8.

18 Consistency Analyzers Consistency

To
AIT
Receiver

A. BRODGESELL (1969, 1982) B. G. LIPTÁK (1995)

M. H. WALLER (2003) Flow Sheet Symbol

Types: Blade, rotary, probe, optical, microwave, radiological

Element Materials: Stainless steel and titanium

Normal Design Up to 250°F (120°C)

Temperature:

Normal Design Up to 125 PSIG (8.6 bars)

Pressure:

Range: 0.01 to 15% consistency

Sensitivity: 0.01 to 0.03% consistency

Repeatability: 0.5% of reading

Inaccuracy: Function of empirical calibration, usually 1% of reading

Cost: Laboratory units, $3000 to $10,000; continuous industrial units, $6000 to $30,000

Partial List of Suppliers: ABB (www.abb.com)

Berthold Technologies (www.berthold.com)
BTG (www.teambtg.com)
CyberMetrics (www.cyber-metrics.com)
DeZurik/Copes-Vulcan (www.dezurik.com)
Electron Machine Corp. (www.electronmachine.com)
Honeywell (www.honeywell.com)
Metso (www.metsoautomation.com)
NDC Infrared Engineering (www.ndc.com)
Ronan Engineering (www.ronan.com)
Thermo MeasureTech (www.thermo.com)
Thompson Equipment Co. (www.teco-inc.com)

INTRODUCTION laboratory, consistency is measured using a gravimetric

By definition, consistency is expressed as a percentage by
dividing the mass of solid material by the total mass of a wet
sample, resulting in units of mass per unit mass. Mechani-
cally, consistency is the resistance to deformation or shear
by fibrous materials, and thus is related to apparent viscosity.
Such materials include wood pulp, dough, tomato paste,
paint, gelatin, or drilling mud. This section will focus on
those methods used for the measurement of consistency in
the paper industry, involving pulp–water mixtures. In the
1
method described in TAPPI Test Method T 240 om-88. Gen-
eral industrial methods used for consistency measurement are
2–4
described in a number of sources.
In order to have good control over the basis weight of
the paper product, it is necessary to maintain the consistency
of the feed constant. An increase in temperature or an increas-
ing inorganic materials content will reduce the viscosity, and
thus apparent consistency, while increasing freeness (ability
of the suspension to release water), increasing fiber length, or
increasing pH will increase the apparent consistency. Pipeline

