Macrostickies Detection via Fluorescence Image Analysis
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Solution Overview
Problem
Current methods for monitoring macrostickies in pulp slurries are laborious and lack continuous monitoring techniques, limiting the efficient use of recycled pulp and real-time process adjustments in the papermaking industry.
Innovation Solution
A method and apparatus utilizing fluorescence image analysis with a hydrophobic dye, such as Nile Red, to detect and quantify macrostickies in real-time within a flowing pulp stream, allowing for on-line characterization of macroscopic contaminants without filtering or sample preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional laborious methods are used to quantify macrostickies, then measurement precision can be achieved, but productivity is severely reduced due to the inability to perform continuous monitoring
Solution Approach 1:
The patent replaces manual laborious quantification methods with an automated optical detection system. The system uses a camera to capture images of macrostickies in the pulp slurry and employs image processing algorithms to automatically quantify them, eliminating the need for manual sampling and analysis while enabling continuous monitoring.
Solution Approach 2:
The patent creates visual copies (images) of macrostickies using a camera system. By capturing images of the macrostickies in their natural state within the pulp slurry and processing these images computationally, the system enables rapid quantification without physical manipulation or labor-intensive procedures.
2Productivity
If real-time monitoring of macrostickies is implemented, then process efficiency is improved, but device complexity increases due to the need for specialized detection equipment
Solution Approach 1:
The patent introduces an intermediary substance (fluorescent dye) that binds to macrostickies and emits fluorescent light when excited by UV light. This intermediary enables the detection system to visualize and quantify macrostickies that would otherwise be difficult to detect, while the overall system remains relatively simple using common components like UV lamps and fluorescent markers.
3Productivity
If macrostickies are monitored in flowing pulp slurry, then continuous monitoring is achieved, but measurement precision is challenged by the dynamic and complex matrix of the slurry
Solution Approach 1:
The fluorescent dye acts as an intermediary that selectively binds to macrostickies and provides a distinct fluorescent signal. This mediator enhances the contrast between macrostickies and the surrounding pulp slurry matrix, enabling precise detection and quantification even in the complex, dynamic environment of flowing slurry.
Solution Approach 2:
The patent exploits fluorescent color changes to detect macrostickies. When the fluorescent dye bound to macrostickies is excited by UV light, it emits characteristic fluorescent light that can be distinguished from the background slurry. This optical property enables precise identification and quantification of macrostickies in real-time within the flowing 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 continuous, real-time monitoring of macrostickies, enhancing process efficiency by allowing for better utilization of recycled pulp and enabling immediate adjustments to prevent equipment deposits and improve paper quality.
Implementation Method 1
injecting a hydrophobic dye into the flow of the aqueous pulp slurry, the injecting performed so that the hydrophobic dye interacts with the contaminants, the interaction causing a change in fluorescent emission
Implementation Method 2
The method uses fluorescence image analysis to identify macrostickies
Data Source
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AI summary
A challenge in using recycled material in the papermaking process is the presence of hydrophobic organics with adhesive properties commonly known as stickies. Hydrophobic agglomerates can result in spots or defects in the final paper product or deposit on papermaking equipment resulting in poor runnability and downtime. Technologies for monitoring and controlling microstickies exist. However, a need exists for a technique to rapidly determine the size and content of macrostickies (diameter > 100 microns) in recycled pulp process streams. The present invention is a device and method to perform real-time macrostickies and/or any visible hydrophobic particle analysis in an aqueous medium. Using the present invention, furnish quality can be monitored and treatment performance can be monitored and controlled. The technique is based on fluorescence image analysis to identify and count sticky particles as well as measure their size