Accurate Measurement of Fertilizer with the CAMSIZER

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Accurate Measurement of Fertilizer with the CAMSIZER

  1. 1. CAMSIZER CAMSIZER® Particle Size and Shape using Dynamic Image Analysis ISO 13322-2 conform HORIBA Scientific & Retsch Technology© Retsch Technology 2011 - 1 CAMSIZER Fertilizer Webinar November 16th 2011 Host: Ian Treviranus, HORIBA Instruments Speaker: Dipl.-Ing. Gert Beckmann Retsch Technology GmbH
  2. 2. Content * CAMSIZER measurement principle * Intelligent matching of sieve results * SGN, UI and other calculations * Q & A session Device 1. Measuring Principle 2. Measurement Results Application 3. CAMSIZER Applications© Retsch Technology 2011 - 2 in the Fertilizer Industry 4. Competing Measuring Methods
  3. 3. History Retsch Technology Development of CAMSIZER XT for agglomerating powders Development of Development 1µm-3000µm CAMSIZER & of AutoSampler System CRYSTALSIZER 2003 2011 1999 2001 2002 2006© Retsch Technology 2011 - 3 New shape functions Improvement of CAMSIZER® Announcement of of CAMSIZER, with AutoHeight, LED technology, first Online-Installations Software, improved resolution, sharpness and contrast Particle size analyzers in Europe
  4. 4. Comparison between Static  Dynamic Image Analysis© Retsch Technology 2011 - 4 ISO 13322-1 ISO 13322-2
  5. 5. Content Device 1. Measuring Principle - Two Camera-System - Resolution 2. Measurement Results Application 3. CAMSIZER Applications© Retsch Technology 2011 - 5 in the Fertilizer Industry 4. Competing Measuring Methods
  6. 6. Measuring Principle Two-Camera-System m Zoo c Basi© Retsch Technology 2011 - 6 Basic-Camera Zoom-Camera
  7. 7. Measuring Principle Resolution CCD - Basic CCD - Zoom Detection of particles One pixel is element of a projection when at least half of the pixel is covered.© Retsch Technology 2011 - 7
  8. 8. Measuring Principle One Camera Setup Dynamic Range: xmin to 50 • xmin© Retsch Technology 2011 - 8 Drawback: tight dynamic range
  9. 9. Measuring Principle CAMSIZER Principle (Two Cameras) Dynamic Factor:© Retsch Technology 2011 - 9 Advantages • Precise full-frame images • Wide dynamic range: 30µm to 30mm
  10. 10. Content Device 1. Measuring Principle 2. Measurement Results - Size - Shape Application© Retsch Technology 2011 - 10 3. CAMSIZER Applications in the Fertilizer Industry 4. Competing Measuring Methods
  11. 11. Measurement Results Particle Size© Retsch Technology 2011 - 11 What is the size of this particle?
  12. 12. Measuring Principle: Sieving Stick Sphere© Retsch Technology 2011 - 12 Coin
  13. 13. Visualization Cumulative distribution 4% 2% Q3 [%] 3g 10% 6g 15 g 15% 90 22.5 g 150 g 80 32% 70 48 g 60 50© Retsch Technology 2011 - 13 20% 40 30 g 30 10% 20 15 g 4% 10 3% 6g 4.5 g 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  14. 14. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 14 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  15. 15. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 15 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  16. 16. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 16 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  17. 17. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 17 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  18. 18. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 18 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  19. 19. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 19 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  20. 20. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 20 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  21. 21. Visualization Cumulative distribution Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 50 50© Retsch Technology 2011 - 21 40 40 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 Particle size x[µm]
