Achieving yourprocess vision

On-line Particle Sizers

Information provides the key to betterprocessing decisions and to improvingoperational efficiency. For particulateprocessing, the Malvern Instrumentsrange of on-line particle sizing systemsdelivers the intense, high qualityinformation necessary for effectivedecision making and control. Highfrequency sampling and analysis, directfrom the process line, and using largenon-destructive sample throughputs, ensure the superior measurementrepeatability and real-time data generation that only on-line systems can bring.

No morerunning blind

Each Malvern Insitecmakes more than amillion measurementsevery year.

Capture the moment 24/7In contrast with traditional off-lineanalysis where samples are taken atinfrequent intervals, Malvern’s on-line particle sizers generate particlesize distribution information everysecond. When fed directly into theplant control system this allowscontrol actions to be taken almostinstantaneously. Streaming feedbackfrom the process allows theidentification and diagnosis of shortduration, transient, or cyclic processupsets, which could contaminate abatch of material but would goundetected in off-line analysis.

Graph 1: Mineral process running at 20t/h. Previously undetected process upsetswere caused when the bed height in the classifier feed hopper fell below a criticalpoint. The problem was resolved by increasing the level of the low alarm.

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Increase sample throughputAnalyzing large amounts of material improves the statistical significance of theinformation. In off-line analysis, it may be that samples as small as 5 grams aretaken just once every shift. Using Malvern process systems, sample throughputover the same period can be up to 10,000 times greater, giving a much moreaccurate representation of the process. The measurement technique leavesparticles unaltered, allowing the product to be returned to the process.

Tighten process confidence limitsWith automatic sampling and measurement, configured to meet the needs of

specific processes and lines, representativemeasurement and repeatability are typicallyfar better than using classical manualsampling techniques. With so much lessuncertainty, confidence limits can betightened and the process can operate closerto its specification limits.

Off-line. At-line. In-line. On-line.Malvern can provide the same measurementtechnique for the laboratory (off-line) and for use at-line, as well as in the process.

“Insitec contributed to our recordproduction year.”Bill Siemering, Vice-President, Ashgrove Cement Company, Inc.

Graph 2: At Ashgrove Cement’sLeamington plant in Utah, cementfineness is traditionally measuredoff-line using an air permeabilitytechnique ("Blaine") and iscorrelated to the strength of thecement at 1,3, 7 and 28 days after setting. Variability in the cement finenessand strength has decreased significantly since the installation of Malvern Insitec for automatic separator control.

Silica production at GRACE Manufacturing GmbH & Co. KG, Worms, Germany.

Getting a good production run for your money

Increase productivity Sweat the assetsOff-line particle size measurementmakes mill start-up a timeconsuming, iterative exercise.Sampling, waiting for themeasurement results, changing theprocess parameters and then waitingfor the mill to reach a steady statebefore sampling again wastes bothmaterial and time. With on-lineparticle size analysis, start-up timescan be reduced to within a singleiteration of the ‘sample-measure-change-wait’ cycle of the off-lineprocedure (see graph 3).

Current particulate processing trends,focused on maintaining industrialcompetitiveness, include improvingproduct selectivity, increasingproductivity, and intensifying theprocess. Plant automation helps inachieving these goals, but dependson access to reliable real-timeinformation. Only Malvern’scontinuous on-line sizing systems

enable true process control andoptimization. Malvern systemsdeliver tried and tested solutionsacross sectors that include cement,powdered metal and mineralproduction, through to themanufacture of pharmaceuticals,toners, powder paints, polymers and foodstuffs.

Process optimization & ROI

Process Plant

Process Control

Process Operation

Optimizedprocess

Improvedproduct

Automaticsampling

Commun-ication

Malvern On-line Sizer

Continuousmeasurement

Real time particle size data transfer

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Toner manufacture at NexPressSolutions Ltd., Kirkby, England.

Graph 3: Mill start-up.

