SpectraFlow On-Line Analyzer

Applications in the Cement Industry

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SpectraFlow Minerals Online Analyzer
Timeline

2006: ABB started development for near infrared online

Crossbelt Analyzer
2007 - 2010: First test and commercial installations in Cement & Iron
Ore applications in Europe & USA
2010: Development of Airslide Application
2011 - 2012: Commercial installations around the globe

2013: SpectraFlow Analytics incorporated as an independent

company & management buy-out of the NIR Online analyzer
technology from ABB

2013 - today: >45 orders received for Cement, Iron Ore, Bauxite, Platinum,
Gold clients globally, since 2016 approved supplier with
FLS

© SpectraFlow | Slide 2
 SpectraFlow Cement Analyzer
Objective and Benefits
▪ Process Improvement
▪ Stockpile Blending
▪ Raw Mill & Cement & Coal Mill Optimization
▪ Use safe and proven method
▪ NIR method uses no ionizing radiation – safety first
▪ Reliable systems for fast real time on-line analysis for
▪ Moisture, CaO, SiO2, Al2O3, Fe2O3, Corg, C3S, C2S, C3A, C4AF, Free Lime,
Organic Molecules
▪ Easy to use equipment
▪ Return on Investment Objectives
▪ Have a very low cost of ownership
▪ Extension of Quarry lifetime
▪ Reducing Fuel Costs
▪ Increased Raw Meal/Cement Quality

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 SpectraFlow On-Line Analyzer
A new development

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 SpectraFlow Cement Analyzer
NIR Analysis Technology

Rails for FTIR

lamp Spectrometer Entry lens of
positioning spectrometer

Light and
dust shield
Lamp

8 lamps 50
Watt each

Lamp holder
Bulk Material

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 SpectraFlow Cement Analyzer
Minerals have a NIR signature

Al2O3

SiO2

Fe2O3

CaO

Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970

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 SpectraFlow Cement Analyzer
Spectral information comparison
XRF PGNAA
▪ Discrete lines for
each element
▪ Calibration based
cps

cps
on integral
intensity of
elemental line

keV MeV

NIR
0.24
▪ Total information of the material
0.22
▪ Minerals and organic Molecules
Absorbance

0.20 ▪ Model based calibration for each element according

the occurance as a phase in the raw material to be
0.18
analyzed
cm-1

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 SpectraFlow Cement Analyzer
NIR Technology – Analytical Calibration Model
▪ Each of the measurements per sample
gives a spectrum.
▪ The chemical composition for each sample
is given by the laboratory analysis
▪ The final step is now to correlate, for each
constituents, the spectra with the
laboratory values. The procedure is called
multi-linear regression.
▪ The calibration models are loaded into the
SpectraFlow system and are ready to use
when the analyzer is delivered
▪ After 1 or 2 month of operation a fine
tuning is performed, possibly remotely and
does not require an engineer on site

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 SpectraFlow Cement Analyzer
Comparison of different analytical methods
XRF PGNAA SpectraFlow

Measurement method Off-line On-line On-line

Goal Quality Control by DIN/ASTM Process Control, Trending Process Control, Trending

Operational Expenses Medium High Low

Analysis Basis Electron Shells Nucleus Molecules and Minerals
Depends on calibration: F(WDX) or From Na (Cf source) or from O
Elements possible All elements incl. H, moisture
Na (EDX) (neutron tube)
Vacuum / Helium, sample
Dependency Belt speed, belt load No nonlinear layering
preparation

Analysis timeframe 40 – 60 Minutes Rolling average 1 Min. with avg. of 48 measurements

Depth of Analysis µm Up to 500 mm µm - mm

Area of measurement Laboratory Conveyor belt Conveyor belt, Air-slide

Reports Elemental Analysis Elemental Analysis Molecules and Phases

Low energy x-rays, local legal Ionizing radiation, legal

Safety No radiation at all, no legal requirements
requirements requirements!

Analytical precision Very High High to low depending on element High

Accuracy
Sampling acc. Medium to Low High High

Total accuracy Medium Medium to High High

Consumables X-ray tube Radioactive source or neutron tube Halogen light bulbs

Annual cost USD 40,000 – USD 60,000 USD 1,000 – USD 2,000

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 SpectraFlow Cement Analyzer
Comparison of different analytical methods
Advantages of NIR over conventional PGNAA analyzers:
→ Only online analyzer to evaluate raw meal and cement

→ Independent of specific element concentrations (e.g. Fe2O3)

→ Independent of belt load changes

→ No drift in the detector

→ Sampling point for XRF at same location

→ Analysis down to the PPM range, also of heavy metals, Hg, etc.

