System and method for inline monitoring of a quality characteristic of sludge

Abstract

A system for inline monitoring of a sludge quality characteristic comprises a vessel configured to receive the sludge within a vessel interior, one or more agitators arranged within the vessel interior to stir the sludge, and a sensor for detecting the quality characteristic. In a first embodiment, the sensor is located within the defined volume and outside a collective, paddle-swept volume. In a second embodiment, the sensor has a sensor area arranged in a conduit located outside a vessel side wall, the conduit having a flow inlet and a flow outlet that are in fluid communication with the vessel interior. A method for using the first and second embodiments is also provided.

Description

introduction

[0001] This disclosure relates generally to systems and methods for inline monitoring of a quality characteristic of a sludge, e.g., a battery electrode sludge.

[0002] As part of the manufacturing process for batteries, such as lithium-ion batteries, it is common practice to test battery electrode sludge in an ex-situ batch process. For example, a sample of the battery electrode sludge can be taken from the processing plant and transported to a test rig where one or more chemical, rheological, or other properties of the sludge are evaluated, such as the viscosity of the sludge in response to shear or the fineness of the particle size (FoG) of the aggregates and components of the sludge. This type of batch process / ex-situ testing must be repeated regularly to monitor the overall quality of the sludge. Description

[0003] The present disclosure shows various embodiments of a system, designs and methods for inline monitoring of a quality characteristic of sludge, which represent a significant improvement over previously known approaches.

[0004] According to one embodiment, a system for inline monitoring of a quality characteristic of a sludge comprises: (i) a vessel having a vessel sidewall defining a vessel interior, wherein the vessel is configured to receive the sludge and contain the sludge within a defined volume located within the vessel interior;(ii) one or more stirrers, each having a respective elongated spindle and a respective paddle or paddles attached to the respective spindle and extending radially outwards from it, each spindle having a respective spindle axis, and the one or more stirrers being arranged such that each spindle is oriented in a generally vertical, generally horizontal or generally diagonal orientation, the respective one or more paddles being arranged within the defined volume, each of the one or more stirrers being configured to rotate about its respective spindle axis such that the rotation of the respective one or more paddles sweeps and defines a respective individual paddle-swept volume, the totality of the individual paddle-swept volumes defining a collective paddle-swept volume;and (iii) a sensor located within the defined volume and outside the collective paddle-swept volume, the sensor being configured to detect the quality characteristic.

[0005] The quality characteristic can be the specific resistance or the dielectric permittivity.

[0006] For each of the one or more stirrers, the respective one or more paddles can be attached to the stirrer via one or more arms.

[0007] The vessel can have a generally vertically oriented longitudinal axis, with one or more of the stirrers arranged such that their respective spindle axes are generally collinear with the longitudinal axis.

[0008] The vessel can have a vessel radius, measured from the longitudinal axis, with the collective paddle-swept volume extending radially outward from the longitudinal axis to a maximum paddle-swept radius such that the maximum paddle-swept radius is smaller than the vessel radius.

[0009] The sensor can be arranged within a sensor radius, measured from the longitudinal axis, such that the sensor radius is larger than the maximum paddle-swept radius and smaller than the vessel radius.

[0010] The system can further comprise an elongated extension with an upper extension end and a lower extension end, wherein the extension is arranged in a generally vertical orientation and the lower extension end is attached to the sensor.

[0011] The extension can be configured as a tube with a lumen inside, and at least one sensor wire can extend within the lumen and be functionally connected to the sensor.

[0012] The sensor can be configured for continuous or intermittent monitoring.

[0013] The sludge may be battery electrode sludge containing ceramic particles.

[0014] The sensor can be positioned within the defined volume at a point that has the lowest flow rate during the rotation of one or more stirrers.

[0015] The sensor may have at least one surface coating made of a ceramic material on a sensor surface of the sensor, a deflector plate arranged to at least partially block a flow of sludge to the sensor surface and configured to reduce a velocity and / or turbulence of the sludge impacting the sensor surface, and a housing surrounding the sensor surface and having a flow inlet for introducing the sludge into a chamber in which the sensor surface is arranged and a flow outlet for discharging the sludge from the chamber.

[0016] The housing may have at least one housing inlet valve connected to the flow inlet, one housing outlet valve connected to the flow outlet, and a conductive shield on at least one inner housing surface and one outer housing surface of the housing.

[0017] According to another embodiment, a system for inline monitoring of a quality characteristic of a sludge comprises: (i) a vessel having a vessel sidewall defining a vessel interior, and a conduit located outside the vessel sidewall, the conduit having a conduit inlet in fluid communication with the vessel interior and a conduit outlet in fluid communication with the vessel interior, the vessel being configured to receive the sludge and contain the sludge within a defined volume located within the vessel interior and the conduit; (ii) one or more agitators located inside the vessel and configured to agitate the sludge; and (iii) a sensor having a sensor area located inside the conduit, the sensor being configured to detect the quality characteristic.

[0018] The sensor can be configured for continuous or intermittent monitoring.

[0019] The sensor may have at least one surface coating made of a ceramic material on a sensor surface of the sensor, a deflector plate arranged to at least partially block the flow of sludge to the sensor surface and configured to reduce the velocity and / or turbulence of the sludge impacting the sensor surface, and a housing surrounding the sensor surface and having a flow inlet for introducing sludge into a chamber in which the sensor surface is located and a flow outlet for discharging sludge from the chamber.

