Wireless reactor monitoring system using passive sensor enabled RFID tag and a method of monitoring process conditions within a reactor vessel

Abstract

This invention discloses a system and method for wirelessly monitoring process conditions within a reactor vessel. A sensor-enabled RFID tag is located within the catalyst bed of the vessel and is used to measure various conditions within the vessel. The sensor-enabled RFID tag is wirelessly linked to a reader, which transmits interrogation signals and receives transponder signals from the sensor-enabled RFID tag, the transponder signals carrying information indicating the measured conditions.

Description

[Technical Field] This application claims the benefit of pending U.S. Provisional Patent Application No. 62 / 616,166, 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 conditions within processing containers such as reactors. [Previous Technology] Reactors containing catalysts are common in oil refineries and chemical plants. When operating such reactors, it is necessary to measure or monitor the process conditions inside the vessel, as this information helps control the reaction conditions within the reactor. Current methods for measuring the conditions inside a reactor vessel require a physical connection to a sensor, such as an electrical or pneumatic connection, which transmits the sensor's measurement information for external display. One example of this measurement device is the use of thermocouples to measure temperature. To measure the temperature at a location inside the reactor vessel using thermocouples, a heat jacket is required. The heat jacket is installed through the vessel wall and extends to the location inside the vessel where the temperature is measured. The aim is to measure and observe process conditions at multiple locations within a reactor vessel and wirelessly transmit the information for collection at these different locations. We have proposed using RF identification tags with sensor capabilities to measure various environmental conditions within the reactor volume and wirelessly transmit the measured information for remote collection. This technology discloses various systems comprising RF identification tag devices coupled in some way to a sensor device used to measure certain environmental conditions and wirelessly transmit this information. An example of this device is described in US 6,720,866. This patent discloses a system comprising a radio frequency identification (RFID tag device) with sensor inputs that cause logic circuitry within the RFID tag device to modify signals transmitted by the RFID tag device. The RFID tag device is passive because it does not have an internal power supply. In fact, it relies on power supplied by RF waves generated by an RF tag reader (interrogator) that activates the RFID tag device. The RFID tag device is adapted to receive input signals from its sensors. This sensor provides measurements of things such as voltage, current, resistance, frequency, pressure, temperature, acceleration, vibration, moisture content, gas percentage, density, flow rate, light intensity, sound intensity, radiation, magnetic flux, pH, or other values. The sensor also provides the RFID tag device with the generation of analog input signals, which the RFID tag device generates signals containing information related to the sensor input signals. The RFID tag reader or interrogator reads these sensor input signals. US 8,106,778 describes another application of radio frequency identification (RFID). This patent discloses a method and system for tracking variable conditions such as location, temperature, humidity, pressure, time, date, and inertial measurements (e.g., velocity and acceleration). The RFID system disclosed in '778 patent includes an RFID sensor capable of measuring conditions at the RFID sensor location. Variable information from the sensor is then stored in the memory of an RFID tag processor of the RFID sensor tag, which then transmits a response signal containing variable information indicating the conditions to an RFID reader. These patents do not disclose or suggest anything regarding the use of RFID tags with sensor functionality to measure process or environmental conditions within a reactor vessel, or the wireless transmission of information related to the measured conditions within the reactor vessel for further reception, processing, and use. In fact, those skilled in the art would not expect RF signals to be transmitted through a vessel containing a certain volume of catalyst particles or hydrocarbons without significant distortion or attenuation, or both. This is because it has previously been believed that catalyst particles containing a significant concentration of catalytic metals would cause RF wave distortion or severe attenuation when the RF waves transmitted by the RFID tag and RF interrogator pass through the catalyst particles. However, we have invented a system and method that provides local sensing of environmental or process conditions at a location within a reactor and provides RF waves containing information representing the measured conditions within the reactor to be wirelessly transmitted through the reactor to a receiver. [Summary of the Invention] Therefore, a system is provided for wirelessly monitoring process conditions within a reactor vessel. The system includes a reactor vessel defining a reaction zone. A catalyst bed comprising catalyst particles is located within the reaction zone, and an RFID sensor is located within the catalyst bed. The RFID sensor is capable of sensing reactor conditions within the reaction zone, receiving interrogation signals, and transmitting RFID transponder signals in response to the interrogation signals. The RFID transponder signals contain information indicating the reactor conditions. The system includes an RFID reader antenna wirelessly linked to the RFID sensor and capable of transmitting interrogation signals and receiving RFID transponder signals in response to the interrogation signals. A method for monitoring process conditions within a reactor vessel defining a reaction zone is also provided, comprising a catalyst bed of catalyst particles located within the reaction zone. An RFID sensor, wirelessly linked to an RFID reader antenna, is located within the catalyst bed. The RFID reader antenna transmits an interrogation signal received by the RFID sensor. In response to the interrogation signal, the RFID sensor transmits an RFID transponder signal containing information indicating reactor conditions within the reaction zone and received by the RFID reader antenna. [Simplified Explanation of the Diagram] Figure 1 is a schematic diagram illustrating an embodiment of the system of the present invention for wirelessly monitoring process conditions within a reactor vessel. Figure 2 is a diagram of an RFID system. The RFID system includes RFID tags with sensor functions in the environment and RFID readers / interrogators. The RFID readers / interrogators are wirelessly linked to the RFID tags with sensor functions and connected to a computer for processing the information contained in the RF signals. Figure 3 is a schematic diagram of the experimental setup used to test the attenuation of RF signals through a catalyst bed and liquid hydrocarbons relative to air. Figure 4 is a graph showing the variation of RF signal intensity with respect to RF frequencies in the range of 500MHz to 2.5GHz under the conditions of RF signal passing through 4 feet of air, 1 foot of catalyst and diesel, and 7 feet of catalyst and diesel.

