PCM结晶监测系统在印度的全自动釜式蔗糖结晶生产线投入使用
1应用背景
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">蔗糖作为食糖的主要成分，由一分子葡萄糖的半缩醛羟基与一分子果糖的半缩醛羟基缩合脱水而成，在食品及调味品等行业中有着十分重要的用途。蔗糖普遍存在于植物界的叶、花、茎、种子及果实中，甘蔗、甜菜及槭树汁中的蔗糖含量尤为丰富。
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">蔗糖生产
font-size:10.5000pt;mso-font-kerning:1.0000pt;">目前
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">大多
font-size:10.5000pt;mso-font-kerning:1.0000pt;">采用蒸发结晶工艺。随着结晶
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mso-font-kerning:1.0000pt;">过程
font-size:10.5000pt;mso-font-kerning:1.0000pt;">的进行
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">糖浆粘度不断变大，使得结晶受扩散控制，
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">从而
font-size:10.5000pt;mso-font-kerning:1.0000pt;">晶体生长缓慢
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">；
font-size:10.5000pt;mso-font-kerning:1.0000pt;">过饱和度的积累
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">加之扩散
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">受
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">，致使
font-size:10.5000pt;mso-font-kerning:1.0000pt;">体系中易发生二次成核
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mso-font-kerning:1.0000pt;">现象
font-size:10.5000pt;mso-font-kerning:1.0000pt;">，导致终产品颗粒度分布大
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">、
font-size:10.5000pt;mso-font-kerning:1.0000pt;">细粉多
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">；
font-size:10.5000pt;mso-font-kerning:1.0000pt;">大量的二次成核现象
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mso-font-kerning:1.0000pt;">，
font-size:10.5000pt;mso-font-kerning:1.0000pt;">又导致体系粘度快速上升，进一步阻碍了结晶物料向晶面的扩散，使得体系小晶核进一步增加，粘度进一步增大，终导致产品收率降低。正是基于以上难点，
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">蔗糖的
font-size:10.5000pt;mso-font-kerning:1.0000pt;">结晶工艺控制尤为重要，如何获得高质量的
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">蔗糖
font-size:10.5000pt;mso-font-kerning:1.0000pt;">晶体
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">越来越受到蔗糖
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">终
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mso-font-kerning:1.0000pt;">产物
font-size:10.5000pt;mso-font-kerning:1.0000pt;">的颗粒大小
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">和粒度
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">性
font-size:10.5000pt;mso-font-kerning:1.0000pt;">是
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">衡量
font-size:10.5000pt;mso-font-kerning:1.0000pt;">产品品质的重要指标
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mso-font-kerning:1.0000pt;">。如何提升产品收率、缩短结晶时间、得到粒度均匀的产品、根据下游用户的需求定制目标产品等等，也是蔗糖企业一直在思考的问题。
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">PCM结晶
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mso-font-kerning:1.0000pt;">监测
font-size:10.5000pt;mso-font-kerning:1.0000pt;">系统能实现对
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mso-font-kerning:1.0000pt;">蔗糖
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">，
font-size:10.5000pt;mso-font-kerning:1.0000pt;">并可根据监控结果实时调整工艺
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">过程
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">，
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">从而得到
font-size:10.5000pt;mso-font-kerning:1.0000pt;">高质量
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">的
font-size:10.5000pt;mso-font-kerning:1.0000pt;">晶体产品
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mso-font-kerning:1.0000pt;">。PCM结晶监测系统
font-size:10.5000pt;mso-font-kerning:1.0000pt;">是快速实现定制客户指定颗粒度晶体产品的有效手段。
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2芬兰Pixact公司PCM结晶监测系统在Balrampur Chini Mills Ltd投入使用
font-size:10.5000pt;mso-font-kerning:1.0000pt;">半自动反应釜
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">始终无法摆脱
font-size:10.5000pt;mso-font-kerning:1.0000pt;">手动操作的弊端，印度制糖公司Balrampur Chini Mills Ltd管理层
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">做出
font-size:10.5000pt;mso-font-kerning:1.0000pt;">了一个重要且有远见的决定
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">：
font-size:10.5000pt;mso-font-kerning:1.0000pt;">他们
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">将位于
font-size:10.5000pt;mso-font-kerning:1.0000pt;">阿尔瓦尔
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">的
font-size:10.5000pt;mso-font-kerning:1.0000pt;">一个80吨的蔗糖间歇煮糖罐
