Inline particle sizing for process control

IPP 70-S - Rugged IndustrialSolution

The new Parsum Particle Probe IPP 70-S/Seuses the established technique of SpatialFilter Velocimetry to make size and velocitymeasurements of gravity-fed, pneumati-cally flowing or fluidized particles from 50-6000 μm, directly in the process line. TheParsumProbes aresmall compactand robust.IP65 dust-proof and wa-terproof, andwith an intrin-sically safeoption, theIPP 70-Se,available, it issuitable forany industrialenvironment -and is alreadyproven in awide range of processing applications.Weighing just 1.5 kg, the probe is easily in-stalled directly in the process line, eliminat-ing the need for sampling. The IPP can beintegrated into new or existing process fa-cilities to provide real-time analysis for fullfeedback control. A range of accessoriesextends its use into high concentration andfluidized bed applications.

Cost-benefit ratio

Continuous monitoring of particle-size dis-tribution increases process transparency,shortens response times in the event ofprocess disturbances, makes continuousquality control possible, precludes chargingerrors, makes new automated solutionspossible, avoids the need to spend time

and money ontaking and

transportingsamples and la-boratory analy-sis. IPP probessecure yourproduct qualityand, by savingon resources,lower your pro-duction costs.Inline particle-size measure-ment with IPPprobes enablesproduction pro-cesses to be

monitored continuously. The output signalsare available to the process managementsystem online. Any deviation from set pro-duct specifications is detected immediately.This ensures the maintenance of consis-tently high product quality with productioncosts minimised. Manual sampling andlaboratory analysis require by comparisonmuch more time. The cost savings are pro-duced not only by the saving on time forlaboratory analysis but also by direct pre-vention of batching errors, remedial work,recycling volumes and the benefits of opti-mised process control.

Measurement PrincipleSpatial Filter Velocimetry

The Parsum Probes use the technique ofSpatial Filter Velocimetry to measure parti-cles. The sensor works on a fiber optic pat-ented measurement principle and simulta-neously measures the size and velocity ofindividual particles. Statistical techniquesassociated with the technique allow calcula-tion of chord length distributions.

It requires no process calibration, allowsconstant measurement with no time gapsin the data. Using Spatial Filter Veloci-metry, size and velocity can be extractedfrom particles as they pass through a laserbeam and cast shadows on to a linear arrayof optical fibers. A signal is generated dueto the particle crossing fiber bundles. Thefrequency of this signal is measured byphotodetectors and is proportional to theparticle velocity. Knowing the spatial filterconstant, the velocity can be calculated. Asthe particle passes through the beam, asecondary “pulse” signal is generated by asingle optical fiber. Knowing the time of thepulse signal, and the velocity v of the mov-ing particle, the chord length of the particlecan be calculated.By accumulating results from individualparticles (typically 10,000-500,000 parti-cles over a period of 1-180 seconds), thechord length and velocity distributions arecalculated. Parameters derived from thechord length distribution e. g. x10, x50 andx90, can be correlated against other particlesize analyzer results.

Process interface

To make the IPP probes serviceable evenunder complicated process conditions (e.g.particle materials which are damp, sticky,abrasive or contain fine dust) a system ofaccessories has been developed which canbe used with all probes designated "-S" and“-Se”. By feeding compressed air to thesensing volume, the optical windows arekept clear using different purge cells. Addi-tional equipment for dispersing particleflow enables the measurement process tobe adapted to different conditions at themeasuring point.

Customisable On-screen display of over-, under-and medium-size fractions and of particle-sizedistribution. Time history of over-, under- andmedium-size fractions together with themedian value of particle-size distribution

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Kontinuierliche Messung der Partikelgrößenverteilung mit IPP70 -SL von Parsum

x10,3 [µm] (l) x50,3 [µm] (l) x90,3 [µm] (l)

Sprühphase 1Trocken-mischen GranulationSprühphase 2

Mischen

Kompaktieren

Monitoring of batch processes

In transient processes such as batch fluid-ised bed granulation the conventionalmethods of particle-size determination of-ten come up against their limits, sincelaboratory analyses are sometimes to handonly after process end.

IPP70-S during a batch granulation process

However, real-time measurement of parti-cle-size distributions enables even thesebatch processes to be modelled in such away that growth can be captured continu-ously and the data is available in time to beutilised for optimum process control. Theoperator thus has available to him whilethe process is running not just copiousprocess data but product-specific data too.

X10, X50, X90 of 3 granulation batches

The costs of manual intervention, batchingerrors and remedial work can in manycases be considerably reduced. Optimisedprocess control enables process time to beshortened. The costs of manual interven-tion, batching errors and remedial work canin many cases be considerably reduced.

