Since 2011, a manufacturer in India has been at the forefront of producing small diameter single-walled carbon nanotubes (SWCNT) for applications ranging from electronics, sensors, semiconductors, EV batteries, medical, filtration, and others.
The Initial Setup: Reliable Flow Control for R&D
During the early research phase, the manufacturer selected Brooks Instrument 3809G and 3750C variable area flow meters for gas flow measurement in their reactors. A Brooks Instrument flow expert worked closely with the team to ensure optimal performance of the instrumentation. Once the team gained enough operational confidence, a decision was made to upgrade to Brooks Instrument SLA5850 Series mass flow controllers (MFCs) for more precise measurement and control of the process gas. MFCs offer advantages like higher accuracy and better repeatability, especially in applications sensitive to pressure and temperature fluctuations.
The Challenge: Choked Flow & Process Challenges
The manufacturer started experiencing major issues with carbon dust and backpressure. The carbon dust was choking or restricting the gas flow from the mass flow meter causing process downtime. The team spent several days cleaning their system and lost thousands of dollars.
Another challenge the team encountered was trying to diagnose the root cause. Was it the gas supply? Hardware issues?
Restricted Flow or Chocked Flow can occur due to a pressure droop or other causes of restricted flow. SLA Series mass flow controllers with the high-speed EtherNet/IP or PROFINET digital protocol offer advanced alarms and diagnostics that can alert the operator to a loss of flow, allowing the issue to quickly be resolved preventing potential process failures.
The Solution: Advanced Diagnostics with BEST Software
The Brooks Instrument flow expert used the BEST software application to diagnose and troubleshoot the restricted or choked flow and recommended the following:
- Clean and recalibrate the mass flow controllers
- Install Adequate Filters to catch any loose carbon dust
- Setup and configure alarms via BEST Software with the RS-485 communication protocol available on the SLA Series mass flow controllers
- Regular on-site technical support to help the manufacturer interpret diagnostic data from the mass flow meter via the BEST software application and take corrective actions with confidence
The Results: Enhanced Process Reliability, Minimal Downtime, and Increased Output
The introduction of SLA Series mass flow controllers with advanced diagnostics and BEST software has led to several key process improvements:
Enhanced Process Reliability
The real-time monitoring of gas flow through BEST software allowed this manufacturer to mitigate the risk of choked flow conditions, ensuring uninterrupted production processing and minimizing potential process failures.
Efficiency in Troubleshooting
Through the BEST software application, the team could assess alarm diagnostics, identify and resolve issues, significantly reducing downtime and the associated financial impact. For a more seamless and efficient approach, Brooks Instrument recommends the SLA Series with the high-speed EtherNet/IP or PROFINET communication protocols connected to a PLC.
Cost Savings
By preventing batch failures and reducing troubleshooting time, the solution not only safeguarded operational efficiency but also potential savings in both time and money.
The collaboration between Brooks Instrument and this manufacturer has resulted in a robust solution that enhances reliability in processing by leveraging advanced mass flow controller technology and comprehensive support from our customer care team.
Scaling with Confidence
Due to rising prospective customer demand and proven system reliability, the team added high-flow SLA5853S mass flow controllers for their new reactors. The manufacturer receives continuous praise from their customers on the quality and size of the SWCNTs.
Bonus: FAQs
Is the SLA MFC and BEST software the right instrumentation to use for choked flow?
While the customer did implement the SLA MFC and BEST software enabled through the RS-485 communication protocol, a more efficient and seamless route would be the SLA MFC enabled with EtherNet/IP or PROFINET communication protocols connected to their PLC.
What is the difference between the SLA5850S and SLA5853S?
The SLA5850S is engineered for standard flow applications, while the SLA5853S controls and monitors higher gas flow rates, making it ideal for large-scale reactors.
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