Advanced technologies for cement manufacturing to gain efficiencies, improve product quality and profitability

Cement manufacturing methods and processes must evolve with increasing speed to accommodate market demands, competitive pressures, new economic realities, and governmental regulations. Thermo Fisher Scientific continues to be your most trusted industry partner in developing and applying technologies that improve the cement manufacturing process with a focus on increasing your profitability.  Explore advanced technologies and how they can be applied to benefit your operations.


Prompt Gamma Neutron Activation Analysis/Pulsed Fast Thermal Neutron Activation (PGNAA/PFTNA)

Used for real-time quality control in process optimization, PGNAA/PFTNA provides high frequency online elemental analysis of an entire raw material process stream. Analyzers using PGNAA/PFTNA are situated directly on the conveyor belt and penetrate the whole raw material cross-section, delivering minute-by-minute, uniform measurement of the entire material stream, not just a sample or surface reading. Cement manufacturers can benefit from this technology in two key ways: quality control of raw materials, and managing coal power generation at their plant.

 

The key elemental components for cement are calcium, aluminum, iron, and silicon. However, sometimes unwanted elements such as magnesium oxide, and alkalis such as sodium, potassium, and sulfur exist within the limestone, clay, and sandstone that are adverse to the process. In these cases, PGNAA technology allows the end user to monitor MgO levels in the limestone and adjust accordingly.

 

This technology is also useful to control the coal blend that powers the plant. This allows cement producers to “mix” low-cost coals with higher costs coals to provide additional cost savings in fuel and a consistent feed to the kiln.

CB Omni Agile Elemental Analyzer

The Thermo Scientific CB Omni Agile uses PGNAA/PFTNA technology to provide real-time online elemental analysis of an entire raw material process stream and delivers the ability to blend, sort and monitor product quality without the need for continuous sampling.

 

ECA-3 Elemental Crossbelt Analyze

The Thermo Scientific ECA-3 Elemental Crossbelt Analyzer is the first on-the-belt, full-stream analyzer to use Prompt Gamma Neutron Activation Analysis (PGNAA) technology, a technique pioneered and commercialized by Thermo Fisher Scientific in 1984 that has been widely employed for online elemental coal analysis of sample streams.

 

CQM Flex

The Thermo Scientific CQM Flex can incorporate an electrically-driven neutron generator, or Californium (252Cf) as its source of neutrons to meet the needs of various application requirements. The CQM FLEX measures and reports levels of sulfur, moisture, total ash, calorific value, ash elemental concentration, and other critical parameters required by both coal consumers and producers to maximize the use of coal resources and reduce pollutants.

CB Omni-R

The Thermo Scientific CB Omni-R package replaces outdated and potentially obsolete analog electronics with modern, state-of-the-art and highly reliable digital electronics. The new CB Omni Random Pulse Processor 4 (RPP4), included in the upgrade, is the most advanced digital signal processor on the market today specifically designed by our scientists and engineers for PGNAA online analyzers.

 


Bulk weighing and monitoring

High accuracy electronic weight scale technology is used on conveyors and supplies real-time volume by weight information to assist both with the accounting of material received from the mine and in the control of feed into the milling circuit. A belt scale system consists of three major elements: the weighing carriage with load cell(s) measures the weight of material on the belt; the belt speed sensor and electronic integrator joins the output signals from the scale load cell(s); and a speed sensor monitors the rate of material flow and the total material passed over the scale.

 

Weighbelt feeders deliver material through an inlet feed section equipped with a manually adjustable vertical slide gate to control material height. The scale carriage/ weighbridge assembly measures the gravitational force of the material and converts this force measurement into an electrical output signal proportional to belt loading. A digital speed sensor continuously monitors the belt speed. The microprocessor-based electronics integrate the two signals to produce and display a true rate and a total weight fed.  The use of this technology enables real-time quality control and process efficiency and is available with our Ramsey Conveyer Belt Systems and Weighbelt Feeders.

