阅读说明：本技术 一种用于在工业过程中监测微生物污染物的方法和设备 (Method and apparatus for monitoring microbial contamination in an industrial process ) 是由 克劳福德·道 亚历山大·伯勒尔 于 2018-10-18 设计创作，主要内容包括：一种用于监测工业过程或工厂(100)的系统(200),其中,使用多个基于阻抗的卫星分析单元(202a)等实时监测所处理的介质并生成警报以触发详细分析从而确定微生物活性,确定是否已经达到诸如微生物活性的临界水平之类的预定标准,或者确定指示将要达到该预定标准的趋势,并启动补救措施。(A system (200) for monitoring an industrial process or plant (100) wherein a treated medium is monitored in real time using a plurality of impedance based satellite analysis units (202a) or the like and an alarm is generated to trigger a detailed analysis to determine microbial activity, determine whether a predetermined criterion, such as a critical level of microbial activity, has been reached, or determine a trend indicative that the predetermined criterion is about to be reached, and initiate a remedial action.)

1. An apparatus for detecting microbial activity in an industrial process, the system comprising:

a plurality of satellite units configured to sample liquid from the industrial process at a plurality of respective locations, wherein each satellite unit is configured to periodically analyze a sample, each satellite unit is configured to perform an impedance analysis to count particles passing through an orifice and measure a size of the particles, wherein each satellite unit is configured to generate sample result data corresponding to the number and size of particles in each sample;

a processing unit configured to compare the sample result data to a predetermined standard and to generate an alarm signal if particle data is outside the predetermined standard; and

a primary analysis unit configured to: after generating the alarm signal, performing a combined impedance and electromagnetic emission analysis on a liquid sample from the industrial process.

2. The apparatus of claim 1, wherein the processing unit is a system controller configured to receive result data from each of the plurality of satellite units.

3. The device of claim 2, wherein the system controller is configured to process the result data to obtain at least one result parameter, wherein the alarm signal is generated if the result parameter is outside of the predetermined criteria.

4. The apparatus of claim 3, wherein the at least one outcome parameter is indicative of a number of particles in the respective sample.

5. The apparatus of claim 3, wherein the at least one outcome parameter is indicative of an average size of particles in the respective sample.

6. The apparatus of any of claims 2 to 5, wherein the system controller comprises a display configured to display real-time information representative of the sample result data.

7. The apparatus of any preceding claim, wherein each satellite unit is configured to analyse a sample every N minutes, where N < 60.

8. The apparatus of any preceding claim, wherein each satellite unit comprises an automated sample retrieval assembly configured to periodically extract samples from the industrial process.

9. The apparatus of any preceding claim, wherein the main analysis unit is configured to perform a combined impedance and fluorescence analysis.

10. The apparatus of any preceding claim, wherein the alarm signal is configured to generate a visual alarm and/or an audible alarm to prompt an operator to analyze a sample in the primary analysis unit.

11. The device of any preceding claim, wherein the alarm signal is configured to automatically analyse a sample in the primary analysis unit.

12. A method for monitoring microbial activity in an industrial process, comprising the steps of:

providing:

a plurality of satellite units at a plurality of respective locations, each satellite unit configured to perform an impedance analysis to count particles passing through an orifice and to measure a size of the particles;

a main analysis unit configured to perform a combined impedance and electromagnetic emission analysis;

periodically sampling a liquid from the industrial process using the satellite unit;

generating sample result data corresponding to the number and size of particles in each sample;

comparing the sample result data to a predetermined standard and if the sample result data is outside of the predetermined standard or the sample result data has established a trend approaching the predetermined standard, analyzing a liquid sample from the industrial process using the primary analysis unit to determine biological activity in the sample.

13. The method of claim 12, wherein the electromagnetic emission analysis is a fluorescence analysis.

14. The method according to claim 12 or 13, comprising the steps of:

generating an alarm signal if the sample result data is outside of the predetermined criteria or the sample result data has established a trend approaching the predetermined criteria.

