Process audit
Department of Mines
|
Sample
|
Description of experiments
|
|
Sampling the hole
|
Depot sampling
|
Chemical analysis
|
Mineralogical studies
|
Ability to shred
|
Clay separation and XRD
|
|
Limestone
|
✓
|
✓
|
✓
|
✓
|
✓
|
º
|
|
Alluvium or marl
|
✓
|
✓
|
✓
|
✓
|
✓
|
✓
|
|
silica stone
|
✓
|
✓
|
✓
|
✓
|
✓
|
º
|
|
Iron ore
|
º
|
✓
|
✓
|
✓
|
✓
|
º
|
|
Gypsum stone
|
º
|
✓
|
✓
|
✓
|
º
|
º
|
Department of stone crusher and mixing hall
|
Sample
|
Description of experiments
|
|
Chemical analysis
|
Mineralogical studies
|
Sieve granulation
|
|
Entrance to the mixing hall (exit of the crusher)
|
✓
|
✓
|
✓
|
|
Exit from the mixing hall
|
✓
|
✓
|
✓
|
|
Investigating the operation of the stacker and reclaimer and determining the number of layers in the mixing hall and determining the amount of pile sugars and its effects on material fluctuations.
|
|
Calculation of the homogenization factor of the mixing hall using the standard deviation of LSF and CaO of materials entering the mixing hall - leaving the mixing hall - at least 48 samples
|
Department of grinding raw materials and furnace feed
|
Sample
|
Description of experiments
|
|
Chemical analysis
|
Mineralogical studies
|
Ability to cook
|
Thermal analysis
|
Granulation distribution
|
Sieve granulation
|
Sorting
|
|
material mill
|
✓
|
✓
|
✓
|
✓
|
✓
|
º
|
º
|
|
Furnace feed
|
✓
|
✓
|
✓
|
✓
|
✓
|
º
|
º
|
|
Separator input material
|
º
|
º
|
º
|
º
|
✓
|
º
|
º
|
|
Coarse material (return separator)
|
º
|
º
|
º
|
º
|
✓
|
º
|
º
|
|
the product
|
º
|
º
|
º
|
º
|
✓
|
º
|
º
|
|
Materials inside the mill
|
º
|
º
|
º
|
º
|
✓
|
✓
|
º
|
|
Bullets in the chambers
|
º
|
º
|
º
|
º
|
º
|
✓
|
✓
|
|
Calculation of silage homogenization factor of raw materials using standard deviation of LSF and CaO of furnace feed and raw material mill - at least 48 samples
|
|
Investigating the factors affecting the decrease or increase of baking ability (mineralogical studies, chemical analysis, thermal analysis and granulation distribution)
|
|
Checking the charging of mills and comparing it with standard conditions (manufacturer company)
|
|
Drawing the Trump diagram and checking the separator efficiency
|
|
Checking and calculating the grinding and powdering process inside the mill
|
Baking department
|
Sample
|
Description of experiments
|
|
Chemical analysis
|
Mineralogical studies
|
Ability to shred
|
Determination of SO 3 , LOSS and alkalis
|
Calculation of calcination
|
|
Output of cyclones
|
º
|
º
|
º
|
✓
|
✓
|
|
Inlet
|
º
|
º
|
º
|
✓
|
✓
|
|
Clinker
|
✓
|
✓
|
✓
|
º
|
º
|
|
Gas analysis measurement, temperature, static pressure, dynamic pressure in the inlet, chimney outlet, calciner outlet, calciner inlet, preheater outlet (cooling tower inlet), ID fan outlet, cooling tower outlet, inlet to fan ID , electrofilter inlet, inlet material mill output material mill, separator fan input (cyclone output), separator fan output, chimney output
|
- Investigating the indicators of raw materials in terms of chemical - physical and mineralogical aspects
- Investigating process and operating indicators including analysis of gases, temperature, pressures, etc. . .
- Calculation of the amount of leakage in different parts of the baking department
- Mass and energy balance in different sections and consumption analysis in each section
- Investigation and analysis of energy consumption and how parameters change, their effect on consumption and optimal conditions
- Summarizing and preparing at the beginning of the chapter executive and application proposals and determining the future goals of energy optimization
- Thermal simulation and examination of temperature gradient and determination of heat loss points
|
Cement mill department
|
Sample
|
Description of experiments
|
|
Chemical analysis
|
Physical tests
|
Granulation distribution
|
Sieve granulation
|
Sorting
|
|
The final cement product
|
✓
|
✓
|
✓
|
º
|
º
|
|
Separator input material
|
º
|
º
|
✓
|
º
|
º
|
|
Coarse material (return separator)
|
º
|
º
|
✓
|
º
|
º
|
|
the product
|
º
|
º
|
✓
|
º
|
º
|
|
Materials inside the mill
|
º
|
º
|
✓
|
✓
|
º
|
|
Bullets in the chambers
|
º
|
º
|
º
|
✓
|
✓
|
- Checking the charging of mills and comparing it with standard conditions (manufacturer company)
|
- Drawing the Trump diagram and checking the separator efficiency
|
- Checking and calculating the grinding and powdering process inside the mill
|
mechanical
|
Service description
|
|
General visit to the mechanical system and equipment of the line
|
|
Control of material transfer systems
|
|
Inspection of gearboxes in terms of sound, vibrations and temperature
|
|
Control of hydraulic, pneumatic and compressor systems
|
|
Visiting the performance of utility systems
|
|