QUALITY CONTROL

AND ITS IMPACT ON PLANT

PROCESS CONTROL
By

Anis HAIDER
President of ITECA

PROCESS CONTROL
IN A
CEMENT PLANT

1
 PROCESS CONTROL

It should never be underestimated that the

cement manufacturing process, is
essentially a mineral transformation
process, that needs to be monitored by
directly controlling the product at each
transformation stage

PROCESS CONTROL

TRADITIONALLY THE SAMPLES ARE

COLLECTED MANUALLY AND BROUGHT BACK
TO THE PLANT LABORATORY TO BE ANALYSED
MANUALLY FROM ONCE AN HOUR TO ONCE A
SHIFT

THE RESULTS ARE THE GIVEN TO THE PLANT

OPERATORS, SO THAT THEY CAN ADJUST THE
PRODUCTION PROCESS

2
 PROCESS CONTROL

WHAT ARE THE DRAWBACKS OF

THE TRADITIONAL METHOD :

LOW FREQUENCY

LARGE LAG TIME

HUMAN ERRORS

PROCESS CONTROL

CENTRALIZED AUTOMATIC
LABORATORIES

3
 Centralised Automatic Laboratory

Automatic Laboratory
Raw meal 1 Raw meal 2 Kiln Feed Hot Meal Clinker Cement 1 Cement 2

Field network

Transport
fan
FreeLimeAnalyser CarbonSulphurAnalyser

Toplantsystem
Gas Dust (LIMS,PLC,etc.)
(XRF/XRD) extraction
PSD
Technical room system
Workstation
Mill&
Instructionsto Press
rawmillweight Central
feeders control Vision
cabinet Software
Bridge
PSDAnalyser Workstation
XRF/XRD
Workstation Composite
samples Movable
RawMix XRF control
Control XRD Laboratory network console
Software

4
 On line Process Control

Precalciner
Cement
Additives Silo
Additives Blending Silos
Quarry
Raw Mill Clinker Cement
Preblending
Silo Mill
Cooler
Crusher Kiln

Chemical Loss on Gas Free Mineral Carbon Particle

Composition Ignition Sampling Lime Structure Sulphur Size
Al - Fe - Ca - Si - S - P - K
& Analysis

7/h 2/h Continuous 5/h Continuous 6/h Continuous

RAW MIX HOT MEAL CLINKER CEMENT

On line Process Control

Advantages over centralised automatic laboratory

Analysis at a higher frequency

o
energy savings and more stable quality

o Normally cheaper systems

o Simpler to operate

o Independent systems
no risk of having no analysis at all in the whole
plant

5
 RAW MIX CONTROL

Raw Mix Control

WHY CONTROL THE RAW MIX ?

Check the fineness, especially the %>90microns

The large particle typically come from quartz silica

that is hard to grind. If the %>90microns goes up,
the clinker will be harder to burn, and C2S (Belite)
will be present in clusters that will have an impact
on cement reactivity and strengths

6
 Raw Mix Control
WHY CONTROL THE RAW MIX ?
Check the LSF (Lime saturation factor)

A 1% change in LSF (at constant FCaO) corresponds to a 2% change in C3S

LSF should never exceed 100, as this will result in increase of FCaO
Higher C3S will result in more reactive cement, with higher early strengths
HardeningComparisoninKg/cm 7Days 28Days 180Days 365Days
AliteC3S 322 466 512 584
BeliteC2S 24 42 194 325

Changes in Raw Mix LSF should be maintained below 1%

Raw Mix Control

WHY CONTROL THE RAW MIX ?

Check the Silica Ratio SR (ratio of Si to Al and Fe)

If the Silica Ratio goes up for a given LSF, the C3S

will go up but less molten liquid will be formed
(less C3A and C4AF). So a dusty kiln, less coating,
and the clinker combination will be more difficult

Changes in SR should be kept below 0.1

7
 Raw Mix Control
WHY CONTROL THE RAW MIX ?

Check the Alumina Ratio AR (ratio of Al to Fe)

The Alumina Ratio determines the quantity of flux

or liquid formed at low temperatures (around
1330C) and also has an impact on cement (high
C3A will have higher heat of hydration)

