BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to control systems in general and, more particularly, to a control system for a solvent-dewaxing unit.
SUMMARY OF THE INVENTION
A system controls a dewaxing unit in which solvent is mixed with waxy oil at some ratio of solvent to waxy oil and the solvent-waxy oil mixture is chilled to some filtering temperature by a chiller to become a slurry mix which is provided to a filter. The filter provides a dewaxed oil and solvent mixture and wax. The control system includes apparatus for controlling the flow rate of the waxy oil and the solvent in accordance with control signals so as to control the solvent-waxy oil dilution ratio. The flow rates of the solvent and the waxy oil are sensed and signals are provided corresponding to the sensed flow rates. A source provides reference signals corresponding to limits for the viscosity of the slurry mix at the filtering temperature. Apparatus determines the viscosity of the waxy oil and the refractive index of the solvent to provide corresponding signals. The temperature of the slurry mix is sensed and a temperature signal is provided. A circuit provides the control signals to the control apparatus in accordance with the sensed flow rate signals, the sensed temperature signal, the refractive index signal and waxy oil viscosity signal so that the apparatus controls the flow rates of the solvent and the waxy oil to achieve a desired viscosity of the slurry mix at the filtering temperature.
The objects and advantages of the invention will appear hereinafter from a consideration of the detailed description which follows, taken together with the accompanying drawings, wherein one embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for illustration purposes only, and are not to be construed as defining the limits of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a simplified block diagram of a control system, constructed in accordance with the present invention, for controlling the dilution ratio of solvent to waxy oil in a dewaxing unit, which is shown in partial schematic form.
FIG. 2 is a diagrammatic representation of the filter shown in FIG. 1.
FIGS. 3 and 4 are detailed block diagrams of the control unit and the set point signal means, respectively, shown in FIG. 1.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a conventional type dewaxing unit in which waxy oil enters by way of a line 3 and co-mingles with a solvent which may be MEK/Toluene, entering by way of a line 5 to form a solvent-waxy oil mixture which is provided to a chiller 8. Chiller 8 chills the solvent-waxy oil mixture to approximately 0.degree.F at which point wax in the waxy oil solidifies. The chilled slurry mix provided by chiller 8 is applied to a filter 9 which removes the wax and provides the dewaxed oil and solvent for further processing. Filter 9 also receives solvent by way of line 10 for use in washing as hereinafter explained.
Referring to FIG. 2, there is shown a representation of filter 9 in which the slurry mix enters a tank 14. Tank 14 holds the slurry mix to a level permitting a drum 18 to have a canvas surface passing through the slurry mix. An internal vacuum is provided in drum 18 which is also continually being washed by wash solvent spray from line 10. As drum 18 rotates its canvas surface passes through the slurry mix, the vacuum draws the liquid portion of the slurry mix through the canvas leaving the wax on the surface of the drum 18. As drum 18 rotates the wax is carried to the top of drum 18 where it is washed by spray solvent from line 10. The wash solvent penetrates through the caked wax and mixes with the solvent dewaxed oil solution inside drum 18. As the drum rotates further, the wax is scraped off by a member 22 leaving a fresh canvas surface to filter more oil.
The present invention controls the dilution ratio of solvent to waxy oil entering chiller 8 so as to control the viscosity of the slurry mix to obtain an optimum condition utilizing the following equations. The dilution D of the slurry mix is the ratio of the solvent flow rate FR.sub.s to the charge waxy oil flow rate FR.sub.c.
A factor X may be determined from equation 2.
the factor X has a relationship to the viscosity V.sub.mo of the slurry mix at 0.degree.F as shown in equation 3.
where J, C, L, H, G and F are defined in the following equations. ##EQU1## where RI is the refractive index of the solvent at 20.degree.C, C is the fractional concentration of MEK in the solvent, K.sub.1 and K.sub.2 are constants having value ranges of 1.3775 to 1.4965 and 0.05 to 0.119, respectively, and preferred values of 1.4965 and 0.119, respectively.
where V.sub.DO is the dewaxed oil viscosity in centistokes and K.sub.3 and K.sub.4 are constants having value ranges 1 to 1.5 and 2 to 3, respectively, and preferred values of 1.054 and 2.5, respectively.
where K.sub.5, K.sub.6 lie within ranges of 2 to 3 and 0 to -10, respectively, and have preferred values of 2.569 and -7.06, respectively.
where K.sub.7, K.sub.8 lie within ranges of 0 to -10 and 0 to 10, respectively and have preferred values of -8.758 and 6.22, respectively.
where K.sub.9, K.sub.10 lie within ranges of 0 to -10 and 0 to 10, respectively, and have preferred values of -4.544 and 3.37, respectively.
where K.sub.11, K.sub.12 lie within ranges of 10 to 20 and -5 to -15, respectively, and have preferred values of 13.482 and -10.16, respectively.
where K.sub.13, K.sub.14 lie within ranges of 0 to -10 and 0 to 10, respectively, and have preferred values of -4.775 and 5.6, respectively.
