Digital Imaging for Industrial Water Deposit Monitoring
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Solution Overview
Problem
Industrial water systems face inefficiencies due to mineral and biofilm deposits on heat exchange surfaces, which reduce energy efficiency and require effective monitoring and removal methods.
Innovation Solution
A digital imaging system is used to analyze deposits on substrates in industrial water systems, capturing images to identify and quantify deposit features, determine heat transfer resistance, and monitor trends, with the option for in-situ cleaning using electrochemical methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If digital imaging is used to detect deposit on heat exchange surfaces, then measurement precision of deposit is improved, but device complexity increases
Solution Approach 1:
A transparent window is introduced as an intermediary component between the water system and the imaging device, allowing optical access to the heat exchange surface without requiring direct contact or complex disassembly. This simple mediator enables precise deposit detection while maintaining system simplicity.
Solution Approach 2:
The patent replaces complex mechanical sampling or contact-based measurement methods with optical imaging technology. The imaging device captures images of the heat exchange surface through the transparent window, substituting mechanical interaction with non-contact optical detection, thereby improving measurement precision without proportionally increasing device complexity.
2Reliability
If continuous monitoring of heat exchange surfaces is implemented, then reliability of system operation is improved, but use of energy increases
Solution Approach 1:
Instead of continuous monitoring, the system performs periodic imaging at predetermined time intervals or based on operational criteria. This periodic action maintains system reliability by regularly detecting deposit formation while significantly reducing energy consumption compared to continuous monitoring. The imaging device can be triggered by timers, operational parameters, or event-driven conditions.
3Productivity
If early detection of deposit formation is achieved through imaging, then productivity of water system is improved, but device complexity increases
Solution Approach 1:
The imaging system performs preliminary detection of deposit formation at early stages, before deposits significantly impact heat transfer efficiency. By detecting deposits early, the system enables timely cleaning or treatment actions, maintaining productivity. The transparent window facilitates this preliminary action by providing continuous visual access without interfering with system operation.
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 early detection and prevention of deposit formation, improving energy efficiency by reducing heat transfer resistance and enabling targeted cleaning processes, thereby maintaining optimal system performance.
Implementation Method 1
heating the substrate while the substrate contacts the industrial water in the industrial water system to form deposit on the substrate
Implementation Method 2
A camera is configured to capture digital images of the substrate when located in the fluid flow channel
Implementation Method 3
A plurality of temperature sensors is configured to measure a temperature gradient across the heated substrate
Data Source
AI summary
Systems for and methods of monitoring and analyzing deposit in an industrial water system are provided. The methods comprise heating a substrate while the substrate contacts industrial water in the industrial water system to form deposit on the substrate. A series of digital images of the substrate while the substrate contacts the industrial water in the industrial water system is created. A region of interest in the series of digital images of the substrate is defined. A deposit feature in the region of interest in the series of digital images of the substrate is identified. The deposit feature in the region of interest in the series of digital images of the substrate is analyzed to determine a deposit trend of the substrate in the industrial water system. Generally, the systems are configured so as to be capable of carrying out one or more of the methods.