Superior chemical control

for the cement industry

QCX/BlendExpertTM
2 3

Why use advanced Challenges in cement production

quality control?

Are you a cement producer Advanced quality control from Benefits Cement producers face many challenges. Total capex is limited for QCX/BlendExpert boasts a simple and
wanting to make the most out FLSmidth ensures that cement plants • Improved chemical control results in QCX/BlendExpert helps them overcome: new plants intuitive user interface, making it easy
of your plant investment? deliver superior, steadier cement stability of operations and delivers Tight control of raw material blending for operators to use.
Then you will understand that quality, with cost efficient additive fast payback on investment: Competitiveness relies upon negates the requirement for expensive
strict quality control is critical. control and reduced fuel - lower fuel consumption in the kiln obtaining good quality products blending silos. Silos can be considered Pressures to reduce CO2 and
consumption. The result? Increased and preheater. at low cost storage buffers only and this dramatically other emissions from cement
Quality control systems are production stability and higher - reduced equipment wear and QCX/BlendExpert optimises raw material reduces the need for capital expenditure. production
essential in minimising profitability. longer lifetime of mechanical parts blending to meet peak quality targets. QCX/BlendExpert also compensates for Alternative fuels are becoming an
variability in material - less thermal stress is a direct benefit poor functioning blending silos on increasingly important option for
composition throughout the In addition, FLSmidth’s high level of QCX/BlendExpert’s chemistry The upshot is reduced fuel consumption existing plants. cement plants to reduce their CO2
cement manufacturing process, control system, QCX/BlendExpert™, control. and stable kiln operation. This, in turn, footprint.
controlling all chemical eliminates the need for specific
• Up to 60% lower standard
leads to less thermal stress on kiln parts, Skilled technicians are limited,
compositions. sampling and analysis of raw materials
deviation of LSF.
such as lining, resulting in fewer and with high staff turn-over rates With QCX/BlendExpert kiln operation
into feeders. In addition it displays shorter kiln stops. QCX/BlendExpert is a world class control is more stable and this enables stricter
and manages dynamic bias correction • No need for sampling, sample system, meaning the complex task of control of emissions. In addition, the
from any online analyser in the preparation and analysis of raw controlling varying raw material qualities use of alternative fuels, without
process. material – chemical values are is no longer manual. jeopardising clinker quality, opens
accurately estimated. new possibilities for many cement
• Reduced need for blending silos. plants.
• Higher alternative fuel substitution
rate.
• Steady 24/7/365 control philosophy.
• New, intuitive user interface,
providing easy overview of ‘next
step’ operation.
• Fast trouble-shooting of material
feeders through direct monitoring
of feeder operation.
• Improved accuracy and enhanced
benefits from online analysers
through dynamic bias correction.
• Best use of use of raw materials and
additives, leading to cost savings.
• Optimal control of material
blending during upset conditions
– no need to switch to manual
control.
• Existing users of QCX/BlendExpert
V7 will enjoy significant improve-
ments when upgrading to V8.
4 5

Results achieved

Local conditions are an important factor Auto correction of the online QCX/BlendExpert proves that it’s possible
when comparing data from different analyser to operate a cement line with a direct
plants. These include: Some plants trust their online analyser feed from the quarry to the mill or from
• Fluctuating raw material quality. to provide correct analysis, however this the mill to the kiln.
• Blending efficiency before and after is not always the case.
the raw mill. This feature is effective when an existing
• Material handling problems. QCX/BlendExpert advanced process homogenising silo is not functioning
• Available feeder capacities. modelling takes all material process well and not blending to the desired
delays into equation and ccompares factor. 4 8
What may be considered poor control between the quick online analyser
6,9
performance figures at one plant with results with the more correct analysis No need for sampling and 3,5 CEM II/B-M 42,5 N CEM II / A-LL 52,5 N CEM I 52,5 R
2011 2015 2016 2011 2015 2016 2011 2015 2016
‘easy’ raw materials, could be from the laboratory XRF. analysis of raw material
2,1 1,3 0,8
considered excellent performance at a The raw material estimator has proven 3 1,5 1,3 1,0 6

plant with more difficult conditions. Dynamic bias correction of the online to be as accurate as the physical samples 1,7 1,55,3 1,4
2,5 2,4 5
analyser is based on this. This bias taken from the raw materials, thus

