Biofuel Inventory Measurement with Pressure and Temperature Compensation
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Solution Overview
Problem
Biofuel production processes face inaccuracies in determining total fermentation biomass inventory due to uncontrolled pressure and temperature fluctuations, leading to sub-optimal production rates and operational inefficiencies, as existing sensors rely on constant conditions that are not met in practice.
Innovation Solution
A system and method that receive measured biomass inventory values and vapor space pressure to determine pressure-compensated inventory, combined with net biomass flow calculations based on fluctuating temperature and density, to provide a normalized weighted sum for accurate total inventory determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors rely on constant pressure and temperature conditions for measurement, then measurement simplicity is maintained, but measurement precision deteriorates due to uncontrolled fluctuations in actual process conditions
Solution Approach 1:
The patent applies parameter changes by introducing pressure compensation and temperature/density correction factors to the measurement system. The controller receives pressure measurements from pressure sensors and temperature/density measurements from separate sensors, then adjusts the biomass inventory calculation based on these parameters. This resolves the contradiction by maintaining measurement accuracy under varying conditions without requiring a completely complex new measurement system,而是 by modifying the existing measurement approach with additional parameter corrections
Solution Approach 2:
The patent uses pressure compensation as an intermediary mechanism to eliminate the effect of pressure fluctuations on level measurements. By measuring pressure separately and using it to compensate the level sensor readings, the system indirectly corrects for pressure effects without requiring direct measurement of biomass inventory under pressure. Similarly, temperature and density measurements serve as intermediaries to correct for thermal expansion effects
2Productivity
If production operation is pushed closer to maximum capacity to improve productivity, then production efficiency increases, but reliability deteriorates due to risk of overflow or underflow
Solution Approach 1:
The patent implements feedback control by continuously monitoring the corrected biomass inventory level and using this information to control the filling and draining operations. The controller receives corrected level measurements and adjusts process parameters to maintain inventory within safe boundaries. This feedback mechanism allows the system to operate closer to maximum capacity while maintaining reliability, as the real-time monitoring and adjustment prevent overflow or underflow conditions
Solution Approach 2:
The patent applies preliminary action by determining the corrected biomass inventory level before making control decisions about filling and draining operations. By having accurate inventory information available in advance, the system can proactively adjust operations to maintain safe operating margins, enabling higher productivity without compromising reliability
3Productivity
If batch fermentation parameters are adjusted to optimize production rate, then productivity improves, but manufacturing precision deteriorates due to constraints on the entire plant operation
Solution Approach 1:
The patent applies universality by using the same corrected inventory measurement system and control approach for both batch fermentation processes and continuous processes. The level sensors, pressure compensation, and temperature/density correction mechanisms serve multiple functions across different process types. This multi-functional approach allows coordinated optimization of batch and continuous operations, improving overall productivity while maintaining manufacturing precision through consistent control methodology
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the accuracy of biomass inventory tracking, allowing for more precise control and optimization of biofuel production processes, enabling operation closer to maximum capacity without risking overflow or underflow, thus improving overall production efficiency.
Implementation Method 1
a plurality of level sensors coupled to a corresponding plurality of batch fermenters and configured to measure fermentation batch inventories... at least one pressure sensor coupled to the batch fermenters and configured to measure vapor space pressure... determining pressure compensated fermentation batch inventories based on the fermentation batch inventories and the vapor space pressure
Implementation Method 2
a biomass temperature sensor coupled to the batch fermenters and configured to measure biomass temperature... a biomass density sensor coupled to the batch fermenters and configured to measure biomass density... determining corrected fermentation batch inventories based on the pressure compensated fermentation batch inventories, the biomass temperature, and the biomass density
Data Source
AI summary
System and method for determining total inventory of batch and continuous biomass inventories in a biofuel production process. Measured biomass inventory values are received, including batch inventories from multiple batch fermenters and at least one continuous beer well inventory. The values are premised on a controlled vapor pressure of the batch fermenters and beer well(s), where the pressure fluctuates in an uncontrolled manner. A measured vapor pressure for the batch fermenters and beerwell(s) is received, and pressure compensated inventory values determined based on the measured inventory and pressure values. Measured biomass input flow to the batch fermenters and output flow from the beerwell(s) are received, and are premised on a constant biomass temperature and density, where biomass temperature and density fluctuate in an uncontrolled manner. The total inventory of batch and continuous inventories is determined based on the measured flows and the pressure compensated inventory values, and stored.