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Outotec PSI® 500i Datasheet 10000007663e Revision A

Outotec PSI® 500i Particle size analyzer

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1. PSI 500i analyzer

PSI 500 particle size analyzer is an on-line size

measurement system for mineral slurries. It is used in
controlling wet mineral processes, primarily grinding,
classification re-grinding and thickening. PSI 500i
automatically takes samples from one to three process
streams and measures their particle size distribution in
the range of 1-500 µm. The analyzer displays the
analysis results on touch screen display and reports
them to the plant’s automation system for real-time
process control.
The system operates on a continuous basis 24 hours a
day, with minimal manual maintenance needs. The
daily maintenance routines include checking the
sampling system and cleaning possible trash buildup in
the secondary sampler. Otherwise the maintenance
needs are covered by preventive maintenance calls by
Outotec Customer Service.
The particle size analysis is based on laser diffraction
using a patented multiple scatter calculation method to
enable the measurement with dense slurries. Due to the
fundamental nature of the analysis principle, no
calibration against a reference analysis is required for
volumetric size distribution measurement A linear
calibration model can be used to convert the results to
approximate other size measurement methods (sieve,
sedigraph etc.) based on regression modeling of
calibration results.
There are three options for the optical focal length in
the system, to optimize measurement for the particle
size range of interest. There is a wide variety of
particle size distribution characteristics that can be
selected as outputs to the plant automation system
through the interactive analyzer configuration displays.
The primary sampling from the process stream is
normally engineered in the analyzer delivery project
using the range of primary samplers, to ensure
satisfactory representativeness and trouble-free
transport of the sample to the analyzer. Figure 1. PSI 500i particle size analyzer and
primary sampler

Outotec PSI® 500i Datasheet
2. Analyzer system structure
The PSI 500i particle size analyzer is shown in Figure
1. This unit includes secondary and calibration
sampling, dilution unit, pneumatics, I/O, local control
panel and optical sensor head.
Figure 2. PSI 500i analyzer system flow sheet
2.1. Primary sampling
PSI 500i can handle at most three sample lines and
supports automatic flushing for the following Outotec
sampler types: LSA, NLA, PSA and CPS.
Representative sampling with straight sample transfer
piping are essential for dependable particle size
measurement. PSI 500i can be located close to the
sampling points so that the sample transport distance is
short and continuous gravity flow can be used.
Recommended primary sample flow is 50-100 l/min.
Provisions for automatic flushing and cleaning of the
sampler and the sample line guarantee high availability
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In addition to PSI 500i itself, the complete analyzer
system requires also primary sampling and a dilution
water tank. These items are also supplied as a part of
PSI 500i delivery by Outotec. Figure 2 shows a
simplified flow sheet of the complete system.
of the system. Samples will be typically returned back
to process by gravity.
2.2. Dilution water tank
The dilution water tank is needed to ensure that the
diluted sample entering the measurement head is free
of small air bubbles that would appear as particles in
the analysis. Suitable de-aeration is achieved by 1.2 m3
water volume free surface tank. The water tank can be
located within 20 m distance from the analyzer. A
centrifugal pump lifts the dilution water pressure up to
4 bar.

