Direct Line Sampling Valve for Dense Slurry Analysis
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Solution Overview
Problem
Current methods for analyzing dense slurries in process flows face challenges due to signal penetration issues and stratification, leading to inaccurate representation and delayed real-time analysis, which can result in process control problems.
Innovation Solution
A direct line sampling system that uses a sampling valve structure to capture a representative sample from the process flow, dilute it inline, and analyze it in real-time, preventing stratification and ensuring accurate characterization of the process flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dense slurry is sampled for analysis, then the process flow can be characterized, but the dense particles prevent light signals from penetrating, making accurate analysis impossible
Solution Approach 1:
The patent extracts a representative sample from the dense slurry flow and separates it into a dilution chamber where particles are isolated and diluted with fluid. This extraction removes the harmful density concentration that blocks light signals, allowing individual particles to be analyzed without signal penetration issues.
Solution Approach 2:
The patent introduces a dilution fluid as an intermediary substance that mixes with the sampled slurry in the dilution chamber. This intermediary fluid reduces particle concentration and density, creating a transparent medium that allows light signals to penetrate while still carrying the particulate matter for analysis.
2Ease of operation
If a point sample is taken from a single location in the process flow, then sampling is simplified, but flow stratification causes the sample to be unrepresentative of the entire flow
Solution Approach 1:
The patent segments the sampling process into multiple stages: a sampling probe takes a point sample, which is then further segmented into smaller particle concentrations through the dilution chamber. This segmentation transforms an unrepresentative point sample into a representative diluted sample that accurately characterizes the entire slurry flow.
Solution Approach 2:
The patent transitions from spatial sampling (point in flow) to temporal/concentration sampling by diluting the sample over time in the dilution chamber. This dimensional change allows the system to capture representative particle characteristics that would be missed in a single-point spatial sample.
3Productivity
If sampling devices are used to capture a point sample, then sampling can be performed, but the sampler structure changes fluid velocity and causes further stratification
Solution Approach 1:
The patent uses the dilution chamber as an intermediary environment that receives the sample from the sampling probe and neutralizes the velocity disruption effects. The chamber provides a controlled transition zone where the sampled fluid is gradually diluted, preventing further stratification while maintaining sampling capability.
4Measurement precision
If a sample is taken to a lab for analysis, then detailed examination can be performed, but considerable manpower and time are required, preventing real-time results
Solution Approach 1:
The patent implements self-service analysis by integrating the dilution and analysis capabilities directly at the process flow location. The system automatically dilutes and analyzes particles in real-time without requiring manual sample handling, transportation, or laboratory processing, eliminating time delays and manpower requirements while maintaining analysis precision.
5Measurement precision
If heavier particles are present in the sampled flow, then the slurry composition is accurately represented, but particles drop out of the sample due to velocity changes
Solution Approach 1:
The patent uses the dilution fluid as an intermediary that supports heavier particles throughout the sampling and analysis process. The diluent provides buoyancy and continuous suspension, preventing heavier particles from dropping out due to velocity changes, while still allowing them to be accurately represented and analyzed.
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, real-time analysis of process flows, reducing the risk of out-of-control conditions by providing a representative sample that is not affected by stratification, thus improving process control and reducing manpower and time delays.
Implementation Method 1
In another embodiment, a diluent control line is provided that opens into the outlet line upstream of the analysis instrument. The diluent from the diluent control line provides a lifting force on the particles that counters gravity.
Implementation Method 2
A sampling valve structure is provided that is disposed in the flow line and is configured to separate a sample volume from the flow for analyzing the characteristics of the flow. The sampling valve structure includes a sampling chamber in communication with the flow line such that the process flow passes through the chamber.
Data Source
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AI summary
A direct line sampling system includes a flow line for a process flow, a diluent flush line for a diluent, and a sampling valve structure disposed in the flow line. The sampling valve structure includes a sampling chamber and has a first position in which the sampling chamber is in communication with the flow line so as to provide a path for the process flow through the sampling chamber. The sampling chamber captures a sample from the process flow when the sampling valve structure switches to a second position in which the sampling chamber is in communication with the diluent flush line. The diluent flushes the sample to a mixing chamber disposed downstream of the diluent flush line where the sample is diluted. An outlet line extends from an outlet of the mixing chamber to an analysis instrument configured to analyze particles in the diluted sample of the process flow.