  22. 22. Visualization Visualisierung Cumulative distribution & Fractions Q3 [%] p3 [%] 90 90 80 80 70 70 60 60 Particles < 330 µm Q3(50 ) 50© Retsch Technology 2011 - 22 40 Particles < 250 µm 40 Q3(36) 30 30 20 20 10 10 45 50 63 100 140 250 500 1000 2000 4000 6000 250 µm 330 µm Particle size x[µm]
  23. 23. Measurement Results Particle Size xc min xarea xFe max “width” “diameter over “length” projection surface” A xc min xFe max© Retsch Technology 2011 - 23 CAMSIZER results are compatible xarea with A‘ = A sieve analysis
  24. 24. Measurement Results Comparison of Size Definitions xc min  xArea  xFe max Q3 [%] Sample A_Basic_0.2%_xc_min_001.rdf Sample A_Basic_0.2%_x_area_001.rdf Sample A_Basic_0.2%_xFemax_001.rdf 80 70 60 50 40© Retsch Technology 2011 - 24 30 20 10 0 0.2 0.4 0.6 1 2 [mm] x x[mm] different different size definitions results
  25. 25. Measurement Results Reproducibility© Retsch Technology 2011 - 25 Calibration with traceable standard => Absolute accuracy
  26. 26. Calibration Results Whitehouse Standard XX030© Retsch Technology 2011 - 26
  27. 27. Features Maintenance-Free by Venturi-Flushing© Retsch Technology 2011 - 27
  28. 28. Content Device 1. Measuring Principle 2. Measurement Results Application 3. CAMSIZER Applications in the Fertilizer Industry© Retsch Technology 2011 - 28 4. Competing Measuring Methods
  29. 29. Areas of Application Places of Installation • laboratories • next to manufacturing line • optimized quality control of product and process • research institutes / universities Examples of Applications • fertilizer© Retsch Technology 2011 - 29 • salt • crop protection • pharmaceuticals • food (human and animals) • •
  30. 30. © Retsch Technology 2011 - 30 Features Quality Control
  31. 31. Specific Fertilizer Features© Retsch Technology 2011 - 31 UI and SGN values (Literature) *100
  32. 32. Specific Fertilizer Features SGN and UI values also with CAMSIZER© Retsch Technology 2011 - 32
  33. 33. Applications - Fertilizer CAMSIZER-Advantages Fertilizer Analysis of size and shape of© Retsch Technology 2011 - 33 broken granulated coated fertilizers
  34. 34. Applications – Fertilizer Different Fertilizer Product Types, Different Production Methods, as well as Different Sizes and Shapes© Retsch Technology 2011 - 34
  35. 35. Sampling and Sample Splitting Sample Quantity in Mass or Volume ISO 13322-1 in Relation to the Particle Size© Retsch Technology 2011 - 35 A Sufficient Sample Quantity is Based on the Number of Particles
  36. 36. Sampling and Sample Splitting Separation of fine and coarse particles Separation happens during - Transport processes (container, train and truck) - Feeding processes (funnels, vibration feeders, belts) - and Storage (bulk pile, silo)© Retsch Technology 2011 - 36
  37. 37. Separation of fine and coarse particles Separation happens because of different sizes© Retsch Technology 2011 - 37 Particles having Particles with different sizes similar sizes keep separate homogenety in mix
  38. 38. Sampling and Sample Splitting Separation of fine and coarse particles Segregation (separation by size) happens during - Filling processes (silo) - Feeding processes (bulk pile) - Accumulation of fines in the middle of the pile© Retsch Technology 2011 - 38
  39. 39. Applications – Fertilizer How to attach small „Dust“ Particles to the larger Granules to get a „better“ Product? Fertilizer producer coats the granules with petrochemical oil and amine to bind the dust to the granules for better handling to avoid accumulation of dust Large Dust Large Granule Granule Agglomerate with Coating© Retsch Technology 2011 - 39 Dust sticks to particle because of the Coating
