Wireless detection systems for extreme and harsh environments

Abstract

A system comprising a container having walls that define its volume. The container may contain a medium. The system also comprises a wireless detection system comprising a plurality of sensor nodes distributed in the medium and capable of wirelessly transmitting a first data signal containing one or more parameters or states within the container; a plurality of wall-penetrating communication systems mounted on the walls of the container and communicating wirelessly with the plurality of sensor nodes, transmitting a first communication signal, a first power signal, or both through the walls of the container, receiving a first data signal, and transmitting a second data signal through the walls of the container; and a control system communicatively coupled to the wireless detection system and capable of determining and profiling one or more parameters / states based on the second data signal.

Description

Technical Field

[0001] The present disclosure generally relates to wireless sensing systems. More specifically, the present disclosure relates to a wireless sensing system for monitoring and profiling the conditions inside a container in extreme or harsh environments.

Background Art

[0002] Monitoring and profiling the conditions inside a sealed container such as a reactor provides useful information, inter alia, for understanding reaction kinetics, catalyst performance, safety parameters, and system efficiency. This information is particularly useful when the environment inside the sealed container is extreme or harsh. For example, certain processes are carried out at sub-ambient or elevated temperatures (e.g., temperatures below 0 degrees Celsius (°C) or above 150 °C), sub-ambient or elevated pressures (e.g., pressures less than 0.10 megapascal (MPa) and up to 21 MPa), and corrosive conditions. To avoid undesirable process conditions that can affect system performance in these extreme / harsh environments, sensors are used to monitor parameters such as pressure and temperature and provide insights regarding the conditions inside the sealed container. There are sensors available for monitoring parameters and conditions in extreme / harsh environments, but these sensors require a physical connection (e.g., an electrical connection or a pneumatic connection) between the sensor and an external control system. For example, a thermocouple requires a physical connection to an external control system for signal communication to enable temperature monitoring in a harsh environment. Generally, a container utilizing a thermocouple has a thermowell that extends through the wall of the container to the location where the temperature is to be measured. However, since the location of temperature measurement is limited to the area near and around the container wall, high and / or low temperature spots in other areas of the container away from the wall may not be detected. Therefore, the temperature at these locations may not indicate the temperature across the entire container. As such, thermocouples may not provide reliable insights regarding what is occurring inside the container.

[0003] In addition, existing wireless sensors generally use electromagnetic signals to communicate wirelessly with remotely located control systems. However, certain containers may be made of materials that interfere with or attenuate signals. For example, in oil refineries and chemical plants, containers used as reactors are made of metal (e.g., steel). Metallic materials have a shielding effect and are not suitable for effectively passing electromagnetic signals transmitted from wireless sensors within the container to remote control systems and vice versa. Furthermore, wireless sensors generally require a power source (e.g., a battery). However, when wireless sensors are used in industrial-type containers such as reactors in oil refineries or chemical plants, it may not be feasible to replace or recharge the power source within the wireless sensor without dismantling the container and removing the wireless sensor.

[0004] Furthermore, monitoring and profiling parameters / conditions in extreme and / or harsh environments can be difficult due to various factors such as thermal stress, mechanical stress, electrical stress, radiation stress, and / or chemical stress. Doing so presents additional challenges, particularly when done wirelessly. For example, without a wired connection, sensors used in these environments may lack the precision and reliability of measurements. Therefore, there remains a need for wireless sensors that can be used to monitor and profile the conditions inside a container over all or part of its volume, and that can withstand extreme or harsh environments while providing accurate and reliable measurements. Moreover, since wireless sensors used in extreme and / or harsh environments are not accessible for extended periods (e.g., without shutting down the system and / or dismantling it) and are not easily replaceable, it is advantageous for them to operate independently with little or no maintenance (e.g., battery replacement / recharging). [Overview of the Initiative]

[0005] In one embodiment, the system includes a container having walls that define its volume. The container may include a medium. The system also includes a wireless detection system comprising a plurality of sensor nodes, each distributed in the medium, capable of measuring one or more parameters or states within the container and wirelessly transmitting a first data signal containing one or more parameters / states; and a plurality of wall-penetrating communication systems, each mounted on the wall of the container, communicating wirelessly with the plurality of sensor nodes, transmitting a first communication signal, a first power signal, or both through the wall of the container, receiving a first data signal, and transmitting a second data signal through the wall of the container; and a control system, communicatively coupled to the wireless detection system, capable of determining and profiling one or more parameters / states based on the second data signal.

[0006] In another embodiment, a method for monitoring and profiling the state inside a container using a wireless sensing system includes the step of transmitting a first signal to a through-wall communication system mounted on the wall of the container. The through-wall communication system may wirelessly communicate with one or more sensor nodes distributed together with the medium contained within the container. The method also includes wirelessly transmitting a second signal from the through-wall communication system to one or more sensor nodes in response to the first signal. One or more sensor nodes include an antenna capable of receiving the second signal. The method also includes measuring one or more parameters associated with the state to be profiled in response to the second signal. The sensor nodes include sensors capable of measuring one or more parameters in response to the second signal and the generated first data signal. The method also includes transmitting a first data signal to the through-wall communication system, which includes information associated with the measured one or more parameters, the location of one or more sensor nodes, or both. The first data signal is an electromagnetic signal. The method further includes using a processor to determine and profile the state inside the container based on the first data signal. The processor is part of a control system that is communicatively coupled to a wireless sensing system.

[0007] Additional features and advantages of exemplary implementations of the present disclosure are described below, some of which will be evident from the description or may be acquired by implementing such exemplary implementations. Such features and advantages may be realized and acquired by means and combinations specifically indicated in the appended claims. These and other features may be more fully evident from the following description and the appended claims or may be acquired by implementing the exemplary implementations described below. [Brief explanation of the drawing]

[0008] The advantages of this disclosure may become apparent by reading the detailed description below and referring to the drawings. [Figure 1] This is a schematic diagram of a system according to one embodiment of the present disclosure, which includes a container and a wireless detection system, the wireless detection system including a plurality of wireless sensor nodes distributed within a medium contained in the container and a wall-penetrating communication system. [Figure 2] Figure 1 is a block diagram of a portion of the container of the system according to one embodiment of the present disclosure, thereby the wall-penetrating communication system includes an internal module coupled to the inner surface of the container and an external module coupled to the outer surface of the container. [Figure 3] Figure 1 is a block diagram of a sensor node of a wireless sensing system that may be used with the system of one embodiment of the present disclosure, wherein the sensor node includes a sensor and an antenna for wirelessly transmitting and receiving electromagnetic signals. [Figure 4] Figure 1 is a block diagram of an internal module of a wireless detection system that may be used in the system, wherein the internal module includes signal and power transducers, as well as frequency converters and amplifiers for converting acoustic signals into electromagnetic signals, and antennas for wirelessly receiving and transmitting electromagnetic signals. [Figure 5]Figure 2 is a schematic diagram of a portion of the container according to one embodiment of the present disclosure, wherein the external module includes transducers arranged in an array. [Figure 6] Figure 2 is a cross-sectional view of a portion of the container according to one embodiment of the present disclosure, wherein the external module includes transducers arranged in a disc-like configuration, each transducer wirelessly transmitting an acoustic signal to a single transducer in the internal module. [Figure 7] This is a flowchart of a method for monitoring and profiling parameters / states using the system shown in Figure 1, according to one embodiment of the present disclosure. [Modes for carrying out the invention]

[0009] One or more specific embodiments of the present disclosure are described below. These embodiments described are examples of the technology disclosed herein. In addition, not all features of actual implementations may be described herein in order to provide a concise description of these embodiments. It should be understood that, as in any engineering or design project, in the development of any such actual implementation, numerous implementation-specific decisions are made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which may differ from implementation to implementation. Furthermore, it should be understood that such development efforts, while complex and time-consuming, are nevertheless routine design, fabrication, and manufacturing tasks for those skilled in the art who are interested in the present disclosure.

