RU2795107C2 - Wireless monitoring and profiling of reactor parameters using multiple sensor-equipped rfid tags and multiple transceivers - Google Patents

Abstract

FIELD: wireless monitoring.

SUBSTANCE: invention relates to a system and a method for wireless monitoring the process parameters inside a reactor vessel via a wireless communication channel. The technical result is achieved by implementing a system for wireless monitoring and profiling of process parameters inside the reactor chassis, containing plenty of radio frequency identification (RFID) tags equipped with a sensor, placed throughout the catalyst bed in the vessel and used to determine various parameters inside the vessel. Sensor-equipped RFID tags are encoded with immutable identification numbers and wirelessly linked to transceivers, enabling triangulation techniques to be used to determine and profile process parameters throughout said reaction zone.

EFFECT: ability to make three-dimensional profiles of the determined parameters of the working medium inside the reaction zone of the reactor.

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Description

[0001] This application claims priority under pending US Provisional Application No. 62/616,155, filed January 11, 2018, the contents of which are incorporated herein in their entirety by reference.

FIELD OF TECHNOLOGY

[0002] The present invention relates to a system and method for wireless monitoring and 3D profiling of parameters within a process vessel, such as a reactor.

BACKGROUND OF THE INVENTION

[0003] For refineries and chemical plants, reactors containing a catalyst are common. In the operation of such reactors, it is necessary to determine or control the process parameters inside the reactor vessel, since such information can help control the conditions for the chemical reaction to occur inside the reactor vessel. Existing methods for determining the parameters inside the reactor vessel require a physical connection, including an electrical or pneumatic connection, with a sensor that transmits the data received by the sensor for external display. One example of such measuring devices is the use of thermocouples to determine temperature. The use of a thermocouple to measure temperature at a location within the reactor pressure vessel requires a thermocouple sheath. The thermocouple sheath passes through the wall of the housing and reaches a location where the temperature inside the housing is measured.

[0004] It is desirable to be able to measure and monitor process parameters at locations within the reactor vessel and transmit data wirelessly to be collected and processed at a remote location. In addition, it is desirable to be able to create a three-dimensional profile of the parameters throughout the volume of the reaction zone formed in the housing. To this end, the use of sensor-equipped radio frequency identification (RFID) tags is proposed to measure several parameters in the reactor volume, including pressure, temperature, fluid chemistry, vapor and liquid chemistry, pH and flow rate, and wireless transmission of measured data for their remote collection and processing.

[0005] An example of a sensor-equipped RFID tag for measuring work environment parameters is described in US 7,397,370. This patent provides a system that monitors the working environment using a plurality of radio frequency identification ("RFID") nodes. The system may include an RFID tag with a unique identification ("HO") number assigned to it, configured with a sensor for measuring data regarding the working environment and an antenna for wirelessly transmitting the measured data to the processing system. The transmitted information received by the processing system contains measured data about the working environment together with the assigned identification number, and is processed to perform monitoring of the working environment and changes in the controlled working environment.

[0006] The use of sensor-equipped RFID tags to measure and track work environment variables is described in yet another US 8,106,778. This patent discloses a method and system that provides the ability to track variables using radio frequency identification (RFID). An RFID tag with a sensor is used to measure a variable, including location, temperature, pressure, and humidity. In response to the interrogation signal transmitted by the RFID reader, the RFID tag with the sensor transmits a signal that contains the identification data assigned to the tag with variable data characterizing the measured parameter. This response contains both variable data and non-variable data so that the measured parameters can be associated with the tag's identity. The RFID reader may also receive a plurality of response signals, each of which is transmitted from one of the plurality of RFID tags. In this case, at least one of the plurality of response signals may comprise variable data indicative of a measured parameter on a respective one of the plurality of RFID tags and identification data of the respective one of the plurality of RFID tags.

[0007] Published patent application US 2007/0215709 describes an RFID-based sensor that includes an RFID electronic circuit integrated with the sensor. The sensor element of the sensor is configured to change the state of conductivity when exposed to the physical parameters of the external environment in which the sensor is located. Such physical parameters may include the presence or absence of gas, light, sound, temperature, pressure, moisture and/or other parameters of the working environment. In response to the RF signal transmitted by the RFID interrogator, the RFID-based sensor transmits, for reception by the RFID interrogator, an identification (ID) number and other data related to the current or previous exposure of the RFID-based sensor to one or more physical parameters. An RFID-based sensor can also be powered by RF energy transmitted by an RFID interrogator.

[0008] US Pat. No. 9,317,795 describes an RFID sensor system comprising an array of sensor elements located on a surface. Each sensor element contains an RFID chip, an antenna operatively coupled to the chip, and a pressure-responsive material located on the antenna. The RFID reader system provides an interrogation signal to each sensor element, which, when pressure is applied to the pressure-responsive material of the pad sensor element, transmits the signal back to the RFID reader via an associated antenna.

