1. SpectraFlow Online Analyzer Iron Ore / Sinter Application
Christian Potocan
© SFA Ltd
April 20, 2017 | Slide 1

2. Contents History Near Infra Red (NIR) – The Technology
The Model Development
Comparison of different analytical methods
SpectraFlow in the Sinter Production Process
SpectraFlow – The hardware setup
References
© SFA Ltd.
April 20, 2017 | Slide 2

3. History – SpectraFlow: a real success story
2006: ABB started the development of the SpectraFlow Analyzer
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 conveyor belt 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: Foundation of SpectraFlow Analytics and transfer of the SpectraFlow business from ABB to SFA
2013: 10 successful installations around the world and multiple orders received. SpectraFlow is established in the market and technically mature
© SFA Ltd.
April 20, 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
There were 3 main objectives which the development of an analyzer had to fullfill.
NIR is a very well proven online analysis technique in the organic industry. The task was it to make this technology suitable for the inorganic industry. The main challenge was, that the inorganic industry has no laboratory enivronment. The hardware and the calibration needs to be therefore very robust
No hazardous components can be used, as for customers it is very difficult to obtain permits and licenses. The analyzer must be operatable without any of these
It has to be a real online analyzer: «real» means, that there is no interaction with the raw material and therefore no sampling should be necessary. Interaction with the raw material always means corrosion and therefore a high maintenance effort. No interaction with the raw material means low maintenance and no disturbance of the process. The other huge advantage is, that a much higher measurement frequency is possible (64 scans per minute instead of 1 sample an hour)
© SFA Ltd
April 20, 2017 | Slide 4

5. Fredrickson : Characterisation of hydrated Alumina by NIR 1954
NIR Technology - Minerals have a NIR signature
SiO2
Fredrickson : Characterisation of hydrated Alumina by NIR 1954
Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970
Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970
FeO
CaO
It was long known, that with NIR it is possible to measure minerals. However only since the computing power was available it is possible to evaluate this huge amount of data created in real time. SiO2, CaO and FeO are the most important constituents in the Iron Ore/Sinter industry
Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970
© SFA Ltd
April 20, 2017 | 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
Symmetrical stretching
Asymmetrical stretching
In plane scissoring
Out of plane wagging
Out of plane twisting
In plane rocking
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
SpectraFlow works very similar to any other analytical method: Energy is emitted, when this energy hits the target it is penetrated. In case of SF the molecules and the mineral structure starts to vibrate. This vibration consumes energy and the reflected remaining energy is afterwards measured with the Spectrometer. The consumed energy is the fingerprint of the raw material.
As also the mineral structure starts to vibrate, SF can also be calibrated on mineral phases.
The form of energy used by SpectraFlow is light.
© SFA Ltd
April 20, 2017 | 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
Once the reflected remaining energy is going into the SpectoMeter it has to be transferred into a interferogram. The interferogram is the visual representation of the energy left. By seperating the reflected energy into 2 paths and then bringing them together an interferogram is produced. This interferogram has to be afterwards translated into a spectra, which is the visual representation of the chemical composition. This is done by a Fourier Transformation, for what the Spectrometer is a FTIR (Fourier Transformation InfraRed) Spectrometer.
Belt Conveyor
Iron Ore Mix
© SFA Ltd
April 20, 2017 | Slide 7

8. Model development - The Principle
FeO %
CaO 0.95 %
SiO2 1.3 %
H2O 5.6 %
TRAINING =
CALIBRATION
How much FeO, CaO, SiO2 and Moisture does this Spectra mean?
The analyzer has to be trained, to translate the Spectra into the chemical composition
© SFA Ltd
April 20, 2017 | 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
To calibrate the analyzer we need samples from the location, where we intend to measure and the samples should represent the complete chemical range of the to be measured material. Together with the sample we need the accurate chemical composition by XRF from the customer.
We analyze in our laboratory and samples and make the model based on the XRF analyzes delivered with the samples. Typically 20 samples are needed, dependent on number of constituents and their ranges
© SFA Ltd
April 20, 2017 | Slide 9

