Robotic Quality Control Lab
Head (Technical Services)
Wonder Cement Limited 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, the corporate culture of Wonder Cement is built on the values of quality, trust and transparency. An emphasis on technological superiority enables the company to differentiate their offerings through impeccable quality and effective communication. Further, with an extensive network of dealers, they endeavour to earn a place in the premium segment of the market.
The group had set up two Ultra-Modern cement plants in the year 2012 (Line 1) and 2015 (Line 2); in July’19, Line 3 was inaugurated. With this new addition, the group holds a combined capacity to manufacture 9.50 MTPA Clinker at Nimbahera, district Chittorgarh, Rajasthan. Further, the cement producing capacity from Nimbahera, Rajasthan plant is 8.00 MTPA, while from grinding unit at Nardana, Maharashtra is 2.00 MTPA. After the completion of one more grinding unit at Badnawar, Madhya Pradesh by the end of this year, the total cement production capacity will be 12.00 MTPA.
The plant has been set up with technical collaboration from Thyssenkrupp and Pfeiffer Ltd., 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, maximum emission of 30 mg which enable the plant to be clean and dust free, are available. Also, the Captive Power Plant (CPP) of 40 MW capacity is present to cater the power requirements.
Further, the limestone mines have superior quality lime stone deposits, possessing cement grade quality that give 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 favorable constituents required for durability of concrete.
In addition, Wonder Cement’s plants are equipped with advanced technology equipment like Cross Belt Analyser having Combi CBA with CNA technology, Pre-blending equipment’s 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, etc.; these equipment ensure consistency in the product quality parametres, making them the best in the category of cement manufacturers.
The company has an extensive network of channel partners in the states of Rajasthan, Madhya Pradesh, Gujarat, Haryana, Delhi, Punjab, Uttar Pradesh, Uttarakhand and Maharashtra, to cater the customer needs effectively. In addition, they have Regional offices in New Delhi, Ghaziabad, Gurugram, Jaipur, Ahmedabad, Indore and Nashik to ensure regular support and services to customers.
The most advanced technology, which helps Wonder Cement in consistently manufacturing good quality cement and makes them different from the other cement manufacturers, 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; the 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.
The supported and 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 throughput capacity of 10-20 samples will apply; but higher numbers in one robot cell are achievable (240 samples/day). 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. The time required for one sample analysis is just 18 minutes.
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. The sequence control of this computer includes priority handling, intelligent handling of equipment failure situations and much more. Further, 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.
AMT (Advanced Module Technology)
AMT optimally integrates and harmonises the required sample preparation and analysis components, and still has an extremely small footprint. The AMT configuration is designed to ensure highest standard of efficiency. It provides impressively high sample throughput rates, easy operation and consistent modularity. The sample reception and preparation units (pneumatic tube, fine grinding, and tablet pressing and cleaning modules) as well as the analyser units (fluorescence spectrometer, diffractometer, laser granulometer and colour difference analyser), are all placed within reach of the robot. The 6-joint robot supplies all the analyser units with prepared samples, ultimately supporting 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, such as 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, the set x alkali cycles inside the kiln system are controlled, x sulphate phases are determined and the cement quality chemically controlled.
Further, 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. Moreover, the application of Rietveld software, the latest generation diffractometer generates a complete diffractogram and enables 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 the first company in North India to use 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).
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