Outotec PSI® 500i Datasheet
2.3. Secondary sampling
The secondary sampler cuts representative 0.01-0.03 l
slices out of the primary sample flow, by moving the
sample line across a stationary secondary sample
cutter. This cutter has a programmable wash spray to
prevent clogging and cross contamination of samples.
The cutter opening and cutting speed can be adjusted to
set the sample volume to a suitable range according to
the primary sample flow rate and sample properties.
The sample is fed to the dilution unit through optional
demagnetizer and dispersion unit.
The number of secondary sample cuts is automatically
controlled using the optical transmission signal in the
sensor head, to ensure optimal measurement
conditions. If the transmission is too low the number of
cuts is decreased to allow more water to be mixed to
the flow, and vice versa.
Another cutter in the secondary sampler cuts manually
requested calibration samples or programmable
composite samples at the original (process) solids
content for laboratory analysis. The calibration sample
cutter has a manually controlled wash spray to prevent
clogging.
2.4. Sample demagnetizer and dispersion options
If samples contain more than 2 – 4% ferromagnetic
minerals, e.g. magnetite, the particles tend to
agglomerate and are measured as larger particles. The
sample demagnetizer option applies an electronically
controlled oscillating magnetic field to the samples,
and the demagnetized particles are dispersed with
ultrasound dispersion.
The ultrasound option can also be used alone to
disperse slurries with fine agglomerating particles to
retrieve a particle size distribution resembling the
original distribution.
2.5. Diluter Unit
The patented diluter unit adds water to the slurry
sample sufficiently so that the slurry entering the
measurement flow cell passes enough light. The top
portion of the dilution unit has relatively still flow
conditions in order to let entrained air to rise to the
surface. A froth killing water spray is introduced from
the top to break large bubbles.
The water is mixed to the slurry from two feed points.
The spray water addition is controlled using the level
signal. A screen stops trash and oversized particles
before they block the flow cell.
The total sample volume in the dilution unit is ca. 9
liters. The water flow at the outlet is 10 l/min.
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2.6. Optical Sensor Head
The optical sensor head is equipped with a solid-state
diode laser, a transmission flow cell with sapphire
windows to pass the laser beam through the sample and
a ring detector to measure the scattered light
distribution from the other side of the flow cell.
The flow cell provides a smooth duct channel for the
sample flow. The flow is turbulent to provide good
presentation of large particles. The diameter of the
measurement area is 10 mm at the center of the flow.
The flow cell outlet tube has a pinch shutoff valve to
leave the cell full of water when the analyzer is not in
operation.
2.7. Probe Control Set
The analyzer control cabinet has an integrated
industrial PC hosting a controller application for the
sampling/dilution, a local user interface for displaying
the equipment status and analysis results on the field as
well as for setup and maintenance operations.
The PC hosts software to control and configure the
optical sensor head. The control application
synchronizes the measurement with the sampling
control sequence and provides user interfaces for
measurement and diagnostic data transfer to the plant
automation system.
The measurement sequence starts with a sample cutting
phase where the secondary samples are introduced into
the diluter, and ends with a draining phase where all
particles from the secondary sample are passed to the
optical sensor head. The particle size signal is an
average over the measurement cycle, weighted by the
apparent %solids of the diluted sample. Before the next
measurement, the diluter is completely flushed, and a
background check for the optical measurement head is
done at set intervals.
The control application provides a status/data display
and records the data and events into a history database
for viewing and diagnosing.
A simplified remote HMI view with a web browser or
full control of the analyzer with a remote desktop
software are available. Both choices utilize an Ethernet
connection. The remote desktop connection can be
used for local operator monitoring, parameter setup and
service diagnostics. Outotec service contract remote
diagnostics/services are available through optional
secured internet or dial up connection.
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Outotec PSI® 500i Datasheet 10000007663e Revision A

Figure 3. Analyzer status display on local control Figure 5. The operation of the analyzer is controlled
panel by interactive configuration displays.

Figure 4. Particle size distribution display on local

control panel Figure 6. It is possible to measure manually
introduced external sample.

Measuring head Focal length D50 range D2 – D98 range

OLE 5112 100 mm 2.5 -125 µm 0.5 – 200 µm

OLE 5212 200 mm 5.0 – 250 µm 1.0 – 400 µm

OLE 5312 300 mm 7 – 350 µm 1,5 – 600 µm

Figure 7. Measuring head models are optimized for specific size ranges

Outotec PSI® 500i Datasheet
3. Specifications
3.1. Sample streams
The basic version of PSI 500i can be connected to one
primary sample line. With additional sample inlet
options PSI 500i is capable of taking up to three
primary sample streams.
Primary sample flow rate: 50…100 l/min
typical, depends on sample solids content and
size distribution
Maximum solids content: up to 70% w/w,
sample has to flow freely
Primary sample line: Inlet OD 60 mm / G2”
Primary sample reject fitting: OD 76 mm /
G2½”
Secondary sample reject fitting: OD 25 mm
3.2. Sample handling
Sample dilution to 0.5% (vol.) typical, dilution is
controlled automatically for suitable laser beam
transmission through the diluted sample
Composite sampling of undiluted sample with
timed intervals
Cleaning of primary sampler with automatic
sample/flush valves by timed intervals or manual
command
Adjustable secondary and composite sampler
cutter openings
Automatic secondary sampler and manually
controlled composite sampler cutter cleaning by
integrated water sprays
Demagnetizer and dispersion options
3.3. Analytical
Size range: 1- 500 micrometers, size range can
be optimized according to application.
Measurement data output: 40 fractions (%vol.
±x µm or mesh), particle size percentiles (µm at
x %), Blaine number (m2/kg), specific surface
area (m2/cm3)
Precision: 1-2% (rel.) for Dv(50) particle size
based on a glass bead sample.
Accuracy: when compared to other particle
sizing methods than laser diffraction, differences
are noticed due to different influence of particle
shape, particle specific gravity etc. to the
analysis. The system allows correlation of the
measured particle size data to other
measurements by independent calibration
samples; however, this correlation is application
dependent
Measurement interval: typically 3 min / sample
line
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4. Options
4.1. Additional Sample Inlet
PSI 500i can be upgraded with one or two additional
sample inlet options to enable sampling from
maximum of three process lines.
4.2. Demagnetizer and ultrasound dispersion option
For samples with significant magnetite content,
demagnetization is required together with ultrasound
dispersion to de-agglomerate the particles.
Fine particles with an agglomeration tendency can be
dispersed with the ultrasound dispersion option.
4.3. Analyzer Remote Station
The analyzer remote station is a Windows® PC for:
defining the run time parameters remotely
managing analysis data
collecting diagnostic data from the analyzer
displaying the analyzer status and analysis results
remote diagnostics
Normally the analyzer remote station is set up in the
control room.
4.4. Acid Window Wash Option
For contaminating samples, PSI 500i can be equipped
with a washing system to assure that optical sensor
head windows and dilution mechanism remain clean.
4.5. Salt Water Accessories
If salt water or other corrosive medium is used for
dilution and washing, PSI 500i can be supplied with
acid proof steel valves
5. Installation
5.1. Max dimensions
PSI 500 analyzer unit:
- 2071 (H) x 1200 (W) x 930 mm (D)
- 82” (H) x 47” (W) x 37” (D)
Dilution water tank:
- 1304 (H) x 1022 (W) x 1206 mm(D),- 51 “ (H) x
40” (W) x 47” (D)
Water pump with cover
- 520 (H) x 820 (W) x 320 (D) mm, 21 “ (H) x 32”
(W) x 13” (D)
Pump control box 430 (H) x 300 (W) x 240 (D)
mm ,17 “ (H) x 12” (W) x 9,5” (D)
5.2. Weight
PSI 500i analyzer: 250 kg, 550 lbs
Dilution water tank (empty): 165 kg, 365 lbs
Dilution water tank (full): 1365 kg, 3010 lbs
Water pump and control box: 35 kg, 80 lbs

