Industrial Material Balance Modeling With Reclaim Stream Stitching
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Solution Overview
Problem
Conventional software is inadequate for modeling complex industrial operations with multiple interconnected systems, particularly in achieving material balance when reclaim material is involved, as it requires detailed definitions of incoming and outgoing flows and loads that are difficult to define based on readily available data.
Innovation Solution
A computer-implemented method and system that provides a graphical user interface for administrators to generate a visual model of industrial systems, allowing for the categorization and automatic balancing of material streams, including the calculation of incoming and outgoing streams and the introduction of stitching elements for reclaiming spent material, which balances demand and available reclaimed material quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional software such as spreadsheets is used for material balance development, then basic calculations can be performed, but the software is not well suited for modeling complex operations with multiple interconnected systems
Solution Approach 1:
The system segments the industrial system into discrete elements (process units, streams, recovery systems) that can be independently defined and interconnected. Each element has standardized attributes (incoming streams, outgoing streams, material loads) that can be configured separately, allowing complex systems to be built from manageable components through the visual modeling interface.
Solution Approach 2:
The patent transitions from traditional spreadsheet-based flat data structures to a multi-dimensional visual model that includes spatial relationships (process flow diagrams), hierarchical relationships (elements containing streams), and temporal dynamics (real-time balancing). This dimensional expansion enables representation of complex interconnected systems that cannot be effectively modeled in conventional two-dimensional spreadsheets.
2Measurement precision
If detailed definition of balancing method for incoming and outgoing flows is required, then material balance accuracy improves, but the definition process becomes difficult based on readily available data
Solution Approach 1:
The system performs automatic material balancing through real-time calculation engines that compute incoming and outgoing streams based on element configurations and operational data. The automated balancing algorithms continuously adjust material flows to satisfy conservation principles, eliminating the need for manual detailed definitions while maintaining high accuracy through systematic computational methods.
Solution Approach 2:
The system pre-configures standardized element templates with default balancing methods and stream relationships. During setup, users select from pre-defined element types (process units, recovery systems, storage tanks) that come with built-in balancing logic, eliminating the need to define balancing methods from scratch for each element while allowing customization when needed.
3Loss of substance
If stitching elements are added to balance reclaimed material demand and availability, then material conservation improves, but the system complexity increases
Solution Approach 1:
Stitching elements serve as intermediary components that connect recovery systems to process units, enabling the flow of reclaimed materials through the system. These elements act as mediators that balance the mismatch between reclaimed material availability and demand, automatically calculating required flows and integrating multiple streams while maintaining overall material balance throughout the industrial system.
Data Source
AI summary
Disclosed herein are systems and method for managing material balance between incoming and outgoing streams of material in an industrial system. A method may include providing a graphical user interface (GUI) that enables a system administrator to generate a visual model of the industrial system that includes (1) elements that are interconnected in the industrial system, and (2) streams including at least one incoming stream of material to each element and at least one outgoing stream of material from each element. The method may include receiving, via the GUI, a plurality of parameters of the elements and the streams such as material chemistry, user demand of each user element of the user elements, and flowrate for each stream of the streams. The method may include determining a category of each stream and automatically balancing, by a processor, incoming and outgoing streams for each element.