analyser
Integrated ELTRA Analyser CS800
4 analysis/h
PROBLEM : FINENESS AND STRENGTHS ARE UNSTABLE
SOLUTION ON LINE PARTICLE SIZE CONTROLSOLUTION : ON LINE PARTICLE SIZE CONTROL
CEMENT CONTROL
Particle Size Analyser
Continuous measurement
CEMENT CONTROL
Vertical
Particle Size Analyser
chute at classifier outlet
Sampling in a Sampling in a vertical chutevertical chute
outlet
ITECA Sampling gsystem
MALVERN InsitecInsitec
CEMENT CONTROLParticle Size Analyser
Cement
y
Vertical h t tchute at
separator outlet
SchematicSchematic
MALVERN Insitec
ITECA Sampling
tsystem
Particle Size AnalyserCEMENT CONTROL
In situ installationsIn situ installations
Particle Size Analyser
LAFARGE Milaki ITALCEMENTI Rombas
(Greece) (France)
Particle Size AnalyserCEMENT CONTROL
Application: Ashgrove Leamington USAApplication: Ashgrove Leamington USA
Particle Size Analyser
Particle Size AnalyserCEMENT CONTROL
Application: Ashgrove Leamington USAApplication: Ashgrove Leamington USA
Particle Size Analyser
CEMENT CONTROL
Particle Size Analyser
Grinding optimisationGrinding optimisation
Particle Size Analyser
250
300
150
200
Q1-Q4 1998 during
50
100
Q1 Q4 1998 duringmanual control
Q3-Q4 1999 duringautomatic control
0
Production increaseCiments Calcia : + 5 %Grasim Bathinda : + 5% Ash Grove : + 8 % Return on investmentsReturn on investmentsAsh Grove : + 8 %Consumption decrease : 4 to 8 % Production stability : standard deviation reduced by 20 to 40 %
ON LINE PROCESS CONTROLC l iConclusions
Complete On Line instrumentation to control the cementComplete On Line instrumentation to control the cementmanufacturing process
Higher frequency results, means that it is possible to bettercontrol the process, and therefore save energy costscontrol the process, and therefore save energy costs
Typical payback for each of these instruments is < 1 YEARTypical payback for each of these instruments is < 1 YEAR
ON LINE PROCESS CONTROLON LINE PROCESS CONTROLReferences
Raw Mix control: 15 analysers Hot Meal control: 10 analysersClinker control: 95 analysers Cement control: 80 analysers
Customers: LAFARGE, ITALCEMENTI, HOLCIM, VICAT, CIMPOR, CEMEX, TITAN, ASHGROVE,
BUZZI, HEIDELBERG, VOTORANTIM…
THANK YOU FORTHANK YOU FOR YOUR ATTENTION
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