In order to operate plants safely and effectively, information on the flow behavior in the apparatus is required, which can be observed by detecting the phases (e.g. lactose crystals in liquid whey). Plant operation and construction require this data in real time, ideally recorded inline, i.e. directly at the point of action, e.g. from the center of the apparatus.

The problem is that this data is rarely available. Only basic parameters such as temperature or pressure are available, but these cannot describe the complex flow behavior in the apparatus.

As a result, the system operator operates his system blindly or on the basis of experience and empirical estimates. The resulting product, e.g. the crystal, does not have the necessary quality and has to be reworked in further process steps at great expense. In the event of malfunctions during operation, the causes can often only be guessed at, making it impossible to quickly develop an effective solution. Plant manufacturers can usually only compensate for these process uncertainties by making generous safety allowances when designing their equipment in order to ensure unrestricted operation of the equipment.

The bottom line: from an economic point of view, there is potential for savings in terms of investment and operating costs, while on the ecological side there is a lower demand for energy and input materials.

It is precisely at this point that the IPS team will record the flow behavior in the apparatus. This is made possible by providing the real-time parameter shape of the disperse phase. This includes, for example, the particle size distribution, the particle shape and the phase fraction.

Currently available sensors are rare, especially inline versions, and cannot provide the shape of the disperse phase with sufficient temporal and spatial resolution.

IPS will eliminate this deficiency with its ARIMOS product line, which will be developed during the two-year project period and will be commercially distributed after the subsequent spin-off. Key milestones for the founding team are therefore

• Development of an optical imaging sensor(ARIMOS) with a unique measuring principle and patent-protected design, which images the shape of the disperse phase with a high contrast ratio and constant imaging scale.
• Design of the sensor for demanding operating conditions and potentially explosive atmospheres.
• Development of analysis software(ARIMOS analyze), which examines the shape of the disperse phase autonomously and in real time.
• Development of a process prediction(ARIMOS smart), which assesses and predicts the process quality by linking process data and image data, including the occurrence of malfunctions.
• Development of a process control(ARIMOS control), which realizes a direct control of the fluid dynamics on the basis of the process information obtained from the image data.

IPS thus generates a high benefit for plant operation and design. Unplanned downtimes are reduced and processes can be operated more safely, efficiently and therefore more sustainably. The systems run with reduced energy and reactant consumption. In addition, the equipment can be designed with lower safety margins and achieve a shorter time-to-market.

The IPS - Inline Process Solutions project (FKZ: 03EFTRP033) is funded by the Federal Ministry for Economic Affairs and Climate Protection and the European Social Fund as part of the EXIST program.

Contact person for the project: Dr.-Ing Anne Friebel

Webpage: https://inline-process.solutions/