In-Situ Optical Sensor for Hazardous Chemical Concentration
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Solution Overview
Problem
Industrial process streams pose challenges for accurate chemical concentration measurements due to hazardous conditions, making manual sampling dangerous and prone to errors, including contamination and environmental changes.
Innovation Solution
A sensor device with a sample cavity that mixes a reagent with the fluid sample from the process stream, illuminated by a light source, and uses optical sensors to generate data, which is then corrected for environmental attributes to determine analyte concentrations, allowing for in-situ measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sampling is used to measure chemical concentrations in industrial process streams, then measurements can be performed with existing laboratory equipment, but the process becomes dangerous due to hazardous conditions and prone to errors from contamination and environmental changes
Solution Approach 1:
The patent introduces an in-situ sensor device as an intermediary between the hazardous process stream and the measurement system. The sensor device includes a sample cavity that interfaces with the process stream through a window, allowing optical measurements to be performed without direct human exposure to hazardous conditions. This mediator enables safe while accurate measurements by separating the measurement function from the hazardous environment.
Solution Approach 2:
The patent replaces manual mechanical sampling with an automated optical measurement system. Instead of physically extracting samples with containers and transporting them to laboratories, the system uses light sources and optical sensors to perform non-contact chemical concentration measurements directly in the process stream, eliminating the mechanical sampling process and associated contamination risks.
2Measurement precision
If manual sampling and relocation to laboratory is performed, then measurements can be conducted with controlled equipment, but time is lost due to sampling, relocation, and testing delays
Solution Approach 1:
The patent performs measurement preparation actions in advance by positioning the sensor device directly in the process stream before sampling is needed. The sample cavity is pre-configured with reagent mixing capabilities and optical measurement pathways, so when measurement is required, the system can immediately begin measurements without time-consuming sample collection, transport, and setup procedures.
Solution Approach 2:
The sensor device performs self-contained measurements within the process stream environment. The device includes integrated reagent storage and mixing capabilities, allowing it to prepare its own measurement reagents on-demand without external laboratory support. The optical measurement system operates autonomously, eliminating the need for external laboratory equipment and personnel.
3Productivity
If in-situ measurements are performed directly in the process stream, then real-time data can be obtained, but environmental factors such as temperature and pressure may interfere with measurement accuracy
Solution Approach 1:
The patent compensates for environmental parameter variations by using ratio-based measurement techniques. The system measures both the analyte signal and a reference signal, then calculates the ratio between them. This approach cancels out the effects of temperature, pressure, and other environmental factors that affect both signals equally, maintaining measurement accuracy despite harsh process conditions.
Solution Approach 2:
The system incorporates environmental sensing capabilities that continuously monitor temperature, pressure, and other process parameters. This feedback information is used to adjust measurement parameters and apply correction algorithms, ensuring accurate concentration measurements even as environmental conditions fluctuate during operation.
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 accurate, timely, and safe chemical concentration measurements directly within the process stream, reducing exposure risks and maintaining measurement accuracy by correcting for environmental factors.
Implementation Method 1
a light source that is configured to illuminate the mixed sample in the sample cavity
Implementation Method 2
an optical sensor that is configured to receive light from the mixed sample and generate sensor data based on the received light
Data Source
AI summary
In an embodiment, a fluid concentration measurement system is disclosed that includes a sensor device including a sample cavity that is configured for insertion into an industrial process stream. The sample cavity is configured to obtain a fluid sample from the industrial process stream and to mix a reagent with the fluid sample in the sample cavity to form a mixed sample. The sensor device includes a light source that is configured to illuminate the mixed sample in the sample cavity and an optical sensor that is configured to receive light from the mixed sample and generate sensor data based on the received light. The sensor device includes at least one processor that is configured to obtain the sensor data, correct the sensor data for at least one attribute of the industrial process stream and determine a concentration of a target analyte based on the corrected sensor data.