[0009] In these publications, there is no description or proposal for the use of sensor-equipped RFID tags to measure process parameters or the working environment inside the reactor vessel or wirelessly transmit data related to the measured parameters inside the reactor vessel for their further reception, processing and use. In addition, these publications lack a description or any information about the provision of wireless monitoring and compilation of three-dimensional profiling of physical parameters inside the reaction zone formed in the reactor vessel.

[0010] At the same time, the present invention provides a system and method that provides for the local perception or measurement of parameters of the working environment or process at locations throughout the reaction zone of the reactor and the implementation of wireless transmission of sensor-equipped RFID tags to multiple receivers of radio frequency waves containing identification specific label data and data characterizing the measured parameter inside the reactor. This allows three-dimensional profiles of the parameters within the reaction zone to be drawn.

SUMMARY OF THE INVENTION

[0011] In this connection, a system is proposed for wireless monitoring and profiling of process parameters inside a reactor vessel. The reactor vessel of the system forms a reaction zone that contains a catalyst bed containing catalyst particles and a plurality of sensor-equipped RFID tags disposed within the catalyst bed. The system has transceivers that include a first RFID transceiver antenna, a second RFID transceiver antenna, and a third RFID transceiver antenna. The first RFID transceiver antenna is wirelessly connected to each of the plurality of sensor-equipped RFID tags and configured to transmit a first interrogation signal and receive a first RFID tag response signal transmitted in response to the first interrogation signal. The second RFID transceiver antenna is wirelessly connected to each of the plurality of sensor-equipped RFID tags and configured to transmit a second interrogation signal and receive a second RFID tag response signal transmitted in response to the second interrogation signal. A third RFID transceiver antenna is wirelessly connected to each of the plurality of sensor-equipped RFID tags and configured to transmit a third interrogation signal and receive a third RFID tag response signal transmitted in response to said third interrogation signal. Each sensor-equipped RFID tag of the plurality is encoded with a unique immutable identification number and configured to measure a reactor parameter within the reaction zone, receive interrogation signals from transceivers, and, in response to the interrogation signals, transmit RFID tag response signals. RFID tag responses contain data characterizing the unique, immutable identification numbers and reactor parameters associated with sensor-equipped RFID tags. The system provides the definition and compilation of three-dimensional profiles of process parameters throughout the reaction zone.

[0012] A method for wirelessly monitoring and profiling process parameters inside a reactor vessel is also provided. This reactor vessel forms a reaction zone that contains a catalyst bed containing catalyst particles and a plurality of sensor-equipped RFID tags disposed within the catalyst bed. The catalyst bed is characterized by its height and width or diameter. The method includes transmission of interrogation signals by at least three RFID transceiver antennas. Polling signals are received by each sensor-equipped RFID tag. In response to the interrogation signals, each sensor-equipped RFID tag transmits its respective RFID tag response, which contains data indicative of a unique immutable identification number and environmental conditions associated with the sensor-equipped RFID tag. The RFID transmit/receive antennas receive the corresponding RFID tag responses, which are processed to generate 3D process profiles within the reaction zone.

BRIEF DESCRIPTION OF GRAPHICS

[0013] FIG. 1 is a schematic representation of an embodiment of the invention for a system for wireless monitoring and 3D profiling of process parameters within a reactor vessel reaction zone.

[0014] FIG. 2 is a plan view of the cross section A-A of the reactor vessel shown in FIG. 1.

[0015] FIG. 3 is a diagram showing some of the elements of a wireless reactor monitoring and 3D profiling system for process parameters inside the reactor reaction zone. 3 shows one RFID sensor-equipped tag of a plurality of RFID sensor-equipped tags disposed within the catalyst bed and at least three RFID readers/interrogators that are wirelessly connected to the sensor-equipped RFID tag. The RFID readers/interrogators are connected to a computer system for processing the data contained in the received RF signals transmitted by the sensor-equipped RFID tag.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Embodiments of the invention include both a system and a method for wireless monitoring and 3D profiling of process parameters throughout a reaction zone formed in a reactor vessel.

[0017] Three related provisional patent applications have been filed concurrently with this patent application, entitled "SP2118 - Wireless monitoring and profiling of reactor parameters using a plurality of sensor-equipped RFID tags with known locations", "SP2119 - Wireless monitoring and profiling of parameters reactor using arrays of sensor-equipped RFID tags placed at known heights of the reactor" and "SP2066 - Wireless monitoring system for the reactor using a passive sensor-equipped RFID tag" with serial numbers 62/616.148, 62/616.185 and 62/616.166, respectively.

[0018] Parameters measured inside the reactor vessel may include process or fluid parameters, including pressure or temperature values at various locations within the reactor vessel. The parameters measured may also include other parameters such as vapor and liquid percentages, flow rates, pH, and chemistry of the fluids contained within or passing through the reactor vessel.

