We’ve found that our cement production articles are some of the highest viewed content on our blog site. So, we’ve put together a list of our blog articles related to the cement production process and analysis. Here are a dozen of our most read cement articles, in no particular order:
Are You Mining Minerals for Cement, or for Concrete? Many people use the words cement and concrete interchangeably. However, these are actually two, somewhat different things. Cement is the grey powdery stuff that when mixed with sand, rock, gravel and water forms concrete. The concrete is the final product used in buildings, roads, infrastructure, etc. You can think of cement as the “glue” that holds the sand and gravel and re-bar (reinforcement bar) together to make concrete.
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PGNAA Improves Process and Quality Control in Cement Production.
Traditional cement plants conduct material analysis by taking samples from a transfer tower to a lab for analysis. PGNAA analyzers are online systems installed on the conveyor belt, so materials are measured continuously and in real time with much better representation. Errors associated with off line sampling are eliminated and the raw materials can be sorted and blended correctly. Eliminating the tower also reduces construction and maintenance costs and downtime from tower issues. PGNAA data can be combined with XRF lab results for improved process optimization. Read the story of a cement processing plant that installed a cross belt analyzer with PGNAA technology to optimize their operational efficiency and product quality.
Can an online analyzer help reduce energy consumption of the cement plant? Kiln feed material with high chemistry variations requires more fuel in the kiln to properly react and more energy at the finish mill to grind over-reacted clinker. By using an online analyzer to minimize chemistry variation, fuel and energy consumption can be reduced and process upset conditions avoided.
Where should I place an online cement analyzer to help ensure consistent raw material quality? When considering where to place an online analyzer, discuss key application parameters and process goals including stockpile blending, sorting, raw mix proportioning or any additional installation locations with the manufacturer’s representative or application specialist.
Increasing Clinker Quality through Automation.
Clinker quality depends on raw material composition. If the raw materials are inappropriate, or if they are blended improperly, buildings and roads made from the concrete will have poor strength and durability. Because consistent clinker quality is so critically important in making high-performance concrete to avoid devastating building failures, cement manufacturers are investing in new technology to improve the process.
Combine Online and Lab Analysis for Optimal Cement Stockpile and Raw Mix Chemistry. Watch this recent webinar, Cement Online Analyzer Performance and Calibration, for a complete overview of how these powerful technologies can work together to provide consistent kiln feed, greater throughput, streamlined processes, and more comprehensive analysis.
VIDEO: FLUXANA Meets Cement Clients’ Needs With Wavelength-Dispersive XRF. FLUXANA’s clients are moving away from wet chemistry analysis and toward XRF technology, so they are increasingly demanding easy-to-use instrumentation that achieves the production control they need. Watch this 5-minute video interview where Dr. Rainer Schramm, Managing Director of FLUXANA, describes his experience using a newly-designed XRF spectrometer for high-precision analysis.
15 Frequently Asked Questions about Cement Analysis. Process control, constant monitoring of cement production, and analysis of the data is needed to help ensure quality products reach the customer. In addition, proper analysis coupled with actions taken as a result of the data, can help lengthen the life of the quarry, reduce fuel consumption , incur less waste, and minimize raw material costs – all of which affect your bottom line. Here’s are answers to your questions so you can make the most of your cement process.
XRF Helps Bring Alternative Fuels to the Cement Industry. The chemical composition of alternative fuels determines their performance as well as their pollution potential. Elements such as chromium (Cr), cobalt (Co), nickel (Ni), vanadium (V), zinc (Zn), tin (Sn) and antimony (Sb) contribute to fuel efficiency by providing transfer mechanisms into the clinker and surroundings.However, alternative fuels can also contain toxic elements such as lead (Pb), cadmium (Cd), mercury (Hg) and thallium (TI) that could affect kiln performance or pollute the environment. Thus knowing the exact chemical composition of alternative fuels is a critical but extremely challenging part of the cement production process.
Can Stockpile Chemistry be Controlled to Meet Cement Quality Targets if there are Chemistry Variations Across an Entire Quarry? Whether the stockpile is longitudinal or circular, online cement analysis systems allow consistent stockpiles, with minimal variations within and between piles. The analyzer can track the chemistry of the stockpile compared to the target chemistry and determine the preferred proportions of the source raw materials.
XRF/XRD Combined Instrumentation Can Provide Complete Quality Control of Clinker and Cement. Clinker is ground to a fine powder in a cement mill and mixed with gypsum to create cement. The powdered cement is then mixed with water and aggregates to form concrete that is used in construction. The composition of clinker, such as free lime, has to be closely monitored to ensure the quality of the cement. Excess free lime results in undesirable effects such as volume expansion, increased setting time or reduced strength. Free lime must be monitored constantly during the process to allow the operator to determine and maintain the optimum operating temperature of the kiln in order to obtain maximum reactivity and to reduce thermal consumption. When reactivity is increased, grinding of the raw meal, and therefore energy, can be reduced.
VIDEO: Elemental Analysis for Cement. In this animated video, you’ll see how continuous online analysis of raw materials used in making cement is done. The online elemental analyzer provides chemistry analysis every minute to allow quick and accurate changes to be made to the process, so consistent raw material quality results with minimal deviation.
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