Packed Column Flooding Detection via Acoustic SPC
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Solution Overview
Problem
Conventional methods for predicting the flooding point in packed columns are inaccurate, rely heavily on empirical parameters and human judgment, and are not applicable to all types of packed columns, leading to inefficiencies and operational risks.
Innovation Solution
A real-time prognosis method using online data collection of pressure drops, calculation of a steadiness index, and statistical analysis with control limits to detect flooding phenomena, independent of human decisions and empirical parameters, through Statistical Process Control (SPC) methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If empirical correlations and models are used to predict the flooding point, then prediction capability is provided, but prediction accuracy is insufficient due to dependency on empirical parameters
Solution Approach 1:
The patent replaces empirical mechanical/correlation-based prediction models with an acoustic wave-based detection system. By installing receptors on the external surface of the column body to collect acoustic wave signals from the liquid inside the packed column, the system objectively detects the flooding point through acoustic signal analysis, eliminating dependency on empirical parameters and improving both accuracy and universal applicability across different packed column types.
2Measurement precision
If visual inspection is used for real-time monitoring, then direct observation of liquid heaping is achieved, but the method is limited to transparent columns and involves human judgment delays
Solution Approach 1:
The patent replaces manual visual inspection with an automated acoustic wave signal collection system. By installing receptors on the external surface of the column body to continuously collect and analyze acoustic wave signals from the liquid inside the packed column, the system achieves automated, real-time detection of the flooding point without human intervention, eliminating both the transparency limitation and human judgment delays.
3Reliability
If gas flow rate is set conservatively at 0.6 to 0.8 of the flooding point, then operational safety is ensured, but production rate and energy efficiency are reduced
Solution Approach 1:
The patent implements a real-time feedback monitoring system using acoustic wave signal receptors that continuously detect the actual flooding point. By providing real-time feedback on the true flooding condition, the system enables dynamic adjustment of gas flow rate, allowing operation closer to the actual flooding point rather than relying on conservative fixed ratios, thereby improving production rate while maintaining safety through continuous monitoring and adjustment.
Data Source
AI summary
A method of real-time prognosis of a flooding phenomenon in a packed column includes steps as follows. An online data collection step is conducted, wherein a plurality of values of the pressure drop are collected from the packed column under operation. A calculation step is conducted, wherein the values of the pressure drop are used to calculate a plurality of values of a steadiness index. A statistical step is conducted, wherein a value of a monitoring statistic is calculated based on the values of the steadiness index. A control step is conducted, wherein the value of the monitoring statistic is compared to a control limit, and an alarm is triggered when the value of the monitoring statistic is greater than the control limit.