Abstract
In the present research work, an electrical resistance tomography (ERT) system is utilized as a means for real-time fault detection and diagnosis (FDD) during a reactive crystallization process. The calcium carbonate crystallization is part of the carbon capture and utilization scheme where process monitoring and malfunction diagnostics strategies are presented. The graphical logic representation of the fault tree analysis methodology is used to develop the system failure states. The measurement consistency due to the use of a single electrode from a set of ERT electrodes for malfunction identification is experimentally and quantitatively investigated based on the sensor sensitivity and standard deviation criteria. Electrical current measurements are employed to develop a LabVIEW-based process automation program by using the process-specific knowledge and historical process data. Averaged electrical current is correlated to the mechanical failure of the stirrer through standard deviation evaluation, and slopes of the measured data are used to monitor the pump and concentrations status. The performance of the implemented methodology for detecting the induced faults and abnormalities is tested at different operating conditions, and a basic signal-based alarming technique is developed.
Highlights
Crystallization has a significant impact on the final characteristics of particulate systems and plays an essential role in the manufacturing stream of various industrial processes such as agricultural chemicals, cosmetics, pigments, food ingredients, and the highly-regulated active pharmaceutical ingredients (APIs)
A major unfavorable aspect of the reactive crystallization processes is the potential to generate a high degree of supersaturation, which increases the possibility of crystal aggregation and agglomeration [4]
Fault detection in the cryscrystallization process of was investigated by utilizing a single sensor of tallization process of CaCO was investigated by utilizing a single sensor of an an electrical electrical resistance resistancetomography tomographysystem
Summary
Crystallization has a significant impact on the final characteristics of particulate systems and plays an essential role in the manufacturing stream of various industrial processes such as agricultural chemicals, cosmetics, pigments, food ingredients, and the highly-regulated active pharmaceutical ingredients (APIs). Real-time anomaly detection and monitoring the functioning stability of the physical–chemical components during crystallization processes are crucial to ensure a reliable operation, minimize performance variations, and, improve product quality and production volumes. There has been recent growth in need of chemical industries for precipitation processes, which lies in the extreme requirement of energy-efficient operation, process intensification, and sustainability [1]. In comparison to cooling and evaporative crystallization, precipitation processes, known as reactive crystallization, can be implemented at a reduced level of thermal energy [2]. A major unfavorable aspect of the reactive crystallization processes is the potential to generate a high degree of supersaturation, which increases the possibility of crystal aggregation and agglomeration [4]
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