Pressure compensated weigh system
BACKGROUND OF THE INVENTION 
     Conventional systems for controlling the mass flow rate of fine materials, such as particulate coal, supplied as a fuel into for example a furnace, such as a coal fired boiler, generally employ load cell based weight rate measuring systems to control the gross mass flow rate of the coal to boilers such as the system described in U.S. Pat. No. 4,490,077. However, such systems do not disclose rapid manual or automatic on-line recalibration of mass flow rate controlling systems within fractions of a second to accommodate changing operating conditions as required by the present invention. 
     U.S. Pat. No. 3,635,082 describes the determination of mass flow from velocity and density measurements of a coal and gas stream using two capacitance transducers mounted a known distance apart in the supply line between a coal storage vessel and furnace. The measurement system described by this patent relies on large signal variations, including introducing a slug of compressed gas into the supply line to produce a marker gap, to observe &#34;slugs&#34; of coal in a gas stream in an industrial process. Such a system would not be compatible with the present invention which requires a uniform mass flow rate of coal introduced to the gasifier over periods of time of approximately 5 seconds or less. 
     Other conventional systems control the mass flow rate by determining the mass flow rate indirectly via optical measurement of the coal concentration within a conduit leading to the furnace. Optical measurements, such as radiation absorption for light, are limited to applications of low coal density suspensions, say less than 10 kg/cubic meter, since light must be transmitted through the coal mixture present in the conduit. For example, German patent publication No. 2554565 describes an indirect method of deriving mass velocity of coal transported to a gasifier by optically measuring the coal concentration at a point in the transport line and from the velocity of separately supplied carrier gas. First, the coal entrains gas as it passes from a storage vessel into a transport line. Additionally, the carrier gas, which is not measured, is introduced to assist the coal in discharging from the vessel to the transport line en route to the gasifier. Since it is the total gas stream in the transport line in addition to other factors which govern the mass flow rate, the invention described by this patent could not be used to control the mass flow rate of coal to a gasifier within the desired accuracy, say plus or minus 2 percent, operated with varying suspension densities of 50-800 kg/cubic meter, which are characteristic of various coal types and at various flow conditions. 
     The present invention is directed to overcoming this problem in the prior art. 
     Applicants are not aware of any prior art which, in their judgment as persons skilled in this particular art, would anticipate or render obvious the present invention. However, for the purpose of fully developing the background of this invention, and establishing the state of requisite art, the following art is set forth: U.S. Pat. Nos. 3,689,045; 4,582,454; 4,488,837; Re 31,676; 4,004,647; 4,482,275, and Chemie-Ing. Tech. 47 105 (1975). 
     SUMMARY OF THE INVENTION 
     The primary purpose of the present invention relates to controlling the mass flow rate of solids and gas mixture to a reactor. In particular, this invention relates to controlling the mass flow rate of particulate solid coal and gas mixture to a pressurized gasifier. 
     Preferably, such an apparatus includes: means for weighing the mixture in a vessel, means for obtaining a signal relative to the weight of the mixture in the vessel, means for transmitting the signal relative to the weight of the mixture in the vessel to a first mass flow rate-indicating means, means for transporting the mixture from the vessel to the reactor, means for obtaining a signal relative to the mass flow rate of the mixture transported to the reactor, means for transmitting the signal relative to the mass flow rate of the mixture to a second mass flow rate-indicating means, and means for combining the signals to obtain a corrected mass flow rate of the mixture transported to the reactor. 
     Preferably, a method for controlling the mass flow rate of solids to a reactor includes: weighing the mixture in a vessel, obtaining a signal relative to the weight of the mixture in the vessel, transmitting the signal relative to the weight of the mixture in the vessel to a first mass flow rate-indicating means, transporting the mixture from the vessel to the reactor, obtaining a signal relative to the mass flow rate of the mixture transported to the reactor, transmitting the signal relative to the mass flow rate of the mixture to a second mass flow rate-indicating means, and combining the signals to obtain a corrected mass flow rate of the mixture transported to the reactor. 
     The various features of novelty which characterize the invention are pointed out with particularity in the claims forming a part of this disclosure. For a better understanding of this invention, its operating advantages and specific object obtained by its uses, reference may be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a preferred embodiment of the invention. 
