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Dynamic Imaging Applications in Sugar Production Alan O’Donoghue, JM Canty International Ltd.

Dynamic Imaging Applications in Sugar Production Alan O’Donoghue, JM Canty International Ltd. S.I.T Annual Technical Conference Mitsui Sugar Co. Ltd, Osaka, Japan 17-20 May 2015.

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Dynamic Imaging Applications in Sugar Production Alan O’Donoghue, JM Canty International Ltd.

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  1. Dynamic Imaging Applications in Sugar Production Alan O’Donoghue, JM Canty International Ltd. S.I.T Annual Technical Conference Mitsui Sugar Co. Ltd, Osaka, Japan 17-20 May 2015 JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  2. Dynamic Imaging - Introduction Dynamic Imaging operates on the basic principle of capturing a real time view of a process, to either support an operator in making process related decisions, or to feed image analysis software which performs specific process measurements A typical Dynamic Imaging consists of 3 common hardware components; JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  3. Dynamic Imaging Sugar Industry Applications Production Applications Turbidity Analyser Fuseview Sight Glass SugarScope™ Crystal Growth Analyser Centrifuge Camera Control Quality Control Applications Sugar Crystal Size Analysis Sugar Crystal Colour Analysis JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  4. Clarifier Output - Turbidity Analyser Mounts fully inline to give real time indication of colour / turbidity on clarifier outlet Cantyvision Client software measures the amount of light entering the camera CCD chip from the light source through the liquid stream, which is related to the turbidity of the fluid JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  5. Clarifier Output - Turbidity Analyser System has the capability to discount bubbles from the calculation, meaning that it is only the colour / turbidity of the fluid which is measured JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  6. Clarifier Output - Turbidity Analyser JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  7. Crystallisation Monitoring - Manual Viewing Unique Manufacturing Process Our unique glass recipe (BoroPlus™) is heated to it’s molten point and poured into the centre of a metallic ring The BoroPlus™ glass fuses / bonds to the metal and is slowly cooled The metal compresses on the glass due to it’s higher coefficient of expansion, putting it under radial compression By fusing glass to metal, a high pressure, high safety, hermetic seal is formed, resulting in a one piece construction Fuseview™ sight glass JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  8. Crystallisation Monitoring - Manual Viewing Tempered sight glasses, cannot be fully tightened in place for fear of cracking the window and ruining the batch. Therefore, there is not a full vacuum seal which causes leaks, and means more energy is required to boil the liquid. By using a Fuseview™ the user is tightening on metal so cannot over torque and damage the window. A full seal is maintained, and so a full vacuum is achieved, meaning huge energy savings JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  9. Crystallisation Monitoring - Manual Viewing The energy required to heat a volume of liquid from one temperature to another can be calculated using the formula Q=mCp(T2-T1) Q = energy required T1 = starting temperature m = mass T2 = finishing temperature Cp = specific heat To heat 1 litre of water from 20°C to a boiling point of 100°C (ambient; 14.7 psi) Q=1(4.186)(100-20) = 334.88kJ / 0.093kWh per litre To heat 1 litre of water from 20°C to a boiling point of 80°C (vacuum; 6.9 psi) Q=mCp(T2-T1) Q=1(4.186)(80-20) = 251.16kJ / 0.070kWh per litre To heat 1 litre of water from 20°C to a boiling point of 60°C (vacuum; 2.9 psi) Q=mCp(T2-T1) Q=1(4.186)(60-20) = 167.44kJ / 0.047kWh per litre JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  10. Crystallisation Monitoring - Manual Viewing JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  11. Crystallisation Monitoring – Crystal Size (Sugarscope™) System features unique fused glass technology and fibre optic lighting Side mounts onto the crystalliser vessel to provide live images of the sugar crystals as they grow Provides early detection of seeding problems, allowing for recycling of the batch if necessary without wasting energy continuing with the process Cantyvision Client software allows for crystal size / shape analysis JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  12. Crystallisation Monitoring – Crystal Size (Sugarscope™) Seeding Seeding + 30 Minutes Seeding + 60 Minutes Seeding + 90 Minutes Seeding + 120 Minutes Seeding + 150 Minutes JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  13. Crystallisation Monitoring – Crystal Size (Sugarscope™) JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  14. Crystallisation Monitoring – Crystal Size (Sugarscope™) Return on Investment: With the annual increase in the production of large grain sugars, it is critical that we optimize our Pan Yields, Crystallization Times and Utilities in producing these products. By having operator’s continuously view / measure the crystallisation process, it is felt that the below can be achieved; • Reduce boiling times by 33% thus increasing number of batches • Overall increase yield by 10% (250,000 lbs/day) • Reduction in annual water / steam usage by 33% (3,200 gals to 2,110gals per strike, 545,000 gals/4,523,500 lbs. of steam per year) Increasing by 250,000lbs/day, would save ½ a shift of processing labour per week, which is 9 less melt days required per year. This gives a saving on staff payments of ~$22k per year. Reducing water / steam usage by 4,523,500 lbs would give a saving of ~$30k based on current energy costs. Total savings for 1 year: ~$52k Estimated total procurement / installation cost: ~$25k per unit (x2) Payback duration: <12 months JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  15. Centrifuge Monitoring - Batch Ethernet camera & light combination unit provides remote view into the centrifuge for continual process monitoring Cantyvision Client software can be used to provide real time continuous measurement of product thickness on the wall of the centrifuge The intensity of light reflection from the surface of the product can be used as an indication of surface fluid / filter process performance JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  16. Centrifuge Monitoring - Batch JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  17. Centrifuge Monitoring - Continuous Ethernet camera & light combination unit provides remote view into the centrifuge for continual process monitoring Cantyvision Client software can be used to provide real time continuous measurement of colour line position • Allows the operator to adjust the feed conditions to maintain a constant colour line position • Avoid washing above the colour line (inefficient due to spacing on screen and subsequent liquid carry over) JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  18. Final Product QC – Particle Colour / Size Both particle analysis and colour analysis can be performed by the one system Product fed in front of first camera for colour speck (front lighting) Product fed in front of second camera for particle size (back lighting) Images retrieved and sent to Cantyvision PC JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  19. Final Product QC – Particle Colour Vision based colour analysis works by passing the sugar crystals in front of a camera an light source (front lighting) to capture images of the particles These images are analysed in real time by Cantyvision Client to provide information on the colour of the particles on a number of different colour scales (YUV, RGB, CIELab) Various colour zones can programmed to only monitor particles of a particular colour ie. whiteness of sugar / black speck detection JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  20. Final Product QC – Particle Colour JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  21. Final Product QC – Particle Size Vision based particle analysis works by passing the sugar crystals between a camera an light source (back lighting) to capture images of the particles These images are binarised by the Cantyvision software These images are analysed in real time by Cantyvision Client to provide information on a number of different parameters (major axis, minor axis, perimeter, aspect ratio etc.) JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  22. Final Product QC – Particle Size JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  23. OUTPUT OPTIONS OPC - Open Connectivity for Process Control Canty provides both an OPC client and server to connect Cantyvision software to our customers’ digital control systems. This comes standard with Cantyvision 4-20mA Output - Ethernet Output Module Canty also offers an Ethernet 4-20mA current loop Cantyvision across a network, and convert it to a 4-20mA current loop signal. This is a separate DIN rail mounted module that can be purchased as an accessory. MS Excel Output PPM, PPB, major diameter, minor diameter, area and perimeter are measured and logged into an Excel spreadsheet for each particle detected. JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

  24. Thank You! For Further Information on this product please visit www.jmcanty.com. JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621

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