  40. 40. Applications - Fertilizer Only complete Fertilizing provides good Nutrition Plant availability Optimum soil condition Ch© Retsch Technology 2011 - 40 al k / Anything else Ca lc iu is wasted money m en og and tr ni pollution 2nd fertilizing of our environment 1st fertilizing id ric ac ho po p t os as h ph
  41. 41. Applications – Fertilizer A German Fertilizer Producer is mining and producing K Cl, Mg SO4 and K SO4© Retsch Technology 2011 - 41 Before 2000 => Sieve analysis 0.05 – 2.5 mm After 2000 => CAMSIZER analysis
  42. 42. Applications – Fertilizer© Retsch Technology 2011 - 42 Shaft Mining of Potash K Cl
  43. 43. Applications – Fertilizer© Retsch Technology 2011 - 43 Handling of Potash K Cl
  44. 44. Bulk Blending Companies and Farmers want the Same Size of the Components Ch© Retsch Technology 2011 - 44 al k / Ca lc iu m en og tr ni 2nd fertilizing 1st fertilizing id ric ac ho po p t os as h ph
  45. 45. Applications – Fertilizer Fertilizer in the Silo© Retsch Technology 2011 - 45
  46. 46. Applications – Fertilizer Railcar Loading© Retsch Technology 2011 - 46
  47. 47. Applications – Fertilizer Urea Fertilizer (also for AdBlue / BlueTec)© Retsch Technology 2011 - 47 OC(NH2)2
  48. 48. Prilling Applications – Fertilizer Prilling Wheel Prilling = Multiple Core Encapsulation© Retsch Technology 2011 - 48
  49. 49. Applications – Fertilizer Fluidized Bed Granulation© Retsch Technology 2011 - 49 Top-Spray Bottom-Spray Tangential-Spray
  50. 50. Applications – Fertilizer Urea Agglomerates© Retsch Technology 2011 - 50
  51. 51. Applications - Fertilizer CAMSIZER for Fertilizer© Retsch Technology 2011 - 52
  52. 52. Applications – Fertilizer Previous Size Measurement System© Retsch Technology 2011 - 53
  53. 53. Applications - Fertilizer Previous Roundness Measurement System© Retsch Technology 2011 - 54
  54. 54. Applications - Fertilizer CAMSIZER Test Fertilizer© Retsch Technology 2011 - 55
  55. 55. Applications - Fertilizer Sample Taking Fertilizer not ive tat© Retsch Technology 2011 - 56 en res rep with spoon from bag
  56. 56. Applications - Fertilizer Extreme Segregation because of Bimodal Size© Retsch Technology 2011 - 57
  57. 57. Sampling and Sample Splitting Sample Splitting© Retsch Technology 2011 - 58
  58. 58. Sampling and Sample Splitting Sample Splitting not Re© Retsch Technology 2011 - 59 pr ive es tat en en ta res t iv e rep
  59. 59. Sampling and Sample Splitting Sample Splitting tive enta Repres© Retsch Technology 2011 - 60
  60. 60. Sampling and Sample Splitting Sample Splitting© Retsch Technology 2011 - 61
  61. 61. Applications - Fertilizer Sample Splitting Fertilizer Mix Riffle© Retsch Technology 2011 - 62 Splitter Re pr es en tat ive
  62. 62. Applications - Fertilizer Mixture of Fertilizers Sample Sample Sample© Retsch Technology 2011 - 63 Blue = bimodal sample Green = monomodal Poly S Red = 3-modal Mixture
  63. 63. Applications - Fertilizer 3-Size Mixture© Retsch Technology 2011 - 64
  64. 64. Applications - Fertilizer Improved Product Fertilizer Sample Sample Sample© Retsch Technology 2011 - 65 Blue = monomodal Poly S Green = “1.5”-modal Urea + Phosphate Red = “1.5”- modal Mixture of 3 products
  65. 65. Slow Release Applications – Fertilizer Fertilizer Particulates • Urea Core • Sulfur Layer • Polymer Coating Urea Urea Core Core + Sulfur layer Outer Polymer Coating© Retsch Technology 2011 - 66 Inner Sulfur Coating Urea Nutrient Core Urea Core + Sulfur layer + Polymer Coating
