Wireless monitoring and profiling of reactor conditions using plurality of sensor-enabled RFID tags and multiple transceivers

Abstract

This invention discloses a system and method for wirelessly monitoring process conditions within a reactor vessel. A plurality of sensor-enabled radio frequency identification (RFID) tags are positioned at unspecified or random locations throughout a catalyst bed within the vessel, and are used to measure various conditions within the vessel. Each sensor-enabled RFID tag is individually coded with an identification code and wirelessly linked to multiple transceivers. The use of multiple transceivers allows the application of triangulation methods to identify the position of each sensor-enabled RFID tag in three-dimensional space, and allows querying each sensor-enabled RFID tag to receive a response transponder signal carrying information indicating the sensed conditions within the reactor.

Description

[Technical Field] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 616,155, filed January 11, 2018, the entire disclosure of which is incorporated herein by reference. This invention relates to a system and method for wirelessly monitoring and three-dimensionally analyzing conditions within a processing vessel such as a reactor. [Previous Technology] Reactor vessels containing catalysts are common in oil refineries and chemical plants. When operating such reactors, it is necessary to measure or monitor the process 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 the sensor's measurements for external display. One example of such a measuring device is the use of thermocouples to measure temperature. To measure the temperature at a location within the reactor vessel using a thermocouple, a thermocouple sheath is necessary. The thermocouple sheath is mounted through the vessel wall and extends to the location within the vessel where the temperature is measured. There is a need for the ability to measure and observe process conditions at locations within the reactor vessel and wirelessly transmit the information for collection and processing at remote locations. Furthermore, there is a need to provide a three-dimensional overview of conditions throughout the volume of the reaction zone defined by the vessel. We have proposed using radio frequency identification (RFID) tags with sensor capabilities to measure several conditions within the reactor volume, such as pressure, temperature, fluid composition, steam and liquid composition, pH value, and flow rate; and to wirelessly transmit the measured information for remote collection and processing. An example of an RFID tag with sensor functionality for measuring environmental conditions is described in US 7397370. This patent presents a system for monitoring an environment using a plurality of radio frequency identification (“RFID”) assemblies. The system may include: an RFID tag having an associated unique identification (“ID”) code, sensors configured for sensing information about the environment; and an antenna 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 code, and is processed to provide information for monitoring the environment and changes in the monitored environment. Another reference describing the use of RFID tags with sensor functionality to measure and track variable environmental conditions is US 8,106,778. This 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 containing associated tag identification data and variable data representing the measured condition. The response signal contains both variable and non-variable data, allowing the measured condition 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 contain variable data representing the measured condition at each of the plurality of RFID tags and tag identification data of each of the plurality of RFID tags. Patent publication US 2007 / 0215709 discloses an RFID-based sensor comprising an RFID circuitry system integrated with the sensor. The sensor element is configured to change its conductive state based on 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 and other information associated with the current or previous exposure of the RFID-based sensor to one or more physical conditions for reception by the RFID interrogator. The RFID-based sensor may also be powered by RF energy transmitted 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, and when the pressure-sensitive material of the sensing element is compressed, the sensing element transmits a signal back to the RFID reader via the coupled antenna. These disclosures do not reveal or suggest anything regarding the use of sensor-enabled RFID tags to measure process or environmental conditions within the reactor vessel, or the wireless transmission of information relating to the measured conditions within the reactor vessel for further reception, processing, and use. These disclosures fail to further reveal or teach anything regarding the provision of physical conditions within the reaction zone defined by the reactor vessel for wireless monitoring and three-dimensional analysis. However, we have invented a system and method for locally sensing or measuring environmental or process conditions at a location throughout the reaction zone of a reactor, and for wirelessly transmitting RFID tags with sensor functionality to multiple receivers of RF waves containing specific tag identification information and information indicating the measured conditions within the reactor. This allows for three-dimensional analysis of conditions within the reaction zone. [Summary of the Invention] Therefore, the present invention provides a system for wirelessly monitoring and analyzing process conditions within a reactor vessel. The reactor vessel of the system defines a reaction zone, the reaction zone including a catalyst bed comprising catalyst particles and a plurality of RFID tags with sensor functionality disposed within the catalyst bed. The system includes a plurality of transceivers, each including a first RFID transceiver antenna, a second RFID transceiver antenna, and a third RFID transceiver antenna. The first RFID transceiver antenna is wirelessly linked to each of the plurality of RFID tags with sensor functionality and is capable of transmitting a first interrogation signal and receiving a first RFID transponder signal in response to the first interrogation signal. The second RFID transceiver antenna is wirelessly linked to each of the plurality of RFID tags with sensor functionality and is capable of transmitting a second interrogation signal and receiving a second RFID transponder signal in response to the second interrogation signal. The third RFID transceiver antenna is wirelessly linked to each of the plurality of RFID tags with sensor functionality and is capable of transmitting a third interrogation signal and receiving a third RFID transponder signal in response to the third interrogation signal. Each of a 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 interrogation signals from a transceiver, and responding to the interrogation signals by transmitting an RFID transponder signal. The RFID transponder signal contains information representing the unique, non-mutable identifier and the reactor conditions associated with the sensor-enabled RFID tag. This system is provided for determining and performing three-dimensional analysis of process conditions throughout the reaction zone. A method for wirelessly monitoring and analyzing process conditions within a reactor vessel is also provided. The reactor vessel defines a reaction zone comprising a catalyst bed including catalyst particles and a plurality of sensor-enabled RFID tags disposed within the catalyst bed. The catalyst bed is characterized by having a height and a width or diameter. The method includes transmitting interrogation signals via at least three RFID transceiver antennas. Each sensor-enabled RFID tag receives the interrogation signal. In response to the interrogation signal, each sensor-enabled RFID tag transmits its associated RFID transponder signal, the signal containing a unique, non-mutable identification code and information about the surrounding conditions associated with the sensor-enabled RFID tag. The RFID transceiver antennas receive the associated RFID transponder signal, which is processed to provide a three-dimensional analysis of the process conditions within the reaction zone. [Simplified Explanation of the Diagram] Figure 1 is a schematic diagram illustrating an embodiment of the system of the present invention for wirelessly monitoring and three-dimensionally analyzing 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 is a diagram illustrating some components of a system for wireless reactor monitoring and three-dimensional analysis of conditions within the reactor's reaction zone. Figure 3 illustrates a single sensor-enabled RFID tag among a plurality of sensor-enabled tags placed within the catalyst bed, and at least three RFID readers / interrogators wirelessly linked to the sensor-enabled RFID tag. The RFID readers / interrogators are connected to a computer system for processing information contained in the received RF signals transmitted by the sensor-enabled RFID tag.