1323
© 2003 by Béla Lipták
1324 Analytical Instrumentation
velocity also can influence the consistency reading for mechan-
ical sensors and, therefore, it is advisable to measure consis-
tency in turbulent locations at constant flow rate. Consistency
is also related to turbidity and sludge or suspended solids
detectors.
IN-LINE CONSISTENCY MEASUREMENT
Forty years ago, consistency was considered to be a mature
measurement, almost totally relying on mechanical devices
for shear force measurements in the 2 to 5% range. Today,
we still rely on mechanical shear force measurements, but in
addition, we have devices utilizing light scattering, light
transmission, nuclear radiation, radio waves, and micro-
waves. Mechanical measurement devices might be catego-
rized as either static (a fixed probe or blade) or moving
(blades, rotating disks, or propeller). The development of
high-intensity light-emitting diodes 25 years ago allowed
further development of optical consistency sensors. These
gauges relied on scattered or transmitted light for measure-
ment up to 4% consistency.
5 element for consistencies greater than about 1%. In rotary
Several other approaches to consistency measurement
have been attempted with varying degrees of success. Gamma
attenuation devices measure consistency on the basis of den-
sity changes. Recent developments in plastic scintillation
detector technology have improved sensitivity and stability.
6 terms of bone-dry consistency, but rather some arbitrary,
Because the density difference between fibers and water is
very small, high sensitivity is a must. Unfortunately, fillers
are quite dense, and if present in the pulp, will yield a false
high reading. Similarly, the presence of air will yield false
low readings.
Microwave measurement techniques offer the promise of
being independent of pulp type, fiber length, brightness,
color, and flow rate. The most prevalent commercial tech-
nique is the measurement of propagation velocity, or time of
flight through the stock, which is a function of the relative
permittivity of the material. Because of the factor of 10
difference in the dielectric constant of water and wood fiber,
velocity is a strong function of consistency. These microwave
devices measure both fiber and filler, and compensation must
be made for the filler amount and type. In addition, this
method is sensitive to air, conductivity, and temperature, for
which compensation must be made.
One commercial device quotes specifications of a mea-
suring range up to 8% consistency (C), with a sensitivity and
accuracy of 0.0005% C at a flow velocity in the range of 1
7
to 16 ft/sec (0.3 to 5 m/sec). A similar microwave propaga-
tion technique uses the phase difference between an original
wave and one that passed through the stock to determine
consistency. This device is claimed to be resistant to the
effects of contamination and bubbles, with a range of 1 to
8
10% consistency.
Ideally, the complete process stream should be exposed
to the sensor, but in very large flows this is not practical and,
therefore, samples are taken. The sample should be taken
© 2003 by Béla Lipták
WATER WATER
VERTICAL
HORIZONTAL
FIG. 8.18a
Installation of blade-type consistency transmitter in vertical and
horizontal pipelines. (Courtesy of DeZurik/Copes-Vulcan.)
from the center of the pipe, usually from the discharge of a
centrifugal pump so that separation or settling of solids is
minimized (Figure 8.18a).
Mechanical Devices
These consistency-measuring instruments detect consistency
of the process fluid as shear forces acting on the sensing
devices, the shear force is reflected as the torque required to
maintain the sensor at constant speed, as the imbalance of a
strain-gauge resistance bridge, or as a turning moment. The
instruments are calibrated in-line; thus, the output is not in
reproducible value.
Stationary sensors depend on the process flow for mea-
surement, and for such instruments, the output is affected by
the velocity of the flow. For blade sensors, the sensor contour
is designed to minimize flow effects on the output over the
operating flow range. On the other hand, rotating sensors do
not depend on process flow for a measurement. While these
units are also sensitive to flow velocity variations, they gener-
ally can be used over wider flow ranges. In addition, the rotary
motion of the sensor produces some self-cleaning action,
whereas the fixed sensors depend on either a properly designed
contour or an upstream deflector to prevent material hang-up.
Probe Type This sensor transmitter functions as a resis-
tance bridge strain gauge. The bridge elements are bonded
to the inner wall of a hollow cylinder that is inserted into the
process. The shear force acting in the cylinder, due to the
consistency of the process fluid, causes an imbalance of the
resistance bridge. The amount of imbalance is proportional
to the shear force and the consistency of the process fluid.
The resistance bridge is powered from a recorder that also
contains the AC potentiometer electronics. Pipeline velocity
must be measured as compensating information, and a deflec-
tor in the pipe upstream of the probe prevents accumulation
9
of strings and like material.
The sensor is mounted through a threaded bushing fur-
nished with the unit. Flowing velocity must be between 0.5
and 5.0 ft/sec (0.15 and 1.5 m/sec) in order to obtain repeat-
ability, of around 0.1% of bone-dry consistency, up to 16%.
 8.18 Consistency Analyzers 1325

AIR
BLEED ROTARY
NOZZLE AIR SUPPLY
SENSOR
PNEUMATIC
RELAY
COARSE FEED BACK
ZERO UNIT
ADJUST
3-15 PSIG
OUTPUT
FORCE TORQUE
FINE ZERO POSITIVE
BAR
ADJUST FEED BACK TORQUE ARM
UNIT (CONNECTED TO MOTOR HOUSING)
FULCRUM
+ NEGATIVE
FEED BACK UNIT
SENSOR −
FLOW SENSITIVITY
ADJUSTMENT AIR NOZZLES
TRANSMITTER SCHEMATIC

