SpectraFlow Online Analyzer Cement Application Christian Potocan 2013-11-28

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 © SFA Ltd. 28/11/2013 │ Slide 2

SpectraFlow Timeline 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 © SFA Ltd. April 1, 2017 | Slide 3

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 © SFA Ltd. 28/11/2013 │ Slide 4

NIR Technology - Minerals have a NIR signature Al2O3 SiO2 FeO CaO Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970 © SFA Ltd. 28/11/2013 │ Slide 5

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 © SFA Ltd. 28/11/2013 │ Slide 6

NIR Technology - Principle of the measurement FTIR Spectrometer Industrial PC with Soft PLC Input Lens, which ascertains parallel beams inside spectrometer Lamp shining at the material Light Paths Lamp shining at the material TCP/IP Connection to RMP Belt Conveyor/Airslide Raw Material/Meal © SFA Ltd. 28/11/2013 │ Slide 7

Model development - The Principle CaO 45.50 % SiO2 10.95 % Al2O3 3.3 % Fe2O3 0.66 % TRAINING = CALIBRATION 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 © SFA Ltd. 28/11/2013 │ Slide 8

Model development - The calibration process 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 © SFA Ltd. 28/11/2013 │ Slide 9

Comparison of different analytical methods © SFA Ltd. 28/11/2013 │ Slide 10

SpectraFlow - Position in Cement production process AIRSLIDE SPECTRAFLOW CROSSBELT Homoge- nizing Silo Blending Bed Raw Mill SPECTRAFLOW AIRSLIDE Cement Mill Kiln (Clinker) Cement © SFA Ltd. 28/11/2013 │ Slide 11

SpectraFlow – Crossbelt Application FTIR Spectrometer Light and dust shield Lamp Use 4 lamps 50 Watt each Lamp holder Bulk Material © SFA Ltd. 28/11/2013 │ Slide 12

SpectraFlow – Crossbelt Application – Quarry Optimization HIGH LSF LOW LSF VARIABLE LSF SPECTRAFLOW ANALYZER HOW MUCH MATERIAL WITH WHICH LSF IS CURRENTLY ON THE STOCKPILE ? FEEDBACK TO THE MINE MANAGEMENT © SFA Ltd. 28/11/2013 │ Slide 13

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 © SFA Ltd. 28/11/2013 │ Slide 14

SpectraFlow – Airslide Application Illumination Head Spectrometer Box © SFA Ltd. 28/11/2013 │ Slide 15

KILN FEED QUALITY AT THE RAW MILL WITHOUT ANY SAMPLING SpectraFlow – Airslide Application – Raw Mill Optimization SAMPLING STATION SPECTRA-FLOW Blending Bed Silo KILN FEED QUALITY AT THE RAW MILL WITHOUT ANY SAMPLING Raw Mill ONLINE SAMPLE DATA ADJUSTMENT EVERY 3-5 MINUTES IN REAL TIME SPECTRAFLOW AIRSLIDE ANALYZER MEASURING PRESSING GRINDING AUTOMATIC LABORATORY © SFA Ltd. 28/11/2013 │ Slide 16

SpectraFlow – Airslide Application – Raw Mill Optimization 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 © SFA Ltd. 28/11/2013 │ Slide 17

SPECTRAFLOW AIRSLIDE ANALYZER SpectraFlow – Airslide Application – Cement Mill Optimization SPECTRA-FLOW Cement Mill Cement ONLINE DATA SPECTRAFLOW AIRSLIDE ANALYZER © SFA Ltd. 28/11/2013 │ Slide 18

SpectraFlow – Airslide Application – Cement Mill Optimization 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 © SFA Ltd. 28/11/2013│ Slide 19

SpectraFlow – Result Comparison – SF vs PGNAA © SFA Ltd. 28/11/2013│ Slide 20

SpectraFlow – Result Comparison – SF vs XRF + = Sampling Station value 40 min Highly visible dynamic in a very narrow range between 41.8 and 43.1 % CaO line = SpectraFlow value 1 min CaO SiO2 Al2O3 Fe2O3 © SFA Ltd. 27/11/2013 │ Slide 21

SpectraFlow – Result Comparison – SF vs XRF Control by automatic Sampling Station (40min sample) Control by SpectraFlow Measurement by SpectraFlow (1 value each minute) Measurement by Sampling Station (one value each 40 minutes which comes one hour after sampling) © SFA Ltd. 28/11/2013 │ Slide 22

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