    
    
     DESCRIPTION OF A PREFERRED EMBODIMENT 
     Generation of synthesis gas occurs by partially combusting organic or carbonaceous fuel, such as coal, at relatively high temperatures in the range of 800°-2000° C. and at a pressure range of from about 1-200 bar in the presence of oxygen or oxygen-containing gases in a gasifier. Oxygen-containing gases include air, oxygen enriched air, and oxygen optionally diluted with steam, carbon dioxide and/or nitrogen. 
     In the present invention, the fuel and gas mixture is discharged from a feed vessel apparatus, preferably having multiple outlets, each outlet being in communication with at least one burner associated with the gasifier. Typically. a gasifier will have four burners in diametrically opposing positions. Generally, the burners have their discharge ends positioned to introduce the resulting flame and the agent of combustion into the gasifier. 
     Of particular importance in the manufacture of synthesis gas is the uniform manner in which the particulate fuel is introduced to the burners within the gasifier, and in particular, the uniform mass flow rate of the fuel. Fluctuations of coal mass flow rate to burners within a coal gasification reactor, hereinafter referred to as a gasifier, are detrimental to the gasifier&#39;s performance. For example, fluctuations of the coal mass flow rate can cause inefficient combustion of fuel within the gasifier, i.e. zones of under heating generated next to zones of overheating in the gasifier. As a result, in the zones of underheating the fuel is not completely gasified and in zones of overheating the fuel is completely converted into less valuable products, viz. carbon dioxide and water vapor. Additionally, damaging heat fluxes to the burner face can cause thermal stresses on the burner face possibly resulting in shorter burner life. Furthermore, locally high temperatures in the gasifier could damage the refractory lining which is normally arranged at the inner surface of the gasifier wall. 
     Based on the reasons identified above, maintaining a uniform mass flow rate of coal and gas mixture to a gasifier is essential to effectively operating a gasifier. Since the residence time of a gasifier can be 5 seconds or less, the coal mass flow rate should preferably be constant over periods of this order and preferably over shorter periods to maintain constant local conditions. 
     Measurement and automatic on-line control and recalibration of coal mass flow rate to the burners of a gasifier by conventional means, such as weigh cells, are too slow to ensure constant mass flow rate to the burner of a gasifier over time periods stated above. Similarly, other systems for controlling the mass flow rate by determining the mass flow rate indirectly via optical measurement of the coal concentration within a conduit leading to the furnace are limited to applications of low coal density suspensions. Furthermore, the capability of directly measuring the mass velocity of the coal, rather than using optical measuring techniques, allows the flexibility of operating the process at varying and higher suspension densities, say 150-800 kg/cubic meter and at varying moisture contents of coal, which are characteristic of different coal types. 
     The present invention employs a combination of mechanical components, advanced electronic technology integrated by computer software to yield a weight rate measurement system that can measure mass flow rates of coal and gas mixtures contained in vessels maintained at high pressures, say greater than 200 psig, within plus or minus 2% accuracy as compared with plus or minus 5-10% accuracy for conventional loss-in-weight measurement systems. The present invention utilizes the fast response, e.g. seconds or less, of a mass flow rate-indicating device, which accuracy may drift over time, e.g. hours or days, due to e.g. moisture in the mixture, combined with the slowly responding, e.g. minutes, but longer term accuracies in changes in the total mass from weigh cells to yield rapid and more accurate loss-in-weight measurements than conventional systems. In a like manner, this invention permits manual or automatic on-line recalibration of the mass flow rate-indicating devices used in the measurement system. 
     An advantage of the present invention is controlling the mass flow rate of a coal and gas mixture to a gasifier having a residence time of five seconds or less and thereby, preventing zones of underheating and overheating within the reactor. 
     Another advantage of the present invention is protection of the burners and refractory lining within the gasifier due to preventing zones of underheating and overheating. 
     An additional advantage of the present invention is more efficient conversion of solid fuel in the production of synthesis gas. 
     A further advantage of the present invention is the capability to directly measure the mass velocity of the coal, and thereby allow the flexibility of operating the process at varying and higher suspension densities, say 150-800 kg/cubic meter and at varying moisture contents of coal, which are characteristic of different coal types. 
     Although the invention is described hereinafter primarily with reference to particulate coal, the method and apparatus according to the invention are also suitable for catalysts and other finely divided reactive solids which could be partially combusted, such as lignite, anthracite, bituminous, brown coal, soot, petroleum coke, and the like. Preferably, the size of solid carbonaceous fuel is such that 90 percent by weight of the fuel has a particle size smaller than 100 mesh (A.S.T.M.). 
