AUTOMATION USINGQCX (Quality Control Using Computers and X-Ray)

The objective is to obtain the knowledge involved in industrial automation of Cement

manufacturing process with the help of QCX process, which consists of 3 stages namely,
Autosampling, Sample Preparation and Blend Design. Once the process of cement
manufacturing is studied thoroughly QCX process is applied. The first stage, Autosampling
is done to obtain a sample of the cement manufactured, the required sample is prepared in
the Sample Preparation stage as per requirement and the prepared sample is tested for
corrective action/automated action done in the Blend Design stage. The cement
manufacturing process gives an insight into the need for automation by QCX process which
is characterized by the various points of sampling. Moving into the first stage of QCX
process the Auto sampling stage involves the layout of Autosampling, various types of
samplers and their operations, the mode of transport to the next stage (Sending stations
and pneumatic transport). The next stage, Sample Preparation, involves the preparation of
required sample and testing the sample for analysis (using XRF/XRD), interpreting the
data from the analysis with QCX and XRF software interfacing. The Blend Design Stage
involves a separate application, Blend Expert, that executes the automation process. The
fundamental requirements of the QCX process would be the electrical necessities and
interface with QCX software for analysis and monitoring of data.

CONTENTSOF STUDY
CEMENT PROCESS
QCX PROCESS OVERVEIW
SAMPLING AND SAMPLE PREPARATION
ELECTRICAL REQUIREMENTS
CONTROL
NETWORKING/INTERFACING
CEMENT PROCESS

FLOW DIAGRAM
RAW MATERIAL

CRUSHING

STACKING & RECLAIMING

GRINDING & BLENDING

PYROPROCESSING

CLINKER COOLING & GRINDING

ANALYSIS & PACKAGING

To manufacture cement the cement process is carried out. What do we require for
producing cement? We need the raw materials, lime stone (CaC03), clay (alumina and silica)
and iron (iron ore). The raw materials are obtained from the quarries by blasting them to
obtain large rocks of calcium carbonate (of typically 1.5m size). We cannot use such huge
rocks, so they are fed into crushers of 3 stages in order to reduce size. The first stage of
crushing involves the Jaw Crusher which contains 2 plates as shown in the diagram (a)
where one plate is fixed and the other is oscillated so that the pressure at the end
reduces the size of the rock to around 150-300 mm. The 2 nd and 3rd stages involve
Gyratory Crushersthat contain a roller which pressurizes the incoming material as shown in
the figure (b). The 2nd stage reduces the size to around 40-120 mm and 3rd stage reduces
the size to around 5-25 mm. This way with a size of around 20mm the raw material lime
stone rock can be used for further processes.
Clay and iron ore are mixed through the crushers. Now the material containing Cac03,
alumina, silica and iron are in different compositions in different sections of the material.
They need to be arranged in a proper way and homogenized for uniformity of raw
materials. So the material is undergoes a Stacking process where the incoming non-uniform
material is arranged. This can be done using different techniques like Chevron, Windrow,
Circular Pile as shown. Once the material is stacked Reclaiming is done. For Chevron and
Windrow type reclaiming is done with scrapers slicing the pile layer by layer whereas for
circular pile reclaiming is done as it is stacked obtaining uniformity in the reclaimed
material.

------- CHEVRON PILE

------ WINDROW PILE

RECLAIMER USING SCRAPERS FOR CHEVRON AND WINDROW

STACKING FOLLOWED BY RECLAIMING IN CIRCULAR PILE

Next the homogenized material is passed on to a conveyor belt for addition of cement
additives. The additivesplay a major role for improving the quality of cement and is a key
area of interest for the QCX process which will be discussed in the QCX section. The
additives added for cement at this stage are Bauxite(for alumina), Sand( for silica), Iron
Ore( for iron) and high purity limestone ( for Cac03). Once the additives are added the
material is grinded in a VRM( vertical roller mill). The VRM consists of 3 rollers as shown
which produce pressure of up to 80M Pa. The Blower moves the material upward to the
silos.

This reduces the size of the material to few micrometer or powdery/pulverized form.

