In-Line Chemical Blending Control for Variable Output Flow
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Solution Overview
Problem
Continuous in-line blending systems face challenges in maintaining accurate flow ratios and stability when output rates change, leading to potential waste and decreased accuracy due to oscillations and difficulties in restarting with balanced flow, especially when using PID control architectures and surge tanks.
Innovation Solution
An on-demand blending system that uses real-time metrology and proportional flow control to dynamically adjust flow rates, maintaining concentration accuracy within 1% of the target range by actively calculating mass balances and controlling flow rates, eliminating the need for fixed storage volumes and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PID control architecture with surge tanks is used for continuous in-line blending, then flow stability can be maintained, but system complexity increases and waste is generated due to oscillations and difficulties in restarting with balanced flow
Solution Approach 1:
The patent removes the surge tank component from the blending system, replacing it with a direct in-line blending approach. This extraction of the intermediate storage element simplifies the system architecture while maintaining flow stability through advanced control algorithms that manage flow transitions without requiring buffer storage.
Solution Approach 2:
The patent replaces the mechanical surge tank-based flow stabilization approach with an electronic control system that uses sensors and actuators to dynamically adjust flow rates. This substitution eliminates the need for large physical buffer volumes while achieving similar or superior flow stability through real-time feedback control.
2Manufacturing precision
If large-volume batches are prepared to overcome measurement imprecision, then concentration accuracy improves, but manufacturing space requirements increase and batch processing time is extended
Solution Approach 1:
The patent replaces mechanical batch mixing in large tanks with in-line continuous blending equipped with real-time sensors and automated control systems. This substitution enables precise measurement and control of constituent fluid ratios using electronic metering devices, achieving high concentration accuracy without requiring large batch volumes or extensive manufacturing space.
Solution Approach 2:
The patent implements real-time feedback control using sensors that continuously monitor the composition of the blended stream. This feedback mechanism allows the system to detect and correct any deviations from the target concentration immediately, enabling high precision blending in continuous mode without the need for large batch volumes that would be required in open-loop batch processing.
3Manufacturing precision
If large-volume batches are processed, then measurement imprecision is reduced, but productivity decreases due to prolonged mixing and cleanup time
Solution Approach 1:
The patent implements continuous in-line blending that operates without interruption, eliminating the start-stop nature of batch processing. The system maintains continuous flow and mixing, allowing for uninterrupted production while achieving precise measurements through real-time monitoring. This continuity eliminates idle time between batches and reduces overall manufacturing cycle time.
Solution Approach 2:
The patent replaces manual batch processing operations with automated in-line blending systems that continuously mix and monitor fluid compositions. This automation eliminates the need for manual sampling, testing, and adjustment operations that prolong batch processing time, while maintaining or improving measurement accuracy through continuous electronic monitoring and control.
4Device complexity
If fixed-rate continuous blending is implemented, then system simplicity is maintained, but adaptability to changing production rates is reduced
Solution Approach 1:
The patent implements dynamic control capabilities in the in-line blending system, allowing flow rates and constituent ratios to be adjusted in real-time based on changing production requirements. The system uses programmable controllers and variable speed actuators to adapt to different production rates while maintaining blending precision, transforming a potentially static system into a flexible, responsive platform.
Solution Approach 2:
The patent designs the in-line blending system with universal control capabilities that can handle multiple product formulations and production rates using the same hardware platform. The system's programmable logic and adjustable parameters allow it to adapt to different blending ratios, flow rates, and product specifications without requiring physical reconfiguration, achieving multi-functionality while maintaining relative system simplicity.
Data Source
AI summary
This in-line active and reverse calculating mass balance blending system can maintain a chemical at desired control points, such as with respect to concentration, temperature, and/or pressure, while the output flow rate is changing dynamically to a point of use. A blending unit is configured to receive and blend at least two species and deliver a mixture at selected concentrations to points of use. A controller can be configured to determine a mass balance to maintain the concentrations in the mixture using information from metrology systems and a flow in an output to the at least one point of use. The controller also can be configured to maintain a concentrations in the mixture within a concentration range by controlling flow rates to the blending unit.