Real-time process optimization in the production of refractories
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 chemical composition of magnesite and other refractory raw materials supplied for crushing, separation and then for heat treatment enables to optimize the process and operating costs, control stockpile formation, significantly reduce energy consumption and avoid high costs for heavy media separation. Based on the reliable and accurate data received from MAYA online LIBS analyzers, operators can immediately response to changes in the material characteristics without the need to wait several hours for laboratory results. Such prompt process control based on LIBS online analysis helps to meet high demands from end users for resistance of refractories and lining quality and avoid possible claims, while considerably reducing energy consumption and costs for processing of off-grade raw materials.
Read how one of our customers implemented cost-effective automated grade sorting solution for refractory materials
Examples of installation
- 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
The concentration of impurities significantly effects on the properties, quality consistency of refractory products and the price of the finished products.
MAYA OnLine analyzers provide accurate continuous analysis of chemical composition of material flows directly on a conveyor belt without any hazardous radiation.
Your benefits with MAYA Online analyzers
- 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