Dynamic tracking of fast liquid-liquid dispersion processes with a real-time in-situ optical technique

Monitoring of the drop size in dispersion processes is a key factor in process operation and control. A real-time in-situ optical technique was developed to facilitate rapid data acquisition on drop size average and distribution in dispersion processes. The technique was tested through its application to unstable dispersion processes including a liquid-liquid dispersion, an abnormal emulsion, and a suspension polymerization. The technique lends itself easily to multiple site measurements and can provide improved understanding of the dynamics of fast and complex dispersion processes. The technique is able to track the characteristic intervals of reactive and non-reactive dispersions. These intervals are transient and steady states in the dispersion process, transient and growth stages in the abnormal emulsion and transition, quasi-steady state, growth, and identification stages in the suspension polymerization cases studied. The robustness and speed of data acquisition and processing make the technique suitable for on-line monitoring and control of a wide range of related processes.