SBIR Phase I: Measurement and Control of Mass and Velocity Rates in Bulk Solids Distribution Systems

这项小型企业创新研究（SBIR）第一阶段项目展示了使用一种新的非侵入性振动声学方法的可行性，该方法可以同时测量高分支气动输送管道内的固体和空气流速。该方法确定与管道内固体和气体流动以及声发射直接相关的管道的特征振动；它是通过连接到管道外部的加速度计来测量的。目前，市面上还没有一种廉价的、无创的无线系统，可以用于测量和控制工业环境中典型的高分支管道中的固体和气体流速。在所有情况下，这种情况导致材料使用和分配效率低下，能源浪费，工艺操作未优化，运营成本更高。研究目标侧重于确定振动声强度和相关频率在50-10,000 Hz之间，这将定义方法的灵敏度和可重复性，其作为自标准化和独立方法的潜力，以及创建商业过程控制仪器的技术要求。由于振动声学测量将在典型的设备和过程噪声较大的工业现场完成，因此预期的技术结果将为后续演示奠定坚实的基础并提高方法的可信度。该项目更广泛的影响/商业潜力在于无线过程控制仪器（PCI），它可以提高过程效率，并对高分支气动输送系统中固体和气体流动的非侵入性测量有了科学的理解。通过控制这些系统中的固体输送，提高了材料的使用效率，提高了产品质量和工艺性能。例如，在需要采集振动声数据的工业现场，成功实施振动声PCI可以减少高达40%的材料使用，同时每年节省64万美元的成本。在美国强制安装排放设备的行业中，振动声学方法每年可降低3.84亿美元的成本，PCI的商业销售额可达到1.55亿美元。通过减少制造、运输和使用固体试剂的能源消耗，节省成本和创造业务将对社会产生有益的影响；降低发电成本；改善环保表现；减少温室气体排放；同时，降低了消费者成本。此外，对于美国每个人消费或使用并影响的工业生产的商品和高价值产品，需要提高使用气动输送控制散装固体输送的效率。

This Small Business Innovation Research (SBIR) Phase I project demonstrates the feasibility of using a new, non-invasive vibroacoustic method that simultaneously measures solids and air flow rates within highly-branched pneumatic conveyance piping. The method determines characteristic vibrations of the piping that is directly related to solids and gas flow, and acoustic emission, within the piping; it is measured via the attachment of accelerometers onto the outside of the piping. Currently, no inexpensive, non-invasive and wireless system is commercially available that can be used to measure and then control solids and gas flow rates in highly-branched piping typical of industrial settings. In all cases, this situation leads to inefficiencies in materials use and distribution, wasted energy, non-optimized process operation and higher operating costs. The research objectives focus on determining vibroacoustic intensities and associated frequencies between 50-10,000 Hz that will define method sensitivity and repeatability, its potential as a self-standardizing and stand-alone approach, and the technical requirements for creating a commercial process control instrument. Because the vibroacoustic measurements will be accomplished at an industrial site where significant equipment and process noise is typical, the anticipated technical results will create a solid foundation and enhance method credibility for subsequent demonstration.The broader impact/commercial potential of this project is in wireless process control instrumentation (PCI) that enhances process efficiencies, and in the scientific understanding of non-invasive measurements of solids and gas flows within highly-branched pneumatic conveyance systems. By controlling solids conveyance in these systems, materials usage efficiencies are increased, and product qualities and process performances are raised. As an example, successfully implementing a vibroacoustic PCI at the industrial site at which the vibroacoustic data are to be acquired could decrease its materials usage by up to 40% with a concomitant cost savings of $640,000/yr. Within US industries mandated to install emission equipment, the cost reductions offered by the vibroacoustic method are $384 million per year, and commercial sales of the PCI could reach $155 million. The cost savings and business created would beneficially impact society through decreased energy consumption for manufacturing, transporting and using solid reagents; decreased electrical generation costs; improved environmental performance; decreased emissions of greenhouse gases; and, decreased consumer costs. Furthermore, increased efficiencies in the control of bulk solids delivery using pneumatic conveyance is needed for commodities and high-value products produced by industry that are either consumed or used by, and impact, every person in the US.