XOPTIX Online Laser Particle Size Analyzer

Overview

The XOPTIX Online Laser Particle Size Analyzer is an industrial-grade, real-time particle size monitoring system engineered for continuous in-process measurement of dry or pneumatically conveyed powders and granular materials. Designed specifically for integration into active production lines—including cement, minerals, chemicals, pharmaceuticals, and food processing—the instrument employs full-range laser diffraction coupled with Mie scattering theory (with Fraunhofer approximation optionally configurable) to deliver precise, physics-based particle size distribution (PSD) data directly from process streams. Its optical architecture complies strictly with ISO 13320:2019 for laser diffraction particle sizing, ensuring metrological traceability and inter-laboratory comparability. Unlike offline or batch-based analyzers, the XOPTIX operates without sample extraction, dilution, or dispersion media—enabling true 24/7 unattended operation with sub-second measurement cycles and zero calibration drift over extended deployment periods.

Key Features

• True online, in-situ measurement: Direct optical interrogation of particles within pneumatic conveying lines, gravity-fed chutes, or equipment discharge points (e.g., air classifier outlets, jet mill exits)
• Single-unit integrated design: All optical, electronic, and purge subsystems housed in a single IP65-rated enclosure—no external controllers, separate lasers, or auxiliary fluid modules required
• Self-cleaning optical path: Integrated compressed-air purge system with programmable one-touch activation to remove dust accumulation on windows and lenses
• High-resolution detection: 16-bit analog-to-digital conversion across the entire photodetector array—delivering 16× greater dynamic range and signal fidelity than conventional 12-bit systems
• Robust field deployment: Engineered for ambient temperatures from −10 °C to +55 °C and vibration-prone environments; no moving parts in the optical path
• Zero-calibration operation: Factory-aligned optical train with thermally stabilized He–Ne or diode laser source; no user-performed alignment or recalibration needed during service life

Sample Compatibility & Compliance

The XOPTIX supports continuous analysis of dry, free-flowing particulates ranging from ~0.1 µm to 2000 µm in equivalent spherical diameter (ESD), depending on optical configuration and process velocity. It is compatible with materials including Portland cement clinker, limestone, fly ash, titanium dioxide, lactose, and ceramic precursors—provided they remain suspended or entrained in gas-phase transport. The system meets ISO 13320:2019 requirements for instrumental validation and reporting of D10, D50, D90, span, and full PSD histograms. For regulated industries, raw measurement logs and configuration histories can be exported in CSV or XML format to support 21 CFR Part 11-compliant data archiving when paired with validated third-party SCADA or MES platforms.

Software & Data Management

The XOPTIX includes an embedded Linux-based control unit with a local 7-inch resistive touchscreen interface for real-time visualization of PSD trends, statistical summaries, and alarm thresholds. Remote access is supported via Ethernet (TCP/IP) using standard Modbus TCP or OPC UA protocols for seamless integration into plant-wide automation networks. Configuration and historical data review are managed through the XOPTIX Configuration Studio—a Windows-based desktop application that enables users to define custom reporting intervals, define pass/fail criteria per product grade, and generate PDF-formatted compliance reports. All measurement events—including timestamp, ambient temperature, laser power stability, and purge cycle status—are logged with microsecond precision and retained onboard for ≥30 days.

Applications

• Cement manufacturing: Real-time monitoring at separator outlet, kiln feed, and finished product silo discharge to maintain Blaine surface area consistency
• Mineral processing: Closed-loop control of grinding circuits by feeding PSD feedback to mill motor speed and classifier vane angle actuators
• Pharmaceutical dry powder inhalers (DPIs): In-line verification of micronized API aerodynamic particle size prior to blending and capsule filling
• Chemical catalyst production: Detection of agglomeration onset during fluidized-bed calcination or spray drying
• Food & feed milling: Early warning of screen wear or hammer mill tip-speed degradation via modal shift in coarse fraction (>100 µm)

FAQ

Does the XOPTIX require periodic optical recalibration?
No. The optical path is factory-aligned and thermally stabilized; no user-performed calibration is necessary under normal operating conditions.
Can it operate in explosive atmospheres (ATEX zones)?
Yes—optional ATEX-certified variants (II 2G Ex db IIB T4 Gb / II 2D Ex tb IIIC T135°C Db) are available upon request.
What maintenance is required beyond the automated purge cycle?
None. The system is sealed and contains no consumables, lubricants, or replaceable optical components during its rated service life of ≥8 years.
How is representative sampling ensured in vertical gravity chutes?
XOPTIX field engineers perform site-specific flow profiling and install customized isokinetic sampling probes or tangential insertion ports to minimize segregation bias.
Is raw scatter pattern data accessible for third-party modeling?
Yes—full 2D intensity matrix files (in HDF5 format) are exportable via USB or network for advanced Mie inversion or machine learning training.