Robotic quality control lab from Wonder Cement
Robotic quality control lab from Wonder Cement

Robotic quality control lab from Wonder Cement

R.K. Marble group had set up ultra modern cement plants in 2012 (line 1), in 2015 (line 2) and recently in July 2019 line 3 has been inaugurated. The combined capacity of the group is to manufacture 9.50 MTPA clinker at Nimbahera, Chittorgarh district in Rajasthan.

Wonder Cement is a cutting-edge cement manufacturing company with an ambition to establish itself as a leading player in the industry. Enriched with the heritage of R.K. Marble, a leading name in the marble industry, our corporate culture is built on the values of quality, trust and transparency. An emphasis on technological superiority enables us to differentiate our offering through impeccable quality and effective communication. With an extensive network of dealers, we endeavour to earn a place in the premium segment of the market.

Our cement producing capacity from Nimbahera, Rajasthan plant is 8 MTPA, from grinding unit at Nardana, Maharashtra is 2 MTPA. After completion of one more grinding unit at Badnawar, Madhya Pradesh by the end of this year, our total cement production capacity will be 12 MTPA.

The plant has been set up with technical collaboration from ThyssenKrupp and Pfeiffer, Germany, who are world leaders in cement technology. The entire design of the plant is based on the latest environment norms, with the help of Reverse Air Bag House and ESP, we are having maximum emission of 30 mgs, which enables the plant to be clean and dust free. We have captive power plant (CPP) of 40 MW capacities to cater the power requirements.

Our limestone mines have superior quality lime stone deposits, possessing cement grade quality that gives high early strength and ultimate long-term strength. Additional characteristic features of lime stone are low alkali, low magnesia and low chloride contents which are highly favourable constituents required for durability of concrete.

Our plants are equipped with advance technology equipment like cross belt analyser having Combi CBA with CNA technology, pre-blending equipment for all the raw materials, robotic technology POLAB for quality control, inline calciner at pre-heater for proper burning, polytrack cooler, closed circuit grinding system with high efficiency separators for maintaining optimum particle size distribution, these all ensures consistency in our product quality parameters and makes us in the best category of cement manufacturers.

We are having extensive network of channel partners in Rajasthan, Madhya Pradesh, Gujarat, Haryana, Delhi, Punjab, Uttar Pradesh, Uttarakhand and Maharashtra to cater to the customer needs effectively. In addition to this, the company has regional offices at New Delhi, Ghaziabad, Gurugram, Jaipur, Ahmedabad, Indore and Nashik to ensure regular support and services to customers.

The most advance technology, which helps us in manufacturing consistent good quality cement, and that makes us different from the entire cement manufacturer is POLAB AMT - Robotic Quality Control Lab.

POLAB configuration consists of a standard industrial robot placed in the centre of a circular arrangement of sample preparation and analytical equipment. Samples normally arrive automatically from the connected automatic sample transport system.

It offers a very high flexibility in terms of the number and types of equipment handled by the robot. Supported, fully automated preparation and analysis disciplines relevant to the cement industry include powder or fused bead preparation for x-ray analysis, particle sizing by laser or by conventional sieving analysis, sulphur/moisture combustion analysis, physical testing and collection of shift/daily composites.

For the typical cement lab project, a through put capacity of 10-20 samples will apply; but higher numbers in one robot cell are achievable (240 samples/day). The POLAB computer integrates the system components. It identifies incoming samples, downloads the relevant sample-handling specification and controls all intelligent devices in the configuration.

Sequence control includes priority handling, intelligent handling of equipment failure situations and much more. POLAB provides high quality in sample preparation and analysis. Quality not only meets the performance of the very competent lab scientist but is highly consistent over time. Thus, there are no fluctuations from shift to shift in analytical levels due to small differences in the practical procedures undertaken by human operators. Sampling is done at different stages like raw mill sample, C.F. Silo sample, kiln feed sample, clinker sample, ground cement sample and dispatch cement sample. Time required for one sample analysis is just 18 minutes.

AMT (Advanced Module Technology) optimally integrates and harmonises all required sample preparation and analysis components and still has an extremely small footprint. The AMT configuration is designed to ensure the highest standard of efficiency and provides impressively high sample throughput rates, easy operation and consistent modularity. The sample reception and preparation units (such as pneumatic tube, fine grinding, tablet pressing and cleaning modules) as well as the analyser units (such as fluorescence spectrometer, diffractometer, laser granulometer and colour difference analyser) are all placed within reach of the robot. The six-joint robot supplies all the analyser units with prepared samples and thus supports simultaneous analyses.

Pneumatic tube module: The samples of all initial, intermediate and finished products that are automatically taken at short intervals from the individual sections of the production process are sent in capsules to the pneumatic tube module. The subsequent volumetric dosing process takes place without contamination and is totally dust-free. The module permits manual loading and removal of pneumatic dispatch capsules, as well as the storage of reserve samples (e.g. for physical investigations).

Optimum process control: The aim of optimum process control is to provide comprehensive knowledge about the material compositions and properties before and during the production process. Based on the Spectrometer analysis, the x raw meal mixtures are optimally calculated and set x alkali cycles inside the kiln system are controlled and x sulphate phases are determined and the cement quality chemically controlled. The particle size fractions determined in the laser granulometer are the basis for controlling the separator speed or for operation of a higher ranking, intelligent mill regulation system, such as POLEXPERT® MCE. Through the application of rietveld software, the latest generation diffractometers generate a complete diffractogram and enable exact identification of all clinker phases in a matter of minutes. This opens totally new perspectives for regulating the material quality, operating the kiln under consideration of substitute fuels and optimising the cement manufacturing process.

Wonder cement is first company in North India that is using POLAB AMT, which eliminates human errors in sample collection, testing and analysing and ensures consistent quality of raw materials, intermediate product (clinker) and final product (cement).

ABOUT THE AUTHOR: Hitesh Mogra, Head - Technical Services, Wonder Cement

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