[0020] The housing may have at least one housing inlet valve in contact with the flow inlet, one housing outlet valve in contact with the flow outlet, and a conductive shield on at least one inner housing surface and one outer housing surface of the housing.

[0021] The pipeline may include at least one of the following elements: a pipeline inlet valve in fluid communication with the pipeline inlet, a pipeline outlet valve in fluid communication with the pipeline outlet, and a flow rate control arranged in a pipeline channel of the pipeline to regulate the flow rate of the sludge through the pipeline channel.

[0022] The cable can have a conductive shield on at least one inner cable surface and one outer cable surface of the cable.

[0023] According to a further embodiment, a method for inline monitoring of a quality characteristic of a slurry comprises: (a) providing a system comprising: (i) a vessel having a vessel sidewall defining a vessel interior, wherein the vessel is configured to receive the slurry and contains the slurry in a defined volume located within the vessel interior;(ii) one or more stirrers, each having a respective elongated spindle and one or more paddles attached to the respective spindle and extending radially outwards from it, each spindle having a respective spindle axis, and the one or more stirrers being arranged such that each spindle is oriented in a generally vertical, generally horizontal or generally diagonal orientation, the corresponding one or more paddles being arranged within the defined volume, each of the one or more stirrers being configured to rotate about its corresponding spindle axis such that a rotation of the corresponding one or more paddles sweeps and defines a corresponding individual paddle-swept volume, a totality of the individual paddle-swept volumes defining a collective paddle-swept volume;and (iii) a sensor located within the defined volume and outside the collectively paddle-swept volume; (b) adding the sludge to the vessel; (c) stirring the sludge with the one or more stirrers; and (d) capturing the sludge with the sensor to determine the quality characteristic of the sludge.;

[0024] According to a further embodiment, a method for inline monitoring of a sludge quality characteristic comprises: (a) providing a system having (i) a vessel having a vessel sidewall defining a vessel interior, and a line located outside the vessel sidewall, the line having a line inlet in fluid communication with the vessel interior and a line outlet in fluid communication with the vessel interior, (ii) one or more agitators located in the vessel interior and configured to agitate the sludge, and (iii) a sensor with a sensing area located in the line; (b) adding the sludge to the vessel; (c) agitating the sludge with the one or more agitators; and (d) sensing the sludge in the line with the sensor to determine the sludge quality characteristic.The system may include a conduit channel defined within the conduit, which connects the conduit inlet and conduit outlet to fluid flow, and the method may further include: (e) opening a conduit inlet valve located in the conduit channel near the conduit inlet, or a conduit outlet valve located in the conduit channel near the conduit outlet, or both. The method may also include: (f) closing the conduit inlet valve or the conduit outlet valve, or both.

[0025] The above features and advantages, as well as other features and advantages of the present teaching, are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teaching as defined in the attached claims, when considered in conjunction with the attached drawings. Brief description of the drawings Fig. Figure 1 is a schematic cross-sectional side view of a system for inline monitoring of a quality characteristic of a sludge according to a first embodiment. Fig. Figures 2-3 are schematic cross-sectional top views of the system of Fig. 1 along line II, corresponding to two different configurations. Fig. Figure 4 is a schematic cross-sectional side view of a system for inline monitoring of a quality characteristic of a sludge according to a second embodiment. Fig. Figures 5-6 are schematic cross-sectional top views of the system of Fig. 4, seen along line II-II, according to two different configurations. Fig. Figure 7 is a schematic side view of a sensor with a deflector plate and a housing. Fig. Figure 8 is a block diagram of a sludge composition. Fig. Figure 9 is a block diagram with various quality characteristics. Fig. Figure 10 is a flowchart of a housing for a sensor. Fig. Figure 11 is a flowchart of a channel for the second execution. Fig. Figure 12 is a flowchart of an initial procedure for inline monitoring of a quality characteristic of a sludge, for use with the first implementation of the system. Fig. Figure 13 is a flowchart of a second procedure for inline monitoring of a quality characteristic of a sludge for use with the second version of the system. Detailed description

[0026] With reference to the drawings, where identical numbers denote identical parts in the different views, a System 20 and Methods 100, 200 for inline monitoring of a quality characteristic QC of a sludge 10 are shown and described here, according to a first design D1 and a second design D2, as detailed below. This System 20 and embodiments D1, D2 and Methods 100, 200 represent a significant improvement over previously known approaches for batch processes / ex-situ tests, which must be repeated periodically and separately, since the System 20 and Methods 100, 200 disclosed here provide approaches for inline / in-situ monitoring of one or more quality characteristics QC of a sludge 10 in real time.

[0027] Starting from the first embodiment D1, shows Fig. 1 a schematic cross-sectional side view of a system 20 for inline monitoring of a quality characteristic QC of a sludge 10, and Fig. Figures 2-3 show schematic cross-sectional top views of system 20. Fig. 1, seen along line I - I, according to two different configurations.

[0028] In this first embodiment D1, the system 20 comprises a vessel 22, one or more agitators 30, and a sensor 43 configured to detect the quality characteristic QC. The vessel 22 has a vessel side wall 23 that defines a vessel interior 28 within the vessel 22. The vessel 22 is configured to receive the sludge 10 (e.g., via pipes or conduits not shown) and to contain the sludge 10 in a defined volume 29 located within the vessel interior 28. The vessel 22 can, for example, have a generally cylindrical shape (or another suitable shape) and a generally vertically oriented longitudinal axis A, with a vessel radius R. v , measured from the longitudinal axis A. A longitudinal direction L can run parallel to the longitudinal axis A, with the longitudinal direction L having opposite upward and downward directions U, D as well as a radially outward direction R. o, pointing outwards from the longitudinal axis A, and a radially inwards direction R i , which points inwards from the longitudinal axis A.

