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SpectraFlow Online Analyzer Cement Application
Christian Potocan 2013-11-28
© SFA Ltd.28/11/2013 │ Slide 2
Contents History Near Infra Red (NIR) – The Technology The Model Development Comparison of different analytical methods SpectraFlow in the Cement Production Process SpectraFlow Crossbelt Application SpectraFlow Airslide Application Results of SpectraFlow measurement References
SpectraFlow Timeline
© SFA Ltd. April 10, 2023 | Slide 3
2006: ABB started the development of near infrared technology for cement application 2007: First trials in the USA and Switzerland 2008: Test installations for limestone quarry and sinter in Italy, Norway and Germany 2009: First commercial installation on a crossbelt in a cement plant in Slovakia 2010: First tests for the airslide application 2011: Multiple installations around the globe: Saudi Arabia, Oman, Iran, Pakistan, Germany
and Switzerland 2012: First commercial installation on an airslide after the raw mill in Switzerland and Brazil 2013: SpectraFlow Analytics incorporated Ltd as an independent company 2013: SpectraFlow Analytics established in the market and multiple orders sent and received
from Turkey, Germany, Thailand, Austria, and Oman
NIR Technology - Objectives of the development Select a proven and accepted analysis technique that will give fast and reliable analysis Make sure that no hazardous materials are needed in the operation of the system
Eliminate radioactive sources, neutron generators or X-Ray components Eliminate the need for permits or licences for the operation of the system
Provide real-time on-line analysis for any kind of bulk material by a single technology to analyse all
Molecules Mineral phases Module parameters
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NIR Technology - Minerals have a NIR signature
Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970
SiO2
CaO
FeO
Al2O3
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NIR Technology - Principle of the measurement When energy (light) hits any matter this matter gets excited and starts to vibrate This vibration is characteristic for any mineral or molecule and according to that consumes a specific
energy
As the amount of energy emitted is known and the amount of energy reflected is measured, the amount of energy consumed is calculated
The consumed amount of energy is the mineralogical fingerprint of the raw material As the information of the raw material is determined out of the movement of the crystal structure and
molecules and not the elements, all elements can be measured
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NIR Technology - Principle of the measurement
Industrial PC with Soft PLC
TCP/IP Connection to RMP
Raw Material/Meal
Lamp shining at the material
Lamp shining at the material
FTIR Spectrometer
Input Lens, which ascertains parallel beams inside
spectrometer
Ligh
t Pat
hs
Belt Conveyor/Airslide
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Model development - The Principle
CaO 45.50 %
SiO2 10.95 %
Al2O3 3.3 %
Fe2O3 0.66 %
How much CaO, SiO2, Al2O3, Fe2O3 and Moisture does this Spectra mean? The analyzer has to be trained, to translate the Spectra into the chemical composition
TRAINING
=
CALIBRATION
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• To develop the relationship reference material has to be supplied
• The reference material has to represent the range of the material to be measured
• The reference material has to be delivered with accurate chemical analysis
• Depending on the complexity of the application 20 to 50 samples are needed to develop the initial calibration
• The samples are measured in a dynamic mode and the spectra for the different materials are obtained
Model development - The calibration process
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Comparison of different analytical methodsXRF PGNAA SpectraFlow
Offline Online OnlineX-Ray Tube Radioactive Source LightbulbsElectron Shells Nucleus Molecules, Mineral Phasesdependent on Calibration: from F (WDX) or Na (EDX)
from Na (Cf source) from O (neutron tube)
all elements: including H
Vacuum, Sample Preparation Belt Speed, Belt Load no nonlinear layeringµm Up to 500 mm µm - mmReflexion Transmission Reflexion
Conveyor Belt Conveyor Belt, Airslide
Elemental Analysis Elemental Analysis Mineral Phases, OxidesFair to Good Poor GoodSeconds Minutes Seconds
Analytical Error
very lowhigh to low dependent on Element
low
AccuracySampling Error
high to very high low very low
Total Error high to very high low very low
X-Ray tube Radioactive Source light-bulbsConsumables
