Why Aeris is a gamechanger for quality control
Quantitative phase analysis (QPA) is a key quality control analytical method for mining, steel, aluminum, and cement plants worldwide. By identifying crystalline phases in a material, its composition – and value – can be defined quickly and precisely. The importance of accurate phase quantification is that small variations in material composition can result in substantial losses of valuable products, energy, or processing time. QPA, therefore, can have a direct impact on the financial success of a production facility.
Reproducible sample handling, accuracy in measurement, and a consistent approach to analysis are all the responsibility of QC managers because better data can help the business design, improve, and make processes more efficient. Similarly, accurate testing is vital to assess raw materials, sign off the product, and broker the optimum value at both ends of the value chain.
As a result, choosing the right instrument for QPA is an important responsibility. In this blog, we’ll outline why the Aeris XRD is a great choice for QPA across the primary materials industry, providing high degrees of precision in a practical, easy-to-use format.
The applications of quantitative phase analysis
Quantitative phase analysis identifies the composition of the sample. The application details vary between industries, but the fundamental principles remain the same. Most inorganic solids are polycrystalline, meaning they are composed of atoms and molecules that are arranged in many different structures or phases. Each crystalline phase is an identifiable different material. Furthermore, the relative quantities of each phase in a multiphase material can be ascertained.
Most of the time QPA is used to measure material composition to adhere to a processing ‘recipe’ and therefore generate the final product for which QPA is also used to ‘pass-fail’ the final material. Measuring and responding to material composition deviations early enough in a process can prevent ‘fails’ at the final quality control measurement thus making savings in the manufacturing cost.
Measuring incoming raw materials can enable process engineers to mix them appropriately with other materials and adhere to the required recipe. Measuring compositions can enable process engineers to predict energy requirements, and data scientists to track and predict the final product performance.
The link between QPA and production profit changes depending on the application; In mining, this can indicate how much it will cost to mine, crush, and grind an ore. In cement production, QPA of inputs and outputs is key to ensuring the long-term structural resilience of the cured cement. In metals refinement, QPA is needed to ensure the metal reaches the required composition for target certification, such as the quantities of ferrite or austenite in steel.
What’s the best choice for quantitative phase analysis?
Precision is the highest priority when selecting a method for QPA, but there are other factors to consider. Some have to do with the analysis itself, such as the speed of the analysis and its cost – does it require extensive and expensive sample preparation? The human factor is also key: is the technique easy to use reproducibly, or does it require a specialized operator?
Many cement, metals, and mining plants are in increasingly remote locations, so there is a growing emphasis on simplifying the QPA technique and using automation. In this context, X-ray diffraction with the Malvern Panalytical Aeris system emerges as a powerful solution to QPA needs across many industries.
Enhance your quality control with Aeris XRD
The Aeris achieves precision through its high-quality components such as the PIXcel1D detector. If there are specific requirements due to materials composition types, its modular build means you can easily augment your instrument with plug-and-play attachments like the 1Der detector.
The customization opportunities don’t stop there. There is a range of possible configurations and even models designed with the standards of specific industries in mind, like the Aeris Cement and Aeris Metals editions. And if you’re looking for automation, Aeris’ sample loading mechanism enables samples to be queued on a sample changer or presented in a belt automation system.
Beyond precision, the purpose of Aeris is to simplify the tasks of its operators. With RoboRiet software, composition analysis can be automated and provides QC pass-fail or trend analysis. The main technical lead can utilize expert-level access to specify measurement and analysis routines which are used in a protected push-button workflow by inexperienced users. With OmniTrust, data auditing and compliance with industry regulations is enabled. On top of that, Smart Manager provides continuous monitoring of system health to streamline maintenance and maximize instrument uptime.
Why choose Malvern Panalytical?
The Aeris system combines the insights we’ve drawn from over 80 years of experience in XRD instruments. From stable goniometers and the latest robotics to the integrity of our data collection software and analysis software packages, we innovate on what works well to bring you a simplified and streamlined workflow. With a compact format and low cost of operation, Aeris is a highly profitable addition to any mining, cement, catalyst, or metal refining plant.
If you’d like to discuss the benefits of Aeris further or even book a personal demonstration, please contact our experts today.
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