Operating experience with online analyzer for automatic raw mix control in Belgian cement plant

A description is given of the process instrumentation used in an ongoing modernization of a cement plant. This modernization is being accomplished by reorganizing the process around a new 5.4 m diameter by 90 m long rotary kiln with five-stage preheater and precalciner. The plant has thus increased its clinker production capacity from 3600 mtpd by three old kilns to 5000 mtpd with the new kiln in the first phase. It will be increased further to 7200 mtpd by the addition of a second preheater and a fourth grate in the cooler, both of which are provided for in the layout. The new production equipment concept consequently has to address the following particular circumstances: (1) requirement to phase out progressively, over a period of ten years, existing systems such as those for raw meal, fuels, clinker and cement; (2) requirement to integrate and phase in new systems in an optimal fashion; (3) implementation of a new concept including new material handling systems for the 7200 mtpd capacity. The raw mix control and the prompt gamma neutron activation analysis (PGNAA) instrumentation are discussed