Measurement Principle
ReportsRepeatability
Possible Measurement Positions
Source of EnergyMeasurement Method
Analysis BasisElements possible to measure
Measurement time
DependencyDepth of Analysis
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SPECTRAFLOWCROSSBELT
Blending Bed Homoge- nizing
SiloRawMill
SPECTRAFLOWAIRSLIDE
CementMillKiln (Clinker) Cement
SPECTRAFLOWAIRSLIDE
SpectraFlow - Position in Cement production process
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Bulk Material
Use 4 lamps 50 Watt each
FTIR Spectrometer
Lamp
Lamp holder
SpectraFlow – Crossbelt Application
Light and dust shield
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SPECTRAFLOWANALYZER
HIGH LSF LOW LSF VARIABLE LSF
HOW MUCH MATERIAL WITH WHICH LSF IS CURRENTLY ON
THE STOCKPILE ?FEEDBACK TO THE MINE
MANAGEMENT
SpectraFlow – Crossbelt Application – Quarry Optimization
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SpectraFlow – Crossbelt Application – Quarry Optimization
The SpectraFlow is used to real-time control the raw material from the quarry to the blending bed to Reduce the LSF variations on the blending bed Have full control of the current chemical composition and real tons (due to the moisture
measurement) of the blending bed Extend the usage of the quarry as highly variable raw material can be used Introduce completely new quarry management strategies either manual or automated
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SpectraFlow – Airslide Application
Spectrometer BoxIllumination Head
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DATA
ONLINE
SAMPLE
SpectraFlow – Airslide Application – Raw Mill Optimization
Blending Bed
Silo
RawMill
AUTOMATIC LABORATORY
GRINDINGPRESSINGMEASURING
SAMPLING STATION
SPECTRA-FLOW
SPECTRAFLOWAIRSLIDE ANALYZER
ADJUSTMENT EVERY 3-5
MINUTES IN REAL TIME
KILN FEED QUALITY AT THE RAW MILL WITHOUT ANY SAMPLING
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A “must-have” device for every cement plant Control the chemical composition of the Raw Meal Control the additive input in real time Decrease the analyses frequency in the laboratory, as the sampling station is used for
reporting only SpectraFlow controls the LSF, SM, AM of the Raw Meal Kiln Feed quality after the Raw Mill
SpectraFlow – Airslide Application – Raw Mill Optimization
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CementMill Cement
SPECTRA-FLOW
DATA
ONLINE
SPECTRAFLOWAIRSLIDE ANALYZER
SpectraFlow – Airslide Application – Cement Mill Optimization
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Finished Cement
The SpectraFlow Analyzer is situated after the Cement Mill(s)• Control the SO3 content• Control of Cement Quality, when changing products
• Reduction of product in intermediate silos
SpectraFlow – Airslide Application – Cement Mill Optimization
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SpectraFlow – Result Comparison – SF vs PGNAA CaO
35
37
39
41
43
45
47
49
51
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2008-10-2120:42
2008-10-2121:40
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2008-10-2123:34
SOLBAS Training Set Gamma Metrics SOLBAS Test Set Prediction
SiO2
5
7
9
11
13
15
17
19
21
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2008-10-2120:42
2008-10-2121:40
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SOLBAS Training Set Gamma Metrics SOLBAS Test Set Prediction
Al2O3
0.5
1.5
2.5
3.5
4.5
5.5
6.5
7.5
8.5
9.5
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2008-10-2120:42
2008-10-2121:40
2008-10-2122:37
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SOLBAS Training Set Gamma Metrics SOLBAS Test Set Prediction
Fe2O3
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
2008-10-2119:45
2008-10-2120:42
2008-10-2121:40
2008-10-2122:37
2008-10-2123:34
SOLBAS Training Set Gamma Metrics SOLBAS Test Set Prediction
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SpectraFlow – Result Comparison – SF vs XRF
Highly visible dynamic in a very narrow range between
41.8 and 43.1 % CaO
+ = Sampling Station value 40 min
line = SpectraFlow value 1 min
CaO
SiO2
Al2O3
Fe2O3
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SpectraFlow – Result Comparison – SF vs XRF
Measurement by Sampling Station
(one value each 40 minutes which comes one hour after sampling)
Measurement by SpectraFlow (1 value
each minute)
Control by SpectraFlowControl by automatic Sampling Station (40min sample)
Reference List
© SFA Ltd.28/11/2013 │ Slide 23
SpectraFlow Analytics Ltd
Seestrasse 14b CH-5432 Neuenhof
Tel: +41 56 406 12 12 Fax: +41 56 406 12 10
www.spectraflow-analytics.com
info@spectraflow-analytics.com