Sturtevant, a manufacturer of material processing equipment, is using an Insitec on-line particle size analyser from Malvern Instruments to tailor solutions for specific customer applications.
Sturtevant has been using the Insitec on the development of an optimised mill for processing Trona, a reactive sorbent for the removal of harmful pollutants from flue gas.
'On-line particle size analysis provides maximum process insight with minimal manual input,' said Steve Coulombe, product manager, Sturtevant.
'This knowledge accelerates and improves product and process optimisation, allowing us to provide a better service to customers.
'The solution developed for Trona milling is a great example of what can be achieved and has potential towards becoming a standard within the power plant industry,' he added.
Injecting Trona (sodium sesquicarbonate) directly into a flue gas stream removes sulphur trioxide ahead of desulphurisation, reducing the likelihood of 'blue plumes' and decreasing levels of acid rain.
At-plant trials with a Simpactor 6HD impact mill and an Insitec on-line particle size analyser show that the mill can handle feeds of varying coarseness, producing a consistently fine material that minimises injection levels.
Low levels of spent sorbent in the fly ash waste permit its incorporation in cement making the stream a saleable by-product, or reduce waste disposal costs.
'Trials at the power plant were successful,' said Alon Vaisman, who led the trial from the Malvern side.
'With on-line particle size analysis in place, the customer could see how the process was performing in real time and the consistency of the product.
'The solution minimises both emissions and operating costs,' he added.
The Insitec is a laser diffraction system for the on or in-line measurement of particles in the size range 0.1 to 1,000 microns.
Capable of delivering four complete particle size distributions per second it can track even rapidly changing processes in real time, providing a data stream for optimal process control.
Fully automated analysis from sample extraction through to measurement minimises manual input.
