I-Corps: Consistency sensor for process monitoring of two-phase products

I-Corps项目更广泛的影响/商业潜力是为复杂的两相产品开发过程监控传感器。由于同时发生了大量的机械剪切和化学反应，使得误差范围很窄，因此实现两相产品所需的一致性非常复杂。目前，没有技术可用于测量产品的实时一致性。两相产品的例子包括油脂、蛋黄酱、酱汁、果酱、花生酱、纸张等。例如，在油脂生产中，混合酸和碱所需时间的差异导致稠度的变化。对于蛋黄酱来说，如果鸡蛋和乳化剂在加油过程中没有很好地分散和水化，乳液就会破裂。产品的一致性由于原料的变化、配料的加料速率和人为错误而变化。稠度不符合规定标准的批次产品被丢弃。所提出的传感器技术可能有助于了解当前的复杂工艺及其热力学，以实现每批两相产品的可重复一致性，从而提高利润率并消除产品和能源的浪费。这个I-Corps项目是基于过程监控传感器单元（PSU）的开发，用于测量两相产品在制造过程中的实时一致性。两相产品包括在釜中混合固体和液体成分，直到达到所需的稠度。所提出的PSU测量实时累积熵生成值，根据热力学原理开发，并与产品的一致性进行比较。驱动电机的功率和产品的温度可以用来确定过程工业中的累积熵。该方法已应用于几个不可逆的复杂系统，研究表明，最终产物的累积熵产生是恒定的。建议的PSU可以确保产品在每个阶段都具有正确的一致性。此外，PSU还可用于触发警告信号，以便工艺工程师及时采取纠正措施，保证产品符合标准和质量。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of a process monitoring sensor for complex, two-phase products. Achieving the desired consistency of two-phase products is extremely complex due to a multitude of occurrences of simultaneous mechanical shearing and chemical reactions, allowing a narrow margin of error. Currently, no techniques are available to measure the real-time consistency of the product. Examples of two-phase products include grease, mayonnaise, sauces, jam, peanut butter, paper, and others. In grease production, for example, the difference in time taken to mix the acids and bases leads to consistency variation. For mayonnaise, the emulsion can break if the egg and emulsifying agents are not well dispersed and hydrated during oil addition. The consistency of the product varies due to the variation in the raw materials, feeding rate of the ingredients, and human errors. The batch of product having a consistency that does not meet set standards is discarded. The proposed senor technology may help understand the prevailing complex processes and their thermodynamics necessary to achieve a repeatable consistency of two-phase products for every batch, thus improving profit margin and eliminating waste in product and energy.This I-Corps project is based on the development of a process monitoring sensor unit (PSU), employed to measure the real-time consistency of two-phase products during their fabrication process. Two-phase products involve mixing solid and liquid ingredients in a kettle until the desired consistency is achieved. The proposed PSU measures the real-time accumulative entropy-generation values, developed in accordance with principles of thermodynamics and compares with consistency of the product. The power of the driving motors and the product’s temperature may be employed for determining the accumulative entropy in process industries. The proposed approach has been applied to several irreversible complex systems and the research has revealed that the accumulative entropy generation of a finished product remains constant. The proposed PSU may ensure the product has the right consistency at every stage. In addition, PSU may also be used to trigger warning signals for prompt corrective action by the process engineer, guaranteeing the products meet standards and quality.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.