Integrated quality assurance from the quarry to the raw meal silo

1 Overview of the raw meal production process: Blending bed, raw meal production, homogenization

2 Course of the LSF standard deviation in a process without optimization: LSF standard deviation, blending bed homogenization, correction materials, kiln feed meal, after crusher, after blending bed, after mill

3 Reduction in LSF standard deviation through the use of EO/RMP with an online analysis system: LSF standard deviation, blending bed homogenization, correction materials, kiln feed meal, after crusher, after blending bed, after mill

4 Input mask for the quarry segments

6 MPC prediction for time point t and comparison at time point t + 1

7 EO/RMP blending bed display with analysis values

8 Typical NIR absorption spectrum for limestone

9 EO/RMP control with data from the sampling station (approx. left-hand one third) and change-over to data from the Airslide Analyzer (approx. right-hand two thirds). – Blue = EO/RMP control using data from the Airslide Analyzer – Orange = minutely values from the Airslide Analyzer – Yellow = 40-minutely laboratory values

10 Compensation during change-over of blending bed (Grey = dosing device actions. Vertical line = approximate time the new blending bed was started)

Dies ist ein Blindtext

If lime, marl and clay from different sources in variable quality and alternative raw materials are fed to a mixing process, a specific strategy for the mix-bed structure and in controlling the material composition before the mill is required. ABB there has such a system, which is presented in the following.

1 Introduction

Highly variable material in the quarries, the usage of alternative raw materials (for instance fly ashes and sewage sludges) as well as the cost pressure regarding the employed corrective materials: these factors total up to form a complex set of tasks when manufacturing raw meal for the production of cement clinker. This situation calls for the use of integrated mixture control concepts starting in the quarry control the blending bed stacking and assure minimum standard deviation of the lime standard and other moduli upstream of the mill and in the material taken from the...