Chnages in AR should be kept below 0.1

Raw Mix Control

TRADITIONAL CONTROL

TRADITIONALLY ONE HOUR COMPOSITE

RAW MIX SAMPLES ARE COLLECTED MANUALLY
AND BROUGHT BACK TO THE PLANT LABORATORY
TO BE ANALYSED ONCE AN HOUR

THE RESULTS ARE THE GIVEN TO THE PLANT

OPERATORS, SO THAT THEY CAN ADJUST THE
WEIGH FEEDERS THAT CONTROLS THE FEED
TO THE RAW MILL

8
 Raw Mix Control
What are the major drawbacks with the traditional
method ?

Non representative sampling system

Low frequency control

Long lag time

Human error

Raw Mix Control

What are the major drawbacks with the traditional
method ?
Frequency of control
100

LSF
1 HOUR

Change only every hour : large fluctuations

100
LSF

1 HOUR

Increased frequency : smaller fluctuations and target hit more often

Higher average LSF values higher C3S more reactive cement

9
 Raw Mix Control
Best location to take a sample
Precalciner

Blending Silos
Kiln Dust
Additives
Quarry

Preblending Raw Mill

Crusher Kiln

At the input of the feed to the blending silo including the

kiln dust where applicable, as :
this is the final product including kiln dust
takes into account the raw mill grinding circuit residence
time of the different raw material components

Raw Mix Control

Requirements for an efficient raw mix control system

Representative & reliable sampling system

High quality sample preparation

Repeatable & reliable analysis

High frequency control

10
 Raw Mix Control
Typical layout Major oxides quantification
+ raw mix control software
Automatic control of the weight
Sampling in a chute Sampling in an airslide feeders
Slot Sampler
Screw
Sampler

Mixing
Piston
Sampler

Mechanical
Transport

On site EDXRF
analyser

Up to 7 analysis
per hour To plant PLC or Raw
Mix Control
Up to 2 sampling Software:
points controlled Ca, Si, Al, Fe, etc.
with 1 single
analyser

Raw Mix Control Case Study

Automatic raw mix control system as
installed in a plant in India

Analyser Sampling

Sample Transport

11
 Raw Mix Control Case Study
Results 10:29:00
10:49:00
13,32
13,54
3,12
3,23
2,96
3,04
42,68
42,72
0,993
0,976
2,19 1,05
2,16 1,06
11:09:00 13,50 3,27 2,98 42,69 0,978 2,16 1,10
Raw mix Analyser(FX-3500)
Time 11:29:00 13,69 3,31 3,06 42,59 0,962 2,15 1,08