→ Actual 1 minute values

Advantages of NIR over Lab Automation:

More reactive in case of
→ High variation coming from the pile or additive

→ Small homogenizing silo

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 SpectraFlow On-Line Analyzer
Crossbelt Application

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 SpectraFlow Cement Analyzer
Position of Analyzer - Mine/Stockpile Optimization
Quarry / Area A Decision by quarry
Quarry / Area B Quarry / Area C
Limestone management
Clay Marl
or
Blending Software on
material demand

On-line analysis
Stockpile
Raw CaO
composition
Material SiO2
LSF, KH
delivery Al2O3
Tonnage
Fe2O3
NIR normalized
H2O
Analyzer

Crusher Belt scale Blending

bed

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 SpectraFlow On-Line Analyzer
Airslide Application

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 SpectraFlow Cement Analyzer
Position of Analyzer – Raw Mill Optimization

NIR
Blending Bed
Additives Analyzer
Airslide
Sampler
Raw Homo
Mill Silo
One

Sample transport
Analysis data analysis
Automatic set-points data
for on-line for weigh feeders by
analyzer every
blending software minute
comparison

(Semi) Automated Laboratory

Analysis Pressing Grinding

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 SpectraFlow Cement Analyzer
Position of Analyzer – Cement Mill Optimization

NIR
Analyzer
Airslide

Cement Mill
Cement
Silos

Online
Data
New Feeder Setpoints
in real time

Raw Mix Proportioning Control Software

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 SpectraFlow On-Line Analyzer
Hardware Installation

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 SpectraFlow Cement Analyzer
Crossbelt Analyzer Installation

Spectrometer
compartment

Illumination
unit and dust
protection
cover
Electronic
cabinet and
communication
unit
Mounting frame
supplied by the
customer

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 SpectraFlow Cement Analyzer
Airslide Analyzer Installation

Cooling system Spectrometer

compartment
Illumination unit
and dust
protection cover Inspection & cleaning
opening

Shutter Tight air seal

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 SpectraFlow Cement Analyzer
Analyzer Pictures

Spectrometer
Compartment

Service Flap
which can be
opened to
access the
lights
Overall view Service flap open
Entry for the
reflected Interfaces
Infrared into
Power Supply for
Spectrometer
the spots
Spots as Industrial PC
Infrared (IPC)
Sources View on rails and lamps Electronic cabinet
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 SpectraFlow On-Line Analyzer
Measurement results

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 SpectraFlow Cement Analyzer
Measurement Results for Raw Meal

CaO 44.00 2.50 Fe2O3

43.80 2.45
2.40
43.60
2.35
43.40 2.30
43.20 2.25
2.20
43.00
2.15
42.80 2.10

Al2O3 3.60 SiO2

14.00
3.50
13.80
3.40
13.60
3.30
13.40
3.20

3.10 13.20

3.00 13.00

XRF NIR

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 SpectraFlow Cement Analyzer
Measurement Results for Raw Meal
LSF comparison: set point vs. SpectraFlow vs. XRF
104.00
103.00
102.00
101.00
100.00
99.00
98.00
97.00
96.00
1
9
17
25
33
41
49
57
65
73
81
89
97

161
105
113
121
129
137
145
153

169
177
185
193
Set Points SpectraFlow XRF

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 SpectraFlow On-Line Analyzer
Operation Cost / ROI Objectivs

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 SpectraFlow Cement Analyzer
Maintenance
Weekly: Cleaning by compressed air (appr. 5 min)
Bi-Monthly: Referencing (appr. 20 min)
Annually: Changing of the source (light bulbs) (appr. 1 hour)

Under normal quarry conditions: no recalibration required

Remote service can cover 98% of all questions and assist local team in problem solving
Sources (light bulbs) are inexpensive and can be shipped internationally

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 SpectraFlow Cement Analyzer
Maintenance
Crossbelt Analyzer:
Client reference: appr. € 3.000 p.a.
(experience over 5 years)

Airslide Analyzer:
Client reference: appr. € 800 p.a.
(experience over 3 years)

NIR technology has the lowest operating cost for any kind of online analyzer

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 SpectraFlow Cement Analyzer
Case Study
Case Studies: Airslide Analyzer:
Improvement Kiln Feed : 0.7 LSF StDev

Assumptions:
▪ reduction of 1 LSF Stdev in kiln feed reduces 0.1 GJ/t clinker
▪ Daily clinker production: 6,000 tpd
▪ Kiln energy consumption: 2.85 GJ/t of clinker
▪ Price of fuel: €0.04 / l
▪ Cost savings in fuel €147’221 per year

Payback of the analyzer 2 years

Assumption: reduction of 1 LSF Stdev in kiln feed reduces 0.1 GJ/t clinker

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 SpectraFlow On-Line Analyzer
Benefits

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 SpectraFlow Cement Analyzer
Benefits
▪ No radioactive materials used
→ very low cost of operation and maintenance

→ no operational permits or extra personnel required

▪ Most accurate measurement for organic and inorganic constituents

→ Real time analysis of relevant operational parameters like CaO, SiO2, Al2O3, Fe2O3,
Cl, Hg, NaO, K2O, C3S, C2S, C3A, C4AF, Free Lime, Organic Molecules
▪ Independent of belt load changes
▪ Only analyzer for airslide application
▪ No sampling or by-pass required
▪ No re-calibrations required
▪ Low maintenance

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SpectraFlow Analytics Ltd
Haerdlistrasse 15 CH-8957 Spreitenbach
Tel: +41 56 406 12 12 Fax: +41 56 406 12 10
www.spectraflow-analytics.com
info@spectraflow-analytics.com