In-line Rheological Sensor for Real-time Viscosity Monitoring
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Solution Overview
Problem
Current methods for monitoring rheological properties in liquid processing systems, especially for non-Newtonian fluids, are time-consuming, require skilled operators, and result in sample loss, and do not provide real-time accurate data for process control, especially when raw material changes occur frequently.
Innovation Solution
A device that uses a power law model to determine the consistency (K) and flow behavior index (n) of liquids in-line, utilizing two-point measurements and sensors to calculate these parameters in real-time, allowing for continuous monitoring and improved process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional viscometers or rheometers are used to monitor viscosity, then changes in the final product can be detected, but the monitoring is time-consuming and requires skilled operators
Solution Approach 1:
The patent replaces traditional mechanical viscometers and rheometers with an electronic measurement system that uses sensors to detect pressure differential and flow rate, then calculates viscosity electronically. This substitution eliminates the need for manual sample extraction and laboratory analysis, enabling continuous real-time monitoring without requiring skilled operators to interpret results.
2Measurement precision
If samples are extracted for viscosity analysis, then product quality can be monitored, but sample loss occurs and hygienic applications require discarding tested samples
Solution Approach 1:
The measurement system is installed directly within the liquid processing pipeline, allowing the system to monitor its own output continuously without requiring external sample extraction. The sensors measure pressure differential and flow rate in-line, eliminating the need to withdraw samples that would otherwise be discarded for hygienic reasons.
3Measurement precision
If rheological parameters are measured for non-Newtonian fluids, then product properties can be monitored, but the measurements are insufficient because viscosity depends on shear rate caused by processing equipment
Solution Approach 1:
The system measures viscosity at multiple different flow rates (which correspond to different shear rates) and uses these variations to calculate both the consistency index K and flow behavior index n for power law models. By capturing how viscosity changes with flow rate, the system obtains complete rheological characterization that accounts for shear rate dependency, enabling accurate prediction of product behavior under different processing conditions.
4Ease of operation
If traditional monitoring methods are used, then operator control is maintained, but accurate real-time data for process control is not provided
Solution Approach 1:
The system continuously measures pressure differential and flow rate, calculates viscosity in real-time, and provides immediate feedback to the control system. This enables automatic process adjustments based on actual product properties, improving productivity by eliminating delays between measurement and control action while maintaining operator oversight through the user interface.
Data Source
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AI summary
A method for a liquid processing system is provided. The method comprises the steps of providing a first flow of liquid through a predetermined geometry (R 1 , L 1 ); determining the flow rate (Q 1 ) through said geometry and the pressure drop (Δp 1 ) across said geometry (R 1 , L 1 ) for said first flow of liquid; providing a second flow of liquid through a predetermined geometry (R 2 , L 2 ); determining the flow rate (Q 2 ) through said geometry and the pressure drop (Δp 2 ) across said geometry (R 2 , L 2 ) for said second flow of liquid; and calculating the consistency (K) and the flow behaviour index (n) for said liquid using said geometries (R 1 , R 2 , L 1 , L 2 ) and the flow rate (Q1, Q2) and pressure drop (Δp 1 , Δp 2 ) for said first and second flow of liquid.