Presentation on theme: "Melbourne Continuous On-line Measurement of Process Mineralogy for Quality Control and Optimisation using X-ray Diffraction Dr Peter Storer Principle Scientist,"— Presentation transcript:
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
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
Melbourne Cement Plant, Utah USA – October 2001 Cement Mill building Product conveyor tube Analyser room
Melbourne Auger sampling from mill product Cement conveyor at 100-150 tph
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.
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.
Melbourne Trend of gypsum states after mill stoppage Mill Restart
Melbourne Trend of gypsum states for constant mill exit temperature
Melbourne Showing the clinker temperature when hemihydrate increased
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.
Melbourne Trend of Production Type change showing limestone addition
Melbourne Trend of Loss results on Finished Cement Limit Number of Cases 1020 30 40
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
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!