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 compact L-shaped probes, the laser diffraction sensor MYTOS forms a robust on-line process analysis system. A single-point sampling probe 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 system even finest, cohesive 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 in process lines with mass flow rates from 1 kg/h to over 3 t/h. The high-frequency recording of measured data under process-related conditions supports integrated quality inspection and optimised process control.
For the sampling from the process line, two compact L-shaped probes are available in the form of the static probe and the pneumatic pivoting probe that can be integrated in product-carrying process lines with an installation height of just 150 mm. The static probe is suitable for single-point sampling in pipes with a diameter from 65 mm to 250 mm. The sampling tip is freely adjustable in terms of immersion depth and tilt angle and is locked in the optimum sampling position in the process line. For adjustment to the product and to the mass flow, conveyor lines with a diameter of 6 mm and 10 mm are available. In terms of the coating for the lines, you can choose between abrasion-resistant NBR, conductive EPDM, anti-adhesive PTFE and extremely durable Vulkollan®. Depending on the design of the probe, product temperatures from -20°C to 150°C and applications in potentially explosive areas (ATEX) are safely handled. The dosage of the extracted sample amount depends on the selection of the interchangeable probe tips with diameters ranging from 1 mm to 20 mm. A blow-back device is used in combination with a pinch valve to ensure that the system remains free of particles between measurements, during standby or during the performance of reference measurements.
For GMP-compliant pharmaceutical applications, in which blow-back into the process is not permitted, the pneumatic pivoting probe is available as an alternative for pipe diameters from 150 mm to 200 mm. During reference measurements and in phases where no measurement is performed, the probe rotates its opening out of the product stream and thus remains free of unwanted particle ingress. Thanks to the pneumatically operated variation of the tilt angle of the probe, different areas of the product stream can be dynamically sampled for the measurement. The choice of probe calibre with diameters from 2 mm to 10 mm allows the optical concentration for the laser diffraction analysis to be determined via the extracted sample amount. The system can be adapted to a large number of products and processes and can be operated with product temperatures from -20°C to 100°C as well as in potentially explosive areas (ATEX) – if required. The pivoting probe is equipped with parts in contact with the product made of stainless steel, PTFE, FEP and EPDM and is designed for cleaning in place (CIP).
The subsample obtained by using either L-shaped probe 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. 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.
- 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
- Compact single-point sampling in the process line with L-shaped probes
- Static probe or pneumatic pivoting probe | Installation height 150 mm
- 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
Sectional view of the pneumatic pivoting probe, which is integrated in the process line, for extraction of a sample for on-line analysis
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.
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.
