Particle sizing in real-time with laser diffraction for dry, even cohesive powders ranging from 0.25 µm to 3,500 µm directly connected to the process
Together with the representative sampler TWISTER, the laser diffraction sensor MYTOS forms a perfectly coordinated and robust on-line process analysis system. The sampler is integrated in the process line, takes a sample and feeds it directly to the particle size analysis. Thanks to the use of the integrated RODOS dry dispersion in the MYTOS, even finest, cohesive or magnetic powders can be reliably dispersed and measured. The interplay between sampling, dispersion and laser diffraction sensing enables continuous real-time analyses of dry powders and granules with particle sizes ranging from 0.25 µm to 3,500 µm – directly connected to process lines with diameters from 38 mm to 800 mm and mass flow rates from 1 kg/h to over 100 t/h. The representative, high-frequency recording of measured values under process-related conditions enables integrated quality inspection and optimised process control.
For reliable on-line particle size analysis, representative and continuous sampling is just as much a prerequisite as the full dispersion of the primary particles. The TWISTER sampler, which is integrated in the process line, scans the entire pipe cross-section on a spiral path and ensures that all regions are sampled with equal weighting. The representative subsample is fed into the MYTOS system, which is installed close to the process, and dispersed in the downstream RODOS injector and measured in the measuring zone of the MYTOS laser diffraction system in the free aerosol jet. The information gained in real-time about the particle size distribution can be provided via standard communication interfaces to a process control system for monitoring or for process control.
In order to adjust the sampling to the product and to the process conditions, calibres of 4 mm, 6 mm and 10 mm are available for the TWISTER sampling tip and for the MYTOS dispersing line. The handling of the ejected sample in an enclosed bypass line enables safe and reliable analysis even for highly reactive or potentially explosive products under a protective atmosphere. Even toxic or pharmaceutically active substances can be handled safely and with practically zero emissions. After measurement, the sample can optionally be returned to the process, disposed of via an extraction system or made available for further analyses via a cyclonic separation.
The TWISTER sampling system can be switched into standby mode, in which it is hermetically sealed against the process and against unnecessary particle ingress. If necessary, due system maintenance or servicing can be performed without interrupting the process. The mechanical system of the TWISTER is fully encapsulated against the product stream, so no particles can come into contact with moving parts or gaskets. To clean the sampler and the dispersing line during operation, an integrated blow-back device can be used optionally after every measurement. Sheath flow and air purge ensure that the optical components are kept clean. The measuring system is virtually maintenance-free as a result. Regular reference measurements and the autofocusing of the detector combine to provide a system that is always ready to perform.
Customization to the specific process environment and to the products that are to be measured is achieved in close cooperation with your process engineers and our experienced engineering team. Special designs for potentially explosive atmospheres (ATEX) and for regulated environments (GMP) are also part of our portfolio.
- Particle size and particle size distribution
- For dry, fine to coarse grained, also cohesive powders and granules
- For product temperatures from -20°C to 150°C
- For continuous real-time analyses at the process | on-line
- 6 high-resolution measuring ranges from 0.25 µm to 3,500 µm | R2 to R7
- Dynamic and representative sampling in the process line
- on-line measurement outside the process line under process-related conditions
- Connection to process control systems | TCP/IP, OPC, Modbus®, Profibus®, PLC signals
- Monitoring of multiple process lines with a single sensor | Multiplex installation
- ATEX and GMP optional
All on-line systems can be optionally equipped with a manual sample feed, which comprises the vibratory feeder VIBRI and a stainless steel hopper. The systems are equipped with a VIBRI platform and the corresponding connections as standard. The hopper is mounted with a clamp connection onto the sensor system in place of the hose line of the sampler. This upgrade enables manual off-line measurements and is also required for re-certification of the systems with reference material.
In cases where particle size needs to be monitored on multiple process lines, the capturing of measurement data can be done with just one MYTOS laser diffraction system and multiple samplers installed in the different lines. Sequential sampling provides the sensor with samples from the different lines one after the other via a collector. Fast measurement and cleaning cycles effectively prevent the risk of cross-contamination during processing of the individual samples from different origins.