Direct measurement in theFluidised Bed

Direct measurement in the fluidised bedmakes it possible in the event of deviationfrom the set particle size to take actionssuch as changing spray pressure and sprayvolume, adjusting airflow or altering theprocess temperature automatically. Themeans thus exist for implementing auto-mated processes by incorporating particle-size measurement in new process-controlschemes and/or assistance systems to helpthe plant operator.

Measurement in the High-Shear Mixing Process

The long probe IPP 70-SL allows the instal-lation in large scaled process vessels likehigh-shear mixer.

IPP 70-SL installed in ahigh shear mixer

x10, x50, x90 of a High-Shear Mixing Process

Long Probe IPP 70-SL

Just like the smaller IPP 70-S standardmodels, the IPP 70-SL provides the com-plete particle size distribution within arange from 50 µm through 6,000 µm inreal time. In large mixers, granulators orfluidized bed systems, measurements canbe made in various representative spots.For very deep process vessels, this meansthe measurement does not have to bemade near the surface or wall any more.The design principle of the probe facilitatesits design in various lengths, tailored to theintended application. The range of length isfrom 40 cm to approximately 4 m.

System Configuration

A complete measurement system com-prises one IPP 70 probe and an measure-ment computer at process level. Themeasurement system works continuously,without user intervention. Up to 4 individ-ual IPP probes may be connected to ameasurement computer simultaneously.Several measuring points far removed fromone be linked at a central control-roomcomputer via Ethernet (TCP/IP) by web-server technology, OPC protocol or4…20 mA interfaces.The interfaces are freely settable to charac-teristic particle properties x10, x50, x90...)

Pharma-Options

The IPP 70-S,-Se,-SL are available with op-tions to support their use in the pharma-ceutical industry.Pharma-Option 1: „Verification Kit“a test device that allows operators to checkthe basic function of the probe to ensurethat installation performance can be main-tained. The software/hardware interfacemakes it possible to perform a one-click ca-libration of the whole measurement systemthat can be stored. (With instruction guidefor OQ/IQ).Pharma-Option 2: „Material Traceability”All the documents necessary to ensure thematerial traceability of all contact compo-nents. For each 316L contact part a 3.1certificate is supplied. Polished surfaces forthe probe’s contact areas (Ra<0.5) to aidcleaning/sterilization.Pharma-Option 3: „ParsumView“Parsum View is a new designed user inter-face for the measurement software, whichhelps to fulfill the GMP-requirements ofpharmaceutical production. The most im-portant features are:

It works in a network (Ethernet) orstand-alone

Detailed user access control withflexible user levels

User and Password Management Safe storing of measurement values

and settings in SQL-database Audit-Trail

Screenshot ParsumView

IPP 70-SL

Parsum IPP 70 - The standard unit

for all types of Granulate materials,

for all Fluid Bed Processes

for Mixing, Milling, Grinding and a lot more

Main Features in brief: Real-time sensor Measures particles with average size 50 - 6000μm and velocity up to 50 m/s Easily installed directly into gravity-fed, fluidized bed or pneumatic lines Automatic feedback to central control room or computer by 4…20 mA Interface and by Web-Server tech-

nology over Ethernet (TCP/IP) or by OPC-Server Minimal installation effort No alignment required, no field calibration needed Strong stainless steel construction Window cleaning eliminated operation of Spatial Filter Velocimetry Pharma Options available

Technical Data:Materials 316L SS for In-line probe, Sapphire, epoxy resin optics

Pressure-cast aluminium for electronics enclosureData rate: Up to 20,000 particles per second, dependent on process conditionsMax Operating Pressure 4 barOperating Temp -20°C to 100°C at measuring point, -10°C to 60°C on housingDimensions Tube length = 280 mm (11 in), diameter = 25 mm (1 in) for IPP 70-S and –Se

Tube length = 0,4 …4 m, diameter = 50 mm (2 in) for IPP 70-SLAir Supply adjustable air flow meters, Pulse flow with adjustable timer or

continuous air, Flow Requires instrument grade compressed airMaximum cable length: 100 m

ATEX-Certification for IPP 70-SeEC-Type Examination Certificate:

IBExU02ATEX1009Labeling of the Probe IPP 70-Se:

II 1/2 G Ex ib op is IIB T4II 1/2 D Ex tD A20/A21 IP65 T 80°C

Labeling of feeding device:II (2) GD [Ex ib] IIB(according to EN60079-0, EN60079-11, EN60079-26,EN60079-28, EN61241-0, EN61241-1)

Sales Contact:

Germany, Austria and Switzerland:Parsum GmbH, Germanywww.parsum.de info@parsum.de

All other countries:Malvern Instruments WorldwideSales and service centers in over 50 countries. Fordetails visit www.malvern.com/contact