FORCE BAR
TO PNEUMATIC
F1 TRANSMITTER
F3
SEAL FLUSH
WITH PIPE
F2 WALL
(FULCRUM)
MATERIAL SENSOR
FLOW BLADE
SHEAR FORCE
F1
BLADE DETAILS
FIG. 8.18b
Stationary blade sensor and transmitter schematic. (Courtesy of
Invensys Process Systems/Foxboro.)
Blade Types The sensing element of this instrument is a
fixed blade, specially shaped to minimize the effects of veloc-
ity. As shown in Figure 8.18b, material flowing past the blade,
which is positioned along the line of flow, creates a shear
force. Velocity of the process produces two drag forces, F1
and F2, whose resultant F3 acts through the fulcrum. The
moment arm of F3 is therefore zero, and the effect of velocity
on the measurement is negligible over a range of 0.75 to
5 ft/sec (0.23 to 1.5 m/sec).
Changes in consistency up to the 12% level are transmit-
ted through the blade to the force bar, causing small changes
in the relationship between flapper and nozzle. Therefore, the
relay unit output pressure changes until the force due to the
feedback unit balances the shear force. The instrument can
be mounted on any line 4 in. (100 mm) or larger. Mounting
is through a 2-in. (50-mm) flange supplied with the instru-
ment. Most new instruments use electronic systems for force
measurement, replacing pneumatic devices.
Moving-blade devices stroke the blade, cutting across the
flow in the plane of the blade, measuring the time required
to complete the stroke. Higher consistencies will require a
longer time, and vice versa. Compensation for velocity is
affected by a deflector mounted upstream.
RANGE
ADJUSTMENT
FIXED
RESTRICTIONS
DIFFERENTIAL
BOOSTER
20 PSIG
AIR SUPPLY
OUTPUT
3-15 PSIG
FIG. 8.18c
Air schematic of rotating sensor.
Rotating Sensors This unit consists of a motor-driven,
ribbed disk immersed in the process fluid. The disk is rotated
at constant speed, and variations in torque output by the
motor are sensed by a torque arm. The motor is suspended
by flexure bearings and anchored to the torque arm, which
senses motor reaction torque. The tip of the torque arm is
located between two air nozzles so that minute movements
of the arm, caused by torque variations, are reflected as
changes in two air output pressures (Figure 8.18c). The nozzle
pressures are fed back to bellows that react to the torque
arm movement by exerting an opposing force until equilib-
rium is reached between increased nozzle pressure and the
force exerted by the torque arm. In many cases, electronic
systems for torque measurement have replaced pneumatic
devices.
Although this unit is less sensitive to flow changes than
the strain gauge and force balance types, problems are
introduced by the shaft seal required for this design. The
torque variations must reflect only consistency changes
and, therefore, shaft friction variations are detrimental to
the measurement.
One of the latest mechanical transmitters has the appear-
ance of two blades on a rotating disk. It is claimed to measure
torque and consistency from 1 to 14% on an absolute basis by
operating on the pulp while in plug flow. The establishment

© 2003 by Béla Lipták

1326 Analytical Instrumentation

Light Light Light Backscattering

Source Source Source Depolarization

A B C
Laser
D D light Absorption

Stock Capillary with

Sample flow

D2 D Detector
Filter or FIG. 8.18e
D Polarizer Measurement principle of the kajaaniRM-200 C for woodfree pulp.
(Courtesy of Metso Automation.)
D1

FIG. 8.18d
A variety of optical sensors.

of plug flow requires a calming length (L) determined from

10
the following equation:
L = R/[7 D%C] 8.18(1)
where
L is in feet
R is flow in gallons per minute
D is pipe diameter in inches
%C is percent consistency
Optical Sensors
The range of these measurements is generally 1% and below
for transmission devices, and up to 4% for reflection sensors.
Accordingly, optical devices, either in transmission or scatter
mode, are the sensors of choice for low consistencies, relying
on the fiber’s interaction with light, as shown in Figure 8.18d
for three types of sensors.
Sensor A uses linearly polarized light from either a halo-
gen bulb or a semiconductor laser, which is passed through
the measurement cell. The transmitted light is split into two
beams, one passing through a second transverse-plane polar-
izing filter, the other passing through a third in-plane polar-
izing filter. The beams are detected by photodiodes and com-
bined to produce a relative depolarization signal, which is a
function of the total fiber and filler. The signal is insensitive
to brightness, color, freeness, or soluble additives.
Sensor B is based on the transmittance of light as a
function of consistency. Unfortunately, this sensor is rela-
FIG. 8.18f
The kajaaniRMi for wood-containing pulp. (Courtesy of Metso
Automation.)
Measuring Woodfree Pulp Optical sensors are frequently
used to manage retention on a paper machine by measuring
the total consistency at the head box and in the machine white
water early and late in the forming zone. One such device,
the kajaaniRM-200 C, is illustrated in Figure 8.18e.
This device is similar to sensor A in Figure 8.18d, in that
a polarized light beam is directed through a glass capillary
cell, where the sample continuously flows. The transmitted
light is directed through a special aperature disk for scattering
measurements, and then through a second polarizer, which
splits the light into cross-polarized and parallel-polarized
components that are detected by photodiodes. The depolar-
ization signal mainly indicates the total consistency of the
sample, and the attenuation of light is affected by the total
consistency and filler consistency. Attenuation is strongly
affected by scattering and light absorption. Since backscat-
tering and attenuation are influenced by small particles, filler
consistency is calculated from these signals.
12

