TRACKING AND PROPERTIES CONTROL SYSTEM FOR BULK MATERIALS

• US 20090266891A1
• Filed: 04/23/2009
• Published: 10/29/2009
• Est. Priority Date: 04/23/2008
• Status: Active Grant

• Current Assignee: Engineering Consultants Group
• Original Assignee: Engineering Consultants Group
• Inventors: BAZANT, Martin Z., SANTUCCI, Michael, SCAVUZZO, James, MISAL, Nilimb
• Granted Patent: US 8,042,736 B2
• Time in Patent Office: Days
• US Class Current: 235/385
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 10/0832 Special goods or special handling procedures, e.g. handling of hazardous or fragile goods
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials
• CPC Class Codes: G06Q 50/28 Logistics, e.g. warehousing, loading, distribution or shipping

Abstract

The invention provides a system of devices and a set of methods for accurately characterizing, tracking and controlling bulk material flows. Measurements of input material properties, dynamical measurements involving identifiable tags, and fast, discrete simulations are combined to predict and control the composition of bulk material exiting a container, such as a silo, bunker or hopper. In one embodiment, a system is provided for a coal-fired power plant where the properties of coal are assessed, then the coal is marked and tracked to provide the plant'"'"'s operators improved control over the coal mixture and target bulk properties as it makes its way from a coal receiving station to delivery for combustion in a furnace.

Claims

1. A tracking system for bulk materials comprising:

at least one container that receives a bulk material which drains therefrom by gravity at a container exit, wherein said bulk material has an upper free surface that can be subsequently covered upon receipt of additional bulk material;

a plurality of identifiable tags placed in the material at different locations on said free upper surface;

a recording system that detects physical properties of the bulk material, wherein said recording system associates said physical properties with at least one said identifiable tag;

a reader positioned proximal said container exit so as to read said identifiable tags passing therethrough; and

a controller connected to said recording system and said reader to monitor and predict the flow of the bulk material through said container.

2. The tracking system according to claim 1, wherein said controller updates flow predictions based upon placement of said identifiable tags on said upper free surface and when said identifiable tags exit said container.

3. The tracking system according to claim 1, further comprising:

a variable belt drive system connected to said controller, said variable drive system controlling delivery of the bulk material to said container.

4. The tracking system according to claim 3, wherein the bulk material is stored in different sections according to grade and is drawn by said variable belt drive system.

5. The tracking system according to claim 4, further comprising:

a blending station connected to said controller and receiving the bulk material from said variable belt drive system, wherein said controller causes said blending station to blend the different grades of the bulk material prior to delivery to said container.

6. The tracking system according to claim 5, wherein said controller adjusts operation of said variable belt drive system and said blending station in realtime to control the predicted composition of the bulk material leaving the container at future times.

7. The tracking system of claim 1, wherein the bulk material comprises solid fossil fuels, such as coal.

8. The tracking system of claim 1, wherein the bulk material comprises raw materials for biofuel, such as corn, sugarcane, switchgrass, or woodchips.

9. The tracking system of claim 1, wherein said identifiable tags, which can be identified as they exit the container, are selected from the group consisting of radio-frequency identification (RFID) devices, and particles of distinct color, chemical/physical signature, or having a bar code.

10. The tracking system of claim 1, wherein the identifiable tags are radioactive particles, which can be located in the bulk material by external detectors.

11. The tracking system of claim 1, wherein said controller employs an event-driven stochastic algorithm, such as the spot model.

12. A method of tracking bulk materials in at least one container drained by gravity, comprising:

adding bulk material, which has different grades, to a container;

seeding the bulk material with identifiable tags, wherein said tags are associated with physical properties of the bulk material'"'"'s grade;

monitoring placement of said identifiable tags in said container and when said identifiable tags exit said container; and

adjusting delivery of the bulk material to said container based on the monitored flow of the bulk material therethrough.

13. The method according to claim 12, further comprising:

predicting the flow and mixing of the bulk material through said container based on the monitored flow of the bulk material.

14. The method according to claim 13, wherein the bulk material is coal.

15. The method according to claim 13, further comprising:

utilizing an event-driven stochastic algorithm with discrete particles to predict the flow of the bulk materials.

16. The method according to claim 13, further comprising:

selecting said identifiable tag from the group consisting of radio-frequency identification devices, particles of distinct color, a chemical signature, a physical signature, a bar code, and radioactive particles.

17. The method according to claim 13, further comprising:

receiving the bulk material;

analyzing and associating properties of the bulk material with said identifiable tags according to the bulk material'"'"'s grade; and

storing the bulk material in designated areas according the the bulk material'"'"'s grade.

18. The method according to claim 17, further comprising:

drawing the bulk material from the designated areas based on the predicted flow of material through the container and the desired property of the bulk material exiting said container.

19. The method according to claim 18, further comprising:

blending the bulk materials from the designated areas prior to entry of the bulk material into said container.

20. A method for tracking coal in a coal-fired power plant using radio frequency identification markers, comprising:

receiving coal at a receiving station;

designating physical properties of received coal as preliminary material data;

writing to identifiable tags from said preliminary material data, and sending tag information and said preliminary material data to a controller;

distributing said identifiable tags within the coal;

segregating the coal into sections according to said preliminary data;

blending the coal from at least one of said sections at a blending station;

designating revised physical properties of the blended coal as revised material data;

updating said identifiable tags in the blended coal with said revised material data;

sending updated tag information and revised material data to said controller;

delivering the blended coal to a furnace to generate a desired power output; and

generating signals by said controller to control blending and delivering to obtain a desired mixture of the coal supplied to said furnace.