Systems for measuring and profiling process conditions within a reactor vessel and methods 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. An array of sensor-enabled RFID tags is positioned at a known height within a catalyst bed in the vessel and is used to measure various conditions within the vessel. The sensor-enabled RFID tags are encoded with individual identification codes and wirelessly connected to multiple transceivers. The use of multiple transceivers allows the application of triangulation methods to identify the position of each of the sensor-enabled RFID tags in three-dimensional space and to interrogate each sensor-enabled RFID tag to receive a responsive transponder signal carrying information representing the conditions sensed within the reactor.

Description

[Technical Field] This application claims the benefit of pending U.S. Provisional Patent Application No. 62 / 616,185, 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 containers 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 for 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 to wirelessly transmit the information remotely for collection and processing. Furthermore, it is desirable to provide a three-dimensional distribution of conditions throughout 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 to 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 emitted by an RFID reader device, the RFID sensor tag emits a signal containing associated tag identification data and variable data indicating the measurement conditions. The response signal contains 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 contain variable data indicating 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 emitted by an RFID interrogator, the RFID-based sensor emits 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 the reactor vessel, or the wireless transmission of information related to the measured conditions within the reactor vessel for further reception, processing, and use. Nor do these disclosures reveal or teach anything regarding the provision of wireless monitoring of conditions within the reactor vessel or the analysis of the physical conditions within the reaction zone defined by the reactor vessel. However, we have invented a system and method that uses sensors-enabled RFID tags to provide localized sensing or measurement of environmental or processing conditions at specific heights or levels within a reactor. Specific tag identification information and information indicating the measured conditions within the reactor are carried by RF waves, which are wirelessly transmitted by the sensors-enabled RFID tags to one or more transceivers. This allows for the profiling of conditions within the reaction zone. [Summary of the Invention] Therefore, a system is provided for wirelessly monitoring and profiling processing conditions within a reactor vessel. The reactor vessel of the system defines a reaction zone containing a catalyst bed with catalyst particle height, within which an array of sensor-enabled RFID tags at a known height is embedded. The system includes a transceiver comprising a first RFID transceiver antenna and a second RFID transceiver antenna. The first RFID transceiver antenna is wirelessly connected to each sensor-enabled RFID tag in the array and is capable of transmitting a first interrogation signal and receiving a first RFID transponder signal transmitted in response to the first interrogation signal. The second RFID transceiver antenna is wirelessly connected to each sensor-enabled RFID tag in the array and is capable of transmitting a second interrogation signal and receiving a second RFID transponder signal transmitted in response to the second interrogation signal. Each sensor-enabled RFID tag in the array is encoded with a unique, non-mutable identifier and is capable of sensing reactor conditions within the reaction zone, receiving interrogation signals from the transceiver, and transmitting an RFID transponder signal in response to the interrogation signal. The RFID transponder signal contains information representing the unique, non-mutable identifier and one or more reactor conditions associated with each sensor-enabled RFID tag. The system is used to determine reactor conditions at a known height within the catalyst bed and to analyze the processing conditions within the reaction zone. A method for wirelessly monitoring and profiling processing conditions within a reactor vessel is also provided. The reactor vessel defines a reaction zone containing a catalyst bed with catalyst particle height, within which an array of sensor-enabled RFID tags is placed at a known height within the catalyst bed. The method includes transmitting interrogation signals via at least two RFID transceiver antennas. The interrogation signals are received by each sensor-enabled RFID tag in the array. 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 distribution of processing 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, 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 is a diagram illustrating some components of a system for wirelessly monitoring and analyzing conditions within the reaction zone of a reactor. Figure 3 shows a single sensor-enabled RFID tag array placed at a known height within the catalyst bed, and at least two RFID readers / interrogators wirelessly connected to the array's sensor-enabled RFID tags. The RFID readers / interrogators are connected to a computer system for processing information contained in the received RF signals emitted by the sensor-enabled RFID tags.

Implementation Method

Claims

1. A system for measuring 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 particle size ranging from 0.1 mm to 200 mm and including an inorganic oxide component and a metal component with a metal concentration ranging from 0.1 to 30% by weight. The catalyst bed is characterized by having a depth ranging from 0.5 to 20 meters and a width ranging from 0.5 to 20 meters. An array of RFID tags is included, wherein each RFID tag in the array is placed at a known height within the catalyst bed and is surrounded by a layer or envelope of the catalyst particles having an inorganic oxide component and a metal concentration ranging from 0.1 to 30% by weight. The array includes a thickness ranging from 0.5 to 20 meters; a first RFID transceiver antenna wirelessly connected to each sensor-enabled RFID tag within the array and configured to transmit a first interrogation signal and receive a first RFID transponder signal transmitted in response to the first interrogation signal; and a second RFID transceiver antenna wirelessly connected to each sensor-enabled RFID tag within the array and configured to transmit a second interrogation signal and receive a second RFID transponder signal transmitted in response to the second interrogation signal; wherein each sensor-enabled RFID tag within the array is encoded with a unique, non-mutable identification code. The tag is configured to: sense a reaction condition within the reaction zone; receive the first interrogation signal and the second interrogation signal; and in response to the first interrogation signal, transmit the first RFID transponder signal; and in response to the second interrogation signal, transmit the second RFID transponder signal, wherein the first RFID transceiver antenna is placed at a known location away from one of the permitted RFID tags, wherein the second RFID transceiver antenna is placed at a known location away from one of the permitted RFID tags, wherein the first RFID transceiver antenna and the second RFID transceiver antenna are placed at known locations and are at known distances relative to each other and the permitted RFID tags, such that triangulation... The system is used to identify the point location of each sensor-enabled RFID tag in the three-dimensional space of the reaction zone; and each of the first RFID transceiver antenna and the second RFID transceiver antenna is operatively connected to a signal processing system, the signal processing system providing components for providing the first interrogation signal and the second interrogation signal to the first RFID transceiver antenna and the second RFID transceiver antenna and for receiving the first RFID responder signal and the second RFID responder signal emitted by each of the sensor-enabled RFID tags in the array; thereby, the conditions at a specific location and a known height within the reaction zone are determined and analyzed in the three-dimensional space.

