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View additional product information for CB Omni Agile Online Elemental Cross-Belt Analyzer - FAQs (CBOMNIAGILE)
25 product FAQs found
Justifying any decision around online analysis requires careful and fair consideration of the associated upside.
For a decision around dedicated sampling/analysis stations for a new build, we recommend making a conservative estimate of savings in materials and not underestimating the value of time. A few months' saving on the construction timeline translates directly into an earlier swing from expenditure to income, an inflection point that cannot come soon enough for most projects.
For process control, consider the current situation to determine the magnitude of possible gains. For example:
- What is a recovery improvement worth for your process?
- If you could reduce impurities in the concentrate, what would that mean for selling price?
- What’s the difference in flotation reagent consumption, best to worst current case? What would be the savings if you consistently hit the best case?
- How much are you overmilling over milling to avoid overly coarse material exiting the grinding circuit? What would be the energy savings if you weren’t? Online analysis should pay its way, and easily, so calculations such as these should readily highlight optimal areas for economic implementation and provide evidence to support investment.
In the grinding circuit, under-grinding typically means poor metal recovery (mineral processing) or sub-standard product (cement). Over-grinding, on the other hand, drives up energy consumption and results in undesirable levels of fines. Milling just enough, balances these competing impacts. Online real-time particle sizing analysis makes it possible both to identify an optimal setpoint for particle size and then reliably maintain it.
In a flotation plant, there is an analogous balance to establish. Poor separation means excessive metal loss while excessive reagent addition is expensive and environmentally undesirable. Here, real-time elemental analysis can provide the information needed to identify the operational sweet spot and optimal control in the face of changes in particle size, ore mineralogy, and pulp density.
In both cases, with real-time data, changes tend to be more frequent but smaller, i.e., the plant stabilizes, with automated control minimizing variability.
If you are aiming for automated process control, then that is only practical with high availability and 95% should be an absolute minimum. Otherwise, switching to and from manual process control will be arduous and problematic with respect to operational efficiency. If availability is not demonstrably high, then operators cannot rely on an analyzer, whether control is manual or automated, and it never becomes an integral part of the control architecture.
When implementing online analysis, there are two key questions to consider: What can I measure? And what can I control to affect that measurement?
Let’s take grinding circuit control as an example. A measurable variable is the particle size of the exiting material, and it can be controlled by parameters such as mill throughput and speed of rotation. How often to measure is then the next question. With manual control, a large interval between measurements inhibits an operator’s ability to adjust the process effectively. There is a long lag between taking action and seeing the result. Increasing measurement frequency, to the limit of real-time measurement, improves feedback allowing the operator to learn how to 'steer' the circuit more effectively. The result will be steadier operation with an automated, well-tuned control loop, the best solution for driving variability to a minimum.
If you can measure and tightly control a vital characteristic of a key stream, in a grinding or flotation circuit, or elsewhere on the plant, then the rewards can be substantial. If you can’t influence a measurable parameter, then there is far less impetus to measure it at all, or with any frequency, though measurement may still be valuable for upset monitoring. Focus on how you would use data if you had it to identify the best places for investment and the frequency of measurement that will be most useful.
Well-designed dedicated analyzers require only minimal cleaning and maintenance for reliable operation over the long-term. The sample transport associated with centralized systems, on the other hand, requires the addition of pumps and small-bore sample lines adding additional complexity and failure points to the system. These have potential to affect data availability and cost of ownership due to the maintenance, running costs, and emissions associated with pump operation. Such systems are often installed with good intentions and a sound understanding of the practice required to keep them in good working order, but over the years, enthusiasm and rigor have tended to dwindle. Abandoned lines are common with centralized analyzers, an important point to note when assessing upfront CAPEX.
The other significant difference between multi-stream and dedicated analyzers is measurement frequency. For streams that justify real-time measurement, or as close as is feasible, dedicated analyzers are unbeatable.
If you have the freedom of a new build, then it’s vital to be aware of the broader ramifications of choosing dedicated slurry sampling and analysis stations which are linked with the criticality of head loss and pumping costs. All slurry sampling is associated with head loss, but it can be minimized by selecting a dedicated, low pressure drop sampler with integral analyzer to deliver lower plant heights and/or less pumps. With the smart use of dedicated stations, it is therefore possible to save on construction materials (concrete and steel) and costs, and at the same time shorten project timelines. These are major gains. In contrast, centralized analyzers, however good, necessitate a more complex process flow diagram with all the inefficiencies that go along with it.
