Sensor Calibration for Sulfur Extraction Monitoring
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Solution Overview
Problem
Current methods for monitoring sulfur concentration in caustic streams during sulfur extraction processes from hydrocarbons are either offline, infrequent, qualitative, or limited by the use of electrode systems, which lack accuracy and efficiency.
Innovation Solution
A process for calibrating sensors, such as ORP sensors, used in sulfur extraction processes by comparing sensor data with calibration data from offline analyses, and adjusting calibration as needed to ensure accurate sulfur concentration measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline laboratory analysis is used to measure sulfur concentration, then measurement accuracy is maintained, but monitoring frequency is too infrequent and operational efficiency decreases
Solution Approach 1:
The patent replaces manual offline laboratory analysis with an automated online sensor system that continuously monitors sulfur concentration. The sensor system substitutes the mechanical/chemical analysis process with an automated detection mechanism, enabling continuous real-time monitoring without sacrificing measurement accuracy through proper calibration procedures.
Solution Approach 2:
The sensor system performs self-calibration by automatically comparing its readings against established calibration curves and adjusting its output accordingly. This self-service capability eliminates the need for frequent manual laboratory analysis while maintaining measurement accuracy, thereby resolving the contradiction between continuous monitoring and measurement precision.
2Ease of operation
If manual testing is performed at the unit, then some sulfur concentration data is obtained, but the results are very qualitative and lack precision
Solution Approach 1:
The patent replaces qualitative manual testing with a quantitative sensor-based measurement system. The sensor system substitutes subjective manual assessment with objective electrical or optical detection, providing precise numerical sulfur concentration readings while maintaining ease of on-site operation through continuous automated monitoring.
3Adaptability or versatility
If electrode systems are used to measure mercaptide concentration, then some measurement capability is provided, but the system has limitations and only applies to mercaptides
Solution Approach 1:
The patent implements a sensor system with multiple sensing capabilities that can detect various sulfur compounds including mercaptides, hydrogen sulfide, and organic sulfides. This multi-functional sensor platform replaces the limited electrode system, providing universal applicability across different sulfur species while improving measurement reliability through redundant detection methods and cross-validation.
4Productivity
If online sensors are deployed for continuous monitoring, then monitoring frequency and productivity improve, but calibration requirements increase system complexity
Solution Approach 1:
The sensor system incorporates automated self-calibration functionality that periodically compares readings against stored calibration curves and adjusts its measurement output without manual intervention. This self-service calibration process reduces system complexity by eliminating the need for complex manual calibration procedures while maintaining continuous monitoring capability and measurement accuracy.
Solution Approach 2:
The system implements feedback mechanisms where sensor readings are continuously compared against calibration standards, and calibration drift is automatically detected and corrected. This feedback loop simplifies the overall system by providing automated calibration management, reducing the burden of manual calibration while ensuring continuous accurate monitoring.
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 enables continuous, accurate monitoring of sulfur concentrations in caustic streams, improving the reliability and efficiency of sulfur extraction processes by ensuring that sensor data remains aligned with established calibration standards.
Implementation Method 1
obtain, with an ORP sensor, an ORP data regarding the rich caustic stream
Data Source
AI summary
Systems and processes for removing sulfur compounds from a hydrocarbon stream. Sulfur compounds are extracted from a hydrocarbon feed stream with a caustic stream to provide a treated hydrocarbon stream and a rich caustic stream. The sulfur compounds in the rich caustic stream are oxidized in the presence of a catalyst to provide a lean caustic stream. The lean caustic stream is returned to extract sulfur from the hydrocarbon stream. Data such as a concentration of sulfurs species and degree of caustic saturation with the sulfur species in the rich caustic stream may be provided by a sensor, compared against other real-time or historical data and used to provide a recommended adjustment to process conditions associated with an extraction unit, or an oxidation unit, or both.