Fluidized Bed Reactor Particle Size Measurement
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Solution Overview
Problem
Existing methods for estimating the size of polysilicon particles in fluidized bed reactors are inaccurate and lack real-time measurement capabilities, often resulting in particle fouling and contamination of pressure sensors.
Innovation Solution
A system comprising a fluidized bed reactor with non-reactive liners and pressure sensors positioned at the inlet and outlet to measure gas pressure, which is then processed using an algorithm to determine the size of polysilicon particles without direct contact, allowing for real-time and accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are positioned inside the reaction chamber to measure gas pressure, then real-time particle size measurement is enabled, but the sensors become fouled and contaminated by polysilicon particles
Solution Approach 1:
The patent introduces a non-reactive liner as an intermediary barrier between the polysilicon particles and the pressure sensors. The liner is positioned between the reaction chamber and the sensor location, allowing pressure measurements to be taken without the sensors being in direct contact with the particles. This mediator prevents particle fouling and contamination of the sensors while maintaining the ability to measure gas pressure for particle size determination.
2Measurement precision
If particles are removed and cooled for size measurement, then accurate particle size determination is achieved, but real-time measurement capability is lost due to considerable delay
Solution Approach 1:
The patent replaces the mechanical approach of physically removing and cooling particles for measurement with a non-contact gas pressure measurement system. By using pressure sensors to measure gas pressure in real-time within the reaction chamber and applying algorithms to convert pressure data into particle size information, the system eliminates the need for particle removal and cooling processes, thereby achieving real-time measurement capability.
3Ease of operation
If stoichiometric methods are used to estimate particle size, then measurement can be performed without direct particle contact, but the measurement accuracy is unsatisfactory
Solution Approach 1:
The patent employs feedback mechanisms by continuously monitoring gas pressure and using this information to determine particle size in real-time. The system uses algorithms that process pressure sensor data to provide continuous feedback on particle size, enabling both non-contact measurement and high accuracy simultaneously. The feedback loop allows for real-time adjustments and maintains measurement precision without requiring direct particle contact.
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
Enables precise and non-invasive real-time determination of particle size, preventing sensor fouling and contamination, and improving the accuracy of particle size estimation in fluidized bed reactors.
Implementation Method 1
The pressure sensor is positioned adjacent the reactor and is configured to measure a gas pressure in at least one of the inlet and the outlet of the reactor
Data Source
AI summary
Systems and methods are provided for determining the size of particles within a fluidized bed reactor for use with thermally decomposable silicon-containing gas. The pressure of gas adjacent a gas inlet and adjacent a gas outlet of the reactor are measured with pressure sensors. An algorithm is applied to at least one of the pressure measurements to determine the size of particles within the reactor. The determined size of the particles can be used to control the operation of the reactor.