Key features are source type/strength and detector size/quality since these define measurement uniformity across the belt and data quality. More powerful sources mean higher neutron counts, in effect, a higher signal, while multiple sources provide more uniform coverage across the belt. Larger or better-quality detectors more effectively capture gamma rays released by the sample with multiple detectors enabling more uniform capture across the belt.
To maximize the value of a cross belt analyzer for a specific application, you should therefore look for flexibility and performance with respect to both source and detector with a view to optimizing for either repeatability or uniformity across the belt, depending on which is more important. Weight, size, and ease of installation are also critical factors when it comes to the practicalities of installing an analyzer.
PFTNA/PGNAA offers moderate to excellent detection capability for industrially relevant lighter elements such as calcium, chlorine, sulfur, aluminum, silicon, magnesium, sodium, and hydrogen which are less easily detected by XRF. Elements with an atomic number of 20 or less release fluorescent X-rays that are less energetic, relative to heavier elements, and therefore more easily attenuated, which makes XRF more challenging in slurry.
PTFNA and PGNAA are both neutron activation analyses which means measurement is reliant on a neutron source. With PTFNA, the source is an electrical neutron generator while with PGNAA, it is a radioactive isotope such as Californium 252. Other than neutron source, which affects suitability for certain applications, the two techniques are essentially identical.
AccuLINK Software is available that provides continuous comparisons with the lab and timely, automatic calibrations. The software 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.
Learn more about AccuLINK software here (https://www.thermofisher.com/order/catalog/product/ACCULINK).
There are no moving parts so maintenance is minimal. In isotope-based systems, the isotope will need to be periodically "refreshed". Our recommendation is to add half the original amount at each half-life of the isotope. Additionally, if a neutron generator is used, the tube inside the accelerator head will periodically need to be replaced.
An advanced interface and spectral analysis tool processes, displays and archives data as it simultaneously tracks and monitors the health of the instrument. The data can be accessed by multiple users all at the same time from any remote workstation throughout a plant that is connected to the same network as the main operator console.
Learn more about OmniView online elemental analyzer interface software here (https://assets.thermofisher.com/TFS-Assets/CAD/Datasheets/omni-view-software-datasheet.pdf).
Yes, while online analyzers utilize neutrons in order to perform their measurements, the systems are designed to be completely safe. Leading manufacturers go to great lengths to ensure that personnel are able to work around the analyzer without the need for access restrictions or radiation monitoring.
Note: Thermo Scientific online cement analysis systems are designed so that radiation levels around the sides of the system are significantly below regulation limits and are comparable to what is termed "background radiation" which is essentially the same amount of radiation from day-to-day activities. Shielding materials used in the system allow access around the instrument and ensures personnel safety. The unit is inherently safe and does not require isolation and fencing to keep plant personnel away from the system. Additionally, should a neutron generator system be selected as the source for neutrons, the generator can be turned off at any time.
Essentially two types of neutron sources exist to enable PGNAA: i) A fissionable radioisotope (or combination of radioisotopes) or ii) created electronically by a specialized compact linear accelerator called a Neutron Generator.
Radioisotopes that fission neutrons which can be used for PGNAA are either 252Cf or the combination AmBe. By far, the most common radioisotope utilized is 252Cf for various reasons one of which is safety.
A neutron is a sub-atomic particle that is a component of the nucleus of all elements (except for simple hydrogen).
Prompt Gamma Neutron Activation Analysis (PGNAA) and Pulsed Fast Thermal Neutron Activation (PFTNA) are non-contact, non-destructive analytical techniques used in online analysis systems to determine the elemental composition of bulk raw materials. PFTNA is a form of PGNAA but it uses a Neutron Generator as its source of neutrons as opposed to an isotope. Both of these techniques are known collectively as neutron activation analysis and function by bombarding materials with neutrons.
The neutrons interact with elements in the materials, which then emit secondary, prompt gamma rays that can be measured. Similar to X-ray fluorescence (XRF), each element emits a characteristic energy signature as it returns to a stable state.
Learn more about PGNAA and PFTNA technology here (https://www.thermofisher.com/us/en/home/industrial/cement-coal-minerals/cement-coal-minerals-learning-center/cement-analysis-production-information/pgnaa-pftna-technology.html).