[0019] The invention provides for remote sensing of parameters within a reactor with a plurality of sensor-equipped RFID tags distributed throughout the catalyst bed of the reactor, and in one embodiment, they are installed at random or random locations throughout the reaction zone of the reactor vessel. Sensor-equipped RFID tags wirelessly transmit measured data related to the parameters being determined within the reactor by transmitting radio waves in response to interrogation signals transmitted by multiple transceivers of the system.

[0020] The processing system comprises means, such as a computer with appropriate program code, for processing data contained in signals transmitted from a plurality of sensor-equipped RFID tags to generate a three-dimensional profile of parameters inside the reactor vessel. The system does this by means of transceivers and a plurality of sensor-equipped RFID tags, each of the plurality of sensor-equipped RFID tags providing a means for measuring or sensing one or more operating environment parameters present at locations within and throughout the reaction zone and catalyst bed of the housing. reactor.

[0021] As used herein, each of the plurality of sensor-equipped RFID tags is a device that includes a sensor configured with or operatively associated with a passive RFID tag. The sensor provides a means for measuring a condition or parameter of the working environment or process inside the reactor vessel and means for applying to the associated RFID tag an input signal that contains data characterizing precisely the measured parameter or condition. Passive RFID tags known in the art comprise an integrated circuit coupled to the tag antenna for receiving a polling signal from an RFID transceiver antenna (transceiver) and for transmitting a response tag signal in response to the polling signal.

[0022] The processing system is applied to process signals transmitted by sensor-equipped RFID tags. Because sensor-equipped RFID tags are passive, each of them performs an RFID tag response in response to interrogation signals transmitted from multiple RFID transmit/receive antennas of the system. As noted above, each sensor is integrated with an RFID tag and configured to sense one or more parameters within the reaction zone.

[0023] The sensor element of the sensor-equipped RFID tags is selected from the group of any suitable sensors known to those skilled in the art. Examples of conditions or parameters of the working environment sensed or measured by sensors include pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, mechanical vibrations, radiation, magnetic flux, light intensity, conductivity and sound power. Preferred sensor elements include elements selected from the group consisting of temperature sensors, pressure sensors, chemical sensors, humidity sensors, pH sensors, flow sensors, liquid/vapour sensors, and any combination thereof.

[0024] Each integrated sensor and RFID tag, that is, a sensor-equipped RFID tag, provide a means for measuring a reactor parameter, receiving a polling signal, and, in response to the polling signal, transmitting an RFID tag response signal containing data that characterizes the measured reactor parameter. Patent publications US 2013/0057390, US 9,563,833, US 9,412,061, US 9,035,766 and WO 03/098175 provide examples of sensor-equipped RFID tags. These patent publications are incorporated herein by reference.

[0025] A necessary feature of the invention is that each of the sensor-equipped RFID tags of the plurality is encoded with a unique immutable identification number. This is important because, in response to receiving transceiver signals from each of the multiple RFID transceivers, each sensor-equipped RFID tag transmits RFID tag response signals containing the tag's unique identification data along with variable data measured or determined associated with it. sensor. The transmission of data characterizing the unique immutable identification number of the tag, together with variable data characterizing the parameter of the working environment of the reactor measured or perceived by the RFID sensor, ensures that the transmitted variable data is associated with a particular sensor.

[0026] Sensor-equipped RFID tags are placed throughout the catalyst bed within the reaction zone of the reactor. In a preferred embodiment of the invention, multiple sensor-equipped RFID tags are installed within the catalyst bed at random or random locations. Two or more, for example at least three, transceivers are installed inside or outside the reaction zone at locations such that they are wirelessly connected to sensor-equipped RFID tags placed inside the catalyst bed. The transceivers are installed at known locations and known distances from each other so that their interrogation signals, in combination with tag responses from sensor-equipped RFID tags, can be used to obtain distance and angular direction data for sensor-equipped RFID tags relative to the receiver. - transmitters. The distance and angular direction data should be such that a suitable triangulation method can be applied to determine the point locations of each sensor-equipped RFID tag in the three-dimensional space of the reaction zone.

[0027] A unique immutable identification number associated with each RFID sensor-equipped tag allows each RFID sensor-equipped tag to be identified with its point location in three-dimensional space, which is determined using the aforementioned triangulation method. In addition, the use of a unique immutable identification number makes it possible to associate or associate each of the set of sensor-equipped RFID tags with the reactor parameters it perceives. Thus, each RFID tag equipped with a sensor is capable of receiving an interrogation signal from each of two or more transceivers and, in response to these interrogation signals, transmit response RFID tag signals that contain data characterizing both a unique immutable identification number and a measured reactor parameter associated with the sensor-equipped RFID tag. This makes it possible to compose three-dimensional profiles of the measured parameters of the working medium inside the reaction zone of the reactor.

