Patent Publication Number: US-2012046881-A1

Title: Apparatus and method for measurement of volatile organic compound emissions

Description:
BACKGROUND 
     1. Field 
     Embodiments of the invention generally relate to a volatile organic compound (VOC) emission measurement system. More particularly, certain embodiments of the invention relate to a system, an apparatus, a method and a computer program product for measuring VOC emissions from, for example, a spray paint booth. 
     2. Description of the Related Art 
     The United States Environmental Protection Agency (EPA) requires manufacturers to obtain permits to demonstrate that a company complies with federal and state air pollution control rules. Other countries have similar requirements. The permits usually contain conditions related to acceptable air emissions, operating conditions and record keeping requirements for the company. 
     Operations that use VOC-containing liquids, for example, painting operations, are regulated because VOCs and hazardous air pollutants (HAPs) contribute to the formation of photochemical smog, and can be harmful to human health. Many of the VOCs and HAPs are suspected carcinogens. 
     Currently, manufacturing operations that use VOC-containing liquids use a manual system for recording an amount of and time elapsed for dispensed VOC-containing liquids, which is inefficient and inaccurate. 
     SUMMARY 
     In accordance with an embodiment of the invention, there is provided a system which includes a measuring unit configured to generate a plurality of electronic pulses based on a flow of a volatile organic compound-containing liquid. The system further includes a controller. The controller is configured to generate metadata based on the generated plurality of electronic pulses. The metadata includes information relating to one of a flowrate, a total amount, and a total elapsed time of dispensing the volatile organic compound-containing liquid, and an amount of volatile organic compounds passed through the measuring unit per volume unit of the volatile organic compound-containing liquid to determine an amount of emitted volatile organic compounds. The controller is further configured to display the generated metadata. The system further includes a cleaning unit configured to flush the measuring unit of any remaining volatile organic compound-containing liquid. 
     In accordance with another embodiment of the invention, there is provided an apparatus which includes at least one memory including computer program code, and at least one processor. The at least one memory and the computer program code are configured to, with the at least one processor, cause the apparatus at least to receive a plurality of electronic pulses based on a flow of a volatile organic compound-containing liquid through a measurement unit. The at least one memory and the computer program code are further configured to, with the at least one processor, cause the apparatus at least to generate metadata based on the received plurality of electronic pulses, store the generated metadata, and display the stored metadata. The metadata includes information relating to one of a flowrate, a total amount, and a total elapsed time of dispensing the volatile organic compound-containing liquid, and an amount of volatile organic compounds passed through the measuring unit per volume unit of the volatile organic compound-containing liquid to determine an amount of emitted volatile organic compounds. 
     In accordance with another embodiment of the invention, there is provided an apparatus which includes at least one memory including computer program code, and at least one processor. The at least one memory and the computer program code are configured to, with the at least one processor, cause the apparatus at least to receive one of a plurality of electronic pulses and metadata from a remote controller based on a flow of a VOC-containing liquid through a measuring unit. When receiving the plurality of electronic pulses, the at least one memory and the computer program code are further configured to, with the at least one processor, cause the apparatus at least to generate metadata based on the received plurality of electronic pulses. The at least one memory and the computer program code are further configured to, with the at least one processor, cause the apparatus at least to store the metadata and display the stored metadata. The metadata includes information relating to one of a flowrate, a total amount, and a total elapsed time of dispensing the volatile organic compound-containing liquid, and an amount of volatile organic compounds passed through the measuring unit per volume unit of the volatile organic compound-containing liquid to determine an amount of emitted volatile organic compounds. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying drawings. 
         FIG. 1  illustrates a block diagram of a VOC emission measurement system, in accordance with an embodiment of the invention. 
         FIG. 2  illustrates a block diagram of a measuring unit in the VOC emission measurement system, in accordance with an embodiment of the invention. 
         FIG. 3  illustrates a block diagram of a controller in the VOC emission measurement system, in accordance with an embodiment of the invention. 
         FIG. 4  illustrates a block diagram of a cleaning unit in the VOC emission measurement system, in accordance with an embodiment of the invention. 
         FIG. 5  illustrates a block diagram of a VOC emission measurement system, in accordance with another embodiment of the invention. 
         FIG. 6  illustrates a flow diagram of a method for measuring VOC emissions, in accordance with an embodiment of the invention. 
