ABB solutions aid CEMMAC’s production process
ABB, the power and automation technology group, have successfully installed their SpectraFlow and Raw Mix Preparation (RMP) solutions at CEMMAC’s Portland cement plant in Slovakia.
The material at CEMMAC’s limestone quarry comes from three different zones, yielding a mixture of medium- and low-quality marl and high-quality limestone. However, moisture changes have a significant effect on the marl, making it difficult to measure the concentration with a conventional sampling station.
As a result, the lime saturation factor (LSF) of the raw material arriving at the raw mill often exceeded the upper process limit. CEMMAC therefore sought a solution that would establish a target LSF and significantly reduce LSF variations in their mixing bed.
The answer was found in a combination of ABB’s online analyzer, SpectraFlow, plus their RMP expert optimizer module.
SpectraFlow, which utilizes near infrared spectroscopy (NIRS) to provide the chemical composition data, can be used on any conveyor, regardless of belt width or composition. The system does not require dedicated safety personnel or special operating licenses, nor does the analyzer require any physical contact with the sample material in order to provide data.
Installed in February 2008, this brought immediate improvements for CEMMAC by eliminating the problems caused by the previous sample-based analyzer coming into contact with the moist marl.
In February 2009, a new analyzer strategy model was adopted by CEMMAC. This involves the use of ABB’s RMP solution to take moisture levels into better account in the data and analysis. This system, in combination with SpectraFlow, is now achieving an LSF of 80 ±5 for each 180-tonne segment of a round mixing bed.
According to CEMMAC, pressure on the quarry staff has now been reduced, as they can now refer to the RMP solution for clear guidance on how best to handle the material.
The material at CEMMAC’s limestone quarry comes from three different zones, yielding a mixture of medium- and low-quality marl and high-quality limestone. However, moisture changes have a significant effect on the marl, making it difficult to measure the concentration with a conventional sampling station.
As a result, the lime saturation factor (LSF) of the raw material arriving at the raw mill often exceeded the upper process limit. CEMMAC therefore sought a solution that would establish a target LSF and significantly reduce LSF variations in their mixing bed.
The answer was found in a combination of ABB’s online analyzer, SpectraFlow, plus their RMP expert optimizer module.
SpectraFlow, which utilizes near infrared spectroscopy (NIRS) to provide the chemical composition data, can be used on any conveyor, regardless of belt width or composition. The system does not require dedicated safety personnel or special operating licenses, nor does the analyzer require any physical contact with the sample material in order to provide data.
Installed in February 2008, this brought immediate improvements for CEMMAC by eliminating the problems caused by the previous sample-based analyzer coming into contact with the moist marl.
In February 2009, a new analyzer strategy model was adopted by CEMMAC. This involves the use of ABB’s RMP solution to take moisture levels into better account in the data and analysis. This system, in combination with SpectraFlow, is now achieving an LSF of 80 ±5 for each 180-tonne segment of a round mixing bed.
According to CEMMAC, pressure on the quarry staff has now been reduced, as they can now refer to the RMP solution for clear guidance on how best to handle the material.