St Dev of 28d MPa

St Dev of Raw meal

2,1
Selection of samplers and analysers is correction significantly enhances the eliminating the need for this manual
2 1,9 4
very much specific to the individual value of the online analysis. process. 1,7
cement plant. So is prediction of the 1,5 1,5
1,5 1,4 1,4 3
1,3 1,3
achievable control performance. Maximum use of History
alternative fuels For 40 years, FLSmidth has been a 1
1,0 1,9
2
0,8
While high frequency online analysers Alternative fuels are becoming pioneer in high-level expert systems
can result in improved control important for most cement plants. Using designed specifically for cement 0,5 1
performance, automatic sampling and by-products provides waste applications.
sample preparation result in more management options that can be 0 0
2011 2015 2016 2011 2015 2016 2011 2015 2016 2011 2015 2016 2011 2015 2016
accurate and precise analysis. By economically viable, regionally available The new QCX/BlendExpert solution is
CEM II/B-M 42,5 N CEM II / A-LL 52,5 N CEM I 52,5 R CEM I 42,5 N SR StDev of LSF in Raw meal
integrating these analysis techniques and environmentally sound. the eighth generation of the software
QCX/BlendExpert delivers the vital link to and is based on FLSmidth’s vast 2011 QCX V7
2015 QCX V7 + PGNAA
attain substantial quality improvements. Some alternative fuels generate automation experience. This is evidenced 2016 QCX V8 + PGNAA
chemical constituents, such as alkalis or by more than 700 quality control (QCX)
FLSmidth has continuously chlorides, that must be considered in the systems being successfully installed
demonstrated that QCX/BlendExpert equations when designing the chemical worldwide.
provides considerable control targets of the cement.
Results from Finsementi Lappeenranta plant in Finland. The graph shows clinker strength for 4 different cement types as well as to the far right the std.dev. of LSF in the
improvements compared to manual set It’s designed by FLSmidth’s international
raw meal after the mill. The first bars for each instance (2011 values) represents operation with QCX/AutoSampling and QCX/BlendExpert v7. The second bar (2015
point control. QCX/BlendExpert has a QCX/BlendExpert is designed to handle team of quality experts using the latest
values) represents operation with QCX/AutoSampling and QCX/BlendExpert v7 and a PGNAA before the raw mill. The third bar (2016 values) represents operation with
proven track record of maximising these important factors. control technologies, such as model-
QCX/AutoSampling and a PGNAA before the raw mill and QCX/BlendExpert V8. Considerable improvements were achieved with the new QCX software.
performance improvements. based predictive control, which,
Less homogenising requirements together with today’s powerful PC
Quality improvement When engineering a cement line, processors, enables very complex
Previous versions of QCX/BlendExpert eliminating or reducing the size of the process simulations and corresponding
software performed well. However, with homogenising equipment is often an estimations.
the new V8 software, cement producers important factor. This puts added
have seen a reduction of lime saturation pressure on blending the raw materials.
factor (LSF) standard deviation of 60%
compared to earlier versions.
6 7

What is QCX/BlendExpert? QCX/BlendExpert™ – Mill Application

QCX/BlendExpert is an advanced This can be combined with online The software can be installed on a Based on the analysis of the material The calculated feeder set-points are The software can be configured for any
software solution, which, through analysis instrumentation which provides standard PC, physical or virtual, stand stream, QCX/BlendExpert – Mill automatically implemented via the number of raw mills and/or cement
chemical analysis results, controls: very frequent, however less accurate, alone or on top of another QCX system. continuously integrates material tonnage general plant control system. Taking into mills, and be based on any analysis
• Blending of raw material feed to data. Using a sophisticated and chemical analysis results and account target chemistry, chemical technique (whether in the laboratory or
stockpiles mathematical toolbox and specialised While QCX/BlendExpert is part of compares the expected raw meal quality constraints, process limitations and online) or in any combination of
• Blending of raw materials and application algorithms, QCX/BlendExpert FLSmidth’s suite of QCX solutions, such with the defined quality target. material costs, QCX/BlendExpert will analysers.
additives to raw mills continuously performs complex analysis as QCX/AutoSampling and always strive to produce the desired
• Final cement quality to cement mills. of the chemical conditions and, based QCX/RoboLab, it is still compatible with chemical product quality with minimum
on these results, adjusts the set-point of most other plant control and quality product quality variance.
The QCX/BlendExpert suite of material and additive feeders. control systems.
applications support quality optimisation
from quarry to delivered cement. Rapid complex calculations, which take QCX/BlendExpert – Mill can be
chemistry, tonnages and price, among configured for any number, type and
Optimising quality control starts with many other factors into the equation, make of mills. In addition, mill and
correct automated sampling, sample enable QCX/BlendExpert to adjust the stockpile mix control schemes can be Glanceable operator overview
preparation and X-ray analysis, which feeders more frequently and reliably combined in one system.
ensures a reliable and accurate chemical than any human operator.
evaluation.