Ramsey IDEA Belt Scale System

The Thermo Scientific Ramsey IDEA Belt Scale System delivers gain rate information and totalization function accuracy of ±1% for processes involving non-critical or lower value materials.  The belt scale system consists of three major elements: the weighing assembly measures the weight of material on the belt, the belt speed sensor and electronic integrator joins the output signals from the scale module and speed sensor to arrive at a rate of material flow and the total material passed over the scale.

 

Ramsey Series 14 - 30 Belt Scale Systems

The Thermo Scientific Ramsey Series 14 - 30 Belt Scale Systems allow you to run your high-speed plant and process operations with better-than-normal accuracy. When combined with a speed sensor and belt scale integrator, these conveyor belt scales monitor production output and inventory, and regulate product loadout, while providing vital information for effective management and efficient operation.

Ramsey Flex Belt Scale Integration Solution

Belt scale weighing systems, critical kit for almost every bulk material handling plant, have two core elements – the belt scale, which incorporates the load cells, and the ‘brain’, the electronics for integration, management and control. The new Thermo Scientific Ramsey Flex is the brain: It can be used for new belt scale and retrofit projects, with Thermo Scientific belt scales or many others, and for single-conveyor projects or complex multi-scale systems. 

Ramsey Model 90-125 Mid-Range Weighbelt Feeder

The Thermo Scientific Ramsey Model 90-125 Mid-Range Weighbelt Feeder measures industrial materials at moderate feed rates to reduce material waste, help maintain blend consistency and increase profits. Its unique cantilevered and formed channel frame design provides a strong, sturdy weigh structure and allows for quick and easy maintenance to augment the performance of your process and improve your bottom line.

Ramsey Model 90-150 Low Capacity Weighbelt Feeder

The Thermo Scientific Ramsey Model 90-150 Low Capacity Weighbelt Feeder is uniquely designed and constructed to provide a consistent flow of materials, offer increased sensitivity for more accurate weighing of the lightest materials, and permit quick and easy cleaning and maintenance. These features work together to augment the performance of your process.

 

Ramsey C-Level Continuous Level Indicator

The Thermo Scientific Ramsey C-Level Continuous Level Indicator eliminates failure and maintenance issues with your inventory monitoring and process control system. Ideally suited for bulk solids or liquids, it monitors inventory and process control during load-out or filling. With its unique precision strain gauge sensors press-fit into the support structure, it can operate without concern for failure or maintenance issues caused by the monitored material or process environment. This distinctive design also compensates for temperature changes that can affect the accuracy of bolt-on strain sensors.

Ramsey Mercury-Free Tilt Sensor

The Thermo Scientific Ramsey Mercury-Free Tilt Sensor prevents jitter and provides stability in your hazardous area applications.  This sensor uses advanced technology inside the tilt probe to replicate the same performance found in traditional mercury-based switches.

Ramsey Model 60-23P Under Speed Switch

The Thermo Scientific Ramsey Model 60-23P Under Speed Switch monitors the rotational velocity of a shaft or other rotating equipment within your industrial applications. It utilizes a single-piece construction with no separate control unit and is ideally suited for a wide variety of industrial applications where the need to monitor under speed or slippage conditions exist.

Ramsey Conveyor Protection Switches

The Thermo Scientific Ramsey Conveyor Protection Switches protect your equipment, prevent accidents, and reduce unscheduled shutdowns. The Belt Misalignment Switch (Run Off Switch) and Safety Cable Pull Switch (Pull Cord Switch) are now available with network addressable modules. Ramsey conveyor safety switches also include the Tripper Position Switch. All are used for position information, control signals, and to identify potentially hazardous situations with your process equipment.

Ramsey Series 60-200 Motion Monitoring Systems

Thermo Scientific Ramsey Series 60-200 Motion Monitoring Systems improve monitoring of underspeed, overspeed, and zero-speed conditions on machinery and systems to increase productivity in cement manufacturing. Ramsey Series 60-200 Motion Monitoring Systems reduce downtime and add to your bottom line as they sense the speed variations of rotating parts.

