Online measurement of moisture distribution in pharmaceutical fluidised beds for drying, granulation and coating
Lead Research Organisation:
University of Manchester
Department Name: Electrical and Electronic Engineering
Abstract
Gas-solids fluidised beds are commonly used in the pharmaceutical industry for drying, granulation and coating. Because of the lack of means for online measurement of granule moisture, the fluidised beds are currently operated by trial-and-error, resulting in low operation efficiency (i.e. longer operation time and more energy consumed), and more importantly the product quality cannot be guaranteed. During two recent EPSRC projects (GR/T29383/01, EP/G005702/1), we have made significant progress on fundamental understanding of the complicated gas-solids fluidisation processes and online measurement of granule moisture in fluidised bed dryers, which have been demonstrated on lab-scale fluidised bed dryers both at the University of Manchester (UoM) and in GEA Pharma Systems Ltd and also published in prestigious journals, e.g. AIChE J. In the past 12 months, our EPSRC Follow-on Fund project has allowed the technology to be scaled up from lab dryers to semi-industrial scale dryers and demonstration of the principle of online measurement of granule moisture in semi-industrial scale dryers in an industrial lab environment. This work, in collaboration with GEA and other industrial partners, has generated considerable interest from the pharmaceutical industry, notably AstraZeneca, who has expressed a wish to collaborate on the next stage of development with a view of becoming the first adopter of the technology.
Organisations
- University of Manchester (Lead Research Organisation)
- Beihang University (Collaboration)
- Chinese Academy of Sciences (Collaboration)
- Dalian Institute of Chemical Physics (Collaboration)
- AstraZeneca (United Kingdom) (Project Partner)
- Sherwood Scientific (United Kingdom) (Project Partner)
- UMI3 Ltd (Project Partner)
- GEA Process Engineering NPS Ltd (Project Partner)
People |
ORCID iD |
| Wuqiang Yang (Principal Investigator) |
Publications
Ge R
(2014)
Measurement of particle concentration in a Wurster fluidized bed by electrical capacitance tomography sensors
in AIChE Journal
Haigang Wang (Author)
(2012)
Monitoring fluidised bed coating process with electrical capacitance tomography
Jiamin Ye
(2015)
Image Reconstruction for Electrical Capacitance Tomography Based on Sparse Representation
in IEEE Transactions on Instrumentation and Measurement
Lei Ye (Author)
(2012)
Real-time 3D image reconstruction for ECT
Peng L
(2011)
Evaluation of effect of number of electrodes in ECT sensors on image quality
in IEEE Sensors Journal
Qiu G
(2014)
Investigation of flow hydrodynamics and regime transition in a gas-solids fluidized bed with different riser diameters
in Chemical Engineering Science
Ren Z
(2015)
A Miniature Two-Plate Electrical Capacitance Tomography Sensor
in IEEE Sensors Journal
Rezvanpour A
(2012)
Investigation of droplet distribution in electrohydrodynamic atomization (EHDA) using an ac-based electrical capacitance tomography (ECT) system with an internal-external electrode sensor
in Measurement Science and Technology
| Description | The aim of this research is to apply electrical capacitance tomography (ECT) for online measurement of moisture distribution in pharmaceutical fluidised beds and scale up the application of ECT from a lab-scale fluidised bed to a production-scale fluidised bed. The objective is to optimise the design of the production-scale fluidised bed and to improve operation efficiency of the fluidisation processes. This is the first time that ECT has been scaled-up to a production-scale fluidised bed of 1.0 m in diameter and batch process capacity of 100 kg in a real industrial environment. With a large-scale fluidised bed in a real industrial environment, some key issues on ECT sensor design must be addressed. To validate ECT measurement results, a two-phase flow model has been used to simulate the process in a lab-scale and pilot-scale fluidised bed. The key process parameters include solids concentration and average concentration profiles and frequency spectrum of signal fluctuation obtained by Fast Fourier Transfer (FFT) and multi-level wavelet decomposition in the time domain. The results show different hydrodynamic behaviour of fluidised beds of different scale. The time-averaged parameters from ECT and CFD are compared. Future work on ECT sensor design for large-scale fluidised beds is given in the end of the report. |
