Optical Flow Characterization for Pneumatic Cement Conveying
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Solution Overview
Problem
Current methods for determining the characteristics of dry bulk materials or powders, such as cement compositions, are inefficient and unreliable, often requiring time-consuming and costly processes, leading to potential errors in storage, transfer, and deployment, especially in industries like oil and gas where accurate cementing operations are critical.
Innovation Solution
The use of optical computing devices that analyze dry cements in real-time, allowing for rapid identification of composition, particle size distribution, and other characteristics without the need for extensive sample preparation, enabling immediate adjustments in conveying systems to optimize flow and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement techniques (x-ray diffraction, gravimetric analysis, viscosity testing) are used to analyze dry bulk materials, then measurement precision can be achieved, but the process becomes time-consuming and complex
Solution Approach 1:
The patent replaces complex mechanical and chemical measurement systems (x-ray diffraction, gravimetric analysis, viscosity testing) with an optical measurement system that uses light scattering and absorption principles. The optical computing device analyzes bulk material properties through non-contact optical interactions, eliminating the need for physical sample preparation, chemical reagents, and lengthy laboratory procedures while maintaining measurement accuracy
Solution Approach 2:
The patent introduces an optical computing device as an intermediary between the bulk material and the measurement system. This device uses optical fields as a mediator to extract material characteristics (particle size distribution, composition, flow properties) without direct physical contact or complex sample handling, thereby accelerating the measurement process while preserving precision
2Device complexity
If discrete measurements are taken at specific locations and times in storage containers and pipelines, then measurement complexity is reduced, but measurement precision and reliability deteriorate
Solution Approach 1:
The optical computing device is designed as a universal measurement system that can be deployed in multiple locations (storage containers, pipelines, conveying systems) and adapt to measure different bulk material properties (composition, particle size, flow characteristics) using the same fundamental optical principles, thereby maintaining both simplicity and precision across diverse applications
3Measurement precision
If conventional measurement methods involving chemical mixing and laboratory analysis are used, then measurement precision can be maintained, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical sample preparation devices, chemical reagent systems, and laboratory analysis equipment with a streamlined optical computing device. The system uses optical fields to directly probe bulk material properties in situ, eliminating numerous mechanical and chemical steps while maintaining measurement accuracy through non-destructive optical characterization
4Productivity
If real-time optical analysis is implemented in pneumatic conveying systems, then productivity and response time improve, but device complexity increases
Solution Approach 1:
The optical computing device is integrated into the pneumatic conveying system in a self-service manner, using the existing material flow and pneumatic environment to perform measurements without requiring separate sampling systems, additional conveyance equipment, or complex installation modifications. The system leverages the natural flow conditions to enable real-time analysis while adding minimal complexity to the overall conveying operation
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, real-time analysis of dry cement characteristics, reducing errors and costs by enabling timely remedial actions, improving the quality of cement slurries, and minimizing losses or damages during handling and deployment.
Implementation Method 1
an optical computing device that rapidly analyzes dry cements... allowing for rapid identification of composition, particle size distribution, and other characteristics
Implementation Method 2
Pneumatic conveying system and method using optical flow characterization data... modifying at least one of a feed rate or a differential air pressure in the pneumatic conveyor
Data Source
AI summary
A method includes optically interacting a flow of bulk material or powder in a pneumatic conveyor with an integrated computational element (“ICE”) configured to modify an electromagnetic radiation according to a characteristic of the flow of bulk material or powder. The method includes detecting the modified electromagnetic radiation with a detector, producing an output signal corresponding to the characteristic of the flow, and receiving and processing the output signal with a signal processor to yield a value for the characteristic of the flow. Also, the method includes modifying at least one of a flow rate or an air pressure in the pneumatic conveyor in response to the value of the characteristic of the flow. The bulk material or powder includes a dry cement or a dry cement component.