Allscan n-Gen Cross Belt Analyser in Cement Industry
The AllScan n-Gen cross belt analyser uses world-first neutron generation technology with ground-breaking spectra modelling and powerful statistical analysis in provision of elemental analysis in real time. Installed on a conveyor belt, the AllScan delivers accurate, minute-by-minute elemental analysis and reporting of the chemical composition of bulk materials and key process parameters.
AllScan N-Gen is a quantum leap in analyser technology, delivering higher yields, increased returns, and lower costs for your operation.
- World-best n-Gen analyser innovation
- Simple, intuitive calibration
- Lowest cost of operation in the market
- Maximise output, minimise downtime and costs
- Shore up site and resource sustainability
Theory of Operation
At the heart of the AllScan is Neutron Generation (n-Gen) technology. Material on the conveyor is bombarded with neutrons emitted from a radioactive isotope or neutron accelerator.
RTI has incorporated a revolutionary new neutron generator design into the AllScan n-Gen elemental analyser.
AllScan n-Gen incorporates a sophisticated algorithm - DuraG™ - that separates the effect of belt loading and profile variation on the measured spectra from the effect of elemental variation on the elemental spectra. DuraG™ dramatically reduces measurement error.
AllScan n-Gen also includes - DuraSum - a powerful algorithm that eliminates the need for time-based averaging of data in order to obtain stable results. This means that significant changes in elemental composition are reported almost instantaneously, rather than minutes later. This in turn allows for rapid operational control.
These breakthrough technologies combine with the reliability of the n-Gen measurement technique to deliver the most accurate and responsive coal elemental analyser on the market today.
New cutting edge design eliminates the need for air conditioners to cool the electronics. The AllScan package is provided in a small footprint fully contained, and is the smallest n-Gen on the market.
The AllScan n-Gen comes with an intrinsically safe auto source on/off source drive mechanism.
The generator life span is more than 10 years.
There is a constant output of neutrons, with no decay over time as with Cf-252 sources.
The only maintenance requirement is that re-gassing is required every 2.5 - 3 years. When neutrons collide with an element in the material, gamma rays are emitted with a specific energy unique to that element – in effect, creating a chemical signature for that element. The greater the amount of an element in the material the greater the number of gamma rays emitted with the corresponding specific energy. By measuring the specific energy of the gamma rays that are emitted, and the counts of gamma rays, an accurate analysis of the chemistry of the material is generated on a second-by-second basis.
The AllScan cross belt Cement PGNAA Analyser measures and reports analytical data of relevance for cement production, such as: SiO2, Al2O3, Fe2O3, CaO, MgO, Na2O, K2O, S etc + Moisture as well as customer-defined derived cement chemistry modules like LSF, KH, SIM, ALM etc. Accessible from the touch screen integrated in the control cabinet or utilising various available interface options, the AllCement user interface software presents:
- Configuration data
- Status information
- Last 1-min analysis values
- Tonnage weighted rolling averages
- Configurable trends
- Current accumulated pile
- Previous accumulated pile
- Data from selected piles
The use of AllScan in Quarry and Stockpile management applications at cement plants facilitates significant improvements in pre-blending performance through:
- Optimised utilisation of quarry materials
- homogenised building of the stockpiles to desired target chemistry with minimum variations
Stockpile and Quarry Management
In the cement Stockpile application the AllScan® is typically installed on a conveyor section between crusher(s) and stockpile(s). The AllScan® continuously reports the elemental composition of the conveyed material. The data obtained is used to keep track of the pile build-up and may optionally via 3rd party optimising software be used to direct haul trucks to different sections of the quarry in order to best exploit the quarry over time as well as to optimise the quarry equipment utilisation.
Another important cement plant application for AllScan® is to provide fast on-line analytical data for a Raw Mill quality control application. Here the analyser is placed on a conveyor belt section downstream of the feeders and upstream of the raw mill. The on-line analytical data by AllScan® is the essential basis for 3rd party software QC optimizing schemes, which applied for:
- Green field projects facilitates smaller and therefore less expensive homogenizing silo systems.
- Existing plants may be the ‘repair tool’ for poor functioning silo systems
Raw Mill Feed Quality Control
Both case examples mean significantly reduced variability in the raw mix product from the mill, and ultimately the kiln feed. Consistent kiln feed chemistry in turn leads to better quality clinker, lower fuel consumption per ton of clinker produced, reduced refractory costs etc.
A less frequently applied application; however, increasingly demanded from the market is to install a PGNA Analyser to monitor the delivery of coal/lignite to cement plants. In particular with poor quality lignite or varying coal qualities from a range of different suppliers the installation of AllScan® may provide significant quality improvements by close monitoring of the ash contents and percentage of the incoming coal/lignite.
AllScan® offers easy connectivity to cement plant control systems:
- Application data from the AllScan® are seamlessly transferred to the plant control system and is typically interfaced to 3rd party cement QC software to optimize quarry operations, stockpiling and raw mix proportioning
- AllScan® interfaces by means of applicable electrical standards and communication protocols with well-known DCS & PLC type Plant Control Systems as well as QC optimization software from leading suppliers of cement specific quality control software.