Real time determination of gas solubility and related parameters in manufacturing processes
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IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
G01N-03100
G06F-01900
출원번호
US-0644997
(2003-08-21)
발명자
/ 주소
Chen, Qingyuan
Franda, Robert Josef
출원인 / 주소
Appleton Papers Inc.
대리인 / 주소
Birch, Stewart, Kolasch &
인용정보
피인용 횟수 :
18인용 특허 :
4
초록▼
Methods and apparatuses for determining entrained and/or dissolved gas content of gas-liquid mixtures. Data generated is used to control the True (air-free) or Apparent (air-containing) Density or Entrained Air content of liquids within optimum ranges, e.g. in paper coating processes and in the manu
Methods and apparatuses for determining entrained and/or dissolved gas content of gas-liquid mixtures. Data generated is used to control the True (air-free) or Apparent (air-containing) Density or Entrained Air content of liquids within optimum ranges, e.g. in paper coating processes and in the manufacture of food products, personal care products, pharmaceutical products, paints, petroleum blends, etc. For example, an indirect method of continuously determining the amount of gas entrained in a liquid, by: continuously measuring the temperature, flow rate, and apparent density of the mixture at two different pressure states, and calculating the volume percentage of the gas in the liquid by using equation (28) x?%=VsVs+V(28)wherein V is the volume of the gas-free liquid calculated by equation (23) V=1ρ1-[P2P2-P1?(1ρ1-1ρ2)-RTP2-P1?g?(Δ???PQa)](23)in which P1 and P2 are two different ambient pressures and ΔP=P2?P1, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature, Q is the flow rate, g(ΔP/Qa) is a function for determining the amount of gas being dissolved between P2 and P1, and Vs is determined by equation (27) Vs=TsT?P1?P2Ps?(P2-P1)?(1ρ1-1ρ2)-RTsPs?(P1P2-P1?g?(Δ???PQa)-g?(P1-PsQa)).(27)
대표청구항▼
1. A method for automatically controlling the output of a continuous process with a liquid carrier that contains one or more gases, the method comprising the steps of:a.) setting a quantitative target for volume-% of one or more gases in the liquid carrier; b.) calculating the volume percentage of s
1. A method for automatically controlling the output of a continuous process with a liquid carrier that contains one or more gases, the method comprising the steps of:a.) setting a quantitative target for volume-% of one or more gases in the liquid carrier; b.) calculating the volume percentage of said gas in said liquid sample by using equation (28) wherein V is the volume of the gas-free liquid calculated by equation (23) in which P1 and P2 are two different ambient pressures and ΔP=P2?P1, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature, Q is the flow rate, and g(ΔP/Qa) is a function through which the gas solubility coefficients at a dynamic state are determined; and VS is determined by equation (27) in which Ps and Ts are standard pressure (1 atm) and temperature (0° C.), P1, P2, Ps, ΔP, ρ1, ρ2, R, Q, and T are the same as defined in this claim, and is a function for determining the amount of gas being dissolved between P1 and Ps;c.) comparing the calculated volume-% gas to the target volume-% gas; and, d.) if the calculated volume-% gas in the liquid carrier is greater or less than the target volume-% gas, lowering or raising the amount of gas in the liquid carrier. 2. A method for controlling the output of processing a liquid as mixture in a batch mode, the method comprising the steps of:a.) setting a quantitative target for volume-% of one or more gases in the mixture; b.) subjecting the mixture to two different pressure states and measuring the apparent density of the mixture at each of the two pressure states; c.) calculating the volume percentage of said gas in said liquid sample by using equation (28) wherein Vs is determined by equation (33) in which P1 and P2 are two different ambient pressures, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, Ps and Ts are standard pressure (1 atm) and temperature (0° C.), R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, and C is the gas solubility coefficient at a static state; and V is the volume of the gas-free liquid calculated through equation (32) in which T is the liquid temperature, and P1, P2, ρ1, ρ2, and R are the same as defined in this claim,d.) comparing the calculated volume-% gas to the target volume-% gas; and, e.) if the calculated volume-% gas in the liquid carrier component is greater or less than the target volume-% gas, lowering or raising the amount of gas mixed in the liquid. 3. A method for automatically controlling the output of a continuous process that requires mixing of a solid or liquid component with a liquid carrier component, the method comprising the steps of:a.) setting a quantitative target for weight-% in the liquid carrier component of one or more solids and/or for concentration of one or more liquids in the liquid carrier component; b.) continuously mixing said solids and/or liquids with the liquid carrier component; c.) determining the true density, ρ, by employing equation (24) wherein the volume, V, is calculated from equation (23) in which P1 and P2 are two different ambient pressures and ΔP=P2?P1, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, Q is the flow rate, and g(ΔP/Qa) is a function through which the gas solubility coefficients at a dynamic state are determined;d.) calculating the weight-% of solids and/or the liquid concentration in the mixture from the true density ρ so determined; e.) comparing the calculated weight-% solids or concentration to the target weight-% solids or concentration; and, f.) if the calculated weight-% solids or concentration is greater or less than the target weight-% solids or concentration, lowering or raising the amount of solids or liquids mixed in step b.). 