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Liu Z, Ma Z, Tu Q, Sun S, Xu L, Ge R, Yang W, Wang H. On-line Monitoring of Flow Process in a Spout-Fluid Bed by Combining Electrical Tomography and High-speed CCD Camera. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.118332] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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2
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Investigation of gas-solid heat and mass transfer in a Wurster coater using a scaled CFD-DEM model. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117598] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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3
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Hlava J, Abouelazayem S. Control Systems with Tomographic Sensors-A Review. SENSORS 2022; 22:s22082847. [PMID: 35458833 PMCID: PMC9032538 DOI: 10.3390/s22082847] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/11/2022] [Revised: 03/24/2022] [Accepted: 04/04/2022] [Indexed: 02/04/2023]
Abstract
Industrial process tomography offers two key advantages over conventional sensing systems. Firstly, process tomography systems provide information about 2D or 3D distributions of the variables of interest. Secondly, tomography looks inside the processes without penetrating them physically, i.e., sensing is possible despite harsh process conditions, and the operation of the process is not disturbed by intrusive sensors. These advantages open new perspectives for the field of process control, and the potential of closed-loop control applications is one of the main driving forces behind the development of industrial tomography. Despite these advantages and decades of development, closed-loop control applications of tomography are still not really common. This article provides an overview of the current state-of-the-art in the field of control systems with tomographic sensors. An attempt is made to classify the different control approaches, critically assess their strengths and weak points, and outline which directions may lead to increased future utilization of industrial tomography in the closed-loop feedback control.
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Yaginuma K, Tanabe S, Kano M. Gray-box Soft Sensor for Water Content Monitoring in Fluidized Bed Granulation. Chem Pharm Bull (Tokyo) 2022; 70:74-81. [PMID: 34980737 DOI: 10.1248/cpb.c21-00777] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
Soft sensors are powerful tools for the implementation of process analytical technology (PAT). They are categorized into white-box (first-principle), black-box (statistical), and gray-box models. Gray-box models integrate white-box and black-box models to address each drawback, i.e., prediction accuracy and intuitiveness. Although they have been applied to various industrial processes, their applicability to water content monitoring in fluidized bed granulation has not been reported. In this study, we evaluated three types of gray-box models, i.e., parallel, serial, and combined gray-box models, in terms of prediction accuracy using real operating data on a commercial scale with two formulations. The gray-box models were constructed by integrating the heat and mass balance model (white-box model) and locally weighted partial least squares regression (LW-PLSR) model (black-box model). LW-PLSR was utilized to cope with collinearity and nonlinearity. In the serial gray-box models, LW-PLSR models adjusted the fitting parameters of the white-box model depending on the process parameters for each query. In the parallel gray-box or combined gray-box models, LW-PLSR models compensated for the output error of the white-box or serial gray-box models, respectively. The results demonstrated that all three types of gray-box models improved the prediction accuracy of the white-box models regardless of the formulation. Besides, we proposed the assessment method based on Hotelling's T2 and Q residual for gray-box models using LW-PLSR, which contributes decision support to select gray-box or white-box model. The accurate and descriptive gray-box models are expected to enhance process understanding and precise quality control in fluidized bed granulation.
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Affiliation(s)
- Keita Yaginuma
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd.,Department of Systems Science, Kyoto University
| | - Shuichi Tanabe
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd
| | - Manabu Kano
- Department of Systems Science, Kyoto University
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Yaginuma K, Tanabe S, Sugiyama H, Kano M. Prediction Performance and Economic Efficiency of Soft Sensors for in-Line Water Content Monitoring in Fluidized Bed Granulation: PP-Based Model vs. NIRS-Based Model. Chem Pharm Bull (Tokyo) 2021; 69:548-556. [PMID: 34078801 DOI: 10.1248/cpb.c20-01016] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
Soft sensors play a crucial role as process analytical technology (PAT) tools. They are classified into physical models, statistical models, and their hybrid models. In general, statistical models are better estimators than physical models. In this study, two types of standard statistical models using process parameters (PPs) and near-infrared spectroscopy (NIRS) were investigated in terms of prediction accuracy and development cost. Locally weighted partial least squares regression (LW-PLSR), a type of nonlinear regression method, was utilized. Development cost was defined as the cost of goods required to construct an accurate model of commercial-scale equipment. Eleven granulation lots consisting of three laboratory-scale, two pilot-scale, and six commercial-scale lots were prepared. Three commercial-scale granulation lots were selected as a validation dataset, and the remaining eight granulation lots were utilized as calibration datasets. The results demonstrated that the PP-based and NIRS-based LW-PLSR models achieved high prediction accuracy without using the commercial-scale data in the calibration dataset. This practical case study clarified that the construction of accurate LW-PLSR models requires the calibration samples with the following two features: 1) located near the validation samples on the subspace spanned by principal components (PCs), and 2) having a wide range of variations in PC scores. In addition, it was confirmed that the reduction in cost and mass fraction of active pharmaceutical ingredient (API) made the PP-based models more cost-effective than the NIRS-based models. The present work supports to build accurate models efficiently and save the development cost of PAT.
