GAS PRODUCTION AND STORAGE SYSTEM AND ASSOCIATED METHODS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 63/484,593, which was filed on February 13, 2023, the entire contents of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of systems and methods for the production and storage of various chemicals in gaseous form. More specifically, systems and methods for the monitored and controlled production and storage of low-volumes of certain inherently hazardous gases on an as-needed basis to reduce hazards associated therewith.
BACKGROUND
[0003] There are many gases that are essential to modern life due to their utility in variety of industrial applications. For example, chlorine gas is often useful in the production of chemicals, such as hypochlorous acid, due to its great reactivity. However, it is often impractical to produce and store many of these hazardous gases, such as chlorine gas, as they are toxic and may react with flammable materials. Indeed, in January of 2005, a train crash caused a rupture of a transportation tank leading to a release of 60 tons of chlorine in Graniteville, a small town in South Carolina, which led to 10 deaths and over 250 injuries along with the force evacuation of 5400 residents within one mile thereof for two weeks during decontamination efforts. Since then, the Occupational Safety and Health Administration (OSHA), has logged almost 100 separate accidents involving chlorine in the United States alone. Outside the United States, a container carrying 25 tons of chlorine fell at the Port of Aqaba in Jordan causing 13 deaths and 265 injuries was captured and reported around the world in June of 2022
[0004] Chlorine is so toxic that coughing and vomiting may occur at concentrations as low as 30 parts per million (ppm) and lung damage at 60 ppm. Indeed, just a few deep breaths of gas at concentrations of 1000 ppm can be fatal. The National Institute for Occupational Safety and Health (NIOSH) identifies the immediately dangerous to life and health (IDLH) concentration for chlorine gas at just 10 ppm. Moreover, OSHA has set the permissible exposure limit for elemental chlorine at 1 ppm. Additionally, chlorine gas can cause damage or failures in certain materials due to its great reactivity. Like chlorine, many other gases, such as chlorine dioxide and hydrogen sulfide, are useful but ultimately hazardous in their own ways.
[0005] Given the potential hazards associated with various compounds in gaseous form, like chlorine, chlorine dioxide, and hydrogen sulfide, there are often requirements that they be stored either outdoor or in a well-designed enclosure with an active ventilation system. Indeed, chlorine gas cylinders and storage tanks are considered an occupational hazard, as they should be based on the above examples. However, these substances are often produced and shipped to where they are needed, to be stored until such a time. Accordingly, in circumstances where certain of these hazardous gases are useful, it is preferable to generate such gas on an as-needed low-volume basis such that the risks associated with storage and a potential leak are greatly reduced. Consequently, there remains an unmet need for systems and methods which can safely produce certain hazardous gases on an as needed low-volume basis and which provides enhanced monitoring and control of the generation process to reduce associated risks.
BRIEF SUMMARY
[0006] This summary is provided to introduce in a simplified form concepts that are further described in the following detailed descriptions. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it to be constmed as limiting the scope of the claimed subject matter.
[0007] According to one or more embodiments a gas production and storage system is provided that comprises a vessel comprising a body having a sealed top at one end thereof and a sealed bottom at an opposed end and defining and enclosing an inner chamber. The vessel further comprises a vent port disposed at the top and in fluid communication with an evacuation system for the evacuation of produced gas from the inner chamber and a drain line port disposed at the bottom and in fluid communication with a disposal system for the removal of liquid from the inner chamber, in embodiments. The vessel also comprises at least one input port disposed along the body of the vessel and in fluid communication with at least one of a reagent tank and water tank to supply one of one or more reagents and water to the inner chamber in embodiments. In further embodiment, the vessel also comprises at least one gas retrieval port disposed along the body of the vessel and in fluid communication with at least one of an evacuation system and a use system to allow for the removal of produced gas from the inner chamber. Along the body of the vessel are disposed a plurality of optical sensing modules configured to signal the presence of produced gas in a portion of the inner chamber adjacent the respective sensing module. In certain embodiments, the optical sensing modules are disposed along the body of the vessel between the top and bottom thereof such that the low optical sensing module is between the middle optical sensing module and the bottom of the vessel and the high optical sensing module is between the middle optical sensing module and the top of the vessel. The vessel, in embodiments, further comprises at least one liquid level sensor, such as a float switch, disposed along the body of the vessel between the low optical sensing module and the bottom of the vessel to identify if the fluid in the inner chamber is at or above the level of the liquid level sensor. According to such embodiments, gas production and storage within the inner chamber of the vessel is facilitated and monitored through signals received by each of the optical sensing modules and at least one liquid level sensor to guide transfers relative to the inner chamber through one or more of the vent port, drain line port, at least one input port, and at least one gas retrieval port.
[0008] In embodiments, each optical sensing module has a light emitter and a light receiver disposed on an opposed portions of the body of the vessel in a plane parallel to the top and bottom. In embodiments, the light emitter is configured to provide light within a specified wavelength range and the light receiver is configured to provide light absorbance readings for light associated with the specified wavelength range from the light emitter.
[0009] According to further embodiments, the body of the vessel is transparent or translucent. In certain embodiments, the body of the vessel is transparent or translucent to light within a range of 240 nm to 420 nm.
[0010] According to additional embodiments, the light emitter and light receiver of each optical sensing module is configured for use with light within a range of 240 nm to 420 nm.
[0011] According to one or more embodiments, the light emitter of each optical sensing module is a narrow band LED disposed within a mount attached to the vessel body. According to additional embodiments, the light receiver of each optical sensing module is an optical sensor disposed within a mount attached to the vessel body. In further embodiments, each optical sensing module includes a band pass filter disposed adjacent the light receiver and between the light emitter and light receiver.
[0012] In certain embodiments, a portion of the body of the vessel is disposed between each light emitter and light receiver of each optical sensing module.
[0013] In other embodiments, each optical sensing module further comprises an illumination irradiance sensing window and illumination irradiance feedback sensor to receive a portion of the light produced by the light emitter.
[0014] In specific embodiments, the at least one input port is disposed along the body of the vessel in a plane between and parallel with planes passing through the low sensing module and the bottom of the vessel. In particular embodiments, the at least one gas retrieval port is disposed along the body of the vessel in a plane above and parallel to planes passing through the at least one level sensor and the bottom of the vessel. In at least one embodiment, the at least one gas retrieval port is disposed along the body of the vessel in a plane between and parallel with planes passing through each of the low sensing module and the bottom of the vessel.
[0015] In further embodiments, the system further includes a pH probe disposed at or adjacent to the bottom of the vessel for testing of fluid in the inner chamber.
