Developed for demanding applications: Sample preparation for the cement industry
Precision from the market leader: our range for the cement industry
As a long-standing partner to cement-producing companies, we understand the challenges you face every day. We support you with complete automation and stand-alone machines that precisely match your requirements. We provide solutions for representative sampling and reproducible sample preparation in all process steps of cement production. Good to know: HERZOG is one of the world's leading suppliers of laboratory systems for quality assurance - also in your industry.
Full control over all laboratory and plant data: Our intelligent software systems for data evaluation and control of cement production provide perfect conditions for excellent analysis results. HERZOG automation systems are also a key element in the implementation of sustainable energy concepts, the integration of innovative production processes and the diversification of cement types.
Cost-effective and robust: Our systems are based on a modular and robust design concept and are therefore as easy to scale and durable. And what about us? We are always on the move for you - and are proactively working on technologies today that will help you to succeed in the markets of tomorrow. We will be happy to advise you.
HERZOG Cement: our offer - your advantages:
Products and services perfectly tailored to the requirements of the cement industry
Optimal sample preparation for highly precise and accurate XRF and XRD analyses
Representative sampling for all products in the cement plant
Extensive portfolio and flexible design for clinker sampling
designed for long service life of all components in the plant and laboratory
Sustainable investment security thanks to robust equipment and reliable after-sales service
Cost-efficient, modular implementation concepts for optimal use of your budget
Flexible laboratory design with robot or conveyor automation
powerful software:
Evaluation and monitoring of all relevant process and analysis data in the laboratory and factory using PrepMaster Analytics
Intelligent control of raw meal production and cement blending
Convenient and simple operation of the systems using PrepMaster Core and PrepMaster Entry
Optimal for your application: Customized configuration
As a partner to the cement industry, we offer you all the services you need for your successful automation project from a single source: consulting, engineering, implementation, installation, commissioning, training, and maintenance.
Our solutions ensure perfect sample preparation - with short throughput times, high process reliability and an intelligent overview of all relevant process and analysis data. This gives you a solid basis for maximum analytical accuracy and precision.
When designing your machines, we always consider the demanding conditions in a cement plant. We use highly robust, fail-safe system components so that you benefit from a long lifetime of your HERZOG system.
Your further advantages:
amplers and plant stations adapted to high dust loads, abrasive material properties and extreme temperatures
Low maintenance effort
High process reliability
Sustainable investment security
The production of constant material qualities with minimized energy consumption is one of the central challenges in the cement industry. We are aware of this: The exact and precise analysis of process samples is becoming increasingly important for you, especially because the use of alternative fuels and fluctuating raw meal compositions make the situation even more challenging. The cement blending process is also becoming increasingly demanding and requires precise quality control for accurate feeding of the raw materials.
We have adapted to these requirements and offer you solutions that already anticipate the increasing demands of tomorrow. Our systems for the cement industry provide the optimum basis for accurate and reliable laboratory analyses - and therefore for the cost-effective and resource-saving production of constant material qualities.
HERZOG cement laboratories ensure that your samples are optimally prepared for the special requirements of X-ray fluorescence spectroscopy (XRF), and diffractometry (XRD) analysis.
Your further advantages with HERZOG automation:
High degree of standardization
Elimination of bias due to varying or incorrect manual sample processing
Improved sample throughput
Higher analysis frequency
Early detection of unfavorable trends
Optimized process workflows
We offer our fully integrated laboratory systems alternatively as robot automations and in linear configuration with conveyor belt connection. Both types of HERZOG cement laboratories reliably cover all sample preparation and analysis steps. We provide you with competent support in choosing your laboratory design and all detailed specifications. Key factors for finding the most appropriate layout include the intended sample throughput, the available space and any expansion requirements.
