Continuous On-Stream Mineral Analyser (COSMA)

 

A recent development using XRD techniques, a unique fixed detector, specially designed sample preparation and presentation system and Rietveld codes provides a continuous real time analysis on the true mineral composition of powder streams such as cement or ground clinker. A complete and full analysis is given minute by minute such that trends can be followed and each analysis can be seen in context with the one before, such that high confidence can be had in the trend of the plant.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig 1. Mineral Analysis of cement from cement mill after a hot stop.  Note gypsum dehydration and cement hydration that occurred during mill stop.

 

 

 

The equipment has been developed for use by the cement industry to monitor clinker from the kiln or cement from the cement mill to allow better control and optimization of the process and product quality, leading to cost savings as well as more consistent quality.  Located at line near the cooler or the cement mill, cement requires no further treatment before feeding through COSMA for analysis, but clinker will require grinding.

 

The system includes sampling (virtually continuous), sample transport to COSMA, and pneumatic transport of analyzed sample back into the process operating as a parallel stream to the main product stream.

 

 

 

 

Fig 2 COSMA Analyzer unit and schematic of system for continuous analysis of cement stream.

 

 

Quantitative Phase Analysis information is transmitted to the plant DCS via modbus or Ethernet to provide real time information for plant control purposes.  Some limited information is stored in the on-board computers.