[0016] In particular embodiments, the at least one liquid level sensor of the system comprises a high-level sensor and a low-level sensor. In such an embodiment, the high-level sensor is disposed in a plane between and parallel with planes passing through the low-level sensor and the low sensing module and the low-level sensor is disposed in a plane between and parallel with planes passing through the high-level sensor and the bottom of the vessel.
[0017] According to embodiments, the at least one input port comprises at least one reagent port and a water port. In at least one further embodiment, the at least one reagent port comprises two separate reagent ports.
[0018] According to one or more embodiments, the system further comprises a process control system in communication with each of the optical sensing modules and the at least one level sensor and operably connected to a fluid control system in fluid communication with each of the vent port, drain line port, at least one input port, and at least one gas retrieval port for transfers relative to the inner chamber. In such an embodiment, the control system further calculates a concentration of produced gas in a portion of the inner chamber based on absorbance data signaled from each of the optical sensing modules. [0019] In certain embodiments, the system further comprises a process control system in communication with each of the optical sensing modules, the at least one level sensor, and the pH probe and operably connected to a fluid control system in fluid communication with each of the vent port, drain line port, at least one input port, and at least one gas retrieval port for transfers relative to the inner chamber and wherein each of the fluid control systems comprises at least one of a valve and a pump. In at least one embodiment, the system further comprises a temperature sensor disposed at or adjacent to the bottom of the vessel for testing of the fluid in the inner chamber.
[0020] According to one or more additional aspects, a gas production method utilized within a vessel defining an inner chamber between a body, a sealed top, and a sealed bottom is provided. In aspects, the vessel has a high, middle, and low optical sensing module disposed upon the body thereof between and the top and bottom of the vessel configured to signal a presence of produced gas in a portion of the inner chamber of the vessel adjacent the respective sensing module, at least one liquid level sensor disposed along the bottom of the vessel between the low optical sensing module and the bottom of the vessel, a pH probe disposed at the bottom of the vessel, one or more input ports into the inner chamber through the body of the vessel, a gas retrieval port from the inner chamber through the body of the vessel, a vent port disposed at the top of the vessel, and a drain line port disposed at or adjacent a bottom of the vessel. In further aspects, a process control system is operably connected to a fluid control system in fluid communication with each of the vent port, the one or more input ports, the gas retrieval port, the vent port, and the drain line port, and configured to receive signals from each of the optical sensing modules, the at least one liquid level sensor, and the pH probe.
[0021] In additional aspects, the method comprises identifying a gas status, at the process control system based on signals received from the at least one optical sensing module, associated with the vessel comprising one of empty, under-filled, full, and over-full, wherein an empty gas status is associated with the low optical sensing module not signaling a presence of produced gas, an under-filled gas status is associated with the low optical sensing module, but not the middle optical sensing module, signaling a presence of produced gas, a full gas status is associated with both the low and middle optical sensing modules, but not the high optical sensing module, signaling a presence of produced gas, and an over-full gas status is associated with the high optical sensing module signaling a presence of produced gas. The method also comprises, in aspects, identifying a liquid level status, at the process control system based on signals from the at least one liquid level sensor, associated with the vessel comprising one of low and high, wherein a low liquid level status is associated with the at least one liquid level sensor not signaling a presence of liquid and a high liquid level status is associated with the at least one liquid level sensor signaling a presence of liquid. Also, in aspects, the method comprises identifying a reaction status, at the process control system based on signals from the pH probe, associated with the vessel comprising a proceeding status and a stopped status, wherein the proceeding status and the stopped status are each associated with the pH probe signaling a value within a specified range for each.
[0022] Aspects of the method also include determining a vessel state at the process control system from one or more of each of the gas status, the liquid level status, and the reaction status, determining activation instructions at the process control system from at least one of the vessel state and user input provided to the process control system, and operating a fluid control system in fluid communication with the vessel based on one of the vessel state and the activation instructions. [0023] In certain aspects, operating a fluid control system in fluid communication with the vessel in accordance with the method includes evacuating the produced gas from the inner chamber through the vent port based on activation instructions from the vessel state associated with the over-full gas status.
[0024] In further aspects, operating a fluid control system in fluid communication with the vessel in accordance with the method includes adding fluid through the one or more input ports based on activation instructions from a vessel state based on the stopped status, the low liquid level status, and one of the empty gas status or under-filled gas status.. In additional aspects, operating a fluid control system in fluid communication with the vessel in accordance with the method includes delivering produced gas through the gas retrieval port based on activation instructions from user input. In other aspects, operating a fluid control system in fluid communication with the vessel in accordance with the method includes draining liquid through the drain line port based on activation instructions from a vessel state based on the high liquid level status.
[0025] In various aspects, operating a fluid control system in fluid communication with the vessel in accordance with the method includes evacuating all produced gas through at least one of gas retrieval port and the vent port based on activation instructions from user input. In at least on embodiment, operating a fluid control system in fluid communication with the vessel in accordance with the method includes draining liquid through the drain line port based on activation instructions from user input.
BRIEF DESCRIPTION OF THE FIGURES
[0026] The foregoing, as well as the following Detailed Description, is better understood when read in conjunction with the appended Figures. For the purposes of illustration, there is shown in the figures certain exemplary embodiments; however, the presently disclosed subject matter is not limited to the specific methods and instrumentalities disclosed.
[0027] The embodiments illustrated, described, and discussed herein are illustrative of the present invention. As these embodiments of the present invention are described with reference to illustrations, various modifications or adaptations of the methods and or specific structures described may become apparent to those skilled in the art. It will be appreciated that modifications and variations are covered by the above teachings and within the scope of the appended claims without departing from the spirit and intended scope thereof. All such modifications, adaptations, or variations that rely upon the teachings of the present invention, and through which these teachings have advanced the art, are considered to be within the spirit and scope of the present invention. Hcncc, these descriptions and drawings should not be considered in a limiting sense, as it is understood that the present invention is in no way limited to only the embodiments illustrated.