15. The method of any of claims 12 to 14, wherein the processing unit is a system controller and comprises the steps of:

transmitting sample result data from the plurality of satellite units to the system controller.

16. The method of claim 15, comprising the steps of:

processing the result data using the system controller to obtain at least one result parameter.

17. The method of claim 16, wherein the at least one outcome parameter is indicative of a number of particles in the respective sample.

18. The method of claim 17, wherein the at least one outcome parameter is indicative of an average size of particles in the respective sample.

19. The method of any of claims 14 to 18, wherein the system controller comprises a display configured to display real-time information representative of the sample result data.

20. The method of any of claims 14 to 19, wherein the system controller comprises a display configured to display real-time information representing trends in continuous results data.

21. The method of any of claims 12 to 20, wherein each satellite unit is configured to analyze a sample every N minutes, where N < 60.

22. The method of any one of claims 12 to 21, wherein each satellite unit comprises an automated sample retrieval assembly configured to periodically extract samples from the industrial process.

23. The method of any one of claims 12 to 22, wherein the alarm signal is configured to generate a visual alarm and/or an audible alarm to prompt an operator to analyze a sample in the primary analysis unit.

24. The device of any preceding claim, wherein the alarm signal is configured to automatically cause analysis of a sample in the primary analysis unit.

25. A method of reducing biological activity in an industrial process comprising the steps of:

performing the method of any one of claims 12 to 24;

introducing a biocide to the industrial process if the step of using the primary analysis unit indicates unacceptable biological activity.

26. The method of claim 25, comprising the steps of:

at least one satellite unit is used to monitor the effectiveness of the biocide.

27. The method according to claim 25 or 6, comprising the steps of: introducing a biocide to the industrial process upstream of the satellite unit reporting samples outside the predetermined standard.

28. An apparatus for periodic sampling of a liquid in an industrial process, the apparatus comprising:

a fluid outlet connectable to a liquid conduit;

a metering assembly configured to meter a predetermined amount of liquid from the fluid outlet;

a dilution assembly configured to dilute at least a portion of the predetermined amount of liquid to form an analysis sample;

an analysis unit configured to pass the analysis sample through an aperture and perform an impedance-based particle analysis on the sample, thereby determining the number and size of particles within the analysis sample;

a memory configured to store sample results related to the number and size of particles within the analysis sample.

29. An apparatus for monitoring microbial activity in an industrial process, comprising the steps of:

providing a fluid outlet connectable to a liquid conduit;

metering a predetermined amount of liquid from the fluid outlet;

diluting at least a portion of the predetermined amount of liquid to form an analysis sample;

passing the analysis sample through an orifice and performing an impedance-based particle analysis on the sample, thereby determining the number and size of particles within the analysis sample;

storing sample results relating to the number and size of particles within the analysis sample on a memory.

30. A method of monitoring microbial activity according to claim 29, comprising the steps of:

storing sequential sample results from a plurality of analyses;

the continuous sample results are analyzed for trends approaching predetermined criteria.

31. A method of assessing the efficacy of a biocide comprising the steps of:

providing a sample having microbial activity;

adding a biocide to the sample;

providing a device configured to perform a combined impedance and fluorescence analysis on the sample;

analyzing the microbial activity in the sample using the device to obtain sample result data;

comparing the sample result data to predetermined data to determine the efficacy of the biocide.

32. A method of assessing the efficacy of a biocide as claimed in claim 31 comprising the steps of:

analyzing trends in the sample result data toward predetermined criteria.

Technical Field

The present invention relates to a method and apparatus for monitoring microbial contamination in an industrial process. More particularly, the present invention relates to an apparatus and process that utilizes distributed analysis of particle activity in such processes.

Background

There are many industrial processes that receive a raw or first intermediate material at an end point, perform some operation on the material (e.g., mixing the material, treating by heat or pressure, or chemically changing) to produce a second or final intermediate material or product.