Manually operated QCX/BlendExpert

Stabilise Optimise Maintain

Limit violation

Under performance

QCX/BlendExpert consists of several software modules and is part of FLSmidth’s QCX suite
of products which also includes QCX/AutoSampling and QCX/RoboLab.

QCX/BlendExpert QCX/BlendExpert QCX/BlendExpert QCX/BlendExpert QCX/BlendExpert QCX/OnlineExpert

– Raw Mill – Cement Mill – Coal Mill – L Pile – C Pile

QCX/BlendExpert Basis

QCX/Reporting Standard and advanced reports and trend curves > 1 year data.

QCX/Manager 
Sample handling, various editors, alarm handling, sample viewer.
8 9

Online accounting It demonstrates how QCX/BlendExpert This single loop control enhances the Raw material estimation The combination of the mathematical The model behind the estimator takes
The online accounting of individual raw can operate with laboratory XRF results control accuracy as it makes use of the QCX/BlendExpert raw material toolbox, the process modelling and the into account expected variations in the
material feed streams and other relevant only, or in a combination of laboratory speed of online analysis together with estimation provides a reliable assessment estimators in QCX/BlendExpert ensures concentrations, concentration
materials, such as dust, coal, ash, fly XRF and online analyses incorporating all the accuracy of a laboratory XRF. of the chemistry in the feeders at any that the raw meal composition is constraints and accuracy of the analysis
ash, alkali and ´´bypass, is based on results in the control algorithms. given time. constantly and consistently estimated. methods employed.
weigh feeder signals and depicted in the
below diagram. This feature saves time and money as it Changes in the material compositions The process is modelled in the diagram
eliminates the need for physical are estimated as they happen, so there is below:
sampling, sample preparation and no need to wait for a physical sample
analysis of raw materials – a labor- which is usually only available once per
intensive job conducted regularly on shift.
many cement plants.
Raw materials

Raw mill Kiln dust

Feed
Production Sample Sample
Feed accounting estimate analysis
On-line
PGNAA/PFTNA Feed
Sampler

Composition
estimation
QCX/BlendExpert software
Multiple Feed Estimation

QCX/OnLineExpert
Dynamic Calibration of BMA Lab XRF On-line
EDXRF
QCX/BlendExpert
Mix control

Process flow Analysis data, sample taken

time, process data
Sample flow

Control loop

Analysis data flow

10 11

Automatic feeder offset Automatic handling of Multiple materials per feeder Silo estimation
correction feeder starvation In order to meet the demands of One of the reasons why QCX/
QCX/BlendExpert software ensures If a feeder is in starvation, modern plant conditions, where material BlendExpert has achieved excellent
automatic correction of feeders. QCX/BlendExpert estimates whether it types can rapidly change, QCX/ results is due to its innovative way of
So, if a feeder has been incorrectly can still reach its target in this condition. BlendExpert software can operate with dealing with silo content.
calibrated, or not calibrated at all, If it cannot reach all targets (if it’s losing multiple materials per feeder. Silo content and composition is
QCX/BlendExpert will detect the error a degree of freedom), it will, according estimated in accordance with applied
and correct the feeder set-point to to control philosophy, jeopardise the This results in a fast, flexible and silo models (continuous, layered or
offset it. target(s) which are least important to responsive system, with minimal batch) and current product type. This
the overall clinker quality, for example, operator intervention, when faced with estimation contributes to a very efficient
This unique feature contributes to alumina module (AlM). varying material types. and effective chemical process model
improved overall chemical control The diagram below is a screen shot of where chemistry is still controlled if for
performance. the status of the various raw material instance the mill is stopped and
and additive feeders. additives are still added to the silo.

Chemistry designer tool

In the Control Tuning feature the
operator can experiment with the
1. T
 racking of whether the feeder set-point is within the feeder limits
blending circuit chemistry. Here he or
2. T
 racking of how well the feeders react to set-point changes
she can change feeder settings, material
3. Indication of: Feeder set-point, Working set-point, calculated process value, process value and process value offset. Feeder overview 
qualities, set-points and other variations
and see what kiln feed chemistry such
parameters will bring.