[0010] When describing elements of the various embodiments of this disclosure, the articles “a,” “an,” and “the” are intended to mean that one or more of the elements exist. The terms “equip,” “include,” and “have” are intended to be inclusive and mean that additional elements other than those listed may exist. In addition, references to “one embodiment” or “embodiment” in this disclosure should not be interpreted as excluding the existence of additional embodiments that also incorporate the listed features.

[0011] As used herein, the terms “approximately,” “about,” and “substantially” refer to quantities close to the stated quantity that still perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to quantities that are less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated quantity.

[0012] Various industrial processes (e.g., refineries, chemical plants, the food industry, and the beverage industry) use large vessels (e.g., tanks, containers, reactors, etc.) to perform various functions and processes under extreme or harsh environments. As used herein, terms such as “extreme / harsh environment” and “extreme / harsh conditions” are intended to indicate pressures below ambient to ultra-high pressures (static or uniaxial pressure), temperatures below ambient to ultra-high temperatures (e.g., below -40°C to above 200°C), and one or more physical states (e.g., solid, liquid, gas, or a combination thereof), where the physical state is one or more of corrosive, toxic, radioactive, caustic, flammable, and oxidizing or reducing. Monitoring system parameters and states within these vessels provides a means for understanding reaction kinetics, process conditions, and efficiency, as well as for mitigating undesirable events that may affect system performance and safety. One technique for monitoring system parameters within vessels, such as those used in refineries and chemical plants, is the use of pressure sensors and / or temperature sensors. However, these sensors generally include cables and other wiring for communication with external control / data processing systems. In addition, the positions in which these sensors are positioned within the container are limited. For example, thermocouples used to measure and monitor the temperature inside a container are generally placed along the container wall or in a thermowell located within the container wall. Therefore, temperature measurements may be localized to the area near and around the container wall, and may not reflect the temperature throughout the entire container (e.g., in areas away from the container wall and thermocouple location). Consequently, high-temperature and / or low-temperature spots within the container may not be detected.

[0013] Accordingly, this specification discloses a wireless self-localization sensing system having wireless sensors incorporated into or surrounded by a medium in which chemical reactions and other processes occur. The wireless self-localization sensing system of this disclosure provides local data (i.e., measurements) associated with the reaction and / or process state within a container containing the medium during operation. This is done by utilizing multiple signals of different wavelengths and frequencies to provide power and measure the state within the container. For example, the wireless self-localization sensing system may wirelessly measure and profile parameters within a container using acoustic range signals (e.g., 200 Hz to 20 kilohertz, kHz) and radiofrequency (RF) signals (e.g., 9 kHz to 300 gigahertz, GHz). As will be discussed in more detail below, acoustic range signals are used for wireless communication between external components (located outside the container) and internal components (located inside the container) of the sensing system, and RF signals are used for wireless communication between internal components of the sensing system. The wireless sensor may transmit an RF signal containing data associated with the measured parameters, which is converted into an acoustic signal before being transmitted wirelessly across the container wall to an external component of the wireless sensing system. In this way, the sensor system is free from any spatial or dynamic constraints on its operation. In addition, the sensor node or internal module may be located inside or outside the medium in a harsh environment. An external base station may use information from the acoustic signal to monitor and / or profile, among other things, reaction kinetics, catalyst performance, and safety parameters. The external base station may also trigger an external component of the wireless sensing system of this disclosure to transmit the acoustic power signal, which has been converted into an RF power signal by the internal component, through the container wall. This RF power signal may be used to power one or more wireless sensors in the medium.The localization techniques described herein are superior to conventional multilateration techniques (e.g., angle of arrival, time of arrival, time difference of arrival), which can be limited in moderately reverberant environments because the multilateration metrics are not related to positioning in the simple geometric sense on which systems such as GPS are based. This specification discloses the use of frequency-domain amplitude and phase response in conjunction with a calibration model to determine the sensor position. In addition, in some embodiments in which internal communication is achieved at low RF frequencies, sensor nodes can be localized by using multipoint arrival amplitude, as strong signal attenuation, due to the strong signal attenuation and the corresponding effect of weakening the signals of related modes reflected from the vessel walls, provides high positional accuracy (within 1 inch). By using the wireless sensing systems disclosed herein, the state inside a vessel can be monitored and profiled over the entire vessel, rather than at local locations in or near the vessel.

[0014] With the foregoing in mind, Figure 1 is a cross-sectional view of a system 10 having a container 12 (e.g., a reactor) including a wireless sensor system 14, according to one embodiment of the present disclosure. The container 12 may have an axial axis or direction 16, a radial axis or direction away from the axis 16 18, and a circumferential axis or direction 22 around the axis 16. The conditions inside the container 12 may range from below ambient pressure to very high pressure (static or uniaxial pressure), from below ambient temperature to very high temperature, and be corrosive, and the environment surrounding the container 12 may be on Earth (e.g., located in an oil refinery or chemical plant) or extraterrestrial (e.g., located on a space station, satellite, or space shuttle orbiting space). Partly due to the harsh conditions to which the container 12 and its contents may be exposed, it may be beneficial to periodically monitor and profile the conditions inside the container 12. Gaining insights into the conditions within container 12 can help mitigate harmful events, such as thermal runaway and undesirable pressure buildup, by alerting the operator of system 10. In addition, monitoring and profiling the conditions within container 12 can facilitate an understanding of reaction kinetics and catalyst performance. However, existing sensors are not robust enough to withstand harsh conditions and provide precise, reliable, and accurate measurements that can be used to monitor, profile, or otherwise gain insights into what is happening inside container 12. Furthermore, certain sensors require wired connections for transmitting and receiving signals containing information about the conditions within the container, and for powering the sensors. In certain system configurations and media, wired connections are not feasible and are limited to placement along the container walls. Therefore, as will be discussed in more detail below, the wireless sensing system 14 includes a plurality of sensor nodes 26 to facilitate monitoring and profiling of the state throughout the entire volume of the container 12, the sensor nodes measuring parameters and states within the container 12 and wirelessly transmitting the measured data to other components of the wireless sensing system 14.The parameters / conditions measured include, but are not limited to, pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity, signal attenuation, and sound intensity.

[0015] In the illustrated embodiments, the vessel 12 comprises a plurality of catalyst beds 30 (e.g., reaction zones), each having a plurality of catalyst particles 32. The catalyst beds 30 are spaced apart along the axial axis 16 of the vessel 12 and located at different heights. In certain embodiments, the vessel 12 has a single catalyst bed 30. As discussed above, the wireless sensing system 14 disclosed herein monitors and profiles the state throughout the entire volume of the vessel 12. Accordingly, a plurality of sensor nodes 26 are dispersed within each catalyst bed 30 and surrounded by catalyst particles 32. Essentially, the sensor nodes 26 are mixed with the medium in the vessel 12. In this embodiment, the medium contains catalyst particles 32. In particular, embodiments of the present disclosure are considered in the context of a fixed-bed catalytic reactor. However, as should be understood, the vessel 12 may be any other suitable vessel, such as a moving bed reactor, a boiling bed reactor, a grain silo, a distillation tank, or any other reactor or container, used to contain materials and / or process them under harsh conditions (temperatures below ambient (e.g., -40°C) to extremely high temperatures (e.g., above 200°C), and pressures (e.g., up to 21 MPa), corrosive environments, etc.) at any location on or outside of Earth. Furthermore, the disclosure may also be used in pipelines, aircraft, vehicles (e.g., automobiles, trains, tractors, etc.), engines, etc., without departing from its scope. In addition, the disclosure is considered in the context of catalyst particles as a medium. However, the wireless sensor system 14 may be used in vessels with other mediums (e.g., gases, liquids, plasmas, biological materials, radioactive materials, and / or solid materials).

