SPECTRAFLOW RECEIVES A NEW ORDER FOR ONE CROSSBELT ANALYZER AND ONE AIRSLIDE ANALYZER FROM DCCP CEMENT, IRAQ
DCCP (Dabin Company for Cement Production) ordered one SpectraFlow Crossbelt Analyzer for Stockpile Optimization and one SpectraFlow Airslide Analyzer for Raw Mill Control for their new production unit near Erbil City in the Kurdistan region of Iraq.
About DCCP Cement:
In mid-2023 the Power Construction Corporation of China, Iraq held the foundation ceremony of a new cement manufacturing unit and a power plant project close to the city of Erbil in the Kurdistan region of Iraq. The project consists of a self-provided heavy oil power station and a cement production line with a daily capacity of 6000 tons of clinker. The project was executed in a record 2-year period and production started in early 2025.
SpectraFlow Analytics was chosen for the supply of their online quality monitoring due to its high performance and reliability. This was besides the obvious benefits of the absence of radioactive sources, which eases the import, delivery time, installation, maintenance and operation, all while reducing the operational cost of the analyzers massively in comparison to PGNAA/PFTNA analyzers.
SpectraFlow will install a Crossbelt Analyzer for the pile monitoring and an Airslide Analyzer and a RMP control software for the automatic control of the additive weight feeders.
SpectraFlow Installation for Quarry/Stockpile Optimization:
The SpectraFlow Crossbelt Analyzer is an online analyzer which provides measurements of the quality of raw materials on belt conveyors. The raw material on the conveyor belt is statistically homogeneous, thanks to rigorous mixing by a primary crusher before feed belt, and therefore the analytical results of the SpectraFlow Crossbelt Analyzer are highly representative and have proven to be accurate across world class operations.
By using a SpectraFlow Crossbelt analyzer and a site-specific blending strategy, it is possible to reduce and balance out the high variation in local raw materials. This supports the increase in consistency of the stockpile quality. Variable MgO, Na2O, K2O, Cl and SO3 concentrations in the quarry material can be monitored in addition to the major constituents, allowing for further optimization.
The summarized benefits of the analyzer are:
The analyzer is free of any radioactive sources, neutron generators or any hazardous components. This means that the SpectraFlow Analyzer does not require any permits or licenses regarding importation, operation or maintenance.
The SpectraFlow Analyzer is completely safe. Maintenance can be done by the plant personnel.
Stockpile quality can be optimized to be far more homogeneous and on setpoint. That results in stable and low additive consumption at the raw mill.
Stable feed from the stockpile leads to stable raw mill operation and fine raw meal/clinker quality.
SpectraFlow Installation for Raw Mill Optimization:
The SpectraFlow Airslide Analyzer is based on the same principle as the Crossbelt Analyzer, but instead has been specially designed and optimized for measurement inside an airslide. The airslide provides a dark environment and even more homogenous material, both of which are favourable for NIR measurement. This is because the material goes through multiple mixing stages through the crusher and raw mill and flows at high rates through the airslide, providing a thin continuous layer for optimal surface area representativity.
By using a SpectraFlow Airslide Analyzer and a site-specific raw mix proportioning strategy, the variation in the local raw materials can be balanced out to increase consistency of the raw meal, and therefore kiln feed quality, considerably. As with the Crossbelt Analyzer, contaminant and secondary constituents such as MgO, Na2O, K2O, Cl and SO3 can be monitored simultaneously with general quality control. Improved consistency of the kiln feed results in fewer kiln stoppages and refractory problems and lends towards increased clinker production.
The summarized benefits of the Airslide Analyzer are:
This analyzer too, is free of any radioactive sources, neutron generators or any hazardous components, meaning it is free from the need for permits or licensing regarding importation, operation or maintenance.
The SpectraFlow Analyzer is completely safe, maintenance can be done by the plant personnel. The added benefit of the automatic shutter gate on the analyzer further lowers maintenance frequency.
Used optimally, the Analyzer will support improved raw meal homogeneity and adherence to the setpoint. That results in a more stabilized and optimized kiln operation.
The Airslide Analyzer eliminates the need of automatic sample transport systems, automatic laboratories, high availability of operators and maintenance personal for controlling the raw mill operation.
This SpectraFlow order is the 60th order for the Cement Industry and the 2nd Crossbelt Analyzer and 1st Airslide Analyzer installation in Iraq. SpectraFlow has an installation base of 92 analyzers worldwide, 51 of which are Crossbelt Analyzers, with 41 Airslide Analyzers. SpectraFlow’s installations now cover 31 countries, across all inhabited continents.
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 does not require 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.