Inline Particle Size Analyzer for Mill Control
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Solution Overview
Problem
Existing methods for particle size analysis of bulk materials in mills are often manual and offline, leading to representative sampling issues, delayed error detection, and inefficient operation.
Innovation Solution
An inline particle size analysis device that continuously measures particle sizes of a bulk material as it is ground, integrated with a mill control system to adjust processing parameters in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual offline sampling is used for particle size analysis, then the device complexity is reduced, but the measurement precision and reliability deteriorate due to non-representative sampling and delayed error detection
Solution Approach 1:
The patent replaces manual mechanical sampling operations with an automated inline particle size analysis device that continuously measures particle sizes in the bulk material stream. The measurement device includes a measurement chamber where particles are illuminated by a light source and detected by a sensor, eliminating the need for manual sampling while ensuring representative and continuous measurement data.
Solution Approach 2:
The patent implements continuous particle size measurement throughout the bulk material processing stream rather than intermittent manual sampling. The measurement device is positioned inline with the material flow, allowing uninterrupted monitoring of particle size distribution, which enables timely detection of process deviations and maintains consistent measurement quality.
2Device complexity
If manual offline sampling is used, then the device complexity is reduced, but the loss of time increases due to delayed error detection
Solution Approach 1:
The patent replaces manual sampling and offline analysis with an automated inline measurement system that continuously monitors particle sizes in real-time. The measurement device detects particle sizes as bulk material flows through the measurement chamber, providing immediate feedback on process quality without the time delays associated with manual sampling and laboratory analysis.
Solution Approach 2:
The patent implements real-time feedback through continuous particle size measurement and data processing. The measurement device provides ongoing information on particle size distribution, allowing operators to immediately detect and correct process deviations, thereby eliminating the time loss associated with delayed error detection in manual sampling systems.
3Productivity
If continuous inline measurement is implemented, then the productivity and measurement precision improve, but the device complexity and loss of energy increase
Solution Approach 1:
The patent employs optical measurement principles rather than complex mechanical sampling and analysis systems. The measurement device uses a light source to illuminate particles and a sensor to detect their characteristics, providing continuous particle size data through a relatively simple optical mechanism that integrates seamlessly into the bulk material processing stream.
4Measurement precision
If continuous inline measurement is implemented, then the measurement precision improves, but the use of energy increases
Solution Approach 1:
The patent uses optical energy rather than significant mechanical energy for measurement. The light source provides illumination for particle detection, and the sensor converts optical signals to electrical signals for processing. This optical measurement approach requires minimal energy compared to mechanical sampling and analysis systems, maintaining high measurement precision while minimizing energy consumption.
Data Source
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AI summary
Inline particle size analyzer (4) for continuously measuring the particle size of a continuously extracted sample (3) of a bulk material (2) ground by a mill (1), in particular a free-flowing bulk material (2) ground by a mill (1), the inline particle size analyzer (4) comprising: a main line (10), a secondary line (20), and a particle measuring device (40) provided in the secondary line channel (23), which is designed for continuously measuring the particle size of the extracted sample (3), with a sample inlet (41) and with a sample outlet (42) arranged downstream of the particle measuring device (40) and fluidically connected to the particle measuring device (40), wherein the sample extraction unit has an adjustable sample inlet,whose inlet opening size is adjustable between a first inlet opening size and a second inlet opening size different from the first inlet opening size, wherein the second inlet opening size is larger than the first inlet opening size; mill, method for controlling a mill, computer program product and non-transitory computer-readable storage medium.