[0028] FIG. 1A illustrates a diagram of a gas production and storage system according to one or more embodiments and its fluid communication with other systems, such as an evacuation system, use system, and drain system and accompanying fluid control systems;
[0029] FIG. IB illustrates a diagram of a gas production and storage system according to one or more embodiments similar to that of FIG. 1 A but where the a single input fluid control system is utilized to introduce a variety of reagents and water to the vessel, the vent fluid control system includes both a valve and pump, and the gas retrieval fluid control system includes a standard valve instead of a three-way valve;
[0030] FIG. 2 illustrates a diagram of a gas production and storage system according to one or more embodiments showing the process control system and data flows for sensor data into the process control system and instruction flows for fluid control systems; [0031] FIG. 3A illustrates a perspective view of a gas production and storage system vessel according to one or more embodiments wherein the vessel includes multiple input ports, each for the introduction of a separate reagent or water;
[0032] FIG. 3B illustrates a perspective view of a gas production and storage system vessel according to one or more embodiments wherein the vessel includes a single input port for the introduction of reagents or water;
[0033] FIG. 4A illustrates an elevation view of a gas production and storage system vessel according to the embodiment of FIG. 3A, wherein the produced gas is above a low optical sensing module but below the middle optical sensing module and the inner chamber has a liquid mixture of reagents and water at the bottom above a low level sensor but below a high level sensor;
[0034] FIG. 4B illustrates an elevation cross-section view of a portion of the vessel and attached an optical sensing module of a gas production and storage system according to one or more embodiments; and
[0035] FIG. 5 illustrates an elevation view of a gas production and storage system vessel according to the embodiment of FIG. 4A, wherein the produced gas has been removed but the liquid mixture of reagents and water remain.
DETAILED DESCRIPTION
[0036] The following description and figures are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. In certain instances, however, well-known or conventional details are not described in order to avoid obscuring the description. Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.
[0037] The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. It will be appreciated that same thing can be said in more than one way.
[0038] Alternative language and synonyms may be used for any one or more of the terms discussed herein. No special significance is to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any terms discussed herein, is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification.
[0039] Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods, and their related results according to the embodiments of the present disclosure arc given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. OVERVIEW
[0040] Embodiments of a gas production and storage system 100 that provides for the safe generation and storage of a gas 196 are herein provided. In embodiments, the system 100 and associated method beneficially reduce the risks associated with a hazardous gas 196, like chlorine, chlorine dioxide, or hydrogen sulfide, by reducing the volume stored, at any one time, and by providing the ability to control gas production reactions and storage with feedback to ensure safety and precision. Moreover, the on-demand nature of the gas production allows for storage in a lower pressure vessel, further reducing the risks associated therewith. Indeed, many accidents associated with a hazardous gas stem from the transportation thereof, which inherently increases the risk of an accident, and the pressurized format, which multiplies the damages stemming from an accident. Herein, embodiments of the system 100 provide for the ability to reduce both of those risks by providing a safe, monitored, controlled and automated system 100 for generation of a gas at or near the place of intended use, in a lower volume with less excess stored, and without pressurization.
[0041] As shown in FIGS. 1A and IB, the system 100, in embodiments herein, comprises a vessel 110 having fluid connections to safe disposal systems, such as an evacuation system 188 and drain system 192 to remove, and neutralize as needed, a gas 196 produced and stored therein and any associated liquid 198. In embodiments, the vessel 110 further comprises input fluid connections to reagents 200 and other ingredients, such as water 202, useful to facilitate the gas production reaction and fluid connections for the removal of the produced gas 196 from the vessel 110 to be delivered to a use system 190, such as another reaction vessel or staging tank for use in a manufacturing process. For example, a chlorine gas may be produced in the vessel 110 and delivered therefrom to a use system associated with the production of an aerosol grade hypochlorous acid.
[0042] As shown in FIGS. 3A and 3B, the system 100, in embodiments herein, also comprises at least one liquid level sensor 152, such as a float switch 154, to monitor the amount and level of input fluids, such as reagents 200 and water 202, in the inner chamber 114 of the vessel 110. In use, when the mixed fluid 198 reaches a level, the drain system can be activated to remove it, and neutralize it if necessary. Moreover, the system 100 also comprises a plurality of optical sensing modules 132 disposed at various levels along the body 112 of the vessel 110 to signal the presence of produced gas in a portion of the inner chamber 1 14 of the vessel 110 adjacent to the respective optical sensing module.
[0043] Thereby, in embodiments of use for gas generation, fluids utilized to produce a particular gas 196 are introduced to the vessel 110, and the level sensor(s) 152 provide notice of the amount/level, and the gas 196 is produced rising up from the mixed liquid 198 and the dispersed optical sensing modules 132 provide notice of the amount/level.
[0044] In embodiments where a produced gas 196 is heavier than air, the optical sensing modules 132 can provide notice that the amount of gas produced is at or above the vertical level of a particular optical sensing modules 132 and allow for the utilization of a fluid connection with an evacuation system 188 if the gas rises above a particular level within the inner chamber 114 of the vessel 110. In embodiments where a produced gas 196 is lighter than air, optical sensing modules 132 can work in an opposed fashion, providing notice that a level of produced gas from a top 116 down within the inner chamber 114 of the vessel 110 and allow for the utilization of a fluid connection with an evacuation system 188 if the gas level extends below a particular level within the inner chamber 114 of the vessel 110.
[0045] In embodiments where a produced gas 196 has a similar density to air, the optical sensing modules 132 can be of an embodiment to provide absorbance data associated with light passing through the produced gas 196 which is associated with the concentration of the produced gas 196 and allow for the utilization of a fluid connection with an evacuation system 188 if the absorbance data passes above a level, alone or in conjunction with additional data, such as a pressure relief valve opening in the path of the fluid communication between the vessel 110 and the evacuation system 188 or a pressure sensor in fluid communication with the inner chamber 114 indicating that the vessel 110 is experiencing a pressurization.
[0046] Moreover, in embodiments of use for gas storage, the vessel 110 provides for the use of the optical sensing modules 132 to indicate that the level of the produced gas 196 is constant and to provide for the level of change when the produced gas 196 is removed through the fluid communication with the use system 190. Thereby, potential leaks associated with the vessel 110 or verification of volumes removed to a use system 190 can be identified.
