Periodic Reporting for period 1 - SludgeCam (A smart centrifuge camera for testing dewatering ability of waste-water sludges in hyper-gravity)
Okres sprawozdawczy: 2023-05-01 do 2024-10-31
If you have ever had the need to obtain a compositional analysis of a liquid sample, chances are that a centrifuge was used in its analysis. For example, every time your blood is tested, the amount of erythrocytes (red blood cells) is counted by centrifuging the blood sample. The centrifugal forces bring the solid content of the blood at the bottom of a vial, separating it from the serum, and from the volume of the solid the number of red blood cells can be counted. This type of analysis is done in practically all industrial or laboratory settings, where centrifuges are also used to separate liquids from solids.
A big problem in the application of centrifuges is that one cannot “see” the centrifugation process as it is happening. You can see the output of the centrifugation, but not what happens during the centrifugation. This limits our understanding of the behaviour of the sample under large centrifugal forces. In addition, there is a lot of information in the response of the sample the centrifugal forces that can be used to analyse the sample, for example to extract mechanical properties such as the sample elasticity.
A practical motivation for our project is the dewatering of sludges during waste water treatment. In waste water treatment plants, the solid component of waste water is separated from the water by flocculation. Centrifuges are used to remove the remaining water from the sludges. How much water can we retrieve?This is an important practical question, as the cost of dewatering is high and will become higher in the future
In the ERC Poc “sludgeCam” project our team at TU Delft has developed a camera that enables one to visualise at high spatial and temporal resolution, and with colour images, the centrifugation of samples subject to centrifugal forces as high as 5000 the acceleration of gravity. 5000G in short. To give an idea of the technical challenges we were able to overcome, an object of 1 kg subject to an acceleration of 5000G is subject to an effective compressive force of 5 Tons. Developing hardware that can sustain large centrifugal forces without breaking has been a major challenge. The sludgeCam device is complemented with software which enables an operator to evaluate the mechanical response of the sample to the centrifugal forces. This software enables one for example to monitor the quality of an industrial sample, and not only in the waste water sector. We have, for example, tested yogurt, blood and concrete. Examples of visualisations obtained with our camera can be found in Youtube’ Centrifuge Camera channel www.youtube.com/@CentrifugeCamera
A big problem in the application of centrifuges is that one cannot “see” the centrifugation process as it is happening. You can see the output of the centrifugation, but not what happens during the centrifugation. This limits our understanding of the behaviour of the sample under large centrifugal forces. In addition, there is a lot of information in the response of the sample the centrifugal forces that can be used to analyse the sample, for example to extract mechanical properties such as the sample elasticity.
A practical motivation for our project is the dewatering of sludges during waste water treatment. In waste water treatment plants, the solid component of waste water is separated from the water by flocculation. Centrifuges are used to remove the remaining water from the sludges. How much water can we retrieve?This is an important practical question, as the cost of dewatering is high and will become higher in the future
In the ERC Poc “sludgeCam” project our team at TU Delft has developed a camera that enables one to visualise at high spatial and temporal resolution, and with colour images, the centrifugation of samples subject to centrifugal forces as high as 5000 the acceleration of gravity. 5000G in short. To give an idea of the technical challenges we were able to overcome, an object of 1 kg subject to an acceleration of 5000G is subject to an effective compressive force of 5 Tons. Developing hardware that can sustain large centrifugal forces without breaking has been a major challenge. The sludgeCam device is complemented with software which enables an operator to evaluate the mechanical response of the sample to the centrifugal forces. This software enables one for example to monitor the quality of an industrial sample, and not only in the waste water sector. We have, for example, tested yogurt, blood and concrete. Examples of visualisations obtained with our camera can be found in Youtube’ Centrifuge Camera channel www.youtube.com/@CentrifugeCamera
Most of the research work has been devoted to hardware development. We wanted to build a device that could fit into a commercial centrifuge, so as not to force future clients of our invention to purchase a dedicated centrifuge. So we had to overcome many issues of hardware miniaturisation, to be able to fit all the necessary electronics into a small space. We needed to overcome issues with robustness during prolonged use. Under high G forces, electrical contacts in the first prototype of the device easily break off and the components of the device deformed. Now we can spin samples for one hour without problems. We wanted also to make the device modular, so that future hardware such as sensors or actuators could be adapted with ease. To demonstrate this potential, we have included a simple actuator in our device (details of what this actuator does cannot be disclosed to the general public).
