Unleashing the triple impact of automation on cement production
The cement industry is on a journey, and by the time it reaches its destination, it will have changed for good. The destination? A world built on ‘green’ cement.
Environmental sustainability and cost-efficiency can seem like two signposts pointing in opposite directions. Which one should we follow? But as the cement industry stands at this crossroads, there’s one path that will lead you to both: the pathway of laboratory automation.
Welcome to the automated laboratory
If we take this path, we’ll arrive at a bustling cement plant where the rhythm of automation hums along, executing tasks with precision. This is the automated laboratory. From sample preparation to transportation, and from analysis to result validation and distribution, every process runs like clockwork without human intervention (or human error!). The result? Greater repeatability, lower costs, and a step into a future where the cement industry can truly aim for more ambitious KPIs.
For example, more efficient and highly accurate automated analysis will make it easier to reduce CO2 footprint by using low-clinker cements or using alternative fuels to heat the kiln, as these materials need careful control to avoid unintended effects on quality. Automated analysis also enables manufacturers to save energy while grinding cement, based on particle size distribution, and to preserve resources while using recycled materials, based on chemical composition analyses. This is the triple impact of automation: simultaneous environmental, economic, and performance benefits!
Materials matter
So, let’s look around this automated laboratory. Our first stop is raw material analysis, where the Zetium X-ray fluorescence (XRF) system characterizes major and minor oxides, such as limestone, clay, sand, and bauxite. For superior accuracy, samples are prepared as fused beads with the LeNeo, Claisse Eagon 2, or the brand-new FORJ Claisse Technology fusion instruments.
Also at this stage, the CNA Pentos-Cement vigilantly monitors the material stream with PFTNA technology. Installed directly on the conveyor belt, it acts as the plant’s ever-watchful eyes, collecting real-time data from all the material on the belt without any need to take samples.
Combined with appropriate mix control software, implementing a CNA Pentos-Cement can significantly reduce the stdev lime saturation factor (LSF) of the kiln feed, often achieving a standard deviation approaching 1%. This enables significant energy savings thanks to optimized raw meal feeding the kiln, and even has effects later in the process by producing clinker with less CO2 emissions. These savings can be reinvested into higher productivity, directly increasing profitability.
As an additional bonus, coupling the Zetium XRF and the CNA Pentos cross belt analyser using the O_Blend (see webinar here) software delivers highly accurate data in real time, so that if something is wrong, it can be fixed immediately without waste or downtime.
Combining solutions for next-gen accuracy
As we move forward, we find ourselves in the realm of clinker analysis. Here, the Zetium XRF and the Aeris-Cement XRD systems join forces. Their combination empowers us with a thorough understanding of the clinker, helping to manage alternative fuel or raw material variability effectively, and ensuring its reactivity is always at its best.
Next, we arrive at the cement quality control stage, where the powerful duo of Zetium and Aeris-Cement make another important appearance. Here, they provide a comprehensive automated analysis of sulfates and the composition of blended cements, including ‘low-CO2‘ additives, also called supplementary cementitious materials (SCMs), such as fly ash, granulated ground blast furnace slag, calcined clays, and more. With this knowledge, cement producers can create high-quality, environmentally-friendly cement.
The final stop on our tour brings us to the last grinding steps – the domain of the Insitec particle size distribution analyzer. Particle size distribution is key to cement’s performance, and here it is meticulously monitored. With real-time measurements, this tool assists in optimizing the grinding process and reducing variability – improving the quality of cement and enabling substantial energy savings.
Making the future a reality
Each of these stages is characterized by a blend of advanced sensors, world-class analysis, and smart interfacing and connectivity. With these elements, the cement plant of tomorrow – an ‘Industry 4.0’ plant – becomes a reality, bringing to life automation’s triple benefits of environmental, economic, and performance improvements.
On the journey toward ‘green’ cement, automation is the straight path that leads to a future of efficiency, sustainability, and advanced tech. Are you ready? Let’s go!
Talk to an expert today and unlock the power of automation in your analytical systems – we’re ready to help!
Explore our solutions for the cement industry on our industry hub here.
Further reads
- Turn clays, slag, ash, and fumes into green cement: what a 1Der!
- Combine unparalleled accuracy and repeatability with heightened productivity: FORJ Tray Loader and NWA Injector Options
- Try a synthetic CRM for cement sampling
- Cementing more sustainable production
- 10 rock-solid reasons to trust Mastersizer 3000