[0047] Also, in embodiments of use, the system 100 can provide notice of the removal of all produced gas 196, through the optical sensors 132, and mixed liquid 198 through the level sensor(s) 152. FLUID COMMUNICATIONS
INPUTS
[0048] As shown in FIGS. 1A and IB and described broadly above, embodiments of the system 100 utilize a vessel 110 in fluid communication with a number of storage tanks 194 to facilitated the delivery of stored fluids, such as reagents 200 and water 202, into the vessel 110. As will be described in more detail with respect to the vessel 110 below, these fluid communications are achieved through one or more input ports 124 into the vessel 110. In embodiments, one or more input fluid control systems 180 may also be utilized to facilitate the fluid communication between a storage tank 194 and a vessel 110. In embodiments, each input fluid control system 180 may comprise one or more of a valve 204 and a pump 206. That is, in embodiments where gravity can be utilized or the storage tank 194 is under pressure, a valve 204 alone might be utilized in the fluid communication path (such as a pipe) between the tank 194 and the vessel 110 (though not shown in the figures). In other embodiments, a pump 206 alone may be utilized in the fluid communication path between the tank 194 and the vessel 110 (also not shown in the figures). However, to provide for the ability to isolate a particular pump 206, one or more valves 204 might also be utilized with the pump 206, such as in the input fluid control systems 180 shown in FIGS. 1A and FIG. IB. As shown in FIG. 1A, each storage tank 194 and its contents can be in fluid communication with a single input fluid control system 180, or, as shown in FIG. IB, an input fluid control system 180 may be in fluid communication with more than one storage tank 194 and its contents. In embodiments, the vessel 110 can have a matching number of input ports 124 to the number of input fluid control systems 180. Indeed, the three input fluid control systems 180 of FIG. 1A may be in fluid communication with the vessel 110 through three input ports 124, as in FIG. 3 A, and the single input fluid control system 180 of FIG. IB may be in fluid communication with the vessel 110 through a single input port 124, an in FIG. 3B.
OUTPUTS
[0049] As in FIGS. 1A and IB, embodiments of the system 100 utilize a vessel 110 in fluid communication with safe disposal systems, such as an evacuation system 188, to deal with gas removal, and drain system 192, to deal with fluid removal. As discussed previously, an increased danger exists with the generation and storage of excess amounts of certain gases. To mitigate this risk, embodiments of the system 100 involve fluid communication of the inner chamber of the vessel with an evacuation system 188. The evacuation system 188 comprises components which can safely neutralize and remove the produced gas 196. For example, an embodiment of the evacuation system utilized with a produced gas 196 of chlorine may comprise a chlorine scrubber, such as one utilizing packed beds with misted caustic solution in various stages or towers to achieve neutralization and removal.
[0050] In embodiments, a vessel 110 can be placed in communication with the evacuation system 188 through a vent port 120, described in more detail with respect to the vessel 110 below, alone (as in FIG. IB) or in addition to the gas retrieval port 130 (as in FIG. 1A). While having a vessel 110 in fluid communication with the evacuation system 188 through a single port is simpler in embodiments, having multiple fluid communication paths, through multiple ports, can facilitate a faster removal. Moreover, in embodiments, different or the same evacuation systems 188 may be utilized to remove gas from the vessel 110 through separate ports and such an evacuation system 188 may also be configured to pull and neutralize air from an area in which a vessel 110 is located, such as a room, to provide maximum benefit in case of a leak. In embodiments, a vent fluid control system 186 may be utilized to facilitate fluid communication between the inner chamber 114 of the vessel 110 and the evacuation system 188. In embodiments, this vent fluid control system 186 may comprise either of a valve 204 and a pump 206, as in FIG. 1A, or both, as in FIG. IB. Indeed, in circumstances, the evacuation system 188 may utilize its own pump 206, as in FIG. 1A, to pull the produced gas therethrough, such that having a pump 206 as part of the vent fluid control system 186 may be redundant. Herein, it is understood that the term fluid is utilized to in the standard sense where it identifies both a liquid and a gas. Moreover, it is understood that the term pump may also be understood to identify a variety of types of devices for the purpose, such as (but not limited to) blowers, fans, centrifugal pumps, vacuum pumps, or the like. In embodiments, such as that of FIG. 1A, the evacuation system 188 may also be in fluid communication with the inner chamber 114 of the vessel 110 through a portion of the gas retrieval fluid control system 184, such as the valve 204 thereof. That is, the valve 204 thereof may facilitate the redirection of gas exiting the vessel 110 through the gas retrieval port 130 into the evacuation system 188, instead of onto the use system 190, in embodiments (as in FIG. 1A).
[0051] Similar to above, a vessel can be placed in communication with a drain system 192 through a drain line port 122 in embodiments. Thereby, the liquid 198 which was utilized in the gas production can be removed from the inner chamber 114 of the vessel 110, neutralized, and disposed of. In certain embodiments, the liquid 198 which remains may be easily tested and disposed of, such as where the liquid 198 comprises merely water and NaCl at the termination of the gas production reaction. However, in instances where the liquid 198 may contain other chemicals, systems, such as distillation systems may be utilized to isolate such and additional processes or chemicals may be added to neutralize such for disposal. Moreover, in embodiments, a drain line fluid control system 182 may be utilized to facilitate fluid communication between the inner chamber 114 of the vessel 110 and the drain system 192. As disclosed with respect to other fluid control systems, embodiments of the drain line fluid control system 182 may comprise either of a valve 204 and a pump 206 or both, as in FIGS. 1A and IB. Indeed, in circumstances where gravity may be utilized, the drain line fluid control system 182 may only require a valve 204. However, in instances where the liquid 198 must be moved to another system for treatment, one or more pumps 206 may be required. Likewise, a pump 206 alone may be utilized in embodiments. However, a valve 204 may be useful in embodiments to isolate the pump 206, such as for removal or replacement.
[0052] As in FIGS. 1A and IB, embodiments of the system 100 utilize a vessel 110 in fluid communication with a use system 190. In embodiments, the use system 190 represents the required use of the produced gas 196. For example, in an embodiment where the produced gas 196 is chlorine, the use system 190 may be a hypochlorous acid production system or a water treatment system. In embodiments, a vessel 110 can be placed in communication with a use system 190 through a gas retrieval port 130 in embodiments. Like the other ports mentioned hereto, the gas retrieval port 130 will be described in more detail with respect to the vessel 110. Moreover, in embodiments, a gas retrieval fluid control system 184 may be utilized to facilitate fluid communication between the inner chamber 114 of the vessel 110 and the use system 190. As disclosed with respect to other fluid control systems, embodiments of the gas retrieval fluid control system 184 may comprise either of a valve 204 and a pump 206 or both. However, it is understood that a pump 206 is preferred as it will provide for more precision with regard to amounts removed from the vessel 110. In embodiments, the valve 204 of the gas retrieval fluid control system 184 may allow for the diversion of produced gas 196 to an evacuation system 188.
[0053] Moreover, with respect to all pumps mentioned hereto, it is to be understood that these pumps may, in embodiments, be capable of precision with regard to the amount of fluid they move and may be operated (on, off, and rate manipulation) to allow for titration with respect of fluids into the vessel 110 or out of the vessel 110. Additionally, it is also understood that each of the fluid control systems mentioned previously may further comprise flow rate sensors either integral with or separately utilized with portions of each to monitor amounts passing therethrough and provide precise control of transfers relative to the vessel 110.
