Optimizing cement quality, efficiency, and sustainability through advanced analytical control

From raw material extraction to final certification, cement production depends on fast, reliable information. Thermo Fisher Scientific helps producers maintain quality, improve process control, and lower emissions through smart solutions designed for every stage of production.

Quarry

The process begins in the quarry, where limestone and clay—the foundation of cement—are extracted and evaluated for chemical consistency. Careful control at this first step sets the stage for a smooth, efficient production line.

Get raw material chemistry right from the start to help ensure consistent quality downstream.

Solutions for early-stage quality control

Our solutions provide real-time data on composition and variability, helping operations teams make faster adjustments that help ensure optimal feedstock quality. Along with elemental analysis, real-time dust and radiation monitoring help improve worker safety and environmental control at the extraction site.

Crusher and pre-blending

After extraction, raw materials are crushed and blended to achieve a uniform composition. Proper blending minimizes variations and helps ensure the right mix for the next stage.

Reduce variability early to save time, energy, and cost throughout production.

Solutions that drive consistent blending performance

Our monitoring and control technologies help maintain target blend chemistry across stockpiles and conveyors, improving mix uniformity, reducing rework, and supporting consistent downstream performance.

Raw mill and kiln feed

The raw materials move through milling and heating stages where they are precisely proportioned, ground, and transformed into clinker under high temperatures. Consistent feed quality at this point directly impacts product strength and energy efficiency.

Stable-feed chemistry means less fuel, smoother operation, and better product performance.

Solutions that optimize process stability and kiln performance

Our integrated control and analysis systems monitor mix ratios, feed consistency, and kiln dynamics. This helps ensure efficient operation and uniform clinker formation.

Coal mill and power management

Coal remains a key energy source in cement manufacturing, but the industry is rapidly evolving to integrate alternative fuels that lower CO₂ emissions and reduce dependency on traditional fossil sources.

Balance energy efficiency and sustainability with smarter fuel management.

Solutions that enhance energy efficiency and fuel flexibility

Our fuel analysis and control systems provide the accuracy needed to manage diverse fuel streams, whether they come from coal, biomass, or other secondary fuels. By monitoring composition and calorific value in real time, producers can reduce energy costs and advance their decarbonization goals without compromising performance.

Clinker control

The concentration of each phase plays an important role in the physical characteristics of cement such as strength and setting time.

 

As an example, calcium carbonate (CaCO3) is required in a certain proportion in the raw mix, but it transforms during the clinker production process into various phases known as alite, belite, aluminate, aluminoferrite, and free lime.

While the cement production process before the kiln is focused on the elemental make-up and proportions of the raw materials, after the clinker is produced, the focus shifts to the compounds these elements form.

Solutions that provide comprehensive analysis and timely information

Cement analysis can be achieved using XRF analyzers, while the phases are identified using the XRD platform. The final stage of cement production is to finely grind the cooled clinker and add gypsum and other fillers to control the setting time of the cement and other properties. Mineralogy is important at this stage as well and is measured in the lab by XRD technology. Together, XRF and XRD analysis provides comprehensive, timely information that helps enable production quality, efficiency and profitability.

Finish mill and product QA/QC

After clinker production, materials move to the finish mill, where they are finely ground and blended with gypsum or other additives to create the final cement product. Precise control of composition and fineness at this stage helps ensure reliable strength, setting time, and long-term performance.

Deliver cement that meets every specification, every time.

Solutions that perfect the final grind and product quality

X-ray fluorescence technology is the gold standard for accurate, nondestructive elemental analysis and rapid material characterization to help ensure product chemistry specifications are met.

Production safety

Reliable protection for people and equipment keeps operations running smoothly and reduces unplanned downtime.

Protect your workforce and your investment through smarter safety systems.

Solutions that strengthen safety and uptime

Our real-time monitoring and detection systems help safeguard workers and equipment from radiation exposure, mechanical failure, and other risks, helping to ensure safe, compliant, and efficient plant operation.

Regulatory compliance

Cement manufacturing is responsible for about five percent of global CO₂ emissions. As the industry shifts toward decarbonization, precise emissions monitoring is essential for tracking progress, verifying carbon reductions, and meeting environmental regulations.

Stay compliant, cut emissions, and lead the transition to low-carbon cement production.

The Thermo Scientific iQ Series Instrument Platform is a smart environmental solution for ambient and source gas analysis. As your partner in compliance, our systems are designed with the necessary protocols to help ensure your monitoring reports are accurate and accessible and meet US EPA 40CFR Parts 60 and 75 and other standards worldwide, while providing unsurpassed sensitivity, accuracy and reliability.