[0016] The catalyst particles 32 can be any size and shape typically used in the industry, including any shape (e.g., cylinder, gilobe, trilobe, and quadrallobe), spheres, balls, irregular aggregates, pills, and powder extruded products. The size of the catalyst particles 32 can range from 0.1 mm to 200 mm and can have any composition. Common compositions of catalyst particles 32 include inorganic oxide components such as silica, alumina, silica-alumina, and titania. The composition may further include catalytic metal components such as any transition metals including chromium, molybdenum, tungsten, rhenium, iron, cobalt, nickel, palladium, platinum, gold, silver, and copper. The concentration of the metal component in the catalyst particles can be up to 60% by weight based on the metal, regardless of its actual state, and typically the metal concentration is in the range of 0.1 to 30% by weight based on the metal, regardless of its actual state.

[0017] In addition to the catalyst bed 30, the vessel 12 includes other components such as an inlet 38 and an outlet 40 for receiving and outputting other fluids used, generated, or otherwise contained within the vessel 12. For example, the inlet 38 facilitates the introduction of feed into the vessel 12. Similarly, the outlet 40 facilitates the removal of effluent generated in the catalyst bed 30, including reaction products. The vessel 12 may include additional features not depicted, such as additional flow lines, inlets, outlets, valves, and sensors, among other features.

[0018] The container 12 can be defined by its depth and width. The typical depth of each catalyst bed 30 is in the range of 0.5 to 20 meters, and the typical effective width of each catalyst bed 30 is in the range of 0.5 to 20 meters. Thus, the sensor node 26 may be surrounded (for example, along the circumferential direction 22) by a layer or envelope of catalyst particles 32 having a maximum thickness of 20 meters, and the signals received and / or transmitted by the sensor node 26 require that the bed thickness of the catalyst particles 32 be about 0.5 to about 20 meters or more. For example, only all or part of the sensor node 26 may be surrounded by the catalyst particles 32. As a non-limiting example, the sensor node 26 may be surrounded by 10%, 25%, 50%, 75%, or 100% of the catalyst particles 32. The signals received and transmitted by each sensor node 26 and other components of the sensor system 14 require that the signals pass through the thickness 42 of the walls 46 of the container 12, in addition to passing through the thickness of the catalyst bed 30. The container 12 may be manufactured from a metallic material (e.g., steel), which may attenuate the radio RF signal transmitted by the sensor node 26, thus adversely affecting the accuracy and / or precision of the sensor measurements within the container 12. However, as will be discussed in more detail below, the radio sensing system 14 may use the transmitted data (e.g., measured parameter data) through the wall 46 by converting the RF signal within the container 12 into an acoustic signal. In certain embodiments, the container 12 may be manufactured from a non-metallic material such as plastic, fireproof material, composite material, or any other suitable material.

[0019] As will be discussed in more detail below, each sensor node 26 includes a circuit that facilitates the measurement of conditions within the container 12 and the catalyst bed 30. For example, each sensor node 26 may include an antenna, receiver, transmitter, and other communication components that facilitate wireless communication (e.g., receiving and transmitting signals) with other components of the wireless sensor system 14. For example, each sensor node 26 communicates wirelessly with a wall-penetrating communication system 48, which has an internal module 50 disposed on or otherwise coupled to the inner surface 52 of the wall 46 and an external module 54 disposed on or otherwise coupled to the outer surface 56 of the wall 46. Each catalyst bed 30 may have multiple wall-penetrating communication systems 48 associated with it. For example, each catalyst bed 30 may have two, three, four, five, or more wall-penetrating communication systems 48 surrounding each catalyst bed 30 and spaced apart along the circumferential axis 22. In addition, the wall-penetrating communication systems 48 can be arranged such that each system 48 associated with each catalyst bed 30 is at the same or different heights along the axial axis 16 of the container 12. That is, the wall-penetrating communication systems 48 can be aligned (for example, in the circumferential direction 22) or staggered around each catalyst bed 30.

[0020] Modules 50 and 54 communicate with each other to provide communication and power signals to one or more sensor nodes 26, and act as intermediaries that enable the wireless transmission of data and information acquired by the sensor nodes 26 to an external control system 60. Modules 50 and 54 include one or more transducers, circuits, and other components that facilitate the wireless transmission of signals to and from the sensor nodes 26 through the thickness 42 of the wall 46.

[0021] FIG. 2 is an exploded view of a portion of the vessel 12 illustrating the wall penetration communication system 48. As shown in the illustrated embodiment, the internal module 50 and the external module 54 are positioned facing each other and are radially aligned 22 on respective surfaces 52, 56 of the wall 46. The internal module 50 may include features for modulating and converting a signal received at one frequency to a signal having a different frequency. For example, the internal module 50 may convert a first acoustic signal 64 received from the external module 54 into an electromagnetic signal (e.g., an RF signal) that is wirelessly transmitted to the sensor node 26. Similarly, the internal module 50 may modulate and convert an electromagnetic signal received from the sensor node 26 into a second acoustic signal 68 that includes the sensed parameter or status data and the sensor location information. Data and information from the internal and external components of the wireless sensing system 14 can be wirelessly transmitted through the thickness of the catalyst bed 30 and the wall 46 of the vessel 12 with little or no effect on signal attenuation and the accuracy and reliability of the measurements by converting the signals from acoustic signals to electromagnetic signals and vice versa. In this way, the parameters and conditions within the vessel 12 can be monitored and profiled with the desired accuracy and reliability at any position throughout the catalyst bed 30.

[0022] The external module 54 communicates with the internal module 50 via acoustic signals 64, 68 and also acts as an intermediary between the control system 60 and the internal components of the wireless sensing system 14 (e.g., the internal module 50 and the sensor node 26). As will be discussed in more detail below, modules 50, 46 collectively enable wireless communication between the sensor node 26 and the control system 60. The external module 54 may include one or more transducers, which are arranged in such a manner that they efficiently transmit acoustic energy through the wall 34 and to the internal module 50 without exceeding a threshold for scattering within the wall 34. In addition to transducers, circuits and other components may also form part of the external module 46 to facilitate communication between various components of the wireless sensing system 14. In embodiments in which the external module 46 includes multiple transducers, the transducers may be arranged in clusters, so that each transducer is positioned on the outer surface 56 partially or completely facing the internal module 50. Each transducer in the cluster communicates with the internal module 50. In the illustrated embodiment, a single wall-penetrating communication system 48 having a pair of modules 50, 54 is shown, but as considered above, multiple wall-penetrating communication systems 48 can be distributed at various positions around each catalyst bed 30. The number of wall-penetrating communication systems 48 may be the same for each catalyst bed 30 or may be different. For example, in one embodiment, one catalyst bed 30 may have four wall-penetrating communication systems 48 in the circumferential direction 22 surrounding it, and different catalyst beds 30 in the container 12 may have six wall-penetrating communication systems 48 in the circumferential direction surrounding it.

[0023] During operation, parameters can be determined and the state inside the container 12 can be profiled using data collected in real time from the sensor node 26. For example, returning to Figure 1, the sensor node 26 transmits an RF signal containing data associated with the detected parameters or state and sensor location, which is received as a low acoustic frequency by the control system 60 via the wall-penetrating communication system 48. The control system 60 may receive data signals 70 via a wireless or wired connection. In certain embodiments, the control system 60 is located at a remote location separate from where the plant or container 10 is located. In one embodiment, data signals 70 may be stored in a cloud, and the control system 60 may retrieve the data signals 70 from the cloud to process and profile the parameters and / or state inside the container 12. In addition, the control system 60 may transmit a signal 72 to the wall-penetrating communication system 48. Signal 72 may instruct an external module 54 to provide an acoustic power signal or a communication signal to the internal module 50. In certain embodiments, signal 72 may include instructions for measuring parameters or states, supplying power to the sensor node 26, and providing a sensor node position signal. The control system 60 may include a transceiver / receiver 74 to facilitate communication between the control system 60 and the wall-penetrating communication system 48. The transceiver / receiver 74 may transmit signal 72 and receive data signals 70 for processing.

