Analytical techniques to the rescue

Cement production is a complex process that requires careful optimisation of raw material and fuel usage, all while maintaining high product quality. To achieve these goals, improved analysis and controls at various stages of the manufacturing process are essential. This article explores the use of analytical techniques such as XRF, XRD, and PGNAA in the cement industry, highlighting their advantages in optimising raw material and fuel utilisation, ensuring consistent product quality, and meeting environmental regulations. By leveraging these analytical tools, cement manufacturers can enhance their production processes and achieve greater efficiency and sustainability.

Raw material analysis

Raw material analysis is a critical aspect of cement manufacturing, as it ensures that the correct proportions of essential elements are present. XRF analysis provides an accurate and non-destructive method for determining the elemental composition of raw materials. It can accurately quantify major and minor elements, including oxides of calcium, silicon, aluminium, iron, and other trace elements. XRD analysis complements XRF by providing information about the mineralogical composition of the raw materials.

It can identify the presence of quartz, dolomite, feldspars, carbonates, and other minerals that can impact the quality of the final product. The only drawback of these X-ray techniques is that they only measure samples every couple of hours and they are located in a laboratory at a distance from the relevant location. This is where the benefit of real-time elemental analysis comes in.

The robust control of cement raw materials ensures key cement performance characteristics such as strength and durability. Such control begins at the quarry and extends through the raw mill for raw material blending. It relies on having timely and precise information about the composition of raw materials to ensure proper proportioning of the blend. Prompt gamma neutron activation analysis (PGNAA) and pulsed fast thermal neutron activation (PFTNA) are well established process control technologies for real time elemental analysis of cement. They are non-contact, non-destructive analytical techniques used in online analysis systems to determine the elemental composition of bulk raw materials.

Thermo Fisher Scientific pioneered PGNAA and has decades of experience in its application. Customers are granted access to crucial information to detect and rectify errors and variations during the production process, resulting in a highly homogeneous end product with minimal waste and best performance.

For cement manufacturers, neutron activation analysis is a compelling technique because of its ability to:

• Directly measure key compounds of interest, including Ca, Si, Al, and Fe oxides as well as other important components such as MgO, Na₂O, TiO₂, K₂O, SO₃, Cr and Cl.
• Calculate industry standard parameters, such as lime saturation factor (LSF), C3S, silica modulus, and iron modulus, amongst others.
• Highly penetrating analysis technique to ensure maximum uniformity of measurement.

Enjoyed what you've read so far? Read the full article and the rest of World Cement’s December issue by registering today for free!

Read the article online at: https://www.worldcement.com/asia-pacific-rim/13122023/analytical-techniques-to-the-rescue/