AUTOMATED EXTRACTION SYSTEM
20200338547 ยท 2020-10-29
Inventors
Cpc classification
G01N21/31
PHYSICS
G01N1/2035
PHYSICS
B01L2400/0475
PERFORMING OPERATIONS; TRANSPORTING
B01L3/502
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01L3/00
PERFORMING OPERATIONS; TRANSPORTING
G01N21/31
PHYSICS
Abstract
An automated system which can perform automated sample extraction from a process stream, automated analysis on the sample, and then provide output on the results to process control equipment so that parameters of the processing could be altered in response to the testing.
Claims
1. A device for handling a sample comprising: a pump; a chamber spaced from said pump and having an attached probe; and a valve arrangement; wherein, said pump will provide a liquid sample from a sample source to said chamber, said liquid sample passing through said valve arrangement; wherein, while said sample is moving through said valve arrangement, a liquid additive is simultaneously pulled from an additive source through said valve arrangement and said liquid sample and said liquid additive are mixed; and wherein a measurement can be taken of said liquid sample and liquid additive mixture in said chamber.
2. The device of claim 1 wherein said liquid sample is an emulsion.
3. The device of claim 2 wherein said measurement is performed on said liquid sample while said sample is an emulsion.
4. The device of claim 2 wherein said liquid additive is a solvent separating a first immiscible from said emulsion.
5. The device of claim 4 wherein said measurement is performed on said first immiscible.
6. The device of claim 4 wherein said measurement is performed on what remains of said emulsion after said first immiscible has been separated.
7. The device of claim 2 wherein said emulsion is an oil and water emulsion.
8. The device of claim 7 wherein said additive is toluene.
9. The device of claim 1 wherein said measurement is a fluorescence measurement.
10. The device of claim 1 wherein said measurement is a light absorption measurement.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0056] The following detailed description and disclosure illustrates by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the disclosed systems and methods, and describes several embodiments, adaptations, variations, alternatives and uses of the disclosed systems and methods. As various changes could be made in the above constructions without departing from the scope of the disclosures, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0057] Described herein are a variety of automated systems for liquid handling and testing which are commonly referred to as automated extraction systems or simply AES. AES are generally configured to perform a fully automated liquid-liquid extraction, and to deliver the extract to an analysis cell either in an original mixed form, or a separated form, generally having been mixed with an additive to assist in the analysis, although that is not required. The AES will then also include traditional measurement or analysis tools attached thereto to perform an analysis on the extract such as, but not limited to, measuring the amount of a dispersant or other material in the mixture. Finally, an AES will generally be able to return the tested sample to the process stream, or dispose of it, and provide the results of the measurements performed to a computer or human for analysis.
[0058] Measurement on the extracted sample may be performed by, among other things, using an absorbance or fluorescence measurement to determine the concentration of the extracted solute within the sample. These types of measurements may be performed by any type of testing or measurement instrument known now or later discovered and these instruments will generally be mounted to the AES at fixed points as contemplated later in this discussion. The AES may be used to allow the analysis on the extracted sample to occur prior to separation of components of an emulsion or similar composition, on an emulsion which has been allowed to separate naturally, or on an emulsion to which specific solvents or other additives have been added to induce stronger or faster separation. The latter will generally be the preferred method of operation, however, the AES described herein allow for any and all of such actions to be performed on any sample and can be operated to provide different measurements on a sample in multiple different states based on the test to be performed.
[0059] Embodiments of AES described herein will generally perform the mechanical functions of extracting a sample from a process environment and then manipulating that sample for testing. Often the sample will be withdrawn from a continuous flow (such as through a pipeline) but that is not required and in alternative embodiments sample can be taken from more static sources (such as, for example, settling tanks). As such, the AES will generally be mounted near a process line at which measurement will be performed.
[0060] The AES generally contains components required to operate the handling system and manipulate the sample and will commonly have mounted thereto a selection of apparatus to perform any absorbance, fluorescence, or other measurement on the sample. The system is designed to be mounted remotely in a non-hazardous location, or to be contained within a purged enclosure or other clean room suitable for the particular installation area.
