Representative project case · Cement and mineral processing
Continuous raw-mix moisture visibility before the next process step
A scheduled sample confirms a point in time, but a moving raw-material stream can change between samples. The MW-3000 transmitter and receiver cross the conveyor bed so the plant can follow the material path continuously and decide when a process check is needed.
- System
- MW-3000 transmission microwave
- Material
- Cement and mineral raw mix
- Measurement point
- Across a moving conveyor bed
- Operating decision
- Trend, alarm and supervised adjustment
- Plant
- Regional cement and mineral-blending plant
- Line
- 55–70 t/h raw-mix conveyor
- Previous check
- One laboratory composite every 2 hours
- Review period
- 21 days · 84 valid paired references
The production problem
Raw-mix moisture affects downstream dosing, drying and material balance, yet laboratory results arrive after material has already moved on.
The useful question was not whether laboratory testing should stop. It was how to see the changing stream between reference samples and direct attention to the periods that needed checking.
Decision delay
The previous two-hour composite schedule produced a median 70-minute response after a sustained moisture shift.
Unseen transitions
Product changes and short wet periods could pass the measuring point before the next laboratory result reached the line team.
Adjustment risk
Water addition relied on the latest reference result and operator judgement without a continuous validity status for the moving bed.
How the measurement was placed
Measure through a defined material path
The MW-3000 pair is mounted on one transmitter-receiver axis across the conveyor. Bed depth, density, product identity, alignment, temperature and empty-belt state remain attached to the application record.
- 01
Non-contact transmitter and receiver on opposite sides of the bed
- 02
Height and geometry handled as part of the installation
- 03
4-20 mA and Modbus RTU available for PLC or SCADA mapping
- 04
Time-matched reference samples retained for calibration and acceptance
2.4 GHz non-contact transmission path with the transmitter and receiver across the moving bed.
Ultrasonic height input compensates instantaneous bed-depth change.
Two 4-20 mA outputs and Modbus RTU are standard; further industrial protocols are optional.
Project execution
How the 21-day conveyor trial moved into routine operation
The trial kept installation checks, 84 paired references and the operator response in one commissioning record. The online trend was not released for action until the invalid belt states and comparison method were agreed.
- 01
Survey the measurement path
Confirm transmitter-receiver alignment, bed-depth range, access, guarding, cable routes and the reference-sampling position.
- 02
Connect operating states
Bring belt running, empty-belt, material identity and communications status into the same timestamped record as the moisture value.
- 03
Pair and fix the model
Collect sealed composites across normal material groups, separate model-building and validation periods, then freeze the accepted configuration.
- 04
Approve the response
Use the 30-second valid trend for a sustained-deviation alarm, operator review and supervised water adjustment while retaining laboratory release checks.
From signal to action
A control loop that keeps the laboratory reference
- 01
Observe
The online signal shows the direction and persistence of moisture change.
- 02
Confirm
Operators check material identity, belt state and measurement validity.
- 03
Act
The approved trend triggers a targeted sample, alarm or supervised adjustment.
- 04
Verify
Reference results are paired to the same time window and maintain the calibration.
Operational value
The line moved from delayed confirmation to exception-led control
A 30-second validated trend was used for alarms and supervised adjustment. The laboratory method remained the reference for release and calibration maintenance.
Deviation response
Time from a sustained shift to operator review
Time outside the moisture band
Share of monitored production time
Routine laboratory checks
Reference work redirected to alarms, changeovers and scheduled verification
Less process blind time
Sustained changes become visible between scheduled samples.
More focused sampling
Reference work can focus on changes, product transitions and validation checks.
Control-ready data
A validated value and status can be mapped into the plant control layer.
These results apply to the stated material, installation and validation period. A new site establishes its own target band and response rule with paired reference data.
Project checks
Validation basis
- Online window
- 30-second filtered trend; empty-belt and wrong-product states excluded.
- Reference set
- 84 valid time-matched composites selected from scheduled and exception samples and tested with the plant oven method.
- Decision rule
- Alarm and supervised water adjustment; laboratory result retained for product release.
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