SDIAS Intelligent Analysis System

The SDIAS Intelligent Analysis System is an integrated robotic solution designed for fully automated coal quality analysis. It automates the entire laboratory workflow, including sample receiving, sample homogenization and container opening, weighing, analysis, crucible and oxygen-bomb cleaning, and the recycling of laboratory vessels. Depending on the selected configuration, the system can determine calorific value, total sulfur, moisture, ash, volatile matter, carbon, hydrogen, nitrogen and other coal quality parameters.

With transparent process visualization, real-time data monitoring and complete traceability, SDIAS delivers reliable analytical results suitable for quality control and commercial settlement. It can also integrate seamlessly with automatic sampling, sample preparation and pneumatic sample transport systems, enabling unattended operation across the complete sampling, preparation, transportation, storage and analysis process.

Key Features

Fully Automated, Unattended Operation

One-button operation enables the system to automatically perform sample handling, weighing, analysis, vessel cleaning and result generation. Intelligent notifications provide test status, completion and fault alerts without requiring continuous operator supervision.

Multi-Parameter Coal Analysis

The system can be configured to measure calorific value, total sulfur, moisture, ash, volatile matter, carbon, hydrogen and nitrogen. Proven Sundy calorimeters, proximate analyzers and elemental analyzers are integrated as analytical modules.

Visible and Traceable Testing Process

The transparent enclosure and visual monitoring system allow operators to observe the complete analytical workflow. Sample weights, test conditions and analytical results are recorded throughout the process, improving result controllability, credibility and traceability.

High-Throughput Parallel Analysis

Multiple analyzers and robotic manipulators can operate simultaneously in separate functional zones. Depending on the configuration, the system can complete the full analysis of up to 80 samples within eight hours.

Modular and Redundant Architecture

The modular design allows the type and quantity of analytical instruments to be configured according to different laboratory requirements. Redundant modules help maintain system operation if an individual module is temporarily unavailable.

Seamless Laboratory Automation Integration

SDIAS can connect with automatic sampling systems, sample preparation systems and pneumatic sample transport systems, supporting fully automated operation from sample collection through final analysis.

Automatic Cleaning and Vessel Recycling

Crucibles and oxygen bombs can be automatically cleaned, conditioned and reused. Operators do not need to manually transfer samples or clean weighing and sample-handling vessels.

Safe and Maintainable Design

The system includes personnel-access protection, robot collision protection and pause-and-resume functions. Analytical instruments can also be operated manually if the robotic system is temporarily unavailable.