SiO2 Al2O3 Fe2O3 CaO LSF SM AM 12:16:00 13,36 3,06 2,96 42,77 0,995 2,22 1,03
12:30:00 13,85 3,34 3,09 42,54 0,950 2,15 1,08
00:17:00 13,82 3,25 2,91 42,99 0,966 2,24 1,12
12:50:00 13,56 3,18 3,05 42,59 0,973 2,18 1,04
00:37:00 13,60 3,08 2,82 43,05 0,987 2,31 1,09
13:10:00 13,70 3,26 3,03 42,64 0,964 2,18 1,08
00:57:00 13,71 3,21 2,83 43,16 0,979 2,27 1,13
13:30:00 13,76 3,34 3,06 42,48 0,954 2,15 1,09
01:17:00 13,61 3,11 2,81 43,01 0,985 2,30 1,11
13:50:00 14,03 3,34 3,11 42,46 0,937 2,18 1,07
02:05:00 13,94 3,25 2,86 42,94 0,959 2,28 1,14
14:10:00 13,72 3,31 3,11 42,47 0,956 2,14 1,06
02:25:00 13,69 3,24 2,86 42,77 0,970 2,24 1,13
14:30:00 13,74 3,13 3,09 42,43 0,959 2,21 1,01
02:45:00 13,44 3,06 2,80 42,28 0,980 2,29 1,09
14:50:00 13,75 3,34 3,03 42,45 0,954 2,16 1,10
03:05:00 13,67 3,19 2,77 42,99 0,979 2,29 1,15
15:10:00 13,61 3,23 2,90 42,72 0,974 2,22 1,11
03:25:00 13,42 3,20 2,76 42,79 0,990 2,25 1,16
16:06:00 13,45 3,18 2,83 42,76 0,987 2,24 1,12
03:45:00 13,86 3,27 2,77 42,79 0,961 2,29 1,18
16:26:00 13,61 3,28 2,81 42,81 0,976 2,23 1,17
04:05:00 13,49 3,23 2,85 42,42 0,975 2,22 1,13
16:46:00 13,74 3,10 2,79 42,87 0,974 2,33 1,11
04:25:00 13,76 3,35 2,91 42,78 0,963 2,20 1,15
17:06:00 13,73 3,33 2,80 42,80 0,967 2,24 1,19
04:45:00 13,31 3,30 2,92 42,58 0,987 2,14 1,13
17:26:00 13,43 3,15 2,75 43,11 0,999 2,28 1,15
05:05:00 13,80 3,26 3,14 42,36 0,950 2,16 1,04
17:46:00 13,66 3,21 2,77 42,79 0,975 2,28 1,16
05:25:00 13,25 3,35 3,07 42,17 0,978 2,06 1,09
18:06:00 13,54 3,17 2,73 43,08 0,991 2,29 1,16
05:45:00 13,69 3,39 3,11 42,62 0,959 2,11 1,09
18:26:00 13,62 3,10 2,81 42,82 0,980 2,30 1,10
06:05:00 13,46 3,13 3,11 42,62 0,981 2,16 1,01
18:46:00 13,62 3,18 2,87 42,85 0,978 2,25 1,11
06:25:00 13,73 3,41 3,17 42,68 0,957 2,09 1,08
19:06:00 13,56 3,27 2,89 42,63 0,974 2,20 1,13
06:45:00 13,62 3,35 3,15 42,54 0,962 2,10 1,06
23:03:00 13,45 3,18 2,85 42,98 0,992 2,23 1,12
07:05:00 13,76 3,45 3,10 42,81 0,958 2,10 1,11
23:23:00 13,62 3,24 2,92 42,84 0,975 2,21 1,11
07:25:00 13,70 3,30 2,97 42,64 0,964 2,19 1,11
23:43:00 13,63 3,09 2,89 42,98 0,982 2,28 1,07
07:45:00 13,75 3,27 2,92 42,88 0,967 2,22 1,12
Min 13,25 3,06 2,73 42,17 0,94 2,06 1,01
08:22:00 13,71 3,27 2,93 42,80 0,968 2,21 1,12
Max 14,03 3,45 3,17 43,16 1,00 2,33 1,19
08:42:00 13,59 3,09 2,85 42,78 0,981 2,29 1,08
Ave 13,63 3,23 2,93 42,72 0,97 2,21 1,10
09:26:00 13,52 3,22 2,81 42,96 0,987 2,24 1,15
Std dev 0,16 0,09 0,13 0,22 0,01 0,06 0,04
10:09:00 13,59 3,21 2,94 42,34 0,966 2,21 1,09

Raw Mix Control Case Study

Results

Raw Meal LSF value over 24 hours

sampled every 20 mn, with 0.97 Target
LSF Standard deviation < 0.01

12
 Raw Mix Control Case Study
Results

Raw mix Analyser(FX-3500) Raw mill Lab XRF (Bruker-S4) Kiln feed Lab XRF (Bruker-S4) CLINKER ANALYSIS in Lab XRF (Bruker-S4)

24 Hour LSF SM AM 24 Hour LSF SM AM 24 Hour LSF SM AM 24 Hour LSF AM SM

Min 0,94 2,06 1,01 0,96 2,07 1,05 0,96 2,16 1,06 0,92 1,20 2,09
Max 1,00 2,33 1,19 1,00 2,34 1,20 0,99 2,21 1,12 0,93 1,24 2,17

Ave 0,97 2,21 1,10 0,97 2,24 1,12 0,97 2,18 1,08 0,92 1,22 2,13

Std dev 0,01 0,06 0,04 0,01 0,07 0,04 0,01 0,02 0,02 0,00 0,01 0,03

The plant maintains a low raw mix

standard deviation despite having
diverse raw material sources

HOT MEAL CONTROL

13
 Hot Meal Control
WHY CONTROL THE HOT MEAL ?

Check the actual calcination value at the outlet of the

precalciner
In modern kilns 50 to 60% of the total fuel
consumption is burnt in the precalciner. The
temperature value that is traditionally used to
control fuel usage only gives partial information
on precalciner performance. Knowing the actual
calcination value, it is possible to optimize the fuel
input to obtain a consistent and stable process

Hot Meal Control

WHY CONTROL THE HOT MEAL ?

Check the actual Volatile Cycle in the kiln/precalciner

Control volatile cycle of : Sulphur, Chlorine, Alkalis

To either :

Adjust their content ratio in the fuel or raw meal mix

to avoid build up problems in the precalciner, and
optimize the Sulphur/Alkali ratio
Adjust the kiln by pass gas flow, when such
systems exist, so as to avoid wasting material and
loosing energy

14
 Hot Meal Control
TRADITIONAL CONTROL

TRADITIONALLY A SPOT SAMPLE IS COLLECTED

MANUALLY AND BROUGHT BACK TO THE PLANT
LABORATORY TO BE ANALYSED ONCE A SHIFT

THE RESULTS ARE THE GIVEN TO THE PLANT

OPERATORS, WHO TYPICALLY NEVER USE THE
INFORMATION TO CONTROL THE CALCINER ..