[0029] In addition to the vessel side wall 23, the vessel 22 can have a vessel bottom 24 and an optional vessel lid 25. The vessel side wall 23 can have an inner surface 26 and an outer surface 27. As mentioned previously, the vessel 22 is configured to receive and contain the sludge 10 within a defined volume 29, such that the top of the sludge 10 within the vessel interior 28 extends to a defined volume height H. dv , measured from the bottom of the vessel 24, can reach; this defined volume height H dv may be less than the full height of the vessel interior 28.

[0030] System 20 can have a single stirrer 30, as in the Fig. 1-2 shown, or it can have several stirrers 30, as in Fig. Figure 3 shows four stirrers 30. It should be noted that a “stirrer,” as used here, can have any element or device that can be used to stir, shake, drive, mix, or otherwise move the slurry 10 within the vessel 22. Each stirrer 30 can have an elongated spindle 31 having an upper spindle end 32, a lower spindle end 33, and a spindle axis 35 extending between the upper and lower spindle ends 32, 33. A stirrer 30 can be arranged such that its spindle 31 is generally oriented vertically, for example, by the optional vessel lid 25, as shown in Figure 3. Fig. 1 (as well as in Fig. 2-3). If, for example, the vessel 22 has a generally vertical longitudinal axis A, an agitator 30 can be arranged in a generally vertical orientation such that the spindle axis 35 of the agitator is generally collinear with the longitudinal axis A. Alternatively, the spindle 31 can be oriented in a generally horizontal or generally diagonal orientation (e.g., through the vessel lid 25 or the vessel side wall 23). Regardless of the orientation of the agitator 30 and its spindle 31, the lower spindle end 33 can be arranged within the defined volume 29, while the upper spindle end 32 can be arranged outside the vessel 22 or, optionally, within the vessel 22 (e.g., within the open space above the upper surface of the sludge 10).An electric, hydraulic, pneumatic or mechanical motor (not shown) can be fitted to each stirrer 30 at the upper spindle end 32 to rotate the stirrer 30 about its spindle axis 35.

[0031] Each stirrer 30 can also have one or more paddles 36, each paddle 36 being attached to a lower spindle section 34 of the spindle 31. Each paddle 36 can extend radially outwards from the spindle 31 of the stirrer with an individual paddle-swept radius R. ips extend, with each of the one or more paddles 36 being arranged within the defined volume 29. All paddles 36 used in the system 20 together can form a paddle arrangement 37 extending from the vessel bottom 24 to a paddle arrangement height H paextends upwards. When each stirrer 30 is rotated about its spindle axis 35, the one or more paddles 36 are also rotated about the spindle axis 35. When the one or more paddles 36 of a stirrer 30 are rotated in this way, they can sweep a single paddle-swept volume V ips sweep out and define. In the Fig. In the configuration shown in 1-2, in which only one stirrer 30 is used, for example a single paddle-swept volume V ips swept out by the stirrer 30. In Fig. 3, in which four stirrers 30 are used, however, each stirrer 30 sweeps its own individual paddle-swept volume V ips out, so that a total of four individual paddle-swept volumes V ips result.

[0032] A totality or aggregation of the individual paddle-swept volumes V ips can a collective paddle-swept volume V cpsdefine. In configurations where the system 20 has only one stirrer 30, as in Fig. 1-2, can the collective paddle-swept volume V cps be the same as the individual paddle-swept volume V ips ; and in configurations where the system 20 has two or more stirrers 30, as in Fig. 3. Can the collective paddle-swept volume V cps through an aggregation of the several individual paddle-swept volumes V ips be formed. The collective paddle-swept volume V cps can extend radially outwards from the longitudinal axis A of the vessel 22 to a maximum paddle-swept radius R mps extend so that the maximum paddle-swept radius R mps is smaller than the vessel radius R v .

[0033] It should be noted that a “paddle,” as used here, can comprise any part of an agitator 30 that can be used to stir, shake, drive, mix, or otherwise move the sludge 10 within the vessel 22 when the agitator 30 is rotated about its spindle axis 35. A paddle 36 can assume any suitable size, shape, and orientation. For example, a paddle 36 can be configured as a paddle with a relatively low cross-sectional ratio, as a blade with a relatively high cross-sectional ratio, or in any other suitable shape. Each paddle 36 can have a paddle length L. p and a paddle height H p have. (It should be noted that in Fig. 1 the paddle length L p along the radial inward and outward direction R i , R o and the paddle height H p measured along the upward and downward directions U, D, but the paddle length L p and the paddle height H p(also can be measured in other directions). Furthermore, a paddle 36 can be oriented and attached to a spindle 31 such that when the spindle 31 rotates and the paddle 36 is rotated about the spindle axis 35, the main surface of the paddle points directly into the path of rotation (i.e., the main surface is orthogonal to the tangential component of the path of rotation); alternatively, the main surface of the paddle can be angled with respect to the path of rotation (i.e., the main surface is not orthogonal to the tangential component of the path of rotation).