The Silos here are blending silos where the material is mixed to obtain what is called as
the Raw Mix/Raw Meal. The Raw Meal moves into the next stage of cement process which
is Pyroprocessing. A Dry process method of cement process is the most common and has
advantages over a Wet process method like cost, power efficiency, time. In a Dry process
the Raw Meal is fed into a multi-stage cyclone pre-heater for heating the Raw Meal.
The basic principle of a pre-heater is hot gas coming from a tertiary duct given to a t
cyclone in opposite direction to that of the Raw Meal. The hot gas carries the Raw meal
upward. The temperature difference between the Raw Meal and hot gas causes transfer
of heat from the hot gas to the Raw Meal thus increasing the Raw Meal temperature. The
hot Raw Meal(850-900 deg C) is fed to the pre-calciner heating (to 1000 deg C) for
removing C02. This gives the required Kiln Feed. The Kiln Feed is fed into the Kiln which is
a cylindrical chamber that is tilted at a slope of 4-5 deg downward, rotated at 4-5 rpm,
with a burner at the end. When the Kiln Feed attains a temperature of around 1200-1300
deg C, The aluminate and ferrite turn into a molten state while the CaC03 remains a very
hot solid. In the latter stage of the Kiln where the temperature is 1300-1450 deg C the
belite( dicalcium silicate) and lime Ca0( formed by decarbonation of limestone present)
combine to form alite( tricalcium silicate). The formation of alite occurs due to the
rotation of the Kiln. The mixture obtained is cooled( to around 100-120 deg C) with the
help of a grate cooler that draws atmospheric air which is fed by cooler fans. This air
participates in heat transfer with the mixture thus cooling the mixture and getting
heated. The hot air is passed to the tertiary duct. The cooled mixture is known as Clinker.
Clinker is ideally of 10mm size. The LSF( lime saturation factor) determines the amount of
free lime in the Clinker. The LSF is a key parameter used in the QCX process for quality
control as LSF determines the strength and other important properties of cement. The
Clinkers are fed into a Ball Mill for further grinding in order to reduce size with another
set of additives namely Gypsum( for settling time), Fly ash, Blast furnace Slag( for
strength). Once these processes are done the product obtained is CEMENT which is
packed and ready for use.

QCX OVERVIEW

NEED FOR QCX:

If suppose we do not obtain the desired cement and an analysis of the undesired cement
shows deviation from desired LSF or other parameters we need to reduce the deviation.
For this we need to control/modify the additives in the appropriate stages. This calls for
an automated system not only to control the changes that are required but also minimize
the errors in doing so. For this need (which is basically to improve quality) we require QCX.
Consider these situations- If clinker has undesired LSF=>control in the additives of Raw
Mix is required accordingly,If final cement has undesired settling time, strength=> control
in additives to Clinker is required. Using QCX control can be provided in each and every
stage/sub-stage of the cement process from pre-calcination to stacking to Kiln rotation to
grinding and all others.

STRUCTURE:

QCX consists of 3 stages namely, Autosampling, Sample Preparation and Blend Design. The
first stage, Autosampling is done to obtain a sample of the cement manufactured, the
required sample is prepared in the Sample Preparation stage as per requirement and the
prepared sample is tested for corrective action/automated action done in the Blend Design
stage. The cement manufacturing process gives an insight into the need for automation by
QCX process which is characterized by the various points of sampling. Moving into the
first stage of QCX process the Auto sampling stage involves the layout of Autosampling,
various types of samplers and their operations, the mode of transport to the next stage
(Sending stations and pneumatic transport). The next stage, Sample Preparation, involves
the preparation of required sample and testing the sample for analysis (using XRF/XRD),
interpreting the data from the analysis with QCX and XRF software interfacing. The Blend
Design Stage involves a separate application, Blend Expert, that executes the automation
process. The fundamental requirements of the QCX process would be the electrical
necessities and interface with QCX software for analysis and monitoring of data.
AUTOSAMPLING=== MATERIAL INPUT /MATERIAL OUTPUT

ROBOLAB==========MATERIAL INPUT /DATA OUTPUT

BLEND EXPERT=====DATA INPUT/CONTROL OUTPUT

SAMPLING AND SAMPLE PREPARATION

SAMPLING:

Autosampling is done to obtain a sample of the material which is to be prepared for

testing. The places at which Autosampling is done are known as Sample Points.

