Windowless Flow Cell with Pressure-Controlled Orifices
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Solution Overview
Problem
Conventional optical window materials used in monitoring chemical processes, such as molten salts and mineral slurries, face issues like clouding and material deposition, limiting their effectiveness in extreme conditions like high temperatures and corrosive fluids, and are not compatible with all process fluids, leading to inefficient monitoring and control.
Innovation Solution
The implementation of a flow cell system with windowless optical access, utilizing orifices for fluid flow and passive pressure coupling, allowing for continuous on-line monitoring of process fluids, including molten salts and mineral slurries, without the need for conventional optical windows, enabling analysis of high-temperature, high-radiation, and corrosive fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional optical window materials are used in flow cells for monitoring process fluids, then optical analysis can be performed, but the window materials cloud and deposit after exposure to extreme conditions (high temperature, corrosive fluids, radiation), limiting monitoring duration and reliability
Solution Approach 1:
The patent removes the optical window material from the flow cell system entirely, creating a windowless design where process fluids flow directly through the optical path. This extraction eliminates the component that degrades under extreme conditions, allowing continuous monitoring without replacement or maintenance of window materials.
Solution Approach 2:
The patent introduces a sacrificial barrier layer (such as a Teflon coating or thin film) that acts as an intermediary between the corrosive process fluid and the optical detection system. This barrier layer protects the optical path while allowing sufficient light transmission, and can be replaced independently of the entire flow cell system.
2Reliability
If windowless optical cells with small orifices are used to prevent fluid leakage, then optical access is provided, but the aperture size is limited which restricts optical throughput and signal strength
Solution Approach 1:
The patent uses gas pressure differentials to control fluid flow through the orifice. By maintaining appropriate pressure gradients between the process fluid side and the optical chamber side, the system prevents fluid leakage through the orifice while allowing sufficiently large aperture sizes for optimal optical throughput. The gas pressure acts as a controllable barrier that doesn't physically block the optical path.
3Illumination intensity
If larger apertures are used in windowless optical cells, then optical throughput and signal strength improve, but fluid leakage through the orifice increases due to reduced surface tension containment
Solution Approach 1:
The patent employs gas pressure differentials to counteract the reduced surface tension containment effect of larger orifices. By maintaining appropriate pressure gradients, the system allows larger aperture sizes for improved optical signal strength while preventing fluid leakage through the enlarged opening.
Solution Approach 2:
The patent uses composite structures combining hydrophobic coating materials (such as Teflon) with the orifice structure. This composite approach maintains surface tension containment properties even with larger aperture sizes, preventing fluid leakage while allowing increased optical throughput.
4Ease of operation
If conventional optical windows are used, then optical analysis is enabled, but the windows are damaged or clouded by high temperature, radiation, corrosive and abrasive fluids
Solution Approach 1:
The patent removes the vulnerable optical window material from the system, eliminating the component that suffers damage from extreme conditions. The windowless design allows optical analysis capability while avoiding the damage issues associated with conventional optical windows in harsh environments.
Solution Approach 2:
The patent employs disposable or easily replaceable barrier layers (such as thin Teflon films) that can be quickly replaced when degraded. These sacrificial barriers protect the permanent optical components from damage by extreme conditions, and their low cost and ease of replacement make them economically viable.
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 solution enables near real-time, high-throughput data collection and process optimization, improving process control, product quality, and material accountancy in industrial processes, such as molten salt reactors and minerals processing, by providing reliable and continuous monitoring of fluid composition and properties.
Implementation Method 1
The fluid surface can be vented to a first gas pressure... The one or more orifices can be vented to a second gas pressure. The second gas pressure can be equal to or greater than the first gas pressure.
Data Source
AI summary
A flow cell system includes a vessel and a fluid located in the vessel. A fluid surface of the fluid can be vented to a first gas pressure. The fluid surface can have a first cross-sectional area. The flow cell system includes a conduit in fluid communication with the vessel and positioned downstream of the vessel. The conduit can have a region that includes one or more orifices and has a second cross-sectional area. The second cross-sectional area can be less than the first cross-sectional area. The one or more orifices can be vented to a second gas pressure. The second gas pressure can be equal to or greater than the first gas pressure. Methods for analyzing a process fluid can include characterizing the fluid in the conduit.