Examples of such processes are:

processing of food, including beverages;

treatment of water (for human consumption, as a liquid product, industrial process water, cleaning water, waste water, and other uses);

the treatment of household and industrial chemicals;

processing of petrochemicals;

the treatment of the cosmetic;

the handling of the drug;

processing of oil and gas related products;

treatment of paints and coatings;

treatment of pulp and paper-related products; and

treatment of powder slurries (such as calcium carbonate or titanium dioxide slurries and other powders).

The invention is particularly suitable for the treatment of liquid materials, particularly paints, but may be used in any of the above processes.

In the art of paint processing, several raw materials are provided at the first end point of the process. These raw materials, including fillers, dispersants, pigments, latexes and acrylics, must be mixed and processed in several stages before the final product is produced, which is placed in cans and shipped to customers. During this process, the various materials (in liquid form) pass through long lengths of pipe and then out of the tank. In any given process, there may be several kilometers of piping between the introduction of the raw materials and the final paint product.

The occurrence of microbial activity in this process is highly undesirable. The production of paints with a high microbial load is unacceptable and can cause serious problems (such as unpleasant odours) to the end user.

It is therefore important to check the microbial load in the paint produced by the process on a regular basis.

Until recently, it has been possible to treat liquids with large amounts of biocides in the process. This effectively kills any microorganisms that may adversely affect the product. That is, it is generally undesirable to use large amounts of biocide. Furthermore, recent legislation (in the form of european union biocide regulations) imposes significant restrictions on the types and amounts of biocides that can be used. The united states of america and most other important economic centers have similar regulations.

Currently, the detection of microbial activity is assessed by taking a sample of paint at the end of the process. The sample is sent to a laboratory for analysis. Information about the microbial load may be released after several days or weeks. Detection of excessive microbial activity will result in the plant being shut down and cleaned, and the affected paint will be recalled from the market and disposed of. Clearly, reducing the use of biocides increases the risk of contamination of the sample.

Systems such as the applicant's cfii (cellfeatures ii) device help to increase the speed at which microbial activity can be detected and corrective measures initiated before microbial levels can reach critical levels. The CFII device is a combined impedance and fluorescent particle detection system. The liquid to be analyzed is diluted, exposed to a suitable fluorescent dye and passed through an orifice. The change in impedance is measured to detect particle size, and a laser is used to excite the dye and determine particle fluorescence. In this way, the size and type of particles can be detected and this information can be used to estimate microbial activity. The period is less than three minutes. Such a system is discussed in GB2380792, which is incorporated herein by reference where permitted.

Although the CFII system fundamentally improves analysis time (on the order of minutes rather than days), it is only used in a "batch" context. In other words, the system is used to analyze the final product and determine if the microbial load is unacceptable. If so, the batch needs to be processed or disposed of and the system cleaned.

Disclosure of Invention

There is a need for a method and system that overcomes or at least alleviates the above problems.

According to a first aspect of the invention, there is provided an apparatus according to claim 1.

According to a second aspect of the invention, there is provided a method according to claim 12.

Advantageously, utilizing a combination of satellite units distributed throughout the processing line that perform impedance-based analysis yields several beneficial results. For example:

the system cost is controlled. The invention can be implemented with an impedance only satellite unit as a pre-warning sensor, which is cheaper than a combined impedance/fluorescent unit, which only needs to be analyzed in depth when the microbial load in the product reaches a critical threshold level.

The system responsiveness is improved. The satellite units may be based on very periodic sampling (e.g., every 20 minutes), which reduces the time to detect problems; and the number of the first and second groups,

system intelligence is improved. The use of distributed satellite units means that the location of the problem can be determined and targeted measures can be taken.

The combination of many satellite units with a main analysis unit (with combined impedance and fluorescence) yields a higher performance system than prior art methods.

According to a third aspect of the invention, there is provided an apparatus according to claim 27.

According to a fourth aspect of the invention, there is provided an apparatus according to claim 28.

