Process improvements from raw materials to finished products
We have worked with the Cement Manufacturing Industry for decades and offer a portfolio of products to address your challenges in every stage of the production process, from raw materials sourcing to milling and kiln operations, through energy management, finished product quality and, of course, with worker and environmental safety in mind. We offer a complete range of solutions to improve the cement manufacturing process and increase your productivity and profitability.
Raw materials analysis
Powerful analyzers can help you better understand the composition of your raw materials, and give you more control over downstream production processes.
From the limestone mine, to crushing, blending, the raw mill, kiln and beyond, elemental analysis is a critical component to driving process control, efficiencies, and higher quality end products.
Analysis for better cement Our product offerings have been developed specifically for cement manufacturers to further reduce sample analysis cost, increase sample throughput, deliver better reproducibility, and achieve higher quality results.
Clinker control
The concentration of each phase plays an important role in the physical characteristics of cement such as strength and setting time.
As an example, calcium carbonate (CaCO3) is required in a certain proportion in the raw mix, but it transforms during the clinker production process into various phases known as alite, belite, aluminate, aluminoferrite, and free lime.
While the cement production process before the kiln is focused on the elemental make-up and proportions of the raw materials, after the clinker is produced, the focus shifts to the compounds these elements form
Comprehensive analysis and timely information Cement analysis can be achieved using XRF analyzers, while the phases are identified using the XRD platform. The final stage of cement production is to finely grind the cooled clinker and add gypsum and other fillers to control the setting time of the cement and other properties. Mineralogy is important at this stage as well and is measured in the lab by XRD technology. Together, XRF and XRD analysis provides comprehensive, timely information that enables production quality, efficiency and profitability.
Coal power management
The ability to analyze and adjust the coal mix in-stream enables the plant to reduce energy consumption by using exactly the amount of coal fuel required to meet the specific heating values required to process materials in the kiln and mill.
Kiln feed material with high chemistry variations requires more fuel to properly react and more energy at the finish mill to grind over-reacted clinker.
Actionable information and control capabilities Across the entire process. Online analysis of both coal and raw materials, give cement producers exceptional control over energy consumption, product quality and operational efficiency.
Laboratory materials analysis
Thermo Scientific XRF and XRD instruments provide fast, accurate and reliable qualitative and quantitative analysis for process and quality control for cement manufacturing.
X-ray fluorescence technology is the gold standard for accurate, nondestructive elemental analysis and rapid material characterization to ensure product chemistry specifications are met.
Production safety
Thermo Fisher Scientific offers a variety of products designed to prevent downtime, meet health and safety regulatory requirements, reduce insurance costs and generally protect your most valuable investments.
When it comes to operational efficiency and cost savings, nothing delivers more potential than protecting your workforce and equipment.
A variety of safety measures across the process Our solutions are designed to keep workers safe and productive, reduce liability, mitigate risk, and increase efficiency in the cement production industry.
Regulatory compliance
Cement manufacturing is the source of 5% of global CO₂ emissions, therefore emissions monitoring is critical for cement plants to meet regulatory requirements. Thermo Scientific iQ Gas Analyzers reliably monitor a broad range of pollutants such as CO₂, Nox, SO₂ and CO.
The Thermo Scientific iQ Series Instrument Platform is a smart environmental solution for ambient and source gas analysis. As your partner in compliance, our systems are designed with the necessary protocols to ensure your monitoring reports are accurate and accessible and meet US EPA 40CFR Parts 60 and 75 and other standards worldwide, while providing unsurpassed sensitivity, accuracy and reliability.