Prompt Gamma Neutron Activation Analysis (PGNAA) and Pulsed Fast Thermal Neutron Activation (PFTNA) are non-contact, non-destructive analytical techniques used in online analysis systems to determine the elemental composition of bulk raw materials. Both of these techniques are known collectively as neutron activation analysis and function by bombarding materials with neutrons.
The neutrons interact with elements in the materials, which then emit secondary, prompt gamma rays that can be measured. Similar to X-ray fluorescence (XRF), each element emits a characteristic energy signature as it returns to a stable state.
Learn more about PGNAA and PFTNA technology here (https://www.thermofisher.com/us/en/home/industrial/cement-coal-minerals/cement-coal-minerals-learning-center/cement-analysis-production-information/pgnaa-pftna-technology.html).
The number of controlled moduli is one less than the number of different, controllable material types (i.e., control parameters = n-1 where N is the number of distinctly different materials. 4 different materials will allow the control of 3 quality control parameters, etc.
Yes. One of the most popular uses of cross-belt online analysis systems is controlling stockpile chemistry to meet quality targets, thus ensuring smooth kiln operation and providing flexibility in quarry operations. Whether the stockpile is longitudinal or circular, online analysis systems allow consistent stockpiles, with minimal variations within and between piles. The analyzer can track the chemistry of the stockpile compared to the target chemistry and determine the preferred proportions of the source raw materials.
As an example, if you are trying to blend limestone and clay, here are some considerations for control in the pile. If you have only two distinct materials available, without much chemistry variation within those two material types, then in general terms, a single quality control parameter, such as Lime Saturation Factor (LSF) or an estimate of Alite (tricalcium silicate) using the Bogue equation for Ca3SiO2 (C3S), could be used to control the quality of the pile. If however, the two raw materials you have available actually have chemistry variations such that the limestone and clay can be considered multiple different types of limestone and multiple different types of clay, then in reality there would be more than two materials available for control (e.g., High Grade Limestone, Low Grade Limestone, Low Silica/High Alumina Clay, High Silica/Low Alumina Clay, High Iron Clay, etc.).
This is usually the case within a quarry as typically there are fairly significant chemistry variations across an entire quarry with multiple differing grades of material on different mine benches.
Read additional details on this topic in the blog article: Question About Limestone and Clay Blending in Cement Production (https://www.thermofisher.com/blog/mining/question-about-limestone-and-clay-blending-in-cement-production). Also see RAMOS Raw Mix Optimization Software (https://www.thermofisher.com/order/catalog/product/RAMOS) for additional details about automatically adjusting multiple raw material source feeds to optimize blend proportioning, reduce chemistry variability, and minimize cost.
One of the most popular uses of cross-belt online analysis systems is controlling stockpile chemistry to meet quality targets, thus ensuring smooth kiln operation and providing flexibility in quarry operations. Whether the stockpile is longitudinal or circular, online analysis systems allow consistent stockpiles, with minimal variations within and between piles. The analyzer can track the chemistry of the stockpile compared to the target chemistry and determine the preferred proportions of the source raw materials.
As an example, if you are trying to blend limestone and clay, here are some considerations for control in the pile. If you have only two distinct materials available, without much chemistry variation within those two material types, then in general terms, a single quality control parameter, such as Lime Saturation Factor (LSF) or an estimate of Alite (tricalcium silicate) using the Bogue equation for Ca3SiO2 (C3S), could be used to control the quality of the pile. If however, the two raw materials you have available actually have chemistry variations such that the limestone and clay can be considered multiple different types of limestone and multiple different types of clay, then in reality there would be more than two materials available for control (e.g., High Grade Limestone, Low Grade Limestone, Low Silica/High Alumina Clay, High Silica/Low Alumina Clay, High Iron Clay, etc.).
This is usually the case within a quarry as typically there are fairly significant chemistry variations across an entire quarry with multiple differing grades of material on different mine benches.
Read additional details on this topic in the blog article: Question About Limestone and Clay Blending in Cement Production (https://www.thermofisher.com/blog/mining/question-about-limestone-and-clay-blending-in-cement-production).
Yes. Reducing raw material chemistry variation is one of the primary tenets for installing an online analyzer. Other control parameters such as C3S, C2S, C3A, C4AF, etc. can also be used as control parameters and individual oxides can also be used if desired. An online analyzer coupled with automated high frequency control can help reduce process variability.