[0028] The reactor vessel of the invention may be any suitable vessel made from any suitable material known to those skilled in the art. In many applications, the reactor vessel typically forms a space in which the catalyst is contained and into which the reactants or feedstock are introduced. In one embodiment of the invention, the reactor vessel forms a reaction zone, within which is a catalyst bed containing catalyst particles. The reaction zone may also contain multiple catalyst beds, including those known as stacked catalyst beds. The filling of the reaction zone can be accomplished with any suitable arrangement of catalyst or catalyst beds, including complete filling with catalyst particles or support particles, or both.

[0029] The reactor vessel may be further equipped with an inlet that provides fluid communication to the reaction zone and means for introducing a feed stream, such as hydrocarbons, into the reaction zone. The reactor vessel may also be equipped with an outlet that provides fluid communication from the reaction zone and a means for withdrawing an effluent stream, such as reaction products, from the reaction zone.

[0030] Any type of feed stream or fluid, including water, hydrocarbons, and other chemicals, can be introduced into or contained in the reaction zone of the reactor vessel. Examples of hydrocarbons include light hydrocarbons, such as compounds containing from 1 to 4 or 5 carbon atoms, aromatics, naphtha, kerosene, diesel fuel, gas oil and heavy fuel oil such as fuel oil. The reaction zone typically contains one or more layers of catalyst particles along with any of the above fluids, which preferably contain any of the listed hydrocarbons.

[0031] The catalyst particles in the reaction zone may be of any size and shape commonly used in the industry, including extrudates of any shape (e.g., cylindrical, bipartite, trilobular, and quadripartite), spheres, spheres, composite aggregates, granules, and powders. The catalyst particle size may range from 0.1 mm to 200 mm, but preferably the catalyst particle size ranges from 0.5 mm to 100 mm or from 1 mm to 20 mm and may be of any composition.

[0032] Representative catalyst compositions contain an inorganic oxide component, such as silica, alumina, aluminosilicate, and titanium dioxide. In addition, the catalyst composition may contain a catalyst metal component such as any of the transition metals, including chromium, molybdenum, tungsten, rhenium, iron, cobalt, nickel, palladium, platinum, gold, silver, and copper. The concentration of metal components in the catalyst particles can be up to 60 wt. % based on the metal, regardless of its actual state, and the concentration of the metal, as a rule, is in the range from 0.1 to 30 wt. % calculated on the metal, regardless of its actual state.

[0033] Of the plurality of sensor-equipped RFID tags, they are positioned at random or random locations within the catalyst bed of the reaction zone such that each of the sensor-equipped RFID tags is surrounded by catalyst particles. For a typical reactor, the catalyst bed is characterized by geometric dimensions in terms of thickness and width. For reactors that can be characterized by thickness and width, the typical catalyst bed thickness ranges from 0.5 meters to 20 meters, and the typical effective catalyst bed width ranges from 0.5 meters to 20 meters. Thus, each of the sensor-equipped RFID tags can be surrounded by a layer or shell of catalyst particles having a thickness of up to 20 meters, which requires the interrogation and response signals of the tag to pass through a layer of catalyst particles from about 0.5 meters to about 20 meters thick.

[0034] In a preferred embodiment of the invention, there are at least three RFID transmit/receive antennas, each of which is wirelessly connected to each of the sensor-equipped RFID tags of the plurality. The transceivers are installed at known locations and at known distances from each other. The data relating to the location of the transceivers, combined with the distance and angular direction data related to the location of each of the plurality of sensor-equipped RFID tags obtained by interrogating them with the transceivers, is used in a triangulation technique to determine a point location. in 3D space of each of the plurality of sensor-equipped RFID tags in the reaction zone or catalyst bed of the reactor.

[0035] In a preferred embodiment, the first RFID transceiver antenna is installed at a known location remote from the sensor-equipped RFID tags within the catalyst bed of the reaction zone; provided that the first RFID transceiver antenna is associated or wirelessly connected to each of the sensor-equipped RFID tags of the plurality. The first RFID transceiver antenna is configured to transmit a first interrogation signal to each of the sensor-equipped RFID tags of the plurality and receive first RFID tag response signals from each of the sensor-equipped RFID tags of the plurality.

[0036] In a preferred embodiment of the system of the invention further comprises a second RFID transceiver antenna installed at a known location remote from the sensor-equipped RFID tags within the catalyst bed of the reaction zone; provided that the second RFID transceiver antenna is associated or wirelessly connected to each of the sensor-equipped RFID tags of the plurality. The second RFID transceiver antenna is configured to transmit a second interrogation signal to each of the sensor-equipped RFID tags of the plurality and receive second RFID tag response signals from each of the sensor-equipped RFID tags of the plurality.

[0037] The system also includes a third RFID transceiver antenna installed at a known location remote from the sensor-equipped RFID tags within the catalyst layer of the reaction zone; provided that the third RFID transceiver antenna is associated or wirelessly connected to each of the sensor-equipped RFID tags of the plurality. The third RFID transceiver antenna is configured to transmit a third interrogation signal to each of the sensor-equipped RFID tags of the plurality and receive third RFID tag response signals from each of the sensor-equipped RFID tags of the plurality.

