Economy & Market

Advances in Cement Analysis

Published

10 years ago

July 4, 2016

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Though Blaine analysis is a time tested method of measuring fineness of cement. Today Laser Diffraction technology scores over it mainly due to more accurate and real time measurement. Dr. Michael Caves, India ? Business Development Manager of Malvern AIMIL explains the advantages of laser based particle size analysers.

The final steps in cement manufacturing involve grinding (milling) and blending in order to produce the fine powder that is recognizable as cement. Every step in the manufacture of cement is checked by frequent physical tests, as is finished product, to ensure that it complies with all necessary specifications. Cement is ground to a particular fineness since the influence of particle size on the kinetics of cement hydration and development of strength is well known. A reduction in median particle size generally produces a higher compressive strength. Consequently the fineness of Portland cements has been increased over the years to improve properties such as higher early strengths. Nevertheless, other effects of increased fineness, such as higher water demands and more rapid heat generation in the concrete cannot be ignored. Despite the availability of instrumental methods of measuring particle size distributions, the classical method of air permeametry remains.

Understanding Blaine
Many plants control cement fineness using an air permeability apparatus to measure the Blaine number, a parameter related to the cement particle size. The Blaine surface area measurement has been used since the 1940s to determine cement quality and despite its longevity the limitations of this off-line technique are widely recognized. It is slow and suffers from poor reproducibility, which can lead to significant errors, including unnecessary or inaccurate changes to the classifier speed. Blaine analysis measures the specific surface area of a sample, the surface area per unit mass. Finer particle sizes have higher specific surface area: more area per unit mass, so Blaine is an indirect measure of particle size.

But, Blaine delivers just a single averaged figure. Figure 1 shows analysis of 2 cement samples using a Malvern Mastersizer Laser Diffraction system. Sample 2 contains more fines than sample 1 but also more coarse material. These two differences cancel each other out so average specific surface area remains the same, illustrating why two quite different samples can have the same Blaine. The more important question is ?do we need to know about the difference indicated by the particle size distribution??

Size Distribution Measurements
However two cement samples with identical Blaine figures can show different particle size distributions when measured by laser diffraction. Should we classify these two cements as different or the same?

For answers, we need to look at how the data are used. Cement manufacturers measure Blaine to quantify product quality. The hydration speed of cement particles is a function of particle size and determines the strength of the set cement. Generally, finer particles hydrate more quickly, giving greater strength, and within certain limits finer cement is better cement.

Returning to our samples, these materials will behave differently when used. Very fine cement particles, in the 2 – 3 micron range can cause exothermic cracking. Conversely particles over 50 microns may not hydrate, compromising product strength. Sample 1 contains less of both types of particles and consequently is a superior cement, even though Blaine ranks it the same as sample 2. So, the size distribution data are most certainly relevant.

Switching to laser diffraction
The practicalities of switching to laser diffraction are equally compelling. Laser diffraction, however, is fast and automated. In the lab this means greater productivity and better reproducibility. For processing it means on-line instrumentation and real-time measurement.

Malvern Mastersizer 3000 (Figure 2), which has a measurement range of 0.01 to 3500 microns, is an essential component of a high-quality cement laboratory. Finished products, as well as replacement material such as fly ash and blast furnace slag and fuels, have varying size distributions and so behavioral understanding and prediction requires Mastersizer analysis.

A vital element in successful laser diffraction particle size analysis is ensuring that samples are dispersed properly. In cement manufacture it is the primary particle size of a sample that is most usually the parameter of interest, rather than the size of any agglomerated material present. When using laser diffraction, samples can be dispersed and measured wet in the form of a suspension, or as dry powders. Dry dispersion, using dry compressed air, has a number of advantages, not least its obvious suitability for water sensitive material such as cement. It also avoids the need for solvent based dispersants and is rapid, thus increasing instrument productivity. The dry dispersion accessory, Aero S, available with Mastersizer 3000 has modular dispersion nozzles with different impaction surfaces. Keeping in mind that flow of abrasive material like cement for a prolonged period of time can cause damage to metal surfaces, there are options available for ceramic coated flow paths. It is worth highlighting the value of considering an analyzer that can switch easily between different samples with a minimum of fuss. Being able to change between different types of samples without fear of cross contamination, or to move simply or quickly from dry to wet measurement (or vice versa) as required, can make a real difference to analytical productivity, helping to maximize the return of investment in the system.

Finally, another important reason to switch to laser diffraction is the possibilities the technique offers for on-line analysis. Insitec systems deliver fully automated real-time analysis of cement particle size distribution from 0.1 to 2500 microns and can be configured to suit practically every process.

Conclusion
Whilst traditional Blaine measurements have served the cement industry well since the development of the Blaine method in the 1940s, the efficiency and quality of production of modern cements can be improved greatly by using Laser Diffraction technology. Efficient data acquisition, adaptable methods, and information-rich data explain the increasing use of the Malvern Mastersizer 3000 and Insitec range of systems in cement production around the world.

For more details, pls contact: Malvern Aimil Instruments Pvt. Ltd. Tel : 011-30810244 Fax : 011-26950011, Email : delhi@aimil.com

Economy & Market

Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

Published

7 days ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

1 week ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

3 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com