[0034] Each paddle 36 can have a first paddle end 38 and a second paddle end 39, and these first and second paddle ends 38, 39 can be opposite each other. Each paddle 36 can be connected to the stirrer 30 via one or more arms 40, each arm 40 having a first arm end 41 and a second arm end 42. For example, a first paddle end 38 can be attached to a second arm end 42, with the first arm end 41 attached to the spindle 31 and the second paddle end 39 being away from the spindle 31, as shown in the Fig. 1-2 shown. As another example, a paddle 36 can have an arm 40 attached to each of the first and second paddle ends 38, 39, with both arms 40 attached to the spindle 31. Another example is an arm 40 in the form of a disk with several paddles 36 distributed around the outer circumference of the disk-shaped arm 40, as in the two smaller stirrers 30 in Fig. 3 shown.

[0035] As already mentioned, the paddles 36 (as well as the arms 40, the spindles 31 and the stirrers 30) can be configured in a variety of different ways. These configurations can include dispersion paddles, Cowles paddles, spiral mixing paddles, lamellar paddles, sawtooth paddles, flat paddles, curved / concave paddles, etc.

[0036] The aforementioned sensor 43 can be configured for continuous or intermittent monitoring of the sludge quality characteristic QC. Sensor 43 can be positioned within the defined volume 29 and outside the collective paddle-swept volume V. cpsThe sensor 43 can be arranged in various ways. For example, the sensor 43 can be positioned within the defined volume 29 at a location 47 that has the lowest flow rate during the rotation of one or more agitators 30. This location 47 can be determined empirically by direct measurements of the flow profile within the defined volume 29, or it can be determined computationally or modeled, e.g., by using computational fluid dynamics (CFD) methods.

[0037] In some configurations, the sensor 43 can be located within the defined volume 29 at a sensor radius R. s , measured from the longitudinal axis A, be arranged such that the sensor radius R s larger than the maximum paddle-swept radius R mps and smaller than the ship's radius R vIn other configurations, the sensor 43 can be located at a position within the defined volume 29 that is above the top surface(s) of one or more paddles 36, e.g., above the paddle assembly height H. pa The in Fig. The configuration shown in Figure 1 shows the sensor 43, for example, at a location 47 that is both above the paddle assembly height H pa as well as with a sensor radius R s located which is larger than the maximum paddle-swept radius R mps and smaller than the vessel radius R v is.

[0038] Fig. Figure 7 shows a schematic side view of a sensor 43 immersed in a sludge 10 inside a vessel 28. Note that the dashed lines represent the outer boundaries of an upper individual paddle-swept volume V. ips and a lower individual paddle-swept volume V ipsdisplay, where a horizontal dashed line represents the upper and lower individual paddle-swept volumes V ips separates and both individual paddle-swept volumes V ips together the collective paddle-swept volume V cps Define. Here, sensor 43 is in a radially outward direction R. o from the upper single paddle-swept volume V ips and in a longitudinally upward direction U from the lower single paddle-swept volume V ips arranged, wherein the sensor 43 has a sensor body 44 (e.g., a main part) which includes a sensor element 45 with a sensor surface 45 s The sensor 43 can optionally include a surface coating 48 made of a suitable ceramic material 49 on the sensor surface 45. s have a sensor area of ​​45 s to protect (e.g. from the impact of ceramic particles 14 in the mud 10).

[0039] The sensor 43 can optionally also have a housing 70 and one or more deflector plates 69, as shown in Fig. 7 and in the flow / block diagram of Fig. Figure 10 is shown schematically. One or more deflector plates 69 can be arranged to direct the flow of the sludge 10 to the measuring surface 45. s to at least partially block, and they can be configured to reduce the velocity V and / or the turbulence T of the mud 10 that is applied to the measuring surface 45 s This occurs when the mud 10 moves along a flow direction DOF. For example, as in Fig. As shown in Figure 10, the flow of the slurry 10 has a first velocity V1 and a first turbulence T1 upstream of the one or more deflecting plates 69 and a second velocity V2 and a second turbulence T2 downstream of the one or more guide plates 69, where V1 > V2 and T1 > T2. The housing 70 can accommodate the sensor area 45 ssurround or cover the sensor 43. The housing 70 can have one or more flow inlets 71 for introducing the sludge 10 into a chamber 72 in which the sensor surface 45 s is arranged, and have one or more flow outlets 73 for discharging the sludge 10 from the chamber 72. The housing 70 may include one or more of the following elements: a housing inlet valve 74 in fluid communication with the flow inlet 71, a housing outlet valve 75 in fluid communication with the flow outlet 73, and an electrically conductive shield 78 on one or both inner housing surfaces 76 and an outer housing surface 77 of the housing 70 to reduce potential electromagnetic interference.

[0040] Now to Fig. To return to 1, the system 20 can further comprise an elongated extension 50 with an upper extension end 51 and a lower extension end 52, wherein the extension 50 is arranged in a generally vertical orientation and the lower extension end 52 is attached to the sensor 43. The extension 50 can be configured as a tube 53 with a lumen 54 therein, and at least one sensor wire 46 can extend within the lumen 54 and connect the sensor 43 to a sensor data acquisition system 67. The extension 50 can be made of a corrosion-resistant and / or chemical-resistant material, such as a suitably alloyed or coated metal or a suitably coated plastic, depending on the chemicals used in the sludge 10. Although the extension 50 in Fig. 1 such that it passes through the vessel lid 25 and is generally vertically oriented, the extension 50 may also pass through the vessel wall 23 (with suitable seals, O-rings or the like to prevent leakage of the sludge 10), and / or the extension 50 may be arranged in a generally horizontal or generally diagonal orientation.