In a case study of an online analyzer project that was undertaken with the goal to decrease the standard deviation of the modulus in the production of raw meal, it was found that the online analyzer eliminated the errors that occurred from sampling, since all the material that passed through the belt was analyzed on a real-time basis using Prompt Gamma Neutron Activation Analysis (PGNAA) technology. This eliminated errors that could occur from the time delay for sampling and sample preparation, which was almost 90 mins. With the use of real-time analysis results from the online analyzer and the optimization parameters in the software, the standard deviation of modulus in raw meal production was decreased by 70% for LSF, 50% for SM, and 33% for AM. With the production of more homogeneous and stable raw meal, the clinker quality was also increased. Standard deviation of the free lime content in clinker production was decreased from .72 to 0.37, which was equal to almost 50% improvement. Also, kiln operation became more stable, which is believed to have decreased kiln thermal consumption and increased the life of kiln brick lining.
Yes. A key tenet to minimal energy consumption in a cement manufacturing process is kiln feed with proper chemistry having low variability. High frequency process control using an online analyzer helps ensure this goal becomes a reality.
The control-loop cycle using offline X-ray analysis (laboratory instruments) can be relatively long and many times can miss high frequency variations in the raw material quality in process. With control using an off line X-ray instrument, analysis measurements are made using a very small sample taken from the process. A typical time period between sample collection and laboratory measurement is generally 1 to 2 times per hour. A lot can change and happen in an hour. Any changes implemented based on those results are an hour or two old and the process will likely be different. At times, material proportioning changes based on offline X-ray analysis could be incorrect for current conditions and drive the chemistry further off specification rather than closer to specification.
While laboratory X-ray analysis and process control have been an industry standard for many years, this strategy can be significantly enhanced through the addition of an online analyzer and automated high frequency proportioning control. Online analyzers have the unique ability to measure all the variations in the raw material and with control software can react to those changes every minute. Adjustments to material feed rates are made to smooth out those fluctuations.
The same concept is applied with a pre-blending stockpile control application of an online analyzer but here, the control cycle is a little slower and different because feedback is to mining operations and loaders.
Kiln feed material with high chemistry variations requires more fuel in the kiln to properly react and more energy at the finish mill to grind over-reacted clinker. By using an online analyzer to minimize chemistry variation, fuel and energy consumption can be reduced and process upset conditions avoided.
Another contributor to potential errors when using a material sampling and offline laboratory analysis strategy is that representative samples needed to be sent to a laboratory are quite difficult to obtain. It is in this area where an online analyzer is extremely helpful in reducing energy consumption; it doesn't need a sample, measures all the material and quickly tells mining operations they are sending the wrong material to the plant.
With increased and timely awareness of the quarried material chemical composition, a cement producer can significantly reduce the amount of quarried materials that may have been previously wasted and instead use them in the process. This can have a direct impact on lengthening the life of the quarry and minimizing costs associated with the purchase of outside raw materials.
Online analyzers continuously measure the elemental composition of the entire raw material stream, in real time, being carried on a conveyor belt. The system provides an elemental analysis of the raw materials each minute, without touching the materials, and without errors and costs associated with material sampling for off-line laboratory analysis. The one minute analysis frequency can be adjusted if desired; however, from much experience, it has been found that an analysis every minute is more than adequate to provide significant enhancement to existing process control methodology.
Each cement plant is different and each has unique challenges and requirements. In general, it is good to start by reviewing the use of an online analyzer to control the raw material quality within a pre-blending stockpile. In this application, the online analyzer is located after the primary crusher but before the pre-blending stockpile. Here, the analyzer will monitor material in process from mining operations. If there are adverse materials found within the quarry deposit such as magnesium, alkalis, high sulfur, etc., an online analyzer can provide the immediate feedback needed to identify and avoid those materials.
As well, using an online analyzer to keep a pre-blend stockpile at target chemistry, while at the same time minimizing chemistry variations throughout the pile, ensures that an optimized pre-blend reaches the raw mix proportioning station. Using this strategy, a reduction in the use of higher cost additives later in the process may be realized as well as a reduction in material variability at the raw mill. However, many times, the most benefit can be achieved through the application of the instrument at the raw mix proportioning stage within the process. Here, the analyzer monitors the process by providing high frequency analysis and automatically adjusts raw material feed proportions.
When considering where to place an online analyzer, discuss key application parameters and process goals including stockpile blending, sorting, raw mix proportioning or any additional installation locations with the manufacturer's representative or application specialist.