According to yet another aspect of the present invention, there is provided an apparatus for detecting microbial activity in an industrial process, the system comprising:

a plurality of satellite units configured to sample liquid from the industrial process at a plurality of respective locations, wherein each satellite unit is configured to periodically analyze the sample, each satellite unit is configured to perform an impedance analysis to count and measure a size of particles passing through the orifice, wherein each satellite unit is configured to generate sample result data corresponding to the number and size of particles in each sample;

a processing unit configured to compare the sample result data with a predetermined criterion and to generate an alarm signal if the particle data is outside the predetermined criterion.

According to yet another aspect of the present invention, there is provided a method for monitoring microbial activity in an industrial process, comprising the steps of:

providing:

a plurality of satellite units at a plurality of respective locations, each satellite unit configured to perform an impedance analysis to count and measure a size of particles passing through an orifice;

a main analysis unit configured to perform combined impedance and fluorescence/electromagnetic emission analysis periodically sampling liquid from an industrial process using a satellite unit;

generating sample result data corresponding to the number and size of particles in each sample;

comparing the sample result data with a predetermined standard

The development of the time-varying outcome data on the trend curves is monitored to predict and anticipate further development.

Drawings

Example processes and apparatus according to the invention will now be described with reference to the accompanying drawings in which:

FIG. 1 is a schematic illustration of a first apparatus according to the present invention employed in an industrial process;

FIG. 2 is a view of a subassembly of the apparatus of FIG. 1;

FIG. 3 is a graph of the analysis results from the assembly of FIG. 2.

FIG. 4 is a table of summary results from the subcomponents of FIG. 2.

FIG. 5 is a display of a controller from the apparatus of FIG. 1;

fig. 6 is a flow chart of a method according to the invention.

Detailed Description

Referring to FIG. 1, a schematic simplified plan view of a paint processing line 100 is shown. Line 100 includes three storage tanks 102, 104, 106, each containing a different raw material. Each tank has a respective outflow channel in the form of a storage tank outflow pipe 103, 105, 107. Pipes 103, 105 connect the storage tanks 102, 104 to a first mixing tank 108, the first mixing tank 108 mixing the raw materials from the storage tanks 102, 104. The first mixing tank has an outflow channel in the form of a first mixing tank outflow tube 109.

The first mixing tank outflow pipe 109 flows into the second mixing tank 110. The third tank outflow pipe 107 also flows into the second mixing tank 110, where the materials are mixed in the second mixing tank 110. The second mixing tank 110 has a second mixing tank outlet pipe 111, and the second mixing tank outlet pipe 111 flows into a final storage tank 112.

The final storage tank 112 is configured to sequentially fill a plurality of individual containers in the form of paint trays 114, which are sealed and shipped to customers.

Each of the above components is typically made of steel, in particular stainless steel.

Device

The apparatus according to the present invention is distributed throughout the production line 100 in fig. 1 and is generally referred to as apparatus 200. The apparatus 200 comprises:

a plurality of satellite units 202a, 202b, 202c, 202d, 202e, 202 f;

a controller 204; and the number of the first and second groups,

an analysis unit 206.

Each of the above components will be described in detail.

Satellite units 202a, 202b, etc

Referring to FIG. 2, satellite unit 202a is shown in greater detail. The satellite units are very similar and therefore only unit 202a is shown.

Unit 202a includes a flow circuit 208; a sample flow channel 210; valves 212a, 212 b; a satellite analyzer 214 and a diluent tank 216 having a diluent flow passage 218.

Flow loop 208 includes an entry point 220 and an exit point 222 in fluid communication with storage tank effluent pipe 103. The tube 103 contains a fluid 10 under pressure. Because the exit point 222 is downstream of the entry point, flow is established in the flow loop 208.

The sample flow channel 210 has an inlet opening 224 in fluid communication with the flow loop 208 and flows into the satellite analyzer 214. The valves 212a, 212b can be selectively opened and closed (by the controller of the satellite analyzer) to feed discrete liquid samples to an analyzer 214 of known volume (1 ml in this example).