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Affiliation(s)
- Keita Yaginuma
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd.,Department of Systems Science, Kyoto University
| | - Shuichi Tanabe
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd
| | | | - Manabu Kano
- Department of Systems Science, Kyoto University
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Maung CO, Kawashima D, Darma PN, Takei M. Real-time controlling particle distribution in pneumatic conveyance by electrical capacitance tomography with airflow injection system (ECT-AIS). ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2020.04.019] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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7
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Porzuczek J. Assessment of the Spatial Distribution of Moisture Content in Granular Material Using Electrical Impedance Tomography. SENSORS (BASEL, SWITZERLAND) 2019; 19:E2807. [PMID: 31234567 PMCID: PMC6632094 DOI: 10.3390/s19122807] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/28/2019] [Revised: 06/19/2019] [Accepted: 06/20/2019] [Indexed: 12/01/2022]
Abstract
This paper presents a method for the online determination of the spatial distribution of the moisture content in granular material. It might be essential for the monitoring and optimal control of, for example, drying processes. The proposed method utilizes Electrical Impedance Tomography (EIT). As an exemplary material for experimental research, the black chokeberry (Aronia melanocarpa) was used. The relationship between the electrical impedance of the chokeberry and its moisture content was determined for a wide range of frequencies (20 Hz-200 kHz). The EIT research consisted of both simulation and experimental investigation. Experimental studies of the spatial distribution of the moisture content were performed in a cylindrical vessel equipped with 8 electrodes circumferentially arranged. The voltage signal from the electrodes was acquired simultaneously using the data acquisition module. Due to the high impedance of the chokeberries, exceeding 109 Ω for the dried matter, extraordinary instrumentation was necessary to be applied. On the other hand, raw chokeberry was characterized by a several orders of magnitude lower impedance (103-104 Ω), especially for high frequencies. The wide range of the observed impedance was able to be measured owing to its use of the voltage stimulation instead of the current stimulation (which is most common for EIT). The image reconstruction problem was solved using an iterative Gauss-Newton algorithm and the EIDORS (Electrical Impedance Tomography and Diffuse Optical Tomography Reconstruction Software) package. The obtained results showed a satisfactory ability to localize an insufficiently dried part of the material. Prospective ways to improve the imaging quality are also discussed.
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Affiliation(s)
- Jan Porzuczek
- Faculty of Environmental Engineering, Cracow University of Technology, Warszawska 24, 31-155 Krakow, Poland.
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8
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Peters J, Taute W, Döscher C, Höft M, Knöchel R, Breitkreutz J. Moisture Monitoring in Fluid-Bed Granulation by Multi-Resonance Microwave Sensor: Applicability on Crystal-Water Containing Donepezil Granules. AAPS PharmSciTech 2018; 20:6. [PMID: 30560303 DOI: 10.1208/s12249-018-1209-7] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/20/2018] [Accepted: 10/01/2018] [Indexed: 11/30/2022] Open
Abstract
Multi-resonance microwave sensors have recently been introduced for moisture monitoring of pharmaceutical particulates up to > 20% residual moisture. The extended measuring range compared to previous systems as well as the microwave moisture values independent of other physical attributes make them promising process analytical technology (PAT) tools for various pharmaceutical production processes. However, so far, research focused on measurements on raw materials or drug-free model granulates and has neither evaluated the applicability for materials with crystal water containing excipients nor for active ingredients. In this study, possible influence of crystal water was evaluated using lactose monohydrate and donepezil hydrochloride, an active pharmaceutical ingredient (API) against dementia. The study clearly showed that the contained hydrate does not cause interferences and is not monitored by the applied frequencies. Material-related limits measuring lactose monohydrate were only observed above typical granulation moistures and could be explained using raw resonance curves. Furthermore, the inclusion of donepezil hydrochloride into the monitored formulations and varied process parameters demonstrated the versatility of the microwave resonance sensor system. Inlet air temperature, spraying rate, and air flow were varied according to a 23 full factorial experimental design. A predictive model (R2 = 0.9699, RMSEC = 0.33%) could be established using samples produced with different process parameter settings adjusted according to the corner points of the full factorial design and validated on the center point granulation processes (RMSEV = 0.38%). Thereby, performance on actual formulations and conditions faced during process development could be thoroughly assessed, and hence, another key requirement for applicability in formulation development could be met.