[0024] The data signal 70 may include a plurality of measurements (e.g., temperature, pressure, reactant concentration, product composition, etc.) associated with the operation of the system 10 and / or the performance of the catalyst particles 24. The control system 60 includes a data processing system 76, which may use the data to determine in real time the reaction conditions and / or environmental conditions within the vessel 12, such as the sensor location, among other things. The data processing system 76 has a microprocessor (μP) 78, a memory 80, a storage device 82, and / or a display 84. The memory 80 may include one or more tangible non-transitory machine-readable media, which collectively store a set of instructions for operating the system 10, determining system and reaction parameters, determining reaction and / or environmental conditions, and / or profiling the reaction and / or environmental conditions within the vessel 12. In certain embodiments, the set of instructions may instruct the system 10 to adjust the feed rate, temperature, pressure, or the composition of the reaction product of the system 10, catalyst performance, and any other parameters that may affect the safe operation. For example, in certain embodiments, the control system 60 may include a feedback control element that may receive instructions for automatically adjusting the reactant concentration or feed rate. The feedback control element may transmit a signal to one or more valves that control the reactant / supply flow.

[0025] The memory 80 may include instructions for determining and profiling the reaction conditions and / or environmental conditions within the vessel 12, for determining system parameters during operation, and for providing any other information that may be used to provide actionable guidelines / recommendations regarding the adjustment of parameters, including but not limited to, feed rate, temperature, and pressure, based on the measured parameters. In addition, the memory 80 may include instructions for retrieving the data signal 70 and / or other system information from the cloud. The memory 80 may also store instructions to generate visualizations on the display 84 for the operator of the system 10. The visualizations may include, among other things, plots, data confidence levels, warnings, recommendations, measurements, images, and system parameters, but are not limited thereto.

[0026] The processor 78 can execute instructions stored in memory 80 and / or storage device 82 to process the data signals 70. For example, instructions may cause the processor 78 to determine reaction parameters (i.e., reaction temperature, pressure, or product composition), vary the reaction parameters, and determine a profile of the reaction conditions across the entire volume of the vessel 12. In this way, high-temperature / low-temperature spots within the reactor can be easily identified, and the catalytic performance within each catalyst bed 30 can be determined.

[0027] In addition to monitoring and / or profiling parameters / states within the container 12, the control system 60 also determines the location of the sensor node 26. For example, the control system 60 may send a question signal (e.g., signal 72) instructing the sensor node 26 to send a response signal (e.g., data signal 70). The control system 60 receives the response signal and determines the location of the sensor node 26 via any preferred technique. For example, memory 80 may provide instructions to processor 78 to determine the location of the sensor node 26 within the container 12 via time of arrival (ToA), angle of arrival (AoA), time difference of arrival (TDoA), and combinations thereof. For example, using the ToA technique, processor 78 may determine the distance between the sensor node 26 and the internal module 50 based on the time it takes for the response signal sent from the sensor node 26 to reach the internal module 50. In addition, the control system 60 can determine the position of the sensor node 26 by combining response signals from multiple wall-penetrating communication systems 48.

[0028] sensor node As discussed above, the sensor node 26 measures the reaction state and wirelessly transmits an RF signal containing the measurement data and / or position data to the internal module 50. Figure 3 is a block diagram of the sensor node 26. The sensor node 26 may have an axial axis or direction 90, a radial axis or direction away from the axis 90 92, and a circumferential axis or direction 94 around the axis 90. The sensor node 26 includes a housing or shell 100, which seals or otherwise encapsulates the internal components of the sensor node 26 to protect or isolate the sensor node from the surrounding environment within the container in which they are disposed. The shell 100 may be made of any material suitable for withstanding the environment inside the container and also transmits communication frequencies when in use. For example, the shell 100 may be made of metal or metal alloy, polymer, composite material, refractory material, glass, ceramic, or any other material suitable for the conditions inside the container, and combinations thereof. In one embodiment, the shell 100 is made of alumina. The shell 100 may be a single continuous piece (e.g., a 3D-printed shell) or a plurality of pieces. For example, in one embodiment, the shell 100 includes a plurality (e.g., two, three, four, or more) separate pieces connected to each other or otherwise joined, thereby creating a sealed housing that prevents fluids and other materials in the container from entering the cavity 102. The plurality of pieces of the shell 100 may be joined to each other using any suitable joining technique. For example, the pieces may be joined to each other via adhesive, fasteners, screws, arc welding or laser welding, or any other suitable joining technique. The pieces may include steps, lips, or threads to ensure alignment and sealing. Joining and sealing may be achieved by a combination of one or more methods and may include one or more materials such as sintered silver, nickel, gold, or gold-tin alloy or other alloys, alumina, silica-based adhesives, and may also include nanoparticles, preforms, slurries suspended in aqueous or non-aqueous solutions, and organic binders. In some embodiments, the interfaces between the multiple parts of the shell 100 may preferably be metal-metal interfaces, metal-ceramic interfaces, glass-metal interfaces, or glass-ceramic interfaces.In one preferred embodiment, two halves of densified alumina (e.g., a hemisphere, or a cylinder and a plate) may be laser-welded. In this way, the edges of the ceramic may be coated with a metal or alloy suitable for bonding and joining ceramics via laser welding, such as molybdenum, manganese, Kovar, copper, silver, or gold, ensuring the airtightness of the package in harsh environments. In one embodiment, the shell piece may be separable. This may allow access to the cavity 102 of the sensor node 26 to assemble, replace, and / or repair internal components (e.g., antenna, sensor circuit, power device, etc.). However, in other embodiments, the shell piece is not separable. In certain embodiments, a catalyst may be located within the cavity 102.

[0029] In one embodiment, the shell 100 may have an overcoat. For example, in an embodiment in which the shell 100 has multiple parts, the overcoat may provide a seal around the entire circumference of the shell 100. The overcoat may prevent exposure of means of fastening to the contents of the container (e.g., adhesive, fasteners, screws, etc.). This can reduce contamination of fasteners, screws, bolts and / or leakage of adhesive that may contaminate the contents of the container and / or affect system performance. The overcoat may be any suitable material that does not interfere with signal transmission from the sensor node 26 to other components of the wireless sensing system (e.g., wireless sensing system 14) and is durable in the environment inside the container (e.g., high temperature and pressure, corrosiveness, etc.). In non-limiting examples, the overcoat may include polymer materials, composites, glass, ceramics, refractory materials, or any other suitable material. In one embodiment, the overcoat is an alumina-based material.

[0030] Within the cavity 102, the sensor node 26 includes a sensor circuit, such as an antenna 112 and a plate 114. The plate 114 is a printed circuit board and also holds electronic equipment along with other sensor components that facilitate the measurement of reaction parameters and conditions (e.g., temperature, pressure, etc.) within the container. For example, the plate 114 may support a sensor 116. The sensor 116 may be based on piezoelectric resonator technology, such as a tuning fork, quartz, or planar comb sensor such as a surface acoustic wave (SAW) sensor. With respect to the circuit components, the sensor may include an inductor (L), a capacitor (C), and a resistor, and may be, for example, an LC or RLC resonant sensor, a purely analog or digital electronic sensor, or other suitable sensor capable of measuring reaction parameters and conditions within the container. The sensor elements may include piezoelectric materials such as quartz, langasite, langatite, or other materials such as silicon carbide (SiC), gallium nitride (GaN), or aluminum nitride (AlN). Using a piezoelectric resonator for detection enables detection and communication based on a single device when modulated backscattering is achieved. In addition, high accuracy is maintained over long periods due to the precision of the narrowband resonance and the low drift of the high-purity substrate. Plate 114 may be a ceramic plate or a metallized plate. Non-limiting examples of suitable materials for plate 114 include alumina, silica, aluminum nitride, silicon carbide, copper, aluminum, nickel, or iron-nickel alloys, gold, and combinations thereof. However, any other material suitable for supporting the sensor circuit may be used for plate 114. Plate 114 is operably connected to antenna 112 and provides the antenna with an RF signal 118 containing information representing measurement parameters or conditions around the sensor node 26. The function of plate 114 may also include mechanical support for the antenna, electrical grounding, or acting as a balun. The RF signal 118 may also contain information regarding the position of the sensor node 26 within a container (e.g., container 12).

