{"id":2078,"date":"2014-01-14T08:23:28","date_gmt":"2014-01-14T13:23:28","guid":{"rendered":"http:\/\/admin.acceleratingscience.com\/?p=2078"},"modified":"2026-01-06T20:53:58","modified_gmt":"2026-01-06T20:53:58","slug":"increasingclinkerquality","status":"publish","type":"post","link":"https:\/\/www.thermofisher.com\/blog\/mining\/increasingclinkerquality\/","title":{"rendered":"Increasing Clinker Quality through Automation"},"content":{"rendered":"
\"Clinker<\/a>

Clinker quality depends on raw material composition.<\/p><\/div>\n

Portland cement is the most common type of cement<\/a> in the world. It is used primarily to make concrete, mortar, and grout. Portland cement manufacturing<\/a> begins with mining and then grinding raw materials that include limestone and clay, to a fine powder, called raw meal, which is then heated to a sintering temperature as high as 1450\u00a0\u00b0C in a cement kiln. In this process, the chemical bonds of the raw materials are broken down and then are recombined into new compounds.\u00a0 The resulting clinker (rounded nodules between 1mm and 25mm across) is ground to a fine powder in a cement mill and mixed with gypsum to create cement.\u00a0 The powdered cement is then mixed with water and aggregates to form concrete that is used in construction.<\/p>\n

Clinker quality depends on raw material composition. If the raw materials are inappropriate, or if they are blended improperly, buildings and roads made from the concrete will have poor strength and durability. Recent examples can be found in countries such as China and Qatar where construction projects were suspended when it was discovered that low-quality concrete made from a faulty mix was being used.<\/p>\n

Because consistent clinker quality is so critically important in making high-performance concrete to avoid devastating building failures, cement manufacturers are investing in new technology to improve the process. A recent article in Cement International (verlagbt.de) described how a cement company sought to stabilize the quality of their raw meal to regulate clinker quality.<\/p>\n

Stabilizing the Quality of Raw Meal to Regulate Clinker Quality<\/strong><\/p>\n

The company believed that by implementing the use of high frequency, online analysis and automated control they could produce a more homogenous and stable raw meal. By reducing variability in the raw material chemistry and keeping that chemistry \u201con target\u201d in appropriate ratios, the quality of cement produced remains high and consistent.\u00a0 The company\u2019s goal was to decrease the standard deviation in the variability of their raw meal by 40% using the quality factor called \u201cLime Saturation Factor\u201d as their benchmark. To accomplish their goal, the company installed two new analyzer systems:\u00a0 a laboratory X-Ray Flouresence (XRF) system<\/a> and an online Prompt Gamma Neutron Activation Analysis (PGNAA) system<\/a>.<\/p>\n

The customer uses three raw materials:\u00a0 limestone, clay, and marl in their pre-blending process. The raw materials are crushed separately and are manually sampled every two hours. The samples are analyzed by the XRF system and appropriate pre-mix proportions are calculated to achieve the pre-mix quality target.\u00a0 The three raw materials are then fed into the pre-blending pile. The pre-blended material is then reclaimed and placed into one of three raw material bins prior to the raw mill.\u00a0 High grade limestone and iron ore are, respectively, in the other two bins. Limestone is used to adjust the lime saturation factor (LSF), and iron ore to adjust both the silica modulus (SM) and alumina modulus (AM).\u00a0 An automatic sampler after the mill takes samples of the raw meal every hour, and then transfers the samples to the laboratory via a duct system. Prior to the installation of the online analyzer, the samples were analyzed in the laboratory, the mix ratios then calculated and adjustments made to the raw mix all in a manual process.\u00a0 The time delay for sample preparation and analysis coupled with the potential for sample error made it difficult to optimize control as the raw materials changed.<\/p>\n

