CoriolisMaster FCB/FCH150 and FCB/FCH450 Simultaneous recording of flow rate and density / concentration for the food and beverage industry

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1 Change from one to two columns Application note AN/CORIOLIS/108-EN Rev. A CoriolisMaster FCB/FCH150 and FCB/FCH450 Simultaneous recording of flow rate and density / concentration for the food and beverage industry Combining components accurately and cost-effectively while simultaneously adjusting concentrations in end products Measurement made easy Introduction The general objective when mixing different components is to achieve a particular concentration in the overall mixture. This is relatively straightforward to achieve by means of volumetric, gravimetric or simple mass flow measurements if the individual components have stable concentrations. However, if the concentrations of the individual components vary, these variations must be detected and volume adjustments performed as early as possible in the mixing process in order to avoid subsequent analyses, calculations and corrections. Starting products display natural variations, particularly in the food industry, but the desired outcome of a mixing process is an end product with a specific content of e.g. fat, sugar or alcohol. In most cases, density measurements can be used to determine and calculate concentrations for this purpose.

2 Change from two to one column Change from one to two columns CoriolisMaster FCB/FCH150 and FCB/FCH450 Simultaneous recording of flow rate and density / concentration for the food and beverage industry Instrumentation The mass flowmeters CoriolisMaster FCB/FCH 450 or FCB/FCH 150 supply highly accurate density measurements, which makes them ideal for dosing tasks of this kind. Requirements for measurement Two components (A and B) need to be blended together; the concentration of component A is constant, whereas the concentration of component B varies depending on the recipe value. As well as detecting mass flow with a high level of accuracy on the basis of the Coriolis effect, the device also records the density of the measuring medium independently of this using the resonant frequency of the filled system A 2 C B Fig. 1: Mixture of two components with different concentrations A A Component A (water) B Component B C End mixture 1 Electromagnetic flowmeter 2 Coriolis mass flowmeter 3 Flow rate of A 4 Flow rate of B 5 Density / concentration of B G AN/CORIOLIS/108-EN Rev. A CoriolisMaster FCB/FCH150 and FCB/FCH450

3 Task Fig. 2: Target mixture based on recipe A Component A (water) B Component B: Concentration of 40 %, density of Component B needs to be mixed with water in accordance with a specific ratio, with the aim of achieving a particular concentration in the end mixture. Fig. 4: Illustration of procedure The amount by which the proportion of water in component B differs from the recipe value is determined by measuring the concentration, and then accounted for in the calculations of the quantity of water to be dosed. Fig. 3: Actual mixture A Component A (water) B Component B: Anomalous concentration of 38 %, density of The concentration of component B has dropped, i.e. the same volume of the component contains more water than previously. The volume of water in component B needs to be considered to ensure that the concentration of the end mixture is correct. CoriolisMaster FCB/FCH150 and FCB/FCH450 AN/CORIOLIS/108-EN Rev. A 3

4 Change from two to one column CoriolisMaster FCB/FCH150 and FCB/FCH450 Simultaneous recording of flow rate and density / concentration for the food and beverage industry Solution The concentration of component A (water) is stable and can be recorded using an electromagnetic flowmeter. The concentration of component B varies slightly and is measured using a Coriolis mass flowmeter. The mass flow is converted into volume flow on the basis of the recipe density. At the same time, the Coriolis mass flowmeter records the actual density of component B and converts it into a concentration which compensates for the temperature based on a table stored in the transmitter. This generally results in an exact concentration value; in the event that slight alterations occur for process-related reasons, adjustments can be made to the table. The characteristic curves may shift slightly when the device is used in a normal operating environment instead of a testing/laboratory setting. The medium may contain small amounts of gases, for example, or there may be a slight variation in density for the same Brix content. The field adjustment of density compared to the laboratory value ensures that these variations can be easily corrected. The actual concentration which is determined in this way can then be compared and corrected against the recipe value using an intelligent process regulation and control device. Fig. 5: Relationship between density and concentration G AN/CORIOLIS/108-EN Rev. A CoriolisMaster FCB/FCH150 and FCB/FCH450

