Real-time process optimization in the refractories production
Real-time process optimization in the refractories production
Production of refractory products with the required quality and properties demands continuous monitoring in the process of such constituents as MgO, SiO2, CaO, Fe2O3, Al2O3, Cr2O3, B2O3, MnO2 etc. Real-time information on the chemical composition of magnesite and other refractory raw materials supplied for crushing, separation, and subsequent heat treatment enables optimization of the process and operating costs, control of stockpile formation, significant reduction in energy consumption, and avoidance of high costs for heavy media separation.
Based on reliable, accurate data from Lyncis online LIBS analyzers, operators can respond immediately to changes in material characteristics without waiting several hours for laboratory results. Such prompt process control based on LIBS online analysis helps meet high end-user demands for refractory resistance and lining quality, while avoiding potential claims, while considerably reducing energy consumption and processing costs for off-grade raw materials.
SCADA integration for real-time process control
- Removal of refractory raw materials with high content of impurities coming from waste rocks at earlier stages
- Sorting out high-quality crushed ores with minimum impurities to produce high-grade final products
- Replacement of expensive dense media separation by more efficient ore sorting
- Accurate stockpile formation with the pre-set quality to control the proper dosage of the crushed ore into kilns/furnaces and get the required quality of refractory products
- Analysis of the kiln output to ensure proper grade sorting before production of firebricks and shipping to the end users
Your benefits with Lyncis Online analyzers in refratory production
- Decreased over-consumption of refractory raw materials
- Reduced costs for dense media separation
- Reduced costs for calcination/sintering/smelting of off-grade materials
- Savings in energy consumption
- Higher profits for higher grades of refractory products
- Reduced off-grade product penalties
- Automatic continuous and accurate chemical analysis without sampling and delays. Eliminated human errors and reduced costs for laboratory analysis
- Stable technological process
