Process optimization solutions for the cement industry

	John Murphy III, Production Manager, at Florida Rock Industries, USA: "Together the technologies have revealed how to operate the plant in a very different, much more efficient way. We have reduced costs and have simultaneously improved product quality even though we are now targeting a very much lower Blaine, the standard industry measure used to quantify fineness." Examine in detail the transformation Vulcan Materials achieved by upgrading the finish grinding circuit from manual to automated process monitoring and control. - more about Florida Rock

Cement production is one of the most energy-intensive sectors within the world economy and there is great pressure to reduce its carbon footprint.

Tackling product variability

Increasing throughput

Eliminating over-grinding in the finishing circuit

Reducing product changeover times

Addressing these issues optimizes product quality, increases opportunities for replacement material usage and/or cuts variable costs by improving consistency and reducing waste and energy consumption.

Malvern has rugged, industrialized analyzer solutions that deliver the data required for informed process decision-making. Payback times for these systems are typically low because of the multiple benefits they deliver: improved product quality, increased throughput, less waste, reduced energy consumption.

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What's Next?

Download product overview brochure Live, web-based particle characterization and rheology seminars Interactive particle characterization and rheology presentations Access the particle characterization and rheology knowledge base

In this section

	Industry Overview Around 2.8 billion tonnes of cement were consumed in 2008 world-wide. Find out more about cement production, why the process is so energy intensive and the use of replacement materials to reduce environmental impact.
	Cement process optimization - Understanding and control The key to successful process optimization is understanding plant performance and controlling it to meet production targets. Particle size analysis more sensitively captures finished strength characteristics than conventional Blaine measurement and offers opportunities for real-time monitoring. Gain real insight into your process and product and exploit it for maximum competitive advantage.
	Cement analyzers Complete on-line, at-line and off-line particle characterization systems appropriate to the requirements of the cement industry and specific unit operations.
	Featured presentations:
	On-demand presentation: New web resources for the cement industry and cement In this webinar we will consider how the technique of laser diffraction can provide a means of increasing cement process efficiency without compromising product quality or strength. Starting with lab based measurements; we will consider how the technique provides a modern means of ensuring product consistency with higher precision than traditional surface area measurements. We will then look at how the technique has been applied both within automated 24hrs measurement laboratories and as a full on-line, closed-loop control system, and will evaluate the energy and cost savings which can result.
	Cement process optimization - Case studies:
	Vulcan Materials upgrades finishing circuit by switching from manual to automated process monitoring and control.
	Ash Grove Cement establishes a reliable correlation between on-line particle size data and early strength, and uses it to increase throughput by 5%.
	At-line particle measurement at Holcim Obourg in a fully automated laboratory.
	Castle Cement uses on-line analyzer to improve product consistency, enhance process understanding and cut grade changeover times.
	On-line analysis at Shanghai Allied Cement delivers greater product consistency, simultaneously reducing manual input.