4. The method of claim 3 for continuously coating a substrate, which method comprises:a.) setting a quantitative target for weight-% of one or more solids to be coated onto a substrate; b.) continuously applying the solids to the substrate via a carrier fluid; c.) measuring the apparent density of the slurry; d.) determining the true density of the slurry; e.) calculating the weight-% of solids in the slurry in the manner recited in claim 3; f.) comparing the calculated weight-% solids to the target weight-% solids; and, g.) if the calculated weight-% is greater or less than the target weight-%, lowering or raising the amount of solids applied in step b.). 5. The method of claim 4, in which the substrate is a paper web and the solids component comprises kaolin clay, calcium carbonate, titanium dioxide, or alumina trihydrate.6. The method of claim 3 for controlling the output of a continuous process for preparing a syrup, which method comprises:a.) setting a quantitative target for a concentration of one or more carbohydrates and/or carbohydrate-containing liquids to be blended into a syrup; b.) continuously supplying the carbohydrate and/or carbohydrate-containing liquid and a dilution liquid to a vessel and mixing said liquids to form a slurry; c.) measuring the apparent density of the slurry; d.) determining the true density of the slurry; e.) converting this true density to the calculated carbohydrate concentration; f.) comparing the calculated carbohydrate concentration to the target carbohydrate concentration; and, g.) if the calculated carbohydrate concentration is greater or less than the target carbohydrate concentration, lowering or raising the amount of carbohydrates and/or volume of carbohydrate-containing liquids supplied in step b.). 7. The method of claim 4, in which carbohydrates comprising sucrose and carbohydrate-containing liquids comprising corn syrup and high fructose corn syrup are mixed with a dilution liquid comprising water.8. An indirect method of determining the amount of gas entrained in a liquid in a batch mode, the method comprising the steps of:subjecting a mixture of an incompressible liquid sample and a compressible gas to two different pressure states, measuring the temperature and apparent density of the mixture at each of the two pressure states, and calculating the volume percentage of said gas in said liquid sample by using equation (28) wherein Vs is determined by equation (33) in which P1 and P2 are two different ambient pressures, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, Ps and Ts are standard pressure (1 atm) and temperature (0° C.), R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, and C is the gas solubility coefficient at a static state; and V is the volume of the gas-free liquid calculated through equation (32) 9. An indirect method of continuously determining the amount of gas entrained in a liquid, the method comprising the steps of:continuously measuring the temperature, flow rate, and apparent density of the mixture at two different pressure states, and calculating the volume percentage of said gas in said liquid by using equation (28) wherein V is the volume of the gas-free liquid calculated by equation (23) in which P1 and P2 are two different ambient pressures and ΔP=P2?P1, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature, Q is the flow rate, g(ΔP/Qa) is a function for determining the amount of gas being dissolved between P2 and P1, and VS is determined by equation (27) in which Ps and Ts are standard pressure (1 atm) and temperature (0° C.), and is a function for determining the amount of gas being dissolved between P1 and Ps.10. An indirect method of determining the air-free density of a liquid at a static state, the method comprising the steps of:subjecting a mixture of an incompressible liquid sample and a compressible gas to two different pressure states, measuring the temperature and apparent density of the mixture at each of the two pressure states, and calculating the true density of said liquid sample by using equation (24) wherein V is the volume of the gas-free liquid as determined by equation (32) in which P1 and P2 are two different ambient pressures, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, and C is the gas solubility coefficient at a static state.11. An indirect method of determining the gas-free density of a gas-liquid mixture at a dynamic state, the method comprising the steps of:measuring two different apparent densities of the mixture and two corresponding ambient pressures at which the apparent densities are determined, measuring the temperature and flow rate, and calculating the true density of said liquid sample by using equation (24) wherein V is the volume of the gas-free liquid as determined by equation (23) in which P1 and P2 are two different ambient pressures and ΔP=P2?P1, ρ1 and ρ2 are apparent densities of the liquid sample measured at P1 and P2, respectively, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, and is the gas solubility function.12. An indirect method for determining gas solubility coefficients for a gas-liquid mixture at a dynamic state, the method comprising the steps of:a.) subjecting the said gas-liquid mixture to flow at several different flowrates, Q1, Q2, . . . , Qi; b.) measuring two different apparent densities of the mixture and two related ambient pressures at which the apparent densities are determined at each of the