SPECTRAFLOW ANALYTICS RECEIVES ORDER FOR A CROSSBELT & AIRSLIDE ANALYZER FOR STOCKPILE AND RAW MILL OPTIMIZATION FROM CHERAT CEMENT, PAKISTAN
Cherat Cement Company ordered one SpectraFlow Crossbelt Analyzer and one SpectraFlow Airslide Analyzer plus a RMP control software package for their plant in Lakrai, District Nowshera, Khyber Pakhtunkhwa (KPK) province in Pakistan to optimize the quarry and raw mill operation for their new line 3 project.
About Cherat Cement Company:
Cherat Cement company is a pioneer in the Pakistani Cement industry and founded in 1981. The operation of its plant started in 1985 with a capacity of 1’100 t clinker/day. The capacity on its kiln line was increased step by step and reached in 2005 3’300 t clinker/day. In 2014 the commissioning for the second line started and was completed in 2017 with a capacity of 4’200 t clinker/day. In 2017 the commissioning of line 3 started and will be completed by 2018 with a capacity of 6’700 t clinker/day. With all three kiln lines in operation the daily production will reach more than 14’200 t clinker/day, which makes Cherat Cement the leading producer of cement in the KPK province and one of the main exporter of cement to Afghanistan. The SpectraFlow Crossbelt Analyzer will be installed to monitor the quality of the crusher feed on the new Line 3, while the SpectraFlow Airslide Analyzer will be installed after the raw mill of Line 3. The minute results of the SpectraFlow Airslide Analyzer will be used to adjust the weight feeders before the raw mill in real time.
Operations of Cherat Cement:
Lakrai Cement Plant, 14’200 t clinker/day (3 production lines)
SpectraFlow Installation for Quarry/Stockpile Optimization:
General:
The SpectraFlow Crossbelt Analyzer is the online analyzer to be able to measure raw materials in on belt conveyors. As raw materials from the quarry are processed through a crusher the raw material on the conveyor belt is statistically homogeneous and therefore the analytical results of the SpectraFlow Crossbelt Analyzer are accurate. Based on these accurate results the RMP PreBlending control software will inform the crusher/quarry operators of the actual status of the stockpile and actions can be taken directly. This results in precise control of the stockpile feed and a very homogeneous stockpile at the LSF setpoint.
By using SpectraFlow an increase in the stockpile quality will be achieved.
Summarized benefits are:
- No need of sampling. Sampling from conveyor belts is unrepresentative and slow for process optimization. - Additionally sampling is very work intensive regarding operation and maintenance.
- The analyzer together with the RMP PreBlending control software is fully automating the crusher operation. The analyzer delivers the analytical results and according the setpoint the software is adjusting the feeder into the crusher. (in case there is a separate feeder into the crusher)
- The analyzer together with the RMP PreBlending control software is informing the quarry/crusher operators of the current composition of the stockpile and accordingly the trucks can be coordinated to reach the setpoint of the stockpile (in case all material is fed with one feeder into the crusher)
- Stockpile quality will be homogeneous and on setpoint. That results in stable and low additive consumption at the raw mill.
- Stable feed from the stockpile leads to stable raw mill operation and fine raw meal/clinker quality.
SpectraFlow Installation for Raw Mill Optimization:
General:
The SpectraFlow Airslide Analyzer is the online analyzer to be able to measure raw materials in airslides. As raw materials in airslides are very homogeneous and dry the analytical results of the SpectraFlow Airslide Analyzer are very accurate and based on these accurate results the RMP control software can optimize the weight feeders before the raw mill in real time every minute. This results in very low LSF STDEV without the need of extensive sampling and laboratory efforts.
By using SpectraFlow an increase in the stockpile quality will be achieved.
Summarized benefits are:
- No need of intensive sampling. No automated sample transport system, no automated laboratory required.
- High cost reduction due to reduced laboratory usage (CAPEX, OPEX, man power,…)
- The analyzer together with the RMP PreBlending control software is fully automating the raw mill operation. The analyzer delivers the analytical results and according the setpoint the software is adjusting the weight feeders of the additive bins.
- Adjustment of the weight feeders in real time every minute. No time delay due to sampling, sample preparation,…
- Introducing redundancy for the raw mill control. SpectraFlow is delivering the chemical results for the weight feeder control normally, while as a back-up, the laboratory can be used in the rare case, that the SpectraFlow Analyzer is not available.
- Lower LSF STDEV/better and more consistent raw mill quality
SpectraFlow Analytics Ltd. Switzerland are the experts in providing online analysis for the cement and minerals industry without any radioactive sources nor neutron generators. The NIR technology used for the SpectraFlow Analyzers is not requiring any permits or licenses and there are no restrictions in buying, importing or maintaining the analyzers. This results in very low operating costs and high availability of the analyzers combined with highly accurate measurement results.
