1. SpectraFlow Online Analyzer Cement Application
Christian Potocan

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
© SFA Ltd.
28/11/2013 │ Slide 2

3. 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

4. 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

5. 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

6. 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

7. 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

8. Model development - The Principle
CaO %
SiO %
Al2O3 3.3 %
Fe2O %
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

9. 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

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

11. 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

12. 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

13. 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

14. 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

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

16. 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

17. 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

18. 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

19. 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

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

21. 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

22. 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

23. Reference List
© SFA Ltd.
28/11/2013 │ Slide 23

24. SpectraFlow Analytics Ltd
Seestrasse 14b CH-5432 Neuenhof
Tel: Fax: