CHEMICAL REACTOR SYSTEM AND METHOD REGENERATIVE TURBINE

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CHEMICAL REACTOR SYSTEM AND METHOD REGENERATIVE TURBINE ( chemical-reactor-system-and-method-regenerative-turbine )

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US 2012/0071702A1 Mar.22,2012 algorithmstocalculatethedischargepressuresetpoint.Dis charge pressure control PLC 102 receives and monitors rangedanalogordigitalsignalsfromthedischargepipe75 mounted sensors: discharge pressure sensor 113, discharge temperaturesensor114,anddischargebubbledetectionappa ratus 71, as Well as any other properties of the discharged process Water that the apparatus might be additionally equippedtodetect.DischargepressurecontrolPLC 102con tinuously monitors the various aforementioned discharge pipe75processvariablesandrecalculatesthedischargepres sure setpoint 108 required to collapse the bubbles at the rate and to the siZe required by the particular application. Simi larlytobubblegenerationcontrol,bubblecollapserate,?nal bubble siZe, or total bubble collapse control may require variable discharge pressure and pump rotation speed set pointsasoperationalparameterschange.Dischargepressure controlPLC 102monitorsdischargepipeprocessvariables andcontinuouslyrecalculatesthedischargepressuresetpoint 108 expected to mitigate any variance from bubble collapse speci?cationsforanapplication. [0061] Operationofthedischargepressurecontrolvalve 80,throughoperationofthemotorizeddischargevalvepilot regulator 82 by discharge pressure control PID 103, as directedbypressurecontrolPLC 102,utiliZesignaltypes, signal processing, process variable selectionisuch as dis charge pressure or discharge bubble detection apparatus 71 signaliand operational considerations and control tech niquessimilartotheanalogouspump inletpipe22pressure controlaccomplishedbyinletpressurecontrolPLC 200and PID 201, motorized inlet valve pilot regulator 26 and inlet pressure control valve 24. Remote control of the discharge pressure setpoint 108 by an external computer or device can be relayed through controller logic PLC 211 and discharge pressurecontrolPLC 102.Also,asisthecaseWithmanual pump inlet pipe 22 pressure control, manual discharge pipe 75pressurecontrolispossibleusingpanelmountedoperators (not shoWn) and the feedback from the panel mounted indi catorsincludingvalvepositionindicator110,speedindicator 134,valvepositionindicator132,pump speedindicator115, pump speedindicator215,dischargepressureindicator113, discharge temperature indicator 114, and discharge bubble detectionapparatusindicator71,andthemotoriZeddischarge valvepilotregulator82positionindicator116. [0062] Ashereinbeforesetforth,therotationalspeedset point109oftheregenerativeturbinepump 60canbecalcu lated by the controller 100 considering various factors. For example, the pump motor speed setpoint 109 must be high enoughthattheregenerativeturbinepump 60,When itsimpel ler(FIG.2A, 63)isdrivenatthepump motorspeedsetpoint 109,Willoutputaminimum pressureequaltoorgreaterthen thecalculateddischargepressuresetpoint108.Subsequentto reaching the aforementioned minimum rotational speed, the pump motor speed setpoint 109 can be upWardly (or to a limited degree doWnWardly) adjusted so that the rate of the passageoftheregenerativeturbinepump 60impeller’sbuck ets (FIG. 2A, 64) matches the generated bubble production rate. In this Way the bubbles ?oW singularly into the regen erative turbine pump’s 60 impeller buckets. val)frominletpressurecontrolPLC 200,viathecontroller logicPLC 211,topump motorspeedcontrolPLC 104. [0064] ControllerlogicPLC211,inadditiontoandin support of controller logic 101, also stores and distributes to thecontroller’ssubsystemsPLC 200,102,104uponrequest parametricdatadescribingtheoperationalperformancechar acteristicsandlimitsofthecurrentcon?gurationsoftheappa ratus subsystems, including information about the installed regenerativeturbinepump 60.Thispump con?gurationinfor mation can include performance curve data based on the regenerative turbine pump’s 60 rotational speed, providing speci?cations such as maximum discharge pressure, maxi mum rotationalspeed,orHow rate,horsepoWerrequirement orNPSHr asafunctionoftherotationalspeed.Thiscon?gu rationdataisusedbytheapparatussubsystems’controlPLC 200,102,104toverifysetpointdatarangesandidentifyoutof limitoperationalconditionsandforoperationalerrorcontrol. In addition to this standard pump performance curve infor mation, data regarding the regenerative turbine pump 60 impeller’s (FIG. 2A, 63) design is stored accessible to the controller logic PLC 211 and reported to pump motor speed controlPLC 104,includingthenumberofimpellerbuckets (FIG. 2A, 64) along the circumference of the pump’s impel ler. [0065] ControllerlogicPLC211,usingthestoredsub systemcon?gurationdata,controllerlogic101,carbondiox ide reduction logic 106, and setpoint data 107, 108, 109, retrievesorcalculatesandthentransmitsatoperationstartup an initial discharge pressure setpoint 108 to the discharge pressure control PLC 102 and an initial pump motor speed setpoint109tothepump motorspeedcontrolPLC 104.The discharge pressure control PLC 102 then recalculates the discharge pressure setpoint 108 and transmits it, along With theprocessvariable,eitherthepump dischargepipe75pres suresensor113 signalorthedischargebubbledetectionappa ratus 71 signal, to the discharge pressure control PID 103 so itcanpositionthemotoriZeddischargevalvepilotregulator 82. If the bubble collapse rate is insu?icient, or the ?nal bubble siZe is greater than the invention application speci? cation, or bubbles are to be totally collapsed and yet are stil seenbythedischargebubbledetectionapparatus71,thenthe discharge pressure setpoint 108 is increased. The neWly cal culatedhigherdischargepressuresetpoint108istransmitted directly from discharge pressure control PLC 102 to pump motorspeedcontrolPLC 104.PLC 104evaluatesthecurrent dischargepressuresetpoint108,andusingthestoredregen erative turbine pump performance data, in conjunction With the current pump motor speed setpoint 109, determines Whether the maximum pressure at the current pump motor speed setpoint 109 is greater than the transmitted neWly cal culatedhigherdischargepressuresetpoint108.Ifthecurrent pump motor speed setpoint 109 istoo loW, pump motor speed controlPLC 104calculatesaneWpumpmotorspeedsetpoint 109 to cause the regenerative turbine pump 60 to output at leasttheneW dischargepressuresetpoint108requestedbythe dischargepressurecontrolPLC 102.Conversely,Wherethe collapsedbubblesaretoosmallorthecalculatedcollapserate istoogreat,thedischargepressuresetpoint108,andpossibly the pump motor speed setpoint 109 can be loWered. Both of [0063] Toaccomplishthis,thecontroller100permitsdirect theseprocessescanbeimplementedusingarangedanalogor interactionbetWeendischargepressurecontrolPLC 102and pump motor speed control PLC 104 and relays inletbubble detection apparatus 40 interpolated data that provides the number ofbubbles generatedperminute (orothertime inter digitalsignalrepresentingthespeedsetpoint,calculatedby pump motor speed control PID 105 and transmitted to the variable frequency drive 126, Which in turn varies the poWer frequency suppliedtothepump ’smotor sothatitrotatesatthe

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