Quarry Management in Europe • Presentation of the quarry ... · Quarry Management in Europe On-line Colour Measurement and Minerals Sorting by Image Analysis • Presentation of

Quarry Management in Europe

On-line Colour Measurement and Minerals Sorting by Image Analysis

• Presentation of the quarry and customer’s needs

• Project layout

• First step: Sorting

• Second step: Blending

• Colobserver Description

• Conclusion

• To select different qualities and store them into silos to ensure a reliable blending.

• To increase quarry life expectancy by optimizing its operation.

• To blend different qualities and reach a constant one with the required specifications given by the plant.

Application Aims


Some specifications

• Aspect of the material (hard limestone) may change according to its moisture.

• Particle size of the material is about 0-10mm for one line and 0-80mm for the other one.

• Four silos of 1 500 T, cut directly in the ground,

have to be filled with the corresponding material (four qualities).

• Each silo is equipped with variable extractors at its

bottom.

• Speed of the conveyors is about 1,5 m/s.

Project layout


Crusher

Medium Q Low Q Very Low Q High Q

Jaw Crusher

Off spec silo Colour

measurement (Colobserver)

+ Moisture analyser

Correct Q

Bad Q

0-80 mm

>80 mm

10-80 mm 0-10 mm

Moisture Analyser

Colour Analyser

Colour measurement (Colobserver)

+ Moisture analyser

0-80 mm

Despite the very dusty environment, the system operates properly and is very accurate.

According to the b* value the 0-10mm is recycled and added to the 10-80mm or it is rejected and stored in a low quality silo.

Sorting application 0-10 mm


Sorting application


This first generation of on line analyser has been installed in the quarry in 2004.

Colobserver CL100 #1

Located before the Silos inlet

Sorting application


Crusher


Jaw Crusher



+ Moisture analyser

Correct Q

Bad Q

0-10 mm

0-80 mm

>80 mm

10-80 mm 0-10 mm

Moisture Analyser

Colour Analyser


+ Moisture analyser

Hard Limestone

Particle Size 0 – 80mm


• Material is carried by a belt conveyor 600 mm wide

• Speed is about 1,5m/s

• Aspect of the product may change according to its moisture

Sorting application

Colobserver CL 100

• Colobserver encapsulates the conveyor

• Aspect of the

product may change according to its moisture

• A NIR Sensor communicates with Colobserver to help correcting color variations due to moisture


Sorting application

Colobserver CL 100

• Colobserver software analyses colour in real time

• Product quality is defined regarding thresholds on L*a*b*

• If the new detected quality remains stable more than 1 minute, the Colobserver sends to the plant PLC a request to change silo


Sorting application

New generation: Colobserver CL150 In 2011 the CL 100 was moved to another location to control yellowness of fine product after sieving (0-10 mm), select the white part and recycle it in the process.

A CL150 was put in place to allow use of its new capabilities

Indeed, the CL150 has greater abilities of image analysis and help to detect “blue” stones.

Sorting application


Colobserver CL100 #2

Software of the Colobserver blends itself the different silos according to a colour setpoint

Blending application




Crusher


Jaw Crusher



+ Moisture analyser

Correct Q

Bad Q

0-10 mm

0-80 mm

>80 mm

10-80 mm 0-10 mm

Moisture Analyser

Colour Analyser


+ Moisture analyser

Material comes from the silos and is mixed before the colour sensor by a small fall between two belt conveyors



This Colobserver is located after the silos just before feeding the trucks which carry the material to the plant.



As for sorting application, a NIR moisture sensor is used to help the Colobserver to calculate a true colour.

Silos extraction management One of both

algorithm used to

blend the material

of the silos.

