System and method for wirelessly monitoring and profiling process conditions within a reactor vessel

Abstract

A system and method for wirelessly monitoring processing conditions within a reactor vessel are disclosed. A plurality of sensor-enabled RFID tags are positioned at known locations within a catalyst bed of the vessel and are used to measure various conditions within the vessel. Each sensor-enabled RFID tag is encoded with an individual identification code and wirelessly connected to a transceiver. The transceiver provides interrogation of each sensor-enabled RFID tag to receive a responsive interrogator signal carrying information indicating the three-dimensional location of the sensor-enabled RFID tag and the conditions sensed within the reactor. This allows for three-dimensional profiling of specific measured conditions within the reactor.

Description

[Technical Field] This application claims the benefit of pending U.S. Provisional Patent Application No. 62 / 616,148, filed January 11, 2018, the entire disclosure of which is hereby incorporated by reference. This invention relates to a system and method for wirelessly monitoring and three-dimensionally analyzing conditions within processing vessels such as reactors. [Previous Technology] Reactor vessels containing catalysts are common in oil refineries and chemical plants. When operating such reactors, it is desirable to measure or monitor the processing conditions within the vessel, as this information helps control the reaction conditions. Current methods for measuring conditions within the reactor vessel require a physical connection to a sensor, such as an electrical or pneumatic connection, which transmits sensor measurement information to an external display. One example of such a measuring device is the use of a thermocouple to measure temperature. To measure the temperature at a specific location within the reactor vessel using a thermocouple, a thermocouple sheath is required. The thermocouple sheath is installed through the vessel wall and extends to the location within the vessel where the temperature is measured. The goal is to measure and observe processing conditions at various locations within the reactor vessel, and wirelessly transmit the information remotely for collection and processing. Furthermore, it is desirable to provide a three-dimensional profile of conditions across the entire volume of the reaction zone defined by the vessel. We have proposed using sensors with radio frequency identification (RFID) tags to measure several conditions within the reactor volume, such as pressure, temperature, fluid composition, steam and liquid composition, pH, and flow rate, and wirelessly transmit the measured information for remote collection and processing. Examples of sensors using RFID tags for measuring environmental conditions are described in US 7,397,370. This patent proposes a system that provides for monitoring the environment using a plurality of radio frequency identification (“RFID”) assemblies. The system may include RFID tags having associated unique identification (“ID”) codes, sensors configured for sensing information about the environment, and antennas for wirelessly transmitting the sensed information to a processing system. The transmitted information received by the processing system includes sensed environmental information and the associated identification codes, and is processed to provide monitoring of the environment and changes in the monitored environment. Another reference describing the use of sensors to allow RFID tags for measuring and tracking variable environmental conditions is US 8,106,778. That patent discloses a method and system for tracking variable conditions using radio frequency identification (RFID). RFID sensor tags are used to measure variable conditions such as location, temperature, pressure, and humidity. In response to an interrogation signal transmitted by an RFID reader device, the RFID sensor tag transmits a signal including associated tag identification data and variable data representing the measurement conditions. The response signal includes both variable and non-variable data, allowing the measured conditions to be associated with the tag identification data. The RFID reader device may also receive a plurality of response signals from one of a plurality of RFID tags. In this case, at least one of the plurality of response signals may include variable data representing the measurement conditions at each of the plurality of RFID tags and the tag identification data for each of the plurality of RFID tags. Patent publication US 2007 / 0215709 discloses an RFID-based sensor comprising RFID circuitry integrated with the sensor. The sensor element is configured to change its conductive state based on the physical conditions of its exposure to the surrounding environment. These physical conditions may include the presence or absence of gases, light, sound, temperature, pressure, humidity, and / or other environmental conditions. In response to an RF signal transmitted by an RFID interrogator, the RFID-based sensor transmits an identification (ID) code received by the RFID interrogator and other information associated with the current or previous exposure of the RFID-based sensor to one or more physical conditions. The RFID-based sensor may also be powered by RF energy delivered by the RFID interrogator. U.S. Patent 9,317,795 discloses an RFID sensing system comprising an array of sensing elements disposed on a surface. Each sensing element includes an RFID microchip, an antenna operatively coupled to the microchip, and a pressure-sensitive material disposed on the antenna. An RFID reader system provides an interrogation signal to each sensing element, which is transmitted back to the RFID reader via the coupled antenna when the pressure-sensitive material of the sensing element is compressed. These disclosures do not reveal or propose anything regarding the use of sensors to allow RFID tags to measure process or environmental conditions within reactor vessels, or the wireless transmission of information related to measurement conditions within reactor vessels for further reception, processing, and use. In fact, those skilled in this art would not expect RF signals to be transmitted through containers containing a certain amount of catalyst particles or hydrocarbons without significant distortion or attenuation, or both. This is because it was previously believed that catalyst particles containing significant concentrations of catalytic metals would cause distortion or severe attenuation of the RF waves transmitted by RFID tags and RF interrogators as they pass through the catalyst particles. These disclosures further fail to reveal or teach anything regarding the wireless monitoring and three-dimensional profiling of the physical conditions within the reaction zone defined by the reactor vessel. However, we have invented a system and method that provides local sensing or measurement of environmental or processing conditions at a specific location within a reactor, or wireless transmission via the reactor to an RF wave receiver containing information representing the measured conditions within the reactor. This allows for three-dimensional profiling of conditions within a volume. [Summary of the Invention] Therefore, a system is provided for wirelessly monitoring and analyzing processing conditions within a reactor vessel. The reactor vessel of the system defines a reaction zone containing a catalyst bed comprising catalyst particles and a plurality of sensor-enabled RFID tags disposed at known locations within the catalyst bed. An RFID reader antenna is wirelessly connected or coupled to each sensor-enabled RFID tag and is capable of transmitting an interrogation signal and receiving an RFID transponder signal transmitted in response to the interrogation signal. Each of the plurality of sensor-enabled RFID tags is encoded with a unique, non-mutable identifier and is capable of: sensing reactor conditions within the reaction zone; receiving an interrogation signal; and, in response to the interrogation signal, transmitting an RFID transponder signal containing information representing the unique, non-mutable identifier and the reactor state associated with the sensor-enabled RFID tag. The system is used to determine and analyze processing conditions at specific locations throughout the reaction zone. A method for wirelessly monitoring and profiling processing conditions within a reactor vessel, the reactor vessel defining a reaction zone and including a catalyst bed comprising catalyst particles and a plurality of sensor-enabled RFID tags disposed at known locations within the catalyst bed. The method includes transmitting an interrogation signal received by each sensor-enabled RFID tag via an RFID reader antenna. In response to the interrogation signal, each sensor-enabled RFID tag transmits its associated RFID transponder signal, the signal containing information representing a unique, non-mutable identifier and surrounding conditions associated with the sensor-enabled RFID tag. The RFID reader antenna receives and processes each associated RFID transponder signal. The method is used to determine and profil the processing conditions at specific locations throughout the reaction zone. [Simplified Explanation of the Diagram] Figure 1 is a schematic diagram illustrating an embodiment of the system of the present invention, which is used for wireless monitoring and three-dimensional analysis of conditions within the reaction zone of a reactor vessel. Figure 2 is a plan view of the cross-section AA of the reactor vessel depicted in Figure 1. Figure 3 illustrates some components of a wireless reactor monitoring and three-dimensional profiling system, which includes a plurality of sensor-enabled RFID tags located at known locations within the catalyst bed and an RFID reader / interrogator wirelessly connected to each of the plurality of sensor-enabled RFID tags and connected to a computer for processing information contained in the RF signals transmitted by each of the plurality of sensor-enabled RFID tags.