         FIG. 7  illustrates a flow diagram of a method for measuring VOC emissions, in accordance with another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     It will be readily understood that the components of the invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the system, the apparatus, the method and the computer program product, as represented in the attached figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. 
     For example, while the exemplary embodiments described below are directed to the measurement of VOC emissions from a spray paint booth, it should be appreciated that the exemplary embodiments of the invention are not limited for use with this one particular application. The exemplary embodiments of the invention may be used for any system where the measurement of VOC emissions is desired, for example, during the manufacture or application of petroleum products, insecticides, solvents, cleaners, refrigerants, etc. 
     If desired, the different functions discussed below may be performed in a different order and/or concurrently with each other. Furthermore, if desired, one or more of the above-described functions may be optional or may be combined. As such, the foregoing description should be considered as merely illustrative of the principles, teachings and embodiments of this invention, and not in limitation thereof. 
       FIG. 1  illustrates a block diagram of a VOC emission measurement system, in accordance with an embodiment of the invention. As illustrated in  FIG. 1 , the system  100  may include a controller  110  and a measuring unit  120 . 
     The measuring unit  120  may measure an amount of dispensed VOC-containing liquid and an elapsed time of dispensing the VOC-containing liquid (i.e., an amount of paint sprayed in a spray paint booth over a period of time). 
     The controller  110  may process the measured amount of the dispensed VOC-containing liquid and the elapsed time of dispensing, and generate metadata relating to, for example, a flowrate of the dispensed VOC-containing liquid, a total amount of the dispensed VOC-containing liquid, and a total elapsed time of dispensing, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid (i.e., 3.44 lbs. of VOCs per gallon of primer/paint sprayed) to determine an amount of emitted VOCS (i.e., if 128 ounces (1 gallon) of the VOC-containing liquid is sprayed, then 3.44 lbs. of the VOC is emitted). 
     The metadata may be generated for a specific operator and a specific spray paint booth, or to identify specific parts that have been coated with the VOC-containing liquid. 
       FIG. 2  illustrates a block diagram of a measuring unit in the volatile organic compound emission measurement system, in accordance with an embodiment of the invention. As illustrated in FIG.  2 ., the measuring unit  120  may include a meter  122  and a sensor  124 . 
     The meter  122  may include any type of flow meter that may measure a flow of the VOC-containing liquid through the measuring unit  120 . For example, a helical meter may be used that generates a plurality of electronic pulses that vary with an amount of the VOC-containing liquid flowing through the meter  122 . In a spray paint booth application, the VOC-containing liquid may include, for example, paint, primer, or solvent. The meter  122  may include, for example, a pair of rotating shafts having helixes that mesh together, so that a flow of the VOC-containing liquid through the meter  122  forces the pair of shafts to rotate. At least one of the shafts may include a gear or a sprocket that may include a fixed number of teeth which rotate with the rotation of the pair of rotating shafts. 
     The sensor  124  may be arranged within a close proximity of the meter  122 , so that the sensor  124  may detect the flow of the VOC-containing liquid through the meter  122  (i.e., movement of the teeth on the rotating gear or sprocket). Based on the flow of the VOC-containing liquid through the meter  122 , the sensor  124  may generate a plurality of electronic pulses (i.e., count the number of teeth that rotate past the sensor  124  and generate a plurality of electronic pulses based on this count). 
       FIG. 3  illustrates a block diagram of a controller in the volatile organic compound emission measurement system, in accordance with an embodiment of the invention. As illustrated in  FIG. 3 , the controller  110  may include, for example, a programmable logic controller, that may control the operation of the measuring unit  120 . The controller  110  may include a processor  112 , a memory  114  and a user interface  116 . 
     While a single processor  112  and a single memory  114  are illustrated in  FIG. 3 , multiple processors and multiple memory may be utilized according to other embodiments. 
     The processor  112  may receive the plurality of electronic pulses and may generate the metadata relating to, for example, the flowrate of the dispensed VOC-containing liquid, the total amount of the dispensed VOC-containing liquid, and the total elapsed time of dispensing, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs. The metadata may be generated for a specific operator and a specific spray paint booth, or to identify specific parts that have been coated with the VOC-containing liquid. 