Hot Meal Control

What are the major drawbacks with the traditional method ?

Non representative sampling system

VERY Low frequency control

Long lag time

Human error

Data never actually used to control the process

15
 Hot Meal Control

Requirements for an efficient hot meal control system

Representative & reliable sampling system

Repeatable & reliable analysis

High frequency control (should be done at

least once an hour)

Hot Meal Control

Typical layout
Piston Sampler
PC303

Quenching
system

Sample short
distance Transport

To plant PLC :
Calcination value

Up to 2 analysis
per hour

Loss on ignition
analysis

16
 Hot Meal Control
Typical layout
Piston Sampler
PC303

Quenching
system

Sample short
distance Transport

To plant PLC :
Calcination value
Sulphur Content

Up to 4 analysis
per hour

Carbon Sulphur
Determination

Hot Meal Control Case Study

Automatic hot meal control system as
installed in a cement plant in India

LOI Analyser

CCR to control calciner

Hot meal
Sampler
+ Quencher

17
 Hot Meal Control Case Study
Automatic hot meal control system as
installed in a cement plant in India

Results
Date Time LOIAnalyserResult LabResult Variance
23.01.2013 15.26PM 97,32 97,51 0,19
15.56PM 97,90 97,89 0,01
16.26PM 98,28 97,98 0,30
16.56PM 97,74 97,72 0,02
Average 97,81 97,77 0,04

Data comparison between on line

analyser and plant laboratory

Hot Meal Control Case Study

Results

LOI value is monitored

every 30 mn
Fuel input to calciner
is adjusted based on
the actual LOI data
STABLE and OPTIMUM
calcination value

18
 CLINKER CONTROL

Clinker Control
WHY CONTROL CLINKER ?
Check the Free Lime Value (FCaO%)
-High free lime will have a negative impact on 28 day strengths.
Small hard burned free lime particles hydrate very slowly. They will
hydrate many days after being in contact with water, and double in
size, causing cracks in the concrete

- If the LSF is correctly dosed,

low free lime indicates that the
clinker has been hard burnt.
This results in large Alite
crystals, that are hard to grind,
and the cement has a lower
reactivity.

19
 Clinker Control
WHY CONTROL CLINKER ?
Check clinker mineralogy

Increased usage of alternative fuels, with high ash

content, heavy metal content, Chlorine and Sulphur
content, etc, will have a direct impact on clinker
mineralogy and therefore on cement quality.

Clinker Control
WHY CONTROL CLINKER ?
Use the data to optimize the kiln burner operation

HOURS

20
 Clinker Control
Free Lime and Kiln Data

A high frequency free lime measurement is required (< 20 mn)

Free Lime / Burning Zone T/ Kiln Amps and NOx are closely
correlated over the short term

Over the long term the relation between Free Lime / BZT/ Kiln Amps and
NOx changes

Clinker Control
Free Lime and Kiln Data

o Incremental instantaneous control based on NOx, BZT, Kiln

Amps or a weighted average of the 3

o Clinker is sampled as close as possible to the clinkering zone

and analysed with a high frequency

o Free Lime results are used to update the set points for each of the control
factors

21
 Clinker Control
TRADITIONAL CONTROL
TRADITIONALLY A SPOT SAMPLE IS COLLECTED
MANUALLY FROM THE COOLER DISCHARGE OR
FROM THE PAN CONVEYOR AND BROUGHT BACK
TO THE PLANT LABORATORY TO BE ANALYSED
ONCE AN HOUR

THE RESULTS ARE THE GIVEN TO THE PLANT

OPERATORS, WHO TYPICALLY ONLY USE THE
INFORMATION TO DECIDE TO BYPASS OFF SPEC
CLINKER

Clinker Control

What are the major drawbacks with the traditional method ?