[0038] The first RFID transceiver antenna, the second RFID transceiver antenna, and the third RFID transceiver antenna are installed at known locations and known distances relative to each other or a reference point and relative to the sensor-equipped RFID tags of the plurality thereof, so that for triangulation can be used to determine the pinpoint location of each of the sensor-equipped RFID tags in the three-dimensional space of the reaction zone of the reactor.

[0039] It is preferable to install RFID transceiver antennas inside the reaction zone, since this eliminates the need for the polling and response signals of the tag to pass through the wall of the reactor vessel. However, in another embodiment of the system according to the invention, the RFID transmit/receive antennas are installed or placed outside the reactor vessel.

[0040] The RFID transceiver antennas are operatively connected to one or more readers that provide interrogation signals to the RFID transceiver antennas of the readers and receive RFID tag response signals transmitted by each of the sensor-equipped RFID tags of the plurality. The computer means processes the data carried by each of the RFID tag responses and displays or otherwise outputs data related to the three-dimensional parameter profiles throughout the reaction zone.

[0041] Consider FIG. 1, which is a schematic representation of an embodiment of the invention for a system 10 for wireless monitoring and profiling of process parameters within a reactor vessel 12. The reactor body 12 forms a reaction zone 14. The reaction zone 14 contains a catalyst bed 16 which is filled with and contains catalyst particles 18. The reactor vessel 12 is equipped with an inlet 22 that is operatively connected to conduit 24. The inlet 22 provides a means for fluid communication through conduit 24 and a means for introducing feed into reaction zone 14. Reactor vessel 12 is also equipped with an outlet 26 operably connected to conduit 28 and providing means for fluid communication through conduit 28 and means for withdrawing effluent from reaction zone 14.

[0042] FIG. 1 shows one embodiment of a system 10 of the invention that includes a first RFID transceiver antenna 32, a second RFID transceiver antenna 34, and a third RFID transceiver antenna 36 disposed in a reaction zone 14. The RFID transceiver antennas are mounted in a three-dimensional space of the reaction zone 14 at known locations and at known distances from each other.

[0043] Although in FIG. 1 shows that each of the RFID transceiver antennas is installed within the reaction zone 14, alternatively, one or more of the RFID transceiver antennas may be installed at locations external to the reactor vessel 12. However, it is important to place the RFID transceiver antennas in such a way that they are associated or connected wirelessly with each RFID tag equipped with a sensor 40 of the plurality of RFID tags equipped with a sensor 40 distributed throughout the reaction zone 14 and located inside the catalyst layer 16.

[0044] Although the first RFID transceiver antenna 32 is shown located above the surface 41 of the catalyst layer 16, it will be understood that the first RFID transceiver antenna 32 may be placed anywhere within the reaction zone 14, including within the boundaries of the location and surrounded by particles of the catalyst layer 16 of the catalyst. This also applies to the second RFID transceiver antenna 34 and the third RFID transceiver antenna 36, which are shown below the catalyst layer 16 . These RFID transmit/receive antennas may also be installed anywhere within the reaction zone 14, including within the boundaries of the location and surrounded by the catalyst particles of the catalyst bed 16. As noted above, in each case where the transceiver is placed, it must be wirelessly connected to each sensor-equipped RFID tag 40 of the plurality of sensor-equipped RFID tags 40.

[0045] FIG. 2 is a plan view of the cross section 2-2. The positions of each sensor-equipped RFID tag 40 are shown in FIG. 1 and FIG. 2, which illustrate how a plurality of sensor-equipped RFID tags 40 can be placed or installed at random or random locations throughout catalyst bed 16.

[0046] In operation of the system 10 of the invention, the first RFID transceiver antenna 32 transmits the first interrogation signal 42 to each of the plurality of sensor-equipped RFID tags 40 . This is shown in FIG. 1 with the arrow 42 symbolizing the radio frequency wave transmitted from the first RFID transceiver antenna 32 to one of the sensor-equipped RFID tags 40 of the plurality of sensor-equipped RFID tags 40. However, it is generally accepted that the first interrogation signal 42 is a radio wave that is simultaneously transmitted to all sensor-equipped RFID tags 40 in the plurality distributed throughout the catalyst bed 16 .

[0047] Each of the plurality of sensor-equipped RFID tags 40 receives a first polling signal 42 . In response to the first interrogation signal 42, each sensor-equipped RFID tag 40 respectively transmits its first corresponding RFID tag response signal 44, which contains data indicative of a unique immutable identification number encoded in a particular sensor-equipped RFID tag 40 and data indicative of a variable of the reactor, sensed or measured by and associated with the sensor-equipped RFID tag 40 . The first corresponding RFID tag response 44 is received by the first RFID transceiver antenna 32 and processed by the signal processing system 46 .

