Optical Computing Device for Dry Cement Analysis
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Solution Overview
Problem
Current methods for determining the characteristics and condition of dry bulk materials or powders, such as those used in cement compositions, are often time-consuming, costly, and unreliable, leading to potential contamination and loss of batches, especially in industrial applications like the oil and gas industry where precise cementing operations are critical.
Innovation Solution
The use of optical computing devices that employ integrated computational elements (ICEs) to rapidly analyze dry cements by distinguishing electromagnetic radiation related to specific characteristics, allowing for real-time monitoring and adjustment of blending procedures, reducing the need for extensive sample processing and harsh chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sampling and laboratory testing are used to determine material characteristics, then measurement precision can be achieved, but loss of time and productivity are significantly increased
Solution Approach 1:
The patent replaces manual mechanical sampling and laboratory testing with an optical computing device that uses electromagnetic radiation (light) to rapidly analyze bulk material characteristics in situ. The ICE (integrated computational element) processes optical signals to determine material properties such as particle size, moisture content, and composition without physical contact or time-consuming lab procedures, achieving both precision and speed.
2Measurement precision
If discrete measurements at specific locations are taken, then measurement precision is maintained, but loss of information about the overall material condition occurs
Solution Approach 1:
The optical computing device is designed to perform multiple measurement functions simultaneously. By scanning or using multiple sensors, it can analyze various material characteristics (composition, moisture, particle size) across different locations within the bulk material, providing a comprehensive view of the overall material condition rather than just a single point measurement.
3Loss of information
If probes are inserted into the material to obtain comprehensive information, then measurement coverage is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent extracts the measurement function from complex physical probes that need to be inserted into the material. Instead, it uses non-contact optical sensing that can determine material type and condition from the surface or through the bulk material without physical intrusion, eliminating the complexity of probe insertion, retrieval, and handling while maintaining comprehensive information gathering.
4Measurement precision
If traditional laboratory analysis methods are used, then measurement precision is achieved, but loss of time and increase in operational costs occur
Solution Approach 1:
The patent replaces time-consuming mechanical and chemical laboratory analysis procedures with optical computing using electromagnetic radiation. The ICE processes optical spectra to rapidly determine material composition and characteristics in seconds, enabling real-time quality control and immediate batch disposition decisions without sending samples to the laboratory, thus maintaining precision while dramatically improving productivity.
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 accurate, rapid, and cost-effective analysis of dry cement characteristics, minimizing errors and ensuring the quality of cement compositions, thereby reducing waste and operational costs in industries like oil and gas, food, and pharmaceuticals.
Implementation Method 1
optical computing devices that employ integrated computational elements (ICEs) to rapidly analyze dry cements by distinguishing electromagnetic radiation related to specific characteristics
Data Source
AI summary
A method includes optically interacting a bulk material or powder stored in a storage bin with an integrated computational element ("ICE") configured to modify an electromagnetic radiation according to a characteristic of the bulk material or powder. The method also includes detecting the modified electromagnetic radiation with a detector, and producing an output signal correlated to a value for the characteristic of the bulk material or powder, and receiving and processing the output signal with a signal processor to yield a value for the characteristic of the bulk material or powder. Also, the method includes transmitting a message flagging the storage bin when it is determined that the bulk material or powder is not suitable for continued storage. The bulk material or powder includes a dry cement or a dry cement component.