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Improve product selectivityOn-line particle sizing facilitates real time optimization of the parameters andconfiguration for each process stage, allowing plant to work closer to operationallimits. Reducing overgrinding enables the manufacture of acceptable productwhile working closer to specification limits. Improved yield, consistency andthroughput are achieved alongside a reduction in energy costs. Malvern processsystems provide such accurate data that some product release criteria are based solely on on-line QC measurements.

Plant automation "Lights-out" operationRealizing the goal of the completeautomation of particulate processingfacilities is fast becoming a reality.Many Malvern clients have alreadyclosed the loop between on-lineparticle size measurement and a plantcontrol parameter, the classifier speedfor example. This reduces manpowerfor both plant control and for off-linesampling/measurement, ensuring amore consistent product.

"Each gram saved is a real gain and wecan now performmuch better in asector where highquality is crucial." Hubert Müller, Process Engineer,Siemens Axiva GmbH & Co. KG.

Process intensificationThe drive today is towards processes that are smaller, fasterand less expensive, but have the same (or better) throughputas larger, older plant. Building quality into products inupstream unit operations is increasingly important—forexample at the mill or spray drier stage, using on-line particlesizing as a tool. By improving the product selectivity early inthe process, downstream operations such as classification,can be reduced and potentially completely eliminated.

Sovitec S.A., Belgium—leading glass bead manufacturer.Insitec’s high measurement frequency revealed a fluctuatingparticle size, with a period of about 1 minute. By optimizingthe filter shakedown, the product size distribution over timewas stabilized (graph 4a) and product selectivity wasimproved significantly (graph 4b).

Pharmaceutical milling at Siemens Axiva GmbH & Co. KG,Frankfurt, Germany.

Cement grinding atCiments Calcia,Italcementi Group,Rombas, France.

“Our Insitecinstruments havecontributed to savingover a hundredthousand US dollarsper year in operational costs.”Tom McHugh, Managing Director, NexPress Solutions Ltd.

Graph 4b: Particle size distribution (5h average).

Graph 4a.

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“Insitec is the perfecttool for increasingprocess yield, savingup to a ton of silicaon each productchangeover.”Torsten Krause, Process Engineer,GRACE Manufacturing GmbH &Co. KG, Germany.

Laser diffractionThis tried, tested and proven technology has been

adopted as the standard in most particulate processingindustries. Laser light is scattered by particles and the angular

intensity is measured by a series of photodetectors. Using rigorousMie scattering theory, the complete particle size distribution can be

determined. The technique requires no calibration, and does not require longdata acquisition intervals that can mask true process behavior. Malvern haspioneered the application of this technology over the past 20 years, and is theglobal leader in its implementation in both laboratory and industrial settings.

Particulate measurement engineeringexperts in custom size solutions

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X-Y alignment stage

Lens

Window (receiver)

Window purge air

Automatic valve (outlet)

Laser diode

Sample return

Window (transmitter)

Instrument support bracket

Process flow

Sample probe

Triclamp

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Insitec Eductor System

High concentration measurementsUnique to the Malvern Insitec range of process instruments, is a patented (US 5,619,324) multiple scattering algorithm that enables reliable operation athigh concentration (see graph 5). The use of this algorithm is crucial to ensuringthat particle size measurements are accurate regardless of the instantaneousprocess loading. This is particularly important during plant start-up, shutdown,and process changes.

Robust, repeatable, representative samplingA range of process interfaces can be tailored to meet the needs of differentapplications. The most widely adopted sampler uses an air venturi to aspiratepowder from the process line and to disperse the sample for accuratemeasurement. Such an interface, which has no moving parts, is possible onlybecause of Malvern’s patented high concentration measurement technique.Dynamic samplers are available for high tonnage abrasive solid streams and in-line flow cells can be designed for very dilute processes.

Graph 5: Correcting for multiplescattering effects at high concentration.

