Flexible Cable Thermocouple for Deformed Thermo-Well Tubes
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Solution Overview
Problem
Conventional temperature measuring devices in shell-and-tube heat exchanger-type reactors face difficulties in accurately measuring temperature peaks within the catalyst layer due to thermal expansion and deformation of thermo-well tubes, causing friction and potential breakage of thermocouples, which hinders the ability to monitor temperature profiles effectively.
Innovation Solution
A cable or wire type temperature measuring device with sensors disposed at intermediate portions, allowing axial movement within the thermo-well tube by applying tension, and featuring pulleys for easy positioning and flexibility to compensate for tube deformation, along with dual thermocouples for continuous measurement in case of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional thermocouple is used in a shell-and-tube heat exchanger-type reactor, then temperature measurement is possible, but the thermo-well tube deforms due to thermal expansion at high temperatures (200-500°C), causing friction and potential breakage of the thermocouple
Solution Approach 1:
The patent changes the physical state and mechanical properties of the temperature measuring means by transforming it from a rigid rod-type thermocouple to a flexible cable-type structure. This parameter change allows the measuring means to adapt to thermal deformation of the thermo-well tube without breaking, while maintaining measurement accuracy through the flexible structure that can follow the tube's deformation.
Solution Approach 2:
The patent applies the principle of flexibility by using a cable-type temperature measuring means with flexible construction. The flexible cable can bend and deform along with the thermo-well tube when it expands thermally, preventing mechanical failure while maintaining continuous contact for accurate temperature measurement throughout the reactor length.
2Measurement precision
If the thermo-well tube is deformed by thermal expansion, then temperature measurement can be maintained, but friction resistance increases making it difficult to move the thermocouple along the tube
Solution Approach 1:
The patent changes the mechanical parameters of the temperature measuring means from rigid to flexible. The flexible cable structure can navigate through the deformed thermo-well tube with reduced friction, enabling easy movement along the entire reactor length for comprehensive temperature profile measurement while adapting to thermal deformation.
Solution Approach 2:
The patent introduces dynamic adaptability by using a flexible cable that can change its configuration in response to the thermo-well tube's deformation. This dynamic flexibility allows the measuring means to move easily along the tube despite thermal expansion, maintaining ease of operation while enabling complete temperature profiling.
3Measurement precision
If a rigid thermocouple is used to measure temperature along the entire reactor length, then complete temperature coverage is achieved, but the thermocouple is prone to breakage due to thermal deformation and friction
Solution Approach 1:
The patent fundamentally changes the mechanical parameter of the temperature measuring means from rigid to flexible. This parameter transformation allows the cable to withstand thermal deformation and friction forces without breaking, while maintaining the capability to measure temperature along the entire reactor length through its flexible, adaptable structure.
Solution Approach 2:
The patent applies flexibility to the temperature measuring means, using a cable-type construction that can bend and deform without breaking. This flexible structure maintains mechanical integrity under thermal stress and friction, enabling comprehensive temperature profiling along the entire reactor length without the risk of breakage associated with rigid thermocouples.
4Measurement precision
If the thermocouple is broken during insertion, then measurement is compromised, but the broken thermocouple cannot be withdrawn from the thermo-well tube
Solution Approach 1:
The patent uses a flexible cable-type temperature measuring means that can be easily inserted into and withdrawn from the thermo-well tube. This flexibility ensures that even if the sensor portion is damaged, the entire cable can be smoothly removed from the tube for replacement, maintaining ease of repair and continuous temperature monitoring capability.
Solution Approach 2:
The patent introduces dynamic flexibility to the temperature measuring means, allowing it to adapt during insertion and withdrawal operations. This dynamic characteristic ensures that the cable can be easily removed from the thermo-well tube even after use, enabling straightforward replacement if damage occurs and maintaining continuous temperature monitoring capability.
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
Enables easy and accurate temperature measurement along the entire reactor length, reduces mechanical friction, and allows for continuous operation even if one thermocouple fails, with the ability to replace or repair sensors without disrupting the monitoring system.
Implementation Method 1
a thermocouple (1) inserted into a thermo-well tube (5)
Implementation Method 2
the thermo-well tube protecting the thermocouple is thermally expanded and extremely deformed due to bending or twisting
Data Source
AI summary
Disclosed is a temperature measuring device. The temperature measuring device includes: a thermo-well tube; and a cable or wire type temperature measuring means which is installed in a thermo-well tube, wherein temperature measuring means has temperature detecting sensors disposed at an intermediate portion thereof, and the temperature detecting sensors can be moved axially in the thermo-well tube by applying tension to both ends of the cable or wire type temperature measuring means. The present invention also provides a reaction tube in which the temperature measuring device is disposed axially, and a reactor including at least one temperature measuring device or reaction tube as described above.