Quicker more Frequent Information

With the ITECA range of Online Analysers specifically designed for the cement industry you can get process related information quicker and more frequently than ever before. Using the ITECA online analysis systems improves process intervention response times, it reduces safety risks to personnel, it avoids human error and it drastically increases the available information for decision making. ITECA has been at the forefront of sampling and analysis equipment in the cement industry for more than three decades.

FREE LIME ANALYSER

Free lime is a critical parameter for the optimisation of a kiln and to ensure that quality clinker is produced. Clinker samples can be automatically taken using the ITECA Hot Clinker Sampler and then transported with the ITECA pneumatic sample transport system to the the ITECA Free Lime Analyser. This integrated system requires no human intervention under normal operating conditions and can yield a Free Lime analysis every 15 minutes.

Clinker transported to the Free Lime analyser goes through sample grinding and then precise weighing of predetermined quantities of clinker powder and Glycol. These two components are then mixed and heated which triggers a chemical reaction. The conductivity of the mixture is then measured after a set time and interpreted in terms of Free Lime.

Having frequent and accurate information on the free lime content of clinker will enable the operation to control the kiln in short intervals. This short interval control will avoid over cooking of clinker as well as under cooking clinker. The two main advantages is therefore reduce energy consumption and improved clinker quality.

LOSS ON IGNITION ANALYSER

The ITECA Loss in Ignition analyser has two applications in the cement manufacturing process. The most popular application is to determine the degree of calcination on hot meal before it enters the kiln. The degree of calcination is an indication of how efficient the preheater and pre-calciner is being operated and should be available to kiln operators. Critical control actions should be based on the degree of calcination, like the balance of fuel between the main burner and pre-calciner.

The second application is to control and optimise the amount of cement additives like limestone being added to cement. 

The major advantages of this system is the reduction of energy consumption on the kiln and to optimise the use of cement extenders in order to decrease clinker content in cement while maintaining performance.

RAW MIX ANALYSER

Controlling the raw mix to be introduced to your mill and subsequently to the kiln has never been easier. The ITECA Raw Mix Analyser is a completely automated XRF analyser that can analyse materials from up to three different point in a plant.

The raw meal sample is taken after the milling process and will adjust the raw mix to the mill by controlling the individual raw material feeders. Frequent analysis of up to seven samples per hour is possible, meaning the mill can be controlled on short intervals. By reducing the standard deviation of the raw meal compared to desired setpoints will lead to more efficient operation in the kiln. The main advantages of the raw mix analyser is reduced energy consumption and improved product quality.

BACK-END GAS PROBE

The ITECA Gas Probe have developed a reputation for reliability and accuracy. The system was designed to sample kiln gasses at the inlet of the kiln, avoiding false air from skewing the results. The condition in the part of the kiln is extremely hard on equipment and therefore the design had to be robust and innovative to avoid the usual problems experienced with back en gas probes.

Unlike most back end gas probes the ITECA gas probe do not use purging air to clean the sample tube. ITECA uses 8 bar pressure water blasts to clean the sampling tube in such a way that it does not influence the sampling and analysis process. As a result of the innovative design the ITECA probe do not use a ceramic filter that blocks up after some time.

The back-end gas composition is important to know if a kiln operator want to truly optimise the combustion process and maximise production. With the ITECA Gas Probe it just became easier. The ITECA Gas Probe is compatible with all gas analysers on the market.

ONLINE CLINKER XRD ANALYSER

The ITECA clinker XRD analyser measures the mineral composition of clinker online. The clinker XRD analyser provides key information for the cement manufacturing process to guarantee quality product with optimised kiln conditions and alternative fuels usage.

The clinker XRD analyser is used in combination with the ITECA hot clinker sampler and the ITECA clinker transport system. Clinker samples is taken from the clinker cooler and transported to the analyser where the material is first ground in preparation for analysis.

The ground clinker is fed to the XRD turntable for continuous analysis with a fixed detector. Once the analysis is complete the material is automatically returned to the process. With ITECA clinker XRD analyser the clinker quality is measured according to the Rietveld equations. The information obtained from this analysis is truly powerful in terms of kiln control.

CARBON SUPLHUR ANALYSER

The ITECA Carbon Sulphur Analyser is a versatile machine with several applications in a cement operation. On cement the Limestone and gypsum content can be determined and used for control of the cement mix. The degree of calcination in the pre-calciner can also be determined as well as the sulphur content of clinker, which is useful when using alternative fuels.

The Carbon Sulphur Analyser does calcination at 1350ºC by means of an induction furnace under Oxygen flow. Infrared combustion gas analysis is then used to determine the quantities of the elements in question.

The analyser is capable of analysing up to 4 samples per hour and it can analyse materials from three different sampling points. One analyser can therefore be used on all three applications mentioned.

Online Particles Size Distribution Analyser

The ITECA Online Particle Size Distribution Analyser is used for continuous measurement of the particle size distribution of cement. The online PSD analyser is simply installed on a vertical chute. A section of chute is removed and replaced with a spool section fitted with a screw sampler that passes through the complete material stream ensuring that every particle has an equal probability of being sampled.

The sampled material then goes through a secondary sampler that passes the material through a Malvern Sizer. Finally the material is returned back to the process in the same chute.

The ITECA Online PSD Analyser report near realtime information to the control enabling short interval control. The rapid response to changing material properties will reduce the coefficient of variance on the cement and in so doing result in consistent quality cement with better strength development. The frequent PSD information is also ideal to use in high level control systems on cement milling circuits, which will increase mill throughput and reduce specific energy consumption.