tively sensitive to changes in freeness and color, exhibiting

nonlinear behavior with changes in filler and dissolved solids.
Sensor C uses forward- and backscattered light to pro-
duce a signal combined from the several detectors that is
proportional to consistency. This type of sensor can be used
at much higher consistencies (ca. 4%), and, in general, its
sensitivity to variations in the content of nonfibrous substance
lies between that of sensors A and B. The exception to this
11
rule is filler, for which this sensor is the most sensitive.
Consistency of Pulp Containing Wood For pulp containing
a considerable amount of mechanical fibers, and thus a large
fraction of lignin, the depolarization scheme loses effective-
ness. Another sensor has been developed that uses two light
sources and a combination of optical measurement principles,
including depolarization, absorption, and scattering at several
wavelengths from the ultraviolet (UV) to the near infrared
(NIR). An outline of this sensor is shown in Figure 8.18f.

© 2003 by Béla Lipták

 8.18 Consistency Analyzers 1327

1 3 4

2
DC PEAK AC

5 6 7

8
9 10

1 Light source 6 Peak detector

2 Suspension 7 AC filter
3 Detector 8 Computer
4 Amplifier 9 Input signals
5 DC filter 10 Output signals

FIG. 8.18g
The BTG Wet-end Consistency Analyzer. (Courtesy of BTG Pulp and Paper Technology AB.)

The near-IR semiconductor laser light is polarized, Light Transmission

passed through the cell, and then depolarized, as before, in
Figure 8.18e. UV light from the xenon lamp is directed
VCW
through the cell via a filter and polarizing prism. The forward-
scattered light is directed through the lens and aperature disk
to photodiodes. Backward scattering is also measured for FPC
both the UV and IR lights by detection with a photodiode
VP
before the cell. Light extinction, as well as backward and
forward scattering, is measured at several different wave-
LPC
lengths. The signals are processed to monitor total solids and
13
filler consistencies and flocculation in the sample. VDC
Figure 8.18g shows the components of an analyzer with AC Signal
a sensing scheme that is similar to sensor A in Figure 8.18d,
while Figure 8.18h describes a typical signal trace from this Time
analyzer. A light beam is directed at the suspension, and a
photo detector senses the transmitted light. Three indepen- FIG. 8.18h
dent filters process the detector signal. The first filter deter- A sample signal trace from the BTG Wet-end Consistency Analyzer.
mines the mean value VDC of the transmitted light; the second (From Wold, D., “The Peak Method of Optical Analysis Realizes the
determines the peak value VP; and the third extracts the AC Benefits of Low-Consistency Measurement,” in UpTimes, No. 5,
14 Säffle, Sweden: BTG Pulp and Paper Technology, 1999, pp. 24–25.)
component VAC of the signal.
The peak method used in the analysis assumes that the
suspension is substantially characterized by large and small
particles. The large particles (fibers) form a relatively trans-
parent network within which the much greater number of through the beam and the light is being dimmed only by the
smaller particles (fillers and fines) float freely. Observation suspended fine particles. Thus, the respective amounts of
of a typical suspension over time reveals that the great num- large and small particles in the suspension can be determined
15
ber of small particles is relatively constant, whereas the num- by the mean and peak values.
ber of large particles is few and variable. The average value Referring to Figure 8.18h, VCW is the detector signal for
of the transmitted light determines VDC. clear water and is used as a reference value. The AC signal,
Deviations from this mean value are mainly due to the VAC, is plotted along with VCW , VP , and VDC. The large par-
large particles passing through the light beam. The highest ticle content (LPC) is the difference between VP and VDC,
light intensity and VP occur when no fibers are passing while the fine particle content (FPC) is the difference between