Implementation Method

Claims

1. A system for wirelessly monitoring and analyzing treatment conditions within a reactor vessel, wherein the system comprises: The reactor vessel defines a reaction zone containing a catalyst bed comprising catalyst particles having a metallic component. A plurality of sensor-enabled RFID tags are positioned at known locations within the catalyst bed and surrounded by the catalyst particles. Each of the plurality of sensor-enabled RFID tags is encoded with a unique non-variable identification code. Each of the plurality of sensor-enabled RFID tags is configured to sense reactor conditions within the reaction zone to receive an interrogation signal and, in response to the interrogation signal, to transmit an RFID transponder signal containing information representing the unique non-variable identification code and the reactor conditions associated with the sensor-enabled RFID tag. The signal); and an RFID reader antenna, which is wirelessly connected to each of the plurality of sensor-enabled RFID tags and configured to transmit the interrogation signal and receive the RFID transponder signal transmitted by each of the plurality of sensor-enabled RFID tags in response to the interrogation signal; thereby determining and analyzing the processing conditions at a specific location in the entire reaction area.

2. The system as described in claim 1, wherein the catalyst particles further comprise an inorganic oxide component.

3. The system as described in claim 1, wherein each of the plurality of sensor-enabled RFID tags includes an RFID tag operatively connected to a sensor component for detecting an environmental or processing condition and for providing a signal input to the RFID tag representing the environmental or processing condition.

4. The system as described in claim 3, wherein the RFID reader antenna is located within the reaction zone of the reactor vessel.

5. The system as described in claim 4, wherein the reactor conditions are selected from the group consisting of: pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity and sound intensity.