Implementation Method

Claims

1. A system for wirelessly monitoring process conditions within a reactor vessel, wherein the system comprises: The reactor vessel defines a reaction zone, including a catalyst bed of catalyst particles located within the reaction zone, and an RFID sensor located within the catalyst bed. The RFID sensor is capable of sensing reactor conditions within the reaction zone, receiving an interrogation signal, responding to the interrogation signal, and transmitting an RFID transponder signal containing information indicating the reactor conditions. An RFID reader antenna is also included, wirelessly linked to the RFID sensor and capable of transmitting the interrogation signal and receiving the RFID transponder signal in response to the interrogation signal.

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 the RFID sensor includes an RFID tag operatively connected to one of the sensor components, the sensor component being configured to sense the reactor conditions and provide a sensor input representing the reactor conditions to the RFID tag, wherein the sensor is configured with the RFID tag to provide the RFID transponder signal, the RFID transponder signal containing information representing the reactor conditions.

4. The system as described in claim 3, wherein the RFID reader antenna is located outside the reactor container.

5. The system as described in claim 4, wherein the reactor vessel includes an inlet member providing fluid flow for introducing a feed stream into the reaction zone and an outlet member providing fluid flow 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, vibration, radiation, magnetic flux, light intensity, and sound intensity.

7. The system as described in claim 6, wherein the RFID reader antenna is operatively connected to a reader, the reader being configured to provide the interrogation signal to the RFID reader antenna and to receive the RFID transponder signal from the RFID reader antenna.

8. The system as described in claim 7 further includes a computing component configured with the reader and providing output information relating to the reactor conditions by processing the RFID transponder signal.

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

10. The system as described in claim 9, wherein the reactor vessel includes an inlet member providing fluid flow for introducing a feed stream into the reaction zone and an outlet member providing fluid flow for removing an outflow stream from the reaction zone.

11. The system as described in claim 10, 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, vibration, radiation, magnetic flux, light intensity, and sound intensity.

12. The system as described in claim 11, wherein the RFID reader antenna is operatively connected to a reader, the reader being configured to provide the interrogation signal to the RFID reader antenna and to receive the RFID transponder signal from the RFID reader antenna.

13. The system as described in claim 12 further includes a computing component configured with the reader and providing output information relating to the reactor conditions by processing the RFID transponder signal.

14. A method for monitoring process conditions within a reactor vessel, wherein the method comprises: A reactor vessel defining a reaction zone is provided, comprising a catalyst bed of catalyst particles within the reaction zone, the catalyst bed including an RFID sensor wirelessly linked to an RFID reader antenna; transmitting an interrogation signal received by the RFID sensor via the RFID reader antenna; and in response to the interrogation signal, transmitting an RFID transponder signal via the RFID sensor, the RFID transponder signal including information indicating reactor conditions within the reaction zone and received by the RFID reader antenna.

15. The method as described in claim 14, wherein the catalyst particles comprise an inorganic oxide component and a metal component.

16. The method as described in claim 15, wherein the RFID sensor includes an RFID tag operatively connected to a sensor, the sensor sensing the reactor conditions and providing a sensor input representing the reactor conditions to the RFID tag; and providing the RFID transponder signal containing information representing the reactor conditions.

17. The method as described in claim 16, wherein the RFID reader antenna is positioned outside the reactor container.

18. The method as described in claim 17, wherein the reactor vessel includes an inlet member providing fluid flow for introducing a feed stream into the reaction zone and an outlet member providing fluid flow for removing an outflow stream from the reaction zone.

19. The method as described in claim 18, wherein the reactor conditions are selected from a group of process conditions consisting of: pressure, temperature, chemical composition, steam and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity, and sound intensity.

20. The method as described in claim 19, comprising: A reader is provided that provides the interrogation signal to the RFID reader antenna and receives the RFID transponder signal from the RFID reader antenna.

21. The method as described in claim 20, further comprising: Provide a computing component configured with the aforementioned reader; Process the RFID transponder signal; and display or provide output information related to the reactor conditions.

22. The method as described in claim 16, wherein the RFID reader antenna is positioned within the reaction zone of the reactor vessel.

23. The method as described in claim 22, wherein the reactor vessel includes an inlet member providing fluid flow for introducing a feed stream into the reaction zone and an outlet member providing fluid flow for removing an outflow stream from the reaction zone.

24. The method as described in claim 23, wherein the reactor conditions are selected from a group of process conditions consisting of: pressure, temperature, chemical composition, steam and liquid composition, density, flow rate, pH, vibration, radiation, magnetic flux, light intensity, and sound intensity.

25. The method as described in claim 24, further comprising: A reader is provided that provides the interrogation signal to the RFID reader antenna and receives the RFID transponder signal from the RFID reader antenna.

26. The method as described in claim 25, further comprising: Provide a computer configured with one of the readers; Process the RFID transponder signal; Displays or provides output information related to the reactor conditions.

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