The industrially robust, technologically proven process particle size analyzer
Engineered to withstand the rigors of the process environment, Insitec Dry particle size analyzers use laser diffraction technology to measure particles in the size range 0.1 to 2500 µm. Insitec Dry can be configured to suit practically every dry particulate process, delivering real-time monitoring and control 24/7, with options for:
- Dust zoned hazardous environments.
- Gas or dust zoned hazardous environments.
- Mobile application.
- Abrasive materials.
- Pharmaceutical processes.
Insitec Dry online particle size analyzers deliver fully automated real-time - or manual at-line - size measurement of particulates, in continuous and batch processes having pneumatic or gravity-fed streams. They are used to monitor and control processes ranging from abrasive bulk powders to foods, fine chemicals and pharmaceuticals with strict hygiene standards and subject to stringent regulatory control. To ensure representative sampling, process interfaces are tailored to meet custom needs whether pilot scale or hundreds of tonnes per hour. Every Insitec Dry system offers:
- Base model hardware manufactured to GAMP5 standards and compatible with CIP/SIP requirements to meet specific manufacturing specifications
- Easy to use software and fully automated operation to minimize training requirements and release operator time
- Integration with existing control platforms to simplify development of automated control protocols
- High reliability of >95% with little downtime, minimal maintenance and maximum ROI.
How it works
All Insitec installations are tailored to the unique requirements of the application. They range from simple at-line, manually-fed systems to fully automated, validated on-line solutions for continuous monitoring and multivariate control. Malvern works in partnership with its customers, providing expertise, hardware and software, where and when it’s needed. This ensures cost- effective, successful project implementation and a positive return on investment.
Factors for success
The success of process analysis depends on detailed consideration of three critical components:
- The process interface.
- Sample measurement.
- Data presentation and use.
The process interface
Insitec systems are items of process equipment and operate within the plant environment. Getting the interface between the instrument and the plant right is essential for long-term, trouble-free operation.
Malvern has proven technology for almost every conceivable dry process application. From two-stage auger extraction systems for flow rates of around 100 tph and above, to static samplers, simple eductors and flutes for much lower flow rates. Proven strategies ensure that representative samples are automatically and consistently delivered to the measurement zone, in an appropriately dispersed state and at a suitable concentration for analysis.
Insitec at-line systems run alongside the process and have a manual interface. For automated continuous operation the Insitec is installed in the process line or on an associated sampling loop.
Measurement in an appropriately dispersed state ensures access to relevant data whether it is agglomerates or primary particle size that is of interest.
A dedicated Insitec may be necessary for each measurement point or it may be possible to monitor multiple lines or process steps with a single sensor. This depends on the measurement frequency required.
Well-designed on-line process interfaces:
- Deliver sample that is representative of the bulk.
- Run reliably with minimal maintenance without disrupting the process.
- Recycle analyzed material to minimize waste.
Insitec systems use the technique of laser diffraction to rapidly measure particle size. When applied to dry systems, complete particle size distributions are measured in less than one second, giving instantaneous monitoring. Even processes with fast dynamics can be tracked effectively.
Insitec systems directly measure the process stream. In some processes particle loading or concentration may vary during routine operation. This presents a challenge for many particle measurement systems and can have a detrimental effect on reported particle size. However the patented multiple scattering algorithms associated with all Insitec systems ensure that reported changes in particle size are always reliable and real. These algorithms mathematically correct for the concentration-dependent effect of the source light interacting with not one, but several, particles before reaching the detectors. Measurements are therefore robustly independent of sample concentration.
Insitec produces reliable, timely and complete data, reporting full particle size distributions. These data provide a secure foundation for better process control whether that control is manual or automated.
Data presentation and use
Insitec systems are integrated within the process plant. Typically they are operated from a centralized control room and the measurement results drive routine decision making. Powerful software packages make integration and data interpretation straightforward.
Malvern Link II software provides the functionality required to integrate an Insitec within the existing control system and to automate process control. It allows operation of the analyzer from either a dedicated PC or from existing control mimics. Importantly Malvern Link II is not confined only to Insitec integration. This software also eases integration with other instrument types, simplifying multivariate control.
RTSizer software presents the measurement data in a clear and accessible way. Results reporting can be tailored to industry and customer norms to improve information flow. Insitec data are used to:
- Improve process understanding.
- Deliver instant upset detection.
- Support comprehensive process optimization.
- Automate process control.
Because complete particle size distributions are reported, monitoring and control can be based on whichever size fraction is of interest: the fines, the 3 to 30 micron fraction, the amount of material over 200 microns, for example. Insitec data drive optimized manual control strategies and enable the full automation of process control, delivering substantial economic returns.
- Measurement type 1:
- Particle size
- Measurement range:
- 0.1 to 2500 µm
- Measurement principle:
- Laser diffraction
- Optical models:
- Mie theory
- ±2% on Dv(50) reported using the verification reticle
- Power: (V, Hz, VA)
- 100/240 V
- 10°C – 70°C
- 35% - 80% (non-condensing)
- Enclosure rating:
- RTSizer (for instrument control)
Malvern Link II (for system automation and data link)
- Minimum computer specification:
- Windows XP, 7 and above
- Operating pressure:
- 10 bar (g)
- Maximum distance from instrument to PC:
- 500 m (up to 2 km using fiber optics)
A range of Insitec Dry options meets the specific requirements of different process applications.
Dust zoned hazardous environments An ATEX approved, category 3 system for dry process monitoring in dusty areas rated as zone 22. Designed in accordance with IEC 61241.
Gas or dust zoned hazardous environments The world’s first ATEX intrinsically safe on-line particle size analyzer. Suitable for dry processes in zoned areas: 0, 1, 2 and 20, 21 and 22.
Mobile measurement Insitec Voyager, a mobile particle size analyzer suitable for at- or on-line dry applications. Especially convenient for use when commissioning, for process optimization, and in multi-unit facilities.
Abrasive materials Robust, reliable particle sizing for abrasive materials such as cement, at-line or within an automated lab. Easily engineered for on-line measurement. Hard-wearing internals ensure trouble-free operation with minimal maintenance over the long term.
Pharmaceutical processes Fully validated, customized particle size analyzers for dry process streams that comply with the rigorous regulatory framework applied in pharmaceutical manufacture.
Consultancy Service Malvern Instruments’ consultancy service is designed to demonstrate in situ how continuous real-time particle size analysis can transform plant operation. Successful plant trials with Malvern Insitec encourage 85% of clients to switch to on-line analysis.
Malvern solutions for Insitec Dry
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