     Once the metadata is generated, the processor  112  may store the metadata in the memory  114 . The memory  114  may be coupled to the processor  112  for storing information and instructions to be executed by the processor  112 . The memory  114  may include computer program code  118  embodied on a computer readable non-transitory medium. The computer program code  118  may be encoded with instructions to control the processor  112  to perform the methods discussed below and illustrated in  FIGS. 6 and 7 . 
     The user interface  116  may include, for example, a human machine interface, that may display all the metadata stored in the memory  114 , organized, for example, by operator, time period, VOC-containing liquid type, or combinations thereof. The user interface  116  may serve as a file transfer protocol server and interface to the Ethernet. 
     The processor  112  may further transmit the metadata via a wired or wireless communication (i.e., via email), for example, as individual metadata, groups of metadata, or screenshots of gathered metadata requested by an operator or at pre-set time periods, for example, every 24 hours, to a designated recipient. The designated recipient may include, for example, an operator, a regulating body, such as the United States Environment Protection Agency, an auditor, and an external memory location. The timing of data collection by the measuring unit  120 , the specific metadata to be transmitted and the pre-set time period for metadata transmission may be adjusted using a programmable platform on the user interface  116 . 
     The system  100  may further include a cleaning unit  130 , as illustrated in  FIG. 4 , for cleaning the measuring unit  120 . The cleaning unit  130  may include a plurality of valves  132 , a pump  134  and a solvent tank  136 . The controller  110  may be configured to program the cleaning unit  130  to clean the measuring unit  120  at pre-set times, for example, daily or weekly. The controller  110  may be configured to operate a valve  132  to isolate the meter  122  and the sensor  124  from a flow of solvent through the measuring unit  120 . The controller  110  may also be configured to operate another valve  132 , the pump  134  and the solvent tank  136  to pump solvent from the solvent tank  136  to flush the measuring unit  120  of the VOC-containing liquid. 
       FIG. 5  illustrates a block diagram of a VOC emission measurement system, in accordance with another embodiment of the invention. As illustrated in  FIG. 5 , in certain embodiments, the system  500  may include the controller  110 , the measuring unit  120  and a remote controller  140 . In this case, only one spray paint booth is remotely monitored. Certain embodiments of the invention may include a plurality of measuring units  120  and remote controllers  140  for applications where, for example, multiple spray paint booths are to be remotely monitored. In this case, each spray paint booth may include one measuring unit  120  and one remote controller  140 . The controller  110  and the remote controller  140  may be configured to communicate via a Modbus network using wired or wireless communication, including, for example, satellite communication. 
     The following description of certain embodiments of the invention will be described for the system  500 , as illustrated in  FIG. 5 , including one controller  110 , one measuring unit  120  and one remote controller  140 , where a spray paint booth is remotely monitored. 
     The measuring unit  120  of the system  500  may include the meter  122  and the sensor  124  (not illustrated) and may function in the same manner as discussed above for the system  100 . 
     The remote controller  140  may include, for example, a programmable logic controller, that may control the operation of the measuring unit  120 . The remote controller  140  may include a processor  142 , a memory  144  and a user interface  146 . While a single processor  142  and a single memory  144  are provided, multiple processors and multiple memory may be utilized according to other embodiments. 
     The processor  142  may receive the plurality of electronic pulses from the measuring unit  120  and may generate metadata, relating to, for example, the flowrate of the dispensed VOC-containing liquid, the total amount of the dispensed VOC-containing liquid, and the total elapsed time of dispensing, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs, for the spray paint booth. The metadata may be generated for a specific operator and a specific spray paint booth, or to identify specific parts that have been coated with the VOC-containing liquid. Once the metadata is generated, the processor  142  may store the metadata in the memory  144 . The memory  144  may be coupled to the processor  142  for storing information and instructions to be executed by the processor  142 . The memory  144  may include computer program code  146  embodied on a computer readable non-transitory medium. The computer program code  146  may be encoded with instructions to control the processor  142  to perform the methods discussed below and illustrated in  FIGS. 6 and 7 . 
     As discussed for the system  100 , the controller  110  of the system  500  may include the processor  112 , the memory  114  and the user interface  116  (not illustrated). The processor  112  may retrieve the metadata from the memory  144  of the remote controller  140 , and may store the metadata in the memory  114 . As discussed above for the system  100 , the displayed metadata may be organized, for example, by operator, spray paint booth, time period, VOC-containing liquid type, or combinations thereof. The user interface  116  may serve as a file transfer protocol server and interface to the Ethernet. The processor  112  may further transmit the metadata via a wired or wireless communication, as discussed above for the system  100 . 