  66. 66. Applications – Pharmaceuticals Coating Layer Thickness Urea Pellets are a solid round form of nitrogen fertilizer. The individual pellets are almost spherical with diameters usually between 1000µm and 3000μm, sometimes 5000µm.© Retsch Technology 2011 - 67 Coatings can be measured with an accuracy of 2µm layer coating thickness
  67. 67. Applications – Fertilizer Problems during Fluid Bed Processing Outer External Polymer Coating Inner Sulfur Coating Urea Nutrient Core Particles stick together during the coating and drying© Retsch Technology 2011 - 68
  68. 68. Applications – Fertilizer Type and amount of Time diagram of Salt Content during Interval Fertilizing fertilizer is additional fluid fertilizing two times a week dependent on the soil content, the water quality, the type of plant, and the developing process of the specific plant, Time diagram of Salt Content after single Depot Fertilizing© Retsch Technology 2011 - 69 basic fertilizing of standard soil 30% – 60% of nutrition application can be solved with depot fertilizer
  69. 69. Slow Release Applications – Fertilizer Fertilizer Particulates • NPK + Traces Core • Polymer Resin Layer • “Glue” Layer NPK+ NPK+ Core Core + Polymer Resin Layer Outer „Glue“ Coating© Retsch Technology 2011 - 70 Inner Polymer Resin Coating NPK Nutrient Core NPK+ Core + Polymer Resin Layer + Glue Coating Layer
  70. 70. Measurement Results Particle Shape • Breadth-/ Length- xc min ratio xFe max P • Roundness A© Retsch Technology 2011 - 71 r2 • Symmetry C r1 A convex • Convexity A real
  71. 71. Measurement Results Optical Process Control analysis for size and shape© Retsch Technology 2011 - 72
  72. 72. Measurement Results Urea with Granular Potash Amounts of urea beads and pressed /crushed potash granules in a mixture Q3 [%] AK_22,15g_0,3%_BZ_LB_n Ü_xc_min_001.rdf IA_22,15g_0,3%_BZ_LB_n Ü_mit Aerosil_xc_min_001.rdf A 90 IA + AK_je 22,15g_0,3%_BZ_LB_n Ü_als Mischung_xc_min_001.rdf B A+B B 80 B A 70 60© Retsch Technology 2011 - 73 50 40 A 30 20 10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 b/l
  73. 73. Measurement Results Urea with Granular Potash CAMSIZER can find the mixing ratio of components of Urea Beads and Granular Potash Q3 (round particles) = 32.8%© Retsch Technology 2011 - 74 xc min xFe max 67.2%
  74. 74. Applications - Urea Traditional Measurement Pellets • Sieve analysis 1.0 – 3.0 mm© Retsch Technology 2011 - 75 • Vibrating plate and weighting (amount of broken particles)
  75. 75. CAMSIZER – Advantages Applications - Urea Measuring Broken Beads good product r r broken particle TP-WS 0525_Probe1_BZ_0.5%_xc_min_001.rdf Q3 [%] TP-WS 0525_Probe2_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe3_BZ_0.5%_xc_min_001.rdf 22 TP-WS 0525_Probe4_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe5_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe6_BZ_0.5%_xc_min_001.rdf 21 TP-WS 0525_Probe7_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe8_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe9_BZ_0.5%_xc_min_001.rdf TP-WS 0525_Probe10_BZ_0.5%_xc_min_001.rdf 20% broken 20© Retsch Technology 2011 - 76 19 18 17.4% broken 17 16 15 r1 r2 0.948 0.949 0.950 0.951 0.952 Symm r  Symmetry ~ min 1  r   2
  76. 76. Applications – Fertilizer© Retsch Technology 2011 - 77 Spreading Fertilizer Particulates
  77. 77. Spreading Applications – Fertilizer Fertilizer Particulates Larger pellets can be tubule height (mm) thrown further than smaller pellets The exact size is important to get controlled spreading machine tractor tractor track 1 track 2 conditions© Retsch Technology 2011 - 78 tubule height (mm) tractor tractor track 1 track 2
  78. 78. Applications – Fertilizer Calcium Phosphate Q3 [%] 90 80 70 Sample1_xc_min_001.rdf Sample2_xc_min_002.rdf 60 Sample3_xc_min_004.rdf Sample4_xc_min_007.rdf 50 Sample5_xc_min_002.rdf Sample6_xc_min_002.rdf Sample7_xc_min_001.rdf 40 Sample8_xc_min_001.rdf 30© Retsch Technology 2011 - 79 20 10 0 0.5 1.0 1.5 2.0 2.5 3.0 xc_min [mm] Samples 1-8, following samples show identical results (split samples ?) 1=7, 3=5, 2=8, 4=6
