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Christian Potocan 2013-11-28
SpectraFlow Online Analyzer
Cement Application
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
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.
January 11, 2017 | Slide 3
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
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
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
NIR Technology - Principle of the measurement
FTIR
Spectrometer
TCP/IP Connection to RMP
Input Lens, which ascertains
parallel beams inside
spectrometer
Lamp shining at
the material
Belt
Conveyor/Airslide
© SFA Ltd.
28/11/2013 │ Slide 7
Light Paths
Industrial
PC with
Soft PLC
Lamp shining at
the material
Raw Material/Meal
Model development - The Principle
TRAINING
=
CALIBRATION
CaO 45.50 %
SiO2 10.95 %
Al2O3 3.3 %
Fe2O3 0.66 %

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
Model development - The calibration process
© SFA Ltd.
28/11/2013 │ Slide 9
•
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
Comparison of different analytical methods
XRF
PGNAA
SpectraFlow
Measurement Method
Offline
Online
Online
Source of Energy
X-Ray Tube
Radioactive Source
Lightbulbs
Analysis Basis
Elements possible to
measure
Dependency
Electron Shells
dependent on Calibration: from
F (WDX) or Na (EDX)
Vacuum, Sample Preparation
Nucleus
from Na (Cf source)
(neutron tube)
Belt Speed, Belt Load
Molecules, Mineral Phases
Depth of Analysis
µm
Up to 500 mm
µm - mm
Measurement Principle
Possible Measurement
Positions
Reports
Reflexion
Transmission
Reflexion
Conveyor Belt
Conveyor Belt, Airslide
Elemental Analysis
Elemental Analysis
Mineral Phases, Oxides
Repeatability
Fair to Good
Poor
Good
Measurement time
Analytical
Error
Sampling
Accuracy
Error
Seconds
Minutes
high to low dependent on
Element
Seconds
high to very high
low
very low
high to very high
low
very low
X-Ray tube
Radioactive Source
light-bulbs
Total Error
Consumables
© SFA Ltd.
28/11/2013 │ Slide 10
very low
from O
all elements: including H
no nonlinear layering
low
SpectraFlow - Position in Cement production process
SPECTRAFLOW
AIRSLIDE
SPECTRAFLOW
CROSSBELT
Blending Bed
Homogenizing
Silo
Raw
Mill
SPECTRAFLOW
AIRSLIDE
Kiln (Clinker)
© SFA Ltd.
28/11/2013 │ Slide 11
Cement
Mill
Cement
SpectraFlow – Crossbelt Application
FTIR Spectrometer
Light and dust
shield
Lamp
Use 4 lamps 50 Watt
each
Bulk Material
© SFA Ltd.
28/11/2013 │ Slide 12
Lamp holder
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
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
SpectraFlow – Airslide Application
Illumination Head
© SFA Ltd.
28/11/2013 │ Slide 15
Spectrometer Box
SpectraFlow – Airslide Application – Raw Mill Optimization
SAMPLING
SPECTRASTATION
FLOW
Blending Bed
Silo
KILN FEED QUALITY AT THE RAW
MILL WITHOUT ANY SAMPLING
Raw
Mill
D
A
T
A
O
N
L
I
N
E
S
A
M
P
L
E
SPECTRAFLOW
PRESSING
GRINDING
AIRSLIDE
ANALYZER
AUTOMATIC
LABORATORY
MEASURING
© SFA Ltd.
28/11/2013 │ Slide 16
ADJUSTMENT
EVERY 3-5
MINUTES IN
REAL TIME
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
SpectraFlow – Airslide Application – Cement Mill
Optimization
SPECTRAFLOW
Cement
Mill
D
A
T
A
Cement
O
N
L
I
N
E
SPECTRAFLOW
AIRSLIDE ANALYZER
© SFA Ltd.
28/11/2013 │ Slide 18
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
SpectraFlow – Result Comparison – SF vs PGNAA
SiO2
CaO
51
21
49
19
47
17
45
15
43
13
41
11
39
9
37
7
5
35
2008-10-21
19:45
2008-10-21
20:42
SOLBAS Training Set
2008-10-21
21:40
Gamma Metrics
2008-10-21
22:37
2008-10-21
23:34
2008-10-21
19:45
2008-10-21
20:42
SOLBAS Training Set
SOLBAS Test Set Prediction
2008-10-21
21:40
Gamma Metrics
2008-10-21
22:37
2008-10-21
23:34
SOLBAS Test Set Prediction
Fe2O3
Al2O3
5
9.5
4.5
8.5
4
7.5
3.5
6.5
3
5.5
2.5
4.5
3.5
2
2.5
1.5
1.5
1
0.5
0.5
2008-10-21
19:45
2008-10-21
20:42
SOLBAS Training Set
© SFA Ltd.
28/11/2013│ Slide 20
2008-10-21
21:40
Gamma Metrics
2008-10-21
22:37
2008-10-21
23:34
SOLBAS Test Set Prediction
2008-10-21
19:45
2008-10-21
20:42
SOLBAS Training Set
2008-10-21
21:40
Gamma Metrics
2008-10-21
22:37
2008-10-21
23:34
SOLBAS Test Set Prediction
SpectraFlow – Result Comparison – SF vs XRF
+ = Sampling Station value 40 min
line = SpectraFlow value 1 min
Highly visible dynamic in a
very narrow range between
41.8 and 43.1 % CaO
CaO
SiO2
Al2O3
Fe2O3
© SFA Ltd.
27/11/2013 │ Slide 21
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
Reference List
© SFA Ltd.
28/11/2013 │ Slide 23
SpectraFlow Analytics Ltd
Seestrasse 14b CH-5432 Neuenhof
Tel: +41 56 406 12 12 Fax: +41 56 406 12 10
www.spectraflow-analytics.com
info@spectraflow-analytics.com