[0048] FIG. 1, the first corresponding response signal 44 of the RFID tag is shown by the arrow symbol of the RF wave coming from one of the plurality of sensor-equipped RFID tags 40. It should be understood that each of the sensor-equipped RFID tags 40 will transmit its own individual first corresponding RFID tag response 44 that carries a unique immutable identification number and sensor variable data indicative of the reactor variable sensed or measured by the sensor-equipped RFID tag 40 and associated with her.

[0049] Like the first RFID transceiver antenna 32, similarly, the second RFID transceiver antenna 34 and the third RFID transceiver antenna 36 are individually configured with respect to the plurality of sensor-equipped RFID tags 40. Thus, the second RFID transceiver antenna 34 performs the transmission of the second interrogation signal 48 to each of the plurality of sensor-equipped RFID tags 40 . This is shown by the arrow symbol of the radio frequency wave passing from the second RFID transceiver antenna 34 to one of the sensor-equipped RFID tags 40 of the plurality of sensor-equipped RFID tags 40. However, it should be noted that the second interrogation signal 48 is a radio wave that is simultaneously transmitted to all sensor-equipped RFID tags 40 in the plurality distributed throughout the catalyst bed 16 .

[0050] Each of the plurality of sensor-equipped RFID tags 40 receives a second polling signal 48 . In response to the second interrogation signal 48, each sensor-equipped RFID tag 40 respectively transmits its second corresponding RFID tag response signal 50, which contains data indicative of the unique immutable identification number encoded in the particular sensor-equipped RFID tag 40 and data indicative of a variable of the reactor, sensed or measured by and associated with the sensor-equipped RFID tag 40 . The second corresponding RFID tag response signal 50 is received by the second RFID transceiver antenna 34 and processed by the signal processing system 46 .

[0051] The third RFID transceiver antenna 36 performs transmission of the third interrogation signal 52 to each of the plurality of sensor-equipped RFID tags 40 . This is shown by the arrow symbol of the radio frequency wave passing from the third RFID transceiver antenna 36 to one RFID sensor tag 40 of the plurality of RFID sensor tags 40. However, it should be noted that the third interrogation signal 52 is a radio wave that is simultaneously transmitted to all sensor-equipped RFID tags 40 in the plurality distributed throughout the catalyst bed 16 .

[0052] Each sensor-equipped RFID tag 40 of the plurality receives a third polling signal 52. In response to the third interrogation signal 52, each sensor-equipped RFID tag 40 respectively transmits its third corresponding RFID tag response signal 54, which contains data indicative of the unique immutable identification number encoded in the particular sensor-equipped RFID tag 40 and data indicative of a variable of the reactor, sensed or measured by and associated with the sensor-equipped RFID tag 40 . The third corresponding RFID tag response signal 54 is received by the third RFID transceiver antenna 36 and processed by the signal processing system 46 .

[0053] The first RFID transceiver antenna 32, the second RFID transceiver antenna 34, and the third RFID transceiver antenna 36 are operatively connected to the signal processing system 46 via cables 56, 58, and 60, respectively. The signal processing system 46 provides means for providing interrogation signals to the RFID transceiver antennas and means for processing RFID tag response signals received by the RFID transceiver antennas.

[0054] Signal processing system 46 includes one or more readers 62 coupled to one or more computers 64 via cable 66 that provides a means for communication between readers 62 and computers 64. Computers 64 provide a means for processing first responses. RFID tag signals 44, second RFID tag response signals 50, and third RFID tag response signals 54 received respectively by the first RFID transceiver antenna 32, the second RFID transceiver antenna 34, and the third RFID transceiver antenna 36. Computers 64 provide output data 68 relating to the measured fluid parameters throughout the reaction zone 14 and three-dimensional profiles of the measured fluid parameters throughout the reaction zone 14 for display or storage in a memory device or in any other suitable form.

[0055] FIG. 2 is a plan view of the cross section A-A of the reactor vessel 12 shown in FIG. 1. In FIG. 2 shows how each of the plurality of sensor-equipped RFID tags 40 may be installed at random, random, or random locations within the reaction zone 14 of the reactor vessel 12. In the context of this document, when referring to arbitrary or random locations of sensor-equipped RFID tags 40, it is understood that they can be distributed throughout the catalyst layer 16 without regard to any particular pattern or order. Thus, sensor-equipped RFID tags are not necessarily arranged according to an ordered pattern. In one embodiment of the invention, the sensor-equipped RFID tags 40 are substantially evenly or evenly distributed throughout the catalyst bed 16 at random locations.

[0056] FIG. 3 is an enlarged portion of the diagram comprising a single sensor-equipped RFID tag 40 of a plurality of sensor-equipped RFID tags 40 surrounded by a working environment 70 of catalyst particles 18. In addition, FIG. 3 shows communication with some other elements of the system 10 of the invention, including a first RFID transceiver antenna 32, a second RFID transceiver antenna 34, a third RFID transceiver antenna 36, and a signal processing system 46.

