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The application of an ultrasound tomography (UST) system in a liquid‐phase reactive crystallization process is reported. The measurement system was applied to precipitated calcium carbonate processing where liquid Na2CO3 was added to a CaCl2 solution. Analysis of the measured sound velocity signals from the experiments demonstrated a clear change in the average time‐of‐flight (TOF) delay signals, indicating the detection of the onset of the precipitation and the formation of the microcrystalline stable phase of calcite. Moreover, spatial‐centric TOF signals from the tomographic images were associated with an increase in the overall suspension density. These findings highlight the potential of the UST measurement system for studying the solidification phenomenon during CaCO3 precipitation. [ABSTRACT FROM AUTHOR]

In the current research work, electrical resistance tomography (ERT) was employed for monitoring and visualization of crystallization processes. A first-of-its-kind MATLAB-based interactive GUI application "ERT-Vis" is presented. Two case studies involving varied crystallization methods were undertaken. The experiments were designed and performed involving calcium carbonate reactive (precipitative) crystallization for the high conductivity solution-solute media, and the cooling crystallization of sucrose representing the lower conductivity solution–solute combination. The software successfully provided key insights regarding the process in both crystallization systems. It could detect and separate the solid concentration distributions in the low as well as high conductivity solutions using the visual analytics tools provided. The performance and utility of the software were studied using a software evaluation case study involving domain experts. Participant feedback indicated that ERT-Vis software helps by reconstructing images instantaneously, interactively visualizing, and evaluating the output of the crystallization process monitoring data. [ABSTRACT FROM AUTHOR]

This research work presents a feasibility study to demonstrate the application of Electrical Resistance Tomography and transmission-based Ultrasound Computed Tomography for monitoring and control of micronsized calcium carbonate crystallization process. Herein, precipitated calcium carbonate production is bind to a carbon dioxide absorption process based on hollow-fiber membrane contactor. ERT acquisition system is equipped with 16 electrodes with operating frequency of 156 KHz and image capturing frame rate of 2 Hz. The ultrasound tomography equipment consists of 32 piezoelectric transducers at a frequency of 200 KHz. These sensors are sensitive to changes in suspension density and conductivity. Furthermore, a process control framework is developed by utilizing the fundamental relations of settling velocity of particles. Through simulations in the LabVIEW software, the PI-based feedback controller demonstrates a possibility of setpoint tracking by manipulating the control variable (mixing speed). Upon further investigations, this approach can be used as a multi-dimensional process analytical technology tool for quality assurance and malfunction diagnosis when out-of-specification events occur throughout the entire process. [ABSTRACT FROM AUTHOR]

In this work, an ultrasound computed tomography (USCT) system was employed to investigate the fast-kinetic reactive crystallization process of calcium carbonate. USCT measurements and reconstruction provided key insights into the bulk particle distribution inside the stirred tank reactor and could be used to estimate the settling rate and settling time of the particles. To establish the utility of the USCT system for dynamical crystallization processes, first, the experimental imaging tasks were carried out with the stirred solid beads, as well as the feeding and stirring of the CaCO3 crystals. The feeding region, the mixing process, and the particles settling time could be detected from USCT data. Reactive crystallization experiments for CO2 capture were then conducted. Moreover, there was further potential for quantitative characterization of the suspension density in this process. USCT-based reconstructions were investigated for several experimental scenarios and operating conditions. This study demonstrates a real-time monitoring and fault detection application of USCT for reactive crystallization processes. As a robust noninvasive and nonintrusive tool, real-time signal analysis and reconstruction can be beneficial in the development of monitoring and control systems with real-world applications for crystallization processes. A diverse range of experimental studies shown here demonstrate the versatility of the USCT system in process application, hoping to unlock the commercial and industrial utility of the USCT devices. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]