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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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WhyWhyautomate?automate?
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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WhyWhyautomate?automate?
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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WhyWhyautomate?automate?
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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WhyWhyautomate?automate?
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
24
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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
25
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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
27
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
29
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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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QCX/QCX/OnStreamOnStream
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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QCX/QCX/OnStreamOnStream
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
70
80
90
100
110
120
130
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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20 118
4
13
6
10
15
21731
97
8
16
1
1
14
9
12
5
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)
11 1
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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33 2
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
33 2
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