The satellite analyzer 214 includes several controlled valve-controlled flow channels and is configured to meter diluent from a tank 216 via a channel 218 to dilute the sample to a volume of, for example, 20 ml. A small amount of diluted sample (about 100 μ l) was then passed through the orifice to count and size measure the particles therein using impedance analysis. The satellite analyzer includes a controller 215, the controller 215 having a processor, a memory, and a communication device in the form of an antenna 217 configured to communicate with the system controller 204.

Impedance analysis has been used in the art and is explained, for example, in applicant's prior application EP0844475 (incorporated herein by reference where permitted). In summary, the orifice has a pair of electrodes disposed on opposite sides thereof. The analyzer includes circuitry capable of measuring a signal representative of the change in impedance between the electrodes. The impedance of the diluent (typically the electrolyte) across the orifice is known. As the particles pass through the orifice, the impedance will increase and then decrease. Each "peak" represents a particle, and the height of the peak and/or the area under the peak represents the particle size. Since the orifice is very small (about 30 μm), only one particle can pass at any given time.

The satellite controller 215 stores the result data for each sample and is configured to transmit the measurement result data (representative of the size and number of particles passing through the aperture) to the system controller 204 via the antenna 217.

Once the sample is analyzed, the system is flushed and additional samples are taken. The satellite units sample at a frequency of 20 minutes.

It is important to note that satellite analyzer 214 uses only impedance measurements and does not (in this embodiment) include a means for measuring fluorescence. Therefore, they are simple and inexpensive.

Controller 204

The controller 204 includes a processor, memory, and a display unit. In this embodiment, it is a PC. As described above, each satellite analyzer is in communication with the controller 204. This may be via a wired connection, or may be wireless, such as Wi-Fi, bluetooth (RTM), or similar technologies. The resulting data from the sample impedance measurements is transmitted to the controller 204, which performs data analysis.

Analysis unit 206

The analysis unit 206 combines both impedance analysis and fluorescence analysis. The analysis unit 206 is similar to the applicant's CFII device discussed above, and the impedance measurement is also performed using a laser for fluorescence analysis. This can determine whether fluctuations in particle size and number are indicative of a chemical or biological process (symptom).

Method of operation

Once the production line 100 is started, material flows through the system from the raw material storage tanks 102, 104, 106 to the final storage tank 112. Each satellite unit 202a, etc. samples the material flowing through each pipe at regular (in this embodiment 20 minutes) intervals. Each satellite unit 202a, etc. transmits the measurement result data of each sample to the controller 204.

The controller 204 contains baseline data representing the number and size distribution of acceptable particles for each satellite unit. An example baseline for satellite unit 202a is shown as curve B in S-N plot 300 of fig. 3. The X-axis represents the size (S) of the particles and the Y-axis represents the number (N) of particles of that size. Baseline data may be obtained by calibration (i.e., by analyzing samples having known/acceptable levels of microbial activity) or from stored data. It is noted that a particular number and size distribution of particles is expected despite the presence of microorganisms, and any given sample will contain insignificant chemical (non-biological) particles.

The first result from satellite unit 202a is shown in fig. 3 as profile P1, which is within a predetermined, acceptable range of baseline B. The manner in which the acceptable deviation from B is determined can be chosen by a skilled recipient without undue burden and based on known statistical methods. In this example, for ease of understanding, two parameters will be used, the X-axis coordinate of the peak of the curve (the size of the most numerous particles, or the mode average of the sample), and the area under the curve (representing the total number of particles in the sample). If microbial activity is increased, both would be expected to increase in subsequent samples.

The peak (a) and region (X) of P1 are shown. This data is represented in the first row of the results table 302 of fig. 4, the results table 302 being stored by the controller 204 for each satellite unit. Referring to fig. 5, a visual display graphic 304 provided by the controller 204 for the satellite unit 202a is shown. Graph 304 has a time axis (x-axis) and a particle count axis (y-axis). Three particle count bands are provided, green (low count), yellow (medium count) and red (high count). Sample data points are plotted and the operator can easily identify trends in unacceptable particle counts (red) and take remedial action (as will be discussed below). In practice, multiple curves (one for each satellite unit) may be displayed on the graph 304. Additional graphics with different parameters may also be displayed on the controller display.