| Exploitation Route | Further funding to develop a commercial product with GEA to be used by AstraZenaca. |
| Sectors | Agriculture, Food and Drink,Chemicals,Energy,Environment,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| URL | http://www.eee.manchester.ac.uk/industry/collaborativeprojectswithindustry/visualisationofpharmaceuticalfluidisedbeds/ |
| Description | Our findings have been used in Chinese Academy of Sciences for clean coal combustion, which is important to reduce pollution to the environment. |
| Sector | Energy,Environment |
| Impact Types | Economic |
| Description | Measurement and Optimization of Gas-solid Fluidised Bed Processeses |
| Amount | ¥2,500,000 (CNY) |
| Funding ID | 61320106004 |
| Organisation | National Natural Science Foundation of China |
| Sector | Public |
| Country | China |
| Start | 01/2014 |
| End | 12/2017 |
| Description | Online monitoring of combustion conditions at aero-engine exit by tomography |
| Amount | £12,000 (GBP) |
| Funding ID | 99843 |
| Organisation | The Royal Society |
| Sector | Charity/Non Profit |
| Country | United Kingdom |
| Start | 03/2014 |
| End | 03/2016 |
| Description | Optimisation of methanol-to-olefins fluidised bed reactors by high-temperature electrical capacitance tomography |
| Amount | £102,400 (GBP) |
| Funding ID | 103747 |
| Organisation | The Royal Society |
| Sector | Charity/Non Profit |
| Country | United Kingdom |
| Start | 03/2015 |
| End | 02/2018 |
| Description | Real-time imaging for root canal treatment |
| Amount | £120,000 (GBP) |
| Funding ID | FC00082 |
| Organisation | University of Manchester |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 07/2011 |
| End | 06/2014 |
| Description | Water-cut measurement by a combination of electrical capacitance tomography and RF resonant cavity sensors |
| Amount | £12,000 (GBP) |
| Funding ID | 108029 |
| Organisation | Royal Academy of Engineering |
| Sector | Charity/Non Profit |
| Country | United Kingdom |
| Start | 10/2015 |
| End | 09/2016 |
| Description | Clean coal combustion |
| Organisation | Chinese Academy of Sciences |
| Department | Institute of Engineering Thermophysics |
| Country | China |
| Sector | Academic/University |
| PI Contribution | For clean coal combustion, it is important to optimise the design of circulating fluidised beds. We supplied electrical capacitance tomography (ECT) instrument and worked on image reconstruction algorithms. Two PhD students worked on a collaboration project in Beijing, 3 months each. |
| Collaborator Contribution | Our partner provide test facilities. They worked on modelling of circulating fluidised beds and did experiment using the ECT instrument. |
| Impact | Joint papers have been published on AIChE Journal, IEEE Sensors Journal, IEEE Trans. on Instrumentation and Measurement, Measurement Science and Technology and Powder Technology. |
| Start Year | 2014 |
| Description | Methanol-to-olefins conversion |
| Organisation | Dalian Institute of Chemical Physics |
| Country | China |
| Sector | Private |
| PI Contribution | We supplied electrical capacitance tomography (ECT) instrument and worked on high temperature sensor design and compensation. |
| Collaborator Contribution | They made high-temperature ECT sensors. They contributed methanol-to-oilefins facilities and did experiment. |
| Impact | The research result helped operation of a methanol-to-olefins plant. |
| Start Year | 2012 |
| Description | aero-engine exit imaging |
| Organisation | Beihang University |
| Department | School of Instrument Science and Opto-electronic Engineering |
| Country | China |
| Sector | Academic/University |
| PI Contribution | We work on electrical capacitance tomography for imaging flames. |
| Collaborator Contribution | They worked on TDLS. |
| Impact | We have several joint papers published on IEEE Trans. on Instrumentation and Measurement and other journals. |
| Start Year | 2014 |
| Title | METHODS AND APPARATUS RELATING TO FLUIDISED BEDS |
| Description | A method and apparatus for producing particle density map images of fluidised particles by electrical capacitance tomography (ECT) in a fluidised bed apparatus allows for measuring online the liquid content of fluidised particles during the fluidisation process and for recalibration of the fluidised particle permittivity during fluidisation, allowing for online recalibration of an ECT system when the liquid content of particles changes, such as for fluidised bed drying or granulation processes. Recalibration measurements are made using reference electrodes positioned to measure the capacitance of the densely fluidised particles near the side walls of the fluidised bed. The electrodes of an ECT sensor array may be used to make the recalibration measurements which can be used to provide online liquid content measurement, such as moisture content, for the fluidised particles without stopping fluidisation. The liquid content information may be used for process control. The method may also be used to provide separate images for solids distribution and for total liquid distribution across a plane being imaged. |
