This invention reveals a diagnostic and blockage detection
system for
direct heating process furnaces, aimed at enhancing operational efficiency and safety. The
system comprises an accurate dynamic model of the furnace,
measuring equipment, and a fault identifier, which work in conjunction to monitor and analyze furnace performance. The dynamic model is constructed using thermodynamic principles,
heat transfer, and
mass transfer relationships. It is implemented on a powerful computer and calibrated using dimensional specifications and real
system data. The model incorporates empirical and semi-empirical relations governing the thermodynamic conditions of
crude oil, as well as
heat transfer coefficients in both single-phase and two-phase regimes, considering the effects of
flame height and
combustion conditions. To facilitate real-time monitoring, the system employs various measuring devices, including thermocouples (7) and pressure sensors (6), to capture essential parameters such as fuel flow rate,
combustion air flow rate,
combustion temperature, and the temperature, pressure, and flow rates of input and output
crude oil. These measured values serve as inputs to the
mathematical model, allowing for the comparison of model outputs with actual system performance. The fault identifier is designed to classify data into acceptable and unacceptable categories, issuing alerts when the blockage level in the pipes (10) exceeds predetermined thresholds. This functionality enables operators to take preventive actions, such as clearing blockages or performing maintenance, ensuring optimal furnace operation. Overall, this innovative device significantly enhances the ability to detect and analyze blockages in
direct heating furnaces, thereby improving
operational reliability and reducing
downtime, ultimately contributing to better
process efficiency in industrial applications.