Cement Moisture
Measuring Moisture Builds Profits
Lime is commonly extracted from a limestone quarry and is then loaded into a surge bin using a front loader, along with several tons of clinker material from the kiln. From there, the surge bin feeds a conveyor belt, which in turn feeds a bucket elevator. Additionally, stack fly ash is also fed into the bucket elevator. All of the material from the bucket elevator is then transferred onto a weigh belt conveyor and processed into cement in a kiln. The use of on-line NIR moisture systems has resulted in significant savings in time, materials, waste, and product rework.
To accurately measure the moisture content of the lime, the MoistTech IR3000 is installed over the conveyor belt that connects the surge bin. At this stage, the lime typically has a moisture content of about 4-16%. A plow is installed on the belt before the NIR moisture sensor mount to maintain a bed depth of approximately 3 inches for the cement material. This ensures a smooth surface for the light source from the NIR sensor. MoistTech’s equipment is designed to disregard any readings taken during gaps in product flow on the conveyor belt, providing the most precise data to line personnel.
Control Moisture Levels Now!
non-contact
Our equipment never comes into contact with the product, allowing for less waste
zero drift
Our sensors are guaranteed not to drift over time – which saves time and money
closed loop
Create a closed-loop process by tying a moisture sensor into your PLC. Full control over the line!
no recalibrations
We’ve mastered the art of moisture sensors – your unit will never need to be recalibrated for the same product twice!
Grind. Blend. Mix.
During the initial phase of processing, calcium carbonate with a moisture content of 14-25% is fed into a crusher dryer. It is crucial that the material being discharged from the crusher dryer maintains a moisture content of 10-12% to prevent any accumulation within the equipment. If the moisture content exceeds 12%, adjustments such as reducing the feed rate or increasing the temperature within the dryer would be necessary to maintain optimal conditions. To monitor the moisture content of the discharged material, the IR3000 is employed. This ensures efficient operation and helps avoid costly downtime and labor expenses associated with cleaning out the dryer.
Improve Drying Efficiency
The IR3000 moisture meter data is utilized alongside the total material weight entering the kiln to transmit information through a 4-20mA output signal (or other optional protocols) to the dryer controller or directly into the process control system. This process allows for adjustments to be made to the flow rate or kiln temperature in order to ensure the production of products that meet specifications.
The IR3000 moisture sensor provides data that is utilized for regulating the feed rate into the kiln. The rotating furnace of the drying kiln is precisely controlled to ensure consistent clinker quality. The output signal of the IR3000 can be monitored by the kiln controller or directly integrated into the process control system. The last stage of the production process involves cooling and final grinding of the clinker. The moisture level is maintained within a range of ±0.01%, and laboratory tests have shown an accuracy of ±0.1%. As a result, significant savings in time, materials, waste, and product rework have been reported.
Contact
We offer service and support throughout the world for our moisture measurement sensors and would be happy to connect you with a rep in your area. Contact us today for more information!
Understand the Process
Online Aggregate Moisture – Cement manufacturing can include any number of raw materials. Limestone, sand, shale, clay, iron ore—any combination of these may be what you are using to create your signature mix. You may choose to use the wet or dry method, but either way—moisture is key.