Multi-Additive Delivery With Detachable Sources for No-Shutdown Switching
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Solution Overview
Problem
Existing additive feed systems in commercial production facilities are inflexible, requiring shutdowns for additive replenishment, difficult to switch between additives, and challenging to customize during operation, leading to inefficiencies and high costs.
Innovation Solution
A multi-additive delivery system with detachable additive sources and automated process control, enabling seamless switching and customization of additives without shutdowns, using detachable connectors and computerized flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single additive is fed through permanently hard-piped systems with run tanks and metering pumps, then the additive can be delivered to the reaction site, but production must be shut down when the additive is exhausted and it is difficult to switch to different additives
Solution Approach 1:
The system divides the additive delivery into multiple independent feedlines, each capable of delivering different additives. This segmentation allows one feedline to be switched or maintained while others continue operating, eliminating the need for complete production shutdown when switching additives.
Solution Approach 2:
Each feedline is designed as a universal module capable of delivering any type of additive through standardized components (pumps, meters, injectors). This multi-functionality allows rapid switching between different additives without requiring dedicated infrastructure for each additive type.
2Adaptability or versatility
If permanently hard-piped additive feed systems are used, then additive delivery is established, but the system is difficult to customize or experiment with different additive combinations and concentrations
Solution Approach 1:
The system incorporates dynamic control capabilities through automated metering pumps and programmable controllers that can adjust flow rates, concentrations, and timing of multiple additives in real-time. This allows flexible customization of additive combinations without physical reconfiguration of the hard-piped infrastructure.
Solution Approach 2:
The system includes monitoring and control mechanisms that provide feedback on additive delivery parameters, enabling precise control and adjustment of additive combinations and concentrations. This feedback loop allows for experimentation and optimization of formulations while maintaining stable operation.
3Productivity
If run tanks are used for additive storage and metering, then additive can be fed to the reaction site, but large proportions of tanks may be wasted when only a small amount is needed for a production run
Solution Approach 1:
The system uses precision metering pumps and flow controllers to deliver only the exact amount of additive needed for each production run, rather than transferring entire tank contents. This partial action approach eliminates the need to waste remaining additive in tanks when production requirements are met with smaller quantities.
Solution Approach 2:
The system replaces manual tank transfer operations with automated metering and dosing mechanisms controlled by programmable logic. This substitution enables precise control of additive quantities, eliminating the inefficiencies of manual tank-based delivery where over-transfer and waste were common.
Data Source
Figure 1
AI summary
An apparatus and method for delivery of additives(s), e.g., catalyst, co-catalyst, scavengers, and/or other reaction- or product-modifying agents, to a reaction or mixing site, such as a reaction vessel, offers the capability for multi-additive delivery and customization of additive selection, flow and flow rate, and if desired, mixing thereof, without production train shutdowns. The invention includes at least two additive sources that are detachably connected, with conduit, to the reaction or mixing site, and a process control means, preferably automated, that is capable of initiating, terminating, and determining the rate of flow from the additive sources.