PROCESSING QUALITY CONTROL
Accurate
All images courtesy Malvern.
PARTICLE SIZE REDUCTION techniques
– for instance, crushing, grinding, milling,
pulverisation, and micronisation – are
well established and widely used in the
minerals processing industry. Particle
size is critical because it is an important
variable that often affects product
performance. Particle size reduction
is hugely energy intensive (the power
requirement increases exponentially with
decreasing particle size), but the effect
of over-sized material is very detrimental
to product quality. It is therefore very
important to monitor the extent of particle
size reduction carefully.
On-line particle size measurement is
an increasingly used strategy within the
Figure 1: Particle size measurements for talc at different dilution ratios
72
monitoring
cuts costs
Malvern Instruments Ltd’s David Pugh and Jim
Scotland explain why using on-line particle sizing for
wet processes is advantageous
industry to achieve particle size precision.
Conventionally, off-line analytical
protocols have been applied, which
remain important, particularly for quality
control (QC) applications. However, for
process control and optimisation, the
continuous stream of data produced
by on-line measurement is highly
advantageous. Real-time analysis
significantly enhances process knowledge
and opens up a route to fully automated
process control.
Laser diffraction techniques are widely
used for on-line particle size analyses,
which are now available for dry and wet,
rather than only dry, applications. This
is good news for minerals processors
as wet size reduction operations are
commonplace. Now, even highly
concentrated, sticky, hot slurries can be
measured using analysers such as the
Insitec LPS, a fully automated system
specifically developed for industrial use.
Analysing wet processes
Laser diffraction technology is a rapid,
non-destructive, and condition insensitive
analytical technique for processing.
It consistently generates volumetric
particle size data without the need for
external calibration. A limitation of
laser diffraction systems is the need for
samples to be relatively transparent,
as penetration of light through the
liquid media is essential. Particle size is
determined from the diffraction pattern
produced as light passing through the
suspension is scattered by the particles
within it. If particle concentration is very
high then light will not pass through; in
addition, multiple scattering effects will
pose problems in interpreting the final
diffraction pattern. Many applications will
therefore require dilution of samples.
On-line system design
To benefit fully from an on-line system,
processors need an automated, reliable
unit that can be integrated with existing
process control platforms. Maintenance
November 2006
 QUALITY CONTROL PROCESSING

and operational inputs must be minimal.
Sampling, any sample preparation or
dilution, and analysis, must all be fully
automated. Automated particle size
analysis using laser diffraction is well
established, with off-line systems that
require only push button operation, in
widespread use.
Sampling
For streams that flow easily, a by-
pass loop with automated valving is
an appropriate sampling option. A
representative fraction of the main stream
is routed continuously through to dilution
and analysis, with flow from the analyser
fed back into the process line.
With slurries that are more
concentrated, a continuously flowing
design may not be possible. At high
solids contents, the small bore pipe
work and associated valves at low flow
rate are prone to blockage and would
compromise continuous operation. For
such systems Malvern Instruments has
developed a rotating valve that extracts
the slurry in slugs. The bore of the ball
valve and the speed of rotation are two
of the variables that can be tuned to
deliver the required amount of sample
for dilution. This system avoids blockages
even under the most testing of conditions.
a patented diluent-driven design with
no moving parts based on a coaxial
venturi. It delivers highly representative
dilution. Dilution ratio is controlled by
the number of stages and the internal
nozzle dimensions. Both diluters are self-
cleaning and are engineered to minimise
diluent usage for any application.
On-line analysis in calcium
carbonate production
There are many applications for calcium
carbonate, and each demands different
particle size distributions. A growing
market is the paper industry, where
calcium carbonate is used to produce
a shiny and smooth finish. Very fine
particles of calcium carbonate fill the
gaps between paper fibres giving the
paper a surface gloss. This application
requires powders with a Dv(50) of
approximately 1µ or a Dv(90) of
approximately 2µ. These are produced
in wet milling processes, often in multiple
line facilities. On-line particle size
analysis can provide useful data when
installed in either of two locations.
At the exit of each line, on-line analysis
using manual or automated control
Figure 2: Final product particle size data for calcium carbonate
strategies can monitor final product
quality, ensuring specifications are met
consistently. This approach improves
quality and reduces materials/energy
wastage, but is capital intensive if a
dedicated analyser is installed for each
line.
Alternatively, an on-line feed line
analyser can be installed. Variations in
feed often result in poor product quality
if milling parameters are not properly
adjusted. Here a feed forward control
strategy can be adopted. The common
feed to all the mills is measured, and
the parameters of each unit are varied,
keeping the material produced within
specification. This approach results
in significant process efficiency gains
from relatively low capital investment.
However, it does require significant
up-front effort to establish the required
correlations and does not offer the same
degree of confidence in terms of final
product quality monitoring.
Contributors: David Pugh (process
marketing manager) and Jim Scotland
(European process manager), Malvern
Instruments Ltd

Sample dilution/preparation
Sample preparation can take various
forms. Dilution, the most common
requirement, is ideally carried out using
a compatible solvent, which is recycled
back to the process, in order to minimise
waste treatment costs. Care is needed to
avoid dilution shock, where the nature
of the particles is altered by a sudden
reduction in concentration, so the dilution
process may be carried out in several
stages. All dilution
must be conducted
in a representative
manner.
Insitec LPS
uses a pre- and
cascade diluter in
combination. The
pre-diluter is a glass
tank with pneumatic
stirrer and level
sensors for dilution
factor control. The
cascade diluter is

November 2006 73