  79. 79. Applications – Fertilizer Calcium Phosphate Q3 [%] Sampl e1_xc_min_001.rdf 90 Sampl e2_xc_min_002.rdf Sampl e3_xc_min_004.rdf 80 Sampl e4_xc_min_007.rdf 70 60 50 40© Retsch Technology 2011 - 80 30 20 10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 b/l Samples 1-4 b/l = aspec ratio, 2 groups “1+4” and “2+3”
  80. 80. Applications – Fertilizer Calcium Phosphate Q3 [%] 90 80 70 Sample4_xc_min_004.rdf Sample4_xc_min_003.rdf 60 Sample4_xc_min_005.rdf Sample4_xc_min_006.rdf 50 Sample4_xc_min_007.rdf 40© Retsch Technology 2011 - 81 30 20 10 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 xc_min [mm] Repeatability: 5 consecutive measurements
  81. 81. Applications – Fertilizer Sieve Correlation Calcium Phosphate passing [%] 90 SAMPLE 1_xc_min_001.rdf 80 SAMPLE 1_xc_min_002.rdf SAMPLE 1_xc_min_003.rdf 70 Phosphate Sample 1.ref 60 50 40 30© Retsch Technology 2011 - 82 20 10 0 200 400 600 xc_min [µm] CAMSIZER sieve correlation using Elementary Fitting one single sieve class and entire sample
  82. 82. Competing Measuring Methods Competing Measuring Methods© Retsch Technology 2011 - 83
  83. 83. Competing Measuring Methods Comparison of Methods: Sieving Advantages • robust and industrial-suited • easy handling • references available from user Worn out sieves© Retsch Technology 2011 - 84 • high amount of time and work Disadvantages • low resolution, small number of investigatable classes • limited sample amount • no shape analysis possible
  84. 84. Applications - Urea Sieving problems 1. Move 2. Sliding friction F1 3. Static friction F2© Retsch Technology 2011 - 85 Q3 [%] q3 [%/mm] 5454_PT100_xc_min_008.rdf 90 5454_random_xc_min_009.rdf 450 5454_Huntsman-sieve.ref 80 Round 400 70 particles are 350 60 captured 300 50 without 250 40 rerelease 200 30 150 20 100 10 50 0 0 0.5 0.6 0.7 0.8 0.9 1.0 xc_min [mm]
  85. 85. Competing Measuring Methods Fitting of CAMSIZER result to Sieving© Retsch Technology 2011 - 86 fitted result CAMSIZER-measurement x (red) to sieving * (blue)
  86. 86. Digitale Imaging  Sieving Q3 [%] Sample A_BZ_0.2%_xc_min_001.rdf Sample A_.ref 80 70 60 50 40 30 20 10 0 0.2 0.4 0.6 1 x [mm]© Retsch Technology 2011 - 87
  87. 87. Digital Imaging  Sieving Cubes / Angular Particles Q3 [%] 90 80 RT669_3993_Z_LB_05%_xc_min_001.rdf 70 RT669_RT_3993.ref 60 50 40 30 20 10 0 200 400 600 800 x [µm]© Retsch Technology 2011 - 88
  88. 88. Competing Measuring Methods Fitting of CAMSIZER result to Sieving© Retsch Technology 2011 - 89 fitted result CAMSIZER-measurement x (red) to sieving * (blue)
  89. 89. Digital Imaging  Sieving New elementary fitting with single (narrow) sieve class and { entire distribution Q3 0.9© Retsch Technology 2011 - 90 0.8 0.7 0.6 0.5 0.4 0.3 Elementary 0.2 - Fitting 0.1 0 1.0 1.5 2.0 2.5 3.0 xc_min [mm]
  90. 90. Digital Imaging  Sieving Q3 Q3 0.9 0.9 0.8 0.8 0.7 Q3 – Fitting 0.7 0.6 0.6 0.5 0.5 0.4 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0 0 1.0 1.5 2.0 2.5 3.0 xc_min [mm] 1.0 1.5 2.0 2.5 3.0 xc_min [mm] Elementary Q3 - Fitting 0.9© Retsch Technology 2011 - 91 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 1.0 1.5 2.0 2.5 3.0 xc_min [mm]
  91. 91. 12 Years CAMSIZER 550 installed Instruments worldwide: Nearly on all continents For many applications/industries: Ammonium phosphate, Bulk blending companies, Crop protection, Dicalcium phosphate, Explosives Fertilizer........© Retsch Technology 2011 - 92
  92. 92. End Thank you for your attention!© Retsch Technology 2011 - 93

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