[0031] As discussed above, the sensor 116 transmits an RF signal 118 to the antenna 112. The antenna 112 receives the RF signal 118 and transmits it wirelessly to an internal module (e.g., internal module 50) for further processing. In addition, the antenna 112 wirelessly receives an RF signal from the internal module, and the RF signal may be used to provide power to the sensor node 26 to facilitate the determination of the sensor node's position within its container. Antenna performance generally decreases when the antenna is less than one wavelength in its operating frequency. Therefore, the antenna 112 may be shaped in a manner that maximizes its overall electrical length within the size constraints of the sensor node 26 in order to minimize performance loss. By having the longest possible electrical length under the size constraints of the shell 100, the resonant frequency of the RF signal can be lowered. Due to the small physical size of the shell 100 and its operation at low RF frequencies (low MHz), the antenna 112 used in the sensor node 26 is generally considered to be an electrically miniature antenna with large impedance mismatch, low efficiency, and a narrow frequency bandwidth. The overall radiation performance of an electrical miniature antenna is a function of the physical volume it occupies. One technique for designing an efficient electrical miniature antenna is to bend a wire into a desired shape within a fixed occupied volume. The total length of the wire is adjusted to maintain a resonant frequency at a desired operating frequency. The self-resonant nature of such an antenna provides better impedance matching and higher efficiency. The total length of the wire can be adjusted by the number of turns, radius, and height of the coil, depending on the shape of the structure. To achieve higher radiation efficiency, it is recommended that the radius and height of the coil be maximized relative to the volume. As a non-limiting example, the length of antenna 112 is approximately 2 to 64 centimeters (cm).

[0032] The shape of the antenna 112 is selected so that uniform pressure and stress are applied to the smallest possible volume within the antenna 112. This shape may conform to the shape of the cavity 102 and / or shell 100. As a non-limiting example, the shape of the antenna 112 may be spherical, cylindrical, cubic, rectangular, or any other shape that provides maximum performance and fits within the cavity 102 of the sensor node 26. The antenna 112 may have a curved or helical configuration. In certain embodiments, the antenna 112 extends throughout the cavity 102 in both the axial 90 and radial 94 directions, thereby the antenna adjoins the inner wall 120 of the shell 100 and occupies a portion of the volume within the cavity 102. In one embodiment, the antenna 112 surrounds the entire plate 114 (e.g., in the circumferential direction 94). That is, the antenna 112 may form a cage around the plate 114. In other embodiments, the antenna 112 surrounds only a portion of the plate 114.

[0033] As discussed above, the antenna 112 may have a curved or helical configuration. That is, the antenna 112 is coiled into a desired shape within the cavity 102. The electrical length of the antenna 112 can be adjusted by the number of turns of the coil. The radius of each turn (i.e., curve) of the coil configuration of the antenna 112 is maximized relative to the volume. For example, the radius of each turn of the coil configuration may be approximately equal to the radius of the cavity 102. The antenna 112 may have an omnidirectional radiation pattern, radiating equal power in all directions perpendicular to the central axis 124 of the antenna 112. In certain embodiments, the antenna 112 is tuned to be capacitive, thereby reducing the electrical connectivity and complexity of the sensor node 26. In other embodiments, the antenna 112 includes a ferrite-loaded antenna coil to reduce its physical size when operating in a lower RF frequency range.

[0034] The sensor node 26 can be of any shape and size, depending on the design and configuration of the system used to detect the parameters. As discussed above, the performance of the antenna 112 decreases with size. Therefore, the size of the sensor node 26 is determined by the size of the antenna 112, and the antenna size is selected based on the internal communication frequency that minimizes losses in the medium within the container. When the sensor 116 transmits an RF signal 118 containing data and information about the measured parameters / state and / or location, the selected internal communication frequency is also dependent on the RF propagation characteristics within the container. In addition, the radio sensing system 14 described herein provides real-time sensor localization integrated with the communication waveform, which simplifies the design while reducing the number of components compared to systems with parallel sensing and geolocation information systems. In a preferred embodiment, transmission within the container 12 occurs at frequencies where the plane electromagnetic wave mode is dominant (i.e., high frequencies such as 5 MHz or higher), thereby, sensor node localization is achieved by using coherent pattern matching and implemented by machine learning techniques. Therefore, the shape and size of the sensor node 26 may be determined based on the configuration of the antenna 112 that provides the best performance at a desired internal communication frequency. In non-limiting examples, the sensor node 26 may be spherical, cubic, cylindrical, rectangular, polygonal, or any other suitable shape. The sensor node 26 may be sized to match the particle size of the catalyst particles (e.g., catalyst particles 32) that form the catalyst bed (e.g., catalyst bed 30). That is, each sensor node 26 may have dimensions substantially equal to the dimensions of the catalyst particles in the catalyst bed. For example, the sensor node 26 has a first dimension 126 (e.g., axial dimension, first diameter) and a second dimension 128 (e.g., radial dimension, second diameter) substantially orthogonal to the first dimension. In the illustrated embodiment, dimensions 126 and 128 are substantially the same. However, in other embodiments, dimensions 126 and 128 are different. In certain embodiments, the first dimension 126 may vary along the radial direction 92, and / or the second dimension 128 may vary along the axial direction 90. For example, when the shape of the sensor node 26 is polygonal.Dimensions 126 and 128 can range from approximately 5 millimeters (mm) to over 30 mm, depending on the system design and the medium of the container.

[0035] Wall-penetrating communication system Internal Module As discussed above with reference to Figure 2, the sensor node 26 wirelessly communicates with the internal module 50 via RF signals to provide detected parameters / states and their location information within the container 12. The internal module 50 provides RF power and communication signals to the sensor node 26. In addition, the internal module 50 communicates with the external module 54 via acoustic signals to transmit and receive detection data and power, respectively. As discussed above, the internal module 50 acts as an intermediary between the internal components (e.g., the sensor node 26) and external components (e.g., the external module 54) of the wireless sensor system (e.g., the wireless sensor system 14). The internal module 50 can change and convert acoustic signals from the external module 54 that have passed through the wall 46 into electromagnetic signals (e.g., RF signals) used to wirelessly communicate with the sensor node 26. Accordingly, the internal module 50 includes several features that facilitate communication with the sensor node 26 and the external module 54.

[0036] Figure 4 is a block diagram of an internal module 50 that forms part of a wall-penetrating communication system (e.g., wall-penetrating communication system 48) of a wireless sensor system disclosed herein. In an illustrated embodiment, the internal module 50 may be a circuit which includes an internal signal transducer 140, an internal power transducer 142, a frequency converter and amplifier 146, a rectifier 148, and an antenna 150. The RF antenna 150 transmits and receives signals to and from sensor nodes (e.g., sensor node 26). In non-limiting examples, the antenna 150 may be a dipole antenna, a patch or quarter-wave patch (QWP) antenna, an inverted-F antenna (IFA) or a planar inverted-F antenna (PIFA) antenna, or any other suitable antenna that facilitates the transfer of RF signals 162 to one or more sensor nodes (e.g., sensor node 26) within the container.

