Inline Sampling Compartment for Bulk Density Measurement
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Solution Overview
Problem
Conventional methods for measuring bulk density in spray drying processes are cumbersome, time-consuming, and imprecise, requiring significant interruption to the process and involving manual handling of heavy equipment, which results in inaccurate and non-representative samples.
Innovation Solution
The implementation of an inline sampling method and device that allows material to flow through a sampling compartment, where a column is built up and a fixed volume is removed for precise weighing, minimizing process interruption and reducing sampling errors by avoiding the introduction of disturbances in the material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sampling method is used (stopping flow, disconnecting container, manual scooping), then sample collection is achieved, but process interruption time increases and measurement precision deteriorates
Solution Approach 1:
The sampling compartment is positioned in the material flow path before the collection container, allowing a column of material to build up in advance. When sampling is needed, the compartment can be quickly rotated to discharge the pre-formed column into the container, eliminating the need for time-consuming manual scooping and reducing process interruption.
Solution Approach 2:
The sampling function is extracted from the collection container and placed in a separate, dedicated sampling compartment. This allows the sampling operation to be performed independently without requiring disconnection or movement of the heavy collection container, enabling faster and more precise sampling.
2Ease of operation
If conventional sampling method is used (manual scooping from disconnected container), then sample collection is achieved, but device complexity increases and ease of operation deteriorates
Solution Approach 1:
The sampling compartment is designed to rotate, transforming the static sampling structure into a dynamic one. This rotation mechanism allows the compartment to be positioned in the flow path for sampling and then discharged into the container, simplifying the overall operation by eliminating manual scooping and container disconnection.
Solution Approach 2:
The sampling compartment combines multiple functions: it serves as both the sampling location and the discharge mechanism. By integrating the sampling and discharge functions into a single rotating component, the system reduces operational complexity while improving ease of use.
3Measurement precision
If conventional sampling method is used (scooping material from container), then sample collection is achieved, but measurement precision deteriorates due to tamping and settling
Solution Approach 1:
The material column is allowed to build up naturally in the sampling compartment under controlled flow conditions before sampling. This preliminary formation of the column ensures the material is in a representative, undisturbed state, free from tamping and settling that occur during manual scooping operations.
Solution Approach 2:
The manual scooping mechanism is replaced with a controlled discharge system where the sampling compartment rotates to release the material column. This substitution eliminates the mechanical disturbances of hand scooping while maintaining precise control over the sampling process.
Data Source
AI summary
Methods and devices for inline sampling of a bulk material, such as a powder, are provided. The material's bulk density can be determined from samples drawn using methods and devices described herein. One embodiment of a method of sampling a material allows the material to flow through a sampling compartment, closes off the flow of material below the sampling compartment, builds up a column of material through the sampling compartment, shifts the sampling compartment to remove a slice of material in the column, and places the slice of material into a sample container. A device for sampling a material is provided in another embodiment. The device includes an inlet, an outlet aligned with the inlet, and a sample collector. The sample collector can include at least one through hole and be configured to move such that the at least one through hole can be moved into and out of alignment with the inlet and the outlet.