Cement, Energy and Environment

Hot meal: Sampling, preparation and analysis of hot meal sampled at the lower stage cyclone. The increasing use of alternative fuel, as well as feed of fine ground raw materials after the raw mill (fly ash is one example) puts demand for tighter monitoring of elements like Cl, S, Na and K. Clinker: Sampling, preparation and analysis of clinker. In addition to provide the analysis values for normal QA purposes, free lime and other cement minerals may be determined by XRD for fast feedback to high level kiln control systems. If XRF/XRD combination analyzers are applied also elemental analysis value can be reported . A crushing stage located between sampler and the at-line X-ray container will be required to bring the clinker particle size to below 6 mm before introduction to the Centaurus. Cement: Sampling, preparation and analysis of cement. The objective may be to report elemental analysis (XRF), cement mineral phases (XRD) or both XRF & XRD data and on this basis control the amount of gypsum or other additives. At-line X-ray functionality The basic operation principle is that a primary sampler extracts a small by-pass sample stream from the powder process stream. With typically 8-10 minutes interval, a small sample portion (30-50 cc) is taken from the by-pass stream with a secondary sample spoon and delivered to the top of a Centaurus, which fine-grinds the sample material and via a conveyor band delivers a steel ring with pressed sample powder to the X-ray device. The sample is automatically loaded and analyzed for 1/2 to few minutes, and the steel ring is subsequently returned to the Centaurus for cleaning . Except for the primary & secondary sampling components and the excess sample return components, the system components are located in a robust, air conditioned container suited for the industrial environment. Asides protecting against dust, rain, direct sun exposure, the protective cabin will provide the specified operational temperature for the X-ray spectrometer. The standard scope of a total system configuration comprises: • Project specific primary sampling system, e.g. a screw sampler, an air-slide sampler or other • Sample by-pass tube with secondary sample dosing device • Excess sample return system by gravity or forced via air conveying • Automatic combined mill & press, make Centaurus • X-ray analysis unit (XRF, XRD or XRF/XRD) • One internal 'user' reference sample position for X-ray device drift monitoring • Sampling system local control cabinet • Remote diagnostic service by network connection or modem • Dedusting unit is placed under a roof adjacent to the cabin • Dust proof, air-conditioned cabin (IP54/NEMA). The cabin dimensions (standard size, hwd) are: 2591x3500x2438 mm and it comes with pre-installed air conditioner, lighting and power supplies. Optionally this position may be supplied by the customer, but linked to overall installation & commissioning efficiency it is recommended that the cabin is FLSmidth supply. The container may be supplied with other dimensions. The system components are to be connected via Network cable to a QCX PC placed in the central laboratory/CCR. Same network cable facilitates Internet based communication to FLSmidth's & X-ray supplier's service centre. It is the customer's responsibility to arrange for the network connection and in particular to clear any firewall issues with such connection. The entire pre-assembled system comes "ready-to-install" with project specific programming of sampling control system, designed for the actual sampling configuration, tested prior to delivery and ready for installation. QCX Control of raw meal composition In a 'traditional' raw meal control loop based on laboratory XRF analysis with a wavelength dispersive X-ray spectrometer (WDXRF), a new control sample is typically analyzed every VJ to 1 hour. With an at-line XRF set-up, the control frequency is typically increased to once every 8-10 minutes . With this higher frequency, the raw mix blending is optimised by the full suite of QCX/BiendExpert– Mill software features. lO l I l I