[0037] Communication between components of the wall-penetrating communication system may occur through one or more signal channels. The signal channels provide a path for acoustic signals transmitted through the container wall to communicate with components of the internal module 50. For example, in the illustrated embodiment, the internal signal transducer 140 is part of a first signal channel 152, which provides a path for acoustic communication signals 156 to communicate between the internal module 50 and an external module (e.g., external module 54). These acoustic communication signals 156 may include commands from a control system (e.g., control system 60) instructing a sensor node to measure parameters or conditions within the container. The acoustic communication signals 156 may also instruct the sensor node to provide location and / or power information. In one embodiment, the acoustic communication signals 156 may be a question signal that triggers a response signal from the sensor node to ensure that the sensor node is functioning correctly. The first channel 152 may be a high-frequency channel (e.g., a frequency of at least 5 megahertz (MHz)). In certain embodiments, the first channel 152 may operate at a frequency substantially the same as the RF transmission frequency between the internal module 50 in the container and the sensor node. Similarly, the internal power transducer 142 is part of the second channel 158, which provides a path for the acoustic power signal 160 to communicate between the internal module 50 and the external module. In certain embodiments, the sensor node in the container does not contain a battery or other similar power source. The acoustic power signal 160 is used to wirelessly supply power to the sensor node. The second channel 158 may operate at a different frequency than the first channel 158. In certain embodiments, the second channel 158 operates at a low frequency (e.g., below about 5 MHz). It should be noted that other embodiments of the present disclosure include using a single channel for signals 156, 160 rather than separate channels 152, 158.

[0038] Transducers 140 and 142 facilitate communication with external modules and convert acoustic signals 156 and 160 into electrical signals used to communicate with sensor nodes. Transducers 140 and 142 can be any suitable transducers that convert acoustic energy into electrical energy. In one embodiment, transducers 140 and 142 are piezoelectric transducers. Due to the harsh environment inside the container (e.g., high temperature and pressure), transducers 140 and 142 are selected from materials that are robust and suitable for harsh environments. For example, in embodiments where transducers 140 and 142 are piezoelectric transducers, the piezoelectric material is selected from high-temperature piezoelectric materials that maintain the piezoelectric properties of the piezoelectric material at temperatures above 200°C, retain low electrical conductivity at high temperatures, and efficiently transmit acoustic power across the walls of the container. Examples of piezoelectric materials include, but are not limited to, piezoelectric ceramics or single crystals such as barium titanate, langasite, langatite, and lithium niobate. In addition to high temperature and electromechanical charge coefficient, other suitable properties of piezoelectric materials include good mechanical and thermal stability, and the ability to bond to container walls.

[0039] As discussed above, the internal module 50 converts acoustic signals to RF signals within the container. A frequency converter and amplifier 146 may be used to convert telecommunications signals 162 and power signals 164 to RF signals 168, and to convert RF data signals 170 to acoustic data signals 172. A rectifier 148 may convert signal 146 from alternating current (AC) to direct current (DC) before converting power signals 164 in the frequency converter and amplifier 146, thereby generating a DC power signal 164'. The internal module 50 may also include one or more transmit / receive switches and one or more amplifiers (e.g., low-noise amplifiers and / or power amplifiers) to facilitate the conversion and amplification of signals 162, 164', and 170. For example, each transducer 140, 142 and RF antenna 150 may include respective transmit and receive switches to select either an "inquiry" path or a "response" path. For example, in the "inquiry" path, signals 162 and 164' are converted to RF signal 168 and transmitted by antenna 150 to the sensor node via RF signal 168'. In the "response" path, RF data signal 170 is converted to acoustic data signal 172 and transmitted to the external module via acoustic data signal 172'.

[0040] In one embodiment, in the “query” path, the frequency of signal 156 may be 10 MHz during transmission through the container wall (e.g., wall 46) and is converted to a frequency of 50 MHz (e.g., RF signals 168, 168') used to communicate with the sensor node. Conversely, in the “response” path, the frequency of RF data signals 170, 170' may be converted from 50 MHz to 10 MHz, which transmits an acoustic data signal 172' containing information (e.g., measured parameters / states, sensor location, etc.) from the sensor node to the external module. The “query” and “response” paths may operate one at a time and in opposite directions within the same channel (e.g., first channel 152) to enable wireless communication between a sensor node (e.g., sensor node 26) and components of a wireless sensing system located outside the container (e.g., external module 54 and / or control system 60). Signals 156, 160, 162, 164', and 170 may be amplified before conversion. For example, signals 156, 160, 162, 164', and 170 can be amplified from several millivolts (mV) peak-to-peak to approximately 1 volt (V) peak-to-peak. Similarly, after conversion, the converted signals (e.g., signals 168 and 172) can be amplified to drive RF antenna 150 or transducer 140, respectively.

[0041] Signals 156, 160, and 170 can be converted from acoustic to RF and from RF to acoustic, respectively, using any suitable frequency conversion technique. In certain embodiments, the frequencies of signals 156, 160, and 170 can be converted using a frequency mixing technique. In this technique, the frequencies of signals 156, 160, and 170 are shifted by multiplying them by another signal of a different frequency. For example, if the frequencies of signals 156, 160, and 170 are 10 MHz, they are multiplied by a 40 MHz signal to create signals of 30-50 MHz. Depending on the desired frequency, either the 30 MHz or 50 MHz signal is filtered to create the desired frequency-shifted signal. Another technique that can be used to convert the frequencies of signals 156, 160, and 170 is a harmonic conversion process. In this technique, harmonics of signals 156, 160, and 170 are created, which are further processed to create signals of the desired frequencies. Therefore, the wireless sensing system of this disclosure can wirelessly transmit data and power signals through the walls of a container by converting the frequencies of signals 156, 160, and 170, and can measure the conditions and parameters inside the container using RF signals.

[0042] The internal module 50 is either irremovably bonded to or otherwise fixed to the inner wall of the container (e.g., wall 52). Specifically, the internal module 50 is bonded to the inner surface of the container, which is adjacent to and / or in contact with the medium inside the container (e.g., catalyst bed 30 / catalyst particles 32). Air gaps / pockets between the inner surface of the container and the internal module 50 may attenuate or otherwise affect the transmission of signals 156, 160, 172' through the container wall (e.g., wall 46). Accordingly, in certain embodiments, a coupling agent may be used to bond or otherwise bond the internal module 50 to the inner surface of the container. The coupling agent may fill any air gaps / pockets where an interface may exist between the internal module 50 and the inner surface. The coupling agent may include high-temperature materials that do not degrade or are not impaired under extreme / harsh conditions that may exist inside the container (e.g., temperatures above 200°C and pressures up to 21 megapascals (MPa)). In addition, the difference in the coefficient of thermal expansion between the material used to fabricate the internal module 50 (e.g., piezoelectric material) and the container (e.g., steel, refractory material, etc.) can cause mechanical stress. Therefore, it is desirable that the coupling agent include a material resistant to these stresses. Furthermore, it is also desirable that the coupling agent include a material that provides a low-reflection, low-attenuation transmission path with respect to signals 156, 160, and 172'. As non-limiting examples, suitable coupling agents may include, among other things, silver foil, sintered silver paste, and nickel-based adhesives. In certain embodiments, brazing and / or welding may be used to bond the internal module 50 to the wall of the container.

[0043] In one embodiment, the internal module 50 may include a first part that is immovably coupled to the inner wall of the reactor, as considered above, and a second part that is removable. For example, the internal module 50 may include a base or plate that is immovably coupled to the inner wall of the vessel. The base may have transducers 140, 142, a frequency converter, an amplifier 146, a rectifier 148, an antenna 150, or a combination thereof, removably coupled to it. Therefore, if maintenance or replacement is required, any one of these components can be easily removed.

[0044] External module As discussed above, the internal module 50 communicates with an external module (e.g., external module 54) to wirelessly transmit data and receive power through the container wall (e.g., wall 46) via acoustic signals (e.g., signals 156, 160, 172'). Figure 5 illustrates a container 12 having an external module 54 which can be used to transmit and receive acoustic signals (e.g., signals 156, 160, 172') through wall 48. The external module 56 includes a plurality of transducers 180. In certain embodiments, the external module 56 has a single transducer 180. In the embodiments illustrated, the transducers 180 are arranged in a cluster configuration or array. However, the transducers 180 may be arranged in any other preferred configuration, such as a parallel configuration, a staggered configuration, a block configuration, or any other configuration that facilitates wireless communication between the external module 54 and the internal module.