10. Comparison of different analytical methods
Comparison of Offline (XRF) and Online (PGNAA and SF) is difficult, but this chart should show the similarities and differences.
Analysis Basis: XRF and PGNAA are elementary methods. PGNAA is emitting energy and fire out neutrons from the core. The neutron shift produces gamma rays and these are the fingerprint of the element. XRF is firing out electrons from the shale of the atoms and this electron shift causes floureszenz. This is the fingerprint of the element. SF gets its information out of the movement of the mineral structure. Therefore all elements can be measured, while «light» elements with few neutrons or electrons cant be measured by PGNAA and XRF, because low information is created.
© SFA Ltd
April 20, 2017 | Slide 10

11. Model development - The resulting models
© SFA Ltd
April 20, 2017 | Slide 11

12. Model development - The accuracy of SpectraFlow
These 10 unknown samples were measured by SpectraFlow and the «predicted» values are the results. The «actual» values are the results of the XRF resp. the wet chemical analysis. These results show, that NIR perfectly measures all important components for the Iron Ore/Sinter industry
© SFA Ltd
April 20, 2017 | Slide 12

13. Comparison of different analytical methods
PGNAA can’ t measure iron ore: due to a very high response of Fe all other elements can’ t be recognized
Beside the important elements FeO, CaO and SiO2 also moisture can be measured
© SFA Ltd
April 20, 2017 | Slide 13

14. SpectraFlow - Position in Sinter production process
Control the quality of the Iron Ore for stable Stockpiles
POSITION A
SPECTRAFLOW
ANALYZER
CONTROL SOFTWARE
IRON ORE STOCKPILE A
IRON ORE STOCKPILE B
IRON ORE STOCKPILE C
Control the Bacisity (CaO/SiO2-ratio) of the sinter mix
POSITION B
LIMESTONE
ADDITIVE
WATER
WATER
RETURNS
COKE
COKE
BLENDED ORE
RAW MIX HOPPER
MIXING DRUM
BURN THROUGH AREA
IGNITION HOOD
Lower returns due to more consistant quality of the feed
ROLLER CRUSHER
TO ATMOSPHERE
WIND BOXES
COOLING FANS
HOT SCREEN
GAS CLEANING
FAN
HOT RETURN FINES
COLD SCREENING
© SFA Ltd
April 20, 2017 | Slide 14
BLAST FURNACE
BUNKER
COLD RETURN FINES

15. SpectraFlow – The hardware setup
Spectrometer Box
Control Panel
Illumination Head
The setput is very easy. Only about 200kg in weight and installed in less than 1 day the SF installation doesnt affect the production and no crane or other heavy equipment is needed for the installation.
© SFA Ltd
April 20, 2017 | Slide 15

16. SpectraFlow – The hardware setup
FTIR Spectrometer
Light and dust shield
Lamp
Use 4 lamps 50 Watt each
Lamp holder
Bulk Material
© SFA Ltd
April 20, 2017 | Slide 16

17. SpectraFlow - The hardware setup
Spectrometer Compartment
Flap which can be opened to access the lights
Overall view
Flap open
Entry for the reflected Infrared into Spectrometer
Interfaces
Power Supply for the spots
Industrial PC (IPC)
Light Spots
View of the inside ceiling
Electronic Panel opened
© SFA Ltd
April 20, 2017 | Slide 17

18. SpectraFlow – ROI Calculation of the investment
Increased production due to reduced rejects because of a more stable quality
Calcualtion on a 2 years pay back
SpectraFlow has a payback time of 3 months as the increased throughput is based on the reduction of the rejects
Increased earnings per year after pay back
Increased earnings per year during pay back
© SFA Ltd
April 20, 2017 | Slide 18

19. Reference List (17 analyzers in 10 countries worldwide)
10 commissioned installation worldwide with very satisfied customers.
© SFA Ltd
April 20, 2017 | Slide 19

20. SpectraFlow Analytics Ltd Seestrasse 14b CH-5432 Neuenhof
Tel: Fax:
© ABB Group
April 20, 2017 | Slide 20