Inline Buffer Dilution pH Control via Feedback Compensation
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Solution Overview
Problem
Existing inline buffer dilution systems using flow control struggle to accurately compensate for variability in inlet buffer concentrations, particularly when targeting specific pH levels in ternary blends, as flow meters cannot account for the inherent variability, leading to imprecise pH control and unintended volume additions.
Innovation Solution
A system and method that utilizes a flow meter to monitor the pH tempering solution and incorporates feedback from a pH sensor to adjust the flow of the first buffer concentrate, calculating and compensating for the minority component in the second buffer concentrate to maintain the intended proportion and achieve precise pH control, allowing for accurate blending independent of upstream variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flow control is used to proportion buffer concentrates and diluent, then the blending system can operate with simple equipment, but the system cannot accurately compensate for inlet buffer concentration variability
Solution Approach 1:
The patent implements a feedback control system where pH sensors continuously monitor the blended solution and provide signals to adjust the flow rates of buffer concentrates. This closed-loop feedback enables the system to compensate for inlet buffer concentration variability and maintain precise pH control, resolving the contradiction between simple equipment and high blending accuracy.
Solution Approach 2:
The system dynamically adjusts flow rate parameters based on real-time pH measurements and known inlet buffer concentrations. By changing the flow rate parameters in response to measured pH values and calculated buffer concentrations, the system achieves accurate blending control without requiring overly complex equipment.
2Manufacturing precision
If pH feedback control is used to temper the final blend, then precise pH control can be achieved, but the minority component in the pH tempering solution spoils the intended proportion
Solution Approach 1:
The patent calculates the expected contribution of the minority component in the pH tempering solution in advance, based on known concentrations and flow rates. This preliminary calculation allows the system to pre-adjust the flow rates of buffer concentrates to compensate for the upcoming pH tempering action, thereby maintaining the intended blend proportion while achieving precise pH control.
Solution Approach 2:
The system applies a preliminary counter-adjustment to the buffer concentrate flow rates that anticipates and offsets the effect of the minority component addition during pH tempering. This preliminary anti-action prevents the proportion spoilage that would otherwise occur, allowing both precise pH control and stable blend composition.
3Productivity
If flow meters are used to monitor buffer flows, then the system can maintain target flow rates, but the flow meters cannot account for concentration variability in the inlet buffers
Solution Approach 1:
The patent introduces pH sensors as intermediary measurement devices that indirectly provide information about buffer concentration. Instead of relying on flow meters alone, the system uses pH measurements as an intermediary to detect concentration variability, which then triggers appropriate flow rate adjustments to maintain both productivity and measurement accuracy.
Data Source
AI summary
Liquid blending systems and methods of blending liquids are provided. In particular, systems and methods for compensating binary inlet buffers during inline buffer dilution are provided. The systems and methods can provide blends of diluent, a first buffer concentrate containing a majority of a tempering component, and a second buffer concentrate containing a minority of a tempering component. The flow of the first buffer concentrate can be adjusted based upon the total amount of the tempering component being added to the blend through the first and second buffer concentrates.