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Overview of Electric Field Applications in Energy and Process Engineering. ENERGIES 2018. [DOI: 10.3390/en11061361] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/31/2022]
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Che H, Wang H, Ye J, Yang W, Wu Z. Application of microwave tomography to investigation the wet gas-solids flow hydrodynamic characteristics in a fluidized bed. Chem Eng Sci 2018. [DOI: 10.1016/j.ces.2018.01.032] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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11
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12
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Measurement of moisture content in a fluidized bed dryer using an electrostatic sensor array. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.11.006] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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13
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Goula AM, Kokolaki M, Daftsiou E. Use of ultrasound for osmotic dehydration. The case of potatoes. FOOD AND BIOPRODUCTS PROCESSING 2017. [DOI: 10.1016/j.fbp.2017.07.008] [Citation(s) in RCA: 24] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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Liu R, Li L, Yin W, Xu D, Zang H. Near-infrared spectroscopy monitoring and control of the fluidized bed granulation and coating processes-A review. Int J Pharm 2017; 530:308-315. [PMID: 28743552 DOI: 10.1016/j.ijpharm.2017.07.051] [Citation(s) in RCA: 19] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2017] [Revised: 07/15/2017] [Accepted: 07/18/2017] [Indexed: 12/28/2022]
Abstract
The fluidized bed granulation and pellets coating technologies are widely used in pharmaceutical industry, because the particles made in a fluidized bed have good flowability, compressibility, and the coating thickness of pellets are homogeneous. With the popularization of process analytical technology (PAT), real-time analysis for critical quality attributes (CQA) was getting more attention. Near-infrared (NIR) spectroscopy, as a PAT tool, could realize the real-time monitoring and control during the granulating and coating processes, which could optimize the manufacturing processes. This article reviewed the application of NIR spectroscopy in CQA (moisture content, particle size and tablet/pellet thickness) monitoring during fluidized bed granulation and coating processes. Through this review, we would like to provide references for realizing automated control and intelligent production in fluidized bed granulation and pellets coating of pharmaceutical industry.
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Affiliation(s)
- Ronghua Liu
- School of Pharmaceutical Sciences, Shandong University, Wenhuaxi Road 44, Jinan, 250012, China
| | - Lian Li
- School of Basic Medical Sciences, Shandong University, Wenhuaxi Road 44, Jinan, 250012, China
| | - Wenping Yin
- Shandong SMA Pharmatech co., Ltd, 165, Huabei Rd., High & New Technology Zone, Zibo, Shandong 0533, China
| | - Dongbo Xu
- Shandong SMA Pharmatech co., Ltd, 165, Huabei Rd., High & New Technology Zone, Zibo, Shandong 0533, China
| | - Hengchang Zang
- School of Pharmaceutical Sciences, Shandong University, Wenhuaxi Road 44, Jinan, 250012, China.
