Aug 16 2005
Product consistency and mill control at HIM, specialists in processing hard minerals to fine powders, have been transformed following the installation of a Malvern Insitec on-line particle size analyzer and a Hosokawa Micron classifier.
At HIM’s ball mill facility in Derbyshire, UK, the continuous stream of particle size data produced by the Insitec is used to automatically control classifier speed, with operators simply inputting the established set points for the required grade of silica powder. Product consistency is now exemplary and customer satisfaction and confidence has dramatically increased. The effectiveness of process control has been significantly enhanced and the manpower required to run the unit substantially reduced.
As a result of the improvements in product quality, bulk transfer of the silica powder to the customer is now acceptable; before the changes the product was shipped in paper sacks on pallets. In addition, HIM’s ability to consistently produce a more closely specified product has allowed its customer to access new markets. When off-line sieve analysis was used, the product was specified only in terms of a certain fraction greater than 53 microns, but other parameters are measured continuously, and controlled.
"We now operate 24/7,” says managing director Kelvin Rhodes. "Our throughput has increased by around 60% and we require significantly less manual input in terms of analytical effort. The Insitec system has been highly reliable and maintenance requirements are low, despite operating in a vibrating and harsh environment."
The Insitec is an industrially robust solution for on-line particle size measurement, based on laser diffraction technology. Continuous operation of the Insitec at HIM has been characterized by high reliability and minimal maintenance requirements. The data produced have afforded plant management greater process insight, facilitated plant optimization, particularly during commissioning, and provided HIM with a platform for further process development.
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