[0061] The automatic extraction systems and methods described herein may be used to extract one or more variable volume(s) of liquid samples from a process stream which will generally have within it an emulsion, often of a petroleum or other oil and water such as can be the case with crude oil or similar materials. The systems and methods may also be used to add to this mixture one or more reagents or indicators. These may be added both as the sample is withdrawn and later as the sample is manipulated depending on embodiment and the testing to be performed. These reagents or indicators may provide a measurable reading of the component(s) of the process stream and/or to help separate or identify the components of the process stream. For example, toluene may be added to an oil and water mixture to help the oil and water separate quickly and cleanly. Additionally, the systems and methods may also be used to dynamically dilute one or more samples with a solvent, extract one or more components from a liquid sample, maintain or recreate a colloidal mixture, react one or more reagents with a sample (such as to form a color or a fluorescing tagged molecule), acid/base titration, filter solids from a liquid sample, and other functions each with the ability to control various parameters in the process. The systems and methods may be used with a fluorescence, reflectance, or absorbance-based photometer, but, in an embodiment, any number of other measuring devices or methods known in the art, may be used. These devices may include, without limitation, an ultraviolet-visible spectroscopy or spectrophotometry (UV-VIS), near-infrared (NIR) optical spectrometer, pH electrode, oxidation/reduction potential electrode, conductivity electrode, or temperature measuring device.
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[0063] The AES (100) generally automatically performs a liquid-liquid extraction in a process setting. First, the sample handing system (101) retrieves a known volume of sample from a process stream (commonly via a fast loop connection) and may add a known volume of solvent to the sample. It then mixes the sample and solvent phases to create an emulsion, which allows the solute to transfer to the solvent phase (extract). Next, it transports the extract to a generally separate analysis chamber, and the instrument (103) determines the concentration of the solute by means of fluorescence or other measurement depending on the nature of the solute.
[0064] The sample handling system (101) generally comprises 3 major components as indicated in
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[0066] The pump (113) includes a pneumatic cylinder (131) which, in the depicted embodiment, is connected to a borosilicate glass tube with an internal piston. The pump volume is approximately 150 mL in the depicted embodiment. Positional control of the syringe (113) may be achieved by the use of two proportional pressure regulators.
[0067] The mixing/analysis chamber (115), which is shown in increased detail in
[0068] Fluid may be exchanged between the mixing/analysis chamber (115) and syringe pump (113) until the extraction process is complete or for mixing. Alternatively, the system (100) may be designed so that no fluid ever enters the syringe pump (115) which simply provides for pressure differentials to move the fluid into or out of the mixing/analysis chamber (115) and stream switching valve (111). The mixing/analysis chamber (115) then includes a measurement probe (171), which in the depicted embodiment is a fluorescence probe which makes a final concentration measurement.
[0069] The probe (171) as shown in the embodiment of
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[0071] The sample handling system (101) and instrument (103) are generally designed to be positioned at or near the process stream to be analyzed and will preferably be relatively small. The embodiment of
[0072] In an embodiment, the AES (100) can work as discussed below in conjunction with calibration and measurement of a sample. This description presumes the AES is operating to measure specifics of a crude oil process stream.
[0073] The AES (100) as shown in
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[0075] The measure signal displays the percent of light at the wavelength where the analyte fluoresces. While the reference signal displays the percent of light coming from the light source. The usable range for both measure and reference signals is 0-100%. In the event any of these signals are out of range, an alarm is generally issued and the signal color will change from GREEN to RED on the display to indicate a problem. Such a problem indication may also be transmitted to other systems or to a monitor to allow the process parameters to be changed, if necessary, to respond. The run status (405) component located at the bottom of the screen informs the user of the current operation status of the AES (100). The bar diagram (401) is a visual tool that uses bars to compare data among current and previous measurements. The measurement average value represents the average of ten measurements.
[0076] Upon attempting to leave the home screen (400), the user will be taken to a log in screen (450) a shown in
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[0078] During the calibration, the user is prompted to enter a calibration sample into the system (501) to perform an analyzer calibration. The AES (100) will automatically determine the appropriate settings for the sample range, and store the calibration points (503). The process will typically proceed as follows. [0079] 1. Select the Calibration Screen [0080] 2. The user is prompted to insert the calibration sample, close the bypass outlet valve, and open the calibration sample valve. [0081] 3. The user is prompted to manually enter the concentration of the calibration sample (numeric values only). [0082] 4. The piston pump draws in the calibration sample. [0083] 5. The pump delays to allow sample to settle for a length of time set in Extraction Settings. [0084] 6. The AES performs Auto-Tune to determine the appropriate settings for the calibration sample. [0085] 7. Once the calibration sample measured, a dialogue box will appear indicating that calibration is complete and you will be sent to the Calibration Data Screen for review.
[0086] To create the sample it is first generally determined what concentration to calibrate the AES (100) for. This will typically be selected based on expected process characteristics. In this exemplary procedure, there is provided 100 ppm oil in toluene. The procedure general works as follows: [0087] 1. Fill the 250 mL volumetric flask to the bottom of the neck with toluene. [0088] Using the micropipette and tip, add 0.025 ml of oil to the toluene.
[0092] The probe settings screen (600) of
TABLE-US-00001 Sensor RANGE (RANGE: 0-7) Adjusting will affect both the Measure and Settings Reference outputs; increase this value to decrease Measure and Reference light output INTEGRATION TIME (RANGE: 3-1,000 ms) Adjusting will affect both the Measure and Reference outputs; increase this value to increase Measure and Reference Light output MEASURE GAIN (0-100%) Adjusting will affect ONLY the Measure outputs (PMT-equipped units); increase this value to increase Measure Light output REFERENCE GAIN (RANGE: 0-100%) Adjusting will affect ONLY the Reference outputs; increase this value to increase Reference Light output INITIAL SET Allows the user to normalize the unit without needing to fully recalibrate. DIAGNOSTIC CONCENTRATION Display of the final, calibrated measurement output of the SIGNALS Automated Extraction System OUTPUT SIGNAL (RANGE: 0-100%) The Output Signal is the raw fluorescence signal from the sample at the wavelength of interest. This measurement is derived from the ratio of the measure and reference signals below. ML SIGNAL (RANGE: 0-100%) The Measure Light Signal is a signal from the measure detector when the light source is turned ON. This is the primary signal used for determining the optical fluorescence of the sample. MD SIGNAL (RANGE: 0-100%) The Measure Dark Signal is a signal from the measure detector when the light source is turned OFF. This signal is used to remove the effects of ambient light and electronic noise on the measure detector. RL SIGNAL (RANGE: 0-100%) The Reference Light Signal is a signal from the reference detector when the light source is turned ON. This signal is used to remove the effects of light source drift over long periods of time. RD SIGNAL (RANGE: 0-100%) The Reference Dark Signal is a signal from the reference detector when the light source is turned OFF. This signal is used to remove the effects of electronic noise on the reference detector.
[0093] If calibration (500) is not able to select appropriate settings automatically, it might be necessary to manually adjust the probe settings independent of the Calibration Screen (500). Should this happen, it is generally desirable that using the highest concentration sample the user manually adjust the measure light and reference light between 85-95% of full scale. Minimize the measure dark and reference dark signals. This process is generally depicted in
[0094] The AES Settings screen (700) of
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[0101] While
[0102] The Menu Bar for additional features can be found in the top left corner of the screen (803) and extends to the top right corner of the AES Control Panel App window. It contains a number of dropdown menus where users have access to enable actions such as Sample Measurement, Clean, Backflush, and Auto-Tune while in Normal Mode.
TABLE-US-00002 MENU FILE Open historical data saved as .px2 files BAR Save data from current session as a .px2 file (only viewable in app) Exit the app MODE Idle places the system in an inactive state Sample Measurement enables automatic liquid-liquid extractions Clean initiates a system cleaning cycle that uses solvent to remove leftover sample in the mixing chamber Backflush initiates a cleaning cycle that pumps solvent into the sample line that connects the AES to the process line. Auto-Tune automatically adjusts instrument settings for optimal measurements TOOLS Mode: Normal presents the app without access to manual instrument controls Mode: Administrative is password-protected and gives access to manual instrument controls Log File Location allows the user to change where the log file is saved Display Run Status visualizes the measurement progress Trends: Show Tools displays/hides the graphical tool bar Trends: Enable Layout Changes allows the user to reorganize the graphs within the AES Control Panel App screen HELP Open User Manual as a PDF Demo Mode open the app without being connected to the AES Instrument About the software, including version number APP The currently installed version of the PX2 Control Panel App VERSION
[0103] The Modes (807) dropdown will generally have the following options: Idle, Sample Measurement, Clean, Backflush, and PX2 Auto-Tune. During Idle mode, the system is placed in an inactive state. During Sample Measurement mode, the AES automatically performs liquid-liquid extractions in a process setting. The procedure for Single Measurement is the same, except only one measurement is performed. The following variables must be set in Administrative Mode prior to making measurements: process sample volume, pump delay time, solvent volume, acid volume, mixing cycle count, extraction delay time, and number of measurements to average.
[0104] The sample measurement procedure may be carried out as follows: [0105] 1. The piston pump draws in the process sample. The process sample volume is set in Administrative Mode. [0106] 2. The pump delays for a length of time set in Administrative Mode. [0107] 3. The piston pump draws in the solvent. The solvent volume is set in Administrative Mode. [0108] 4. The pump delays for a length of time set in Administrative Mode. [0109] 5. The piston pump draws in the acid. The volume is set in Administrative Mode. [0110] 6. The pump delays for a length of time set in Administrative Mode. [0111] 7. The Mixing Cycle is initiated. The mixing cycle count is set in Administrative Mode. [0112] 8. The extraction delay allows the extract to settle and allow bubbles to clear before measurements are taken. This length of time is set in Administrative Mode. [0113] 9. The fluorescence measurements are taken by the PX2. The number of measurements to average is set in Administrative Mode. [0114] 10. The piston pump expels all liquid from the mixing chamber. [0115] 11. The cleaning cycle is initiated. [0116] 12. The measurement cycle restarts from Step 1.
[0117] During the Cleaning mode, the AES draws in organic solvent to clean the system. The cleaning cycle procedure will generally involve the piston pump drawing in solvent. The solvent volume is set in Administrative Mode. The pump delays for a length of time set in Administrative Mode. The Mixing Cycle is initiated and repeats a plurality of times. Finally, the piston pump expels all liquid from the mixing chamber.
[0118] During the Backflush mode (which is a variation on the cleaning mode), solvent is pumped into the sample line entering the AES. The piston pump draws in solvent and again, the solvent volume is variable in Administrative Mode. The pump delays for a length of time set in Administrative Mode. Finally, the piston pump expels all liquid from the mixing chamber.
[0119] During the Auto-Tune mode, the user is prompted to enter a calibration sample into the system to perform an analyzer calibration. The AES will automatically determine the appropriate settings for the sample range, and store the calibration points. The AES should be Auto-Tuned on the highest concentration sample. The Auto-Tune procedure may operate as follows: [0120] 1. The user is prompted to insert the calibration sample, close the bypass outlet valve, and open the calibration sample valve. [0121] 2. The user is prompted to manually enter the concentration of the calibration sample (numeric values only). [0122] 3. The piston pump draws in the calibration sample. The calibration sample volume is variable in Administrative Mode. [0123] 4. The pump delays to allow sample to settle for a length of time set in Administrative Mode. [0124] 5. The AES performs Auto-Tune to determine the appropriate settings for the calibration sample. [0125] 6. The automated calibration procedure continues by prompting the user to add calibration samples in order of descending concentration.
[0126] The Tools (809) dropdown has the following options: Normal Mode, Administrative Mode, Log File Location, Display Run Status, Show Tools, and Enable Layout Changes. Normal Mode is the default mode that the AES system opens up to. In this mode, the user can view the live graphs and access the different measurement modes, however, the user cannot change any of the measurement variables. To view and edit measurement variables, the user must log into Administrative Mode (803).
[0127] Administrative Mode (803) is the password protected mode where the user may view and edit the measurement variables, access AES diagnostics, and manually enter calibration points. Entering Administrative Mode opens a new panel (805) on the left side of the frame with the following tabs: AES Settings (851), Sensor Settings (853), Sensor Measurements (855), and Diagnostics (857).
[0128] The AES Settings tab (851) as shown in
TABLE-US-00003 TUNER RANGE (0-7) Adjusting will affect both the Measure and Reference outputs; increase this value to decrease Measure and Reference light output INTEGRATION TIME (3-5,000 ms) Adjusting will affect both the Measure and Reference outputs; increase this value to increase Measure and Reference Light output MEASURE GAIN (0-100%) Adjusting will affect ONLY the Measure outputs (PMT-equipped units); increase this value to increase Measure Light output REFERENCE GAIN (0-100%) Adjusting will affect ONLY the Reference outputs; increase this value to increase Reference Light output CALIBRATION Manually adjust the PX2's calibration points AVERAGING (1-16) Adjusting will change the number of measurements averaged together to smooth readings INTERVAL (250-60,000 ms) Adjusting will change the measurement interval (time between each individual measurement). This does not change the rate at which data is logged to file (see Section 7 for Log File Setup information).
[0129] The Sensor Measurements Tab (855) is provided in
[0130] The Diagnostics Tab (857) is shown in
[0131] Returning from Administrative Mode (803) to the Normal Mode (801) screen, The Log File Location can be changed using the option as indicated in screen (811) in
[0132] The qualifier generally, and similar qualifiers as used in the present case, would be understood by one of ordinary skill in the art to accommodate recognizable attempts to conform a device to the qualified term, which may nevertheless fall short of doing so. This is because terms such as spherical are purely geometric constructs and no real-world component or relationship is truly spherical in the geometric sense. Variations from geometric and mathematical descriptions are unavoidable due to, among other things, manufacturing tolerances resulting in shape variations, defects and imperfections, non-uniform thermal expansion, and natural wear. Moreover, there exists for every object a level of magnification at which geometric and mathematical descriptors fail due to the nature of matter. One of ordinary skill would thus understand the term generally and relationships contemplated herein regardless of the inclusion of such qualifiers to include a range of variations from the literal geometric meaning of the term in view of these and other considerations.
[0133] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.
[0134] It will further be understood that any of the ranges, values, properties, or characteristics given for any single component of the present disclosure can be used interchangeably with any ranges, values, properties, or characteristics given for any of the other components of the disclosure, where compatible, to form an embodiment having defined values for each of the components, as given herein throughout. Further, ranges provided for a genus or a category can also be applied to species within the genus or members of the category unless otherwise noted.