Online Crystal Size Measurement Device for High-Solid Crystallization
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Solution Overview
Problem
Existing online measurement methods for crystal size and shape distribution in high-solid-content crystallization processes face challenges such as crystal overlap, blockage, and inaccurate measurements due to high crystal content, particularly exceeding 10%.
Innovation Solution
An online measurement device incorporating a solution amplifier, peristaltic pump, constant-temperature tank, and dilution device for non-contact measurement, which dilutes the high-solid-content solution and uses a high-transmittance material to prevent blockage and maintain accurate imaging, allowing for continuous and intermittent measurement of crystal morphology and size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the image method is used to measure crystal shape in high-solid-content crystallization process, then crystal shape measurement is possible, but measurement accuracy deteriorates due to crystal overlap and poor transmittance when solid content exceeds 8%-10%
Solution Approach 1:
The patent introduces a light guide as an intermediary component to transmit light through the crystal slurry. The light guide collects light from the measurement region and conducts it to the camera, improving light transmission efficiency and enabling accurate imaging in high-solid-content conditions where direct optical measurement fails due to poor transmittance and crystal overlap.
Solution Approach 2:
The patent transitions from traditional 2D imaging to 3D confocal microscopy measurement. By using optical sectioning and z-axis focusing, the system can selectively measure crystal shapes at different depths, avoiding the overlap problem in 2D images and enabling accurate crystal morphology measurement in high-solid-content crystallization processes.
2Measurement precision
If FBRM probe is immersed into crystallization kettle to measure crystal chord length, then crystal size measurement is achieved, but probe blockage and corrosion occur, and hydrodynamic characteristics are destroyed
Solution Approach 1:
The patent extracts the measurement function from the immersed probe configuration and relocates it to an external optical measurement system. By using a light guide and camera positioned outside the crystallization kettle, the system eliminates the need for probes inside the slurry, thereby preventing probe blockage, corrosion, and disruption of hydrodynamic characteristics while maintaining crystal size measurement capability.
3Ease of operation
If in-situ measurement device is placed at outer side of crystallization kettle, then non-contact measurement is achieved, but measurement accuracy deteriorates due to crystal blur, overlap and pseudo-adhesion in images
Solution Approach 1:
The patent employs confocal microscopy with optical sectioning capability to achieve 3D measurement of crystals. By focusing at specific z-positions and using optical sectioning to eliminate out-of-focus light, the system resolves crystal overlap and blur problems that plague traditional 2D imaging, thereby improving measurement accuracy while maintaining non-contact measurement operation.
Solution Approach 2:
The patent introduces a light guide as an intermediary optical transmission medium to improve image quality. The light guide collects and transmits light from the crystal slurry to the camera with reduced scattering and absorption, thereby enhancing image clarity and reducing crystal blur and overlap artifacts in non-contact measurement.
4Reliability
If external-circulating measurement method is used to measure crystal in pipeline, then integrity is not affected by sampling, but pipeline blockage occurs due to crystal growth on wall and sedimentation
Solution Approach 1:
The patent extracts the measurement function from the circulating pipeline system and implements it through a localized optical measurement system using a light guide and camera. This eliminates the need for continuous circulation and sampling, thereby preventing crystal growth on pipeline walls and sedimentation while maintaining measurement integrity through direct optical observation of crystal slurry.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate measurement of crystal size and shape in solutions with solid content above 10%, reducing pipeline blockage and temperature variation issues, and allowing for both continuous and intermittent measurement while recycling and storing the solution.
Implementation Method 1
a peristaltic pump (5) communicated with the other end of the crystallization kettle; the solution amplifier, the peristaltic pump (5) and the crystallization kettle (9) form a complete passage through a pipeline (4)
Implementation Method 2
uses a high-transmittance material to prevent blockage and maintain accurate imaging
Implementation Method 3
An online measurement device incorporating a solution amplifier, peristaltic pump, constant-temperature tank, and dilution device for non-contact measurement, which dilutes the high-solid-content solution
Implementation Method 4
constant-temperature tank, allowing for continuous and intermittent measurement of crystal morphology and size distribution
Data Source
AI summary
An online measurement device for crystal size and shape in a high-solid-content crystallization process includes a solution amplifier, a measurement device, a peristaltic pump, a crystallization kettle, a dilution device and a solution storage tank. A crystal-containing solution is arranged in the crystallization kettle; an inner wall of the solution amplifier is smooth, one end is an amplification end, and the other end is a contraction end. The contraction end is communicated with one end of the solution storage tank and one end of the crystallization kettle. The amplification end is communicated with the dilution device and the peristaltic pump. The peristaltic pump is communicated with the other end of the crystallization kettle. The solution amplifier, the peristaltic pump and the crystallization kettle form a complete passage through a pipeline. A measurement instrument of the measurement device is arranged at the outer side of the solution amplifier.