FBG Sensor Array for Reactor Temperature Monitoring

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Solution Overview

Problem

Existing temperature measurement technologies for fixed bed reactors, such as thermocouples, suffer from limitations like periodic monitoring, incomplete coverage, poor corrosion resistance, and susceptibility to electromagnetic interference, making real-time and accurate temperature monitoring in high-temperature environments challenging.

Innovation Solution

A reactor temperature measurement system utilizing a Fiber Bragg Grating (FBG) sensor array with multiple sensors arranged axially and radially within the reactor, coupled with a fiber grating demodulator to separate and demodulate temperature sensing optical signals, ensuring real-time monitoring and improved accuracy, and is annealed to withstand high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermocouples are used for temperature measurement, then temperature data can be collected, but the measurement accuracy decreases over time due to poor corrosion resistance and electromagnetic interference susceptibility

Engineering Contradiction:
Improvelong-term stable workVSAvoidmeasurement accuracy
Core Design Contradiction:
ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces traditional thermocouple-based electrical measurement systems with optical fiber-based measurement systems. The FBG sensor uses optical wavelength shifts to detect temperature changes, eliminating the electrical components that are susceptible to electromagnetic interference and corrosion. This substitution of measurement principle fundamentally resolves the reliability-precision contradiction by using an inherently more robust sensing mechanism.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs FBG sensors whose Bragg wavelength shifts in response to temperature changes. By monitoring the wavelength shift parameter rather than electrical resistance or voltage, the system achieves high measurement precision while maintaining reliability in harsh environments. The optical wavelength parameter is immune to electromagnetic interference and corrosion effects.

Inventive Principle:
Principle #35Parameter changes

2Ease of operation

If manual point temperature measurement is used, then equipment is simple to operate, but real-time monitoring capability is lost due to periodic inspection requirements

Engineering Contradiction:
Improveoperation simplicityVSAvoidreal-time monitoring capability
Core Design Contradiction:
Ease of operationVSLoss of time

Solution Approach 1:

The patent implements continuous real-time temperature monitoring through the FBG sensor array, which continuously measures temperature at multiple positions simultaneously. The optical fiber network and demodulation system enable uninterrupted data acquisition, eliminating the periodic inspection gaps inherent in manual methods while maintaining operational simplicity through automated sensing.

Inventive Principle:
Principle #20Continuity of useful action

Solution Approach 2:

The patent uses optical fiber sensors that can be distributed throughout the reactor to create multiple measurement points simultaneously. This allows the system to capture temperature information from numerous locations in real-time, effectively creating a comprehensive temporal and spatial copy of the thermal field without requiring manual intervention at each point.

Inventive Principle:
Principle #26Copying

3Device complexity

If a single thermocouple is used, then the device complexity is low, but monitoring coverage is incomplete leading to safety hazards

Engineering Contradiction:
Improvenumber of sensorsVSAvoidmonitoring coverage
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent divides the temperature monitoring task into multiple segments by deploying an array of FBG sensors at different axial positions within the reactor. Each sensor monitors a specific zone, and the collective array provides comprehensive coverage of the entire reactor volume. This segmentation approach achieves complete monitoring coverage while maintaining relatively simple device architecture through the use of a single optical fiber containing multiple sensors.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent transitions from single-point monitoring to distributed spatial monitoring by arranging FBG sensors along the axial dimension of the reactor. This dimensional expansion from one point to multiple points along a line enables comprehensive coverage of the reactor's thermal profile without proportionally increasing device complexity, as all sensors are integrated into a single optical fiber system.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 enables real-time, all-round temperature monitoring in high-temperature environments, avoiding blind spots and significantly enhancing monitoring accuracy and effectiveness, while being resistant to corrosion and electromagnetic interference.

Implementation Method 1

Fiber Bragg Grating (FBG) can be used as a fiber sensor

Methodology Applied
Scientific EffectBragg Diffraction: Bragg Diffraction

Implementation Method 2

annealing the optical fiber, which includes heating the optical fiber to a temperature above 400° C.

Methodology Applied
Scientific EffectAnnealing: Annealing

Data Source

PatentUS11714010B2Reactor temperature measurement system, reactor and method for preparing a Fiber Bragg Grating
Publication Date: 2023.08.01 SHANGHAI HUAYI NEW MATERIAL
  • US11714010B2 patent drawing
  • US11714010B2 patent drawing
  • US11714010B2 patent drawing

AI summary

A reactor temperature measurement system includes a Fiber Bragg Grating sensor array arranged in a body of the reactor for monitoring temperatures at multiple positions in an axial direction of the body to obtain temperature sensing optical signals; and a fiber grating demodulator, connected to the Fiber Bragg Grating sensor array, and used to demodulate the temperature sensing optical signals. A method for preparing a Fiber Bragg Grating includes preparing a Fiber Bragg Grating by using a single-mode fiber and annealing the Fiber Bragg Grating, which includes heating the Fiber Bragg Grating to a temperature above 400° C. and maintaining for 100 to 200 hours.