flow rates; c.) acquiring off-line the true, gas-free liquid density, ρ*, through one-time measurement; d.) determining the gas solubility coefficients, A0, A1, A2, . . . , Ai, by solving a group of linear equations (19) in which Q1, Q2, . . . , Qi, are the different flow rates generated for obtaining the gas solubility coefficients at a dynamic state, ΔP is the difference of the said two ambient pressures at each of the flow rates, a is an index reflecting the weak influence of flow rate on gas solubility, and S1, S2, . . . , Si are intermediate variables determined by equation (20) in which PI and PII are two different ambient pressures measured at each of the flow rates, ρI and ρII are apparent densities of the gas-liquid mixture measured at PI and PII, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature, Q is the flow rate, and ρ* is the predetermined gas-free liquid density as defined in c.);e.) attaining the gas solubility function upon the solution of the gas solubility coefficients, A0, A1, A2, Ai.13. An indirect method for determining the gas solubility coefficient for a gas-liquid mixture at a static state, the method comprising the steps of:a.) measuring two different apparent densities of the mixture and two related ambient pressures at which the apparent densities are determined; b.) acquiring off-line the true, gas-free liquid density, ρ*, through one-time measurement; c) determining the gas solubility coefficients, C, at a static state by solving equation (30) in which PI and PII are two different ambient pressures, ρI and ρII are apparent densities of the gas-liquid mixture measured at PI and PII, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature, and ρ* is the predetermined gas-free liquid density as defined in b.).14. The method of one of claims 8-13, wherein said two pressure states differ from one another by at least 1 psi, preferably by at least 1 atmosphere.15. The method of one of claims 8-13, wherein said two pressure states differ from one another at least to the extent that the two different apparent densities of said liquid differ from one another by at least 0.2%, preferably by at least 0.5%.16. A direct method of determining the amount of gas entrained in a liquid, the method comprising the steps of:subjecting a mixture of an incompressible liquid sample and a compressible gas to two different pressure states, measuring the temperature and volume of the mixture at each of the two pressure states, determining the changes in volume of the mixture between the two pressure states, and calculating the volume percentage of said gas in said liquid sample by using equation (28) wherein Vs is determined by equation (37) in which Ts is 0° C., P1 and P2 are two different ambient pressures, ΔV is the volume difference of the gas-liquid mixture in a sample chamber between P1 and P2, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, Ps is 1 atm, and C is the gas solubility coefficient at a static state; and V is the volume of the gas-free liquid in the sample chamber determined by equation (36) in which Vt1 is the volume of the gas-liquid mixture in the sample chamber at P1.17. A direct method of determining the air-free density of a liquid, the method comprising the steps of:subjecting a mixture of an incompressible liquid sample and a compressible gas to two different pressure states, measuring the temperature and volume of the mixture at each of the two pressure states, determining the changes in volume of the mixture between the two pressure states, and calculating the true density of said liquid sample by using equation (24) wherein V is the volume of the gas-free liquid as determined by equation (36) in which P1 and P2 are two different ambient pressures, Vt1 is the volume of gas-liquid mixture in the sample chamber at P1, ΔV is the change in volume of gas-liquid mixture in the sample chamber between P1 and P2, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, and C is the gas solubility coefficient at a static state.18. A direct method for determining the gas solubility coefficient for a gas-liquid mixture at a static state, the method comprising the steps of:a.) subjecting a mixture of an incompressible liquid sample and a compressible gas to a sample chamber; b.) compressing or expanding the sample chamber and measuring the volume of gas-liquid mixture, Vt1, at the first pressure state, Pi; c.) compressing or expanding the sample chamber further and measuring the volume of gas-liquid mixture, VtII, at the second pressure state, PII; d.) increasing the pressure of the sample chamber excessively to dissolve all of the free gas and measuring the volume of gas-free liquid in the sample chamber, V; e.) calculating the volumes of the free gas, VI and VII at PI and PII, respectively, VI=VtI?V and VII=VtII?V; f.) determining the gas solubility coefficient, C, by using equation (34) in which PI and PII are two different ambient pressures, VI and VII are volumes of the gas-liquid mixture in the sample chamber measured at PI and PII, respectively, R is the constant of the Ideal Gas Law, T is the liquid temperature.19. The method of claim 18, in which the volume of gas-free liquid in the sample chamber, V is determined with degassing chemicals or by allowing the sample to sit for a sufficiently long time to dissipate all of the free gas bubbles, rather than by the procedure of step d.).20. The method of one of claims 16-19, wherein said two pressure states differ from one another at least to the extent that the two different volumes differ from one another by at least 0.2%, preferably by at least 0.5%.21. The method of one of claims 16-19, wherein