[0057] The sensor-equipped RFID tag 40 includes a passive RFID tag 72 comprising an integrated circuit 74. The integrated circuit 74 stores an immutable identification number that characterizes and is assigned to a particular sensor-equipped RFID tag 40. Sensor-equipped RFID tag 40 further receives variable input data from sensor 76 that is indicative of at least one parameter of operating environment 70.

[0058] Sensor 76 is configured with passive RFID tag 72 and is operatively connected to passive RFID tag 72 via connection 78. Sensor 76 is configured to sense or detect an operating environment parameter 70 using element 80 or any other suitable sensor means capable of delivering into the integrated circuit 74 of an analog or digital input signal characterizing the measured parameter of the working environment. The integrated circuit 74 modulates the RFID tag response signals 44, 50, and 54 upon receipt of a sensor input via connection 78 such that the RFID tag response signals 44, 50, and 54 contain or carry data indicative of the measured parameter within the operating environment 70. The working medium 70 contains catalyst particles 18 inside.

[0059] The integrated circuit 74 is operatively coupled to the RFID tag antenna 82 providing a means for transmitting RFID tag response signals 44, 50 and 54 which, in addition to the tag's individual identification number data, carry variable input data from the sensor 76 indicative of at least one parameter within the working environment 70, which is adjacent to or surrounds the sensor-equipped RFID tag 40. RFID tag response signals 44, 50, and 54 are transmitted in response to RFID tag antenna 82 receiving polling signals 42, 48, and 52, respectively, from first RFID transceiver antenna 32, second RFID transceiver antenna 34, and third RFID transceiver antenna 36 .

Claims (45)

