Questionnaire for CrossBelt™ Analyzer Systems to be used ... lieu/Bang cau hoi cho may phan... ·...

Questionnaire for

CrossBelt™ Analyzer Systems

to be used in

Stockpile Applications

PROPRIETARY INFORMATION

This document contains information proprietary to

Thermo Electron. It is not to be reproduced without

the written consent of Thermo Electron Corp.

Patent Numbers:

4,682,043; 5,342,158; 5,396,071; 5,732,115; 5,825,030

additional patents pending

© Copyright 2003 by Thermo Electron Corporation

5788 Pacific Center Blvd.

San Diego, CA 92121

020420 Rev. C

November, 2003

2

Revisions

Rev. Level Date Notes

/ August, First edition, in accordance with DCN #8794. This

1999 questionnaire has been written for the CB-GN system.

A October Minor revisions.

1999

B April Minor revisions.

2001

C November Added fields for electronic form.

2003

List of Effective Pages

Page(s) Revision

Cover (None shown)

All other pages C

3

CrossBelt Analyzer Questionnaire

In the years Thermo Electron has been supplying Process Optimization Systems to the

cement industry, we have had many successes and many happy users of our products.

In the few cases that our customers have experienced problems in applying our

product, we have identified an insufficient exchange of information between Thermo

Electron and the user as the cause of the problems.

The goal of this document is to improve the information exchange. The more we know

about your plant and the conditions which might influence the location, the

performance, or the application, the better the analyzer is likely to perform and the

greater will be the economic benefit to you. It is for our mutual benefit that we ask you

to spend the necessary time to fill out this form in order to improve our understanding of

the environment in which the analyzer will operate.

Thank you.

Instructions for filling out the questionnaire

Instructions for completing this questionnaire: This questionnaire is set up as a template to be completed on a computer. To move around in the document you can either use the mouse or the tab and back tab key. As you tab through the document it will take you to all the available tabs. If there is an area that does not pertain to your plant you can move past it by using the mouse. The entries may be one of the following: Text, check box, or drop down list. Some drawings are required and should be scanned into your computer and then attached to this document when e-mailed. They can also be faxed if needed.

CrossBelt Analyzer Questionnaire_____________________________ 5788 Pacific Center Blvd.

San Diego, CA 92121 Telephone: 858-450-9811 Fax: 858-452-9250

4

Table of Contents

1. General Information.............................................................................. 5

A. Project Information ........................................................................ 5

B. Ambient Conditions: Environmental conditions at analyzer ...... 5

C. Climate ........................................................................................... 5

2. Application Definition: Stockpile Monitoring....................................... 6

A. Description...................................................................................... 6

B. Blending Process: Analyzer Application/Benefits ........................ 6

C. Proposed Process Flow Diagram: Stockpile Monitoring.............. 7

D. Proposed Interconnect Diagram: Stockpile Monitoring............. 8

E. Calibration Standards.................................................................... 9

3. Material Handling (Sensor).................................................................. 10

A. Mechanics.................................................................................... 10

B. Belt Description ............................................................................ 10

C. Belt Loading.................................................................................. 10

D. Profile ............................................................................................ 12

4. Material Handling (Control System): .................................................. 13

5. Material Composition: Stockpile ........................................................ 14

6. Plant Communications........................................................................ 19

7. Control System Considerations........................................................... 20

A. Quality Control Formulae............................................................ 20

B. Control Parameters: Stockpile .................................................... 22



5

1. General Information

A. Project Information

Company

Your Name

Plant Name

Address

City, State

Country, Zip

Phone

Fax

E-mail

B. Ambient Conditions: Environmental conditions at analyzer

Annual temperature at the Analyzer’s proposed location:

Min ° Max ° Celsius Fahrenheit

Is the atmosphere salty or corrosive? yes no Will there be a significant heat source near the analyzer, such as a kiln or mill?

no yes If yes, name heat source:

Will there be significant vibration of the structure supporting the analyzer?

no yes If yes, estimate severity of vibration:

Other ambient conditions:

C. Climate

% Humidity: Min % Max %

Seasonal Rainfall: Min Max cm in.



6

2. Application Definition: Stockpile Monitoring

A. Description

Describe each stockpile to be monitored:

Tons

(when complete)

Type of Stockpile (Choices are: Circular-Batch

Circular-Continuous

Longitudinal)

Stacker/Reclaimer (Choices are: Homogenizing

Non-homogenizing)

Homogenizing Factor

1

2

3

4

5

B. Blending Process: Analyzer Application/Benefits

In the spaces below please provide the following

a) A brief explanation of the stockpile blending process. Discuss any problems or unusual conditions you experience in stockpile blending.

b) The intended application of the CrossBelt Analyzer, and the benefits expected from it.



