High Temperature Corrosion Sensor with Airflow Cooling
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Solution Overview
Problem
Current high-temperature corrosion monitoring techniques, such as online electrochemical methods, face limitations in accurately measuring corrosion rates and details in real-time due to the need for stable reference electrodes and conductivity, and offline methods are slow and provide post-mortem data, lacking real-time field simulation capabilities.
Innovation Solution
A high-temperature corrosion sensor system integrating a thermocouple, electrical resistance element, and electrochemical noise module with a cooling device, featuring a reliable reference electrode and airflow control for stable temperature management, enabling in-situ monitoring and real-time data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline techniques such as weight loss coupons are used for corrosion monitoring, then accurate and reliable corrosion information can be obtained, but the monitoring process takes long time and cannot provide timely data
Solution Approach 1:
The patent replaces traditional mechanical offline measurement methods (weight loss coupons requiring physical retrieval and laboratory analysis) with an online electrochemical sensing system that provides real-time corrosion rate measurements through electrical impedance spectroscopy and other electrochemical techniques
Solution Approach 2:
The corrosion sensor system performs self-monitoring and self-measurement continuously in-situ, eliminating the need for periodic manual intervention to retrieve samples, thereby providing ongoing real-time data without time loss
2Productivity
If electrochemical methods such as LPR and EIS are used for online corrosion monitoring, then real-time corrosion rate can be measured, but a stable and reliable reference electrode is required and the corrosion medium must have good conductivity
Solution Approach 1:
The patent introduces a pseudo-reference electrode system that uses the corrosion medium itself (molten salt) as the reference, eliminating the need for a separate stable reference electrode. The system measures potential differences relative to the corrosive environment directly, making the reference electrode requirement obsolete
Solution Approach 2:
The patent changes the measurement approach by using electrochemical noise analysis and impedance spectroscopy that do not require a stable reference electrode, instead relying on the inherent electrochemical properties of the corrosion system and statistical analysis of noise signals
3Adaptability or versatility
If a pseudo reference electrode is used in high temperature corrosion monitoring above 600°C, then the sensor can operate in field conditions, but the service life is reduced and field application is limited
Solution Approach 1:
The patent divides the sensor into modular components with separate protection systems, allowing different parts to be optimized for their specific functions and replaced independently, thereby extending overall system service life in field conditions
Solution Approach 2:
The patent incorporates protective measures in advance, including temperature control systems and protective coatings, to prevent premature failure of the sensor in high-temperature field environments, thereby extending service life before deployment
4Measurement precision
If galvanic corrosion principle is used to collect corrosion information, then corrosion rate can be measured, but the selection of exotic metal is critically important and polarization induced by galvanic coupling may change the corrosion mechanism
Solution Approach 1:
The patent extracts the measurement function from the galvanic coupling system itself and implements it through separate electrochemical sensing electrodes that do not interfere with the natural corrosion process, eliminating the need for exotic metal selection and avoiding polarization effects
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
The system provides accurate, real-time corrosion monitoring in high-temperature environments, extending sensor lifespan and reducing maintenance costs by detecting corrosion events promptly, thus preventing unexpected failures.
Implementation Method 1
a thermocouple, a ER element and a ECN module together in one corrosion sensor
Implementation Method 2
The online techniques are mostly based on the principle of electrical resistance (ER)
Implementation Method 3
adding a cooling device or a temperature-control system
Implementation Method 4
a cooling device or a temperature-control system
Data Source
AI summary
A high temperature corrosion sensor is provided having (i) a housing having an external wall and an internal wall, the internal wall of the housing forming a chamber of the housing, (ii) a stainless steel tube inserted into the chamber, (iii) a ceramic tube wherein at least a portion of the ceramic tube is inserted into the stainless steel tube, (iv) an airflow tube that extends through the chamber, and (v) a sensor probe having a first working electrode, a second working electrode, a reference electrode, a positive electrical resistance, a negative electrical resistance, and a thermocouple, wherein at least a portion of each are encapsulated into a ceramic casting that is located at one end of the housing. Methods of measuring corrosion within a power plant environment are provided.