© 2003 by Béla Lipták

1328 Analytical Instrumentation
VCW and VP . The total consistency is obtained by summing
LPC and FPC.
The consistency measurement at 30% for TMP or CTMP
pulp is based on dielectric measurement of the water content
and an optical measurement using an NIR technique with
reflectance spectroscopy. This technique is based on the res-
onance vibration of water, which appears as absorption bands
in the infrared region of the spectrum. A typical sensor uses
four fixed wavelengths of the spectrum—two located in the
absorption bands of water and two in a region where the
16
effect of water is minimal.
SUMMARY
While convenient from an installation standpoint, mechanical
in-line instruments are all sensitive to flow variations. Fixed
sensors are more likely to be plagued by material buildup,
particularly if the sample contains fibers. Rotating sensors
are self-cleaning because sensor motion will tend to spin off
any material; however, variations in shaft seal friction can be
troublesome. The newer optical sensors have found great
utility at low consistencies, and the search for alternative
methods for consistency measurement continues.
References
1. Consistency (Concentration) of Pulp Suspensions, T 240 om-88,
TAPPI Test Methods, 1, Atlanta, GA: TAPPI Press, 1988.
2. Jansson, I., Ed., Accurate Consistency, Säffle, Sweden: BTG Pulp and
Paper Technology AB, 1999.
3. Ostroot, G. F., The Consistency Control Book, Atlanta, GA: TAPPI
Press, 1993.
4. Waller, M. H., Measurement and Control of Paper Stock Consistency,
Instrument Society of America Monograph 5, Research Triangle Park,
NC: ISA, 1983.
5. Jack, J. S., Bentley, R. G., and Barron, R. L., “Optical Pulp Consistency
Sensors,” Pulp & Paper Canada, 91(2): T76–80, 1990.
6. Petersen, D. E., “Nuclear Density Consistency Meter Evaluation,”
Proceedings, 1994 Process Control Symposium, Atlanta, GA: TAPPI
Press, 1994, pp. 9–12.
7. “MIC-2300 Consistency Sensor,” Data Sheet D2009/0en, BTG Pulp
and Paper Technology AB, Säffle, Sweden, 2000.
© 2003 by Béla Lipták
8. “Consistency Sensor,” http://www.cyber-metrics.com/consiste.htm,
CyberMetrics, Alpharetta, GA, 1998.
9. Thompson, H. A., “Consistency Control, Medium and High Range,”
1986 Engineering Conference Proceedings, Atlanta, GA: TAPPI Press,
1986, pp. 593–596.
10. Preikschat, E., “ISO-Torq: The Next Generation of Rotating Consis-
tency Transmitters,” TAPPI Journal, 82(7): 133–139, 1999.
11. Reed, H. W. and Corbett, J. O., “Optical Consistency Measurement,”
in Instrumentation in the Pulp & Paper Industry, Research Triangle
Park, NC: Instrument Society of America, 1985, pp. 21, 25–35.
12. Kaunonen, A., Lehmikangas, K., Nokelainen, J., and Tikkanen, P.,
“Practical Experiences of How to Control Wet End Operations Using
Continuous Retention Measurement,” Proceedings, 1991 Papermakers
Conference, Seattle, WA, April 8–10, 1991, Atlanta, GA: TAPPI Press,
1991, pp. 39–45.
13. Kaunonen, A., “Improving Runability and Quality through Consistency
Measurement and Control,” Paper Technology, 38(3): 41–48, 1997.
14. Wold, D., “The Peak Method of Optical Analysis Realizes the Benefits
of Low-Consistency Measurement,” in UpTimes, No. 5, Säffle, Sweden:
BTG Pulp and Paper Technology, 1999, pp. 24–25.
15. Shaw, P. and Fladda, G., “A Modern Approach to Retention Measure-
ment and Control,” Paper Technology, 34(3): 36–40, 1993.
16. “High Consistency Measurement, above 30%,” http://www.consistency.
com/templates/main.cfm?id=616.
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