7

C. Proposed Process Flow Diagram: Stockpile Monitoring

Please draw a sketch of the material handling system feeding the CrossBelt Analyzer.

Please INCLUDE belt speed (variable or constant), weigh scales, conveyors and transfer points leading to the analyzer with details of material proportions and distances.

Example of process sketch:

Attach the sketch of your intended flow diagram along with a sketch of your current flow diagram (if different). Please scan you flow diagram and attach it to this document or fax the diagram separately.

PRINTER

LIMESTONEFROM

QUARRY

OPCON /PREBOS

111 BC3

PRIMARYCRUSHER

SECONDARYCRUSHER

700 to 800 TPH

CIRCULARSTOCKPILE

DEMANDS/ADVISORIES

TOQUARRY

BELTCONVEYOR

111 BC2

BELT WIDTH 1200mm

WEIGH SCALEElectronics

CROSSBELT

ANALYZER



8

D. Proposed Interconnect Diagram: Stockpile Monitoring

Please draw a sketch of the intended or desired interconnect diagram for the CrossBelt Analyzer.

Example of interconnect sketch:

Make a sketch of your intended interconnect diagram, scan it and attach to this document or fax if necessary.

SUPERVISORY NETWORK

SERIAL LINK

PLC/FIELD NETWORK

WORKSTATION

ELECTRONICSCROSSBELTANALYZER

WORKSTATION

OPCON

BRIDGE

PLC

PLC



9

E. Calibration Standards

The calibration standards normally provided with a CrossBelt analyzer cover the following oxide ranges:

Range (in percent) Oxide

Max Min Span (max – min)

SiO2 24 4 20

Al2O3 10 0 10

Fe2O3 10 0 10

CaO 53 18 35

K2O 3 0 3

MgO 6 0 6

Na2O 3 0 3

SO3 3 0 3

Do these oxide ranges characterize the material that will flow through the analyzer?

yes no If another range is required, please specify below.

Range (in percent) Oxide

Max Min Span (max – min)

SiO2

Al2O3

Fe2O3

CaO

K2O

MgO

Na2O

SO3



10

Material Flow

?°

3. Material Handling (Sensor)

A. Mechanics

Width of Belt: cm in.

Conveyor inclination (degrees): °

(Maximum allowed is 18°)

B. Belt Description

Thickness of Belt: mm in.

Manufacturer of Belt:

Model or manufacturer’s product designation:

Belt core material, e.g. cotton, steel, nylon, etc:

Belt composition and consistency: (Please note that the conveyor belt should not contain any chlorine or be steel re-enforced)

Does the existing belt contain steel reinforcement? yes no

Does the existing belt contain any chlorine? yes no

C. Belt Loading

Belt Speed: constant variable

If Constant Speed: m/sec. ft./min.

If Variable Speed: Min m/sec. ft./min.

Max m/sec. ft./min.

Normal m/sec. ft./min.

How is it varied? Inverter Other

How is it indicated?

(Choices are: 0-10Vdc on/off switch, 4-20mA tachometer, 4-20mA inverter, 4-20mA PLC, other)

If other, please specify:



11

Flowrate:

The weigh scale for the analyzer should be installed on the same belt as the analyzer, preferably just before the analyzer.

Distance between weigh scale and analyzer: m ft.

Weigh Scale Accuracy: %

Is the weigh scale on the same belt as the analyzer? yes no

If no, then where is it located?

Is the flow rate given as a sum of multiple weigh scales? yes no

If yes, please describe:

Tons/Hour: Metric U.S. (short)

Min TPH % of time

Max TPH % of time

Normal TPH % of time

Bulk Density: Min gm/cc lbs./cu. ft.

Max gm/cc lbs./cu. ft.

Top Size: Maximum Particle Size (95 percentile)

95% of the particles pass below this size: mm in.

Use the following formula to calculate the conveyor belt loading at the proposed location of the CrossBelt Analyzer:

kg/m_____(c)=sec3600

hour1

_____(b)

1

ton

kg1000_____(a) xxx

(a) = Belt Flow Rate in tons/hour

(b) = Belt Speed in meters/second

(c) = Belt loading in kilograms/meter

For variable speed belt conveyors, please indicate the following:

Minimum Belt Loading: kg/m

Nominal Belt Loading: kg/m

Maximum Belt Loading: kg/m



12

°

Layer 1Layer 2

Layer 3

Belt Size Width: cm in.

Maximum Material Height: cm in.

