Cooling Element Cycle Measurement via Survey Line
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Solution Overview
Problem
Current methods for cooling metallurgical furnaces are inefficient as they lack precise measurement of heat loss in individual cooling element cycles, leading to unbalanced temperature distribution and increased wear on refractory linings, due to the high cost and impracticality of installing individual meters on each cooling element.
Innovation Solution
A method and arrangement that utilize a survey line with a valve arrangement and measuring devices to measure temperature, flow, or pressure of the cooling fluid in individual cooling element cycles, allowing for cost-effective monitoring of each cycle with shared meters and enabling automated data collection, which can be used to optimize cooling fluid flow and detect potential issues like vapor lock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual meters and cabling are installed on each cooling element cycle to measure heat loss, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
Multiple cooling element cycles are merged into a single measurement system. The patent combines several cooling element cycles into one common measurement section where a single meter and cabling setup measures the aggregate flow and temperature of all cycles together, eliminating the need for individual meters on each cycle while still enabling calculation of individual heat losses through mathematical decomposition of the combined measurements
Solution Approach 2:
A single measurement system serves multiple cooling element cycles simultaneously. The universal meter and temperature sensing arrangement measures the combined parameters of multiple cycles, and this single measurement setup provides information that can be used to determine heat loss for each individual cycle through calculation, making the measurement system multi-functional across multiple cycles
2Reliability
If cooling power is focused in high thermal stress areas, then durability of refractory lining is improved, but unbalanced temperature distribution occurs when using static coolers
Solution Approach 1:
The cooling system transitions from static to dynamic operation. The patent implements variable speed pumps for each cooling element cycle that can dynamically adjust their flow rates based on real-time thermal stress conditions and measured heat losses, allowing the cooling power distribution to adapt continuously to changing process conditions and maintain balanced temperature distribution while protecting high-stress areas
Solution Approach 2:
A feedback control system is implemented to balance cooling distribution. The patent uses measured heat loss data from each cooling element cycle as feedback to automatically adjust pump speeds and valve positions, creating a closed-loop control system that continuously optimizes cooling power distribution to maintain balanced temperature distribution across the furnace lining
3Loss of information
If simultaneous measuring of all cooling element cycles is performed, then measurement completeness is improved, but measurement time and system complexity increase
Solution Approach 1:
Measurements from multiple cooling element cycles are merged into a single simultaneous measurement operation. The patent combines the flow and temperature measurements of multiple cycles into one aggregate measurement at a central location, obtaining all necessary data in a single measurement event rather than requiring sequential measurement of each cycle individually
Solution Approach 2:
The system measures aggregate parameters that provide sufficient information without measuring each individual cycle parameter separately. By measuring the combined flow and temperature of multiple cycles together, the system obtains excessive information (total combined parameters) that can be mathematically decomposed to derive individual cycle heat losses, achieving complete measurement coverage with a single partial measurement action
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for precise balancing of cooling across the furnace, reducing wear on cooling elements, optimizing water consumption, and preventing maintenance interruptions by focusing cooling fluid flow on high-stress areas, thereby enhancing operational safety and efficiency while reducing the need for unnecessary sizing and cooling fluid usage.
Implementation Method 1
measuring devices for measuring temperature, flow, or pressure of the cooling fluid flowing in the survey line
Implementation Method 2
measuring devices for measuring temperature, flow, or pressure of the cooling fluid flowing in the survey line
Implementation Method 3
measuring devices for measuring temperature, flow, or pressure of the cooling fluid flowing in the survey line
Implementation Method 4
the rates of flow of the cooling water that carries the thermal energy away
Implementation Method 5
heat loss of each cooling element, but earlier the measuring thereof has been very expensive
Data Source
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AI summary
The invention relates to a method and arrangement for measuring at least one physical magnitude, such as temperature, flow or pressure of the cooling fluid flowing in an individual cooling element cycle (3) of a cooling element (1) in a metallurgical furnace. The arrangement includes a supply header (2) for distributing the cooling fluid and for feeding it to the cooling element cycles (3) of the cooling elements (1), and a collection header (4) for collecting and receiving cooling fluid from the cooling element cycles (3) of the cooling elements (1). The arrangement includes a survey line (5) that is by intermediation of a valve arrangement (6) in fluid connection with at least one cooling element cycle (3), so that the cooling fluid is conducted alternatively through the survey line (5) to the collection header (4) or past the survey line (5) to the collection header (4). The survey line (5) comprises at least one measuring device (7) for measuring at least one physical magnitude of the cooling fluid flowing in the survey line (5), and for measuring the cooling element cycle (3).