6. The system as described in claim 5, wherein the RFID reader antenna is operatively connected to a reader for providing the interrogation signal to the RFID reader antenna and for receiving each RFID transponder signal transmitted by each of the plurality of sensor-enabled RFID tags and received by the RFID reader antenna.

7. The system as described in claim 6 further includes a computing component configured with the RFID reader antenna and providing processing of the RFID transponder signal transmitted by each of the plurality of sensor-enabled RFID tags to provide an output of a three-dimensional profile representing the processing conditions within the reaction zone of the reactor vessel.

8. The system as described in claim 3, wherein the RFID reader antenna is positioned outside the reaction zone of the reactor vessel.

9. The system as claimed in claim 8, wherein the reactor vessel includes an inlet member providing fluid communication for introducing a feed stream into the reaction zone and an outlet member providing fluid communication for removing an effluent stream from the reaction zone.

10. The method of claim 9, wherein the reactor conditions are selected from the group consisting of: pressure, temperature, chemical composition, steam and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity and sound intensity.

11. The system as described in claim 10, wherein the RFID reader antenna is operatively connected to a reader for providing the interrogation signal to the RFID reader antenna and for receiving each RFID transponder signal transmitted by each of the plurality of sensor-enabled RFID tags and received by the RFID reader antenna.

12. The system as described in claim 11 further includes a computing component configured with the RFID reader antenna and providing processing of RFID transponder signals transmitted by each of the plurality of sensor-enabled RFID tags to provide an output of a three-dimensional profile representing the processing conditions within the reaction zone of the reactor vessel.

13. The system as described in claim 1, wherein the catalyst particles surrounding the plurality of sensors that allow RFID tags have a thickness of about 0.5 to 20 meters.

14. A method for wirelessly monitoring and analyzing treatment conditions within a reactor vessel, wherein the method includes: A reactor vessel is provided that defines a reaction zone, wherein within the reaction zone is a catalyst bed comprising catalyst particles having a metallic composition and a plurality of sensor-enabled RFID tags disposed at known locations within the catalyst bed and surrounded by the catalyst particles; wherein each of the plurality of sensor-enabled RFID tags is encoded with a unique, non-mutable identifier and further configured to measure an ambient condition within the catalyst bed associated with the plurality of sensor-enabled RFID tags and, in response to an interrogation signal, transmits information including the unique, non-mutable identifier and the associated ambient condition; the interrogation signal is transmitted via an RFID reader antenna, wherein, in response to the interrogation signal, each of the plurality of sensor-enabled RFID tags transmits its associated response signal; each of the plurality of associated response signals is received via the RFID reader antenna; and the associated response signals are processed to determine and analyze the processing conditions of the entire reaction zone.

15. The method of claim 14, wherein the catalyst particles further comprise an inorganic oxide component.

16. The method of claim 15, wherein each of the plurality of sensor-enabled RFID tags includes an RFID tag operatively connected to one of the sensor components, the sensor component being used to detect an environmental or processing condition and to provide the RFID tag with a signal input representing one of the environmental or processing conditions.

17. The method of claim 16, wherein the RFID reader antenna is positioned within the reaction zone of the reactor vessel.

18. The method of claim 17, wherein the surrounding conditions are selected from the group consisting of: pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity and sound intensity.

19. The method of claim 18, wherein the RFID reader antenna is operatively connected to a reader for providing the interrogation signal to the RFID reader antenna and for receiving each response signal transmitted by each of the plurality of sensor-enabled RFID tags and received by the RFID reader antenna.

20. The method of claim 19, further comprising a computing component configured with the RFID reader antenna and providing processing of the response signals transmitted by each of the plurality of sensor-enabled RFID tags to provide an output of a three-dimensional profile representing the processing conditions within the reaction zone of the reactor vessel.

21. The method of claim 16, wherein the RFID reader antenna is positioned outside the reaction zone of the reactor vessel.

22. The method of claim 21, wherein the reactor vessel includes an inlet member providing fluid communication for introducing a feed stream into the reaction zone and an outlet member providing fluid communication for removing an outflow stream from the reaction zone.

23. The method described in claim 22, wherein the ambient conditions are selected from the group consisting of: pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity and sound intensity.

24. The method of claim 23, wherein the RFID reader antenna is operatively connected to a reader for providing the interrogation signal to the RFID reader antenna and for receiving each response signal transmitted by each of the plurality of sensor-enabled RFID tags and received by the RFID reader antenna.

25. The method of claim 24, further comprising a computing component configured with the RFID reader antenna and providing processing of the response signals transmitted by each of the plurality of sensor-enabled RFID tags to provide an output of a three-dimensional profile representing the processing conditions within the reaction zone of the reactor vessel.

26. The method of claim 14, wherein the interrogation signal and the response signals pass through a bed thickness of catalyst particles of about 0.5 to about 20 meters.

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