Implementation Method

Claims

1. A system for wirelessly monitoring and analyzing process conditions within a reactor vessel, wherein the system comprises: The reactor vessel defines a reaction zone, wherein a catalyst bed comprising catalyst particles is located within the reaction zone; a plurality of sensor-enabled RFID tags disposed within the catalyst bed; a first RFID transceiver antenna wirelessly linked to each of the plurality of sensor-enabled RFID tags and capable of transmitting a first interrogation signal and receiving a first RFID transponder signal in response to the first interrogation signal; a second RFID transceiver antenna wirelessly linked to each of the plurality of sensor-enabled RFID tags and capable of transmitting a second interrogation signal and receiving a second RFID transponder signal in response to the second interrogation signal; and a third RFID transceiver antenna wirelessly linked to each of the plurality of sensor-enabled RFID tags and capable of transmitting a third interrogation signal and receiving a third RFID transponder signal in response to the third interrogation signal; wherein the plurality of sensor-enabled RFID tags... Each RFID tag in the D tag has a unique, non-mutable identification code, and each RFID tag with sensor functionality can sense a reaction condition within the reaction zone, receive a first interrogation signal, a second interrogation signal, and a third interrogation signal, and respond to the first interrogation signal by transmitting the first RFID transponder signal, respond to the second interrogation signal by transmitting the second RFID transponder signal, and respond to the third interrogation signal by transmitting the third RFID transponder signal; thereby, the first RFID transceiver antenna, the second RFID transceiver antenna, and the third RFID transceiver antenna are placed at known locations and at known distances from each other, so that their interrogation signals can be used in conjunction with the transponder signals from the RFID tags with sensor functionality to obtain information about the distance and angular direction of the RFID tags with sensor functionality from the RFID transceiver antennas; thereby, the system is configured to determine the process conditions and analyze (profile) the process conditions through the reaction zone using triangulation methods.

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

3. The system as described in claim 2, wherein each of the plurality of RFID tags having sensor functionality includes an RFID tag operatively connected to a sensor component for sensing an environmental or process condition and for providing a signal input to the RFID tag representing the environmental or process condition.

4. The system as described in claim 3, wherein one or more of the RFID transceiver antennas are located within the reaction zone of the reactor vessel.

5. The system as claimed in claim 4, wherein the reactor vessel comprises: 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.

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

7. The system as claimed in claim 6, wherein each of the RFID transceiver antennas is operatively connected to a signal processing system, the signal processing system providing means for providing the interrogation signal to the RFID transceiver antenna and for receiving the RFID transponder signal transmitted by each of the plurality of RFID tags having sensor functionality.

8. The system as described in claim 3, wherein one or more of the RFID transceiver antennas are located outside the reaction zone of the reactor vessel.

9. The system as claimed in claim 8, wherein the reactor vessel comprises: 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.

