3.2 System:
The Quality Control Lab Automation system comprises with automatic sample
collection station, transport system, sample receiving & preparation station and
XRF cum XRD analyzer for elemental and phase analysis of sample. PSD for raw
meal and cement particle size analysis.
a) The Automatic Sample Collection and Transportation:
The collection of continuous samples from the sampling stations through a variety
of programmable choice is available to suit the nature of materials sampled
and its probable fluctuation in chemistry. The sample so collected for a suit
able period as programmed is automatically homogenized and pneumatically
transported to Robo lab. The human dependency for the above is avoided
and a very high level of sample quality and reliability is achieved along with
the achievement of total reduction of manpower for sample collection.
Sample frequency can be increased or decreased depending on the conditions
applicable from time to time.
b) Sample Receiving and Management:
The receiving station of the auto lab receives samples from 5/6 different
stations as per the programmed schedule and Robo manages the sample for
various tests like particle size distribution, chemistry etc. It separates a back
up sample for any cross checks or manual analysis and also stores an appropriate
amount of sample for day avg. composite sample for each kind of sample. The
automatic sample preparation avoids human error as well as the expensive
man power deployment.
With the help of robot, we can get the XRF/XRD analysis and PSD results
simultaneously for any online correction with advanced expert system of raw
material proportioning and process parameters. The results on any data can
be retrieved at any point of time for reference.
c) Data Management, Raw material proportioning and Process optimization system:
After XRF/ XRD and PSD analysis the data is communicated to QCX software
which instantly calculates the desired mix for the next cycle time and the signal
is passed over to Raw mill weigh feeders for micro level correction to get the
Kiln feed of superior uniformity index or low SD which enables the smooth
and optimum running of the kiln with the aid of EO system paralleled with
control of free lime and PSD for the correct operation conditions of clinkerization
and grinding, resulting in: -
The Robotic Quality & Process Control system, which was believed to be a
sky flying idea once upon a time, has become a down to earth reality today,
adding many more feathers to the cap of Indian cement industry which stands
head and shoulder above the global best.