Cementing more sustainable production
Meeting the demand for higher-quality cement while lowering production costs, using less energy, and generating fewer emissions, all at once? The cement industry is caught (appropriately enough) between a rock and a hard place.
‘Decarbonizing’ the industry requires a broad range of strategies – but one thing they all have in common is the need for rigorous process optimization. Automating process controls, for instance, can reduce waste, energy consumption, and overall costs, but implementing such strategies successfully calls for in-depth process and product analysis and the application of smart technology. When it comes to cement, particle size (fineness) and particle size distribution (PSD) can make or break the optimization process.
A SECURE FOUNDATION FOR SUCCESS
Both these parameters directly influence the cement’s physical and mechanical properties. When the particles are too fine (<2 μm diameter), the cement will set too fast and crack. Large particles (>32 μm), on the other hand, may not fully hydrate during routine use, reducing the strength of the final product. For optimum strength, cement producers should aim to have 50–70% of particles between 2 and 32 μm, depending on the intended grade of the final product.
And for that, they can’t just rely on the sample’s Blaine number: they need complete, accurate, and reliable PSD data, giving them better insight into the characteristics of the final product. Measuring PSD during production is a proven strategy for reducing variability, enhancing product quality, and – ultimately – delivering cost and CO2 reductions by enabling higher throughput, reduced energy consumption, and effective use of replacement materials.
INTRODUCING LASER DIFFRACTION
Fast, efficient, and reproducible particle size analysis for the determination of cement quality and strength starts with laser diffraction. This technique measures the intensity and angular dependence of scattered light as a laser beam passes through the sample, with large particles scattering light at small angles and vice versa. It therefore generates not an average value but a complete PSD, enabling optimal plant control.
Indeed, one major attraction of laser diffraction for the cement industry is that it can be implemented at- or on-line. This makes it relatively easy to apply lab-developed correlations to improve process efficiency and automate process control – with the benefits of increased throughput and reduced costs.
The power of laser diffraction technology
- Complete PSD data – from fine to coarse particles – with a single measurement
- Rapid analysis (lab: <1 minute; line: real-time)
- No calibration needed
- Exemplary reproducibility (<1% RSD)
- International standard defining performance characteristics (SO13320:2009)
- Full automation
- Lab-to-line application
- Minimal manual input required for analysis or maintenance
SYSTEMS FOR EVERY LAB AND EVERY LINE
From the laboratory to the process line, Malvern Panalytical offers a range of systems proven to enhance cement operations.
The latest generation of the world’s most popular particle sizing instrument, the Mastersizer 3000 incorporates expert engineering and applications know-how into every stage of its design, delivering class-leading particle sizing performance in a compact footprint.
- Reliable reference solution for your central/QA/QC lab, for all cement production samples from clinker and raw mix to finished product
- Easily integrated within an automated lab, so you can transfer your Mastersizer 3000 specifications closer to the line
Insitec Cement Labsizer
This robust, fully automated system moves particle sizing into the process environment. The Insitec Cement Labsizer delivers large sample-volume cement measurement, suitable for manual or automated plant laboratories or at-line measurement. Designed for minimal maintenance, it delivers high consistency and reliability, even in challenging plant environments.
- Tough enough to stand up to regular at-line use by process operators, even in dusty, noisy, vibrating environments
- Easily integrated within an automated lab
- Suitable for larger sample sizes
Insitec
Our process analyzer for integrated real-time measurement is designed from the ground up to fulfill the exacting demands placed on process instrumentation. Rugged, robust, and fully automated, the Insitec system is installed on-line and delivers accurate continuous particle size measurement that forms the ideal basis for automated plant control.
- Real-time measurement for continuous monitoring of the finishing circuit
- Optimum platform for automated process control
- Helps save energy and optimize your finish mill performance
A TOTAL SOLUTION FOR HIGH-TONNAGE SAMPLING
Just like particle size analysis, representative and repeatable sampling are also key to plant efficiency. For high-tonnage applications in plants where segregation of cement flow can’t be avoided, primary sampling systems are needed. At Malvern Panalytical, we collaborate with trusted engineering partners to provide the optimum sampling solutions for our cement customers.
With the industry under pressure to decarbonize, let our experts and instruments set up your cement operations for success – with no cracking in sight! Contact us today for more information about our systems and services.
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