Further, the viscosity V.sub.mo of the slurry mix at 0.degree.F may be used to determine the viscosity V.sub.mT of the slurry mix at the filtering temperature using equation 11. ##EQU2## where T is the filtering temperature and constants K.sub.15, K.sub.16, K.sub.17 and K.sub.18 lie within ranges of 0 to 1, 50 to 156, 0 to 1 and 0.5 to 1.5, respectively, and have preferred values of 0.69, 100.0, 0.631 and 0.911, respectively.
The dewaxed oil viscosity V.sub.FO may be determined from equation 12. ##EQU3## where V.sub.210 is the Saybolt Viscosity at 210.degree.F of the dewaxed oil, and K.sub.19, K.sub.20 and K.sub.21 are constants within ranges of 0 to 0.5; 10,000 to 12,000 and 35,000 to 40,000, respectively, and have preferred values of 0.21443; 11,219 and 37,755, respectively. The viscosity V.sub.210 may be determined from the sensed Saybolt Viscosity V.sub.wo, at 210.degree.F of the waxy oil using equation 13.
where .DELTA.POUR is the pour point reduction which is the predetermined difference between waxy oil pour and dewaxed oil pour and constants K.sub.22, K.sub.23 and K.sub.24 lie within ranges of 0 to -0.5, 0.5 to 1.5 and 0 to 0.01, respectively, and have preferred values of -0.2055, 1.0432 and 0.001021, respectively.
Wherever a signal or a voltage in the following description corresponds to a term in an equation, it will be identified as that term.
Referring again to FIG. 1, a refractive index meter 30 samples the solvent in line 5 and provides a signal RI corresponding to the refractive index of the solvent to a control unit 31. Meter 30 disposes of the sample solvent as slop. A flow rate sensor 33 in line 5 provides a signal FR.sub.s corresponding to the solvent flow rate to control unit 31.
A viscosity meter 38 samples the waxy oil in line 3 and provides a signal V.sub.wo, corresponding to the viscosity of the waxy oil at 210.degree.F to control unit 31. Meter 38 disposes of the sample waxy oil as slop. A flow rate sensor 43 senses the flow rate of the waxy oil and provides a signal FR.sub.c corresponding to the flow rate of the waxy oil to control unit 31 and to a ratio controller 47. Ratio controller 47 provides signals E.sub.1, E.sub.2 to values 50 and 51, respectively, in lines 3 and 5, respectively, to control the ratio of solvent to waxy oil. Ratio controller 47 receives a signal D.sub.D corresponding to the desired dilution ratio from set point signal means 53. Set point signal means 53 receives signals X, D and V.sub.mT from control unit 31. Signal V.sub.mT is recorded by recording means 54 to provide a visual indication and record of the viscosity of the slurry mix at the filtering temperature.
Referring now to FIG. 3, signal V.sub.wo is supplied to a logrithmic amplifier 60 which provides a signal log V.sub.wo to a multiplier 62 where it is multiplied with a direct current voltage K.sub.23. Another multiplier 63 multipies a direct current voltage K.sub.24 with another direct current voltage E.sub.3, which corresponds to a predetermined pour point reduction .DELTA.Pour. Summing means 66 sums the signals from multipliers 62, 63 to provide a signal to summing means 68 where it is summed with a direct current voltage K.sub.22. Summing means 68 provides a signal log V.sub.210, corresponding to the log of the dewaxed oil viscosity, SUS at 210.degree.F, to an antilog circuit 70. Circuit 70 provides a signal V.sub.210 to multipliers 73, 74, 75.
Multiplier 75 effectively squares signal V.sub.210 and provides it to another multiplier 78 where it is multiplied with signal V.sub.210 so as to effectively cube signal V.sub.210. Summing means 80 sums the signal from multiplier 78 with a direct current voltage K.sub.21 to provide a signal V.sub.210 .sup.3 +K.sub.21.