     Having thus generally described the apparatus and method of the present invention, as well as its numerous advantages over the art, the following is a more detailed description thereof, given in accordance with specific reference to the drawings. However, the drawings are of process flow type in which auxiliary equipment, such as pumps, compressors, cleaning devices, etc. are not shown. All values are merely exemplary or calculated. 
     Referring to the drawing, an apparatus and method for controlling mass flow rate of a solids and gas mixture to a gasifier 9 operated at elevated pressures, say 1-200 bar, generally includes feeding the mixture from a container (not shown), such as a bunker or silo, into a pressurized vessel, shown illustratively as a feed hopper 11, operated typically at pressures of 3-210 bar. A differential pressure of 2-10 bar between the hopper 11 and the gasifier 9 is maintained preferably by injecting gas into an upper portion of the hopper 11 via line 17 from a pressurized gas source 14 to prevent flashback or ingress of synthesis gas into the hopper 11 and thereby maintain coal flow to the burners of the gasifier 9. The rate of injecting gas, determined by indicator 56, is transmitted via signal 57 to the split range pressure controller 50. The rate of venting gas via line 20, determined by transducer 46, is transmitted via line 48A to the split range pressure controller 50 and via line 48B to a second mass flow rate indicating means 63. 
     A pressure detector, say a transducer 52, transmits a signal 54, to the split range pressure controller 50. Based on the pressure within the hopper 11 the controller 50 transmits a signal via line 47 to operate adjusting valve 82 and via line 36, to operate adjusting valve 16. 
     The pressure controller 50 regulates the rate of change of pressure in hopper 11 to be preferably 1 bar/min. maximum. 
     The hopper 11 is preferably designed so that it is isolated in terms of weight from extraneous forces, such as those caused by the elevated pressure of the hopper 11, by a weight isolating device, for example pressure balanced flex joints 8 or bellows and lateral and vertical constraints, tie-bars 15A, 15B for measuring the weight change of the vessel functions properly. Extraneous forces on the hopper 11. which are unrelated to weighing the hopper 11 and are uncharacteristic of loss-in-weight measurement systems operated at pressures lower than 200 bars and temperature changes lower than 80° C., include pressure forces on connections between the weighed hopper 11 and other mechanical components of the system, mechanical forces due to spring constants resulting from flexible connections, and forces on the weighed hopper 11 due to loading and unloading of vessels associated with the hopper 11, forces due to thermal expansion and contraction of the vessel and/or its supports, and seismic forces due to nearby dynamic equipment and vehicles. 
     A position detector, say a transducer 38, transmits a signal 40 to a first mass flow rate-indicating means, say a preliminary processor 35 such as an analog or digital computing device with the following algorithm: Corrected Weight of Vessel=K 1  * Measured Weight of Vessel+K 2  * bellow movement+K 3  * Vessel Pressure+K 4  * Vessel temperature, where K 1 , K 2 , K 3  and K 4  are calibration constants based on a known standard such as a weigh cell at atmospheric conditions. The position indicator 38 responds to the degree of compression in the flex joint 8 so as to allow the present invention to compensate for extraneous forces. 
     Preferably, the present invention employs both preliminary and primary processors of a system for controlling the mass flow rate of the coal and gas mixture to the gasifier as described hereinafter in further detail. 
     A means for weighing the mixture contained in the hopper 11, such as one or more load cells 13, shown for illustrative purposes as positioned at approximately the center of gravity of the weigh vessel and its contents when full, but could be placed anywhere on the outer walls of the vessel, although one skilled in the art would recognize that the load cells and other supports could preferably be positioned in a symmetrically-spaced arrangement around the perimeter of the vessel at an elevation above the center of gravity when the vessel is empty or full. A weight detector, say a transducer 33, transmits a signal 34 to the preliminary processor 35 which preferably includes a weight rate indicator controller. 
     A temperature detector, say a transducer 42, transmits a signal 44 to the preliminary processor 35 to monitor the temperature of the coal and gas mixture within the hopper 11. 