[0041] As in Fig. As shown in Figure 8, the sludge 10 can be a battery electrode sludge 12 containing ceramic particles 14. The battery electrode sludge 12 can, for example, be intended for a lithium-ion battery and contain an active material (e.g., LiCoO2, LiNiO2, LiNiMnCoO2) that provides lithium ions, an organic solvent (e.g., N-methyl-2-pyrrolidone or NMP), a polymer binder (e.g., polyvinylidene fluoride or PVDF), and a conductive additive (e.g., carbon black). The ceramic particles 14 in the battery electrode sludge 12 can consist of aluminum oxide, silicon dioxide, aluminosilicate, zirconium silicate, etc.

[0042] How the block diagram in Fig. As shown in section 9, the quality characteristic QC can be a specific resistance QC. r of the mud 10, a dielectric constant QC dp of the sludge 10 and / or another quality characteristic QC o of the mud 10 be.

[0043] Fig. Figure 4 shows a schematic cross-sectional side view of a system 20 for inline monitoring of a quality characteristic QC of a sludge 10, and Fig. Figures 5-6 show schematic cross-sectional top views of system 20. Fig. 4, seen along line II-II, according to two different configurations.

[0044] In this second embodiment D2, the system 20 comprises a vessel 22, one or more stirrers 30, and a sensor 43 configured to detect the quality characteristic QC. The vessel 22 shown here for the second embodiment D2 is similar to the vessel 22 shown for the first embodiment D1, except that here the vessel 22 has a line 55 located outside the vessel 22. Here, the vessel 22 has a vessel side wall 23 defining a vessel interior 28, and a line 55 located outside the vessel side wall 23, which has a line wall 60. The line 55 has a line inlet 56, which is in fluid communication with the vessel interior 28, and a line outlet 57, which is also in fluid communication with the vessel interior 28, with a line channel 63, which is in fluid communication with the line inlet and the line outlet 56, 57.It should be noted that the conduit 55 can generally be vertically oriented, so that the conduit inlet 56 is positioned above the conduit outlet 57, as shown in . Fig. 4 shown, or in a generally horizontal orientation, such that the line inlet and line outlet 56, 57 are positioned at approximately the same height (e.g., measured from the vessel bottom 24), as in Fig. 5-6, or in other suitable orientations, such as a generally diagonal orientation. The conduit 55 can have a generally arcuate or curved overall shape 64 with a vertex 65 extending outwards from the outer surface 27 of the vessel side wall 23. The vessel 22 is configured to receive the sludge 10 and to contain the sludge 10 within a defined volume 29, wherein, in the second embodiment D2, the defined volume 29 is located both inside the vessel 28 and in the conduit 55. The one or more agitators 30 are arranged inside the vessel 28 and are configured to stir the sludge 10, and the sensor 43 has a sensor area 45. s , which is located in line 55. Optionally, the sensor area can be 45 s be located at or near the apex 65 of line 55.

[0045] Fig. Figure 11 shows a block / flow diagram of a line 55 for the second embodiment D2. As shown in the diagram, the line 55 can have one or more line inlet valves 58 in fluid connection with the line inlet 56, a line outlet valve 59 in fluid connection with the line outlet 57, a pump 68, and a flow rate controller 66 arranged in the line channel 63 for controlling a flow rate FR of the sludge 10 through the line channel 63. The flow of the sludge 10 can have a first flow rate FR1 upstream of the flow rate controller 66 and a second flow rate FR2 downstream of the flow rate controller 66, such that FR1 > FR2. Although in Fig. 11. Where the elements are shown in a specific order along the direction of flow DOF – i.e., a line inlet valve 58, then a line inlet 56, then a pump 68, then a flow rate controller 66, then a line outlet 57, and then a line outlet valve 59 – it should be noted that these elements may occur in a different order than in the example shown. Optionally, the line 55 may have an electrically conductive shield 78 on one or both inner line surfaces 61 of the line wall 60 and on one outer line surface 62 of the line wall 60.

[0046] Now that the first and second versions D1, D2 have been disclosed, it can be seen how the system 20 can be used in the respective first and second methods 100, 200 for inline monitoring of a quality characteristic QC of a sludge 10.

[0047] Fig. Figure 12 shows a flowchart of the first method 100. In block 110, a system 20 according to the first embodiment D1 is provided, comprising: (i) a vessel 22 having a vessel sidewall 23 defining a vessel interior 28, wherein the vessel 22 is configured to receive the sludge 10 and to contain the sludge 10 within a defined volume 29 located within the vessel interior 28;(ii) one or more stirrers 30, each of which has a respective elongated spindle 31 and a respective paddle or paddles 36 attached to the respective spindle 31 and extending radially outwards from it, each spindle 31 having a respective spindle axis 35 and the one or more stirrers 30 being arranged such that each spindle 31 is oriented in a generally vertical, generally horizontal or generally diagonal orientation, the spindle 31 and the paddles 36 generally being diagonally oriented, the respective one or more stirrers 36 being arranged within the defined volume 29, each of the one or more stirrers 30 being configured to rotate about its respective spindle axis 35 such that a rotation of the respective one or more stirrers 36 sweeps a respective individual paddle-swept volume V; ipsrinses out and defines, whereby an entirety of the individual paddle-swept volumes V ips a collective paddle-swept volume V cps defined; and (iii) a sensor 43 located within the defined volume 29 and outside the collective paddle-swept volume V cps The process is arranged as follows: In block 120, the sludge 10 is placed into vessel 22. In block 130, the sludge 10 is stirred with one or more agitators 30. In block 140, the sludge 10 is detected by sensor 43 to determine the quality characteristic QC of the sludge 10.

