The University of Sheffield and Johnson Matthey plc KTP 24_25 R4

A new ultrasonic sensor will listen to the sound of particles moving through industrial slurries, letting manufacturers measure and control them in real time. The problem is straightforward: when you mix solid particles into a liquid—whether for making catalysts, food, or drugs—you need to know the size and concentration of those particles to ensure quality. Current methods often require stopping the process to take a sample, which wastes time and energy. This project, a collaboration between the University of Sheffield and Johnson Matthey, builds an online sensor that uses ultrasound to track particles as they flow. The technology is being developed first for slurries used in hydrogen fuel catalysts, where particle consistency directly affects performance. If it works, manufacturers could adjust their processes on the fly, cutting waste and improving efficiency. The same sensor could later be adapted for food processing—think chocolate or sauces—and pharmaceutical production, where particle size determines how a drug dissolves in the body. This is applied engineering, not fundamental science. The goal is a practical tool that makes industrial processes faster, cheaper, and more consistent, with ripple effects across multiple industries.