 


X-ray fluorescence

X-ray fluorescence spectroscopy (XRF) is a non-destructive analytical technique used to determine the elemental composition of materials. XRF analyzers work by measuring the fluorescent (or secondary) X-rays emitted from a sample when excited by a primary X-ray source. Each of the elements present in a sample produces a set of characteristic fluorescent X-rays, or “unique fingerprints.” These fingerprints are distinct for each element, making XRF analysis an excellent tool for quantitative and qualitative measurements. In cement manufacturing, XRF is used for analysis of raw materials, clinker, and finished product.

Niton XL2 Plus Handheld XRF Analyzer

The Thermo Scientific Niton XL2 Plus Handheld XRF Analyzer lets you confidently perform elemental analysis anywhere in the plant or field.  When durability, performance, and productivity are top of mind, industrial businesses rely on the Niton XL2 Plus handheld XRF analyzer for fast results and low detection limits. Identify material composition and contaminants or obtain geochemical data. The Niton XL2 Plus provides operators the ability to scan a broad range of materials in one versatile analyzer.

ARL OPTIM'X Cement Analyzer

The Thermo Scientific ARL OPTIM'X Cement Analyzer provides all the advantages of wavelength dispersive X-ray elemental analysis at a fraction of the cost of higher-powered systems. Its innovative optics, small footprint, and ease of operation and maintenance lead to a significantly lower cost of ownership without sacrificing precision or sensitivity.

ARL 9900 Simultaneous Sequential XRF

The Thermo Scientific ARL 9900 Total Cement Analyzer provides fast process monitoring during the critical phases of cement manufacturing. It combines XRF analysis to determine the elemental composition of the material, and XRD analysis to provide mineralogical information about how the various elements are combined together to ensure the integrity of the final product. Undertaking both types of analysis has traditionally called for two separate X-ray instruments, maintained and operated at significant cost to the user. But the integration of an innovative compact X-ray diffraction system allows both techniques to be included in the same ARL 9900 instrument with significant advantages to the user.

 

ARL QUANT’X EDXRF Spectrometer

The Thermo Scientific ARL QUANT'X EDXRF spectrometer offers performance, versatility and reliability of elemental analysis. Its compact desktop design, close-coupled optics and advanced electrically cooled detectors provide analytical precision in a wide dynamic range from ppm to percent elemental concentrations.

ARL PERFORM'X Sequential X-Ray Fluorescence Spectrometer

The Thermo Scientific ARL PERFORM'X Sequential X-Ray Fluorescence Spectrometer can evaluate up to 90 elements in nearly any solid or liquid sample. Industries as diverse as metallurgy, petroleum, polymers, mining, glass, cement, and refractories as well as labs dealing with geochemistry, materials science, environmental research, and forensics will benefit from its performance and versatility. Additionally, this innovative spectrometer integrates bulk elemental analysis with mapping and small spot analysis for advanced materials characterization.


X-ray diffraction

Quickly obtain detailed phase and structural information of your crystalline materials using X-ray diffraction (XRD), a versatile and nondestructive analytical technique. The discovery of X-ray diffraction (Bragg’s Law) enabled physicists, chemists, material scientists and metallurgists to study structure-property relationships leading to a multitude of new discoveries in materials science and technology.

While X-ray fluorescence (XRF) analysis determines the elemental composition of a sample, it does not provide information about how the various elements are combined together.  Such mineralogical information is only available through X-ray diffraction. In a typical crystalline sample, XRF might measure for example the total Ca concentration. XRD permits analysis of the phases or compounds in crystalline materials such as rocks, minerals and oxide materials and products. In the same sample, XRD takes the analysis a stage further and gives information about CaO, CaCO3, Ca(OH)2 contents and other Ca phases.

ARL EQUINOX 100 X-ray Diffractometer

The Thermo Scientific ARL EQUINOX 100 X-ray Diffractometer is a dedicated XRD instrument for QA/QC applications.  Occupying a third of the space of a conventional diffractometer, this stand-alone, transportable benchtop instrument offers true flexibility. No external water cooling is required, and it plugs into a standard electrical power outlet. This instrument simplifies operation without sacrificing speed or performance. Thanks to a specific real time detection mode, measurements are completed in a few seconds.