Improving the Process<\/strong><\/p>\n

To improve upon the process and control system, the plant installed a Prompt Gamma Neutron Activation Analysis (PGNAA)-based crossbelt online elemental analyzer<\/a> in conjunction with automatic raw material blending software after the corrective bins but before the raw mill. Being that PGNAA is an entirely penetrating analysis technology, the online analyzer provides minute-by-minute analysis results of the entire material stream, not just a surface analysis.\u00a0 The high frequency analysis results are transferred to the automated blending software every minute where new mixing ratios are calculated. \u00a0The software is integrated with the control system and weigh feeder set points are adjusted automatically every minute.\u00a0 The existing automated sample system is now used simply as a secondary check to periodically ensure the online analyzer remains calibrated with the laboratory X-Ray system.<\/p>\n

With the new system in place, this company realized significant improvements in their quality process.\u00a0 They decreased the hourly standard deviation of their Lime Saturation Factor by 70%, decreased the standard deviation of their silica modulus by 50%, and decreased the standard deviation of their alumina modulus by 33%, all while maintaining target chemistry.\u00a0 The culmination of these improvements translates to better clinker quality, lower fuel costs, and more efficient operations overall.<\/p>\n

How would you increase your clinker quality? \u00a0Comment below.<\/p>\n

Update: Visit the\u00a0Cement Production center<\/a>\u00a0on our website, with free resources to help you optimize your cement making process.
\n\"\"<\/a><\/h2>\n","protected":false},"excerpt":{"rendered":"

