Chemical Industry Solutions

The powder section of the chemical industry is a large category that contains a wide range of applications including coal, graphite, powered coatings, chemical catalysts and plastics to name a few. The processes in the chemical industry include size reduction, classifying, spray drying, mixing, blending, drying, grinding, filling, and separation. These processes involve producing, fine powders, liquids or slurries. There are several techniques and literally thousands of applications but they all have one critical property in common, and that is particle size.

In the United States, the chemical industry is a $450 billion a year business that is one of the largest employers with over a million employees. Today in these difficult economic times, the chemical industry faces more challenges than ever. With lackluster demands and continuous rising costs, it's now more important than ever for manufacturers to seek more efficient and stable processes. In achieving the best economic advantage, the chemical industry is searching to:

• Maximize yield and minimize energy use
• Simplify plant operation
• Initialize Automatic Process Control

In this section

	Industry overview Particle size is a critical parameter in the chemical industry. Knowing the particle size of the powder in real time gives chemical manufacturers a step ahead on their process. Particle size is one of the key variables in controlling process equipment such as grinding devices and classifiers in the chemical industry. Ultimately, accurate particle size information can help any chemical process run more smoothly and Malvern has years of experience with on-line particle sizing in hundreds of chemical process lines. .
	Industry concerns Chemical manufacturers realize that they must stay ahead of their competition. This accounts, in part, for the growth over the years in searching out new process solutions to improve process performance. Using real time particle size analysis is one way chemical manufacturers like you are reducing their energy costs and maximizing their yields. .
	Malvern chemical analyzers and automation Complete in-line particle characterization systems, including providing the particle size distribution, appropriate to the requirements of the chemical industry and unit operations.
	Case studies - For more information, see:
	Relating Granulator Speed to Particle Size A customized solutions expert in fine chemicals and semi-conductor operations installed a Parsum probe below their spray dryer and determined that they could control particle size by changing the RPM of their rotating disk granulator.
	Milling Overloading Reduced by Process Understanding. A pharmaceutical company's milling overload problems were reduced by getting a better understanding of their comminution process.
	Optimizing Milling for Pilot Drug Trials A pharmaceutical manufacturer experienced difficulties in optimizing their comminution systems for pilot drug trials. The challenges arose from dealing with changes in particle size specifications and differences between products.
	Reducing the Milling Process Start-up Times See the start-up benefits that on-line particle size analysis has over off-line analysis in comminution circuits.
	Mineral Milling Optimization Many plants have to re-specify their comminution parameters for new product specifications. For example, a minerals manufacturer in Canada receives three or four requests each year to change the product.
	On-Line Sizing During Milling Reduces Loss of In-Spec Product During Product-Changeover A cement mill needed to minimize the amount of 'in-spec' product sent to 'off-spec' collection bins. Using Insitec systems they were able to better determine when the comminution product changed from a transitionary state to the final specification.
	Predicting Screen Failure in a Screen Milling Environment A Japanese manufacturer of agrochemicals was able to detect when the milling screen would break during comminution. The company is now working on ways of predicting screen failure with the aim of replacing the screens only when absolutely necessary.