D. Profile

Knowing the profile of material as it passes through the analyzer is essential to its performance. Sketch a cross section of materials on the conveyor at the proposed analyzer location. Identify how the material segregates and indicate dimensions. Please include roller width and the current trough idler angle. See example below.

Note: The trough angle of the belt as it passes through the analyzer is 35° (can optionally be 45°). If your trough idlers are at a different angle, a transition will be needed at the entrance and exit points of the analyzer.

Your cross section of conveyor showing raw materials:

Layer 1:

Layer 2:

Layer 3:

Layer 4:

Roller width: mm

Belt trough angle: °

MaterialHeight Limit

(includes beltthickness)

35°

375mm

Limestone (100 to 140mm)

Clay (40 to 50mm)

Sand (0 to 20mm)



13

4. Material Handling (Control System):

Table 1 Instructions

Please provide information on feeder capacity. If more than one feeder is used for any given source, insert the data about the feeder and the transit time under the same source name, in a new column.

In part 1, with feeder we mean a generalized feeding system, i.e. a unit receiving a demand and able to fulfill that demand (e.g., a weigh feeder, a series of bins with controlled openings followed by a weigh scale on the belt, a variable speed apron feeder followed by a weight scale controlled by a PLC.) The information is needed to check if the existing or planned feeders meet the requirements of the analyzer control software.

In part 1, if it is not possible to measure the transit time, please indicate if it is an estimate.

The min and max transit time rows give the customer the possibility to include valuable information in case some variable speed belt or, for instance, a crusher is installed in between the material source and the analyzer.

Table 1

Feeder or Weigh Scale Specifications

Source Name

Max Design Capacity

(Tons Per Hour)

Minimum Controllable Capacity (Tons Per Hour)

Maximum Controllable Capacity (Tons Per Hour)

% Error Maximum Design Capacity (Percent)

Analog Output, Zero (Tons per hour)

Analog Output, Full (Tons per hour)

Material Transit Time

Source Name

Feeder Response Time (Seconds)

Weigh Scale Response Time (Seconds)

Min Material Transit Time (Seconds) Max

Are there material handling issues such as plugging or large material clumps due to high moisture? no yes If yes, please explain:



14

5. Material Composition: Stockpile


Sources

Use the multiple copies of Table 2 to identify the names of each raw material source to be included in the raw mix.

Percent Weight of Total

Indicate the source’s percent weight of the total stockpile.

Composition

For each source, estimate the average, min, max, and standard deviation of the oxide composition. Indicate the sample time (e.g., core samples, 10 minutes, 1 hour, 24 hours, etc.). Report current oxide composition as one of three bases:

1. Loss-free basis: Oxide analysis does not include Loss On Ignition (LOI) or moisture.

2. Dry raw basis: Oxide analysis includes LOI, but not surface moisture.

3. Wet raw basis: Oxide analysis includes both LOI and moisture.

State the source of data used to derive these estimates:

Belt Samples

Quarry Drill Hole Samples

Quarry Block Models

Other

Please append your original data to this questionnaire.

Source Flowrate Setpoint (Constraints)

All flowrates and feeder demands are expressed on a wet raw basis. State the average source flowrate (tons per hour), and each hour’s minimum and maximum source flowrate that PREBOS can request during normal operation.



15

Table 2

A. Source Name:

B. Source Average % Wt. Of Total Stockpile: %

C. Composition:

Item Minimum Maximum Average Std Dev

SiO2 % % % %

Al2O3 % % % %

Fe2O3 % % % %

CaO % % % %

MgO % % % %

Na2O % % % %

K2O % % % %

SO3 % % % %

Cl % % % %

Trace % % % %

Moisture* % % % %

Loss on Ignition % % % %

D. Flow Rate Constraints (TPH): Min Max Ave

E. Top Size: mm in.

SAMPLE TIME BASE:

Select reporting basis used for oxides: Loss-free (Excludes moisture and LOI)

Dry Raw (Excludes surface moisture, includes LOI)

Wet Raw (Includes both moisture and LOI)

Select source data: Belt Samples Quarry Drill Hole Samples

Quarry Block Models Other (specify)

# of Samples for Calculations: Sampler Type:

Lab Method: Comments:


* Moisture information is very important if the material is layered.



