The theoretical and experimental investigation of the novel in-line CMOS image sensor was performed. This sensor is aimed to investigate particle size distribution, particle concentration and shape in hydraulic liquid in order to implement the proactive maintenance of hydraulic equipment. The existing instruments such as automatic particle counters and techniques are not sufficiently enough to address this task because of their restricted sensitivity, limit of concentration to be measured and they cannot determine particle shape. Other instruments cannot be used as inline sensors because they are not resistant to the arduous conditions such as high pressure and vibration. The novel mathematical model was proposed as it is not possible to use previously developed techniques based on using optical system and complicated algorithms. This model gives the output signal of the image sensor depending on the particle size, its distance from the light source (LED) and image sensor. Additionally, the model takes into account the limited exposure time and particle track simulation. The results of simulation based on the model are also performed in thesis. On the basis of the mathematical model the image processing algorithms were suggested in order to determine particle size even when this size is lower than pixel size. There are different approaches depending on the relation between the size of the particle and the pixel size. The approach to the volume of liquid sample estimation was suggested in order to address the problem of low accuracy of concentration measurement by the conventional automatic particle counters based on the single photodiode. Proposed technique makes corrections on the basis of particle velocity estimation. Approach to the accuracy estimation of the sensor was proposed and simulation results are shown. Generally, the accuracy of particle size and concentration measurement was considered. Ultimately, the experimental setup was used in order to test suggested techniques. The mathematical model was tested and the results showed sufficient correlation with the experiment. The zinc dust was used as a reference object as there are the particles within the range from 1 to 25 microns which is appropriate to check the sensitivity. The results of experiments using reference instrument showed the improved sensitivity and accuracy of volume measured compared to the reference one.

Advanced monitoring of the spatio-temporal distribution of process parameters in large-scale vessels and containers such as stirred chemical or bioreactors offers a high potential for the investigation and further optimization of plants and embedded processes. This applies especially to large-scale fermentation biogas reactors where the process performance including the biological processes highly depend on mixing parameters of the complex bio-substrates. Sufficient mixing is a basic requirement for a stable operation of the process and adequate process performance. However, this condition is rarely met in agricultural biogas plants and the process efficiency is often reduced dramatically by inhomogeneities in the agitated vessels. Without a doupt, investigation and monitoring of biochemical parameters, such as the fermentation rate, pH distribution as well as O2 and CO2 concentration is of great importance. Nevertheless, also understanding of non-biological parameters, such as fluid dynamics (flow velocity profiles, circulation times), suspension mixing (homogeneity, location of dead zones and short-circuits) and heat transfer (temperature profiles), is necessary to analyze the impact of mixing on the biological system and also to improve the process efficiency. However, in most industrial scale applications the acquisition of these parameters and their spatial distributions in the large-scale vessels is hampered by the limited access to the process itself, because sensor mounting or cable connections are not feasible or desired. Therefore, state of the art instrumentation of such reactors is commonly limited to few spatial positions where it is doubtfully assumed that the measured parameters are representative for the whole reaction mixture. In this work, a concept of flow following sensor particles was developed. The sensor particles allow long-term measurement of spatially distributed process parameters in the chemically and mechanically harsh environments of agitated industrial vessels. Each sensor particle comprises of an onboard measurement electronics that logs the signals of measurement devices, namely temperature, absolute pressure (immersion depth, axial position) and 3D acceleration. The whole electronics is enclosed in a robust neutrally buoyant capsule (equivalent diameter 58.2 mm; sphericity 0.91), to allow free movement with the flow. The sensor particles were tested in pilot fermenters under comparable flow conditions of biogas fermenters. The experiments proved the applicability of the sensor particles and the robustness to resist the harsh environments of mixing processes. Moreover, the results show the capabilities of the sensor particles to monitor the internal conditions of the vessel correctly and thus deliver significant information about the flow regime. Therefore effects of liquid rheology, vessel geometry, impeller speed and axial impeller position on the macro-mixing process were properly detected. Evaluation of the impeller efficiency and the mixing processes was done based on mixing homogeneity, location of dead zones, axial velocity profiles, circulation time distributions as well as average circulation times, acceleration spectra and temperature profiles that were extracted from the measured data. Furthermore, it is shown, that parameters of mixing models such as circulation number, impeller head, PECLÉT-number and variance of suspended solid particles can be estimated from the measured data. The main achievement of this work is therefore the development and validation of instrumented flow followers for the investigation of macro-mixing effects in agitated vessels. The sensor particles show potential for employment to real applications such as biogas fermenters or large bioreactors and to monitor and improve the mixing and heating regimes.

Advanced monitoring of the spatio-temporal distribution of process parameters in large-scale vessels and containers such as stirred chemical or bioreactors offers a high potential for the investigation and further optimization of plants and embedded processes. This applies especially to large-scale fermentation biogas reactors where the process performance including the biological processes highly depend on mixing parameters of the complex bio-substrates. Sufficient mixing is a basic requirement for a stable operation of the process and adequate process performance. However, this condition is rarely met in agricultural biogas plants and the process efficiency is often reduced dramatically by inhomogeneities in the agitated vessels. Without a doupt, investigation and monitoring of biochemical parameters, such as the fermentation rate, pH distribution as well as O2 and CO2 concentration is of great importance. Nevertheless, also understanding of non-biological parameters, such as fluid dynamics (flow velocity profiles, circulation times), suspension mixing (homogeneity, location of dead zones and short-circuits) and heat transfer (temperature profiles), is necessary to analyze the impact of mixing on the biological system and also to improve the process efficiency. However, in most industrial scale applications the acquisition of these parameters and their spatial distributions in the large-scale vessels is hampered by the limited access to the process itself, because sensor mounting or cable connections are not feasible or desired. Therefore, state of the art instrumentation of such reactors is commonly limited to few spatial positions where it is doubtfully assumed that the measured parameters are representative for the whole reaction mixture. In this work, a concept of flow following sensor particles was developed. The sensor particles allow long-term measurement of spatially distributed process parameters in the chemically and mechanically harsh environments of agitated industrial vessels. Each sensor particle comprises of an onboard measurement electronics that logs the signals of measurement devices, namely temperature, absolute pressure (immersion depth, axial position) and 3D acceleration. The whole electronics is enclosed in a robust neutrally buoyant capsule (equivalent diameter 58.2 mm; sphericity 0.91), to allow free movement with the flow. The sensor particles were tested in pilot fermenters under comparable flow conditions of biogas fermenters. The experiments proved the applicability of the sensor particles and the robustness to resist the harsh environments of mixing processes. Moreover, the results show the capabilities of the sensor particles to monitor the internal conditions of the vessel correctly and thus deliver significant information about the flow regime. Therefore effects of liquid rheology, vessel geometry, impeller speed and axial impeller position on the macro-mixing process were properly detected. Evaluation of the impeller efficiency and the mixing processes was done based on mixing homogeneity, location of dead zones, axial velocity profiles, circulation time distributions as well as average circulation times, acceleration spectra and temperature profiles that were extracted from the measured data. Furthermore, it is shown, that parameters of mixing models such as circulation number, impeller head, PECLÉT-number and variance of suspended solid particles can be estimated from the measured data. The main achievement of this work is therefore the development and validation of instrumented flow followers for the investigation of macro-mixing effects in agitated vessels. The sensor particles show potential for employment to real applications such as biogas fermenters or large bioreactors and to monitor and improve the mixing and heating regimes.