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">改造成了
font-size:10.5000pt;mso-font-kerning:1.0000pt;">一套现代化的全自动釜式蔗糖结晶生产线
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">这套
font-size:10.5000pt;mso-font-kerning:1.0000pt;">全自动釜式蔗糖结晶生产线
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">上安装了一套芬兰Pixact公司的PCM结晶监测系统，用于对
font-size:10.5000pt;mso-font-kerning:1.0000pt;">煮糖过程进行监控
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">并
font-size:10.5000pt;mso-font-kerning:1.0000pt;">达到自动控制的目的
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">。PCM结晶监测系统可以
font-size:10.5000pt;mso-font-kerning:1.0000pt;">对蔗糖结晶过程的图像和颗粒度进行实时监测和分析，
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">PCM结晶监测系统
font-size:10.5000pt;mso-font-kerning:1.0000pt;">可以提供高分辨晶体图像、晶体颗粒度（Dv10、Dv50、Dv90等）、晶体颗粒数量、 晶体尺寸变异系数（CV）、MA 、晶体生长速率、晶体尺寸分布、晶体生长过程等重要信息。
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">这是
font-size:10.5000pt;mso-font-kerning:1.0000pt;">印度
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">套
font-size:10.5000pt;mso-font-kerning:1.0000pt;">基于智能算法的现代化的全自动釜式蔗糖结晶生产线，可以在没有人工干预的情况下自动控制整个反应釜的操作
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">IPROINDIA公司
font-size:10.5000pt;mso-font-kerning:1.0000pt;">创造性设计和严谨的工程科学的产物
font-size:10.5000pt;mso-font-kerning:1.0000pt;">。只需要输入几个参数，如
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">煮糖类型
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mso-font-kerning:1.0000pt;">、
font-size:10.5000pt;mso-font-kerning:1.0000pt;">终点锤度和出料液位，之后
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">的
font-size:10.5000pt;mso-font-kerning:1.0000pt;">釜操作
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mso-font-kerning:1.0000pt;">都
font-size:10.5000pt;mso-font-kerning:1.0000pt;">是全自动的，直到釜卸料
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mso-font-kerning:1.0000pt;">、
font-size:10.5000pt;mso-font-kerning:1.0000pt;">并为下一次煮糖流程做好准备。经过验证，整套系统
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">不仅煮糖时间明显缩短，排放和能耗也明显改善，给
font-size:10.5000pt;mso-font-kerning:1.0000pt;">印度制糖公司Balrampur Chini Mills Ltd
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">带来了的收益！
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图2 印度制糖公司Balrampur Chini Mills Ltd煮糖车间现场
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3芬兰Pixact公司PCM结晶监测系统简介
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">芬兰Pixact公司PCM结晶监测系统采用透射光原理设计，由仪器探头末端发出激光透过测试样品，由探头另一端的高分辨率CCD相机接收透射光并对颗粒成像，对于微小颗粒也可以清晰成像，并保证图像质量。利用功能强大的图像算法，分析图像上每一个颗粒的轮廓，从而得到等效颗粒尺寸、颗粒尺寸分布、颗粒尺寸变化趋势、颗粒形态、颗粒径长比、颗粒生长速率等数据。
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">PCM结晶监测系统专为在线结晶工艺过程而设计。它能在结晶过程、制剂过程等研发的各个阶段提供实时在线的晶体图像信息，这些直观的图像信息将大大缩短研发过程，并能使研发人员在原位环境中了解颗粒间的相互作用，对于结晶工艺控制起到非常关键的作用。
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mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">PCM结晶监测系统的测试结果除了高分辨率的晶体图像，还包括：自动生成的晶体数量变化趋势、晶体尺寸变化趋势、晶体颗粒度变化趋势等多方面的数据，这些数据可以帮助客户准确判断何时加入晶种以及避免二次成核等生产问题。
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4 结论
font-size:10.5000pt;mso-font-kerning:1.0000pt;">PCM结晶监测系统可以很好地监控
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mso-font-kerning:1.0000pt;">蔗糖
font-size:10.5000pt;mso-font-kerning:1.0000pt;">的结晶过程。
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">高分辨结晶过程
font-size:10.5000pt;mso-font-kerning:1.0000pt;">图像可以给出结晶釜中晶体形态的直观信息，有助于理解结晶机理、优化结晶工艺、及时发现二次成核、并进行工艺调整。晶体数量曲线可以监控晶浆中的晶体数量，此信息对于晶种的加入时机判断、晶种数量的确定非常有帮助；在不加晶种的情况下，PCM结晶监测系统给出的自发成核晶体数量可以用于判断
mso-hansi-font-family:Arial;mso-bidi-font-family:Arial;font-size:10.5000pt;
mso-font-kerning:1.0000pt;">补料时间点
font-size:10.5000pt;mso-font-kerning:1.0000pt;">，这对于终的晶体产品颗粒度有至关重要的作用。PCM结晶监测系统实时给出的晶体颗粒度信息，可以帮助我们判断晶体的生长情况、晶体尺寸是否满足生产要求、还可以帮助我们判断出料时间点。
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">PCM结晶监测系统可用于优化
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mso-font-kerning:1.0000pt;">蔗糖
font-size:10.5000pt;mso-font-kerning:1.0000pt;">的结晶过程，速度快，效率高，便于快速发现和快速解决工艺问题，有助于提高产品质量的稳定性。同时，PCM结晶监测系统还可用于监控原料中的杂质、优化加晶种方案、控制二次成核、确定补料时间、监控晶体颗粒度分布宽度、调整晶体颗粒度、判定出料时间等。功能性糖醇行业的多个都是我们的客户。
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font-size:10.5000pt;mso-font-kerning:1.0000pt;">北京海菲尔格科技有限公司是芬兰Pixact、美国Remspec、德国ITA INSTRUMENTS、德国TEWS ELEKTRONIK、德国HENTSCHEL、德国proMtec Theisen等品牌在中国市场的授权代理，从事国内的市场推广、应用指导、安装调试、技术支持和售后服务等，在大程度上满足不同客户和应用的需求。