ARL EQUINOX 1000 X-ray Diffractometer

The Thermo Scientific ARL EQUINOX 1000 X-ray Diffractometer delivers real-time measurement in a simple yet powerful benchtop analyzer.  Designed for QA applications and routine X-ray diffraction studies, this high power XRD instrument offers maintenance free, simplified operation while providing high resolution performance. The operating conditions are saved in the software; at the end of the experiment an analysis report summarizes operating conditions and tasks completed. With a 30-position auto sampler, it can be run in a batch mode and unattended.


Radiation detection

Mining industries and those that utilize mined minerals are exposed to a variety of naturally occurring radiation sources.  And because of the extensive use of radioactive measurement and analysis techniques (e.g. X-ray and Gamma ray analyzers) in cement production, the potential for exposure increases dramatically.  Both natural and man-made sources of radiation are potentially dangerous and life threatening if not managed appropriately.

Detection of various types of radiation throughout the manufacturing process is paramount to worker safety and quality control.  Radiation detection technology can be delivered by way of multiple devices, each suited for the type of radiation to be monitored, the environmental circumstances, and source.

Handheld radiation detection devices provide real time detection of gamma radiation with accurate dose rate measurements, verify the radioactive find and assess whether radioactivity is of natural or artificial (man-made) origin. Portable devices with high sensitivity neutron response and alarm threshold can be worn to monitor gamma sensitivity and energy compensated dose rate measurement.

RadEye Area Monitor

Extend the application range to convenient and cost-effective gamma and neutron area monitoring with the Thermo Scientific RadEye Area Monitor. The enclosure adapts several different types of RadEye instruments for area monitoring applications.

 

RadEye B20 and B20-ER Multi-Purpose Survey Meters

Quickly identify mixed radioactive surface contamination in facility and field environments with the Thermo Scientific RadEye B20 and B20-ER Multi-Purpose Survey Meters. Simple, robust and reliable contamination and dose rate measurement tools for characterizing alpha, beta, gamma and X-ray radiation. RadEye B20 and B20-ER Multi-Purpose handheld Geiger counters provide an on-site solution for industrial workers.

RadEye SPRD and SPRD-ER Personal Radiation Detectors

Respond quickly and decisively to real radiation threats with the new standard in detection and interdiction of illicit radiation. The Thermo Scientific RadEye SPRD and SPRD-ER Personal Radiation Detectors are handheld radiation monitors that offer a unique combination of detector sensitivity and intelligent alarming to help ensure detection in the most challenging applications while eliminating nuisance alarms. Additionally, the RadEye SPRD and SPRD-ER radiation detector identifies and categorizes specific types of radiation or radioactive material,and can be configured to support your missions or user skills.


Tramp metal detection

Tramp metal can stop your operation and cause expensive damage to your equipment. That is why proactive operators and owners consider tramp metal detectors to be an essential part of their operation. A tramp metal detector minimizes lost production time and helps you save money by providing an economical and reliable means to protect expensive crushers, conveyors and other process equipment from damage by tramp metal. It can detect all types of metallic scrap, including bucket teeth, manganese steel mantles, bore crowns, bar scrap, chains, wear plates, and tools. It can even detect tramp metal when buried in wet conductive materials. And, because it is insensitive to materials with high magnetic permeability and electrical conductivity, this tramp metal detector can be used in applications where conventional metal detectors produce an unacceptable false alarm rate.

 

Ramsey Oretronic IV Tramp Metal Detectors

Prevent your profit from turning into scrap. Thermo Scientific Ramsey Oretronic IV Tramp Metal Detectors protect expensive crushers, conveyors and other process equipment from damage by tramp metal. Designed for belt conveyors moving coal, iron pellets, minerals, aggregates, and other bulk materials, Oretronic Tramp Metal Detectors detect all types of metallic scrap that conventional metal detectors may miss.