Non representative sampling system

Low frequency control

Long lag time

Human error

Information is only a POST MORTEM

22
 Clinker Control
Best location to take a sample
Precalciner

Clinker
Silo

Cooler
Kiln

At the discharge of the kiln before the cooler as :

there is no lag time between clinker production and
sample collection
Coating being larger and not crushed at this point can
be removed selectively from the actual clinker

Clinker Control
Clinker sampling systems

Cooler
Kiln

Under
grate
Sampler
Cooler

Cooler
discharge
Kiln discharge Sampler

23
 Clinker Control
Sample Transport system

Bend

Receiving cyclone
Sending station
Diverter (several lines)

Clinker Control
Sample Transport system

24
 Clinker Control
Analyser using glycol extraction and conductivity

Analysis cell

Heating
Preparation Mixing of clinker + glycol
cell Conductivity measurement

CaO + (CH2OH)2 H2O + (CH2O)22- + Ca 2+

Clinker Control
At Line XRD Analyser

Solid state detector

Clinker is ground to fine powder

The sample is moving on a turntable
On line complete mineralogical
composition of the clinker is given
About 100g/min are analysed

25
 Clinker Control
At Line XRD Analyser

Typical installation

It is possible with this analyser to

determine all the phases of clinker
determine the real clinker quality, not the
one calculated by Bogue
increase the use of alternative fuels, and
determine their effects on clinker on a real
time basis

Clinker Control Case Study

Automatic free lime control system as
installed in a cement plant in India

CCR to control kiln pyroprocessing

Kiln discharge Sampler

Free Lime Analyser

Free Lime data

26
 Clinker Control Case Study
Results

The plant managed to optimize

the free lime value and maintain a
low standard deviation
Average = 1%
Std dev = 0.1%

In case of upset conditions, the

plant can catch the off spec
clinker immediately before it goes
into the clinker silo

Clinker Control Case Study 2

Free Lime and Kiln Data

US Plant With 2 wet kilns % free lime

1
0,9
0,8
% Free lime

0,7
0,6
0,5
K-1
0,4
0,3
K-2
0,2
0,1
0
1 2 3

Date

1 : Analysis not used to control the kiln (over burnt clinker)

2 : Manual control of kiln using free lime (higher free lime rate but unstable)
3 : Kiln Expert System connected to the analyser (stable and higher free lime rate)

27
 Clinker Control
Savings
Direct Savings
A 0,5 % increase in free lime results in :

15 Kcal / Kg CK of fuel savings

1 KWh / Ton CK of electricity savings

Indirect Savings
Manual analysis labour cost

Cost of handling production rejects

Post production incident costs

CEMENT CONTROL

28
 Cement Control
WHY CONTROL CEMENT ?
Check the Gypsum Content (CaSO42H2O)
Gypsum is the set retarder for Ordinary Portland Cement (OPC).
Without gypsum, ground clinker exhibits flash setting in a few
minutes, due to the rapid hydration of calcium aluminates
SO3 Settingtime,min Compressivestrength,Mpa Heatofhydration,Kcal/kg
percent Initial Final 1day 3day 7day 28day 12hour 1day 3day 7day 28day
1.80 115 150 17.7 37.4 53.8 61.6 22.5 33.2 45.4 59.3 67.2
2.10 130 165 20.9 40.2 59.0 65.4 28.2 33.2 44.5 63.0 65.7
2.40 135 180 20.9 32.1 47.8 62.0 46.0 54.2 63.2 80.3 88.5

But gypsum also has an impact on strength and heat of hydration.

If gypsum content is too high the heat of hydration will increase
and strengths will decrease

It should therefore be maintained within a narrow tolerance

Cement Control
WHY CONTROL CEMENT ?
Check the Limestone Content (CaCO3)

Optimize limestone content, as per regulatory norms

It should therefore be maintained within a narrow tolerance.

Limestone being much cheaper then clinker, limestone usage
when allowed should be maximized

29
 Cement Control
WHY CONTROL CEMENT ?
Check Cement Fineness

Cement fineness has a direct relation with concrete performance:

Early strengths
Heat of hydration
Long term strengths

Cement Control
WHY CONTROL CEMENT ?
Check Cement Fineness
- Electrical energy used in the grinding process accounts for 1% of the
worlds energy supply
- Milling is very inefficient: < 5% of energy goes into size reduction, the
rest is wasted as heat

A balance has to be struck between :

Over grinding results in high milling costs and creates
an excess of particles < 2 mm
This leads to the cement curing exothermically, setting
too fast (cracking) and increases water demand
And
Under grinding where particles > 32 mm are not being
fully hydrated even after long curing periods thus
reducing the final strength

30
 Cement Control
TRADITIONAL CONTROL
TRADITIONALLY A COMPOSITE SAMPLE IS COLLECTED
MANUALLY FROM FEED TO THE TRANSPORT SYSTEM
TO THE CEMENT SILOS AND BROUGHT BACK
TO THE PLANT LABORATORY TO BE ANALYSED
ONCE AN HOUR

THE RESULTS ARE THE GIVEN TO THE PLANT

OPERATORS, WHO USE THE INFORMATION TO ADJUST
THE SEPERATOR AND THE CEMENT MILL WEIGH
FEEDERS

Cement Control

What are the major drawbacks with the traditional method ?

