SpectraFlow Online Analyzer Iron Ore / Sinter Application

Transcription

1 Christian Potocan SpectraFlow Online Analyzer Iron Ore / Sinter Application März 13, 2018 Slide 1

2 Contents. März 13, 2018 Slide 2 History Near Infra Red (NIR) The Technology The Model Development Comparison of different analytical methods SpectraFlow in the Sinter Production Process SpectraFlow The hardware setup References

3 History SpectraFlow: a real success story. März 13, 2018 Slide : ABB started the development of the SpectraFlow Analyzer 2007: First trials in the USA and Switzerland 2008: Test installations for Limestone Quarry and Sinter in Italy, Norway and Germany 2009: First commercial installation on a conveyor belt in a Cement plant in Slovakia 2010: First tests for the airslide application 2011: Multiple installations around the globe: Saudi Arabia, Oman, Iran, Pakistan, Germany and Switzerland 2012: First commercial installation on an airslide after the Raw Mill in Switzerland and Brazil 2013: Foundation of SpectraFlow Analytics and transfer of the SpectraFlow business from ABB to SFA 2013: 10 successful installations around the world and multiple orders received. SpectraFlow is established in the market and technically mature

4 NIR Technology - Objectives of the development März 13, 2018 Slide 4 Select a proven and accepted analysis technique that will give fast and reliable analysis Make sure that no hazardous materials are needed in the operation of the system Eliminate radioactive sources, neutron generators or X-Ray components Eliminate the need for permits or licences for the operation of the system Provide real-time on-line analysis for any kind of bulk material by a single technology to analyse all Molecules Mineral phases Module parameters

5 NIR Technology - Minerals have a NIR signature März 13, 2018 Slide 5 SiO2 Fredrickson : Characterisation of hydrated Alumina by NIR 1954 Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970 Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970 FeO CaO Hunt, Salisbury: Visible and Near Infra Red Spectra of Minerals and Rocks 1970

6 NIR Technology - Principle of the measurement März 13, 2018 Slide 6 When energy (light) hits any matter this matter gets excited and starts to vibrate This vibration is characteristic for any mineral or molecule and according to that consumes a specific energy Symmetrical stretching Asymmetrical stretching In plane scissoring Out of plane wagging Out of plane twisting In plane rocking As the amount of energy emitted is known and the amount of energy reflected is measured, the amount of energy consumed is calculated The consumed amount of energy is the mineralogical fingerprint of the raw material As the information of the raw material is determined out of the movement of the crystal structure and molecules and not the elements, all elements can be measured

7 NIR Technology - Principle of the measurement März 13, 2018 Slide 7 FTIR Spectrometer Industrial PC with Soft PLC Input Lens, which ascertains parallel beams inside spectrometer TCP/IP Connection to RMP Lamp shining at the material Light Paths Lamp shining at the material Belt Conveyor Iron Ore Mix

8 Model development - The Principle März 13, 2018 Slide 8 TRAINING = CALIBRATION FeO % CaO 0.95 % SiO2 1.3 % H2O 5.6 % How much FeO, CaO, SiO2 and Moisture does this Spectra mean? The analyzer has to be trained, to translate the Spectra into the chemical composition

9 Model development - The calibration process März 13, 2018 Slide 9 To develop the relationship reference material has to be supplied The reference material has to represent the range of the material to be measured The reference material has to be delivered with accurate chemical analysis Depending on the complexity of the application 20 to 50 samples are needed to develop the initial calibration The samples are measured in a dynamic mode and the spectra for the different materials are obtained

10 Comparison of different analytical methods März 13, 2018 Slide 10 Measurement Method Source of Energy Analysis Basis Elements possible to measure Dependency Depth of Analysis Measurement Principle Possible Measurement Positions Reports Repeatability Measurement time Accuracy Analytical Error Sampling Error XRF PGNAA SpectraFlow Offline Online Online X-Ray Tube Radioactive Source Lightbulbs Electron Shells Nucleus Molecules, Mineral Phases dependent on Calibration: from from Na (Cf source) from O all elements: including H F (WDX) or Na (EDX) (neutron tube) Vacuum, Sample Preparation Belt Speed, Belt Load no nonlinear layering µm Up to 500 mm µm - mm Reflexion Transmission Reflexion Conveyor Belt Conveyor Belt, Airslide Elemental Analysis Elemental Analysis Mineral Phases, Oxides Fair to Good Poor Good Seconds Minutes Seconds very low high to low dependent on Element low high to very high low very low Total Error high to very high low very low Consumables X-Ray tube Radioactive Source light-bulbs