     In certain embodiments of the invention, the processor  142  may receive the plurality of electronic pulses from the measuring unit  120  and may store the plurality of electronic pulses in the memory  144 , instead of generating metadata based on the plurality of electronic pulses. In these embodiments, the processor  112  of the controller  110  may retrieve the plurality of electronic pulses in the memory  144 , and may generate the metadata, as discussed above in the system  100 . Hence, metadata relating to the flowrate of, the amount of, and the time elapsed dispensing the VOC-containing liquid may be generated in either the controller  110  or the remote controller  140 . Additionally, metadata relating to an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs may also be generated in either the controller  110  or the remote controller  140 . 
     The system  500  may further include the cleaning unit  130 , as illustrated in  FIG. 4  and discussed for the system  100 , configured to clean the measuring unit  120 . The cleaning of the measuring unit  120  may be locally controlled by the remote controller  140  or remotely controlled by the controller  110 . 
     For certain embodiments that include a plurality of measuring units  120  and a plurality of remote controller  140  for remotely monitoring and controlling a plurality of spray paint booths, the processor  112  may retrieve the metadata from the memory  144  of each remote controller  140 , may store all the metadata in the memory  114 , and may display all the organized metadata on the user interface  116  for each respective spray paint booth. These embodiments of the invention may also include a plurality of cleaning units  130  (i.e., one cleaning unit  130  configured for each measuring unit  120 ). Each cleaning unit  130  may be locally controlled by the remote controller  140  or remotely controlled by the controller  110 . 
     The processors  112  and  142  may be of any type suitable to the local technical environment, and may include one or more of general purpose computers, special purpose computers, microprocessors, digital signal processors (DSPs) and processors based on multi-core processor architecture, as non-limiting examples. 
     The memory  114  and  144  may be of any type suitable to the local technical environment and may be implemented using any suitable data storage technology, machine or computer readable storage medium, such as semiconductor-based memory devices, flash memory, magnetic memory devices and systems, optical memory devices and systems, fixed memory and removable memory, as non-limiting examples. 
       FIG. 6  illustrates a flow diagram of a method for measuring VOC emissions, in accordance with an embodiment of the invention. The method may include receiving a plurality of electronic pulses from a measuring unit based on a flow of a VOC-containing liquid through the measuring unit (step  610 ). The method may further include generating metadata based on the received plurality of electronic pulses (step  620 ), and storing the metadata in a memory (step  630 ). The generated metadata may relate to at least one of a flowrate of the dispensed VOC-containing liquid, a total amount of the dispensed VOC-containing liquid, and a total elapsed time of dispensing, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs. The metadata may be generated for a specific operator, a specific spray paint booth, or to identify specific parts that have been coated with the VOC-containing liquid. 
     As illustrated in  FIG. 6 , the method may include displaying the stored metadata (step  640 ). The method may also include transmitting the metadata to a designated recipient (step  650 ). The designated recipient may include, for example, an operator, an auditor, and an external memory location. The method may further include cleaning the measurement unit (step  660 ), and adjusting a timing of data collection by the measuring unit  120 , and a transmission time period for the metadata using a programmable platform on a user interface (step  670 ). 
     The step of receiving may include receiving the plurality of electronic pulses from a measuring unit including any type of flowmeter that may measure a flow of the VOC-containing liquid through the measuring unit and a sensor configured to generate the plurality of electronic pulses. The measuring unit may be locally or remotely located. 
     The step of displaying the metadata may include organizing and displaying the metadata for a specific operator, spray paint booth number, or time period. 
     The step of transmitting may include transmitting the metadata via a wired or wireless communication, for example, as individual metadata, groups of metadata, or screenshots of gathered metadata requested by an operator or at pre-set time periods, for example, every 24 hours, to a designated recipient. The designated recipient may include, for example, an operator, an auditor, and an external memory location. 
     The step of cleaning the measurement unit may include operating a plurality of valves, a pump and a solvent tank to isolate the meter and the sensor of the measurement unit, to flow a solvent through the measurement unit, and to flush the measurement unit of the remaining VOC-containing liquid. 
