Reach a new level of cement production quality control

Reducing manual tasks

QCX/BlendExpert – Mill takes on the complex process of controlling raw material and additive blend to consistently meet product quality targets, with minimum variance. Based on the analysis of the material stream, the software continuously integrates material tonnage and chemical analysis results, comparing the expected raw meal quality with quality targets. The software can adjust the feeders more frequently and reliably than manual control.

And it has a unique ability to handle upset conditions without the need for your operators to intervene. Where other systems would simply switch back to manual control, QCX/BlendExpert software reliably adjusts feeder settings, even in the case that a feeder has been incorrectly calibrated. Where a feeder is in starvation, the system will estimate if it can still reach quality targets in that condition.

In addition, by accurately estimating the chemistry in the feeders at any given time, the need for physical sampling, sample preparation and analysis is greatly reduced. This labour-saving software is a complete system, saving you time and money, and allowing your highly skilled staff to focus on other tasks.

Advanced chemical control

QCX/BlendExpert – Mill gives you real-time control over your chemistry. Raw meal composition is constantly estimated, and changes in the material compositions are assessed as they happen. The software adjusts the feeder set-points taking target chemistry, chemical constraints, process limitations, and material costs into consideration. It gives you accurate, online accounting of individual raw material feed streams and other relevant materials, such as dust, coal, ash, fly ash, alkali and bypass, based on weigh feeder signals.

The innovative silo estimation feature reliably estimates silo content and composition in accordance with applied silo models (continuous, layered or batch) and current product type.

And the handy ‘control tuning’ tool allows you to experiment with different process inputs like feeder settings, material qualities, set points and other variations to see the results.

Flexible

QCX/BlendExpert - Mill can be configured for any number, type and make of mills. It can be based on any laboratory or online analysis technique, or in any combination of analysers. In addition, it can operate with multiple materials per feeder to meet the demands of modern plant conditions, where material types can rapidly change.

Quality stockpile formation using 3D modelling technology

Do you have an accurate picture of your stockpile?

Complete raw material control enables you to make the most of your process. The best raw mix goes in. The highest quality product comes out. Our latest QCX/BlendExpert software with unique Pile feature uses 3D modelling technology to give you the greatest possible insight to your stockpile. What does that mean to your operation? It means:

• Greater understanding of stockpile composition

• Reduced need for further blending operations

• More stable kiln operation

• Lower fuel consumption and emissions

• Increased alternative fuel utilisation

• Optimum product quality

How does it work?

The programme continuously measures material tonnage and chemical analysis, and compares this with the target quality to automatically calculate optimal feed rates. With the addition of a controllable feed device, specified quantities can be fed to the pile automatically. This advanced software has options to optimise your pile tonnage and chemistry any time during pile build up, and even determine optimum pile composition according to material cost.

Now you can engineer your stockpile chemistry so it is as close as possible to raw mill product specifications. You can make the most of the materials in your quarry. You can reduce the consumption of costly additives. This unmatched level of control at the start of your process saves you time and money – and gives you less variance in your end product.

Dynamic accounting capabilities 

What difference could total stockpile control make to your operation? Taking into account the target chemistry, available raw materials in the quarries and material costs, QCX/BlendExpert - Pile is able to give you advanced data in smart, easy-to-read graphs and tables. Not only does it accurately document stockpile chemistry, it presents 3D views of the pile showing the chemistry variations within the layers. And it works the same way whether you have a longitudinal or circular stockpile. Even customised accounting models are available on request.

Advanced analysis methods

QCX/BlendExpert - Pile uses state-of-the-art Prompt Gamma Neutron Activation Analysis (PGNAA) or Pulsed Fast Thermal Neutron Activation (PFTNA) for the on-line elemental analysis of material streams. But if needed, it can also operate using more traditional methods such as a sampling tower or newer technologies based on light emissions.

New highly advanced 3D modelling 
The highly advanced 3D modelling of the pile chemistry gives a unique opportunity to visualize the chemistry as it is stacked and reclaimed. The better you understand your stockpile, the fewer problems you have at the end cone.