Online Free Calcium Analyzer

Adapted for Intelligent Cement Industry Laboratories | Fully Automated Online Testing | Precise Control of Clinker Calcination

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Product Overview

The ITECA online free calcium analyzer is specifically designed for quality control in cement production. Fully Automatic Online Free Calcium Analyzer for Clinker Focusing on the core requirements of rapid sampling, precise analysis, and real-time data feedback for hot clinker at the cement kiln head, this solution replaces the traditional manual sampling and manual chemical titration methods, enabling fully automated operations across the entire workflow—from sampling and sample delivery to sample preparation and analysis.

The product is deeply tailored to meet the digitalization and intelligent transformation needs of cement enterprises, seamlessly integrating with DCS systems and APC kiln expert optimization control systems, thereby providing… for the clinker calcination process. High-frequency, precise, real-time Its free calcium detection data thoroughly addresses the industry’s longstanding pain points—namely, the lag, significant measurement errors, and high labor costs associated with conventional free calcium analysis—making it a core quality‑control instrument for cement plants to stabilize kiln conditions, enhance product quality, reduce energy consumption, and enable intelligent process management.

Industry Pain Points and Application Requirements

In the cement clinker production process, free calcium is a key quality indicator that guides kiln calcination and optimizes production control; however, conventional analytical methods face multiple bottlenecks:

Severe testing delays : Traditionally, sampling points are located at the clinker cooler’s discharge chute. After cooling in the grate cooler, sampling, sample preparation, and manual analysis, the resulting data are fed back with a lag of more than one hour relative to kiln operation, making it impossible to reflect real-time fluctuations in kiln conditions.
High labor and time costs : Manual sampling and manual chemical titration require dedicated personnel, involve cumbersome procedures, and result in low testing efficiency.
Data errors affect production. : Manual operations introduce subjective errors, and offline inspection data cannot accurately guide production;
Poor adaptability of intelligent systems Offline data cannot be integrated into the kiln expert optimization control system in real time, thereby hindering the intelligent upgrade of cement production.

As the cement industry advances its digital transformation, Fully automatic, online, high-frequency Free calcium detection equipment has become an essential tool for production and quality control in cement enterprises.

Core Technological Advantages

Direct sampling from the kiln and real-time monitoring: Innovatively adopting a direct sampling technique at the kiln outlet, this approach overcomes the challenge of high‑temperature sampling of hot clinker, eliminating the need for long‑distance sample transport and significantly improving analytical turnaround time.
High-frequency monitoring, precise control: Achieve the highest 4 times per hour Free calcium analysis delivers high‑frequency data output that fully meets the demands of real‑time production control, enabling precise, dynamic adjustments to kiln operating conditions.
End-to-end automation, unattended operation: The entire workflow—sampling, sample transfer, sample preparation, analysis, and data upload—is fully automated, eliminating the need for manual intervention, reducing laboratory labor costs, and preventing human‑induced operational errors.
Data interconnection, intelligent collaboration: Standard communication interfaces are included, enabling real-time integration of test data into the enterprise DCS system. When used in conjunction with the APC kiln‑expert optimization control system, this solution maximizes calcination control accuracy.
Stable and reliable, industry-proven: The detection principle has been validated by vast amounts of industrial data, delivering high accuracy and stable performance, and is well-suited to the continuous production requirements of cement plants.

System Composition

The ITECA online free calcium analysis system features a modular design and consists of Sampler, transmission system, analyzer Composed of three core modules, it offers flexible installation and convenient operations and maintenance:

Sampler Unit: Installed at the kiln outlet discharge point, it comprises a beam-type sampler, a screening unit, a return-material system, a cooling system, and an on-site control cabinet, enabling automated sampling, cooling, and pre‑treatment of high‑temperature clinker.

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Hot clinker sampler

Transmission System: It consists of dedicated pipelines, a booster fan, and a receiving station, enabling sealed, rapid transport of samples from the sampling point to the analyzer while preventing sample contamination and loss.
Analyzer Unit: It integrates a grinding mill, a sample‑retention unit, a quantitative feeding device, an electronic balance, an ethylene glycol reaction system, measurement equipment, a robotic arm, and an intelligent control system, enabling fully automated sample analysis and data output.

Free Calcium Analyzer

Detection principle

The equipment adopts Ethylene Glycol Extraction – Conductivity Detection Method The analytical procedure is precise and efficient: after grinding the clinker sample, an ethylene glycol solution is added, and an extraction reaction is carried out under stirring and heating conditions. Free calcium oxide in the clinker is electrolytically converted into calcium ions, with the solution’s electrical conductivity exhibiting a linear relationship to the calcium ion concentration. The electrical conductivity is accurately measured using a conductivity meter, and the resulting value is converted via a systematic algorithm to directly determine the free calcium oxide content.

This detection principle has been extensively validated through industry-wide practice, Precise and reliable, with rapid response. It is a mature and preferred solution for the rapid determination of free calcium in the cement industry.

Application Value and Benefits

Production Control Optimization Real-time data guides calcination control, precisely optimizes primary coal consumption, and ensures stable kiln operation.
Significant cost reduction and efficiency gains : Reduce manual labor in laboratory testing, improve testing efficiency, increase clinker production, and lower overall energy consumption;
Stable and controllable quality : Eliminate human error, standardize testing procedures, and ensure consistent clinker quality;
Supporting Intelligent Transformation : Address the shortcomings in online monitoring and drive the transformation and upgrading of cement production from manual control to intelligent automation.