10. The system as described in claim 9, wherein the reactor conditions are selected from the group of environmental conditions consisting of: pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH value, vibration, radiation, magnetic flux, light intensity, and sound intensity.

11. The system as claimed in claim 10, wherein each of the RFID transceiver antennas is operatively connected to a signal processing system, the signal processing system providing means for providing the interrogation signal to the RFID transceiver antenna and for receiving the RFID transponder signal transmitted by each of the plurality of RFID tags having sensor functionality.

12. A method for wirelessly monitoring and analyzing process conditions within a reactor vessel, wherein the method comprises: A reactor vessel is provided defining a reaction zone, wherein a catalyst bed is provided within the reaction zone, the catalyst bed comprising catalyst particles and a plurality of sensor-enabled RFID tags disposed within the catalyst bed; each of the plurality of sensor-enabled RFID tags is encoded with a unique, non-mutable identification code and further configured to measure an ambient condition within the catalyst bed associated with the sensor-enabled RFID tag and to transmit a response signal in response to an interrogation signal, the response signal containing information representing the unique, non-mutable identification code and the ambient condition associated with the sensor-enabled RFID tag; by means of a first An RFID transceiver antenna transmits a first interrogation signal received by each of the sensor-enabled RFID tags; in response to receiving the first interrogation signal, each of the sensor-enabled RFID tags transmits a first associated RFID transponder signal received by the first RFID reader antenna, the RFID transponder signal containing information representing its unique, non-mutable identification code and surrounding conditions associated with the sensor-enabled RFID tag; the first associated RFID transponder signal is received via the first RFID transceiver antenna; and a second RFID transceiver antenna transmits the first interrogation signal received by each of the sensor-enabled RFID tags. Each of the RFID tags receives a second interrogation signal; in response to receiving the second interrogation signal, each of the sensor-enabled RFID tags transmits a second associated RFID transponder signal received by a second RFID transceiver antenna, the second associated RFID transponder signal containing information indicating its unique, non-mutable identification code and surrounding conditions associated with the sensor-enabled RFID tag; receives the second associated RFID transponder signal via the second RFID transceiver antenna; transmits a third interrogation signal received by each of the sensor-enabled RFID tags via a third RFID transceiver antenna; in response to receiving the third interrogation signal, each of the sensor-enabled RFID tags transmits a third associated RFID transponder signal received by the third RFID transceiver antenna, the third associated RFID transponder signal containing information indicating its unique, non-mutable identification code and surrounding conditions associated with the sensor-enabled RFID tag; receives the third associated RFID transponder signal via the third RFID transceiver antenna; and processes the first associated RFID transponder signal, the second associated RFID transponder signal, and the third associated RFID transponder signal.By placing the first, second, and third RFID transceiver antennas at known locations and at known distances from each other, their interrogation signals can be combined with the transponder signals from the RFID tag with sensor functionality to obtain information about the distance and angular direction of the RFID tag with sensor functionality from the RFID transceiver antenna; thereby determining the process conditions and analyzing the process conditions penetrating the reaction zone using triangulation methods.

13. The method of claim 12, wherein the catalyst particles comprise an inorganic oxide component and a metal component.

14. The method of claim 13, wherein each of the plurality of tags having sensor functionality includes an RFID tag operatively connected to a sensor element for sensing an environmental or process condition and for providing a signal input to the RFID tag representing the environmental or process condition.

15. The method of claim 14, wherein one or more of the RFID transceiver antennas are located within the reaction zone of the reactor vessel.

16. The method of claim 15, wherein the reactor vessel comprises: 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.

17. The method of claim 16, wherein the reactor conditions are selected from the group of environmental conditions consisting of: pressure, temperature, chemical composition, steam and liquid composition, density, flow rate, pH value, vibration, radiation, magnetic flux, light intensity and sound intensity.

18. The method of claim 17, wherein each of the RFID transceiver antennas is operatively connected to a signal processing system, the signal processing system providing means for providing the interrogation signal to the RFID transceiver antenna and for receiving the RFID transponder signal transmitted by each of the plurality of RFID tags having sensor functionality.

19. The method of claim 14, wherein one or more of the RFID transceiver antennas are located outside the reaction zone of the reactor vessel.

20. The method of claim 19, wherein the reactor vessel comprises: 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.

21. The method of claim 20, wherein the reactor conditions are selected from the group of environmental conditions consisting of: pressure, temperature, chemical composition, steam and liquid composition, density, flow rate, pH value, vibration, radiation, magnetic flux, light intensity and sound intensity.

22. The method of claim 21, wherein each of the RFID transceiver antennas is operatively connected to a signal processing system, the signal processing system providing means for providing the interrogation signal to the RFID transceiver antenna and for receiving the RFID transponder signal transmitted by each of the plurality of RFID tags having sensor functionality.

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