HERZOG robot cement laboratory
Your advantages:
High flexibility in sample routing
Simple system expansion
Linear HERZOG cement laboratory
- Receipt of pneumatic carrier by laboratory station HR-LA
- Optional: magazine function for the creation of various composite samples
- Dosing into sample cups for particle size analysis as well as pulverizing and pelletizing
- Transport via conveyor belts to machines and analyzers
Your advantages:
low space requirement
outstanding cost efficiency
Easy maintenance
We support your value creation with maximum
Your advantages:
Option to integrate third-party components into HERZOG systems (e.g. sample preparation machines in the laboratory, samplers and operating stations in the factory)
Simple integration of HERZOG machines and components into existing systems from other suppliers
Step-by-step replacement of system components
Manageable, phased investments
Shift of part of investments from CapEx to OpEx
Expert advice on all technical and organizational issues
The situation:
As a cement manufacturer, you are facing increasing demands in terms of sustainability, which must be balanced with economic criteria. Accurate process control alone is not enough to meet international climate targets. The CO2 certificate trade introduced in 2005 requires the optimization of cement production by means of improved data reliability in terms of CO2 emissions.
The background:
studies have shown that a five percent deviation in the most important process monitoring parameter LSF leads to an increase in CO2 emissions of up to 16.4 kg CO2 /t clinker. Similarly, CO2 emissions from carbon-based fuels increase by 17.2 kg CO2 /t clinker with a similar five percent variation in LSF.
The solution:
HERZOG systems for sampling, laboratory automation and data analysis ensure the future-proof monitoring and control of your analysis and production processes. We accompany you professionally and as partners on your way to greater sustainability.
Our software provides you with significant advantages: The HERZOG PrepMaster Suite is a fully integrated SCADA system that can be used for the automation, control, recording and evaluation of all processes and data in your laboratory. The PrepMaster Suite is fully scalable, modular, and flexibly upgradable.
Our smart industry module PrepMaster Analytics manages the recording, documentation, evaluation and monitoring of all relevant data in your laboratory.
PrepMaster Analytics at a glance:
- Module of the HERZOG PrepMaster Suite
- Comprehensive overview of all important KPIs
- Improved process efficiency
- Optimized reproducibility of sample preparation and analysis
- Processing of all analytical data
- Processing of all analytical data
- Organization of service tasks
In addition to the default features, PrepMaster Analytics offers you numerous functions that are specifically tailored to the requirements of your industry:
PrepMaster Analytics - Functions for your cement laboratory:
- Value sets function
- Configuration and clear presentation of relevant analyzers (e.g. XRF, XRD, grain size analysis, colorimetry)
- Automatic updating of the data record
- Authorization of users
- Possibility to enter and change data manually
- Worksheet configuration function
- Simple definition and modification of processes
- Comfortable configuration menu
- Selection of sample preparation steps and parameters as well as analytical instruments and programs without programming knowledge
- Automatic logging of all changes
- Comprehensive review Options
- Condition Monitoring tool
- Module for monitoring vibratory disk mills
- Automatic control of all grinding operations
- Fast detection of irregularities
- Long-term monitoring of the condition of the grinding set (grinding vessel, ring, and stone) using SPC methods
- Module for determining the grindability
- Automatic determination of the grinding energy
- Basis for automatic calculation of material-specific grindability in combination with PSD analysis
- Online availability of results - for immediate integration in production planning (ideal for granulated blast furnace slag and clinker)
The HERZOG Raw Mix Control module is part of PrepMaster Analytics and was specially developed for controlling raw meal compositions in cement production.
Your advantages:
Automatic processing of laboratory and analysis data
Automatic calculation of belt feeder values using an optimization algorithm based on production specifications
Consideration of chemical composition, costs, and CO2-emissions
Implemented model predictive control (MPC) for fast and efficient adjustment to target values
Avoidance of excessive reactions through MPC algorithm
Continuous comparison with raw meal values measured in the laboratory
Compensation for possible deviations from nominal chemical composition
Clear presentation of all relevant data on PrepMaster Analytics Dashboard
Parameterization of numerous parameters in a clearly structured configuration menu
Detailed advice from the HERZOG team of experts
Individual system customization for perfect integration into production processes
Cement industry: our solutions
All HERZOG Cement components have been specially designed to meet the challenges of your industry and are perfectly tailored to each other. We offer integrated solutions that are precisely customized to your requirements.
