SPECTRAFLOW ANALYTICS INSTALLED SUCCESSFULLY AN AIRSLIDE ANALYZER FOR RAW MATERIAL OPTIMIZATION FOR TAIHEIYO CEMENT, JAPAN

 

Spreitenbach 2019-10-31

Taiheiyo Cement is the largest cement manufacturer of Japan and operates today 9 integrated plants all over Japan. Beside the operations in Japan, the company also operates 3 plants in the USA, 3 in China and 1 in Vietnam and the Philippines. Taiheiyo is renowned for their energy efficiency and high product quality by using state-of-the-art technologies, including the SpectraFlow Online Analyzer. Also the environmental footprint of the production is very important for the Taiheiyo group and by using radioactive free online analyzers a further step for higher sustainability is taken.

 

About Taiheiyo Kamiiso:

The Kamiiso plant is located in Hokkaido, the most northern island of Japan. With a production of around 4 Mio tons of cement the plant serves customers in Hokkaido and with a marine terminal right at the production site also customers in other areas of Japan and overseas.

 

Taiheiyo Kamiiso plant installed the airslide analyzer in the beginning of this year and was integrating the results into their plant work-flow since several month. After the successful installation the sampling frequency can be reduced and the overall kiln feed stability improved. After this first successful project Taiheiyo is now evaluating further possible installation locations in their group.

 

SpectraFlow Installation for Raw Material Grinding Optimization:

 

General:

The SpectraFlow Airslide Analyzer is the online analyzer to be able to measure raw materials in airslides. As raw materials in airslides are very homogeneous and dry the analytical results of the SpectraFlow Airslide Analyzer are very accurate and based on these accurate results the RMP control software can optimize the weight feeders before the raw mill in real time every minute. This results in very low LSF STDEV without the need of extensive sampling and laboratory efforts.

 

By using SpectraFlow an increase in the raw meal quality will be achieved.

 

Summarized benefits are:

• No need of intensive sampling. No automated sample transport system, no automated laboratory required.

• High cost reduction due to reduced laboratory usage (CAPEX, OPEX, man power,…)

• The analyzer together with the RMP Raw Mix Proportioning control software is fully automating the raw material grinding. The analyzer delivers the analytical results and according the setpoint the software is adjusting the weight feeders of the additive bins.

• Adjustment of the weight feeders in real time every minute. No time delay due to sampling, sample preparation,…

• Introducing redundancy for the raw mill control. SpectraFlow is delivering the chemical results for the weight feeder control normally, while as a back-up, the laboratory can be used in the rare case, that the SpectraFlow Analyzer is not available.

• Lower LSF STDEV/better and more consistent raw mill quality

This SpectraFlow order is the 36th order for the Cement Industry and the 30th installation in Asia. This order raises the installed based in Japan to 8 analyzers (1 Airslide, 7 Crossbelt) and worldwide to 48 analyzers (24 Crossbelt & 24 Airslide).

 

SpectraFlow Analytics Ltd. Switzerland are the experts in providing online analysis for the cement and minerals industry without any radioactive sources nor neutron generators. The NIR technology used for the SpectraFlow Analyzers is not requiring any permits or licenses and there are no restrictions in buying, importing or maintaining the analyzers. This results in very low operating costs and high availability of the analyzers combined with highly accurate measurement results.