Automated Particulate Dosing System with Quick-Release Hatch
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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, making them costly and unreliable, especially for processors requiring frequent small additions.
Innovation Solution
A controlled addition system comprising a vessel with a quick-release hatch, a weighing device, piping with metering valves, and a controller, along with a particulate material emptying device that can refill from disposable plastic pails, allowing for precise and automated addition of particulate material, minimizing operator exposure and improving inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual handling methods (ladles, shot pots) are used for small quantities of additives, then the system complexity is reduced, but material loss increases and measurement precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical handling (ladles, shot pots) with an automated dosing system that uses a scale for precise measurement and controlled dispensing. The system automatically transfers additives from containers through a dosing chamber into the process stream, eliminating the need for manual scooping and pouring operations that cause spillage and loss.
Solution Approach 2:
The system enables self-service operation where the automated dosing mechanism handles the entire process of measuring and adding additives without operator intervention. The scale automatically tracks material usage, the system controls the dispensing rate, and inventory levels are monitored automatically, freeing operators from manual handling tasks while preventing material loss through precise control.
2Device complexity
If manual handling methods are used, then device complexity is reduced, but measurement precision and recording accuracy deteriorate
Solution Approach 1:
The patent replaces imprecise manual estimation and paper-based logging with an electronic scale integrated into the dosing system. The scale continuously measures the weight of additives being dispensed and automatically records the data, providing precise real-time measurement and digital documentation without requiring manual reading and transcription.
Solution Approach 2:
The system incorporates feedback through the scale that continuously monitors additive consumption and provides real-time data to the control system. This feedback loop ensures accurate measurement of each dose added and maintains a running total of usage, enabling precise tracking and automatic inventory management without human error.
3Device complexity
If operators manually handle additives in close proximity, then equipment cost is reduced, but health safety risks increase
Solution Approach 1:
The patent replaces manual handling operations with an automated dosing system that encloses the additive transfer process within a controlled chamber. The system uses automated mechanisms to transfer additives from storage containers through the dosing chamber into the process stream, eliminating operator proximity to loose powder and preventing dust generation in the workspace.
Solution Approach 2:
The automated dosing chamber acts as an intermediary between additive storage and the process injection point. All transfers and dispensing operations occur within this enclosed intermediate space, isolating operators from direct contact with loose additives and preventing dust from reaching the operator environment.
4Productivity
If large tote bins (907 kg) are used for storage, then shipping frequency is reduced, but weight resolution and control precision deteriorate
Solution Approach 1:
The patent segments the large 907 kg tote bin storage into multiple smaller, manageable portions using the automated dosing system. The system can handle smaller container sizes (such as 20-50 lb pails) and dispense precise small quantities, allowing the total inventory to be divided into multiple smaller units that maintain measurement precision while still providing adequate supply duration.
Solution Approach 2:
The system provides dynamic adaptability in handling different container sizes and dispensing rates. Rather than being fixed to large tote bins, the automated dosing mechanism can accommodate various container formats and adjust its operation to maintain precise weight resolution regardless of the total inventory size or container configuration.
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
Enables accurate, automated, and cost-effective addition of small quantities of catalysts and additives, reducing waste and health risks, while ensuring precise monitoring and recording, thus enhancing process stability and reducing the risk of premature shutdowns.
Implementation Method 1
a second valve for transferring a first stream of pressurized gas from a source of pressurized gas to the vessel
Data Source
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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 quick-release hatch located on the top of the vessel.