     A signal 60 relative to the pressure within the hopper 11 is transmitted from the controller 50 to the preliminary processor 35. The processor 35 includes means for combining the signals relative to the weight, deflections, the pressure within the hopper 11, and the temperature to obtain a first signal 62 relative to a mass flow rate of the coal and gas mixture exiting the hopper 11. 
     To facilitate discharge of the coal from the hopper 11 via opening 25, pressurized gas from a pressurized gas supply source 78 can be supplied at substantially a constant flow rate measured by flow meter 84 into the lower portion of the hopper 11 through line 22. The rate of the gas supplied to the hopper 11 is regulated by adjusting valve 81. 
     The coal and gas mixture is pneumatically transported via conduit 27 to the gasifier 9, preferably by injecting pressurized gas from a pressurized gas supply source 79 supplied via line 30 and regulated by adjusting valve 80. 
     Preferably density, pressure, velocity, and temperature detectors, say transducers 64, 68, 66, and 70, respectively, transmit signals 65, 69, 67, and 71, respectively, to a second mass flow rate-indicating means, say a primary processor 63 such as an analog or digital computer programmed such that it is (1) capable of carrying out calculations to derive an instantaneous mass flow rate based on signals 65, 69, 67 and 71 and (2) compensates the errors in this instantaneous mass flow signal by using the corrected mass flow rate calculated by preliminary processor 35, the latter signal having a relatively slow response time but better accuracy than the mass flow signal derived instantaneously. 
     Additionally, signal 77A from transducer 76 for indicating the rate of transport gas into the conduit 27, and signal 85A from transducer 84 for indicating the rate of aerating gas into the lower portion of the feed vessel 11, are preferably transmitted to the primary processor 63. 
     Preferably, data concerning the water content and ash content of the coal and gas mixture are provided such that corresponding indicators 72, 74, respectively, transmit signals 73, 75 respectively, to processor 63 to obtain a more accurate corrected mass flow rate of the mixture transported to the gasifier 9. It is recognized by those skilled in the art that data relative to the water content of the mixture can be obtained by A.S.T.M.-D 3173-85 or by using infrared, nuclear magnetic resonance (NMR), microwave attenuation or similar state of the art techniques. Likewise, data relative to the ash content can be obtained by ASTM D 3179-82 or by using nuclear devices such as two-source gamma ray systems, etc. 
     Signals relative to the corrected mass flow rate or corrected density of the mixture to the gasifier 9 are then transmitted to means for controlling the mass flow rate or density of the mixture to the gasifier 9. For example, signals 77B and 85B are transmitted from controller 63 to valve 80 and 81 to adjust the rate of injecting transport gas and aeration gas repectively. Likewise, signal 83 can be transmitted from controller 63 to pressure controller 50 which in turn transmits either a signal 47 to adjust the rate of venting gas from hopper 11 via valve 82, or a signal 36 to adjust the rate of make-up gas to hopper 11 via valve 16, thereby changing the pressure in the feed vessel and thus changing the mass flow rate to the gasifier. 
     Furthermore, a signal 86 relative to the corrected mass flow rate of the mixture to the gasifier 9 is preferably transmitted to means for controlling a rate of oxygen supplied by a pressurized source 88, such as a preliminary controller 87. The controller 87 which receives a signal of flow meter 90 transmits a signal 91 to operate adjusting valve 89 so that the required flow rate is reached. Since the atmosphere of the gasifier 9 should be a reducing environment, selectively controlling the weight ratio of oxygen to mixture introduced to the gasifier 9 is desirable. Preferably, the ratio is maintained so that the ratio of oxygen to moisture and ash free coal is in the range of 0.6 to 1.2, more preferably 0.8 to 1.0. Controlling the ratio can be accomplished in various ways including selectively controlling the rate of oxygen-containing gas 88 introduced into the gasifier 9 via valve 89 as described above. 
     Although the system for controlling the mass flow rate is shown in FIG. 1 in its distributed form as discrete components, it would be readily understood by those skilled in the art that these components could be combined into a single unit or otherwise implemented as may be most convenient for the particular application at hand. Furthermore, although the preferred embodiment has been shown as using an electronic process control system for controlling the mass flow rate of coal transported to the gasifier, it is also understood by those skilled in the art that some components of the present invention could be effected using manual or pneumatic controls. 
     The foregoing description of the invention is merely intended to be explanatory thereof, and various changes in the details of the described method and apparatus may be made within the scope of the appended claims without departing from the spirit of the invention.