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.
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 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?
The Brooks Instrument flow expert used the BEST software application to diagnose and troubleshoot the restricted or choked flow and recommended the following:
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.
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.
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.
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.
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.