[0054] Additionally, it is also to be noted that in certain embodiments, a pressurized flushing inert gas may be introduced through to the vessel 110 directly or through one or more of the input ports 124 to clear and clean the interior of the vessel 110 and lines in fluid communication therewith. Such an operation may be utilized to render the system 100 safe for maintenance operations in embodiments.
VESSEL
GENERALLY
[0055] In embodiments, the system herein further comprises a vessel 110, as shown in FIGS. 3A, 3B, 4A, and 5. In such embodiments, the vessel 110 comprises a cylindrical body 112 with a sealed top 116 and bottom 118 that defines an inner chamber 114. However, while a cylindrical body 112 is shown in the referenced figures, the body 112 might be a different shape in other embodiments. Also, while a sealed top 116 and bottom 118 is preferred to reduce the potential for leaks, in further embodiments one or more of the top 116 and bottom 118 may be removably attached to the body 112.
PORTS
[0056] In embodiments, the vessel 110 may have a plurality of ports, mentioned before, including one or more input ports 124, a vent port 120, a drain line port 122, and a gas retrieval port 130, as shown in FIGS. 3 A and 3B. Each of these ports may comprise a one-way valve and mechanical linkage for pipe, tubing, or other means for fluid communication for transfers relative to the vessel 110 in embodiments. For example, the vessel 110 may have reagent ports 126 and water ports 128 as input ports 124, as in FIG. 3A. Thereby, each port 124 may provide for fluid communication of a specific reagent or water into the inner chamber 114 of the vessel 110. Moreover, these input ports 124 may be one-way to allow the entry of fluid into the inner chamber 114 but not out therethrough. In embodiments, as in FIG. 3B, a single input port 124 may be utilized and the input fluid control system 180 may be capable of switching between and transferring a variety of fluids, as in FIG. IB. Regarding the vent port 120, the drain line port 122, and the gas retrieval port 130, these may be one-way valves which allow the transfer of fluids out of the vessel 110 therethrough but not in therethrough. Moreover, in embodiments, the vent port 120 may comprise a pressure relief valve and may provide a triggering signal to the evacuation system 188 when triggered, such that the system acts to remove the gas and lower the pressure in the vessel 110 thereafter, preventing a leak therefrom. In addition, each of the ports may further comprise a flow rate sensor, or the like, to provide feedback about the amount of fluid transferred relative to the vessel 110.
[0057] In embodiments the ports may be strategically located to be most useful relative to the liquid 198 and produced gas 196. For example, in embodiments where the produced gas 196 is heavier than air, a gas retrieval port 130 may be located at a point just above where the highest liquid level is, generally above the highest liquid level sensor 152 and any input ports 124 — such as in FIGS. 3A, 3B, 4A, and 5. Thereby, the gas retrieval port 130 will maximize the ability to retrieve produced gas 196 from the inner chamber 114 of the vessel 110 while avoiding the introduction of liquid 198 therein. Likewise, in embodiments where the produced gas 196 is lighter than air, a gas retrieval port 130 may be located at a point at or near the top 116 of the vessel 110. In embodiments, where the density of the produced gas 196 is similar to air, the gas retrieval port 130 may be disposed anywhere above the highest liquid level.
OPTICAL SENSING MODULES
[0058] In embodiments, the system 100 also includes a vessel 110 having optical sensing modules 132 disposed about portions thereof which are configured to signal the present of produced gas 196 in a portion of the inner chamber 114 adjacent to the respective module 132. As shown in FIGS. 3A, 3B, 4A, and 5, an embodiment of the system 100 includes three optical sensing modules 132 located along the body 112 of the vessel 110 between the top 116 and bottom 118 including a low disposed nearest to the bottom 118 of the vessel 110, a high disposed nearest to the top 116 of the vessel 110, and a middle disposed between the low and high optical sensing modules. Thereby, in cases where the produced gas 196 is heavier than air, changes in the concentration can indicate the level of the produced gas 196 in the inner chamber 114 from the liquid 198 level up. Thereby, signals received from optical sensing modules 132 by the control system can indicate the level of a produced gas 196, like chlorine, within the inner chamber 114 at three distinct levels, or points, in the embodiments of FIGS. 3A, 3B, 4A, and 5, all of which have low, middle, and high optical sensing modules. Moreover, in cases where the produced gas 196 is lighter than air, changes in the concentration can indicate the level of the produced gas from the top 116 of the vessel 110 down at the three levels, with the lowest optical sensor 132 indicating that the vessel is in danger of being over-filled. Moreover, in embodiments, it is to be understood that the number of optical sensing modules 132 can be anywhere from two or more, not just the three shown in the previously mentioned embodiments. Thereby, the system 100 can provide a variable level of precision with respect to the ability to monitor a gas generation process or storage of a produced gas 196.
[0059] In embodiments, each optical sensing module 132 includes a light emitter 134 which transmits directed illumination, such as a light beam of a specific wavelength or within a specific wavelength range or band, through the inner chamber 114 of the vessel 110 and into a light receiver 138, such as a photodetector, which converts light into an electrical signal associated with an absorbance measurement. The light receiver 138 is disposed in the path 142 of the light beam on an opposed side of the inner chamber 114. In embodiments, the optical sensing modules 132 provide for an indication of the presence of produced gas 196 intersecting the path 142 of the light beam. In further embodiments, the optical sensing modules 132 allows for the determination of concentration of produced gas 196 in the portion of the inner chamber 114 encompassing the path 142 of the light beam.
[0060] In at least one embodiment, a portion of the optical sensing modules 132 may pass through the body 112 of the vessel 110, so that the light therefrom passes directly through the inner chamber 114. However, in other embodiments, the optical sensing modules 132 include a light emitter 134 which produces a light beam and is arranged to transmit that beam through the body 112 of the vessel 110, as indicated in FIG. 4B. In embodiments, the wavelength of the light associated with each optical sensing module 132 may be selected in one of the requisite absorption spectra for the produced gas 196. For example, the light beam produced by the light emitter 134 is within a range of 240 nm to 420 nm in at least one embodiment, as this is in accordance with the gas absorption spectra for chlorine. However, the light beam produced by the light emitter 134 may be within any useful range in accordance with the gas absorption spectra for any other produced gas 196, such as chlorine dioxide, hydrogen sulfide, or others. For example, the light beam could be within the range of 167 nm to 250 nm for hydrogen sulfide and 240 nm to 460 nm for chlorine dioxide. In embodiments, absorbance measurements of the light beam signaled by an associated light receiver 138 can be used to calculate the concentration of produced gas 196 in the path 142 of the light beam. [0061] In various embodiments, the light emitter 134 described above can be an LED 136 which produces a light beam within a specified wavelength range, such as 240 nm to 420 nm, and be contained within a mount 146 affixed to the body 112 of a vessel 110 as shown in FIGS. 4B. Although an LED 136 has been identified as the light emitter 134 in the embodiment of FIG. 4B, any type of light source capable of producing a stable light beam within a useful range could be utilized in other embodiments.
