Multi-density array controller for emulsion phase elevation

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Solution Overview

Problem

Current methods for measuring and controlling emulsion layers in industrial vessels lack precision and simplicity, often requiring multiple nuclear density gauges and complex calibration processes, which limits their effectiveness and introduces noise into density measurements.

Innovation Solution

A highly sensitive density measurement system with multiple source-detector pairs and a computing device that calculates precise emulsion phase boundaries by obtaining density readings from these pairs, enabling accurate identification and control of emulsion phase heights and bordering information, thereby simplifying the control loop functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple nuclear density gauges are used to identify phase boundaries, then measurement coverage is improved, but device complexity and calibration requirements increase

Engineering Contradiction:

Improvephase boundary identification accuracyVSAvoidcontroller input capacity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple density gauge measurements into a single multi-density array controller. The controller receives density signals from multiple gauges and processes them collectively to identify phase boundaries, reducing the number of separate controller inputs needed while maintaining measurement precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-density array controller serves multiple functions: it processes density measurements from multiple gauges, identifies phase boundaries, determines emulsion layer characteristics, and provides control outputs. This single device replaces what would otherwise require multiple separate measurement and control systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If traditional automatic controllers are used with multiple density gauges, then density measurement coverage is improved, but controller feasibility is reduced due to singular feedback parameter requirements

Engineering Contradiction:

Improvedensity measurement coverageVSAvoidcontroller feasibility

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent transforms multiple singular density parameters into a unified multi-density profile. The controller processes density signals from multiple gauges and converts them into phase boundary identification and emulsion layer characteristics, changing the parameter representation from multiple scalar values to a comprehensive density distribution that can be directly used for control.

Inventive Principle:

Principle #35Parameter changes

3Extent of automation

If calibration-based methods are used to automate emulsion layer control, then automation is improved, but system complexity and calibration maintenance requirements increase

Engineering Contradiction:

Improveemulsion layer control automationVSAvoidcalibration system requirements

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The multi-density array controller performs automatic phase boundary identification and emulsion layer characterization by processing density measurements from multiple gauges. The system self-regulates by continuously monitoring density profiles and adjusting control outputs based on detected phase boundaries, reducing reliance on external calibration procedures.

Inventive Principle:

Principle #25Self-service

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

This approach provides a more precise, limitless, and simplistic method for processing density measurements, enabling effective depiction and automatic control of emulsion phases in industrial vessels, overcoming the limitations of traditional systems by integrating multiple control loop signals into automatic controllers.

Implementation Method 1

Each of the source-detector pairs include a radioactive source and a radiometric detector

Methodology Applied

Scientific EffectRadiation attenuation: Absorption (EM radiation)

Data Source

PatentUS11733138B1Multi-density array controller

Publication Date: 2023.08.22 VEGA AMERICAS INC

AI summary

A disclosed system determines the elevation of an emulsion phase in a vessel. The system includes more than one source-detector pairs connected to the vessel and a computing device. Each of the source-detector pairs include a radioactive source and a radiometric detector, and are positioned at an elevation measured from the bottom of the vessel. The computing device is connected to the source-detector pairs, and is configured to identify the height of an emulsion phase using an upper boundary target density and a lower boundary target density. The height of the emulsion phase is identified by obtaining density readings from at least two of the source-detector pairs, calculating an upper boundary emulsion phase elevation and calculating a lower boundary emulsion phase elevation, each calculation using the density readings, and at least one of the upper boundary target density, and the lower boundary target density.