Tight control of every step in production process is of utmost importance for achieving the maximum efficiency and quality of cement. From stock pile management, production of raw meal, preparation of kiln feed and the production of clinker right through to the final mixing of the end product the control is driven by the elemental, mineralogical composition and particle size analysis.

The latest demands on CO2 emissions drive the use of alternative fuels and the production of blended cements using supplementary cementitious materials like slag, fly-ash, pozzolan or silica fume. Here, elemental and mineralogical analyses of the intermediate and final products as well as fuels become even more important, while accurate and precise measurement of fineness is critical for optimal grinding. This requires reliable and rugged solutions for steering the process in the most cost-effective way for the highest quality cement or concrete. Malvern Panalytical offers solutions that meet these demands and seamlessly integrate into the production process.

With our cement industry and application knowledge, Malvern Panalytical instruments enable:

  • Control of mill operation through analysis of composition and fineness of raw mill feed
  • Check of mill operation through quality control of raw meal
  • Check of composition and material balances (e.g. K, Na, S, Cl) through filter/ESP dust analysis
  • Identify causes for coating formation
  • Kiln feed analysis through consistency check between raw mill product, kiln feed and clinker analyses, material balances (e.g. K, Na, S, Cl), silo blending efficiency, burnability, heat consumption
  • Analysis of cyclone samples / hot meal samples to check dust separation efficiencies, and degree of calcination, material balances (e.g. K, Na, S, Cl), silo blending efficiency, fuel burn–out
  • Check of coal mill operation, fuel consumption, ash absorption in clinker, material balances (e.g. K, Na, S, Cl), burn–out in calciner, NOx –formation
  • Check fuel consumption, sulphur absorption in clinker, material balances (e.g. K, Na, S, Cl) and NOx –formation
  • Clinker analysis to check kiln operation and clinker quality and material balances (e.g. K, Na, S, Cl)
  • Analysis of finished cement to check mill operation, gypsum and SCM additions as well as quality of the finished cement (e.g. EN 197, ASTM C150, ASTM C595 and ASTM C1157).

Insitec range

Insitec range

Robust, reliable, real-time particle sizing

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Measurement Particle size
Particle size range 0.1µm - 2500µm
Technology Light Scattering, Laser Diffraction
Dispersion type Wet, Dry, Spray, Wet and Dry

Mastersizer range

Mastersizer range

World's most popular particle size analyzers

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Measurement Particle size
Particle size range 0.01µm - 3500µm
Technology Light Scattering, Laser Diffraction
Dispersion type Wet, Dry, Wet and Dry

Aeris

Aeris

XRD made easy

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Measurement Crystal structure determination, Phase identification, Phase quantification
X-ray tube anode material Cu /Co (option)
Technology X-ray Diffraction (XRD)

CNA range

CNA range

Online elemental analyzers for effective control of many industrial processes

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Measurement Chemical identification, Elemental analysis, Contaminant detection and analysis, Elemental quantification
Accuracy 1% (non-condensing)
Technology Pulsed Fast Thermal Neutron Activation (PFTNA)

Zetium

Zetium

Elemental excellence

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Measurement Thin film metrology, Elemental analysis, Contaminant detection and analysis, Elemental quantification
Elemental range Be-U
Resolution (Mn-Ka) 35eV
LLD 0.1 ppm - 100%
Sample throughput Up to - 240per 8h day
Technology X-ray Fluorescence (XRF), Wavelength Dispersive X-ray Fluorescence (WDXRF)

Insitec range

Insitec range

Robust, reliable, real-time particle sizing

Mastersizer range

Mastersizer range

World's most popular particle size analyzers

Aeris

Aeris

XRD made easy

CNA range

CNA range

Online elemental analyzers for effective control of many industrial processes

Zetium

Zetium

Elemental excellence

More details More details More details More details More details
Measurement Particle size Particle size Crystal structure determination, Phase identification, Phase quantification Chemical identification, Elemental analysis, Contaminant detection and analysis, Elemental quantification Thin film metrology, Elemental analysis, Contaminant detection and analysis, Elemental quantification
Particle size range 0.1µm - 2500µm 0.01µm - 3500µm      
X-ray tube anode material     Cu /Co (option)    
Accuracy       1% (non-condensing)  
Elemental range         Be-U
Resolution (Mn-Ka)         35eV
LLD         0.1 ppm - 100%
Sample throughput         Up to - 240per 8h day
Technology Light Scattering, Laser Diffraction Light Scattering, Laser Diffraction X-ray Diffraction (XRD) Pulsed Fast Thermal Neutron Activation (PFTNA) X-ray Fluorescence (XRF), Wavelength Dispersive X-ray Fluorescence (WDXRF)
Dispersion type Wet, Dry, Spray, Wet and Dry Wet, Dry, Wet and Dry      

Mastersizer range

Aeris Cement edition

The Cement edition of Zetium

Insitec range

CNA range

Mastersizer range Aeris Cement edition The Cement edition of Zetium Insitec range CNA range

World's most popular particle size analyzers

Optimize cement production

The new element in cement

Robust, reliable, real-time particle sizing

Online elemental analyzers for effective control of many industrial processes

More details More details More details More details More details
Technology
Laser Diffraction
X-ray Diffraction (XRD)
Wavelength Dispersive X-ray Fluorescence (WDXRF)
Energy Dispersive X-ray Fluorescence (EDXRF)
Pulsed Fast Thermal Neutron Activation (PFTNA)