Malvern LinkSystem integration Malvern Link is based on anindustrial SCADA package, IntellutioniFix, which is delivered as standardwith every Malvern process system.Providing an automated processinterface for sampling and valvecontrol, it also enables communicationwith plant DCS and allows thedevelopment of context-specific user interfaces. Process Instrument serial

link (30m max)

Insitec Electronics

OPCLink

PLC commse.g. Modbus

PLC

PC Serial Link (500m max)

INSITEC PC (MS-Windows NT4/2000)

Active–X Link

Valve & SensorAutomation

Air

Real-time sizing software RTSizer controls the instrument and

analyzes the data. It is capable ofcalculating all standard size parameters, including

Dv10, Dv50, Dv90,%< X µm and D[4,3], which aredisplayed in standard model-independent particle size distributions and as trendcharts. It is a real-time NT-based system that allows the viewing of historical datawhile measurement is underway. Security levels can be set for different users.RTSizer is an open application, interfacing to most modern plant controlpackages directly, or through the intermediary of Malvern Link.

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Malvern Link Template

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Designed for process useInsitec process measurement systems are designed from the beginning forindustrial use. The units are compact, IP65 certified (dust-tight and waterproof),and vibration proof. The instrument forms part of a very flexible systemconfiguration, both for the process and for the automation interface. An intrinsically safe option is also available.

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Malvern Instruments Limited Enigma Business Park

Grovewood Road Malvern

Worcs WR14 1XZ

U.K. Tel: +44 (0)1684 892456

Fax: +44 (0)1684 892789

Malvern Instruments Inc.

10 Southville Road Southborough

MA 01772 U.S.A.

Tel: +1 (508) 480-0200 Fax: +1 (508) 460-9692

Malvern Instruments GmbH Rigipsstraße 19

71083 Herrenberg

Germany Tel: +49 (0) 7032 97770

Fax: +49 (0) 7032 77854

Malvern Instruments S.A. Parc Club de L’Université

30, Rue Jean Rostand91893 Orsay Cedex

France Tél: +33 (1) 69 35 18 00 Fax: +33 (1) 60 19 13 26

Malvern Instruments Nordic AB

Box 15045, Vallongatan 1 750 15 UPPSALA

Sweden Tel: +46 (0) 18 55 24 55

Fax: +46 (0) 18 55 11 14

Malvern Instruments JapanSORIO-3, 6th Floor, 2-2-1 Sakaemachi,

Takarazuka, Hyogo 665-0845

Tel: +81 (0)797 85 5060Fax: +81 (0)797 85 5657

www.malvern.co.uk

Ref: MRK397-01

The ProcessRegister your interest with Malvern and a representative will arrange to visit so that we fully understand your objectives, requirements and time-scales. Our appointed project manager will co-ordinate installation with your input, and conduct a survey to agree the optimal location for the instrument. We ask you to undertake site preparation and the addition of sample ports to the process line in advance of Malvern engineers installing and commissioningthe measurement system.

The Team Malvern's engineers work directly with suppliers, systems integrators and end-users to configure products to clients’ needs. Malvern employs a team ofspecialists—process and automation engineers, particulate scientists and fieldservice technicians—to provide support and maintenance after purchase, andsets the industry standards for flexible service programs, extended warranties and on-site training.

The CompanyMalvern Instruments characterizes particulate systems using laser diffraction,ultrasonics, photon correlation spectroscopy and zeta potential measurement.

Malvern Process Systems, a wholly-owned division of Malvern Instruments Ltd.,specializes in the application of these technologies to on-line solutions, and isexpert in automated particulate sampling and measurement.

• Global network of sales and service personnel

• World-wide project co-ordination for multinational companies

• Quality service before, during and after the sale

• On-call technical support and helpdesk

• Custom engineering for your specialist measurement needs

• Responsive customer service

• Sampling and automation consultancy

• On-site training and web seminars

• Certification and conformance to quality standards including ISO9001 and CE badging

• Compact, high speed, accurate and durable process instrumentation

Malvern Instruments is part of Spectris plc, the precision instrumentation andcontrols company.

www.spectris.com

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