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ICCC 2007 Montreal, Canada Continuous On-line Measurement of Cement and Clinker Mineralogy for Quality Control and Optimisation using X-ray Diffraction.

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Presentation on theme: "ICCC 2007 Montreal, Canada Continuous On-line Measurement of Cement and Clinker Mineralogy for Quality Control and Optimisation using X-ray Diffraction."— Presentation transcript:

1 ICCC 2007 Montreal, Canada Continuous On-line Measurement of Cement and Clinker Mineralogy for Quality Control and Optimisation using X-ray Diffraction Dr Peter Storer Principle Scientist, FCT-ACTech

2 Raw Materials processed to Cement Minerals

3 Continuous On-Stream XRD ►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

4 Ash Grove Cement Plant – October 2001 Cement Mill building Product conveyor tube Analyser room

5 Auger sampling from mill product Cement conveyor at tph

6 Sampling Schematic XRD

7 Cement Sampling Schematics – Multiple lines Three sample lines COSMA

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

9 Automatic Sample Presentation FeedscrewTurntable Moving sample maximizes number of particles analyzed

10 Diffraction Pattern – analysed by Reitveld analysis

11 Particle Statistics are Important! We cannot use Stationary Samples

12 Diffraction Peaks at Characteristic Angles, Only when the alignment is right.

13 Particle Statistics are Important! Rotating Turntable

14 Rietveld quantitative analysis ►Automatic Mineral Phase Analysis ►Parameters optimised for the plant conditions ►Most parameters are fixed for continuous analysis ►Data sets analysed as rolling average every minute ►Accurate analysis obtained – verified by tests on known samples and shift samples (eg. Elemental Analysis compared to Lab XRF, Free lime (CaO) compared to wet chemistry.)

15 Mineral Analysis – as it happens!

16 Monitoring the Cement Continuous XRD analysis provides trended data, showing the composition of the material throughout the day. Trends provide much more information than spot or composite samples. Composite samples are like the average of the trends.

17 Trend of gypsum states after mill stoppage

18 Trend of gypsum states for constant mill exit temperature

19 Showing the clinker temperature when hemihydrate increased

20 Trend of Type change showing limestone addition

21 Trend of Loss results on Finished Cement Limit Number of Cases

22 Examples of Free Lime variation in clinker 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.

23 Free Lime Excursion Jan27 Jan28 Jan Percent Alite, Belite Percent Free Lime AliteBelitebLime Underburning…

24 Free Lime Excursion – Excess free lime in Kiln Feed

25 Summary ►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

26 Summary ►Raw Material monitoring/control at the Product stage allows optimum additive control. ►Limestone, Gypsum ►Quality Monitor “Like having my best lab guy working 24/7!”

27 Thank you! … Questions?

28 Continuous Material Analysis for cement production

29 Fuel


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