Process control
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Stepping up to optimal control
Consistent control of the finish grinding circuit at a precisely defined set-point will give superior product quality at a competitive cost. Key to achieving this goal is:
- Sensitive, reproducible particle size measurement in a process relevant time frame
- A detailed understanding of how different control parameters impact product quality
- An effective control strategy
Laser diffraction particle sizing technology is harnessed via off-, at-, in- or on-line analytical solutions. Options for control therefore range from manual manipulation on the basis of routine off-line measurement to fully automated multivariate control driven by continuous real-time analysis. Automating both analysis and control requires an investment of time and capital, but the potential economic rewards are high.
Malvern provides a comprehensive, integrate approach for cement producers looking to improve process control:
- Specifications transfer from off-line systems in the laboratory to at- and on-line analyzers working in the process environment
- Trials using a mobile real-time analyzer, coupled with expert-led consultancy, allow detailed calculation of the economic benefits of switching to continuous measurement
- Real-time process solutions are designed to meet the rigors of cement manufacture and have proven operational reliability in the field
- Results reporting is individually tailored to each manufacturer and/or reported in the form of Blaine numbers for easy acceptance
Whatever the current analytical and operating regime Malvern has the knowledge and experience to evaluate the potential benefits of a change, and provides the tools to make it happen.
In this section
Maximise the benefit of off and at-line system - exploit the understanding generated by particle size distribution measurement
Fully automated off-line laser diffraction systems deliver highly reproducible particle size measurements for cement. Unlike Blaine measurement, which provides a single averaged figure for each sample, laser diffraction delivers complete size distributions. These data can be used to develop correlations between specific size fractions and strength, and provide more sensitive, reliable information for process control. At-line measurement integrates analysis more closely with operation, making the analytical regime more responsive to processing needs. Regular, highly reproducible analysis provides a sound basis for process control and opportunities for automation.
Full automation with on-line particle fineness - optimal control on the basis of real-time process insight
On-line real-time particle size measurement makes it easier to manually control the grinding circuit effectively, even through transient periods of operation such as start-up or grade change. However, the full benefits of continuous measurement are realized through automated multivariate process control. A well-designed, optimally tuned system keeps the plant operating at an economically advantageous set-point, with no manual input, delivering maximum cost benefit.
Evaluate potential savings - Confidently estimate ROI before making a change
An investment in process instrumentation is ranked and justified according to company-specific CAPEX criteria. This makes it essential to confidently quantify rather than qualify potential payback. Malvern offers tools to assist, including: expert sector knowledge, consultancy with an in situ technology trial, and a spreadsheet for systematic evaluation of the potential upside.
More Information: Consultancy Service