1. System for wireless monitoring and profiling of process parameters inside the reactor vessel, comprising: said reactor vessel which forms a reaction zone, wherein inside said reaction zone is a catalyst bed containing catalyst particles; a plurality of sensor-equipped RFID tags installed within said catalyst bed; a first RFID transceiver antenna wirelessly connected to each of said plurality of RFID sensor-equipped tags and configured to transmit a first interrogation signal and receive a first RFID tag response signal transmitted in response to said first interrogation signal; a second RFID transceiver antenna wirelessly coupled to each of said plurality of RFID sensor-equipped tags and configured to transmit a second interrogation signal and receive a second RFID tag response signal transmitted in response to said second interrogation signal; And a third RFID transceiver antenna wirelessly connected to each of said plurality of RFID sensor-equipped tags and configured to transmit a third interrogation signal and receive a third RFID tag response signal transmitted in response to said third interrogation signal; wherein each RFID sensor-equipped tag of said plurality is encoded with a unique immutable identification number, and wherein each sensor-equipped RFID tag is configured to measure a response parameter within said reaction zone, receive said first interrogation signal, said second interrogation signal, said third interrogation signal, and, in response to said first interrogation signal, transmit said first RFID tag response signal, and , in response to said second interrogation signal, transmitting said second RFID tag response signal, and in response to said third polling signal, transmitting said third RFID tag response signal; wherein said first, second, and third RFID transceiver antennas are installed at known locations and known distances from each other, so that their interrogation signals, in combination with response signals from sensor-equipped RFID tags, can be used to obtain distance and angle data. directions of sensor-equipped RFID tags with respect to RFID transmit/receive antennas, at the same time, the system is configured to determine the parameters of the technological process and compile their profiles throughout the said reaction zone by triangulation. 2. The system of claim 1 wherein said catalyst particles contain an inorganic oxide component and a metal component. 3. The system of claim 2, wherein each of said sensor-equipped RFID tags from said plurality comprises an RFID tag operably coupled to a sensor means for measuring an operating environment or process parameter and for supplying said RFID tag with an input signal indicative of said operating parameter. environment or process. 4. The system of claim 3 wherein one or more of said RFID transmit/receive antennas are installed within said reaction zone of said reactor vessel. 5. The system of claim 4, wherein said reactor vessel comprises an inlet providing fluid communication for introducing a feed stream into said reaction zone and an outlet providing fluid communication for withdrawing an effluent stream from said reaction zone. 6. The system according to claim 5, in which the said parameter is selected from the group of parameters of the working environment, consisting of pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, mechanical vibrations, radiation, magnetic flux, light intensity flow and sound power. 7. The system of claim 6 wherein each of said RFID transceiver antennas is operatively coupled to a signal processing system providing means for applying said interrogation signals to said RFID transceiver antennas and for receiving said RFID tag response signals transmitted by each of said sensor-equipped RFID tags of said plurality. 8. The system of claim 3, wherein one or more of said RFID transmit/receive antennas are installed outside of said reaction zone of said reactor vessel. 9. The system of claim 8, wherein said reactor vessel comprises an inlet providing fluid communication for introducing a feed stream into said reaction zone and an outlet providing fluid communication for withdrawing an effluent stream from said reaction zone. 10. The system according to claim 9, in which the said parameter is selected from the group of parameters of the working environment, consisting of pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, mechanical vibrations, radiation, magnetic flux, light intensity flow and sound power. 11. The system of claim 10, wherein each of said RFID transmit/receive antennas is operatively coupled to a signal processing system providing means for providing said interrogation signals to said RFID transmit/receive antennas and for receiving said RFID tag response signals transmitted by each of said sensor-equipped RFID tags of said plurality. 12. Method for wireless monitoring and profiling of process parameters inside the reactor vessel, including: providing said reactor vessel that defines a reaction zone, wherein within said reaction zone is a catalyst bed containing catalyst particles and a plurality of sensor-equipped RFID tags disposed within said catalyst bed; wherein each of said sensor-equipped RFID tags of said plurality is encoded with a unique immutable identification number and is further configured to measure environmental conditions within said catalyst bed that are associated with said sensor-equipped RFID tag and, in response to the polling signal, transmit a response signal that contains data characterizing said unique immutable identification number and said environmental conditions associated with it; transmitting, by the first RFID transceiver antenna, a first interrogation signal which is received by each of said RFID sensor-equipped tags; transmitting, in response to the arrival of said first interrogation signal, each of said sensor-equipped RFID tags of its first corresponding RFID tag response received by said first RFID transceiver antenna, which contains data characterizing its unique immutable identification number and the environmental conditions associated with said sensor-equipped RFID tag; receiving said first RFID transceiver antenna of said first corresponding RFID tag response signals; transmitting, by the second RFID transceiver antenna, a second interrogation signal which is received by each of said RFID sensor-equipped tags; transmission, in response to the arrival of said second interrogation signal, of each of said sensor-equipped RFID tags of its second corresponding RFID tag response signal received by said second RFID transceiver antenna, which contains data characterizing its unique immutable identification number and the environmental conditions associated with said sensor-equipped RFID tag; receiving said second RFID transceiver antenna of said second corresponding RFID tag response signals; transmitting, by the third RFID transceiver antenna, a third interrogation signal which is received by each of said RFID sensor-equipped tags; transmission, in response to the arrival of said third interrogation signal, of each of said sensor-equipped RFID tags of its third corresponding RFID tag response signal received by said third RFID transceiver antenna, which contains data characterizing its unique immutable identification number and the environmental conditions associated with said sensor-equipped RFID tag; receiving said third RFID transceiver antenna of said third respective RFID tag response signals; And processing said first respective RFID tag responses, said second respective RFID tag responses, and said third respective RFID tag responses; wherein said first, second, and third RFID transceiver antennas are installed at known locations and known distances from each other, so that their interrogation signals, in combination with response signals from sensor-equipped RFID tags, can be used to obtain distance and angle data. directions of sensor-equipped RFID tags with respect to RFID transmit/receive antennas, at the same time, the process parameters are determined and profiled throughout the reaction zone by triangulation. 13. The method of claim 12 wherein said catalyst particles comprise an inorganic oxide component and a metal component. 14. The method of claim 13, wherein each of said sensor-equipped RFID tags of said plurality comprises an RFID tag operably coupled to a sensor means for measuring a work environment or process parameter and for supplying said RFID tag with an input signal indicative of said work parameter. environment or process. 15. The method of claim 14, wherein one or more of said RFID transmit/receive antennas are installed within said reaction zone of said reactor vessel. 16. The method of claim 15, wherein said reactor vessel comprises an inlet providing fluid communication for introducing a feed stream into said reaction zone and an outlet providing fluid communication for withdrawing an effluent stream from said reaction zone. 17. The method according to p. 16, in which the said parameter is selected from the group of parameters of the working environment, consisting of pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, mechanical vibrations, radiation, magnetic flux, light intensity flow and sound power. 18. The method of claim 17, wherein each of said RFID transmit/receive antennas is operatively coupled to a signal processing system providing means for providing said interrogation signals to said RFID transmit/receive antennas and for receiving said RFID tag response signals transmitted by each of said sensor-equipped RFID tags of said plurality. 19. The method of claim 14, wherein one or more of said RFID transmit/receive antennas are installed outside of said reaction zone of said reactor vessel. 20. The method of claim 19, wherein said reactor vessel comprises an inlet providing fluid communication for introducing a feed stream into said reaction zone and an outlet providing fluid communication for withdrawing an effluent stream from said reaction zone. 21. The method according to claim 20, in which the said parameter is selected from the group of parameters of the working environment, consisting of pressure, temperature, chemical composition, vapor and liquid composition, density, flow rate, pH, mechanical vibrations, radiation, magnetic flux, light intensity flow and sound power. 22. The method of claim 21, wherein each of said RFID transceiver antennas is operatively coupled to a signal processing system providing a means for applying said interrogation signal to said RFID transceiver antennas and for receiving said RFID tag response signals transmitted by each of said sensor-equipped RFID tags of said plurality.

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