Multiplier 74 multiplies signal V.sub.210 with a direct current voltage K.sub.20, to provide a signal K.sub.20 V.sub.210. A divider 83 divides the signal from multiplier 74 with the signal from summing means 80 to provide a corresponding signal. Multiplier 73 multiplies signal V.sub.210 with a direct current voltage K.sub.19 to provide a signal K.sub.19 V.sub.210. Subtracting means 85 subtracts the signal provided by divider 83 from signal K.sub.19 V.sub.210 to provide a signal V.sub.DO corresponding to the dewaxed oil viscosity in centistokes.
A natural log function generator 90 receives signal V.sub.DO from subtracting means 85 and provides a signal 1n V.sub.DO, corresponding to the natural log of the dewaxed oil viscosity, to a plurality of multipliers 93 through 98 receiving direct current voltages K.sub.10, K.sub.12, K.sub.14, K.sub.6, K.sub.8 and K.sub.4, respectively, and providing product signals. The product signals from multipliers 93 through 98 are summed with direct current voltages K.sub.9, K.sub.11, K.sub.13, K.sub.k, K.sub.7, and K.sub.3, respectively, by summing means 100 through 105, respectively, to provide signals J, K.sub.o, L, G, H and F, respectively.
Refractive index signal RI is subtracted from a direct current voltage K.sub.1 by subtracting means 110. A divider 111 divides the signal provided by subtracting means 110 by a direct current voltage K.sub.2 to provide a signal C corresponding to the fractional concentration of MEK in the solvent. A multiplier 112 effectively squares signal C to provide a signal C.sup.2.
A multiplier 115 multiplies signal C.sup.2 with signal J to provide a signal JC.sup.2. Another multiplier 117 multiplies signal C with signal K.sub.o to provide a signal K.sub.o C. Summing means 120 sums signal JC.sup.2, signal K.sub.o C and signal L to provide a corresponding signal to a multiplier 122.
A divider 130 divides signal FR.sub.s with signal FR.sub.c to provide a signal D corresponding to the dilution ratio of solvent to waxy oil. Summing means 131 sums signal D with a direct current voltage E.sub.4 corresponding to a value of 1 provide a signal (1+D) to a divider 133. Divider 133 divides the D signal with signal (1+D) to provide a signal X. A multiplier 135 receiving signal X effectively squares signal X to provide a signal X.sup.2.
A multiplier 140 multiplies signal H from summing means 104 with signal C from divider 111 to provide a signal HC to summing means 141. Summing means 141 sums signal HC with the G signal to provide a signal (HC+G).
A multiplier 143 multiplies signal X with signal (HC+G). Summing means 145 sums the signals from summing means 105, and multipliers 122 and 143 to provide a signal ln V.sub.mo which corresponds to the natural log of the viscosity of the slurry mix at 0.degree.F in centistokes.
Signal ln V.sub.mo and temperature signal T are used to develop signal V.sub.mT corresponding to the viscosity of the slurry mix at the filtering temperature. A divider 147 divides signal T with a direct current voltage K.sub.16 to provide a signal T/K.sub.16. A multiplier 148 squares signal T/K.sub.16 to provide a signal (T/K.sub.16).sup.2.
Summing means 145 provides signal ln V.sub.mo to multipliers 151, 152 and to summing means 155. Multiplier 151 multiplies signal ln V.sub.mo with a direct current voltage K.sub.15 to provide a signal K.sub.15 (ln V.sub.mo). A multiplier 158 multiplies signal K.sub.15 (ln V.sub.mo) with signal (T/K.sub.16).sup.2 to provide a signal K.sub.15 (ln V.sub.mo)(T/K.sub.16).sup.2 to summing means 155. Summing means 155 provides a signal ln V.sub.mo +K.sub.15 (ln V.sub.mo)(T/K.sub.16).sup.2 to subtracting means 160.
Multiplier 152 multiplies signal ln V.sub.mo with a direct current voltage K.sub.18 to provide a signal K.sub.18 ln V.sub.mo to summing means 163. Summing means 163 sums signal K.sub.18 ln V.sub.mo with a direct current voltage K.sub.17 to provide a signal (K.sub.17 +K.sub.18 ln V.sub.mo). A multiplier 165 multiplies the signals from divider 147 and summing means 163 with each other to provide a signal (K.sub.17 +K.sub.18 ln V.sub.mo)(T/K.sub.16).
Subtracting means 160 subtracts signal (K.sub.17 +K.sub.18 ln V.sub.mo)(T/K.sub.16) from the signal provided by summing means 155 to provide a signal ln V.sub.mT. Anti-log circuit 170 receives signal ln V.sub.mT and provides signal V.sub.mT.