Applicable International Standards and Methods
StandardStandard TitleApplicable Samples
ISO 1928Coal and coke — Determination of gross calorific valueCoal and coke
ISO 18125Solid biofuels — Determination of calorific valueSolid biofuels
ISO 9831Animal feeding stuffs, animal products, and faeces or urine — Determination of gross calorific value — Bomb calorimeter methodAnimal feeding stuffs, animal products, faeces, and urine
ISO 1716Reaction to fire tests for products — Determination of the gross heat of combustion (calorific value)Solid products
ASTM D5865Standard Test Method for Gross Calorific Value of Coal and CokeCoal and coke
ASTM D240Standard Test Method for Heat of Combustion of Liquid Hydrocarbon Fuels by Bomb CalorimeterLiquid hydrocarbon fuels
ASTM D4809Standard Test Method for Heat of Combustion of Liquid Hydrocarbon Fuels by Bomb Calorimeter (Precision Method)Hydrocarbon fuels
ISO 29541Coal and coke — Determination of total carbon, hydrogen and nitrogen — Instrumental methodCoal and coke
ISO 609Coal and coke — Determination of carbon and hydrogen — High temperature combustion methodCoal and coke
ISO 16948Solid biofuels — Determination of total content of carbon, hydrogen and nitrogenSolid biofuels
ISO 14891Milk and milk products — Determination of nitrogen content — Routine method using combustion according to the Dumas principleMilk and dairy products
ISO 16634Food products — Determination of the total nitrogen content by combustion according to the Dumas principle and calculation of the crude protein content — Part 1: Oilseeds and animal feeding stuffs; Part 2: Cereals, pulses and milled cereal productsFood products, oilseeds, and animal feeding stuffs
ISO 13878Soil quality — Determination of total nitrogen content by dry combustion (“elemental analysis”)Soil
ASTM D5373Standard Test Methods for Determination of Carbon, Hydrogen and Nitrogen in Analysis Samples of Coal and Carbon in Analysis Samples of Coal and CokeCoal and coke
AOAC 46-30Crude Protein — Combustion MethodCereals and cereal products
AOAC 990.03Protein (Crude) in Animal Feed: Combustion MethodAnimal feed
AOAC 992.15Crude Protein in Meat and Meat Products: Including Pet Foods — Combustion MethodMeat, meat products, and pet foods
AOAC 992.23Crude Protein in Cereal Grains and Oilseeds: Generic Combustion MethodCereal grains and oilseed products
AOAC 993.13Nitrogen (Total) in Fertilizers: Combustion MethodFertilizers
AOAC 997.09Nitrogen in Beer, Wort, and Brewing Grains Protein (Total) by Calculation: Combustion MethodBeer, wort, and brewing grains
AOCS Ba 4e-93Generic Combustion Method for Crude ProteinOilseeds
ASTM D7582Standard Test Methods for Proximate Analysis of Coal and Coke by Macro Thermogravimetric AnalysisCoal and coke
ASTM D8339Standard Test Method for the Analysis of Flue Gas Desulfurization Solids by Macro Thermogravimetric AnalysisFlue gas desulfurization solids
ASTM C311/C311MStandard Test Methods for Sampling and Testing Coal Ash or Natural Pozzolans for Use in ConcreteCoal ash and natural pozzolans
ISO 20336Coal and coke — Determination of total sulfur by Coulomb titration methodSolid mineral fuels

Specifications

Parameters Determined: Calorific value, total sulfur, moisture, ash, volatile matter, carbon, hydrogen, nitrogen, and other coal quality parameters

Testing Throughput: Up to 80 samples within 8 hours, depending on the system configuration

Ignition Method: Heating-rod ignition or laser ignition, configurable according to user requirements

Environmental Requirements:
Ambient temperature: 20–24°C, maintained relatively stable and compliant with calorific-value testing requirements
Relative humidity: 30–75% RH

Gas Requirements:

Oxygen for Calorific-Value Testing:
Purity: ≥99.5%, non-electrolytic oxygen
Flow rate: 6 L/min
Pressure: 3 ± 0.1 MPa

Nitrogen for Optional CHN Analysis:
Purity: ≥99.5%
Flow rate: 8 L/min
Pressure: 0.26 ± 0.01 MPa per CHN analyzer

High-Purity Oxygen for Optional CHN Analysis:
Purity: ≥99.99%
Flow rate: 8 L/min
Pressure: 0.26 ± 0.01 MPa per CHN analyzer

High-Purity Helium for Optional CHN Analysis:
Purity: ≥99.999%
Flow rate: 1.5 L/min
Pressure: 0.18 ± 0.01 MPa per CHN analyzer

Compressed-Air Requirements: Oil-free and moisture-free; flow rate ≥120 L/min; pressure ≥0.6 MPa

Water-Supply Requirements: Purified or demineralized water; flow rate ≥5 L/min; water pressure specified as 0.15–0.4 MPa

Drainage Requirements: Floor drain with an opening diameter of at least Ø30 mm

Power Supply: AC 380 V ±10%, 50 Hz ±1 Hz

Maximum Power: 60 kW

Robot Foundation Load Capacity: 400 kg/m²

Application Notes

We are compiling our practical application experience into a growing collection of technical articles that will be published here regularly.

If you have an immediate analytical challenge before then—whether in mining, energy, advanced materials, or PFAS analysis—contact the Sundy Technology Application Laboratory. We provide customized method development, application optimization, and technical support to help you achieve reliable analytical results.