2. The system as described in claim 1, wherein each sensor in the array allows an RFID tag to include an RFID tag operatively connected to a sensor component for sensing an environmental or processing condition and for providing a signal input representing the environmental or processing condition to the RFID tag.

3. The system as described in claim 2, wherein one or more of the first RFID transceiver antenna and the second RFID transceiver antenna are located within the reaction zone of the reactor vessel.

4. The system as claimed in claim 3, 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.

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 2, wherein one or more of the first RFID transceiver antenna and the second RFID transceiver antenna are located outside the reaction zone of the reactor vessel.

7. The system as claimed in claim 6, 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.

8. The system as described in claim 7, 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.

9. 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 the reaction zone contains a catalyst bed comprising catalyst particles having a particle size ranging from 0.1 mm to 200 mm and comprising an inorganic oxide component and a metal component having a metal concentration ranging from 0.1% to 30% by weight, and the catalyst bed is characterized by having a depth ranging from 0.5 to 20 meters and a width ranging from 0.5 to 20 meters, and an array of RFID tags is placed at a known height within the catalyst bed and surrounded by a layer or envelope of the catalyst particles having a thickness of 0.Within a range of 5 to 20 meters, each of the sensor-enabled RFID tags in the array is encoded with a unique, non-mutable identifier and further configured to measure an ambient condition within the catalyst bed associated with the sensor-enabled RFID tag and to emit a responsive signal in response to an interrogation signal. This responsive signal contains information representing the unique, non-mutable identifier and the associated ambient condition. A first RFID transceiver antenna is placed at a known location away from the sensor-enabled RFID tags, and the first RFID transceiver antenna transmits a first interrogation signal received by each of the sensor-enabled RFID tags. In response to the received first interrogation signal, each of the sensor-enabled RFID tags transmits a first associated RFID transponder signal received via the first RFID transceiver antenna, the first associated RFID transponder signal containing information representing its unique, non-mutable identifier and the surrounding conditions associated with the sensor-enabled RFID tag; receives the first associated RFID transponder signal via the first RFID transceiver antenna; places a second RFID transceiver antenna away from one of the known locations of the enabled RFID tags, and transmits via the second RFID transceiver antenna the signal received via the sensor-enabled RFID tag. Each of the RFID tags receives a second interrogation signal; in response to receiving the second interrogation signal, each of the sensors allows each of the RFID tags to transmit a second associated RFID transceiver signal received via the second RFID transceiver antenna, the second associated RFID transceiver signal containing information representing its unique, non-mutable identifier and the surrounding conditions associated with the sensor-enabled RFID tag; receives the second associated RFID transceiver signals via the second RFID transceiver antenna; and processes the first associated RFID transceiver signal and the second associated RFID transceiver signal; applying triangulation to identify... The sensor-enabled RFID tag is positioned at a point in the three-dimensional space of the reaction zone, wherein each of the first RFID transceiver antenna and the second RFID transceiver antenna is operatively connected to a signal processing system. The signal processing system provides components for providing the first interrogation signal and the second interrogation signal to the first RFID transceiver antenna and the second RFID transceiver antenna, and for receiving the first RFID transponder signal and the second RFID transponder signal emitted by each of the sensor-enabled RFID tags in the array, thereby determining and analyzing the conditions in the entire reaction zone in the three-dimensional space.

10. The method of claim 9, wherein each of the sensors in the array includes an RFID tag operatively connected to the sensor component for sensing an environmental or processing condition and for providing a signal input representing the environmental or processing condition to the RFID tag.

11. The method of claim 10, wherein one or more of the first RFID transceiver antenna and the second RFID transceiver antenna are located within the reaction zone of the reactor vessel.

12. The method of claim 11, 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.

13. The method described in claim 12, wherein a reactor condition is 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.

14. The method of claim 9, wherein one or more of the first RFID transceiver antenna and the second RFID transceiver antenna are located outside the reaction zone of the reactor vessel.

15. The method of claim 14, 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.

16. The method described in claim 15, wherein a reactor condition is 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.

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