Referring to FIG. 4, an analog-to-digital converter 180, in set point signal means 53, converts analog signal V.sub.mT to digital signals and provides them to a storage register 183. Storage register 183 is controlled by a pulse E.sub.6 to enter digital signals from converter 180 as hereinafter explained. Storage register 183 provides digital signals to a digital-to-analog converter 184 which provides a signal E.sub.7 corresponding to the stored V.sub.mT signal to comparators 188 and 189. Comparator 188 compares signal E.sub.7 with a direct current voltage E.sub.8 corresponding to an upper limit for the viscosity of the slurry mix at the filtering temperature. Similarly, comparator 189 compares signal E.sub.7 with a direct current voltage E.sub.9 corresponding to a lower limit for the viscosity of the slurry mix at the filtering temperature. When the signal E.sub.7 is greater than signal E.sub.8, comparator 188 provides a low level output and when signal E.sub.7 is less than the signal E.sub.9, comparator 189 provides a low level output. When signal E.sub.7 is within the limits of signals E.sub.8 and E.sub.9, comparators 188, 189 provide high level outputs. Thus, by selecting an extremely narrow range between the limits, the viscosity V.sub.mT of the slurry mix at the filtering temperature can be substantially held to a particular value. Comparators 188, 189 are used to increase or decrease the dilution ratio as hereinafter explained.
Signal X is applied to analog-to-digital converter 190 where it is converted to digital signals and applied to a storage register 191 receiving pulse E.sub.6. Storage register 9 provides digital signals to a digital-to-analog converter 193 which provides an analog signal E.sub.10 corresponding to the stored signal X. Summing means 195 sums signal E.sub.10 with a direct current voltage E.sub.11 corresponding to a predetermined change .DELTA.X to be made in x. Summing means 195 provides a signal X.sup.1 to an electronic single pole, single throw switch 196 corresponding to an increase value for X. Similarly, subtracting means 197 subtracts voltage E.sub.11 from signal E.sub.10 to provide a signal X.sup.11 to a switch 199 corresponding to a decrease value for X.
For the condition that the viscosity V.sub.mT is greater than its upper limit, the output from comparator 188 goes to a low level triggering a flip flop 200 to a set state. In a set state, flip flop 200 provides a high level signal to a switch 196 rendering switch 196 conductive to pass the signal for summing means 195. When flip flop 200 is in a clear state, it provides a low level output to switch 196 rendering it non-conductive to block the signal from summing means 195. The passed signal from switch 196 is applied to subtracting means 203 and to a divider 204. Subtracting means 203 subtracts the passed signal X.sup.11 from voltage E.sub.4 to provide a signal l=X.sup.11 to divider 204. Divider 204 divides the passed X.sup.11 signal from switch 196 with the signal from subtracting means 203 to provide a signal D' to an electronic single pole, double throw switch 205.
The high level signal from flip flop 200 passes through an OR gate 207 to control switch 205 to pass signal D' from divider 204 as the D.sub.D signal. When flip flop 200 is in a clear state and another flip flop 209 is also in a clear state, OR gate provides a low level output causing switch 205 to pass signal D from divider 130 in control unit 31 as the D.sub.D signal.
Since switch 205 is controlled by flip flop 200 to pass signal D' as the D.sub.D signal the set point position in ratio controller 47 changes accordingly. Controller 47 provides signal E.sub.1, E.sub.2 accordingly to increase the solvent to waxy oil ratio.
Similarly, when the viscosity V.sub.mT of the slurry mix is lower than its lower limit, comparator 189 triggers flip flop 209 to a set state. The high level output from flip fop 209 passes through OR gate 207 to control switch 205 as heretofore explained. The high level voltage from flip flop 209 also controls switch 199 to pass a signal X' from subtracting means 197 corresponding to a decreased value for X to subtracting means 203 and divider 204. The result is that D.sub.D will change accordingly to reduce the dilution ratio.
A high level output from either flip flop 200 or 209 passes through OR gate 207 to enable an AND gate 212 to pass timing pulses E.sub.14 from a clock 216 to a counter 218. Counter 218 is essentially used as a time delay. The count in counter 218 is decoded by a decoder 220 and upon reaching of a predetermined count triggers a one shot multivibrator 224 which provides pulse E.sub.6 to enter the values into registers 183, 191. Pulse E.sub.6 also triggers another one shot multivibrator 225 which provides a reset pulse to flip flops 200 and 209 to reset them to the clear state.
The invention as heretofore described controls a solvent dewaxing unit to achieve a desired viscosity for slurry mix at a filtering temperature. The system includes sensors sensing the flow rates of the solvent and waxy oil, the temperature of the slurry mix entering a filter, the refractive index of the solvent and the viscosity of the waxy oil, and controls the dilution ratio of solvent to waxy oil.