| IP Reference | WO2009030876 |
| Protection | Patent granted |
| Year Protection Granted | 2009 |
| Licensed | No |
| Impact | As a result of continuous support from EPSRC, this patent (WO/2009/030876) has been filed by UMIP and licensed to GEA. It covers EU, USA, Australia, China and India. Fluidised beds are commonly used in the pharmaceutical industry. However, they are operated by trial-and-error because of the lack of online tools to measure the process. This patent details how to measure the moisture of particles and the moisture distribution in a fluidised bed by electrical capacitance tomography. The invented ap |
| Title | METHODS AND APPARATUS RELATING TO FLUIDISED BEDS |
| Description | A method and apparatus for producing particle density map images of fluidised particles by electrical capacitance tomography (ECT) in a fluidised bed apparatus allows for measuring online the liquid content of fluidised particles during the fluidisation process and for recalibration of the fluidised particle permittivity during fluidisation, allowing for online recalibration of an ECT system when the liquid content of particles changes, such as for fluidised bed drying or granulation processes. Recalibration measurements are made using reference electrodes positioned to measure the capacitance of the densely fluidised particles near the side walls of the fluidised bed. The electrodes of an ECT sensor array may be used to make the recalibration measurements which can be used to provide online liquid content measurement, such as moisture content, for the fluidised particles without stopping out stopping fluidisation. The liquid content information may be used for process control. The method may also be used to provide separate images for solids distribution and for total liquid distribution across a plane being imaged. |
| IP Reference | US2010213953 |
| Protection | Patent granted |
| Year Protection Granted | 2010 |
| Licensed | Yes |
| Impact | As a result of continuous support from EPSRC, this patent has been filed by UMIP and licensed to GEA. It covers EU, USA, Australia, China and India. Fluidised beds are commonly used in the pharmaceutical industry. However, they are operated by trial-and-error because of the lack of online tools to measure the process. This patent details how to measure the moisture of particles and the moisture distribution in a pharmaceutical fluidised bed by electrical capacitance tomography. The invented appr |
| Description | General Chair of 2018 IEEE International Instrumentation and Measurement Technology Conference |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | This is the IEEE Instrumentation and Measurement Society flagship conference. It will be the first time for the conference to be held in the UK. More than 500 people from all over the world would come Manchester to attend this conference. It will be a good opportunity for UK academics and industrialists to make contact with people working in instrumentation and measurement from outside the UK. |
| Year(s) Of Engagement Activity | 2015 |
| Description | IEEE Distinguished Lecturer |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Public/other audiences |
| Results and Impact | I gave more than 30 Distinguished Lectures on electrical capacitance tomography and industrial applications, in Bahrain, Brazil, China, Germany, India, Korea, Malaysia, Mexico, Norway, Poland, Singapore, Sweden, UK, and USA |
| Year(s) Of Engagement Activity | 2010,2011,2012,2013,2014,2015,2016 |
| Description | honorary Chair of IEEE International Conference on Imaging Systems and Techniques |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | I am a key organiser of this IEEE series conference. Every year more than 100 people working on imaging system and techniques attend this conference, creating a platform for them to exchange ideas, make new contacts and disseminate their research outcome. |
| Year(s) Of Engagement Activity | 2008,2009,2010,2011,2012,2013,2014,2015,2016 |