       FIG. 7  illustrates a flow diagram of a method for measuring VOC emissions, in accordance with another embodiment of the invention. The method may include receiving one of a plurality of electronic pulses and metadata from a remote controller based on a flow of a VOC-containing liquid through a measuring unit (step  710 ). The method may further include, when receiving the plurality of electronic pulses, generating metadata based on the received plurality of electronic pulses (step  720 ). Further, the method may include storing the metadata in a memory (step  730 ). The metadata may relate to at least one of a flowrate of the dispensed VOC-containing liquid, a total amount of the dispensed VOC-containing liquid, and a total elapsed time of dispensing, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs. The metadata may be generated for a specific operator, a specific spray paint booth, or to identify specific parts that have been coated with the VOC-containing liquid. The method may further include displaying the stored metadata (step  740 ). 
     Steps  750  to  770  of the method, as illustrated in  FIG. 7 , may be similar to steps  650  to  670  discussed above for the method illustrated in  FIG. 6 . 
     Further to the discussion above, it is to be understood that in an embodiment of the invention, the steps and the like may be changed without departing from the spirit and scope of the present invention. In addition, the method described in  FIGS. 6 and 7  may be repeated numerous times. 
     A computer program code  118 ,  148  according to certain embodiments of the invention, may be composed of modules that are in operative communication with one another, and which are designed to pass information or instructions to a communication device, such as a mobile node or a user equipment, a personal computer, a handheld device, such as a mobile, a cellular telephone, or a personal digital assistant (PDA) having wireless communication capabilities, a portable computer having wireless communication capabilities and a portable unit or a terminal that incorporates combinations of such functions, as non-limiting examples. 
     The computer program code  118 ,  148  may be configured to operate on a general purpose computer or an application specific integrated circuit (ASIC). 
     The computer readable (i.e., non-transitory) storage medium may include any media or means that may contain, store, communicate, propagate or transport the instructions for use by or in connection with an instruction execution system, apparatus, or device, for example, a disk media, computer memory, or other storage device. Non-transitory storage medium does not include a transitory signal. Examples of non-transitory storage medium may include, for example, a computer-readable medium, a computer distribution medium, a computer-readable storage medium, and a computer program product. 
     The embodiments of the invention discussed above may be implemented by hardware, computer software executable by one or more of the processor  112  of the controller  110  and the processor  142  of the remote controller  140 , or by a combination of hardware and software. 
     The software and/or hardware may reside on the controller  110 , the remote controller  140 , or other mobile communication devices. If desired, part of the software and/or hardware may reside on the controller  110 , part of the software and/or hardware may reside on the controller  140 , and part of the software and/or hardware may reside on other mobile communication devices. In an embodiment of the invention, software, or an instruction set may be maintained on any one of various conventional computer-readable media. 
     In accordance with an embodiment of the invention, there is provided a computer program product embodied on a computer readable storage medium. The computer program product is encoded with instructions to control a processor to perform a process. The process includes receiving a plurality of electronic pulses based on a flow of a volatile organic compound-containing liquid through a measurement unit, and generating metadata based on the received plurality of electronic pulses. The metadata includes information relating to one of a flowrate, a total amount, and a total elapsed time of dispensing the volatile organic compound-containing liquid, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs. The process further includes storing the generated metadata, and displaying the stored metadata. 
     In accordance with an embodiment of the invention, there is provided a computer program product embodied on a computer readable storage medium. The computer program product is encoded with instructions to control a processor to perform a process. The process includes receiving one of a plurality of electronic pulses and metadata from a remote controller based on a flow of a VOC-containing liquid through a measuring unit. When receiving the plurality of electronic pulses, the method further includes generating metadata based on the received plurality of electronic pulses, storing the metadata, and displaying the stored metadata. The metadata includes information relating to one of a flowrate, a total amount, and a total elapsed time of dispensing the volatile organic compound-containing liquid, and an amount of VOCs passed through the measuring unit per volume unit of the VOC-containing liquid to determine an amount of emitted VOCs. 
     One having ordinary skill in the art will readily understand that the invention as discussed above may be practiced with steps in a different order, and/or with hardware elements in configurations which are different than those which are disclosed. Therefore, although the invention has been described based upon these preferred and non-limiting embodiments, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions would be apparent, while remaining in the spirit and scope of the invention. Thus, the example embodiments do not limit the invention to the particular listed devices and technologies. In order to determine the metes and bounds of the invention, therefore, reference should be made to the appended claims.