In this advanced feature it is also

2 possible to call up historical settings and
results and investigate various scenarios
around these events. This gives a
chance to plan for variations in
1 chemistry coming from the quarry or
from alternative raw material suppliers
and evaluate if such materials can be
accepted and still reach the control
targets.

3
12 13

QCX/OnlineExpert Reporting, trending

and alarm handling

To maximise the benefits of online Dynamic bias compensation of This calculation takes into account all Reporting
analysers, it’s necessary to implement a PGNAA/PFTNAA/NIR delays and material additions which QCX/BlendExpert is designed to operate
high-level control system such as While a mix control application based occurred from when the material passed together with QCX/Reporting. This
QCX/BlendExpert. It integrates the solely on online analysis will provide fast the online analyser, to when the module generates the required reports
online analysis data stream with the less and frequent (however less accurate) reference sample was taken. for shift, day, month and chemical
frequent, but more accurate, central control performance, QCX/BlendExpert preformance.
laboratory XRF results to produce offers a unique function where the Below is a QCX/BlendExpert graph
accurate process chemistry data. results from both the online analysis and showing the results of the dynamic It offers approximately two years of
laboratory XRF spectrometer are used in calibration of a PGNAA. CaO proves to data storage capacity and manages all
The QCX/OnlineExpert software module a single control loop. be off target with considerable reports as well as trend curves.
handles data from a range of online variations. However, this does not affect
analysers, such as PGNAA, PFTNAA and QCX/BlendExpert calculates the bias the QCX/BlendExpert controls as it The extensive and flexible report
NIR. compensation of the online analyser accounts for the bias associated with generation and graphic presentation
dynamically. every sample analysed by the PGNAA. facilities provide:
Apart from the communication driver to • Configuration of general QA reports.
the online analyser, the software module This means that every analysis from the • Configuration of customer specific
1. The 0-line where all PGNAA results should be
handles the important function of bias online analyser is verified against the 2. Al203 is too low
reports
compensation. more accurate chemistry obtained by the 3. The line shows that the PGNAA is far off in it´s • Auto-generation of reports.
laboratory analysis. Ca0 analysis and that the measurements vary
• Automatic scheduling of reports
a lot.
• Report availability on the QCX
Report showing chemical results of one sample
website
• Report availability via email.
• Configuration of trend packages.
• Fast trending chemical results
• Trending up to 10 sample analyses in
one view.

Alarm handling
Sampling, analysis or equipment alarms
and non-critical events are logged in
order for the laboratory personnel to
keep track of ‘bad’ samples and other
1
important events, such as maintenance
scheduling.
2
Event historian
3 An event historian keeps track of alarms
and events. The live event lists and
historical events are tracked and
recorded. This record is useful should
Event historian showing historical events in the system there be discussion regarding events or
alarms or a need to review them.
14 15

Eight steps to a successful

quality control solution

FLSmidth’s eight-step
implementation process
1. Project planning: An FLSmidth project manager 5. Operator and super-user training: FLSmidth
prepares a start-to-finish strategy. representatives train operators in the new system.

2. Client process interviews: FLSmidth engineer 6. Remote monitoring and fine-tuning: As the
interview the client regarding the blending control strategy final part of commissioning, FLSmidth makes small
and process model. adjustments to the system remotely – this requires an
internet connection to the system.
3. Application design and process strategy
review: FLSmidth designs the right solution based on the 7. After sales service: After commissioning is
site interviews. complete, FLSmidth transitions the project to the service
phase.
4. Primary system commissioning: Commissioning
is completed and the system is implemented and 8. Establishing long-term support: FLSmidth can
monitored onsite. support the system with software updates and ensure that
it runs as efficiently as possible.

When FLSmidth initiates an advanced more. For solutions to operate reliably

control project, a dedicated project and efficiently, it needs to be
manager is assigned to coordinate all implemented correctly. FLSmidth’s
activities over the lifetime of the project. eight-step implementation model
provides the professional support
As the main contact for the plant, the necessary to ensure the system meets all
project manager is involved in the requirements and expectations.
implementation process right from the
start, providing the plant with a clear
and detailed project plan that contains
key deadlines, project meetings and
 C 09-16 800-173-ENG-V1

Copyright © 2017 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties
(express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com/spa

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