Evaluate potential savings

Within the manufacturing environment justifying investment in an on-line laser diffraction particle size analyzer requires an estimation of payback time and/or return on investment. Comparing this against CAPEX criteria for the company informs the decision-making process. In reality the economic benefits of real-time particle size measurement will be different for every plant. Current practice determines the baseline and the way in which the data are used will influence the endpoint. For example, retaining manual process control following the installation of an on-line system will not deliver the same cost benefit as switching to automated control.

An estimate of payback for the finish cement grinding circuit can be developed by assessing likely savings from:

• Quicker product changeover
• Less over-grinding
• Reduced waste
• Increased throughput
• Reduced manpower requirements

Less tangible gains arise from the enhanced product quality that on-line measurement delivers. However on the minus side, there is the issue of risk which relates to confidence in the technology and its ability to deliver. The Malvern consultancy service addresses this, combining an in situ plant trial with expert advice. It enables accurate scoping of the potential benefits of real-time monitoring, simultaneously building confidence in the technology.

Finally, case studies are an excellent source of data for estimating payback. For example, by upgrading its cement finishing circuit using an Advanced Process Control (APC) solution from Pavilion Technologies (a Rockwell Automation company) and real-time particle size analysis from Malvern Instruments, Vulcan Materials has achieved:

• A 15% improvement in one-day strength (although the plant is now targeting a 10% lower Blaine)
• A 20% reduction in specific energy consumption, the amount of energy used to mill each tone of cement
• A 15% reduction in ball mill charge

Based on energy savings alone this company estimates that the payback period for the entire project (advanced control system and on-line particle size analyzer) is less than one year.

To read the full case study, click here

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