In-Line UV-VIS Monitoring of Metal Sulfate Concentrations
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Solution Overview
Problem
Existing methods for monitoring the concentration of metal sulfates in industrial processes, such as NiSO4, CoSO4, and MnSO4, are time-consuming and costly due to manual grab samples and are hindered by upstream process residuals, making precise process control difficult.
Innovation Solution
An in-line monitoring method using UV-VIS spectroscopy and additional measurements like Raman spectroscopy, mass density, and refractive index to determine individual and total metal sulfate concentrations, with calibration by laboratory spectrometers for accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual grab samples are used for analysis, then measurement precision can be achieved, but productivity decreases and time consumption increases
Solution Approach 1:
The patent replaces manual mechanical sampling operations with an automated optical measurement system. UV-VIS spectroscopy instruments mounted in-line on pipes automatically measure metal sulfate concentrations without requiring manual grab samples, thereby maintaining measurement precision while eliminating time consumption and labor costs associated with manual sampling
Solution Approach 2:
The system enables self-service monitoring where the process stream itself serves as the sample source. The in-line spectroscopic measurement system continuously analyzes the flowing solution directly in the pipe, eliminating the need for external manual sampling operations and providing continuous real-time concentration data
2Manufacturing precision
If manual grab samples are performed frequently, then process control accuracy improves, but loss of time increases
Solution Approach 1:
The patent implements continuous in-line measurement using UV-VIS spectroscopy that operates without interruption throughout the process. The optical sensor continuously monitors metal sulfate concentrations in the flowing stream, providing uninterrupted real-time data that enables continuous process control without the time losses associated with periodic manual sampling
Solution Approach 2:
The system substitutes manual sampling and laboratory analysis with automated optical measurement technology. The in-line spectroscopic system provides immediate concentration readings directly in the process stream, eliminating the time required for manual collection, transportation, and laboratory analysis while maintaining or improving control accuracy
3Productivity
If in-line measurement is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional optical measurement system that can detect multiple metal sulfate concentrations (NiSO4, CoSO4, MnSO4) simultaneously using a single UV-VIS spectroscopy instrument. This universal approach avoids the need for multiple separate measurement systems, thereby improving productivity while limiting the increase in device complexity
Solution Approach 2:
The system uses optical radiation (UV-VIS spectrum) as an intermediary to non-contactly measure metal sulfate concentrations. This optical mediation allows continuous in-line measurement without physical contact with the process stream, simplifying the measurement system compared to traditional sampling methods while enabling continuous monitoring
4Measurement precision
If multiple measurement methods are used for different metal sulfates, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional optical measurement system that can detect multiple metal sulfate concentrations (NiSO4, CoSO4, MnSO4) simultaneously using a single UV-VIS spectroscopy instrument. This universal approach avoids the need for multiple separate measurement systems, thereby improving productivity while limiting the increase in device complexity
Solution Approach 2:
The patent segments the measurement approach by using specific wavelength ranges within the UV-VIS spectrum for different metal sulfates. Different portions of the optical spectrum are assigned to detect specific metal concentrations, allowing simultaneous multi-analyte measurement with a single instrument through spectral decomposition and multivariate analysis
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 fast, reliable, and precise in-line monitoring of metal sulfate concentrations, facilitating efficient process control and reducing manual intervention, thus enhancing production efficiency.
Implementation Method 1
In-line obtaining a UV-VIS measuring spectrum of the solution, for example, by using ultraviolet or ultraviolet-visible or near infrared electromagnetic waves
Implementation Method 2
at least one in-line measurement which is sensitive to the total concentration of the metal sulfates
Data Source
AI summary
A method for in-line monitoring of the concentration of metal sulfates in a solution. The method includes: obtaining in-line a UV-VIS measuring spectrum of the solution; determining in-line the concentration of CoSO4 and NiSO4 by analyzing in-line the UV-VIS measuring spectrum; determining in-line the total metal sulfate concentration; and determining in-line the concentration of MnSO4, based at least on the determined concentration of NiSO4, the determined concentration of CoSO4, and the determined total metal sulfate concentration. Advantageous embodiments of an in-line measuring system and an installation assembly with the in-line measuring system are also disclosed.