[0062] In embodiments like that of FIG. 4B, the light receiver 138 can be an optical sensor 140, such as a photodetector, which is configured to be sensitive to, i.e., receive and respond to, light within the useful wavelength range and be similarly contained within a mount 146 affixed to the body 112 of the vessel 110. The optical sensor 140, or photodetector, converts photons of the projected light beam into electrical signals in embodiments. The characteristics of the light beam affect the signal in embodiments. The characteristics of the light beam can be affected by absorption or scattering as the light beam passes through the produced gas 196 in the inner chamber 114 along the path 142 in such embodiments. The resulting light beam detected by the optical sensor 140 produces a signal in accordance with the affected characteristics of the light which provides an absorbance measurement in such embodiments.
[0063] In use, the relationship of absorbance to the concentration of a produced gas 196 can be determined empirically, in particular embodiments. For example, pure chlorine gas (with a concentration of 100%) can be introduced into the path 142 of the light beam of an optical sensing module 132. From the absorbance measurement and known properties of the optical sensing module 132, such as the length of the path 142, a constant relationship (such as a molar attenuation constant) can be determined. Thereby, the now empirically determined relationship can be utilized to calculate the concentration for the produced gas 196 with the optical sensing module 132.
[0064] In certain embodiments, the optical sensing modules 132 can include a band-pass filter 144 adjacent the light receiver 138 in the path 142 of the light beam and held within the mount 146, shown in FIG. 4B. Band-pass optical filters 144 are used to selectively transmit light within a portion of the light spectrum while rejecting all other wavelengths. The band-pass optical filter 144 identified in FIG. 4B, provides filtering to reduce the effects of ambient light not associated with the range of the light beam on the optical sensor 140. In embodiments, the use of such a bandpass optical filter 144 increases the signal to noise ratio, producing more reliable results from the optical sensor 140. Indeed, the materials the band-pass optical filter 144 is made of or with can vary to provide the ability to allow the transmission of light within a select range of wavelengths, such as a range particularly useful to the detection of a particular produced gas 196 in embodiments. Moreover, the materials the band-pass optical filter 144 is made of can vary to provide a desired optical density, to enhance the signal to noise ratio in embodiments.
[0065] In various embodiments, at least portions of the body 112 of the vessel 110 might be transparent or translucent to at least light within the utilized wavelength range. In embodiments, these may be select portions of the body 112, like windows that are disposed on opposed sides of the body 112 and allow for the light from the optical sensing modules 132 to pass therethrough and through the inner chamber 114. However, in at least one embodiment, the entire body 112 may be transparent or translucent as in FIG. 3A to light within the utilized wavelength range. Moreover, in embodiments a transparent or translucent vessel 112 may be disposed within a room or area separate from light sources that generate light within the utilized wavelength range to prevent noise in the readings of the light receiver 138. As also shown in Fig. 4B, the optical sensing module 132 may further include an illumination irradiance sensing window 148 and feedback optical sensor 150 within the illumination mount 146 to receive light from the light emitter 134 in embodiments. In such embodiments, a process control system 164, discussed below, may receive signals from the illumination irradiance feedback optical sensor 150 and calibrate the absorbance measurements based thereupon thereby enhancing the signal to noise ratio associated with the optical sensing module 132. Similarly, it is also foreseen that, in certain embodiments, the absorbance measurements might also be compensated to account for ambient light. Such compensation might further be aided by other optical sensors capable of determining ambient light conditions whereby compensation might be based on signals therefrom in embodiments.
LIQUID LEVEL SENSORS
[0066] In embodiments, the system 100 has at least one liquid level sensor 152 to provide indication of liquid at or above a specified level within the vessel 110. As briefly touched on before, the gas retrieval port 130 is preferably located at or above the highest liquid level in embodiments. In embodiments, one or more liquid level sensors 152 are utilized to facilitate the identification of that liquid level and to allow the drain line fluid control system 182 to move liquid 198 from the inner chamber 114 to the drain system 192, thereby keeping the liquid level below that highest allowable point. While a single liquid level sensor 152 may be utilized, preferably an embodiment would utilize at least 2 liquid level sensors, a low indicating the presence of any liquid 198, and a high indicating the need to remove liquid 198, as in FIGS. 3A, 3B, 4A, and 5. In further embodiments, additional liquid level sensors 152 might be utilized to provide precision with respect to the amount or level of liquid in the vessel 110. Additionally, additional liquid level sensors 152 can also provide indications of a leak, or defective equipment, if a known volume of liquid is introduced to the vessel 110 and is expected to reach a calculated height but fails to reach such a level within the inner chamber 114. In embodiments, the liquid level sensor 152 can be a float switch 154, as in FIG. 3 A. However, the liquid level sensor 152 may be some other useful alterative in other embodiments.
[0067] In embodiments, the gas retrieval port 130 is disposed between a high liquid level sensor 152 and the lowest optical sensing module 132 in FIG. 3 A, to ensure the system identifies circumstances where gas, specifically gas that is heavier than air or another gas in the chamber that it is displacing, is actually present to be removed. Moreover, the input ports 124, such as the reagent ports 126 and water port 128 are disposed at the same level as the highest liquid level sensor 152 in FIG. 3A, to indicate when the liquid 198 level rises to meet those input ports 124.