[0045] The transducers 180 can be attached to the outer surface 56 of the container 12 in a manner similar to that of the internal modules (e.g., internal module 50). For example, the transducers 180 can be bolted, screwed, glued, brazed, welded, or otherwise bonded to the outer surface 56. In one embodiment, each transducer 180 is attached to and fixed to a plate (e.g., a metal plate), which is then bonded to the outer surface 56. Each transducer 180 can be positioned / placed on the plate in such a manner that fixing the transducers 180 to the plate achieves efficient transmission across the thickness of the wall 48 at a desired power concentration. The plate can be attached to the outer surface 56 via any suitable bonding means, e.g., screws, bolts, fasteners, adhesives, welding, etc. Similar to the internal modules, coupling agents can be used to attach the transducers 180 to the outer surface 56 or the plate, and / or the plate to the outer surface 56. The coupling agent can fill any air gaps / pockets between the transducer 180, the plate, or both, and the outer surface 56.

[0046] The transducer 180 may transmit signals (e.g., signals 154, 160) through the wall 48 at the same or different frequencies. For example, in one embodiment, a portion of the transducer 180 may transmit signals at frequencies of approximately 100 kHz to 5 MHz, and another portion of the transducer 180 may transmit signals at frequencies of approximately 5 MHz to 20 MHz. However, in other embodiments, each transducer 180 of the external module 54 transmits the same frequency through the wall 48. In embodiments in which the external module 54 includes an array of transducers 180, as shown in Figure 6, each of these transducers may be a low-frequency transducer (e.g., 250 kHz), each transmitting acoustic signals 156, 160 to a single transducer in the internal module. In embodiments where the external module 54 includes a single transducer 180, this transducer transmits high-frequency acoustic signals 156, 160 (e.g., less than 1 MHz), and the high-frequency acoustic signals maintain a dense beam of transmitted acoustic energy as they penetrate the wall 48 without exceeding a threshold for scattering within the wall 48. In non-limiting examples, the transducer 180 may be lead, lead zirconate titanate, or any other suitable piezoelectric material. Unlike the internal module, the transducer 180 is not exposed to the harsh environment within the container 12, so the piezoelectric material does not need to operate at temperatures above 100°C.

[0047] To ensure efficient power transfer through the wall 48, the transducer 180 has an impedance matched to the transducer of the internal module. Efficient delivery of the acoustic power signal (e.g., acoustic power signal 160) to the internal module facilitates wireless power supply to the sensor nodes in the catalyst bed and avoids the use of batteries to power the sensor nodes. Thus, the container 12 does not require dismantling to replace the sensor nodes and / or sensor node batteries. For example, in an embodiment in which the external module 54 includes a single transducer 180, the frequency of the acoustic power signal may be about 1 MHz. This frequency is sufficient to provide the desired beam of acoustic energy through the wall 48 without undesirable attenuation. In embodiments having multiple transducers 180, the frequency of the signal may be less than 1 MHz, depending on the number and arrangement of the transducers 180. For example, referring to Figure 6, the transducers 180 are arranged on the outer surface 56 of the array in such a manner that each transducer 180 points toward a single transducer 140, 142 of the internal module 50. The outer surface 56 may be curved. Therefore, the transducers 180 are arranged in such a manner that the array conforms to the curved outer surface 56. For example, a first portion 182 of the transducer 180 may be placed flat on the outer surface 56, while another portion 184 of the transducer 180 may be angled, making the array of transducers 180 a disc configuration (or satellite configuration). As considered above, coupling agents may be used to fill any air gaps / pockets. Arranging the transducers 180 in this manner provides the desired transmission efficiency despite the use of lower frequencies (e.g., frequencies below 500 kHz). This arrangement also provides the desired power transmission across the thickness 42 of the wall 48.

[0048] The external module 54 can communicate with a control system (e.g., control system 60) via a wired or wireless connection. The transducer 180 can receive a signal from the control system and trigger communication with the sensor node. The external module 54 also provides the control system with a response signal from the sensor node containing information about detected parameters or states within the container, sensor location, power level, etc.

[0049] In certain embodiments, the wireless sensing system disclosed herein does not include an external module 54. In this particular embodiment, the internal module 50 may be directly connected to a control system via a wired connection. Accordingly, the internal module may not need to convert acoustic signals to RF signals and vice versa. Therefore, transducers, converters and amplifiers, and rectifiers may be omitted from the internal module 50. For example, the control system may provide an RF communication signal to the antenna of the internal module. This RF communication signal is transmitted wirelessly to a sensor node 26. In response to the RF communication signal, the sensor node 26 wirelessly transmits an RF data signal to the internal module, which is then transmitted to the control system. In certain embodiments, the frequencies of the RF communication signal and the RF data signal are the same. However, in other embodiments, the frequencies of the RF communication signal and the RF data signal are different. For example, the RF communication signal may be higher than the RF data signal, or vice versa.

[0050] Embodiments of the present disclosure also include methods for wirelessly monitoring and / or profiling parameters and / or conditions inside a container in a harsh or extreme environment. Figure 7 is a block flowchart of Method 200, which can monitor and / or profile parameters and conditions inside a container using a wireless sensing system disclosed herein (e.g., wireless sensing system 14). Method 200 includes transmitting a first signal from an external module to an internal module (block 204). For example, as considered above, the external module (e.g., external module 54) includes a transducer (e.g., transducer 180) that wirelessly transmits acoustic signals (e.g., acoustic signals 156, 160) through the thickness (e.g., thickness 42) of the wall (e.g., wall 48) of the container (e.g., container 12). The acoustic signal is received by transducers (e.g., transducers 140, 142) in an internal module (e.g., internal module 50) located inside the container and enters a "query" path that enables communication with a sensor node (e.g., sensor node 26).

[0051] Method 200 also includes converting the first signal into a first RF signal (block 208). Upon reception, the transducer of the internal module converts the first signal into an electrical signal (e.g., signals 162, 164) that is provided to a converter (e.g., frequency converter and amplifier 146). The converter modifies the electrical signal by changing the frequency of the electrical signal to convert it into an RF signal (e.g., RF signal 168). The converter may also amplify the signal.

[0052] Method 200 includes converting the first signal into a first RF signal and then transmitting the first RF signal from an internal module to a sensor (block 210). For example, as considered above, the internal module includes an antenna (e.g., antenna 150) that receives the first RF signal and transmits the first RF signal wirelessly to a sensor node. The first RF signal triggers the sensor node to measure a desired parameter or condition to be profiled within the vessel (block 214). For example, the sensor node may measure temperature, pressure, and / or pH. The sensor node may also measure the concentration of the composition of feed and / or effluent, such as reactants, products, by-products, and contaminants. In certain embodiments, the first RF signal may provide power to the sensor node.

[0053] Method 200 also includes wirelessly transmitting a second RF signal from the sensor node to an internal module (block 216). The second RF signal (e.g., RF data signal 170) includes information (e.g., data) about parameters or states, locations, and / or power levels to be profiled.

[0054] Similar to the first signal, the second RF signal is converted into a second signal in the internal module (block 220). For example, the antenna of the internal module receives the second RF signal and transmits it to the converter via a "response" path. The converter modifies the second RF signal by changing its frequency and converting it into an acoustic second signal (e.g., acoustic data signal 172). The converter may also amplify the second signal before transmitting it to the external module through the container wall (block 224).

[0055] Method 200 also includes wirelessly transmitting a second signal from an external module to a base station (block 226) and determining the state based on the second signal (block 230). As discussed above, a control system (e.g., control system 60) receives acoustic data signals 70, 172 containing detected parameters and / or states, information about the location of sensor nodes, and other information. The control system processes the information to determine and / or profile the detected parameters to obtain insights into the processes occurring within the vessel. For example, the control system may profile temperature or pressure over time. This can facilitate, among other things, the determination of reaction kinetics and catalytic performance.

