Real-time particle size measurement from below 0.1 µm to 3,000 µm in suspensions, emulsions and slurries with ultrasonic extinction in process lines from DN50 to DN200
The robust ultrasonic extinction sensor OPUS is integrated via a bypass (BP) adapter in process lines with diameters of 50 mm to 200 mm and monitors the particle size distribution in continuous real-time analysis and the concentration of suspensions and emulsions in a range of below 0.1 µm to 3,000 µm. The acoustic measurement method offers outstanding capabilities for in-line and on-line measuring, even in highly concentrated media. Using sound waves means that analyses can be performed in their original state regardless of the transparency of the material system – without dilution and under process conditions. The continuous acquisition of measurement values enables optimised process and quality control in wet grinding circuits, classification or in mixing processes as well as in crystallisation, polymerisation and particle synthesis.
The ultrasonic extinction allows for an extremely robust design with a finger probe that withstands a temperature range of -20°C to 120°C, high pressures up to PN40, aggressive media and abrasive product streams. All components coming into contact with the product are adapted to the respective conditions and are designed in resistant materials: Finger, measurement zone and stainless steel housing (type 1.4571 | type 1.4539 optional) or highly corrosion-resistant nickel-chromium-molybdenum alloy (Hastelloy® C-22, type 2.4602), acoustic windows made of vitreous carbon (Sigradur®) and seals made of PTFE (Teflon™) or FFKM (Kalrez®). When required, sensor cooling with compressed air is available for continuous operation at high process and ambient temperatures. Safe operation in hazardous areas (ATEX) is ensured through an optional overpressure enclosure.
The OPUS sensor is integrated into the pipeline carrying the product via a bypass (BP) adapter that is attached to the measuring finger. The adapter is installed with flange connections (standard sizes DN50 | DN100 | DN150 | DN200) in a section of pipeline approximately 300 mm in length so that the entire product stream flows through the BP adapter. A portion of the product stream is passed directly through the OPUS measuring zone while the remaining partial flow circulates around the measuring fingers within the adapter in the bypass. Depending on the product to be measured, the measurement gap positioned centrally on the adapter is opened between 1 mm and 10 mm, and records an analysis volume of up to 1,000 l/h depending on the flow rate.
This type of installation is suitable for process lines with nominal sizes of DN50 to DN200 and flow volumes of up to 10,000 l/h and can be performed either directly in the main product flow (in-line) or in a diverted partial flow (on-line). The installation of the OPUS sensor with the BP adapter and the bolted flange connections is self-supporting – depending on the dimensions and load capacity of the process line. Alternatively, the weight of the sensor can also be incorporated via an optional standby (SB) rack.
The OPUS system can be flexibly incorporated in a control system using common communication standards such as Modbus® RTU, Modbus® TCP, Profibus®, OPC (Open Platform Communications ), TCP/IP, FTP or analogue PLC signals in order to set up the remote-controlled or autonomous carrying out of measurements. The information gained in real-time about the particle size distribution and the concentration are provided to the process control system for process monitoring or for process control.
Individual, customer-specific adaptation to the existing process environment and to the products that are to be measured takes place in close cooperation with the customer's process engineers and is accompanied by our experienced engineering team. Special equipment for potentially explosive areas (ATEX) is, of course, also part of our portfolio. We are also happy to provide alternative flange connections, pressure levels and special lengths upon request.
- Particle size, particle size distribution and concentration
- For suspensions, emulsions and slurries with particle concentrations up to 40 volume percent
- Product temperatures from -20°C to 120°C | pH values from 1 to 14 | Pressure level PN40
- For continuous real-time analyses in the process | in-line and on-line
- Highly resolved measuring range from < 0.1 µm to 3,000 µm | 31 measuring points
- For installation in pipelines from DN50 to DN200 with bypass adapter
- Measurement under process conditions | No product removal or sample preparation
- Connection to process control systems | Modbus®, Profibus®, OPC, TCP/IP, SPS signals
- ATEX optional