Continuous Making of Complex Fluids Inline Rheology Monitoring and Data-Based Control

Continuous Making of Complex Fluids Inline Rheology Monitoring and Data-based Control

Dr.-Ing. Francesc Corominas (P&G)

25 January 2017

Workshop – Tackling the Future of Plant Operation – Frankfurt

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 636942 Procter & Gamble

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2 Complex liquids and rheology profiles

Rheology profile is critical for the product and the process Rheology profile depends on RMs, Process, Temp, kinetics, …

3 Filling the small compartments of the pouch. Technical challenge.

• Sustainability, efficiency, performance : Nil water, high activity detergent - > high viscosity Non-Newtonian Complex fluid

• Production scale : -> need to fill the compartments very rapidly

• Liquid must go into the cavity, otherwise pouch leaks and generates scrap/waste -> Extremely tight operating window: liquid rheology is critical In-line sensors and Process Control system

1- We need reliable sensors to measure the properties of the liquids in-line 2- We need an integrated control to keep the liquid properties on target

Perfumes Polymers Opacifier Dyes Solvent Structurant

Continuous Mixing and Dispersion process

Output (variables to act on): Input (variables to sense) : Integrated Structurant / solvent level Liquid Rheology curve Control

5 Continuous formulation of complex liquids

Project objective :

Control of the liquid rheology in the continuous mixing process, by having an affordable in-line rheology sensor and an integrated control.

Desired achievements at the end of the project : Installation and Demonstration in the Pilot Plant. Assessment of the reliability, accuracy and precision. Understand capabilities and limitations. Assessment of the robustness of the sensor under potential fouling / walls build-up. Robustness of the sensor under different liquids. Demonstration of the Integrated process control, based on in-line rheology measurement. Expected impact

Increase product quality Short term Increase productivity Reduction of scrap and waste

Superior products Mid term Speed to market Holistic superior environmental position

7 P&G Pilot Plant

8 Study of the system dynamics

• Input : step in structurant flow rate • Output : HSR viscosity of the product

9 Study of the system dynamics

• Input : step in structurant flow rate • Output : LSR off-line viscosity of the product

10 Study of the system dynamics

11 In-line rheology sensor. Preliminary results.

12 Achievements first 24 months

• The sensor device requirements and specifications were very well defined during month 1 in the project. Also the pipe dimensions.

• The liquids relevant for this case study have been fully characterized in terms of their rheological behavior and ultrasound propagation.

• The time response and the dynamics of the continuous mixing process/system has been assessed and quantified through several tests in the pilot plant.

• The dynamics and time response of the system are being analyzed and used in order to design the right Process Control Strategy (UNICA)

• We have already done trials with the prototype of the in-line rheology sensor from TNO.

13 Thank you!

Dr.–Ing. Francesc Corominas

Email: [email protected]

Website : www.consens-spire.eu

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