Your sampling equipment should perfectly match your sample material and the installation situation at the sampling point. That's why you can choose from a wide range of different samplers with numerous configuration options. Our specialists will work closely with you to decide on your ideal sampler. By the way: HERZOG can also implement systems for sampling under ATEX conditions on request.
Sampling of powder material
HR-KN clinker sampler
- three model types
- optimum adaptability for different representativeness requirements, space conditions and grain size distributions
- Flexibly configurable clinker plant station
- manageable investment
- Low logistical effort
Hot meal sampler HR-KNH
- developed for the safe and reproducible sampling of hot meal
- Hydraulic drive with high power intensity and dynamics
- Pushing through solidification and adhesions on the shaft wall
- Maximum temperature of the sample material of 900 °C with rapid subsequent cooling to below 40 °C
- Easy commissioning and maintenance thanks to movable design
- Uncomplicated positioning at the sampling point
When designing the HERZOG samplers, plant and laboratory stations as well as all pneumatic tube and control elements, we focused on the specific requirements of the cement industry. All elements have also been optimally tailored to each other.
Your advantages:
- Efficient pre-preparation of the sample during operation (crushing, splitting)
- Delay-free transportation to the laboratory
- Contamination-free sample handling
Excerpts from our range:
HR-B and HR-BM plant stations
Transport of powder or crushed clinker samples from the plant to the laboratory
Can be combined with different samplers
Dosing of required sample volume into pneumatic carrier
Optional: vacuum transport system for material transport
Option to remove sample via door instead of sending it to the laboratory
HR-BM: 15-litre mixer for collecting spot samples
HR-LKC clinker plant station
Numerous variants available - for an optimum fit with every cement plant
Adaptation of all process steps such as crushing, cooling, splitting, and dosing to the properties of the clinker
Solutions available for confined spaces: e.g. by placing the crusher and splitter in a separate frame and sending samples using another separate unit
Automatic laboratory station HR-LSP
Pneumatic tube station for robot automation
Receiving the pneumatic carrier
Dosing of the sample material in the laboratory
Minimization of residual material formation and cross-contamination
Sample emptying within pneumatic tube stations - for fast machine reuse, short handling times and an increased sample throughput
Automatic laboratory station HR-LA
Pneumatic tube station for linear automations
Receiving the pneumatic carrier
Dosing of sample material
Minimization of residual material formation and cross-contamination
Sample emptying within pneumatic tube stations - for fast machine re-use, short handling times and increased sample throughput
Our compact HP-MP mill and press is the standard machine for automatic grinding and pelletizing of cement and its preliminary products.
Your advantages:
- Optimally adapted for use in cement laboratories
- as a stand-alone machine, in robot automation or linear systems with belt connection
- Numerous functions and options
- Simple operation
- Compact dimensions
- Production of pressed pellets for XRF and XRD analysis
- fine grinding, e.g. with maximum counting rate of SiO2 and CaO without reducing the crystallite size of the clinker phases - ideal for the analysis of clinker
- Excellent repeatability of sample preparation
- Tool condition monitoring of grinding vessel and important wear parts - for automatic detection of anomalies
- Constant long-term reproducibility
Borate fusion is a standard method for sample preparation of oxide samples from cement production and is used in numerous industrial and research laboratories. Sample preparation by means of fusion eliminates confounding factors such as particle size effects and matrix interferences. In addition, the glass beads produced by fusion are characterized by high homogeneity and structural consistency.
Our fully automatic inductive HAG-HF fusion system enables the preparation of up to several hundred samples per day.
Your advantages:
Fully automated sample preparation for X-ray fluorescence analysis
valuable instrument for controlling complex cement production processes
Automatic execution of the fusion steps: Dosing of sample and flux, mixing of sample, melting, pouring into dish and cleaning of platinum ware
Proven standard solution for automatic fusion in numerous cement laboratories worldwide
Compliance with all requirements of ISO 29581-2 for precision and ASTM C114 for precision and accuracy of sample preparation and analysis
The compact HERZOG AtLineLab allows you to carry out automatic sampling, sample preparation and analysis in the midst of your cement plant.