11 Model development - The resulting models März 13, 2018 Slide 11 Model for FeT on Pos A Model for SiO2 on Pos A Predicted Concentration [%] Predicted Concentration [%] XRF Concentration [%] XRF Concentration [%] Model for CaO on Pos A Model for Al2O3 on Pos A Predicted Concentration [%] Predicted Concentration [%] XRF Concentration [%] XRF Concentration [%]

12 Model development - The accuracy of SpectraFlow März 13, 2018 Slide 12 Iron (FeT) Sample Number actual/% predicted / % Rel Error / % SiO2 Sample Number actual/% predicted / % Rel Error / % CaO Sample Number actual/% predicted / % Rel Error / % Al2O3 Sample Number actual/% predicted / % Rel Error / %

13 Comparison of different analytical methods März 13, 2018 Slide 13 Measurement Method Source of Energy Analysis Basis XRF PGNAA SOLBAS Offline Online Online X-Ray Tube Radioactive Source Lightbulbs Electron Shells Nucleus Molecules, Mineral Phases Elements possible to dependent on Calibration: from Na (Cf source) all elements: including H measure PGNAA can t from measure F (WDX) or Na iron (EDX) ore: from O due (neutron to tube) a very high response Dependency Vacuum, Sample Preparation Belt Speed, Belt Load no nonlinear layering Depth of Analysis of Fe µm all other elements Up to can 500 mm t be recognized µm - mm Measurement Principle Reflexion Transmission Reflexion Possible Measurement Positions Reports Repeatability Accuracy Analytical Error Sampling Error Conveyor Belt Conveyor Belt, Airslide Beside the Fair important to Good elements Poor FeO, CaO and GoodSiO2 also Seconds Minutes Seconds moisture can be measured Measurement time Elemental Analysis Elemental Analysis Mineral Phases, Oxides very low high to low dependent on Element high to very high low very low Total Error high to very high low very low low Consumables X-Ray tube Radioactive Source light-bulbs

14 SpectraFlow - Position in Sinter production process Control the quality of the Iron Ore for stable Stockpiles POSITION A SPECTRAFLOW ANALYZER IRON ORE STOCKPILE A IRON ORE STOCKPILE B IRON ORE STOCKPILE C CONTROL SOFTWARE Control the Bacisity (CaO/SiO2- ratio) of the sinter mix RAW MIX HOPPER GAS CLEANING IGNITION HOOD TO ATMOSPHERE FAN WATER WATER MIXING DRUM WIND BOXES POSITION B RETURNS BURN THROUGH AREA HOT RETURN FINES COKE COKE ROLLER CRUSHER HOT SCREEN COOLING FANS BLENDED ORE LIMESTONE ADDITIVE Lower returns due to more consistant quality of the feed BLAST FURNACE COLD SCREENING BUNKER März 13, 2018 Slide 14 COLD RETURN FINES

15 März 13, 2018 Slide 15 SpectraFlow The hardware setup Spectrometer Box Control Panel Illumination Head

16 SpectraFlow The hardware setup März 13, 2018 Slide 16 FTIR Spectrometer Light and dust shield Lamp Use 4 lamps 50 Watt each Bulk Material Lamp holder

17 SpectraFlow - The hardware setup März 13, 2018 Slide 17 Spectrometer Compartment Flap which can be opened to access the lights Overall view Flap open Entry for the reflected Infrared into Spectrometer Light Spots Interfaces Power Supply for the spots Industrial PC (IPC) View of the inside ceiling Electronic Panel opened

18 ABB Group März 13, 2018 Slide 20 SpectraFlow Analytics Ltd Seestrasse 14b CH-5432 Neuenhof Tel: Fax: