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Ian Haley
Outline of Modules 1
The Basics
Part 1 - What is Particle Size
Part 2 - Presentation Method and Weighting Part 3 The Importance of Shape Part 4 Count-based Measurement
Outline of Modules
Statistics and Data Handling
Part 8 - Understanding the Mean, Median and Mode of a Particle System
Part 9 Precision and Accuracy Part 10 Correlating FBRM to Other Data Part 11 - Channel Grouping and Statistics Part 12 Signal Aliasing
Ian Haley
Particle Size
Many particles are complex Three-dimensional objects. Yet we want to represent their size by just one number.
Particle size = 326 m But how was it calculated? And what does this tell us about the particle and others like it?
Size
What is the size of this particle?
10mm
Size
But what is the size of this particle?
50mm
10mm
By volume
By surface area
By settling velocity
By sieve analysis
Ian Haley
By volume
By surface area
By settling velocity
By sieve analysis
The physical property we use has a major effect on the way in which particle size is calculated. 10
11
Mean diameter
Number-based dist. = 55.0 m Area-based dist. = 99.1 m
Diameter: 10m
Diameter: 100m
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Equal Volumes
Number-based dist. = 10.1 m Area-based dist. = 18.2 m
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A Total number Diameter Surface area Total volume 1 particle 100 m 31,400 m2 524,000 m3
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Number
8 6 4 2 0 10 100 1 1
Diameter (m)
1E+06 1E+06
Volume Distribution
Volume (m3)
10m
Diameter: 100m
Diameter (m)
15
Diameter (m)
1E+06 1E+06
Volume (m3)
Diameter: 100m
5,220
0E+00 10 100
Diameter (m)
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Number
1000
10m
1
200
0 10 100
Diameter (m)
1E+06 1E+06
Volume Distribution
Volume (m3)
100m
10
100
Diameter (m)
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Number
1000
10m
Diameter (m)
1E+06 1E+06
Volume Distribution
1044050
Volume (m3)
100m
100m
Diameter (m)
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Initial particle system Total number Total surface area Total volume Number mean diameter Volume moment mean diameter 27 particles 847,000 m2 14,140,000 m3 100.0 m 100.0 m
After breakage of one particle 1026 particles 1,161,800 m3 14,140,000 m3 12.3 m 96.7 m
Relative change 3700% increase 37% increase 0% 87.7% decrease 3.3% decrease
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Probability (%)
All three distributions have the same mean but significantly different distributions!
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Mean = 12.2 m
Mean = 15.2 m
The size distribution is presented as: a) Total number b) Total length (based on projected area) c) Total surface area d) Total volume of particles within each size classification
Number Distribution
Length Distribution
Area Distribution
Volume Distribution
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FBRM No Weight
Emphasizes changes to the fine (small) end of the distribution
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Time=90 min
Time=180 min
Time=90 min
Time=180 min
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#/s 50-1000 m
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In this example, the squareweighted distribution does not detect small changes in the concentration of fine material.
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However, the squareweighted distribution is very sensitive to the amount of coarse material.
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Fines
Coarse
30
The physical property selected to characterize size of the particles, for example:
Diameter Chord length Projected area Surface area Volume Settling rate Response of electrical, optical, or acoustical field Number-based distribution Length-based distribution Area-based distribution Volume-based distribution Scale (log vs. linear) Channel grouping Count vs. normalized
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- Property
Sphere having the same settling rate Sphere fitting through the same-size sieve aperture Sphere producing a similar diffraction pattern No shape assumption - Chord length distribution Calculation Number Length Area Volume
Ian Haley
24.7 m
100 m
The surface area of the needle is 60% greater than that of the sphere.
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5 m 18 m
50 m
Calculate the diameter of a sphere with the same volume as the cylinder
A spherical equivalent diameter based on volume (VSED)
How does the VSED relate to the length and width of this particle? The surface area of the cylinder is 73% greater than the sphere! A needle will handle and flow differently to a sphere!
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24 m
100 m
Calculate the diameter of a sphere with the same volume as the cylinder
A spherical equivalent diameter based on volume (VSED)
The cylinder has doubled in length; but the diameter of the equivalent
sphere has only increased by 33%
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YES!
NO!
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Run 5
Run 5
Run 6
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The further particle shape moves away from a sphere, the less accurate
instruments based on a spherical equivalent model become.
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Ian Haley
Conversely.
Some instruments derive their data by measuring particles individually The data is sensitive to changes in population The distribution is expressed as size vs number These are count-based techniques
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size regions
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Ian Haley
Focused beam
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PVM image illustrating the view from the FBRM Probe Window
Probe detects pulses of Backscattered light And records measured Chord Lengths
This core patented technology is called Focused Beam Reflectance Measurement [FBRM]
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Outbound:
Return:
Note: Particles between the window and the measuring zone will reflect light that will be detected as background signal. This will significantly degrade the signalto-noise ratio.
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10 9 8 7 6 5 4 3 2 1
Counts
1 2 3 4 5 6 7 8 9 10 Chordlength [a.u.]
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Ian Haley
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Sphere
Sphere
Needle Needle
Platelet
Platelet
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60
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Ruf, A., Worlitschek, J, Mazzotti, M. Modeling and Experimental Analysis of PSD Measurements through FBRM. Part & Part Syst Characterization. 17 (4), 167-179, 2001.
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Ruf, A., Worlitschek, J, Mazzotti, M. Modeling and Experimental Analysis of PSD Measurements through FBRM. Part & Part Syst Characterization. 17 (4), 167-179, 2001.
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Ruf, A., Worlitschek, J, Mazzotti, M. Modeling and Experimental Analysis of PSD Measurements through FBRM. Part & Part Syst Characterization. 17 (4), 167-179, 2001.
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Distributions
How do we define a collection of particles of differing size and/or shape?
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500
400
Count/sec
300
200
100
0
1 3 5 7 15 Dimension 25 40 65
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Part 7: An Outline of Different Particle Characterisation Methods and the Effect of Particle Shape
Ian Haley
PVM Technology
Particle Video Microscope Microscope quality images, in-process and in real time
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t=10mins
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t=25mins
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t=45mins
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Normalized distribution
Distribution Assuming all
particles are spheres
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Laser Diffraction
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80
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What instrument permits us to monitor this critical parameter? Is sampling or safety an issue?
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25m
50m
25m
32m
Mean
= 28m (9+25+25+32+50)/5
Median = 25m (50% greater than this size; 50% smaller than this size) Mode = 25m (most common occurrence)
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25m
50m
25m
80m
32m
120m
Mean = 49m (9+25+25+34+50+80+120)/7 Median = 32m (50% greater than this size;50% smaller than this size) Mode = 25m (most common occurrence)
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25m
50m
25m
32m
5m 5m
5m
5m
Mean
= 18m (5+5+5+5+9+25+25+34+50)/9
Median = 9m (50% greater this size;50% smaller than this size) Mode = 5m (most common occurrence)
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Mean: +75%
Median: +22% 89
Mean: -35%
Median: -64%
Mean: -40%
PVM
Median: -67%
90
Mean: -40%
Median: -67%
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Conclusions
The mean, median and mode are all averages used to characterize
particle systems
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Ian Haley
Accuracy
- The ability of an instrument to yield results that are as
close as possible to the absolute properties possessed by a sample.
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Accuracy
When discussing accuracy it is important to specify:
- The absolute property in question. (e.g. absolute chord length, true
diameter, etc)
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96
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95% Confidence
Interval = +/-5.0%
8.0
Measured Value
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True Mean = 4.0 Measured Mean = 4.0 95% Confidence Interval = +/50%
8.0
Measured Value
Time (minutes)
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True Mean = 4.0 Measured Mean = 6.0 95% Confidence Interval = +/5.0%
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Measured Value
100
Why is this true? Any given statistic is primarily the function some specific region of the chord length distribution. Some regions may have more or less counts depending on the particle system.
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Sensitivity Defined
The ability to of the instrument to respond to a real change in the process parameter of interest. The higher the sensitivity, the smaller the real change in process the instrument is able to detect.
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Is this noise?
Or is there insufficient information to provide a signal of sufficient stability (precision)?
8.0
Measured Value
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104
2 sec.
5 sec.
10 sec. 1 min.
5 min.