BASIC STRUCTURE:
SAMPLERSAMPLER

MIXERMIXERDIVERTER

DOSING DOSING

SENDING STATION SENDING STAION

EQUIPMENTS;

SAMPLER-(PSM, CLINKER, HOT MEAL, AIR SLIDE)

DIVERTER-(2 Pos, 4 Pos)
BLOWER-(Return Form, Transport Form)
PNEUMATIC TRANSPORT

SAMPLERS:

PSM- PSM Sampler contains a pipe with holes located in the sampling environment( a chute
with sample flow). The pipe is connected to a rotating screw operated with a 3 phase
geared motor (refer electrical requirements). The rate of sampling /sample amount is
controlled by the screws rotation. The PSM Sampler is an average sampler i.e mixes the
sample material obtained over a certain period of time to get an average of the sample.
The sampler contains a mixer to mix the obtained sample. In an automatic sampler the
sample amount required is taken by a dosing unit and sent to the sending station (all
automatically) whereas in a manual sampler there is a collection unit after the mixer for
manual collection. The excess amount of material is fed either by gravity (PSM-G) or by
return blower (PSM-C). Used for Raw Meal sampling. PSM Sampler operates at 1 KW
power.

AIR SLIDE-Air Slide sampler uses air vents to push the material for sampling into a pipe
with holes which is rotated with a motor. The sample rate is controlled by the pipe
rotation.In an automatic sampler the sample amount required is taken by a dosing unit and
sent to the sending station (all automatically) whereas in a manual sampler there is a
collection unit after the mixer for manual collection. Used for Raw Meal sampling. It
operates at 3.5 KW power

CLINKER SAMPLER-Clinker Sampler contains a grated spoon which is slide operated. Once
the spoon collects the clinker sample the sample is fed to a crushing and grinding unit
after which the sample is dosed for sending station/ manually collected. It operates at 5.5
KW power.

HOT MEAL SAMPLER-Hot Meal Sampleris used to sample the Kiln Feed where there is
spoon which is slide operated and samples the hot material. The Hot sample is then cooled
either with air/water jacketed cooling from a separate chamber. It operates at 4 KW
power.
DIVERTER:

A Diverter is used to transport 1 sample/material at a time in a desired direction. A

diverter contains a control unit and a gear assembly. The gear rotates the transport tube
to a position. A 2 Pos Diverter and 4 Pos Diverter allow transport to 2 and 4 different
directions respectively. 2 Pos has bi-directional movement whereas 4 Pos has uni-
directional movement of gear assembly.

BLOWER:

A Blower consists of a suction valve, a blowing valve and a motor. It contains 2 outlets, 1
main and 1 exhaust. For blowing operation the blowing valve is connected to main outlet
whereas the suction valve is connected to the exhaust valve. Similarly for suction
operation the suction valve is connected to main outlet and the blowing valve is connected
to the exhaust valve. The return blower is used for suction operation in samplers and both
operations are used for transportation of material. The root valves allow transport of
material to autolab/manual lab.

PNEUMATIC TRANSPORT:
SAMPLE PREPARATION:

Robolabconsists of the necessary equipments for Sample preparation and testing of the
sample.

STRUCTURE:

RECEIVING STATIONTRANSPORT BLOWER---BALANCE-----MILLING-----PRESS-----

XRF UNIT

EQUIPMENTS:

*BALANCE-Measures the weight of the receiving sample and the sample is passed on to
Turn Table Rack. The control unit checks if the sample is to be passed from the weight
input from the balance. A samples weight should not be more than 23-25g.

*CENTAURUS-A combined Mill and Press for obtaining the sample in a suitable form for
testing. The press gives the sample either in a ring or in a pellet form.

*TURN TABLE RACK-A storage access to the Robot/Conveyor of the lab for transport of
sample to/from places like XRF, Receiving Station, Centaurus .

*CONVEYER-Used for transport of sample and has various control elements such as
direction, start, stop etc:

*XRF & QCX INTERFACING ROOM- XRF is used to analyze the sample and data obtained
is monitored with interfacing with QCX by a network of computers. XRF uses X-Rays which
strike the sample prepared. The intensity of the reflected ray indicates the quantity of
the element and the angle of reflection indicates the type of element present.