[0048] Fig.Figure 13 shows a flowchart of the second method 200. In block 210, a system 20 according to the second embodiment D2 is provided, comprising: (i) a vessel 22 having a vessel sidewall 23 defining a vessel interior 28, and a line 55 arranged outside the vessel sidewall 23, the line 55 having a line inlet 56 in fluid communication with the vessel interior 28 and a line outlet 57 in fluid communication with the vessel interior 28, (ii) one or more stirrers 30 arranged in the vessel interior 28 and configured to stir the sludge 10, and (iii) a sensor 43 with a sensor area 45 s, which is located in line 55. In block 220, the sludge 10 is filled into vessel 22. In block 230, the sludge 10 is stirred with one or more agitators 30. And in block 250, the sludge 10 in line 55 is detected by sensor 43 to determine the quality characteristic QC of the sludge 10.

[0049] In this second method 200, the system 20 can have a conduit 63 defined in the conduit 55, which connects the conduit inlet 56 and the conduit outlet 57 to fluid flow. Method 200 can further include, in block 240, the opening of a conduit inlet valve 58 located in the conduit 63 near the conduit inlet 56, or of a conduit outlet valve 59 located in the conduit 63 near the conduit outlet 57, or both. Method 200 can also include, in block 260, the closing of the conduit inlet valve 58 or the conduit outlet valve 59, or both.

[0050] As someone with relevant technical knowledge will recognize, the system 20 and the method 100 of the present disclosure can be represented or arranged in a variety of different configurations and embodiments.

[0051] According to one embodiment, a system 20 for inline monitoring of a quality characteristic QC of a sludge 10 comprises: (i) a vessel 22 having a vessel side wall 23 defining a vessel interior 28, wherein the vessel 22 is configured to receive the sludge 10 and to contain the sludge 10 within a defined volume 29 located within the vessel interior 28;(ii) one or more stirrers 30, each of which has a respective elongated spindle 31 and a respective paddle or paddles 36 attached to the respective spindle 31 and extending radially outwards from it, each spindle 31 having a respective spindle axis 35 and the one or more stirrers 30 being arranged such that each spindle 31 is oriented in a respective generally vertical, generally horizontal or generally diagonal orientation, the respective one or more stirrers 36 being arranged within the defined volume 29, each of the one or more stirrers 30 being configured to rotate about its respective spindle axis 35 such that a rotation of the respective one or more stirrers 36 sweeps a respective individual paddle-swept volume V; ips rinses out and defines, whereby an entirety of the individual paddle-swept volumes V ipsa collective paddle-swept volume V cps defined; and (iii) a sensor 43 located within the defined volume 29 and outside the collective paddle-swept volume V cps is arranged, with sensor 43 configured to detect the quality characteristic QC.

[0052] The quality characteristic QC can be at least one of the following: specific resistance QC r and dielectric permittivity QC dp .

[0053] For each of the one or more stirrers 30, the respective one or more paddles 36 can be attached to the stirrer 30 via one or more arms 40.

[0054] The vessel 22 can have a generally vertically oriented longitudinal axis A, wherein one or more of the stirrers 30 are arranged such that their respective spindle axes 35 are generally collinear with the longitudinal axis A.

[0055] Vessel 22 can have a vessel radius Rv , measured from the longitudinal axis A, have, where the collective paddle-swept volume V cps from the longitudinal axis A radially outwards to a maximum paddle-swept radius R mps extends so that the maximum paddle-swept radius R mps smaller than the vessel radius R v is.

[0056] The sensor 43 can be used within a sensor radius R s , measured from the longitudinal axis A, be arranged such that the sensor radius R s greater than the maximum paddle-swept radius R mps and smaller than the vessel radius R v is.

[0057] The system 20 can further comprise an elongated extension 50 with an upper extension end 51 and a lower extension end 52, wherein the extension 50 is arranged in a generally vertical orientation and the lower extension end 52 is attached to the sensor 43.

[0058] The extension 50 can be designed as a tube 53 with a lumen 54, and at least one sensor wire 46 can extend within the lumen 54 and be fitted with the sensor 43.

[0059] The sensor 43 can be configured for continuous or intermittent monitoring.

[0060] The sludge 10 may be a battery electrode sludge 12 containing ceramic particles 14.

[0061] The sensor 43 can be positioned within the defined volume 29 at a point 47 which has the lowest flow rate FR during the rotation of one or more stirrers 30.

[0062] The sensor 43 can have at least one surface coating 48 made of a ceramic material 49 on a sensor surface 45 s of the sensor 43, a deflector plate 69, which is arranged such that it directs a flow of the mud 10 to the sensor surface 45 sat least partially blocked, and is configured to measure a velocity V and / or turbulence T of the sensor area 45 s to reduce the impact of sludge 10, and have a housing 70 that surrounds the sensor area 45 and has a flow inlet 71 for letting the sludge 10 into a chamber 72 in which the sensor area 45 is arranged, and a flow outlet 73 for letting the sludge 10 into a chamber 72 in which the sensor area 45 is arranged.