ADDITIONAL PROBES
[0068] In embodiments, the system 100 further comprises one or more additional probes, i.e., sensors which provide feedback, that determine information useful to the gas generation process or storage of a produced gas 196. In embodiments, these probes may form part of a reaction monitoring system utilized to identify and manipulate characteristics of a reaction, such as the rate of bubble formation during gas generation processes. For example, in embodiments, the system 100 may utilize a pH probe 156 mounted through a portion of the vessel 110, such as the bottom 118, to monitor the pH of the liquid 198, as FIG. 4A, and, thereby, the reaction of the reagents 200 to form a gas 196, such as chlorine, and/or the necessity for a moderator, like water 202. Indeed, the rate of progress of the gas generation process may be monitored through the pH of the liquid 198 and can indicate when a liquid 198 should be removed, in embodiments. In addition or in place of the pH probe 156, a temperature and/or pressure probe may be utilized to provide information about a reaction in embodiments. Indeed, in certain embodiments, a pH, temperature, and/or pressure probe may be required to ensure that the liquid 198 is safe to be drained. Moreover, as relating to bubble formation specifically, an accelerometer, microphone, or some optical system could be utilized to provide feedback on the rate of the gas generation reaction. For example, an microphone sensor may be utilized in embodiments to utilize the different acoustic impedance of sound in liquid and gas to provide feedback on bubbling. Compared with an optical bubble sensor, a microphonic based sensor has no strict requirements on the color, transparency and light transmittance on the body of a vessel, and has no requirements on the light transmittance and transparency of the liquid. Moreover, in certain gas generation processes an optical bubble sensor, such as a camera or plethora of cameras, can be utilized with or in place of any other sensor to provide further feedback. For example, an optical system can track a fluid level and/or visibility through a liquid, at moments when reagents and other liquids are not being added, to identify that air bubbles are forming. Indeed, in embodiments, an optical level sensor could detect turbulence of the liquid level indicating bubbling in conjunction with a camera system detecting the visibility of a visual indicator through the liquid which can be impeded by bubbling.
[0069] In embodiments, the feedback from the sensors mentioned above (pH, temperature, pressure, accelerometer, microphone, or optical sensors) or other sensors can provide important information about the gas production process, including the rate of reaction based on the rate of bubble formation. This particular feedback, in embodiments, can inform the addition of reagents, to prolong or speed up a reaction, the introduction of additional substances to moderate or stop a reaction, like water in a chlorine gas generation process, and/or appropriateness of draining liquid, such as when the reaction is completed. In embodiments, this feedback may be utilized in conjunction with the process control system 164, discussed below, to control operation of various input fluid control systems 180, the operation of the drain line fluid control system 182, or even the potential operation of the vent fluid control system 186, such as in the case of a runaway reaction.
PROCESS CONTROL SYSTEM
[0070] In embodiments, the system 100 further comprises a process control system 164, as shown in FIG. 2, to receive all data generated by the optical sensing modules 132 and sensors, provide a vessel state 172, accept user input 174 — including requests for the delivery of produced gas 196 — and generate activation instructions for the various fluid control systems. While the prior described system 100 could be utilized in a user-monitored and user-operated fashion, a computing device may be utilized as a process control system 164 to provide for precise monitoring and automated activation of various portions of the system 100 in embodiments. In FIG. 2, data connections are shown through the dashed lines and certain data objects, identified below, are shown in accordance with certain data connections between the process control system 164 and particular components.
[0071] As shown in FIG. 2, one embodiment of the system 100 comprises a process control system 164 which receives absorbance data 158 from the optical sensing modules 132, fluid height data 160 from the liquid level sensors 152, and pH data 162 from a pH probe 156. In embodiments utilizing temperature probes, pressure probes, and bubble detection systems (accelerometer, microphone, and optical sensors) that data would also be provided to the process control system 164. The process control system 164, in embodiments, can store the data received, and is configured to produce a gas status 166 from the absorbance data 158, a liquid level status 168 from the fluid height data 160, and a reaction status 170 from the pH data 162.
[0072] With respect to the gas status 166, the absorbance data 158 can provide an indication of the presence of produced gas 196 at a particular level, and a concentration 178 in certain embodiments. In at least one embodiment, the gas status 166 could indicate that the vessel 110 is empty if the none of the optical sensing modules return absorbance data indicating the presence or concentration of produced gas, that the vessel is under-filled based on particular absorbance data from just one of the optical sensing modules (such as the lowest in the case of chlorine gas), that the vessel is full based on particular absorbance data from two of the optical sensing modules (such as the low and middle for chlorine gas), and that the vessel is over-full based on the absorbance date from all three of the optical sensing modules (such as the low, middle, and high).
[0073] With respect to the liquid level status 168, the fluid height data 160 can provide an indication of liquid 198 at or above a particular level. In at least one embodiment, the liquid level status 168 could indicate that the liquid level is low or high based on the fluid height data 160 received from a single level sensor 152, such as one disposed at the level of the input ports 124. In the embodiment of FIG. 2, the liquid level status 168 could indicate that the liquid level is empty based on the lack of fluid height data 160 from the lowest liquid level sensor 152, low based on fluid height data indicating the presence of fluid at the lowest liquid level sensor 152 but not the highest liquid level sensor 152, and high if both low and high liquid level sensors 152 indicate the presence of fluid in their fluid height data 160.
[0074] With respect to the reaction status 170, the pH data 162 can provide indication of whether a reaction is occurring based on whether or not the pH meets a threshold requirement in embodiments. Moreover, in embodiments, the rection status 170 could be based on data from other probes or, in place or in addition to the pH probe 156, as has been discussed previously above. That is, the reaction status 170 may be determined by data from a number of probes and sensors, beyond just the pH data 162, and the reaction status 170 can include or incorporate the rate of reaction, as indicated by bubble formation.
[0075] In embodiments, the process control system 164 is configured to generate a vessel state 172 from one or more of the gas status 166, liquid level status 168, and reaction status 170. In certain embodiments, the vessel state 172 can automatically trigger certain activation instructions 176. For example, a vessel state 166 associated with an over-full gas status 166 could automatically trigger activation instructions 176 to the vent fluid control system 186 to evacuate some or all of the produced gas 196 to the evacuation system 188 in embodiments. Similarly, a vessel state 166 associated with a high liquid level status 168 could automatically trigger activation instructions 176 to the drain line fluid control system 182 in embodiments. However, in embodiments, the activation instructions 176 could be delayed by a reaction status 170 indicating that a reaction is still occurring and that the liquid 198 might not be suitable for removal at that time. Moreover, activation instructions 176 can also be generated by the process control system 164 based on user input 174, in addition to or in place of the vessel state 172 in embodiments. Indeed, the process control system 164 may generate activation instructions 176 for a gas retrieval fluid control system 184 based on user input 174 requesting produced gas 196 be sent to the use system 190 in embodiments. Moreover, the process control system 164 may generate activation instructions 176 for one any of the other fluid control systems based on user input 174 and the vessel state 172 in embodiments. Indeed, the process control system 164 may generate activation instructions 176 for both the vent fluid control system 186 and drain line fluid control system 182 upon user input 174, pending the vessel state 172 associated with a stopped reaction status 170, in embodiments. Thereby, the vessel might be serviced or placed in a standby mode without a risk of a hazardous release of produced gas. Moreover, activation instructions 176 from user input 174 for the input fluid control system 180 may be delayed based on the indication of a vessel state 172 associated with a high liquid level status 168.
