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ThyssenKrupp Polysius Page no. 1

Laboratory Automation Technology for optimized process control and utilization of alternative fuels

Shripad Vakil / Thomas Verspohl

Polysius IndiaA division of

ThyssenKrupp Industries India

8th Green Cementech 2012

Hyderabad, May 25th, 2012



Optimal Monitoring

Optimized Process

The Quality Control System



Quality Control - Requirements

� Monitoring and quality control of raw materials, intermediate products and finished product

Input Output

� Optimal use of raw materials and additives

� Reduction of fuel consumption



Quality Control – Routine Sampling Points

Hot mealfrom thehot mealchute

Clinkerbehind thecooler (orfrom the cooler)

Raw meal behindraw mill

Cementbehind thecement mill

Raw material

Raw meal at kiln feed



Sampling – Raw Meal and Cement

for raw meal and cement.Installation in a chute.

for raw meal and cement.Installation in an air slide.

Screw Sampler

Trough Sampler



Sampling – Hot Meal and Clinker

Hot Meal Sampler

Clinker Sampler

for hot meal sampling.- Max. temperature at sampler: 1100 °C- Closed circuit for cooling water- Sample output temperature <100 °C

Installation in Clinkerdischarge chute.



A Modern Quality Control System – Configuration

PGNAA

Labo

rato

ryP

lant

POLAB® Computer

AQC Software

Sample receiving andsample preparation

XRDXRF



XRF & XRD Analysis

Rietveldevaluation

C3S monoclinic (NISHI)C2S beta (MUMME)

C3A cubicC4AF Colville

LimeAnhydrite

GypsumBassanite Bezou

Mineralogical compositionXRD

Calibrationcurves

Pressedtablet

Al2O3Fe2O3CaCO3SiO2K2ONa2O3MgOSO3

Chemical compositionXRF



Quality Control – Sample Preparation for XRF & XRD

Sample

Vibratory disc millwith grinding aid dosing

Ground material Pressed tablet

Press



Sample Preparation for XRF & XRD - Requirements

XRF: required: High fineness avoid: Overgrinding

XRD: required: Crystallinity, homogeneity,avoid: Texture, preferred orientation, destruction of mineral structures

High demands on the sample preparation

Efficient grindingSmooth grindingControlled pressingReproducibility



Automatic Preparation Module

Sample preparationfor XRF and XRD

Optimised grinding vessel:Efficient grindingSmooth grinding

Adjustable pressing force andconfigurable pressure holding time:Controlled pressing

Programmable sample preparationprocedures:Reproducible sample preparation



Advantages

Minimization of the crystal destruction

- Higher peak intensity

XRD Gypsum peak - POLAB APM vs. Ordinary vibratory d isc mill

APM

Ordinary vibratory disc mill

0

2000

4000

6000

8000

10000

12000

11,2 11,4 11,6 11,8 12

2 Theta Degrees

Inte

nsity

(cp

s)



Mineralogical evaluations:

� Calculation with BOGUE formula is misleading

when alternative fuels are used

Rietveld

Bogue

C3S

[wt-

%]

no secondary fuelphotosewage +

waste oil

simplified from Neubauer 1997Möller 2002

50

85

samples

Bogue is based on the chemical composition

Rietveld is based on the mineralogical composition

The Quality Control System - POLAB ® APM



Grinding, pressingComposite samples Co-ordinating

Receiving,

sending, dosing

Quality Control System

Functions



Benefits of monitoring the clinker minerals

Control of the temperature profile in the preheater/kiln system

Optimization of the energy intake

Prevention of “Overburning”

Maximization of usage of alternative fuels

Control of the clinker properties for better grindability

Prediction of the 28-day compressive strength of the finished product

The Quality Control System - POLAB ® APM



Benefits for the Environment

Homogenous Raw Material Composition smooth kiln operation, less fuel consumption

Increased usage of Alternative Fuels less conventional fuel needed

Optimized usage of Fly ash, slag etc. less clinker has to be burned

Optimized free lime. less fuel needed

Raw Material preparation

Preheater

Kiln

Clinker Grinding



Conclusion

� Dedicated samplers: representative sampling

� Optimized sample preparation: reproducible analysis results

� Advanced quality control algorithms:high potential for process optimization

� Pneumatic tube system: fast and reliable sample transport

� Modular extendable system:Tailored to the requirements of each application

� Optimized usage of alternative fuels

� Reduced fuels consumption

� Smooth Kiln Operation



Factory Automation Systems

More than 40 YearsMore than 40 Years

Automation SystemsAutomation Systems

polysius india

Documents

green cemtech

pptthyssenkrupp polysius

sampling raw meal

sampling hot meal

quality control requirements

cementfor raw meal

optimized process control

xrf xrd requirementsxrf