Portland cement is the most common type of cement in the world. It is used primarily to make concrete, mortar, and grout. Portland cement manufacturing begins with mining and then grinding raw materials that include limestone and clay, to a fine powder, called raw meal, which is then heated to a sintering temperature as high<\/p>\n","protected":false},"author":142,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_kad_blocks_custom_css":"","_kad_blocks_head_custom_js":"","_kad_blocks_body_custom_js":"","_kad_blocks_footer_custom_js":"","_monsterinsights_skip_tracking":false,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[8],"tags":[13,14,15,16,17,18],"division":[],"class_list":{"0":"post-2078","1":"post","2":"type-post","3":"status-publish","4":"format-standard","6":"category-cement","7":"tag-cement-2","8":"tag-clinker","9":"tag-limestone","10":"tag-mining-2","11":"tag-quarry","12":"tag-software","13":"entry"},"_selected_authors":[1211],"_selected_reviewers":[],"acf":[],"yoast_head":"\nClinker 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Download this handy periodic table and X-ray energy reference guide to help in analyzing your mining samples. \u00a0It's our treat. Then visit our Mining and Minerals, Cement Production, and Coal Power pages for more goodies. Download Periodic Table.\u00a0 \u00a0","rel":"","context":"In "Elemental\/Geochemical Analysis"","block_context":{"text":"Elemental\/Geochemical Analysis","link":"https:\/\/admin.acceleratingscience.com\/mining\/elemental-geochemical-analysis\/"},"img":{"alt_text":"halloween scene with plastic pumpkin and candy","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/No-Tricks-.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/No-Tricks-.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/No-Tricks-.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/No-Tricks-.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/No-Tricks-.jpg?resize=1050%2C600&ssl=1 3x"},"classes":[]},{"id":13488,"url":"https:\/\/www.thermofisher.com\/blog\/mining\/the-role-of-edxrf-spectrometers-in-the-extraction-of-copper-from-ore\/","url_meta":{"origin":2078,"position":2},"title":"The Role of EDXRF Spectrometers in the Extraction of Copper from Ore","author":"Marlene Gasdia-Cochrane","date":"November 4, 2025","format":false,"excerpt":"Copper extraction is a complex process requiring precise control to ensure high purity. Energy Dispersive X-ray Fluorescence (EDXRF) spectrometers play a vital role by providing fast, non-destructive elemental analysis of ores, concentrates, and intermediate products. This enables mining operations to optimize extraction efficiency, maintain quality assurance, and meet stringent industry\u2026","rel":"","context":"In "Elemental\/Geochemical Analysis"","block_context":{"text":"Elemental\/Geochemical Analysis","link":"https:\/\/admin.acceleratingscience.com\/mining\/elemental-geochemical-analysis\/"},"img":{"alt_text":"a rock showing signs of copper and gold.","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2025\/10\/iStock-1309478061.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":2707,"url":"https:\/\/www.thermofisher.com\/blog\/mining\/potash-a-look-at-the-worlds-most-popular-fertilizer\/","url_meta":{"origin":2078,"position":3},"title":"Potash: A Look at the World\u2019s Most Popular Fertilizer","author":"Ali Somarin","date":"April 8, 2026","format":false,"excerpt":"Potash Explained Potash is one of the most essential fertilizers in modern agriculture, supplying potassium\u2014an irreplaceable nutrient that supports plant growth, crop yield, and overall food production. According to the U.S. Geological Survey (USGS), about 85% of potash is used in fertilizers, underscoring its critical role in global farming systems.\u2026","rel":"","context":"In "Data Management\/Lab Automation"","block_context":{"text":"Data Management\/Lab Automation","link":"https:\/\/admin.acceleratingscience.com\/mining\/data-management-lab-automation\/"},"img":{"alt_text":"potash evaporation ponds at mining site","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2014\/06\/iStock-1362567340.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":13977,"url":"https:\/\/www.thermofisher.com\/blog\/mining\/what-is-in-situ-geochemical-analysis-and-why-it-is-critical-for-modern-field-operations\/","url_meta":{"origin":2078,"position":4},"title":"What Is In Situ Geochemical Analysis \u2014 And Why It Is Critical for Modern Field Operations","author":"Marlene Gasdia-Cochrane","date":"March 13, 2026","format":false,"excerpt":"In situ geochemical analysis has become a cornerstone of modern mineral exploration, mining, and environmental fieldwork. As project timelines tighten and operational costs increase, organizations can no longer afford delays caused by traditional laboratory testing workflows. In situ analysis \u2014 the ability to measure elemental composition directly at the sampling\u2026","rel":"","context":"In "Exploration"","block_context":{"text":"Exploration","link":"https:\/\/admin.acceleratingscience.com\/mining\/exploration\/"},"img":{"alt_text":"Close up of industrial worker holding mineral ore in gloved hands on mining site","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-896157842.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":13986,"url":"https:\/\/www.thermofisher.com\/blog\/mining\/best-practices-for-accurate-in-situ-geochemical-analysis\/","url_meta":{"origin":2078,"position":5},"title":"Best Practices for Accurate In Situ Geochemical Analysis","author":"Marlene Gasdia-Cochrane","date":"March 24, 2026","format":false,"excerpt":"In situ geochemical analysis refers to elemental testing performed directly on geological materials in their natural location, avoiding the delays and costs associated with laboratory testing.\u00a0 While in situ geochemical analysis delivers immediate elemental data, the reliability of those results depends heavily on proper field methodology. Portable analytical technologies used\u2026","rel":"","context":"In "Exploration"","block_context":{"text":"Exploration","link":"https:\/\/admin.acceleratingscience.com\/mining\/exploration\/"},"img":{"alt_text":"Mining truck on a dirt road in the Andes, Chile (near Embalse El Yeso, Caj\u00f3n del Maipo, San Jos\u00e9 de Maipo)","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/mining\/wp-content\/uploads\/sites\/3\/2026\/03\/iStock-2222354034.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]}],"jetpack_sharing_enabled":true,"jetpack_featured_media_url":"","_links":{"self":[{"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/posts\/2078","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/users\/142"}],"replies":[{"embeddable":true,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/comments?post=2078"}],"version-history":[{"count":0,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/posts\/2078\/revisions"}],"wp:attachment":[{"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/media?parent=2078"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/categories?post=2078"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/tags?post=2078"},{"taxonomy":"division","embeddable":true,"href":"https:\/\/www.thermofisher.com\/blog\/mining\/wp-json\/wp\/v2\/division?post=2078"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}