said two pressure states differ from one another by at least 1 psi, preferably by at least 1 atmosphere.22. A method for controlling the output of a process with a liquid carrier that contains one or more gases, the method comprising the steps of:a.) setting a quantitative target for volume-% of one or more gases in the liquid carrier; b.) calculating the volume percentage of said gas in said liquid sample by using equation (28) wherein Vs is determined by equation (37) in which Ts is 0° C., P1 and P2 are two different ambient pressures, ΔV is the volume difference of the free gas between P1 and P2, R is the constant of the Ideal Gas Law, T is the temperature of the liquid sample, Ps is 1 atm, and C is the gas solubility coefficient at a static state; and V is the volume of the gas-free liquid in the sample chamber determined by equation (36) in which Vt1, is the volume of the gas-liquid mixture in the sample chamber at P1, and P1, P2, Ps, ΔV, R, and C are the same as being defined in this claim;c.) comparing the calculated volume-% gas to the target volume-% gas; and, d.) if the calculated volume-% gas in the liquid carrier is greater or less than the target volume-% gas, lowering or raising the amount of gas in the liquid carrier. 23. A method for controlling the output of a process for preparing a carbonated beverage, which method comprises:a.) setting a quantitative target for a concentration of carbon dioxide to be blended into an aqueous medium; b.) supplying carbon dioxide to the aqueous medium in a vessel and mixing those components to form a carbonated aqueous medium in the vessel at a preset “bottling” pressure P0, wherein P0 is the produced “bottling” pressure inside a sealed carbonated beverage container, at which pressure all of the free carbon dioxide is dissolved into the aqueous medium; c.) diverting a carbonated aqueous medium sample from the vessel into a sample measurement chamber at the same “bottling” pressure P0; d.) reducing the aqueous medium pressure from P0 to P1 allowing the dissolved carbon dioxide to start to be released back to the aqueous medium in a free-bubble form while the volume of the sample measurement chamber to be expanded correspondingly; e.) reducing the aqueous medium pressure further from P1 to P2 allowing more dissolved carbon dioxide to be released back to the aqueous medium in a free-bubble form while the volume of the measurement chamber to be expanded further; f.) measuring the change in volume of the carbon dioxide liquid mixture between P1 and P2; g.) determining the volume of free carbon dioxide, Vs, in the carbonated aqueous medium at the standard condition using equation (37) in which P1 and P2 are two different ambient pressures, ΔV is the change in sample volume between P1 and P2, Ps and Ts are standard pressure and temperature, T is the temperature of the liquid sample, C is the gas solubility coefficient at a static state, and R is the constant of the Ideal Gas Law;h.) calculating the carbon dioxide concentration using equation (28) wherein Vs is the volume of free carbon dioxide determined in step g.) and V is the volume of carbonated aqueous medium in the sample chamber at a preset “bottling” pressure P0 upon which no free bubble should present;i.) comparing the calculated carbon dioxide concentration to the target carbon dioxide concentration; and, j.) if the calculated carbon dioxide concentration is greater or less than the target carbon dioxide concentration, lowering or raising the volume of carbon dioxide supplied. 24. A method for controlling the output of a process for preparing a carbonated beverage, which method comprises:a.) setting a quantitative target for a concentration of carbon dioxide to be blended into an aqueous medium; b.) supplying carbon dioxide to the aqueous medium in a vessel and mixing those components to form a carbonated aqueous medium in the vessel; c.) diverting a carbonated aqueous medium sample from the vessel into a sample measurement chamber at the first pressure state, P1, with the presence of free carbon dioxide bubbles in the aqueous medium; d.) reducing the aqueous medium pressure to the second pressure state, P2, allowing more dissolved carbon dioxide to be released back to the aqueous medium in a free-bubble form while the volume of the measurement chamber to be expanded correspondingly; e.) measuring the change in volume of the carbon dioxide liquid mixture between P1 and P2; f.) determining the volume of free carbon dioxide, Vs, in the carbonated aqueous medium at the standard condition using equation (37) in which P1 and P2 are two different ambient pressures, ΛV is the change in sample volume between P1 and P2, Ps and Ts are standard pressure and temperature, T is the temperature of the liquid sample, C is the gas solubility coefficient at a static state, and R is the constant of the Ideal Gas Law;g.) determining the volume of aqueous medium, V, in which no free carbon dioxide bubble is present, by equation (36) in which Vt1 is the volume of gas-liquid mixture in the sample chamber at P1;h.) calculating the carbon dioxide concentration using equation (28) wherein Vs is the volume of free carbon dioxide determined in step f.) and V is the volume of aqueous medium, in which no free carbon dioxide bubble is present, as defined in step g.);i.) comparing the calculated carbon dioxide concentration to the target carbon dioxide concentration; and, j.) if the calculated carbon dioxide concentration is greater or less than the target carbon dioxide concentration, lowering or raising the volume of carbon dioxide supplied.
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