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Customer Testimonials
We have provided a complete set of Sundy testing solutions, including bomb calorimeter, sulfur analyzer, and thermogravimetric analyzer, to the fuel analysis laboratory of Kavçim Cement, a leading integrated cement plant on Turkey’s Black Sea coast. Sundy’s standardized instrument performance bring outstanding practical value to end users. The upgraded solution significantly simplifies daily operations, lowers manual intervention and maintenance costs, and unifies data consistency for routine fuel analysis.We are very satisfied with Sundy’s product quality and technical support, and will continue to promote and recommend Sundy analytical instruments for more industrial laboratory projects in Turkey.
Dr. Karahan, POTANTEK
After more than 10 years of continuous cooperation and market verification, we confirm that Sundy’s products, especially its automatic calorimeters and elemental analyzers, have high precise temperature control, accurate testing results, and ultra-low failure rate. All products are fully compliant with international ISO and ASTM standard, completely meeting the testing demands of coal laboratories, power plants, industrial enterprises, universities and scientific research institutions.We highly recognize Hunan Sundy Science and Technology’s strong production capacity, standardized quality management system, professional technical support team and excellent business credibility. In all our cooperation cases, Sundy has always demonstrated professionalism, reliability and a customer-oriented service attitude.
Dr. Kim, YEONJIN
FAQs

The SDIAS automates the complete coal analysis workflow, including sample bottle receiving, identification, weighing, homogenization, cap opening and closing, sample dosing, analytical testing, crucible handling, oxygen bomb handling, cleaning, and laboratory vessel recycling. Once the test tasks are submitted, the system can operate without continuous manual intervention.

Depending on the installed analytical modules, the system can determine:

  • Calorific value
  • Total sulfur
  • Moisture in the general analysis test sample
  • Ash
  • Volatile matter
  • Carbon
  • Hydrogen
  • Nitrogen

The actual test scope is determined by the selected system configuration.

The system is primarily designed for the fully automated analysis of coal samples. It may also accommodate certain coke samples, provided that the applicable test methods, sample preparation requirements and calorific-value combustion settings are correctly configured.

For coke or samples that are difficult to burn completely, an auxiliary combustion material may need to be selected in the software.

For the automatic dosing mechanism to operate reliably, a 0.2 mm general analysis sample should pass completely through a 0.2 mm sieve. Oversized particles may affect volumetric dosing, sample transfer and weighing stability.

The sample bottle must also contain sufficient material. The manual indicates that a normal sample bottle containing less than approximately 30 g, or a reference-material bottle containing less than approximately 15 g, may be identified as having insufficient sample.

The sample bottle is automatically rotated through a 360-degree homogenization process before sampling. During weighing, the bottle is also tilted and gently vibrated to improve material flow and reduce particle segregation.

This helps improve the representativeness of each test portion.

The system uses a volumetric dosing spoon with a defined volume. After the first portion is weighed, the software calculates the approximate sample density and adjusts the subsequent dosing quantity accordingly.

Two independent weighing modules are provided. Each module can prepare up to ten test portions within approximately 15 minutes, helping reduce moisture changes caused by prolonged sample exposure.

Throughput depends on the number and type of analytical instruments installed, the selected test parameters and the system layout.

The product brochure states that a configured system can process up to 80 samples within eight hours, while the 2.0-series operating manual gives a reference capacity of approximately 30 samples in 5.5 hours or 60 samples in eight hours. The final throughput should therefore be confirmed according to the actual project configuration.

Yes. The SDIAS can interface with upstream systems such as:

  • Automatic sampling systems
  • Automatic sample preparation systems
  • Sample bottle storage and retrieval systems
  • Pneumatic sample transport systems
  • AGV-based sample transfer systems

This allows automation to extend from sampling and preparation through transportation, storage and final laboratory analysis.

The system can read information stored in the chip at the bottom of the sample bottle. Depending on the configuration, it can identify:

  • Sample bottle type
  • Bottle tare weight
  • Sample identification number
  • Test code
  • Required analytical parameters

Optional external card readers and barcode scanners may also be used for sample information entry.