[0063] The housing 70 can have at least one housing inlet valve 74, which is in fluid communication with the flow inlet 71, one housing outlet valve 75, which is in fluid communication with the flow outlet 73, and a conductive shield 78 on at least one of the inner housing surface 76 and the outer housing surface 77 of the housing 70.

[0064] According to another embodiment, a system 20 for inline monitoring of a quality characteristic QC of a sludge 10 comprises: (i) a vessel 22 having a vessel side wall 23 defining a vessel interior 28, and a line 55 arranged outside the vessel side wall 23, the line 55 having a line inlet 56 in fluid communication with the vessel interior 28 and a line outlet 57 in fluid communication with the vessel interior 28, the vessel 22 being configured to receive the sludge 10 and to contain the sludge 10 within a defined volume 29 located within the vessel interior 28 and the line 55; (ii) one or more stirrers 30 arranged inside the vessel 28 and configured to stir the sludge 10; and (iii) a sensor 43 with a sensor area 45 s , which is located in line 55, wherein the sensor 43 is configured to detect the quality characteristic QC.

[0065] The sensor 43 can be configured for continuous or intermittent monitoring.

[0066] The sensor 43 can have at least one surface coating 48 made of a ceramic material 49 on a sensor surface 45 s of the sensor 43, a deflector plate 69, which is arranged to direct a flow of the mud 10 to the sensor surface 45 s to block at least partially, and is configured to impart a velocity V and / or turbulence T to the sensor area 45 s to reduce the impact of sludge 10, and have a housing 70 that surrounds the sensor area 45 and has a flow inlet 71 for letting the sludge 10 into a chamber 72 in which the sensor area 45 is arranged, and a flow outlet 73 for letting the sludge 10 into a chamber 72 in which the sensor area 45 is arranged.

[0067] The housing 70 can have at least one housing inlet valve 74, which is in fluid communication with the flow inlet 71, one housing outlet valve 75, which is in fluid communication with the flow outlet 73, and a conductive shield 78 on at least one of the inner housing surface 76 and the outer housing surface 77 of the housing 70.

[0068] The line 55 can have at least one of the following elements: a line inlet valve 58 which is in fluid communication with the line inlet 56, a line outlet valve 59 which is in fluid communication with the line outlet 57, and a flow rate control 66 arranged in a line channel 63 of the line 55 for regulating the flow rate FR of the sludge 10 through the line channel 63.

[0069] The conductor 55 can have a conductive shield 78 on at least one of the inner conductor surface 61 and the outer conductor surface 62 of the conductor 55.

[0070] According to a further embodiment, a method 100 for inline monitoring of a quality characteristic QC of a sludge 10 comprises: (a) providing a system 20 comprising: (i) a vessel 22 having a vessel side wall 23 defining a vessel interior 28, wherein the vessel 22 is configured to receive the sludge 10 and to contain the sludge 10 within a defined volume 29 located within the vessel interior 28;(ii) one or more stirrers 30, each of which has a respective elongated spindle 31 and a respective paddle or paddles 36 attached to the respective spindle 31 and extending radially outwards from it, each spindle 31 having a respective spindle axis 35, and the one or more stirrers 30 being arranged such that each spindle 31 is oriented in a generally vertical, generally horizontal, or generally diagonal orientation, the spindle 31 and the paddles 36 being generally horizontally or diagonally oriented, the respective one or more stirrers 36 being arranged within the defined volume 29, each of the one or more stirrers 30 being configured to rotate about its respective spindle axis 35 such that a rotation of the respective one or more stirrers 36 sweeps a respective individual paddle-swept volume V; ipsrinses out and defines, whereby an entirety of the individual paddle-swept volumes V ips a collective paddle-swept volume V cps defined; and (iii) a sensor 43 located within the defined volume 29 and outside the collective paddle-swept volume V cps is arranged; (b) adding the sludge 10 to the vessel 22; (c) stirring the sludge 10 with the one or more stirrers 30; and (d) detecting the sludge 10 with the sensor 43 to determine the quality characteristic QC of the sludge 10.

[0071] According to a further embodiment, a method 200 for inline monitoring of a quality characteristic QC of a sludge 10 comprises: (a) providing a system 20 having (i) a vessel 22 having a vessel sidewall 23 defining a vessel interior 28, and a line 55 arranged outside the vessel sidewall 23, the line 55 having a line inlet 56 in fluid communication with the vessel interior 28 and a line outlet 57 in fluid communication with the vessel interior 28, (ii) one or more agitators 30 arranged inside the vessel interior 28 and configured to agitate the sludge 10, and (iii) a sensor 43 with a sensing surface 45 arranged inside the line 55; (b) adding the sludge 10 to the vessel 22; (c) agitating the sludge 10 with the one or more agitators 30;and (d) detecting the sludge 10 within the line 55 with the sensor 43 to determine the quality characteristic QC of the sludge 10. The system 20 may include a line channel 63 defined within the line 55 and in fluid communication with the line inlet 56 and the line outlet 57, and the method 200 may further include: (e) opening a line inlet valve 58 located in the line channel 63 near the line inlet 56, or a line outlet valve 59 located in the line channel 63 near the line outlet 57, or both. The method 200 may also include: (f) closing the line inlet valve 58 or the line outlet valve 59, or both.