5 Sample instrumentation for a mixture correction C D A B Fig. 6: Possible control circuit with correction A Component A (water) B Component B C Actual concentration of component B D Excess water in component B G11889 Change from one to two columns The illustration shows a control diagram involving the calculation of excess water quantities and their incorporation into the water dosing branch. At the same time as recording the concentration of the relevant components, the mass flowmeter also records the mass or volume flow of this medium. This negates the need for an additional flowmeter. All of the calculations including the summation of water volumes are performed by the controllers without any add-on components. The level of accuracy which is achieved can be substantially increased by using a Blendline control method with fault memory and subsequent compensation of temporary deviations. CoriolisMaster FCB/FCH150 and FCB/FCH450 AN/CORIOLIS/108-EN Rev. A 5

6 Change from two to one column CoriolisMaster FCB/FCH150 and FCB/FCH450 Simultaneous recording of flow rate and density / concentration for the food and beverage industry Sample mixture correction Assuming that component B is a mixture of water (with a concentration of 0) and a liquid B (with a recipe concentration KB Rez ), the actual overall concentration for the mixture KB M can be recorded by the mass flowmeter. Calculation of overall concentration: KB M = VB Rez x KB Rez + V W x K W VB Rez + V W A water concentration of K W = 0 results in the following: KB M = Measured concentration of component B KB Rez = Recipe concentration of component B K W = Water concentration ( = 0 ) VB Rez V W = Recipe volume of component B = Volume of excess water Since the overall concentration K BM has been measured and the recipe values are known, the excess water volume can be calculated and used for the purpose of mixture corrections. Calculations can be carried out in the control system or in discrete digital controllers, indicators and videographic recorders from the ABB ControlMaster series. KB M = VB Rez x KB Rez B Rez + V W Products used Coriolis mass flowmeters CoriolisMaster FCB450 and FCH450 Nominal diameter range: DN 10 DN 200 for standard version DN 25 DN 80 for hygienic version Materials: Stainless steel or Nickel alloy C4 / C22 Optional: stainless steel and polished meter tube Measuring accuracy of flow rate measurements: Mass flow: 0.1 % and 0.15 % of measured value Volume flow rate: 0.15 % of measured value G a Accuracy of density measurements for liquids: kg/l, kg/l kg/l with field adjustment Outputs: 0 / 4 20 ma, pulses, active or passive Switch outputs For standard and hygienic applications in integral mount or remote mount designs. With a customized operating mode Densi-Mass for concentration measurements. 6 AN/CORIOLIS/108-EN Rev. A CoriolisMaster FCB/FCH150 and FCB/FCH450

7 Coriolis mass flowmeters CoriolisMaster FCB150 and FCH150 Nominal diameter range: DN 10 DN 200 for standard version DN 25 DN 80 for hygienic version Materials: Stainless steel or Nickel alloy C4 / C22 Optional: stainless steel and polished meter tube Measuring accuracy of flow rate measurements: Mass flow: 0.1 % and 0.15 % of measured value G11881b Volume flow rate: 0.15 % of measured value Accuracy of density measurements for liquids: kg/l, kg/l kg/l with field adjustment Outputs: 2 digital outputs, active or passive Modbus communications For standard and hygienic applications in an integral mount design. With a customized operating mode Densi-Mass for concentration measurements. Electromagnetic flowmeter HygienicMaster FEH300 Nominal diameter range: DN 3 to DN 100 Liner material: PFA Measuring electrode material: SST (AISI 316Ti) or (904L) Sensor material: Stainless steel Flow measurement of conductive liquids: From 5 us, including for fat-containing media FDA-approved materials G11881c EHEDG (cleanability) Medium temperature: up to 130 C (180 C at flanged connection) Measuring accuracy: up to 0.2 % For hygienic applications in an integral mount or remote mount design. CoriolisMaster FCB/FCH150 and FCB/FCH450 AN/CORIOLIS/108-EN Rev. A 7

8 Contact us ABB Limited Process Automation Howard Road, St. Neots Cambridgeshire, PE19 8EU UK Tel: +44 (0) Fax: +44 (0) Mail: ABB Inc. Process Automation 125 E. County Line Road Warminster PA USA Tel: Fax: Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents - in whole or in parts is forbidden without prior written consent of ABB. Copyright 2016 ABB All rights reserved 3KDE010085R3001 AN/CORIOLIS/108-EN Rev. A ABB Automation Products GmbH Process Automation Dransfelder Str Goettingen Germany Tel: Fax: