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Florida Rock is said to have cut energy consumption and improved product quality using a model predictive control package from Pavilion and real-time particle size analysis from Malvern Instruments.

The Cement Grinding Application solution from Pavilion Technologies and the Insitec fineness analyser from Malvern Instruments were installed to automate control and improve the efficiency of the finishing circuit that mills cement to the required fineness.

Specific energy consumption – the amount of energy used to mill each tonne of cement – is now claimed to be 17 per cent lower while, the key performance indicator of one-day strength is said to be up by around 15 per cent.

Florida Rock, part of Vulcan Materials, has estimated a return-on-investment of less than two years, based on energy savings alone.

Recognising that cement strength, and other aspects of cement performance, correlate better with particle size parameters than with Blaine has been fundamental to the success of the project.

The Insitec fineness analyser provides continuous real-time particle size measurement at a rate of up to four complete distributions per second, reporting three specific size fractions to the control system.

At the heart of the Cement Grinding Application lies a multivariate predictive control model that uses data in combination with other routinely measured plant variables, to predict process behaviour and provide closed-loop control.

Malvern Instruments

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