32 - Lab Automation

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FLS Automation June 2002

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ICPS 2002

Laboratory

Automation

&Qualit Control


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WhatWhatis lab automation?is lab automation?

Sampling

Sample transport

Sample preparation Sample Analysis

Control Actions

Storage of data


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WhyWhyautomate?automate?

Do you want to have a consistentand

maybe an improved QC, which will also

give you an improved product?

Different operators do things differently. Thisresults in shifts in analytical level from oneoperator to another. Have you seen that?

Do you know if your sampling isrepresentative? Continous samplingtheoretically the preferred nmethod. Continoussampling is easier done by an automaticsampler than by manual sampling.


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Do you want to have aconsistentandmaybe animproved QC, which will alsogive you an improved product? Some preparation/analytical methods are not

suited for some materials. The right methodmay be difficult in manual operation, but easyto automate.

Would it be of value to you to increase theanalytical schedule? So you would gain moreknowledge of your process? An automaticsystem may be able to process an increased

number of samples compared to an operator Is it easy for you to retrieve data for evaluation

purposes. Automatic systems helps you storeand distribute valuable data.


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Do you want to tighten the qualitycontrol? Do you want to avoid producing

low quality product, but tosave fuel and

energy?

You would need frequent and fast capture ofanalyses and production data. This is not easyto do manually.

It may be obtained by moving the analyticalinstruments into the process thereby saving

sampling and sample transport time,preparation time and analysis time


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Do you want to save construction and/oroperational costs?

Tight quality control allows for optimisation ofprocess lay-out, i.e. reduced blendingfacili ties and controlled use ofdifficult/expensive raw materials


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Lastly, you may also want tosave labourcost.

This may be done by exchanging theoperator/lab tecnician with automatedequipment from sampling to analysis


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Main Purposes of Lab AutomationMain Purposes of Lab Automation

Tight qualitycontrol during

production

On-stream, In-line analysers

etc Automated Lab

system

Qualityrequirements from

customers on

(end) product

Automated Lab

systems


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9Laboratory Automation and On-line Analysis

Centrallaboratoryautomation

or PGNAA

On-line Analysis: PGNAA

XRF

FCaO/PSZ


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Automated Lab SystemsAutomated Lab Systems

Based on very accurate analyticalinstruments, correct sample preparation

methods, reliable sampling and sample

transport systems

Various suppliers (FLSA, Polysius, Pfaff,

Herzog, Iteca ) Possible FLSA solutions will be discussed

in details, competitor solution mentioned!


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FLS Automation lab systemsFLS Automation lab systems


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Laboratory Automation and On-line Analysis

Raw meal Silo

Cement Silos

Kiln

Clinkerstorage

Cement mill

Raw mill

Manual production lab

QCX Scalability:QCX Scalability: SmallSmall

Quarry& Piles


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14Raw meal Silo

Cement Silos

Kiln

Clinkerstorage

Cement mill

Raw mill

Automated production lab

QCX Scalability:QCX Scalability: Medium sizeMedium size

Quarry& Piles


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15ASIA Cement, ThailandASIA Cement, Thailand

QCX S l bilit L


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16QCX Scalability:QCX Scalability: LargeLargeRaw meal Silo

Cement Silos

Kiln

Clinkerstorage

Cement mill

Raw mill

Fully automated production lab

CSTAAS

Plant wide LIMS for

ALL analysis & test data

Quarry& Piles


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17QCX/QCX/RoboLabRoboLab

X-ray room Sample

prep room

XRF

XRD

Mill

Press

Mill

Composites

Fusion

Dosing/

cleaning

Particle Size

Colour

Sample

transport


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QCX/QCX/RoboLabRoboLab- General- General featuresfeatures

Sample receipt

Identification & registration

Sample splitt ing & dosingIndividual preparation recipes

Priority management

Alternative routing in

failure situations

Integrated control and dynamic supervision of :

- Robot

- Prep eqp & Analysis instrms( - Sample transport PLC )


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RecommendationRecommendation

Allow your self time to study your needscarefully

Discuss your needs with qualifiedsuppliers, who knows the process and the

problems most often seen

If any doubt, have a pre-study made onyour materials to ensure the correct

choice of equipment

Balance your investments between

sampling and lab equipment. Where do

you gain the most?

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21Laboratory Automation and On-line Analysis

Central

laboratoryautomation

or PGNAA

On-line Analysis: PGNAA

XRF

FCaO/PSZ

22C i h l i ?C ti t h l i ?


