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

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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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2008-10-2121:40

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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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2008-10-2121:40

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

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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