ELECTRICAL REQUIREMENTS
SUPPLY
PROTECTION
EQUIPMENTS
CONNECTION
SUPPLY:

Electrical Supply is of 2 forms AC (Alternating Current) and DC (Direct Current). ACs

characteristic is changing of polarity at a particular frequency with the same magnitude of
supply voltage whereas DCs characteristic is voltage with same magnitude and polarity. AC
supply has single phase supply and 3 phase supply. Single-phase electric power is the
distribution of alternating current electric power using a system in which all the voltages
of the supply vary in unison. Three-phase system, the currents in each conductor reach
their peak instantaneous values sequentially, not simultaneously; in each cycle of the
power frequency, first one, then the second, then the third current reaches its maximum
value. The waveforms of the three supply conductors are offset from one another in time
(delayed in phase) by one-third of their period. DC supply can be obtained from AC supply
by passing AC supply through a transformer rectifier. A transformer rectifier consists of
coils for stepping down to the DC voltage level required and diodes for rectification into
DC supply.

PROTECTION:

Protection of electrical environment is necessary to avoid damage to appliance and

operator. Protective equipments offer protection to appliances on instantaneous surge in
currents, timed over currents and phase imbalances. Earthing protection offers protection
to operator and appliance over leakage currents. Earthing is connection of an appliance to
the isolated earths conducting surface such that due to resistance offered by earth
there is appliances leakage current flow in this path protecting the operator from doing an
earthing connection. Appliances protection are done by various equipments which are given
below.

EQUIPMENTS:

MCB- An MCB functions by interrupting the continuity of electrical flow through the
circuit once a fault is detected. In simple terms MCB is a switch which automatically turns
off when the current flowing through it passes the maximum allowable limit. Generally MCB
are designed to protect against over current and over temperature faults (over heating).

There are two contacts one is fixed and the other moveable. When the current exceeds
the predefined limit a solenoid forces the moveable contact to open (i.e., disconnect from
the fixed contact) and the MCB turns off thereby stopping the current to flow in the
circuit. In order to restart the flow of current the MCB is manually turned on. This
mechanism is used to protect from the faults arising due to over current or over load.To
protect against fault arising due to over heating or increase in temperature a bi-metallic
strip is used. MCBs are generally designed to trip within 2.5 millisecond when an over
current fault arises. In case of temperature rise or over heating it may take 2 seconds to
2 minutes for the MCB to trip.

MCCB & MPCB- The main difference between these breakers (Moulded Case
Circuit Breakers, Motor Protection Circuit Breakers) & MCBs is that these breakers
have a wider range for tripping whereas MCBs have only a particular fixed value. For
MPCBs the additional advantages are
Thermal protection is used to guard the electric motor against overload. It is based
on an expanding and contracting contact that disconnects the motor if excessive
current is detected. It is very important to know that thermal protection has a delayed
response, to allow the high inrush currents when a motor starts. However, if the motor
 is unable to start for some reason, thermal protection will trip in response to the
extended inrush current.
Magnetic protection is used when there is a short circuit, line fault, or other high
current electric fault. Unlike thermal protection, magnetic protection is instantaneous;
to immediately disconnect the dangerous fault currents.
The main difference between the MPCB and other circuit breakers is that the
MPCB can provide protection against phase unbalance and phase loss. Three-phase
circuit motors require three live conductors with balanced voltages in order to operate
effectively. An unbalance of more than 2% will be detrimental to the motors service
life. If one of the phase voltages is suddenly lost, the effect is even more damaging
because the motor will keep on running with only two phases. The motor protection
circuit breaker is capable of detecting these conditions by measuring the differences
among phase voltages, and disconnects the motor immediately when they occur. It is
important to note that phase current unbalance is normal in three-phase systems that
power separate single-phase loads, but is unacceptable when the three-phase circuit
powers an electric motor.
MPCBs are also equipped with a manual interruption mechanism, allowing
disconnection of electric motors for replacement or maintenance.
Motor protection circuit breakers are available in a wide variety of current ratings,
and one of their best features is that many models allow the current rating to be
adjusted. This means that the same MCPB can be configured to protect motors of
different capacities.