[0056] The technical effects of the wireless sensing systems disclosed herein facilitate the monitoring and profiling of process conditions within a vessel (e.g., a reactor), particularly in harsh or extreme environments. For example, a wireless sensing system includes a plurality of sensor nodes dispersed in the medium contained within the vessel. The sensor nodes use RF signals to measure parameters and / or conditions within the vessel that indicate reaction kinetics and / or catalytic performance. The RF signals include localized data associated with parameters / conditions detected in or near the "field of view" of the sensor node. These RF signals are transmitted wirelessly from each sensor node to an internal module within the vessel via RF data signals. Since the sensor nodes are dispersed throughout the entire volume of the vessel and communicate wirelessly with the internal module, the sensor nodes provide information about parameters / conditions throughout the medium contained within the vessel. Certain existing sensors used in harsh or extreme environments are generally wired and cannot provide information throughout the entire volume of the medium within the vessel. These sensors are generally limited to locations near the vessel wall where wires leading to external system components are located. While wireless sensors exist, these sensors cannot transmit wireless signals through container walls, particularly metal container walls, without signal attenuation. However, the disclosed wireless sensing system uses a combination of acoustic and RF signals to provide wireless communication between a sensor node and a component located outside the container (e.g., a control system). For example, an internal module receives an RF signal from a sensor node, converts the RF signal into an acoustic signal, and wirelessly transmits the acoustic signal to an external module located outside the container (and therefore, the control system). The internal module also converts the acoustic signal received wirelessly from the external module into an RF communication signal, which facilitates communication with the control system and the sensor node. The RF communication signal provides information that triggers the sensor node to provide local data regarding parameters / states within the container. In addition, the control system may provide an acoustic power signal, which is converted in the internal module into an RF power signal that provides power to the sensor node.In this way, the wireless detection system of the present disclosure provides an effective, efficient, and robust technique for wirelessly profiling parameters / conditions in extreme or harsh environments within a container.

[0057] This disclosure can be embodied in other specific forms without departing from its spirit or essential features. The embodiments described should be considered in all respects to be illustrative and not limiting. Accordingly, the scope of this disclosure is indicated not by the foregoing description but by the appended claims. All modifications that fall within the meaning and scope of the equivalents of the claims are encompassed within that scope.

Claims

1. It is a system, A container having walls that define its volume, configured to contain a medium, A wireless detection system, A plurality of sensor nodes, which are distributed in the medium and configured to measure one or more parameters or states within the container and to wirelessly transmit a first data signal including the one or more parameters / states, A wireless detection system comprising: one or more wall-penetrating communication systems, which are attached to the wall of the container, communicate wirelessly with the plurality of sensor nodes, and are configured to transmit a first communication signal, a first power signal, or both through the wall of the container, receive a first data signal, and transmit a second data signal through the wall of the container; A system comprising: a control system which is communicatively coupled to the wireless detection system and configured to determine and profile one or more parameters / states based on the second data signal.

2. The system according to claim 1, wherein each of the one or more wall-penetrating communication systems comprises an internal module attached to the inner surface of the wall of the container, the internal module comprising an antenna, the antenna configured to wirelessly transmit a second communication signal, a second power signal, or both to one or more sensor nodes among the plurality of sensor nodes, and to wirelessly receive the first data signal.

3. The system according to claim 2, wherein the internal module comprises a first transducer, a second transducer, and a frequency and amplitude converter, the first transducer is configured to wirelessly receive a first communication signal, the second transducer is configured to wirelessly receive a first power signal, the frequency and amplitude converter is configured to convert the first communication signal to a second communication signal and the first power signal to a second power signal, the first communication signal and the first power signal are acoustic signals, and the second communication signal and the second power signal are electromagnetic signals.

4. The system according to claim 3, wherein the frequency and amplitude converter is configured to convert the first data signal into the second data signal, the first transducer is configured to wirelessly transmit the second data signal through the wall of the container, the first data signal is an electromagnetic signal, and the second data signal is an acoustic signal.

5. The system according to claim 3, wherein each of the one or more wall-penetrating communication systems comprises an external module attached to the outer surface of the wall of the container, the external module comprising one or more transducers configured to wirelessly transmit the first communication signal and the power signal to the internal module through the wall of the container.

6. The system according to claim 5, wherein the external module comprises a cluster of transducers, and each transducer in the cluster of transducers is configured to wirelessly transmit the first communication signal or the first power signal to the first transducer or the second transducer, respectively.

7. The system according to claim 6, wherein the cluster of transducers is arranged in such a manner that constructive interference occurs when multiple signals are focused into a single signal among the transducers.

8. The system according to claim 2, wherein each of the plurality of sensor nodes comprises a housing defining a cavity, the cavity including a sensor and an antenna, the antenna being configured to wirelessly receive the second communication signal and the second power signal and to wirelessly transmit the first data signal.

9. The system according to claim 8, wherein the antenna is spirally or coiled around the sensor.

10. The system according to claim 8, wherein the housing does not attenuate electromagnetic signals.

11. The system according to claim 1, wherein the first communication signal and the first power signal have frequencies different from the first data signal.

12. The system according to claim 1, wherein the frequencies of the first communication signal and the first data signal are the same.

13. The system according to claim 1, wherein the container comprises one or more catalyst beds containing the medium, and the medium is a plurality of catalyst particles.

14. The system according to claim 1, wherein one or more of the parameters or states are selected from pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity, and sound intensity.

15. The system according to claim 1, wherein the control system is configured to monitor changes in signal strength and attenuation from one or more of the plurality of sensor nodes.

16. A method for monitoring and profiling the conditions inside a container using a wireless detection system, wherein the method is A step of transmitting a first signal to a wall-penetrating communication system mounted on the wall of the container, wherein the wall-penetrating communication system is configured to wirelessly communicate with one or more sensor nodes distributed together with the medium contained in the container; A step of wirelessly transmitting a second signal from the wall-penetrating communication system to one or more sensor nodes in response to the first signal, wherein the one or more sensor nodes are equipped with antennas configured to receive the second signal. A step of measuring one or more parameters associated with a state to be profiled in response to the second signal, wherein the sensor node comprises a sensor configured to measure the one or more parameters in response to the second signal and the generated first data signal, A step of transmitting to the wall-penetrating communication system a first data signal including information associated with one or more measured parameters, the location of one or more sensor nodes, or both, wherein the first data signal is an electromagnetic signal. A method comprising the step of using a processor to determine and profile the state in the container based on the first data signal, wherein the processor is part of a control system communicably coupled to the wireless sensing system.

17. The method according to claim 16, comprising converting the frequency of the first signal to the frequency of the second signal in an internal module, wherein the internal module forms part of the wall-penetrating communication system and is mounted on the inner surface of the wall, and the internal module comprises at least one transducer, a frequency converter and amplifier, and an antenna, wherein the frequency of the first signal is within an acoustic range, the frequency of the second signal is within an electromagnetic range, and the first signal is transmitted wirelessly through the wall of the container.

18. The method according to claim 17, wherein the frequency converter and amplifier comprises converting the first data signal into a second data signal, wirelessly transmitting the second data signal through the wall of the container and to an external module of the wall-penetrating communication system attached to the outer surface of the wall, and transmitting the second data signal to the control system, wherein the second data signal is an acoustic signal and also includes the information associated with the one or more measured parameters, the positions of the one or more sensor nodes, or both.

19. The method according to claim 18, wherein the external module comprises one or more transducers, the one or more transducers configured to receive the first signal through the wall and transmit it wirelessly to at least one transducer of the internal module, and to receive the second data signal and transmit it to the control system.

20. The method according to claim 19, wherein the external module comprises a cluster of transducers arranged in a disc shape, and each transducer in the cluster of transducers is configured to wirelessly transmit the first signal to a single transducer in the internal module.

21. The method according to claim 16, comprising wirelessly providing power to one or more sensor nodes via an electromagnetic power signal transmitted by the wall-penetrating communication system.

22. The method according to claim 21, comprising converting acoustic power signals transmitted through the walls of the container into electromagnetic power signals before providing the power to one or more sensor nodes.

23. The method according to claim 16, wherein the frequency of the first signal is different from the frequency of the second signal.

24. The method according to claim 16, wherein the frequencies of the first signal and the second signal are the same.

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