Plant optimization and control using continuous on-line XRD for mineral phase analysis

Traditional control of the cement manufacturing process from the point of v iew of cost, quality and total optimisation has been based on batch-wise sa mpling and testing of material streams, thereby instigating control actions (changing set points) with considerable lag time. These methods have sever e limitations in their ability to reduce plant fluctuations and achieve opt imised operation. Furthermore, the most significant information for plant a nd final product performance - the mineralogical composition of raw materia ls, clinker cement, gypsum and other materials - has not been available to the plant operator for plant control purposes. A new development has produc ed a continuous on-line mineral analyser using XRD to analyse the various m ineral phases present in dry materials (clinker cement or raw materials) in virtually real time with great accuracy. The ability to analyse a sample s tream continuously for alite, belite, aluminate, ferrite. dihydrate, hemihy drate, anhydrite, limestone, free lime, portlandite or any other phase of i nterest, has major implications for control of the cement manufacturing pro cess. The benefits will come from optimising the total plant based on the v olume of new information generated predicting cement performance as it is b eing produced, controlling to required performance at minimum cost, and bet ter quality monitoring and control without associated laboratory costs.