All the

parameters of the

process (flow

rate, level in the

silos, colour) are

taken into

account by the

software to

calculate blending

adjustments



Conveyor

feeding

management

Two kind of qualities

on the system main

screen, used to load

different trucks

Truck #1 Truck #2 Truck #3



Truck #4 Truck #5 Truck #6

L* Labo=f(L* Colobserver)

y = 0,9469x + 21,72R2 = 0,9665

76

78

80

82

84

86

88

90

92

94

50,00 55,00 60,00 65,00 70,00 75,00 80,00

COLOBSERVER

Lab

Correlation


b* Labo =f(b* Colobserver)

y = 2,211x + 0,645R2 = 0,9794

0

1

2

3

4

5

6

7

8

9

10

0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00

COLOBSERVER

Lab

a* Lab voie sèche =f(a* Colobserver)

y = 0,4011x - 0,5492R2 = 0,9451

-0,4

-0,2

0

0,2

0,4

0,6

0,8

0,00 0,50 1,00 1,50 2,00 2,50 3,00

COLOBSERVER

Labo

Good correlation between

our system and the

laboratory of the quarry.

An equation is used to

correct moisture effects

on the colour.

• Useful information about the instruments

General knowledge

On line Colour measurement

F.O Converter

• Last generation of video camera using Giga Ethernet. • Xenon Lights or LED lights are used depending on the

application

Computer

CC

D D

igita

l v

ideo

cam

era

Giga Ethernet Communication

F.O Converter

optical fibres

General knowledge


R, G, B

X, Y , Z

L*, a*, b*

General knowledge


Image Analysis

Real image is located at the bottom in the middle.

5 other images are made in false colours for each L*a*b* system values.

For instance the image at the right top, created with b*, is an image made by blue and yellow shades (b* axis).

REAL IMAGE

Image Analysis

With thresholds in recomposed images, the system can isolate conveyor, shadows and out of spec product. Thanks to an automatic compensation system, adjustment of thresholds is very stable on time.

Installation

On line colour measurement

•Few cables

required

•Installation of

optical fibres

between

measurement

head and control

room

•Integrated

modem and

Internet ability for

the remote

maintenance

Conclusion


Crusher

Medium Q

Low Q Very Low Q

High Q

Jaw Crusher

Off spec silo


+ Moisture analyser

Correct Q

Bad Q

0-10 mm

0-80 mm

>80 mm

0-80 mm

0-10 mm

Moisture Analyser

Colour Analyser

• Lifetime of the quarry is optimized

• A big part of the 0-10 mm is recycled

• Plant is fed with a stable

and requested quality.

Colobserver® CL 150 Colobserver® CL 100

Part Sizer® Spectrobserver®

On-line colour measurement on stones and powder

On-line Colour Measurement for fine product

On-line Particle Size measurement

Colocompact

Lab colour measurement and image analysis

Colobserver® Slurry

Colour department


On-line colour measurement on slurry

Omya

Imerys Talc de Luzenac

La Provençale

Languedoc Granulats

Socli (Italcementi group)

Cristal Union Sugar group

Nordzucker Sugar group

SVI Sugar Group

Bogazliyan sugar factory (Turkey)

Busco sugar factory (Philippines)

Alta Mogiana sugar factory and Guarani sugar factory

(Brazil)

Cosumar sugar factory (Morocco)

Brindisi sugar factory (Italy )

Pantaleon sugar factory (Guatemala)

Dobrinsky sugar factory (Russia)

Nordzucker Uelzen sugar factory ( Germany)

Souppes-sur-loing sugar factory ( France)

Ouled Moussa sugar factory ( Algeria )

Suiker Unie sugar factory ( Netherlands)

Magdalena sugar factory ( Guatemala )

References

Partner for food industry Con-Tec Partner for mineral industry

Aix en Provence

Paris

www.iteca.fr

Thank you

for you

attention

Partner for food industry

Visit us at booth K12 Hall5

Con-Tec Visit us at booth

J04 Hall5

Partner for mineral industry

Documents

Quarry Management in Europe • Presentation of the quarry ... · Quarry Management in Europe On-line Colour Measurement and Minerals Sorting by Image Analysis • Presentation of