Systems and methods for monitoring solids using mechanical resonator
AssigneeSymyx Solutions, Inc.
InventorsIan Burdett, Timothy Lynn, Oleg Kolosov, Daniel Paul Zilker, Jr., Leonid Matsiev
Life of this patent
Estimating the term…
Abstract
Particle and multi-phase system monitoring methods, systems and apparatus are disclosed. Preferred embodiments comprise one or more mechanical resonator sensing elements. In preferred embodiments a sensor or a sensor subassembly is ported to a fluidized bed vessel such as a fluidized bed polymerization reactor.
Claims77
A method for monitoring fluidized polymer particles in a fluidized bed polymerization reactor system, the method comprising:
- polymerizing a gaseous monomer in a fluidized bed polymerization reactor of the system thereby forming fluidized polymer particles in the fluidized bed polymerization reactor,
- contacting a mechanical resonator with the fluidized polymer particles in the reactor system, and
- monitoring a response of the mechanical resonator to the contacting.
A method for monitoring a bed of polymer particles, the method comprising:
- contacting a mechanical resonator with polymer particles in the bed of polymer particles, the bed further comprising a gaseous fluid in interstitial spaces defined between the polymer particles,
- stimulating the mechanical resonator to generate a response of the mechanical resonator, and
- monitoring the response of the mechanical resonator to the contacting.
A method for monitoring fluidized particles, the method comprising:
- fluidizing particles to form a multi-phase system comprising the fluidized particles and a gaseous continuous phase,
- contacting a mechanical resonator with the fluidized particles,
- stimulating the mechanical resonator to generate a response of the mechanical resonator,
- monitoring the response of the mechanical resonator to the contacting, and
- characterizing the multi-phase system by determining at least one of(i) a localized density, (ii) a granular temperature, (iii) a mixing factor and (iv) a particle-motion property of the particles in the multi-phase system, in each case based on the monitored response of the mechanical resonator.
A method for determining an elastic modulus of particles in a multi-phase system, the method comprising:
- contacting a mechanical resonator with particles,
- stimulating the mechanical resonator to generate a response of the mechanical resonator,
- monitoring the response of the mechanical resonator, and
- determining an elastic modulus of the particles based on the monitored response of the mechanical resonator.
A method for monitoring a polymerization reaction in a fluidized bed polymerization reactor system, the method comprising:
- polymerizing a gaseous monomer in a fluidized bed polymerization reactor of the system thereby forming fluidized polymer particles in the fluidized bed polymerization reactor,
- monitoring the fluidized polymer particles in the reactor system using a sensor comprising a mechanical resonator, and
- determining, based on a monitored response of the sensor to contact of the mechanical resonator with the polymer particles, at least one of (i) an occurrence or extent of agglomeration of the fluidized polymer particles in the system, (ii) an occurrence or extent of polymer sheeting in the system, (iii) a rate of polymerizing in the fluidized bed polymerization reactor, (iv) a level of condensed liquid in the fluidized bed polymerization reactor, (v) an occurrence or extent of channeling of the fluidized polymer particles in the system, (vi) an occurrence or extent of fluidization of the polymer particles in the system, and (vii) an occurrence or extent of plugging of a gas distribution plate in the system.
A method for controlling a process condition in a fluidized bed polymerization reactor system, the method comprising:
- polymerizing a gaseous monomer in a fluidized bed polymerization reactor of the system under a set of process conditions to form fluidized polymer particles in the reactor,
- monitoring a response of a sensor caused by contact of the sensor with the polymer particles in the fluidized bed polymerization reactor system over a period of time, wherein the sensor comprises a mechanical resonator, and
- varying at least one process condition of the set based on a monitored output signal of the sensor.
A system comprising a fluidized bed polymerization reactor system, the fluidized bed polymerization reactor system comprising:
- a reactor vessel having an inlet port, the inlet port being adapted for receiving a gaseous fluid for fluidizing polymer particles in the reactor vessel, and
- a sensor comprising a mechanical resonator, the mechanical resonator comprising a sensing surface adapted for exposure to the fluidized polymer particles within the reactor system, wherein a response of the sensor is indicative of impacts of the fluidized polymer particles against the sensing surface.
An apparatus comprising a sensor for use in monitoring fluidized particles, the sensor comprising:
- a flexural resonator having a sensing surface adapted for exposure to a multi-phase system comprising fluidized particles in at least one of a gaseous continuous phase and a liquid phase, and
- a signal processing circuit in electrical communication with the flexural resonator for receiving an output signal from the flexural resonator during a sensing period, the signal processing circuit configured for processing the received signal to generate data representing at least one of localized density of the fluidized particles, granular temperature of the fluidized particles, mixing factor of the fluidized particles and combinations thereof.
In a fluidized bed polymerization reaction system comprising a reaction vessel, the improvement comprising:
- a sensor comprising a mechanical resonator, the mechanical resonator comprising a sensing surface adapted for exposure to the fluidized polymer particles within the reactor system, wherein a response of the sensor is indicative of impacts of the fluidized polymer particles against the sensing surface.
Dependencies are inferred from the claim text.