16

Table 2

A. Source Name:


C. Composition:


SiO2 % % % %

Al2O3 % % % %

Fe2O3 % % % %

CaO % % % %

MgO % % % %

Na2O % % % %

K2O % % % %

SO3 % % % %

Cl % % % %

Trace % % % %

Moisture* % % % %



E. Top Size: mm in.

SAMPLE TIME BASE:












17

Table 2

A. Source Name:


C. Composition:


SiO2 % % % %

Al2O3 % % % %

Fe2O3 % % % %

CaO % % % %

MgO % % % %

Na2O % % % %

K2O % % % %

SO3 % % % %

Cl % % % %

Trace % % % %

Moisture* % % % %



E. Top Size: mm in.

SAMPLE TIME BASE:












18

Table 2

A. Source Name:


C. Composition:


SiO2 % % % %

Al2O3 % % % %

Fe2O3 % % % %

CaO % % % %

MgO % % % %

Na2O % % % %

K2O % % % %

SO3 % % % %

Cl % % % %

Trace % % % %

Moisture* % % % %



E. Top Size: mm in.

SAMPLE TIME BASE:












19

6. Plant Communications

Which of the above configurations is closest to your desired configuration?

A B C D

If “B”, which of the following PLC protocols is desired?

AB DH+ AB DH

MODICON MODBUS+ MODICON MODBUS

SIEMENS H1 SIEMENS L2

Other (If other, please specify):

ANALYZER

WITH PREBOS

Serial

PLANT

PLC

PLANT

DEVICES

PLC Protocol PLC

PLANT

PLC

Serial

PLANT

DEVICES

4-20mA 0-24V

PLC

PLANT

PLC

Serial

PLANT

DEVICES

Serial MODBUS RTU

TH

ER

MO

EL

EC

TR

ON

SU

PP

LIE

DP

LA

NT

SU

PP

LIE

D

A B C D

4-20mA 0-24V

PLANT

DEVICES

PLC

ANALYZER

WITH PREBOS

ANALYZER

WITH PREBOS

ANALYZER

WITH PREBOS



20

7. Control System Considerations

A. Quality Control Formulae


Select the formulae you use to compute the quality control values. If a quality control value is used at your plant, check the column on the right. If these formulae are different for your plant, modify the table on the next page. IMPORTANT: The control software will be configured to compute the quality control values based on your formulae.

Table 3

Quality Parameter Standard PREBOS Formula Used?

Lime Saturation Factor (LSF) 32322 35.0+65.1+8.2 OFexOAlxSiOx

CaO

Silica Modulus (SM) 3232

2

+ OFeOAl

SiO

Iron Modulus (IM) 32

32

OFe

OAl

C3S )43.1+718.6+6.7(071.4 32322 OFexOAlxSiOxCaOx -

C2S SCSiO 32 ×7544.0-×867.2

C3A 3232 ×692.1-×65.2 OFeOAl (If IM ≤ 0, then C3A = 0)

C2F 3232 ×665.2-×702.1 OAlOFe (If IM > 0, then C2F = 2.5)

C4AF 32×043.3 OFe

% Liquid ONaOKMgOAFCAC 2243 +++×35.1+×13.1

Burnability Index ACAFC

SC

34

3

+

Burnability Factor )++(×3-×10+ 22 ONaOKMgOSMLSF

Loss On Ignition (LOI) 32 SO×0.7-×595.0+×1.1+×786.0 OKMgOCaO

Total Alkali OKONa 22 ×658.0+

Indicate oxide basis used for quality parameter formula calculations.

Default = Loss Free Loss Free Dry Raw



21

Table 3

Quality Parameter Your Formula if Different

Lime Saturation Factor (LSF)

Silica Modulus (SM)

Iron Modulus (IM)

C3S

C2S

C3A

C2F

C4AF

% Liquid

Burnability Index

Burnability Factor

Loss On Ignition (LOI)

Total Alkali

Indicate oxide basis used for quality parameter formula calculations.

Default = Loss Free Loss Free Dry Raw



22

B. Control Parameters: Stockpile


Identify the expected target quality control parameter setpoints (LSF, SM, IM, C3S, C2S, C3A, C4AF, % Liquid, CaO, MgO, Al2O3, Fe2O3, or SiO2) for use in computing optimum blend proportions. If there is more than one stockpile and each has different control parameters, please indicate.

Table 4

Hourly Control Parameter Value Control Parameter Parameter (Choose One)

Min Max Setpoint

1st Quality Factor

2nd Quality Factor

3rd Quality Factor

Blend Demand Units

Check one: Percent of blend composition Feeder TPH

NOTE:

If percent of blend is used, the control system output signals will be scaled from 0 to 100% of the raw blend total flow. The sum of all 6 source demands will be 100%.

If the feeder TPH is used, the control system output signals will be scaled from 0 to each feeder’s maximum TPH. The sum of all 6 source demands will be the total target raw mix flow rate.

Please add anything that you feel is important, but not specified above:

Questionnaire for CrossBelt™ Analyzer Systems to be used ... lieu/Bang cau hoi cho may phan... ·...

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