Particulate Addition System with Sealed Hopper and Automated Weighing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems for adding small amounts of powdered catalysts and additives to industrial processes, such as the FCC process, are inefficient, leading to waste, health risks, and inaccurate recording of usage, which results in financial losses and process instability due to lack of precise control and automation.
Innovation Solution
A controlled addition system with a vessel, metering valve, and micro-PLC controller that allows for precise addition of particulate material, including a particulate material emptying device with a funnel adapter and tilting cradle, and flexible piping with quick disconnect couplings, enabling accurate and automated tracking of additive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If manual handling of loose material or bags is used, then small quantities of additive can be added, but waste through accidental spillage increases and operator exposure to dust increases
Solution Approach 1:
A sealed hopper system acts as an intermediary between the additive storage and the injection point, eliminating direct manual handling. The system uses a controlled discharge mechanism with a seal that maintains containment throughout the transfer process, preventing spillage and dust exposure while enabling precise dosing of small quantities.
Solution Approach 2:
The patent replaces manual mechanical handling (scooping, pouring, bag opening) with an automated controlled discharge system. The mechanism uses a seal and controlled opening/closing action to transfer additive automatically, eliminating the need for operator intervention and the associated waste and exposure risks.
2Quantity of substance
If manual handling of loose material or bags is used, then small quantities of additive can be added, but operator exposure to high levels of ambient dust increases
Solution Approach 1:
The sealed hopper system serves as an intermediary that completely encloses the additive during transfer, acting as a barrier between the dust-generating process and the operator. This eliminates dust exposure while maintaining the capability to handle small quantities precisely.
Solution Approach 2:
The system creates a sealed, dust-free environment for additive handling by enclosing the hopper and using a controlled discharge mechanism. This inert environment prevents dust from escaping into the workspace, protecting operators from exposure.
3Device complexity
If no automatic recording system is used, then the addition system is simpler, but accurate tracking of additive usage is lost
Solution Approach 1:
The system incorporates a weigh module that continuously monitors additive consumption and provides automatic feedback recording. This feedback mechanism tracks usage data without significantly increasing system complexity, enabling precise inventory management and usage tracking while maintaining operational simplicity.
Solution Approach 2:
The weigh module automatically performs the recording function without requiring external intervention or complex data management systems. The system self-monitors and self-records additive usage, eliminating the need for manual tracking while keeping the overall system relatively simple.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An addition system for introducing particulate material into an industrial process is disclosed. The addition system comprises a vessel for holding the particulate material, a weighing device, piping, a controller, and a frame to support the piping. The piping comprises a first valve for transferring the particulate material to the industrial process, and a second valve for transferring a first stream of pressurized gas from a source of pressurized gas to the vessel. The vessel comprises a filling nozzle located on the top of the vessel.