Quality lab data management software to satisfy quality assurance requirements and quality control requirements. The QES suite eliminates paper records for lab results, interim data, staff qualification, instrument certification and many other required values. These products were designed to enable cement operations to control production quality and laboratory management with efficiency and accuracy.
Laboratory Data Management System
Laboratory Data Management System (LDMS) is the leading cement LIMS quality data organization and collection tool in North America and Oceania.
LDMS is designed for ease of use by both the laboratory analysts, for data entry, and to fulfill plant and corporate reporting requirements. The system collects the quality testing data into the plant specific data groups with a common look and feel.
Automatic data collection from laboratory instruments such as balances, calorimeters, particle size analyzers and XRF is done with direct connection interfaces. Automatic correlation of process system parameters, such as kiln feed rate and temperature, with the sample, is available for quick and easy identification of potential problems. Data extraction for reporting uses common desktop tools such as Microsoft Excel to minimize the investment in specific plant reports.
Raw Mix Control System
Variability and raw material uncertainty can prevent a plant from controlling raw mix accurately. Raw Mix Control System (RMCS) can automate the monitoring of raw material chemistry and the plant control system to manage raw material feeder settings and apply target and constraint rules.
The RMCS algorithm uses continuous feeds from on-line sources (e.g. PGNAA or XRD devices) and the lab XRF, and continually adjusts feeder settings. The inner / outer loop control algorithm handles drift correction of online devices.
Feeder performance and the reaction to feeder changes is used to provide a more accurate picture of the raw materials than can be achieved with infrequent raw material analysis.
If the RMCS algorithm has difficulty obtaining an optimal solution based on the SQC rules, email or process alarms can warn the lab analyst.
RMCS is easily configured by the quality manager to set control targets and tune the aggressiveness of the RMCS algorithm. All control and tuning changes are logged for review.
RMCS has been installed at more than 15 cement plants around the world, and helps our customers reduce costs and improve quality.
Waste Fuels Information Management
WFIMS uses the reliable LDMS core to manage commercial waste fuels. Samples are tracked from producer to destruction. The qualification, testing, approvals, blending and disposal certification of Waste Fuels is handled end-to-end. Like LDMS, ranges and limits are simple to configure and give immediate information to the analyst when values exceed tolerance.
An optional tracking module ties together information from shipments and storage locations – aiding in accurate completion of reports and regulatory documentation. The extensive use of bar codes eliminate transcription errors. Containers can be easily identified and located, and the processing status tracked.
Concrete Design & Testing System
With our history in the cement laboratory, Concrete Design & Testing is a logical step. CDTS is more than concrete test results. It tracks concrete results through projects and aids mix design by tracking aggregates and cementitious materials.
CDTS maintains details about all the components in a mix. Aggregate and admixture detail can be reused in new mix designs. Concrete Tests are tracked for projects – allowing for grouping data for research or large projects.
Mix designs can have an unlimited number of components – each with tracked material data.
Because CDTS uses the LDMS core, the data reporting, trending and SQC capability is out-of-the-box and familiar.
Stockpile Management / Historian
Stock piles provide an early line of quality management in the cement process. They can be a buffer to material delivery, provide a blending tool to improve homogeneity, and a mixing point for target chemistry.
Pile Management helps work with stock piles through three main functions: Data Collection, Modelling and Simulation. Data can be collected directly from online sources such as PGNAA devices or other on-line analysers, or through existing control system interfaces. Data is stored in an LDMS data structure.
The Pile Modeler compiles the online analyser data and combines it with process data to provide a detailed set of statistics and build a graphical model of the pile. This is used to provide chemistry details and blending ratio statistics as the pile is stacked and reclaimed. Chemistry from the pile can be used to optimise reclaiming.
A simulation tool is incorporated into Stockpile Management. Previous data or simulations can be used to perform what-if scenarios. The configuration allows modifying the pile dimensions, stacker reclaimer methods (i.e. bridge type, bucket-chain, side scraper), number of windrows etc.