Asynchronous Motor Protection

Most motors used in the industry are a asynchronous motors, also known as squirrel-cage
induction motors. These motors use three-phase power to create a rotating magnetic field,
which in turn magnetizes the rotor an creates rotational movement. When designing the
electrical protection for an asynchronous motor and selecting motor protection circuit
breakers, there are some very important factors to consider that arent present when
protecting other types of electrical circuits.
Asynchronous motors draw a very high inrush current during startup, because they
must establish a rotating magnetic field. This current can reach values of 500% to
800% of the rated value for a few fractions of a second. For this reason, the MPCB
magnetic protection trips at values greater than 10 times the rated current, unlike
some types of miniature circuit breakers which trip at values as low as 3 times rated
current. In these cases, using a circuit breaker other than an MPCB will not even allow
starting the motor before the magnetic protection trips. In order to reduce the inrush
current, a very common practice is to complement the motor protection circuit breaker
with a reduced voltage motor starter.
Asynchronous motors require the three phase conductors to have a balanced
voltage in order to operate properly. If the phase conductors have an unbalance greater
than 2%, the motor will suffer damage over time and will have a reduced service life.
 The electric motor will also tend to overheat, causing additional energy expenses as
waste heat. For this reason, a motor circuit breaker must be able to detect phase
imbalance and disconnect the motor accordingly.
If one of the phases is disconnected completely, the motor will keep operating but
the current in the remaining two phases will rise above the rated value due to the
electrical unbalance, and will probably burn the motors windings. For this reason, motor
protectors must trip immediately as soon as phase unbalance or phase loss is detected.
This is normally achieved by measuring the differences in current among the phase
conductors. If one of the phase currents rises or drops considerably compared with the
other two, it is indicative of unbalance. Likewise, if one of the phase currents drops to
zero while the other two remain, a phase loss has occurred.MPCBs, MCBs, MCCBs are
equipments used for protection of appliances.

OPERATOR PORTECTION:

VOLTAGE ELCBs- Earth Leakage Circuit Breaker- The equipment is connected to

ground by means of earth wire. If any leakage exists there is a voltage difference
between the equipment and ground. As ground is virtually in zero potential hence there
is a path for leakage current to flow to the ground leaving the appliance and operator
unharmed in case of leakage.

RCCBs- Residual Current Circuit Breakers- 2 Coils are connected for phase and
neutral lines separately and with opposite polarity. If there is no leakage the induced
MMF of these coils should cancel out. If this does not happen a third coil gets induced
due to the residual MMF and circuit is tripped by 3rd coil

RELAYS & CONTACTORS

An Electromagnetic Relays are nothing but switches operated by electromagnetic induction

on a magnetic latch. The latch is activated by current flowing through an electromagnetic
coil. Relays can be used for creating control/feedback circuits. An example of a relay is an
auxiliary contactor (normally used for small currents). The latches in non-activated state
are in N.C position (completing the circuit) or in N.O position (breaking the circuit). Once
activated the latch moves from N.C to N.O position either breaking or completing the
circuit as per requirement. A Power contactor is used for large current values and provides
solid N.C and N.O contact before changing state. A Plug-in relay can be used where the coil
is attached manually for the changing of contact terminals.

SOLENOID COILS:
Solenoid Coils have the widest application in the electrical equipments. They can be used in
breakers as mentioned, brakes for motor operation, valve control. Solenoid contract when
activated by current and restore themselves to initial position with a restoring spring once
non-activated.

CONNECTIONS:

Connections follow a simple path in all complex electrical networks. The 2 types of supply
AC & DC are taken and given to a multi-channel circuit breaker for protection and power
distribution for appliances/devices. Next the multi-channel circuit breaker helps
distribute power supply to all areas necessary using terminal blocks allocated for each
appliance. Power supply is given to the control unit (Normally a PLC). An Isolator is also
connected for emergency stop functions. They can be manually operated and can be
operated by the control unit if necessary.Isolator is generally a manually operated
mechanical switch which separates a part of the electrical power. It also has built-in
safety breakers which involve a combination of many safety parameters like
overload/underload voltage, instantaneous/timed overcurrent, phase imbalance, starting
power criterion.

CONTROL UNIT- ( PROGRAMMABLE LOGIC CONTROLLER)

A Programmable logic controller, PLC, or programmable controller is a digital computer
used for automation of typically industrial electromechanical processes. A PLC can be
programmed by RLL syntaxusing the electrical equipments like N.O & N.C contactsand are
executed using the interfacing software provided by the manufacturer.