Services and benefits at a glance:
Sampling of raw meal, clinker and cement samples in a mixer
Generation of a homogeneous and representative average sample
Volumetric dosing in cups
Sample preparation in the automatic compact mill and press HP-MP
Analysis via integrated analysis instrument (XRF, XRD)
Immediate vicinity to the sampling point
Rapid analysis of critical products such as raw meal
Useful addition or alternative to a central laboratory
Combination of all components in a robust, compact housing - optimum protection against dusty environments
Spacious access options for full serviceability
Our products for the cement industry
We have one suggestions for you:
We have 42 suggestions for you:
AtLine Lab:
Standard automation for the cement industry
- Material: Powder samples
- Fully automatic sampling, preparation and analysis
Bead One HF:
Semi-automatic fusion machine
- Glass beads: 29 / 32 / 34 / 36 / 39 mm diameter
- Heating temperature: max. 1300° C, high-frequency induction heating
- Manual dosing, automatic fusion
Bead One R:
Semi-automatic fusion device
- Glass beads: 39 mm diameter
- Heating temperature: max. 1300° C, resistance heating - tube furnace
Manual dosing, automatic fusion
HA-HF 16:
Semi-automatic fusion-system
- Glass beads: 29/32/34/36/39 mm diameter
- Heating temperature: max. 1300° C, high-frequency induction heating
- Semi-automatic sample preparation
HAG-HF:
Fully automatic fusion system
- Glas beads: 29 / 32 / 34 mm diameter
- Heating temperature: max. 1300°C, high-frequency induction heating
Fully automatic sample preparation
HAG-system:
Fully automatic fusion system
- Glas beads: 29 / 32 / 34 / 36 / 39 mm diameter
- Heating temperature: max. 1300° C, high-frequency induction heating
- Fully automatic sample preparation
HP-CA:
Automatic jaw crusher
- Feed grain size: < 15 mm
- Final fineness: < 4 mm
Fully automatic sample preparation
HP-CM AUT:
Automatic mortar crusher
- Material feed size: < 200 mm
- Finale fineness: < 2 mm
- Gap width setting: 0-20 mm
- Fully automatic sample preparation
HP-DT 2:
Dosing device for flux
- Material: Flux
- Manual tray loading, automatic gravimetric dosing
HP-M 100P:
Semi-automatic vibratory disc mill
- Feed grain size: < 10 mm
- Feed volume: 100 ccm
- Semi-automatic sample preparation
HP-MA:
Automatic vibratory disc mill
- Feed grain size: < 5 mm
- Feed volume: 100 ccm
- Fully automatic sample preparation
HP-MP:
Combined mill and pellet press
- Feed grain size: < 5 mm
- Feed volume: 100 ccm
- Fully automatic sample preparation
HP-MS:
Automatic vibratory disc mill
- Feed grain size: < 5 mm
- Feed volume: 100 ccm
- Fully automatic sample preparation
HP-PA:
Automatic pellet press
- Pressed pellets: Steel rings (40 mm, 51.5 mm)
- Max. pressure force: 400 kN
- Fully automatic sample preparation
HP-PS:
Automatic pellet press
- Pressed pellets: Steel rings (40 mm, 51.5 mm)
- Max. pressure force: 400 kN
- Fully automatic sample preparation
HR-B/HR-BM:
Automatic plant station
- Feed grain size: < 5 mm
- Maximal collection volume : 15 l (only for HR-BM)
- Automatic sample collection of powder material and pneumatic transport to laboratory
HR-HSK/B:
Pneumatic tube plant station
- Material: Metal samples (round, oval, double-thickness, cylindrical, conical, etc.), powder samples, others
Manual sending and receipt of carriers within the plant
HR-HS/L / HR-HSK/L:
Pneumatic tube laboratory station
- Material: Metal samples (round, oval, double-thickness, cylindrical, conical and others), powder samples, others