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15
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Investigation of wetting and drying process in a gas-solid fluidized bed by electrical capacitance tomography and pressure measurement. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.07.069] [Citation(s) in RCA: 22] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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16
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Wang H, Qiu G, Ye J, Yang W. Experimental study and modelling on gas–solid flow in a lab-scale fluidised bed with Wurster tube. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.01.025] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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17
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Gosselin R, Durão P, Abatzoglou N, Guay JM. Monitoring the concentration of flowing pharmaceutical powders in a tableting feed frame. Pharm Dev Technol 2015; 22:699-705. [DOI: 10.3109/10837450.2015.1102278] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
Affiliation(s)
- Ryan Gosselin
- Department of Chemical and Biotechnological Engineering, Université De Sherbrooke, Sherbrooke, Quebec, Canada and
| | - Pedro Durão
- Department of Chemical and Biotechnological Engineering, Université De Sherbrooke, Sherbrooke, Quebec, Canada and
| | - Nicolas Abatzoglou
- Department of Chemical and Biotechnological Engineering, Université De Sherbrooke, Sherbrooke, Quebec, Canada and
| | - Jean-Maxime Guay
- Pfizer Global Supply, Process Analytical Sciences Group, Montreal, Quebec, Canada
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18
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Measurement of gas–solids flow in loop seal and external heat exchanger in a circulating fluidized bed. POWDER TECHNOL 2014. [DOI: 10.1016/j.powtec.2014.06.046] [Citation(s) in RCA: 24] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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19
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Generalized characterization of microwave power absorption for processing of circular shaped materials. Chem Eng Sci 2014. [DOI: 10.1016/j.ces.2014.06.029] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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20
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Qiu G, Ye J, Wang H, Yang W. Investigation of flow hydrodynamics and regime transition in a gas–solids fluidized bed with different riser diameters. Chem Eng Sci 2014. [DOI: 10.1016/j.ces.2014.05.006] [Citation(s) in RCA: 43] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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21
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Ge R, Ye J, Wang H, Yang W. Measurement of particle concentration in a Wurster fluidized bed by electrical capacitance tomography sensors. AIChE J 2014. [DOI: 10.1002/aic.14595] [Citation(s) in RCA: 35] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Ruihuan Ge
- Institute of Engineering Thermophysics, Chinese Academy of Sciences, PO Box 2706; Beijing 100190 China
- University of Chinese Academy of Sciences; Beijing 100190 China
| | - Jiamin Ye
- Institute of Engineering Thermophysics, Chinese Academy of Sciences, PO Box 2706; Beijing 100190 China
| | - Haigang Wang
- Institute of Engineering Thermophysics, Chinese Academy of Sciences, PO Box 2706; Beijing 100190 China
| | - Wuqiang Yang
- School of Electrical and Electronic Engineering, The University of Manchester; Manchester M13 9PL U.K
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22
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Analysing drying unit performance in a continuous pharmaceutical manufacturing line by means of mass – Energy balances. Eur J Pharm Biopharm 2014; 86:532-43. [DOI: 10.1016/j.ejpb.2013.12.014] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/08/2013] [Revised: 11/28/2013] [Accepted: 12/20/2013] [Indexed: 11/22/2022]
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23
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da Silva CAM, Butzge JJ, Nitz M, Taranto OP. Monitoring and control of coating and granulation processes in fluidized beds – A review. ADV POWDER TECHNOL 2014. [DOI: 10.1016/j.apt.2013.04.008] [Citation(s) in RCA: 48] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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24
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Zhang W, Wang C, Yang W, Wang CH. Application of electrical capacitance tomography in particulate process measurement – A review. ADV POWDER TECHNOL 2014. [DOI: 10.1016/j.apt.2013.12.003] [Citation(s) in RCA: 39] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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25
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Process analytical tools for monitoring, understanding, and control of pharmaceutical fluidized bed granulation: A review. Eur J Pharm Biopharm 2013; 83:2-15. [DOI: 10.1016/j.ejpb.2012.09.008] [Citation(s) in RCA: 101] [Impact Index Per Article: 9.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/15/2012] [Revised: 09/24/2012] [Accepted: 09/25/2012] [Indexed: 11/18/2022]
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26
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Atuonwu JC, van Straten G, van Deventer HC, van Boxtel AJ. On the controllability and energy sensitivity of heat-integrated desiccant adsorption dryers. Chem Eng Sci 2012. [DOI: 10.1016/j.ces.2012.06.006] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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Rimpiläinen V, Heikkinen LM, Vauhkonen M. Moisture distribution and hydrodynamics of wet granules during fluidized-bed drying characterized with volumetric electrical capacitance tomography. Chem Eng Sci 2012. [DOI: 10.1016/j.ces.2012.03.028] [Citation(s) in RCA: 36] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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29
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Rimpiläinen V, Poutiainen S, Heikkinen LM, Savolainen T, Vauhkonen M, Ketolainen J. Electrical capacitance tomography as a monitoring tool for high-shear mixing and granulation. Chem Eng Sci 2011. [DOI: 10.1016/j.ces.2011.05.044] [Citation(s) in RCA: 34] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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