1000
10.0%
100
10
1.0%
0.1% 1000
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1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, SMD = 1 sec Step Change in Concentration
1500
1500 1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, SMD = 10 sec Step Change in Concentration
1500 1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, SMD = 60 sec Step Change in Concentration
1500 1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, SMD = 120 sec Step Change in Concentration
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1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, Average = 10 Step Change in Concentration
1500
1500 1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, Average = 30 Step Change in Concentration
1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, Average = 60 Step Change in Concentration
1500
1500 1450 1400 1350 1300 1250 1200 -1.0 0.0 1.0 2.0 3.0 4.0 + 1.0 % by weight, Average = 120 Step Change in Concentration
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Ian Haley
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220
200
180
160
140
120
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350
Extrapolating LD data
300
250
Mean (D 4,3)
200
150
100
50
Time (s)
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Optimization of Pharmaceutical Batch Crystallization for Filtration and scale-up Brian K. Johnson, Carol Szeto, Omar Davidson and Art Andrews AIChE Annual Meeting, Los Angeles, CA, November 1997
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15
200 rpm
10
100 rpm
5
Ian Haley
How to Choose the Right Channel Grouping for Your Work & the Affect of the Chosen Grouping on Statistics
Channel Grouping*
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Channel A Definition
A bin with a specific upper and lower limit in microns. Counts with a chord length measured between those limits are put in that specific channel.
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FBRM logarithmic scales are calculated from the linear scale channel
data.
The choice between linear and log scales will change your statistics
Many other particle size instruments use hardware based on a log
scale. They do not provide statistics based on a linear scale.
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Logarithmic Grouping
Each channel width is progressively wider than the
preceding channel width.
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Linear Grouping
All channels have equal width. The distance between the channel midpoints is also equal. Equal resolution is provided throughout the distribution. Each channel has an equal probability of a count being
placed in it.
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Logarithmic Grouping
100-Channel Log Grouping (same data set as linear):
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Linear Grouping
100-Channel Linear Grouping (same data set as log):
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50th Percentile
90th Percentile
12.525th Percentile
500.00 m
776.72 m 250.00 m 12.525% 87.475% 204.35 m
499.96 m
778.21 m 249.96 m 12.53% 87.47% 204.72 m
0.008%
0.2% 0.016% 0.04% 0.006% 0.18%
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Channel Grouping
Rules of Thumb:
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In this example most of the particle counts are less than 100m with an
increase in the number of particles in this range over time
Using a linear scale one-tenth of the channels are for particles less than
100m not very sensitive to change in this region
Using a logarithmic scale two-thirds of the channels are for particles less than
100m much more sensitive to change in this region*
Count
200
800
1000
Count
10 Dimension (m)
100
1000
In this example most of the particle counts are greater than 100m with an
increase in the number of particles in this range over time
Using a linear scale nine-tenths of the channels are for particles greater than
100m very sensitive to change in this region
Using a logarithmic scale one-third of the channels are for particles greater
than 100m much less sensitive to change in this region
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Log scale
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Linear scale
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Linear scale
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Ian Haley
Signal Aliasing
Process Variable
Time (minutes)
141
Time (minutes)
142
Process Variable
Time (minutes)
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Process Variable
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Time (minutes)
144
Process Variable
c) Averaging = 10 measurements
10.0
15.0
20.0
25.0
30.0
35.0
40.0
Time (minutes)
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Part 13: Practical Aspects of Using FBRM: Probe Location and Orientation
Ian Haley
REACTOR TOP
LENGTH
375MM 14.75IN
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Probe Orientation
- Extremes in individual particle density (very low or very high in relation to the carrying solution). Lower solids concentration. Lower carrying solution viscosity. A larger median particle size. A wider particle size distribution. Greater particle shape deviation from a sphere.
Probe Orientation
Smaller differences between particle density and carrying solution density. Higher solids concentration (dispersed-phase liquid). A smaller median particle size. A narrower particle size distribution. Smaller differences between average particle shape and a sphere.
5 7
pipe upstream of the probe - Offers the most uniformly random and representative presentation of the dispersed phase to the measurement zone - Keeps the probe window residue-free
2 4 FLOW 3
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MIXER
PROBE TIP
BAFFLE
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top of the reactor, locate it near the leading side of the baffle
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Mixer Rotation
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Ian Haley
Initial instrument OQ
Uses PVC Reference Standard & Fixed Beaker Stand Unique PVC Standard prepared and measured on new instrument in
Lasentec factory
Standard delivered with instrument to customer Standard measured and compared with factory reference data
Continued instrument PQ
Uses PVC Reference Standard & Fixed Beaker Stand Measure Standard at regular intervals and compare with factory reference
data
158
PVC Measurement:
at the Factory at startup (IQ/OQ) after 3 months (PQ)
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quality of data
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