A PLC contains I/P racks for data from sensors

This I/P is read by the PLC and converted to an I/P image
The I/P image is read by the CPU and processed
Once processing is finished the CPU writes the O/P image which is accessed by the
interface (MODBUS) to the actuators
MODBUS a Serial communication protocol isused to assign the addresses to the inputs and
outputs. A MODBUS command consists of the address of the input or output it is intended
for. If it is 0 then broadcast to all devices (inputs/outputs), if 233=> device attached to
address 233. (refer networking section for serial communication)

PLC PROGRAMS:

A few programs written for simple processes

 NETWORKING
Networking is necessary in QCX as monitoring and access of data, control of devices
through the controller is done with interfacing and linking with computers. Practically we
see that a computer network is an interconnection of various computers to share
software, hardware, resources and data through a communication medium between them.

NETWORK TYPES
MODES OF COMMUNICATION
SET UP OF A NETWORK
MEDIA FOR COMMUNICATION

NETWORK TYPES:

1. Centralized computing.

In this type of system, multiple computers are joined to one powerful mainframe
computer.

The server or mainframe computer has huge storage and processing capabilities.

The computers that are connected to the mainframe or server are called Clients or
Nodes.

These nodes are notconnected to each other; they are only connected to server.

2. Distributed computing

If one computer can forcibly start, stop or control another, the computers are not
autonomous. A system with one control unit and many slaves, or a large computer with
remote printers and terminals is not called a computer network, it is called a Distributed
System.

Distributed computing means that the task is divided among multiple computers.

Distributed computing interconnects one or more personal computers or Workstations.

In distributed computing, the nodes are capable of processing their own data and rely on
network for services other than data processing.
 It allows various services like network sharing, hardware sharing and file sharing.

3. Collaborative computing / Hybrid computing

It is the combination of centralized and distributed computing

In collaborative computing, the nodes are able to serve the basic needs of their users
but they are dependent on some other computers for processing some specific request.

MODES OF COMMUNICATION:

ETHERNET COMMUNICATION:

Ethernet communication is a type of data link in a computer network. Data flow (in bits) is
controlled by a set of rules known as protocols. Ethernet communication obeys TCP/IP i.e
Transmission Control Protocol/Internet Protocol. These protocols bind the data into
packets and map the addresses of the sender and recipient (which are configured/set) and
allow flow of data. In this mode of communication data is bind into packets and only then
sent.

SERIAL COMMUNICATION:

Serial communication involves flow of data bit by bit i.e continuous flow a data. COM ports
in devices are provided for Serial communication. Drivers which are also a set of protocols
govern the data flow for the Serial communication. Example of a COM port is the common
USB port in devices. Every device that needs to be connected to a port has a driver with
which data flow is controlled

WIRELESS COMMUNICATION:

Wireless communication consists of a data link layer protocol that runs over any of
several different physical later (PHY) links. The data link is governed by a special Media
Access Control (MAC) protocol that uses collision avoidance techniques (technically called
Carrier Sense Multiple Access with Collision Avoidance) or CSMA/CAto help handle many
clients on the network communicating at once. Radio waves are used at access point (built-
in) for transmission of data.

SET UP OF A NETWORK:

Configuration of any network is the fundamental aspect to set up a network. To set up a

host network i.e a network based on one master computer, the IP address (Numerical name
of sorts for a device), DNS (domain name of the server) and password are necessary. To
set up a wireless network over a router the IP address of the router and the subnet mask
(route of data flow) must be specified. The subnets are a 32-bit combination used to
describe which portion of an address refers to the subnet and which part refers to the
host.An IP address is an address used in order to uniquely identify a device on an IP
network. The address is made up of 32 binary bits, which can be divisible into a network
portion and host portion with the help of a subnet mask. The 32 binary bits are broken
into four octets (1 octet = 8 bits). Each octet is converted to decimal and separated by a
period (dot). For this reason, an IP address is said to be expressed in dotted decimal
format (for example, 172.16.81.100). The value in each octet ranges from 0 to 255 decimal,
or 00000000 - 11111111 binary.

MEDIA FOR COMMUNICATION:

There are Wired and Wireless means of communication. Wireless is done by routers for a
networking purpose. Wired media consists of many types namely, Co-Axial cables
(Megabits/sec), Ethernet cables (few hundred Kilobits/sec), Fibre Optic cables
(Gigabits/sec).