[0072] While various steps of Procedure 100 have been described as separate blocks and various functions of System 20 as separate modules or elements, it should be noted that two or more steps can be combined into fewer blocks, and two or more functions into fewer modules or elements. Likewise, some steps described as a single block can be divided into two or more blocks, and some functions described as a single module or element can be divided into two or more modules or elements. Furthermore, the sequence of the steps or blocks described herein can be rearranged in one or more different sequences, and the arrangement of the functions, modules, and elements can be rearranged in one or more different arrangements.

[0073] (As used herein, a “module” may comprise hardware and / or software, including executable instructions, for receiving one or more inputs, processing the one or more inputs, and providing one or more corresponding outputs. Note also that in some places in this disclosure reference may be made to a single input, output, element, etc., while in other places reference may be made to a multitude of inputs, outputs, elements, etc. Therefore, no attention should be paid to whether the input(s), output(s), element(s), etc., is / are used in the singular or plural at a particular place in this disclosure, since the singular and plural use of such words should be considered interchangeable unless the specific context requires otherwise.)

[0074] The above description serves for illustration and is not limiting. The dimensions and material types described herein are intended to be illustrative but are in no way limiting and represent exemplary embodiments. In the following claims, the terms "first," "second," "top," "bottom," etc., are used merely as designations and are not intended to impose any numerical or positional requirements on their objects. An element or step mentioned in the singular and preceded by the word "a" or "an" is to be understood as meaning that multiple such elements or steps are not excluded unless such exclusion is expressly stated. Furthermore, the phrase "at least one of A and B" and the phrase "A and / or B" should each be understood to mean "only A, only B, or both A and B."Unless expressly stated otherwise, embodiments comprising one or more elements with a particular property may also include additional elements that do not possess that property. Furthermore, where generic descriptive adverbs such as "essentially" and "generally" are used herein to modify an adjective, these adverbs mean "mostly," "primarily," "for the most part," "to a considerable extent," "to a large degree," and / or "at least 51 to 99% of a possible 100%," and do not necessarily mean "perfectly," "completely," "strictly," "entirely," or "100%."Furthermore, the word "near" can be used here to describe the location of an object or part of it in relation to another object or part of it, and / or to describe the positional relationship between two objects or their respective parts, and can mean "near", "adjacent", "close to", "in the vicinity", "at" or the like.

[0075] This written description uses examples, including the best embodiment, to enable those skilled in the art to manufacture and use devices, systems, and material compositions, and to carry out methods according to this disclosure. The following claims, including their equivalents, define the scope of this disclosure.

Claims

[1] System for inline monitoring of a quality characteristic of sludge, comprising: a vessel having a vessel side wall defining a vessel interior, wherein the vessel is configured to receive the sludge and contain the sludge within a defined volume that is inside the vessel interior; one or more stirrers, each having a respective elongated spindle and one or more paddles attached to the respective spindle and extending radially outward from it, each spindle having a respective spindle axis, and the one or more stirrers being arranged such that each spindle is oriented in a generally vertical, generally horizontal, or generally diagonal orientation, the respective one or more paddles being arranged within the defined volume, each of the one or more stirrers being configured to rotate about its respective spindle axis such that the rotation of the respective one or more paddles sweeps and defines a respective individual paddle-swept volume, a totality of the individual paddle-swept volumes defining a collective paddle-swept volume; and a sensor located within the defined volume and outside the collective paddle-swept volume, wherein the sensor is configured to detect the quality characteristic. [2] System according to claim 1, wherein the vessel has a generally vertically oriented longitudinal axis and wherein one or more of the one or more stirrers are arranged such that their respective spindle axes are generally collinear with the longitudinal axis. [3] The system according to claim 2, wherein the quality feature is at least one of resistance and dielectric permittivity. [4] System according to claim 2, wherein the vessel has a measured vessel radius and wherein the collective paddle-swept volume extends radially outwards from the longitudinal axis to a maximum paddle-swept radius such that the maximum paddle-swept radius is smaller than the vessel radius. [5] System according to claim 4, wherein the sensor is arranged in a sensor radius with respect to the longitudinal axis such that the sensor radius is larger than the maximum paddle-swept radius and smaller than the vessel radius. [6] System according to claim 1, further comprising: an elongated extension having an upper extension end and a lower extension end, wherein the extension is arranged in a generally vertical orientation and the lower extension end is attached to the sensor. [7] System according to claim 6, wherein the extension is configured as a tube with a lumen therein and wherein at least one sensor wire extends within the lumen and is functionally connected to the sensor. [8] System according to claim 1, wherein the sensor is positioned within the defined volume at a location which has the lowest flow rate during the rotation of one or more stirrers. [9] System according to claim 1, wherein the sensor has at least one of the following features: a surface coating made of a ceramic material on a sensor surface of the sensor; a deflector plate arranged to at least partially block the flow of sludge to the sensor surface, and configured to reduce the velocity and / or turbulence of the sludge impacting the sensor surface; and a housing that surrounds the sensor area and has an inlet for letting the sludge into a chamber in which the sensor area is located, and an outlet for letting the sludge out of the chamber. [10] System according to claim 9, wherein the housing comprises at least one of the following elements: a housing inlet valve that is in fluid communication with the flow inlet; a housing outlet valve that is in fluid communication with the flow outlet; and a conductive shield on at least one inner housing surface and one outer housing surface of the housing.

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