Research activity has also been in software development. The camera generates movie files containing millions of instantaneous images of the centrifuged sample. We spent a lot of time developing software algorithms that can translate these images into useful data. For example, we have been able to develop an algorithm that enables one to track the position of the “sedimentation front” over time. Fitting this front to a model of the mechanics of the sample, one can obtain mechanical characteristics of the sample. A version of the software we have developed has an intuitive graphical user interface, with “knobs” and “buttons” that allows a user without much training to modify certain parameters without having to edit the code directly.
We tested the device with industrial samples obtained from research collaborators or directly from industry. Industries interested in our device are industries working in food processing, for example emulsions, materials processing companies, biotech companies, and centrifuge manufacturers.
The commercial interest in purchasing a version of our device is substantial, and we already have potential clients. Thanks to ERC Poc funding, work has been done to develop a business plan for the device and carry out the first step for the application to a patent, in collaboration with a patent attorney of TU Delft. A patent application will be filed soon.
In summary, the main outcomes are a reliable, modular, commercialisable hardware; a preliminary version of the analysis software, with a graphical user interface; testing of the device in the lab with realistic industrial matrices; the generation of a business development plan; and the editing of the patent application document.
Research activity has also been in software development. The camera generates movie files containing millions of instantaneous images of the centrifuged sample. We spent a lot of time developing software algorithms that can translate these images into useful data. For example, we have been able to develop an algorithm that enables one to track the position of the “sedimentation front” over time. Fitting this front to a model of the mechanics of the sample, one can obtain mechanical characteristics of the sample. A version of the software we have developed has an intuitive graphical user interface, with “knobs” and “buttons” that allows a user without much training to modify certain parameters without having to edit the code directly.
We tested the device with industrial samples obtained from research collaborators or directly from industry. Industries interested in our device are industries working in food processing, for example emulsions, materials processing companies, biotech companies, and centrifuge manufacturers.
The commercial interest in purchasing a version of our device is substantial, and we already have potential clients. Thanks to ERC Poc funding, work has been done to develop a business plan for the device and carry out the first step for the application to a patent, in collaboration with a patent attorney of TU Delft. A patent application will be filed soon.
In summary, the main outcomes are a reliable, modular, commercialisable hardware; a preliminary version of the analysis software, with a graphical user interface; testing of the device in the lab with realistic industrial matrices; the generation of a business development plan; and the editing of the patent application document.
Based on the result of the interactions with industrial stakeholders we had during the project, the device has the potential to become a useful analytical tool when used in combination with a laboratory centrifuge. We envision many applications in scientific research, in academic or industrial research departments, where the interest is to get insights into the centrifugation behaviour of liquid mixtures. A second big application area is quick material testing. For example, in industrial plants the device can be used for inexpensive, periodic quality monitoring.
The main obstacle is currently protecting our innovation with intellectual property rights. Obtaining such rights will enable us to talk to have freedom to operate with commercial companies, and sell the first versions of our device or provide services.
In summary this project has enabled us to go from a very preliminary prototype at the basic research level (at technology readiness level 1 or 2) to the experimental proof of concept of a device tested with realistic, industrial samples (at technology readiness level of 3). The development of a business plan and the identification of industrial needs, core activities during the project, enables us to be now ready to apply for further research and commercialisation funding.
The main obstacle is currently protecting our innovation with intellectual property rights. Obtaining such rights will enable us to talk to have freedom to operate with commercial companies, and sell the first versions of our device or provide services.
In summary this project has enabled us to go from a very preliminary prototype at the basic research level (at technology readiness level 1 or 2) to the experimental proof of concept of a device tested with realistic, industrial samples (at technology readiness level of 3). The development of a business plan and the identification of industrial needs, core activities during the project, enables us to be now ready to apply for further research and commercialisation funding.