Flowing Mixture Concentration Measurement Under Variable Conditions
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Solution Overview
Problem
Existing methods for filling and diluting acids into transport containers face challenges in maintaining constant composition and conditions, leading to inaccuracies in mass balance and component ratios due to variable temperature and pressure, especially during thermal effects and changes in mixing ratios.
Innovation Solution
The method involves measuring the mass flow and volume flow of a mixture over a scanning interval, decomposing the mass flow into component masses, and calculating the average content of components to ensure accurate regulation of the acid concentration, using ultrasound flow measurements and mass flow integration to account for changes in temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If concentration meters are used to determine instantaneous or average content during flow, then concentration measurement is achieved, but reliable determination of average content fails when composition and conditions are not constant during flow
Solution Approach 1:
The continuous flow is divided into discrete sampling intervals, with each interval treated as a separate measurement unit. The overall average content is calculated by integrating the product of instantaneous concentration and mass flow rate across all sampling intervals, rather than relying on a single continuous measurement. This segmentation allows accurate representation of variable conditions throughout the filling process.
Solution Approach 2:
The method accounts for changing parameters (concentration, mass flow rate, temperature) by continuously measuring and recording their values at each sampling interval. The calculation uses the actual measured parameters at each moment rather than assuming constant values, thereby adapting to the variable conditions during flow and filling.
2Manufacturing precision
If control processes continuously measure acid concentration and regulate flow to reach target concentration, then concentration control is implemented, but control deviations between target and actual concentrations persist during running time
Solution Approach 1:
The method provides accurate feedback by calculating the true average content based on integrated measurements of instantaneous concentration and mass flow rate. This accurate feedback enables the control system to identify actual deviations from target concentration and adjust control parameters accordingly, improving the precision of concentration control over time.
Solution Approach 2:
The measurement method dynamically adapts to changing flow conditions by continuously updating measurements at each sampling interval. Rather than relying on static or averaged assumptions, the system captures the dynamic behavior of concentration and flow rate variations, providing an accurate representation of actual concentration throughout the filling process.
3Speed
If volumetric flow measurement is performed during dilution processes, then flow rate measurement is achieved, but thermal effects cause temperature changes that impact measurement accuracy
Solution Approach 1:
The measurement system performs multiple functions simultaneously: it measures volume flow rate, determines instantaneous concentration, records temperature, and calculates mass flow rate. By integrating these multiple measurements, the system compensates for thermal effects and provides accurate concentration determination despite temperature variations during the dilution process.
Data Source
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AI summary
Method for measuring the average concentration of a component in a flowing mixture of two or more components (KS, KW), for example, during the filling of a container (5) that is filled by a time-varying inflow and time-varying fraction of the components. The solution consists of using the measured concentration and mass of the flow over a sampling interval to determine the component masses and integrating them separately. The use of component masses is valid under normal process conditions at any point and under all conditions, i.e., especially regardless of temperature and pressure. The ratio of the total mass of a component to the total mass of the mixture reflects the current concentration of the entire measured flow rate—in this case, specifically the mixture in the container—at any given time.The average concentration of the mixture in the container is particularly suitable as an actual value input in a control system for regulating the specified target acid concentration (target acid concentration). In a two-component system, it is sufficient to integrate the masses of both components or one component mass and the total mass of the mixture. The method is also suitable for determining the average concentration of a component in a flowing mixture when fed and measured via multiple feed lines, and also for multi-component mixtures.