Different crucible types are stored in designated positions for sulfur, moisture and ash, volatile matter, calorific value and CHN analysis. Robotic handling devices transfer the crucibles between storage, weighing, analytical and cleaning positions.

The software records crucible usage frequency. When replacement is recommended, the applicable crucible set should be replaced to prevent positioning failures, breakage or interruptions in the automated workflow.

Yes. After testing, used crucibles can be automatically transferred to the cleaning and ignition processes before being returned to storage for reuse.

Volatile-matter crucibles and lids should still be inspected and periodically matched because repeated high-temperature heating may cause deformation.

The calorific-value section can automatically perform:

  • Oxygen bomb storage and transfer
  • Oxygen release
  • Bomb opening and closing
  • Crucible installation
  • Ignition-wire cleaning
  • Bomb washing
  • Addition of approximately 10 mL of test water
  • Oxygen filling
  • Leak testing
  • Transfer to and from the calorimeter

Four oxygen bombs are supplied as a standard configuration, with up to six available as an option.

The automatic oxygen-filling station normally fills the bomb to approximately 2.8–3.2 MPa. The system also checks whether the total pressure and pressure retention meet the configured requirements.

Insufficient cylinder pressure, an incompletely closed bomb, worn seals or leakage at the filling head may result in an oxygen-pressure alarm.

Yes. The software provides calibration and verification functions for the installed analyzers.

Examples include:

  • Calorimeter calibration and verification using benzoic acid
  • Sulfur analyzer calibration using certified reference materials
  • Proximate analyzer calibration using reference coal samples
  • CHN analyzer calibration using either the raw-coal method or gravimetric conversion method
  • Balance calibration using dedicated calibration weights

Only instruments that are online can be selected for automatic calibration.

The software allows users to configure:

  • Blank tests
  • Waste-sample conditioning tests
  • Replicate measurements
  • Reference-material testing at the beginning, during or at the end of a batch
  • Reference-material testing at defined time intervals
  • Drift samples for CHN analysis
  • Automatic supplementary testing when results exceed configured limits

These functions help maintain long-term analytical stability and identify abnormal results.

The software provides dedicated interfaces for:

  • Sample bottle status
  • Crucible status
  • Weighing progress
  • Calorimeter data
  • Moisture, ash and volatile-matter data
  • Total sulfur data
  • CHN data
  • Instrument calibration
  • Balance calibration
  • Task management
  • Alarm records
  • User and role management
  • Summary results and report printing

Individual process areas and equipment states can be monitored in real time.

The system records sample identification, sample location, crucible information, weighing data, instrument results, task information, alarms and operating logs.

Its transparent enclosure and internal cameras also allow the automated workflow to be observed and recorded. This reduces unrecorded manual intervention and supports investigation of abnormal or disputed results.

The system provides fault alarms, fault descriptions, recommended corrective actions, protection logic and fault recovery functions.

Depending on the configured conditions, an unavailable analyzer or weighing module may be automatically disabled or replaced by another available module. After the fault is corrected, the operator can use the alarm-reset function to resume the interrupted workflow.

Yes. The system uses mature standalone analytical instruments as its testing modules. If the robotic handling system is temporarily unavailable, the individual analyzers may still support manual testing, subject to the configuration and operating condition of the installed instruments.

Manual detection and component-control interfaces are also provided for commissioning, maintenance and troubleshooting. These functions should normally be used by trained or authorized personnel.

The normal-temperature section should generally be maintained at 20–24°C, with relative humidity controlled within approximately 30–75% RH. Direct airflow from air conditioners should not blow onto the calorimeters or analytical balances.

Typical utility requirements include:

  • Power supply: AC 380 V, 50 Hz
  • Installed power: approximately 60 kW or above
  • Ethernet connection
  • Oil-free and moisture-free compressed air
  • Low-pressure and high-pressure oxygen
  • Nitrogen and helium for applicable modules
  • Purified or demineralized water
  • Suitable wastewater drainage

The final gas flow rates, pressures, water supply and room layout should be determined from the confirmed system configuration and site preparation drawings.

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