1. Melbourne Continuous On-line Measurement of Process Mineralogy for Quality Control and Optimisation using X-ray Diffraction Dr Peter Storer Principle Scientist, FCT-ACTech Pty Ltd

2. Melbourne Continuous On-Stream Mineral Analyser For Real time Industrial Process Control Automatic Mineral Phase Analysis In Plant On-Stream Location Linked to Plant Control System Continuous Analysis Data Trending Calculated Elemental Analysis COSMA

3. Melbourne Cement Plant, Utah USA – October 2001 Cement Mill building Product conveyor tube Analyser room

4. Melbourne Auger sampling from mill product Cement conveyor at 100-150 tph

5. Melbourne Sample Handling Schematic 1 2 3 4 COSMA

6. Melbourne Cement Sampling – Multiple lines Three sample lines COSMA

7. Melbourne Automatic and Continuous Sample Presentation FeedscrewTurntable Moving sample maximizes number of particles analyzed

8. Melbourne X-ray tube, sample stage and detector Etc.

9. Melbourne Diffraction Pattern – analysed by Reitveld analysis

10. Melbourne Particle Statistics are Important! We cannot use Stationary Samples to Analyse As Received Material

11. Melbourne Particle Statistics are Important! Rotating Turntable

12. Melbourne Nickel Concentrate Samples

13. Melbourne

16. Raw Materials processed to Cement Minerals

17. Melbourne Mineral Analysis – as it happens!

18. Melbourne Free Lime Free lime is monitored in the clinker to ensure it is below the maximum limit. Excess free lime may indicate under burnt clinker or excess CaO in the raw meal. XRD provides the opportunity to clearly identify the cause of excess free lime.

19. Melbourne Free Lime Excursion. 10 20 30 40 50 60 26 Jan27 Jan28 Jan Percent Alite, Belite 0.0 0.5 1.0 1.5 2.0 2.5 Percent Free Lime AliteBelitebLime Underburning…

20. Melbourne Free Lime Excursion –Excess free lime in Kiln Feed

21. Melbourne Gypsum – CaSO 4. 2H 2 O Gypsum is added to clinker in the grinding stage to control the cement setting time. During the grinding process some of the gypsum is dehydrated to plaster of paris. XRD provides the opportunity to monitor the gypsum/hemihydrate ratio.

22. Melbourne Trend of gypsum states after mill stoppage Mill Restart

23. Melbourne Trend of gypsum states for constant mill exit temperature

24. Melbourne Showing the clinker temperature when hemihydrate increased

25. Melbourne Limestone – CaCO 3 Limestone is added to the cement mill to control the cement cost and minimise greenhouse emissions. Different cement types and regulatory standards exist for additions. XRD provides the opportunity to monitor limestone addition.

26. Melbourne Trend of Production Type change showing limestone addition

27. Melbourne Trend of Loss results on Finished Cement Limit Number of Cases 1020 30 40

28. Melbourne Conclusion Continuous On-Stream XRD Analysis for material streams – direct on powder or crushed and ground for coarse samples Control based on mineralogical information – allows timing and direction of control action Kiln operation and burner settings Cement Mill and Separator operation Feed rate control and monitoring Direction of Product to Silos

29. Melbourne Conclusion Raw Material monitoring/control at the Product stage allows optimum additive control. Limestone, Gypsum Dynamic sample presentation allows coarser sample analysis. Ease of sample prep, minimum wear on equipment. Excellent Quality Monitor Like having my best lab guy working 24/7!

30. Melbourne Thank you! … Questions?