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22Competing technologies ?Competing technologies ?

On-line analysis Central laboratory

automationOn-line analysisMain objective : quality control

Applied on more and more sampling points

Central laboratory

Main objectives : quality controland qualityassurance

manpower savings, correct sample

preparation, ...

23QCX & O Li S kPil C l


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23 QCXQCX&&OnOn-Line-LineStockPileStockPileControlControl

Process flow

Accounting

Analysis data

Control loop(manual or auto)

Limestone

Clay

QCX/BlendExpert

QCX/Laboratory

OLA

Feedproportions

PGNAA

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QCX/QCX/BlendExpertBlendExpert & Pile& PileCntrlCntrl

Circular stockpiles:accounting inaccordance with circular coordinates

of stacker and reclaimer, if coordinates

are provided from the PLC.

If not, accounting is simple endless

integration

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QCX/QCX/BlendExpertBlendExpert & Pile& PileCntrlCntrl

Longitudinal stockpiles:the accountingprovides one total average composition

of the stockpile section currently being

stacked = simple batch integration.

After completion status changes to

reclaimed and later historic pile

26 R i th t k il


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Process flow

Accounting

Analysis data

Control loop(manual or auto)

LimestoneSand Pyrite

PGNAA

Control scheme for producing raw mix on the pile

QCX/

BlendExpert

OLA

QCX/Laboratory

Raw mix on the stockpile

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R i th t k il


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Raw mix on the stockpile

Before:Before: Manual stockpile controlManual stockpile control 44 component mixcomponent mix cntrlcntrl before millbefore mill

(P(Polabolab)) LSF stdLSF stddevsdevsout of mill = 4-5out of mil l = 4-5

NowNow:: Two stockpiles (one circular, oneTwo stockpiles (one circular, onelongitudinal)longitudinal)equipped with PGNAAequipped with PGNAA

analysersanalysers(ASYS FSA)(ASYS FSA) Manual feed to pile control includingManual feed to pile control including

additivesadditives

100 % feed100 % feedfrom both piles to raw mills,from both piles to raw mills,thus no mixing before raw millsthus no mixing before raw millsLSF stdLSF stddevsdevsout mill = 1.7-1.9out mill = 1.7-1.9

Future:Future: Automation of additive feedAutomation of additive feed

28QCXQCX && OnOn LineLine Raw MixRaw Mix ControlControl


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QCXQCX&& OnOn-Line-LineRaw MixRaw MixControlControl

Feeder

setpoints

Raw materials

Raw mi ll

Process flow

Sample

Analysis data

Control loop

Average

sample

QCX/BlendExpert

QCX/LaboratorySlow

Control can be based solely on on-line analysis or

in a redundant set-up incorporating lab XRF analysis

Fast

PGNAA

OLAQCX/

OnStreamFast

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QCX/QCX/OnStreamOnStream

Compact and robustcabinet (IP65) with local

control panel Analyses all 4 main

elements:Fe, Ca, Al, Si

Analysis time 2-5 minutes(EDXRF)

Lower investment required

than for PGNAA-basedalternatives

Combines traditional and on-line techniques.

Tighter quality control at lowest possible cost.

30QCX/QCX/OnStreamOnStream lt ti


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Processflow

Excess

material

return

Analyzer cabinet

Blower

OnStream

screw sampler

Processflow

OnStream air slide sampler

alternative

Dosing device

QCX/OnStream cabinet

31QCX/QCX/OnStreamOnStream lt ti


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Processflow

Processflow

OnStream air slide sampler

alternative

ScrewsamplerAir slide

sampler

Dosing device

Excess

material

return

Analyzer cabinet

Blower

OnStream

screw sampler

Dosing device


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33QCX/QCX/OnStreamOnStream ControlControl performanceperformance


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QCX/QCX/OnStreamOnStreamControlControlperformanceperformance

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90

100

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Before QCX/OnStream

LSF

With QCX/OnStreamUS PlantUS Plant19991999

High frequency sampling and analysis

Fast control responseReduced kiln feed variations with small (or poor) silos

Reduced work load for sampling, preparation & analysis

Robust installation

34OnStreamOnStream ttestest resultsresults


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OnStreamOnStreamttestestresultsresults

Static Dynamic Results Results

SiO2 0.078 0.111

Al2O 0.072 0.096

CaO 0.065 0.126

Fe2O3 0.008 0.022

LSF 0.57 0.72Results achieved with 30 secs integration

time for all elements.

L35Online Analytical PerformanceOnline Analytical Performance


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Lab On-line On-line

WDXRF EDXRF PGNAA

( 20 sec ) ( 100 sec ) ( 10 min )SiO2 0.05 0.10-0.20 0.15-0.30

Al2O3 0.015 0.10-0.15 0.12-0.20

CaO 0.025 0.10-0.20 0.25-0.40

( 0.15-0.20 )

Fe2O3 0.004 0.03-0.05 0.03-0.06

Precision ( = repeatabili ty) data incl sample prep forLab WDXRF & sample presentation for On-line EDXRF

ASYS

Online Analytical PerformanceOnline Analytical Performance

L36PrecisionPrecision


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if this isLab WDXRFthen this is

on-line EDXRF

and this is

on-line PGNAA

PrecisionPrecision

L37ErrorError on Dynamic Precisionon Dynamic Precision


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Traditional

Lab WDXRF (20 sec)

On-line EDXRF OSCA3000

(100 sec)

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33 2

44 3

66 4: sampling On-line

PGNAA

(10 min)

: sample preparation

: analysis

CC33SS/ LSF S.dev

ASYS

ErrorErroron Dynamic Precisionon Dynamic Precision

L38ErrorError on Dynamic Precisionon Dynamic Precision


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66 4

99 6

1212 8

CC33SS/ LSF S.dev

Including time for filling of flow cell, compacting,emptying etc, one OnStream cycle is 5 min.

so this would be the fair value to compare with

(5 min)

(10 min)

On-line EDXRF OSCA3000 (5 min)

----- On-line PGNAA -----

ASYS

ASYS

ErrorErroron Dynamic Precisionon Dynamic Precision

L39CC33SS/LSF S.dev


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Manual/off-line

control

+

Lab-XRF

On-line

EDXRF

Based on hourly averagesamples taken at raw mill

outlet and measured on Lab

WDXRF ( = true value)

Lab-XRF

manualsample prep(1 sample/hr)

: Advanced computerized raw mix blending control

Lab-XRF

automatic

sample prep

(RoboLab)(2 samples/hr)

On-line

PGNAA

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66 4

99 6

12 12 8

L40Traditional VsTraditional Vs OnStreamOnStream analysisanalysis


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Traditional VsTraditional VsOnStreamOnStreamanalysisanalysis

Analytical error

Preparation

error

Sampling

error

Traditional

Analytical

& sample presentation

error

OnStream QCX/OnStream com-bines the high freq. ofthe OnStream analy-ser with the high pre-cisionand high accu-racyof lab analyser

QCX/OnStream moni-tors the process dyna-mics; the lab analyserestablish the accurate

chemical levels The redundant struc-

ture is tolerant to er-

rors in one of the instrinstruments

Sampling

error

L41FLSAFLSA recommendationsrecommendations


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FLSAFLSA recommendationsrecommendations

-EDXRF or PGNAA for raw mix control(Choice to some extent pending process lay-out details)

EXDRF has the potential for lowest LSF std.dev. Out of

mill

-PGNAA for stock pile control

where requirements to analysis precision are less

stringent, and for raw mix control when long transport

delays in the material department exists (e.g. Surge

bins)

QCX supports interfacing og all PGNAA models on the market

On-line EDXRF/PGNAAdoes not eliminate the need

for the traditional lab analyser (WDXRF)

L42Future TrendsFuture Trends


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Future TrendsFuture Trends

On-line instrumentation for control ofmaterial properties (chemical analysis,

fineness ) will increase to support Just-

In-Time production:

Reduce material storage's

Recipe control Special products and qualities Fast change of production to

reduce waste Utilise difficult raw materials Power savings

L43Future TrendsFuture Trends


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Future TrendsFuture Trends

Increased demand for documentation andaccountability from both customers (Total

Quality Control) and from authorities on

environmental impact:

System must handle large amount

of data in a safe way Laboratory procedures will be very

stringent and automation will be

wide-spread in other areas of thecement analysis (physical testing,fuel, )

L44AbbreviationsAbbreviations


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AbbreviationsAbbreviations

EDXRF Energy Dispersive X-Ray FluorescenceFCaO Free Lime

FSA Full Stream Analyser

LIMS Laboratory Information Management SystemPGNAA Prompt Gamma Neutron Activation Analysis

PSZ Particle Size Measurement

QCX Quality Control by Computer and X-ray

WDXRF Wavelength Dispersive X-Ray Fluorescence

XRF X-Ray FluorescenceXRD X-Ray Diffraction

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32 - Lab Automation