The QCX/BlendDesigner™ software module is the quality manager's toolbox for mix design from quarry to cement, e.g. determine how to produce a new cement type, minimize cost of raw materials, examine the impact of new raw materials, additives, dust, fuel etc.
The cement plant is described by key locations (material balance points): quarry, pile, raw mill, kiln feed, clinker, cement etc. Raw materials and fuels, characterized by their chemical composition and feed status, may be added at each location. After specifying the quality target, e.g. using chemical analysis or modules like LSF, SIM, ALM etc., at a desired location, the application will determine the optimum mix of raw materials. Cost may be specified for each individual raw material, allowing the application to find the most economical mix. Furthermore, the feed of materials may be constrained (in tons and percent) as well as the chemical quality, e.g. max MgO.
The calculations can be done in wet, dry, LOI (loss on ignition) affected or LOI free basis and is performed simultaneously for all defined balance points. In other words, one can see the consequences for the pile input if the quality target for the cement silo is changed.
The application is based on an intuitively appealing graphical interface. Active-spots in the graphic area provide immediate and easy access to data setup tables and result windows. As shown on the examples on the front page the visualization concept is to import a real picture or a CAD drawing of the actual plant and on this backgrund picture define the data windows in the relevant process locations; e.g. raw mix data at the silo inlet, clinker data at the cooler outlet and so on.
The application provides printout of both data setup and results. Furthermore, an unlimited number of mix scenarios may be stored in a database for future examinations.
Data capture from the on-line control applications QCX/BlendExpert-Pile or QCX/BlendExpert-Mill is another supported feature, which makes it easy to troubleshoot a mix control problem, which may right now need attention in order to avoid large quality fluctuations, or to experiment with new potential raw materials.
As one of the first QCX modules QCX/BlendDesigner is programmed in the new ".net" programming standard. Amongst other features this will provide smart access via intranet or internet to the simulation features. This means that a key specialist from his PC at a corporate head office can support effeciently on a sudden quality control issue on a plant thousand of miles away. And this without having to install any extra software on his PC.
The product is available as an add-on module to any other QCX/BlendExpert module or can be delivered as a stand-alone software package with a minimum of general supporting QCX functionality.
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