Non representative sampling system

Low frequency control

Long lag time

Human error

Blaine values are used for fineness control

31
 Cement Control
Blaine Values

2 samples each with same area but a different particle size distribution

Cement Control
Blaine Values

Blaine number is not a reliable parameter

(especially for blended cements)!!
Identical Blaine number but very different behaviour regarding curing and
thus final mechanical properties

32
 Cement Control
PSD Values

High heat of hydration

Contribution to early
strength
Contribution to late
strengths < 32 microns

Zero contribution to
strengths > 32 microns

Using PSD values it is possible to optimize and stabilize the required

cement properties

Cement Control
Best location to take a sample

At the outlet of the cement grinding circuit before the

transport system to the cement silos as :
this is the final product, including cement dust

33
 Cement Control
C/S Analyser
Sampling in a chute Sampling in an airslide

Slot Sampler
Screw Sampler

Piston
Sampler P11

Screw sampler
Mechanical
Transport To plant PLC :
Limestone &
gypsum rates
Analyser CO2/SO3

Variable pitch = sampling on the whole

cross section of the chute
better representativity

Cement Control
C/S Analyser

- Analyser dedicated to cement

process control
200 crucible - 1 analysis / 10 min
storage system

34
 Cement Control
C/S Analyser

Quantification of limestone & gypsum additives

Optimisation of cement composition

Cement Control
PSD Analyser

Laser diffraction

35
 Cement Control
PSD Analyser
Vertical
chute at
classifier
outlet
Sampling in a
Sampling
vertical chute
system

On line PSD

Cement Control
PSD Analyser

Scheme Vertical
chute at
separator
outlet
On Line PSD

Sampling
system

36
 Cement Control
PSD Analyser

Continuous measurement:
results on a real time basis: %>X m, Dv(X), Blaine number, particle size distribution
15 kg/h of cement are analyzed: representative sample

Cement Control
PSD Analyser

Classifier can then be monitored close to the specification limits

Energy savings on grinding operation

37
 Cement Control Case Study
PSD Analyser
Cement plant in the UK
Product specification change with off line analysis

PSD data not available to the operator during the change from OPC (Ordinary
Portland Cement) to RHPC (Rapid Hardening Portland Cement)
Blaine manual analysis
3 hours required to reach the required specifications
Loss of 100 T of cement!!

Cement Control Case Study

PSD Analyser
Cement plant in the UK
Product specification change with on line analysis
Product change
In spec material
360 500 m2/kg

PSD data available to the operator during the change from OPC (Ordinary
Portland Cement) to RHPC (Rapid Hardening Portland Cement)
Less than 30 min required to reach the required specifications
Savings on purging time

38
 Cement Control Case Study
PSD Analyser
Cement Plant in USA

Summary of the impact of automated control and real time particle size
measurement on production parameters
Before high level After high level With high level
control control, without control and on
on line PSD line PSD

Bucket elevator pwer (kW)

Average 48 60 69
Std. Dev. 3,81 2,35 3,33
Seperator speed rpm
Average 1414 1536 1476

Implementation of a High Level Process Std. Dev. 40 45 22

Control System with an online PSD : Total feed rate (tph)

Average 118 127 136
20.3% Reduction in specific energy
Std. Dev. 4,2 5,7 3,8
consumption
Mill power (kW)
15% throughput increased Average 4884 4902 4468
15% increase in 1 day strength Std. Dev. 21 13 19

10% reduction in Blaine kWh/t 41,8 39,1 33,3

One day strengths (psi)
C3S Concentration decreased
Average 2125,49 2176;54 2454,35
Water demand of cement is stable and low C3S (%)
Average 60,22 61,21 59,69

PROCESS CONTROL
Conclusions

oQuality control data should be used to actually optimize the cement

manufacturing process and not only be used for post portem reporting

o More accurate & higher frequency results, means that it is

possible to better control the process, and therefore
improve quality AND save energy costs

o Most of these solutions have a fast payback < 1 YEAR

39
THANK YOU FOR YOUR
ATTENTION

40