Automated Weight Calibration for Load Cell Material Delivery
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Solution Overview
Problem
Existing material delivery systems for fluid catalytic cracking (FCC) units face inaccuracies and reliability issues due to weight-based measurement systems, which are prone to maintenance failures and downtime, affecting performance and economics.
Innovation Solution
A material delivery system incorporating a delivery vessel with load cells and an automated weight calibration device that applies a known force to ensure accurate measurement and calibration, minimizing downtime and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If weight-based measurement systems are used to deliver materials to FCC units, then material delivery can be automated, but the systems suffer from maintenance failures and downtime that affect reliability
Solution Approach 1:
The load cell system performs self-calibration by automatically applying known test weights and adjusting its own measurement parameters, eliminating the need for manual calibration and reducing maintenance downtime. The system calibrates itself during operation without requiring external intervention or process shutdown.
Solution Approach 2:
The system performs calibration measurements in advance by applying known test weights before actual material delivery, ensuring measurement accuracy is verified and adjusted beforehand. This preliminary calibration action prevents measurement errors during critical delivery operations.
2Strength
If structural components support the pressure vessel to improve stability, then structural integrity is enhanced, but load cells cannot accurately measure catalyst weight
Solution Approach 1:
The support structure is segmented into separate functional zones: dedicated load cell mounting points for measurement and separate structural support elements for integrity. This segmentation allows the load cells to measure only catalyst weight without interference from structural component forces.
Solution Approach 2:
Isolation elements act as intermediaries between the pressure vessel and structural components, preventing direct force transmission that would interfere with load cell measurements. These intermediaries allow structural support while maintaining measurement accuracy by blocking unwanted force paths.
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
The system provides accurate and consistent delivery of materials to FCC units, reducing maintenance needs and associated downtime, thereby enhancing operational efficiency and economic performance.
Implementation Method 1
The sensor is a load cell configured to provide a metric indicative of a weight of material in the pressure vessel
Implementation Method 2
an automated weight calibration device configured to impart a known force onto the at least one load cell
Data Source
AI summary
Material delivery systems, methods of delivering material and methods of calibrating such systems and methods are disclosed. The material delivery system includes a delivery vessel, a load cell, and automated weight calibration device. The delivery vessel has at least an outlet adapted for coupling to an unit. The load cell is configured to provide a metric indicative of an amount of material in the delivery vessel. The automated weight calibration device is configured to impart a known force onto the at least one load cell. A method includes delivering material to a unit and determining how much material is delivered by a change in weight of a delivery vessel, wherein the delivery vessel comprises a load cell; applying a known calibration force to the load cell; and comparing a metric from the load cell of the known calibration with an expected metric.