[0076] In embodiments, the process control system 164 can also provide for automated monitoring during storage circumstances, to monitor for a vessel state 172 change that might indicate the presence of a leak. Additionally, the process control system 164 may be connected with other sensors which may inform automatic issuance of activation instructions 176, such as chlorine sensors being triggered in a room in which the vessel is stored leading to activation instructions 176 for the vent fluid control system 186. Additionally, the process control system 164 may be tied to flow rate sensors, valves 204 and pumps 206 to facilitate the monitoring of the amount of fluids transferred relative to the vessel 110, giving some indication of amounts in portions of the system which might be useful to a user.
USE EMBODIMENT
[0077] In an embodiment of use, the system 100, such as that of FIGS. 1-5, might be utilized to generate and store a produced gas 196 heavier than air, such as chlorine, chlorine dioxide, hydrogen sulfide, and the like. In one embodiment, the process control system 164 might determine that the inner chamber 114 of the vessel 110 is empty based on a vessel state 172 associated with an empty gas status 166 and empty liquid level status 168. Based on the empty vessel state 172 and user input 174 requesting the generation of gas, the process control system 164 might generate activation instructions 176 for the input fluid control system 180 to introduce controlled doses of reagents 200, such as sodium hypochlorite and hydrochloric acid if producing chlorine gas, and water 202. Thereafter, fluid height data 160 from the low liquid level sensor 152 might identify that enough liquid 198 has been added to pass its level and pH data 162 from the pH probe 156 can indicate the presence of a reaction, such as the reaction to create chlorine gas. Thereafter, the input fluid control system 180 may further be signaled to introduce controlled doses until a vessel state 172 associated with a full gas status 166 is identified or enough liquid 198 has been added to reach the high liquid level sensor 152 and an associated vessel state 172 is generated. Given one of the conditions above, the process control system 164 produces activation instructions 176 to the input fluid control system 180 to stop introducing any more reagents 200 and water 202 and wait until the pH probe 156 (and/or other sensors relating to the reaction) registers the reaction is stopped, such as registering a pH of 7 or the lack of bubbling in the liquid 198. If, during that period, a vessel state 170 associated with an over-full gas status 166 is generated, the process control system 164 can activate one of the vent fluid control system 186, and potentially the gas retrieval fluid control system 184, to remove produced gas 196. The removal through the gas vent port 12 and/or the vent port 120 can be to the evacuation system 188 which stores, dissipates, neutralizes, or otherwise renders the produced gas 196 harmless. Otherwise, produced gas 196 can be stored in the vessel 110, awaiting user input 174 for an amount to be sent to one or more use systems 190 through the gas retrieval port 130. For example, a hypochi orous acid production system utilizing chlorine gas might be connected in fluid communication with the gas retrieval port 130 and a specific amount of chlorine gas from the vessel 110 might be requested through the process control system 164. Upon user input 174, the process control system 164 might generate activation instructions 176 for the gas retrieval fluid control system 184 to deliver an amount of gas to a container, process, or system in fluid communication with the gas retrieval port 130.
[0078] As the produced gas 196 is transferred, the level in the vessel 110 may generate a underfull vessel state 172. In response, the process control system 164 might further generate activation instructions 176 for the input fluid control system 180 to input reagents 200 to produce additional gas, as long as a vessel sate 172 associated with a high liquid level status 168 is not identified. In anticipation for additional gas production and the addition of more liquid 198, the process control system 164 might generate activation instructions 176 for the drain line fluid control system 182 to remove liquid 198 from the bottom 118 of the vessel 110. Such removal might be also be pending a vessel state 172 associated with a stopped reaction status 170 specifying pH data 162 registering a specified pH reading or upon condition that the pH reading is acceptable and there is an anticipated introduction of reagents 200 and water 202. The introduction of additional reagents 200 may then continue until a vessel state 172 associated with full gas status 166 is identified or an amount of liquid 198 has been added to reach the high liquid level sensor 152. In embodiments, the vessel state 172 may indicate that the gas status 166 is full but a reaction is occurring, such as by certain pH data 162 or other probe/sensor input (such as sensing bubbles), and that a moderator, such as water 202, needs to be input.
[0079] Upon user input 174 requesting to empty the vessel 110, produced gas 196 may be removed through the vent port 120, and optionally the gas retrieval port 130, until a vessel state 172 associated with an empty gas status 166 is identified. Thereafter, pending a vessel state 172 associated with a stopped reaction status 170, such as having acceptable pH data 162, the process control system 164 generates activation instructions for the drain line fluid control system 182 to remove liquid 198 from the bottom 118 of the vessel 110 until the vessel 110 is empty. Thereby, the vessel 110 might be serviced or placed in a standby mode without a risk of a hazardous release of produced gas 196.
[0080] While various features and elements have been described in general above, it is to be understood that no limitation of the scope of this disclosure is hereby intended. Thereby, elements and features might be utilized in any combination and for any embodiment to which it is particularly useful.
[0081] Any dimensions expressed or implied in the drawings and these descriptions are provided for exemplary purposes. Thus, not all embodiments within the scope of the drawings and these descriptions are made according to such exemplary dimensions. The drawings are not made necessarily to scale. Thus, not all embodiments within the scope of the drawings and these descriptions are made according to the apparent scale of the drawings with regard to relative dimensions in the drawings. However, for each drawing, at least one embodiment is made according to the apparent relative scale of the drawing.
[0082] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
[0083] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present inventive subject matter. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0084] It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
[0085] It will be understood that when an element or layer is referred to as being “on” another element or layer, the element or layer can be directly on another element or layer, or intervening elements or layers may also be present. In contrast, when an element is referred to as being “directly on” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0086] Spatially relative terms, such as “below,” “beneath,” “lower”, “above”, “upper”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. Throughout the specification, like reference numerals in the drawings denote like elements.
[0087] Embodiments of the inventive subject matter are described herein with reference to plan and perspective illustrations that are schematic illustrations of idealized embodiments of the inventive subject matter. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, the inventive subject matter should not be construed as limited to the particular shapes of objects illustrated herein, but should include deviations in shapes that result, for example, from manufacturing. Thus, the objects illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the inventive subject matter.
[0088] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present inventive subject matter. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” “comprising,” “includes” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0089] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this present inventive subject matter belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. The term “plurality” is used herein to refer to two or more of the referenced items. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are now described.
[0090] In the drawings and specification, there have been disclosed typical preferred embodiments of the inventive subject matter and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the inventive subject matter being set forth in the following claims.
[0091] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the forms herein disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.