The Online Laser Diffraction Particle Size Analysis System integrates wet sampling, sample dilution, ultrasonic pre-dispersion, automated particle size measurement, and data communication into a coordinated workflow. Built around the FRITSCH A22 NeXT Nano laser particle size analyzer, the system is designed for automated particle size testing of process slurries, including lithium iron phosphate (LFP) slurry in battery material production.
By connecting sampling points with the particle size analyzer and plant control systems, the solution helps reduce repetitive manual sampling and testing, improve testing workflow consistency, and provide particle size distribution data for production monitoring and process adjustment.
Automated sampling: Controlled valves collect slurry samples from designated process pipelines.
Wet sample preparation: Water addition and ultrasonic pre-dispersion prepare samples for particle size measurement.
Multi-point testing: Multiple sampling locations can be configured for sequential testing and priority-based scheduling.
Laser diffraction analysis: Uses the FRITSCH A22 NeXT Nano laser particle size analyzer for particle size distribution measurement.
Data communication: Automatically generates measurement data and supports transfer to customer systems, including MES and, where configured, DCS-related workflows.
Automated pipeline cleaning: Coordinated valve control supports water flushing of sampling pipelines.
Integrated control: PLC-based control cabinets, touchscreens, a computer, and particle size analysis software coordinate the testing process.
The Online Laser Diffraction Particle Size Analysis System is designed for production environments where frequent slurry particle size testing is required. Instead of relying entirely on manual sample collection and laboratory testing, the system coordinates sample collection, preparation, measurement, and data transfer through an integrated automation workflow.
The system configuration described in the technical proposal includes two laser particle size analyzers, 24 sampling device assemblies, two control cabinet systems, and a data acquisition and processing system.
The number of sampling points, testing sequence, and control logic should be finalized according to the production line layout and project requirements.
Sampling devices are installed at designated locations on the process pipeline. Controlled valves regulate the collection of slurry samples according to the configured sampling sequence and duration.
After sampling, a controlled quantity of clean water is introduced into the sampling assembly. External ultrasonic treatment is then used for sample pre-dispersion before the sample is transferred to the analyzer.
The prepared sample is transferred to the analyzer for measurement. The system uses the FRITSCH A22 NeXT Nano laser particle size analyzer to determine the particle size distribution of the sample.
After each measurement, the software generates particle size data and transfers the results to configured customer systems. The control workflow can also support testing requests initiated by the DCS system, subject to the agreed integration design.
After sampling and measurement, the coordinated valve system can perform water flushing of the sampling pipeline. Cleaning duration and operating sequences are configured according to actual process conditions.
| Component | Function |
|---|---|
| FRITSCH A22 NeXT Nano laser particle size analyzer | Measures particle size distribution |
| Automated sampling assemblies | Collect slurry from designated process locations |
| Solenoid and pneumatic valves | Control sampling, water addition, and sample transfer |
| Flow meter and pressure-reducing valve | Support flow and water-pressure management |
| External ultrasonic device | Supports sample pre-dispersion |
| PLC control cabinets with touchscreens | Coordinate valve operations and system sequences |
| Computer and particle size software | Manage testing procedures and measurement data |
| Data communication interface | Supports integration with customer production systems |
The system software coordinates the sampling and measurement process across configured sampling points. Under the operating arrangement described in the technical proposal, a particle size test takes approximately 3–4 minutes per point. Actual cycle time depends on the sample, measurement settings, transfer process, cleaning requirements, and configured sequence.
Users can configure testing frequency, individual test duration, interval time, and repeat measurements. Where supported by the project configuration, testing points can also be assigned different priorities or selected in response to DCS testing requests.
Measurement results are generated automatically and can be transferred to the customer's MES and other agreed systems. Communication protocols, data fields, and interface requirements should be confirmed during project design.
The following requirements are taken from the supplied technical proposal and should be confirmed against the final installation design.
| Item | Requirement |
|---|---|
| Particle size analyzer | FRITSCH A22 NeXT Nano |
| Electrical supply | Single-phase 220 V, 10 A |
| Stated system power | Less than 2 kW |
| Compressed air | 0.2–0.5 MPa |
| Clean water supply | Clean water pipeline; pressure requirements to be confirmed on site |
| Water and drain connections | Required for sampling equipment and analyzer |
| Sampling control | Automated valve-based sampling and transfer |
| Sample preparation | Water addition and external ultrasonic pre-dispersion |
| Data communication | Computer-based control and configured plant-system interfaces |
The system is designed to support particle size testing of lithium iron phosphate slurry during production. Automated sampling and measurement can provide particle size distribution information for process monitoring and production adjustment.
For battery material production lines that require frequent slurry testing, the system can be configured to coordinate sampling from multiple process locations and transfer measurement results to production management systems.
The automated sampling and measurement architecture may also be evaluated for other slurry processes where the sample characteristics, dispersion method, analyzer compatibility, and process conditions are suitable.
Application suitability should be confirmed through sample testing and engineering evaluation before deployment.
Reduced manual sampling workload
Automated sampling and sample transfer reduce repetitive manual handling and support more consistent testing workflows.
More timely particle size data
Scheduled or requested measurements provide production teams with particle size distribution data for process monitoring and adjustment.
Multi-point testing coordination
A centralized control workflow coordinates sampling points, test sequences, and configurable priorities.
Improved process traceability
Automatic data generation and transfer can reduce manual data transcription and support integration with production records.
Project-specific system integration
Sampling assemblies, control cabinets, software, and communication interfaces can be configured according to the production line layout and integration requirements.
An online laser diffraction particle size analysis system combines a laser diffraction analyzer with automated sampling, sample preparation, control software, and data communication. It is designed to measure particle size distribution from process samples with less manual intervention than a fully manual testing workflow.
The proposed system is designed for lithium iron phosphate slurry particle size testing. Final suitability depends on slurry properties, sampling conditions, dispersion requirements, and the selected analyzer configuration.
The supplied technical proposal indicates approximately 3–4 minutes per sampling point. Actual cycle time depends on measurement settings, sample transfer, cleaning, and the configured workflow.
The proposed solution supports automatic measurement data transfer to customer systems, including MES, and can support DCS-initiated testing workflows where configured. The specific communication interface and integration scope must be confirmed for each project.
The number of sampling points depends on the system configuration and project design. The supplied proposal includes 24 sampling device assemblies. The final allocation and scheduling arrangement should be confirmed during engineering design.
Yes. The proposed system uses coordinated valve control and water flushing to clean sampling pipelines. The cleaning sequence and duration are determined according to site conditions and operating requirements.
Useful information includes the process flow diagram, pipeline layout, sampling locations, slurry characteristics, required testing frequency, analyzer requirements, plant communication interfaces, and available utilities.
Looking for an online laser diffraction particle size analysis system for slurry testing or battery material production?
Contact Exceed Testing to discuss your sampling points, process requirements, testing frequency, and MES/DCS integration needs. Our team can evaluate the application and develop a system configuration based on your production workflow.
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