- Manual sending and receipt of carriers within the laboratory
HR-KN:
Clinker sampler
- Material: Coarse-grain samples
- Feed grain size: < 80 mm (depending on HR-KN type)
- Capacity: 1- 10 l (depending on HR-KN type)
- Automatic or manual sampling
HR-KNH:
Hot meal sampler
- Material: Powder samples (< 900° C)
- Feed grain size: < 200 µm
- Capacity: 50 ccm
- Automatic or manual sampling
HR-LA:
Automatic laboratory station
- Material: Powder samples
- Feed grain size: < 5 mm
- Feed volume: < 320 ccm
- Fully automatic receipt of pneumatic carriers, emptying, dosing and providing of samples
HR-LKC:
Automatic plant station for clinker
- Feed grain size: < 90 mm (depending on HR-LKC type)
- Automatic collection, cooling, crushing, splitting and dosing of clinker samples, pneumatic transport to laboratory
HR-LSP:
Automatic laboratory station
- Material: Powder samples
- Material feed size: < 5 mm
- Feed volume: < 320 ccm
- Fully automatic receipt of pneumatic carriers, unloading, dosing and providing of samples
HR-PN:
Piston sampler
- Material: Powder samples
- Feed grain size: < 200 µm
- Capacity: 150 ccm or 50 ccm per hub (customizable)
- Automatic or manual sampling
HR-RN:
Air slide sampler
- Material: Powder samples
- Feed grain size: < 200 µm
- Capacity: 40 ccm / 5 sec.
- Automatic or manual sampling
HR-SN:
Screw sampler
- Material: Powder material
- Material feed size: < 200 µm
- Capacity: 2,3 l/min
Automatic or manual sampling
HR-W2/HR-W3:
Diverter for pneumatic transport systems
- Material: Metal samples (round, oval, double-thickness, cylindrical, conical, etc.), powder samples, others
- Automatic direction of pneumatic carriers
HSC 550:
Jaw crusher
- Feed grain size: < 50 mm
- Final fineness: < 4 mm
- Manual and automatic sample preparation
HSC 590:
Jaw crusher
- Feed grain size: < 90 mm
- Final fineness: < 4 mm
- Manual and automatic sample preparation
HSC 650D:
Jaw crusher (double-acting)
- Feed grain size: < 50 mm
- Final fineness: < 10 mm
- Manual and automatic sample preparation
HSM:
Manual vibratory disc mill
- Feed grain size: < 5 mm
- Feed volume: 100 ccm, 250 ccm, 10 ccm, 50 ccm
- Manual sample preparation
HSM 50:
Manual vibratory disc mill
- Feed grain size: < 5 mm
- Feed volume: 50 ccm, 10 ccm
- Manual sample preparation
HTP:
Semi-automatic pellet press
- Pressed pellets: Steel rings (40 mm, 51.5 mm), aluminium cups, free pressing
- Max pressure force: 400 kN / 600 kN
- Semi-automatic sample preparation
PrepMaster Analytics:
Analysis software
Software for automatic data acquisition, processing and monitoring of analyses, determination of key performance indicators, tool condition monitoring and reference sample management.
PrepMaster Core:
SCADA software
SCADA software for monitoring and controlling automation systems of any size
PrepMaster Entry:
SCADA software
SCADA software for monitoring and controlling compact automation and systems
PrepMaster IDE:
Integrated Development Environment
Integrated development environment for configuring and programming automations controlled by PrepMaster Core or Entry
PrepMaster Remote
PrepMaster Remote expands PrepMaster from a single-user system to a true multi-user system
TP 20 E:
Semi-automatic pellet press
- Pressed pellets: Steel rings (40 mm, 51.5 mm), aluminium cups, free pressing
- Max pressure force: 200 kN
- Semi-automatic sample preparation
TP und TP/2D:
Manual pellet press
- Pressed pellets: Steel rings (40 mm, 51.5 mm), aluminum cups, free pressing
- Max pressure force: 200 kN / 400 kN
- Manual sample preparation