In fig. 3 to 5, a further profile P2 is shown, in which both the size and the number of particles have grown (peaks increasing from a to B and numbers increasing from X to Y). Turning to P3, the size and number increase again (from B to C, from Y to Z).

The operator can clearly see from display 304 that the trend at satellite unit 202a indicates an increase in particle size and count. This may indicate microbial activity, or a sign of an abnormal chemical process. An alarm may be generated once the monitored one or more parameters enter the red zone.

At this point, the operator takes a sample from the location of satellite unit 202a and brings it to analysis unit 206 for combined impedance/fluorescence analysis. Analysis of this combination ultimately determines whether the increase in size and number of particles is a result of increased microbial activity. If so, the operator adds the biocide upstream of the satellite unit in question.

For example, if satellite unit 202a detects high microbial activity, a problem may arise with the raw material in tank 102. The material may be replaced (after cleaning), switched to a different tank, or a biocide may be added.

Where a biocide is added to the tank 102, for example, a satellite unit is used to verify its effectiveness. The tendency of the particles to increase in size and number will be reversed (i.e., move back into the "yellow" and "green" regions). This occurs when the biocide lyses the microbial cells.

If not, the satellite unit communicates this to the controller. At this point, the operator may attempt to increase the dosage, or modify the type of biocide used. Alternatively, he or she may conduct a more detailed biocide effectiveness test series, as will be discussed below.

It will be noted that the system described herein can pinpoint the source of microbial contamination, which means that targeted remedial action can be taken. This represents a significant improvement in efficiency.

Detailed biocide effectiveness test series

In accordance with the present invention, a combined impedance/fluorescence analyzer can be used to study the efficacy of various biocides until a suitable solution is found.

Referring to fig. 6, such a process 400 is shown. At step 402, a sample is extracted from a batch of material having high/unacceptable microbial activity. At step 404, it is introduced into a combined impedance/fluorescence analyzer (such as CFII). At step 406, the sample is analyzed, and at step 408, biological activity is assessed based on the results.

At step 410, additional samples are collected from the batch. At step 412, a biocide is added. At step 414, it is introduced into a combined impedance/fluorescence analyzer (such as CFII). At step 413, the sample is analyzed, and at step 418, biological activity is assessed based on the results.

The results from the biocide assay are then compared to the original sample from step 408 (without biocide) and to a baseline result set 422. If the biocide reduces microbial activity from the original sample 408 and is within a predetermined tolerance of the baseline data 422, the biocide dosage regimen is considered "OK" and the entire batch can be processed using the same concentration and type.

If the microbial activity is not reduced, or is reduced to a level that is still unacceptable compared to baseline, the method returns to step 410 to try a different biocide and/or higher concentration.

Thus, the analyzer may be used iteratively to determine the most effective biocide regimen for the batch.

Thus, the analyzer can also be used to support and accelerate the experiments required to align challenge tests.

Variants

Variations fall within the scope of the invention.

System 200 may be configured as a fully automated closed loop system. An automatic biocide dispenser may be provided upstream of the at least one satellite unit and automatically activated when the controller 204 detects that the particle parameter moves outside a predetermined range.

The satellite unit need not be connected to a central controller, but may instead generate a local alarm signal (such as a visual alarm or an audible alarm). This may then prompt the operator to perform a comprehensive impedance/fluorescence test. The system is capable of generating result data regarding individual measurements to determine whether predetermined criteria, such as critical levels of microbial load and activity, have been violated.

The system is also able to establish whether a series of successive result data is forming a trend that indicates that a predetermined criterion may be soon reached. Thus, the system is able to anticipate or predict microbial contamination at an early stage and initiate corrective action as measured.