Informatics

The advanced materials analysis instrumentation available to cement producers delivers unprecedented improvements in productivity, efficiency, and profitability.  These improvements can be further extended through specialized software and informatics.  Our systems offer connectivity across and between lab and field instruments, deliver rich information analysis, optimized management controls, and advance the usefulness of your equipment.  By connecting XRF and PGNAA elemental analyzers, for example, you can compare data from both systems to ensure peak operational efficiency.  Other specialized software enables benefits like the automatic, real-time adjustment of raw material feed rates for maximized productivity and quality control.  Our advanced, specialized informatics systems for the cement industry add another layer of return on your technology investment.

AccuLINK

Thermo Scientific AccuLINK is an easy-to-use software package that provides automatic implementation of calibrations into your online analyzer system. The package compares the results of your online crossbelt analyzer with the site laboratory and provides both a statistical and graphical data analysis. By having your online analyzer operating at peak accuracy, the kiln feed will be more consistent, which can lead to greater throughput, fewer BTUs of coal burned per ton of clinker, less electrical cost per ton of clinker and longer brick life.

RAMOS (Raw Mix Optimization Software)

Automatically adjust multiple raw material source feeds to optimize blend proportioning, reduce chemistry variability, and minimize cost with software designed specifically to use high frequency analysis provided by online analyzers. Thermo Scientific RAMOS (Raw Mix Optimization Software) works with a cross belt online analyzer to monitor the chemistry of the raw material being carried on a conveyor and automatically issues optimal blend proportions to meet quality control targets.

COBOS (Coal Blend Optimization System)

Satisfy customer specifications for high quality coal blends while achieving more cost-effective, efficient operations.The Thermo Scientific COBOS Coal Blend Optimization System controls coal sorting and coal blending equipment with software that continuously monitors coal quality. The system blends up to six coal sources to make a "recipe" consisting of up to five quality parameters, such as ash, sulfur, moisture or even ash oxides or ratios of ash oxides. Blend recipes can be predefined for different quality targets and priorities while using fewer high cost or scarce coal resources.


Laboratory automation

Cement manufacturers can further drive process control and efficiencies in their applications with laboratory automation technologies. XRF spectrometers can be fully automated to increase throughput, improve analysis accuracy and decrease costs. This level of automation delivers a complete laboratory workflow solution and can reduce response times, increases sample processing cadence, and improve the availability of automatic sample preparation in highly critical production control environments.

ARL SMS-XY Automation for XRF

Increase your capacity to handle more samples in less time. The Thermo Scientific ARL SMS-XY Automation for XRF permits continuous and unattended operation of Thermo Scientific ARL 9900 series X-ray Spectrometers or Thermo Scientific ARL PERFORM'X WDXRF Spectrometer. Increased automation brings increased analysis quality, lower analysis costs, a more sustainable analysis cadence with predictable and reproducible response times, and a short payback period.

 


Emissions analysis

We have devoted nearly forty years to perfecting the design and execution of demanding operational and environmental monitoring systems. Our state-of-the-art technologies, along with long-term distinguished industry performance, are qualities incorporated with each delivered system.

Our gas and particulate emissions analyzers detect and monitor a complete spectrum of process gases during various stages of production, including but not limited to NO, NO2, NOx, SO2, CO, CO2, Ozone, non-methane hydrocarbons and other gases that a user may require.  Our analyzers utilize a variety of technologies which can include Nondispersive Infrared (NDIR), Chemiluminescence; Pulsed Fluorescence, and Flame Ionization Detection (FID), Atomic Fluorescence; transmissometers, ultrasonic monitors and full extractive and dilution extractive probes. Using a combination of these technologies, you can achieve compliance with regulatory guidelines while meeting your own specific air quality monitoring needs.  These systems are designed to meet US EPA 40CFR Parts 60 and 75 standards while providing unsurpassed sensitivity, accuracy and reliability.

iQ Series Instrument Platform

The Thermo Scientific iQ Series Instrument Platform is a smart environmental monitoring solution for ambient and source gas analysis that affords greater control over instrument performance and data availability. The iQ Series Gas Analyzers are engineered to get smarter over time and help minimize troubleshooting time with a highly precise, yet tough solution.