Outotec PSI® 500i Datasheet
5.3. Typical shipping dimensions
PSI 500i analyzer unit: 350 kg, 3.0 m3
(2170x1140x1220 mm)
Auxiliares box: 150 kg, 0.85 m3
(1200x800x860 mm)
Dilution water tank (empty): 200 kg, 1.6 m3
(1200x1020x1300 mm)
5.4. Power supply
PSI 500i analyzer unit:
- Single phase AC, 230V±10% at 2A
50/60Hz or 115V ± 10 % at 4A 50/60Hz
Dilution water pump:
- Single phase AC, 230V±10% at 4A
50/60Hz or 115V ± 10 % at 8A 50/60Hz
A double conversion (AC/DC/AC) UPS 1 kW / 10 min
is highly recommended to secure trouble-free and
stable operation.
5.5. DCS connection options
Modbus RTU (PSI 500i is master or slave )
Modbus TCP/IP (PSI 500i is slave)
OPC (PSI 500i is server)
Profibus DP (PSI 500i is slave)
Figure 8 PSI 500i analyzer dimensions in mm. NOTE Analyzer with 300 mm optics requires 1200 mm width.
See installation manual for full details and instructions.
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5.6. Remote connection options
Remote desktop diagnostics/service connection
via ethernet (LAN/Internet) or dial up modem
line
Remote display: Web server
5.7. Water
Particle-free (sand filtered, potable) water
Water consumption: 10 l/min (2.7 GPM)
average, max 30 l/min (8 GPM)
Water temperature: max. 40 °C
(wash spray water can be raised up to 80 °C with
AISI 316 diluter unit options)
Inlet in dilution water tank: 1” hose coupling
for water hose of 25 mm inner diameter
5.8. Instrument air
Oil-free dry instrument air 5…10 bar (75…145
psi), no condensation
Air consumption: 17 Nl/min (0.6 cuft/min)
average
Inlet: G½”

Outotec PSI® 500i Datasheet
5.9. Environment
Ambient temperature: 5-45 °C (no direct
sunlight), air conditioned cabin recommended
for temperatures above +35 deg C and heated
cabin below +5 deg C.
Installation altitude: 0 to 5000 m (16000 ft)
above sea level
Sample temperature: 5-50 °C
(with AISI 316 funnel option 80 °C)
Corrosion: AISI 316L, HDPE, POM, sapphire,
rubber, neoprene and silicone when in contact
with sample, frame phosphated AISI 316L,
enclosures powder epoxy coated (60-80 µm)
AISI 304
Moisture: non condensing
Shock: 15 G equivalent / 11 ms
Vibrations: 1 G / 5-150 Hz
5.10. Standards
Plant equipment conforms with European Union
machine directive, low voltage directive and
EMC directive for heavy industrial environment
EMC: heavy industrial environment, EN 50082-2
& EN 50081-2
Environmental tolerance: IP56/NEMA 4X
Laser source meets Class II specifications
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Quality assurance
PSI® 500i Particle Size Analyzer is CE marked
according to the European Union Directives.
The quality system of Outotec (Finland) Oy is ISO
9001 certified. The company has a quality management
policy to ensure that the expectations of customers are
met.
Outotec is a leading supplier of minerals processing
technologies including grinding, flotation, thickening,
filtering, physical separation, and automation
equipment. The company manufactures a wide range of
samplers for on-line analysis, composite, and
metallurgical sampling of mineral slurries, solutions
and dry powders.
You can find more information at www.outotec.com
PSI® Particle Size Analyzer is a registered trademark
of Outotec Oyj.
© 2011 Outotec Oyj. All rights reserved. Information
is subject to change without notice.