Moisture measurement is extremely important during mineral processing from mining to the final product. Mining companies are constantly adjusting moisture to maintain the quality of their product. Testing moisture content throughout the process also provides mineral manufacturers cost savings in energy and fuel costs, as well as having less product waste.
Uncontrolled moisture content can silently erode profitability. Inconsistent moisture levels lead to excessive energy usage during drying, off-spec produkan cts that require rework, and supply chain delays caused by spoilage or product rejection. Ideally, a moisture control system should be able to accurately detect moisture in raw materials, preferably at different stages of the manufacturing process, be easy to maintain, and tough enough to withstand the harsh, abrasive nature of the raw materials and the mixer environment.
Controlling the Ash Residue
In some manufacturing facilities, controlling the ash residue is a critical concern of plant operators. After combustion, the ash residue that is left is sprayed with water to reduce dust and odors which is then transported to landfills/moonfuls. However, too much or too little moisture can create several problems for some manufacturing plants.
Managing the ash residue in a waste-to-recycling application is an important step for many reasons at incineration facilities around the world: from minimizing the possibility of ash dust inhalation and ingestion of employees, to preventing ash being absorbed into the environment, as well as lowering transportation costs due to weight. With NIR moisture sensors, operators will be able to instantly and continuously measure ash moisture and control these problems.
Preventing airborne dust and controlling weight of the ash, it is recommended that a sensor is installed after combustion and moisture spray. From past installations and depending on the matrix of the ash, the optimum moisture range is 15 to 18 percent with a target of 15 percent for control of dust and weight of the ash. The moisture content lowest point is 12 to 14 percent before the ash becomes airborne, and above 25 percent moisture the ash turns into mud that contains surface moisture (liquid) making it heavy and expensive to haul away.
Advances in real-time sensing, data collection, and data analysis and interpretation helps to determine the characteristics of the materials prior to processing providing process efficiency and optimization. Regular measurements of moisture in most manufacturing lines remains a necessity for control of drying, thereby reducing treatment costs.
Additionally, small variations and excess moisture in mixes in some applications can result clumping affecting quality and consistencies. A product that is too dry can result in excess dust. Measuring moisture prior to crushing can control particle size and provide dust suppression. During the drying stage, in-process measurements ensure optimization and elimination of over-drying, which can lead to product that is out of specification, degradation, and an excess of dust.
With continuous online moisture measurement, manufacturing plants will find significant money savings: from savings in transportation due to weight of excess moisture, to savings in water usage for dust suppression and clean-up. Plants also reduce the amount of wear and tear on equipment due to the dust and ash build-up and prevent blockages on the conveyor resulting in shutting down the boiler
Moisture management doesn’t have to be reactive; with MoistTech© inline moisture sensors, manufacturers gain the ability to detect changes as they happen, act immediately, and maintain control over critical variables. When moisture is managed proactively, quality becomes consistent, and that consistency builds customer trust, operational efficiency, and long-term profitability.
