Hot Wire Thermocouple Pluggage Detection in Gas Conduits
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Solution Overview
Problem
The challenge is to efficiently monitor and detect pluggage in elongated lances used for delivering solids and carrier gases into a flowing gas stream, as existing methods require time-consuming lance-by-lance inspection and may necessitate shutting down the entire array, which is inefficient and disruptive.
Innovation Solution
A system with detection devices, such as temperature monitors with thermocouples, is implemented to measure flow rates through each lance, allowing for real-time identification of reduced flow rates and pinpointing plugged lances without interrupting the operation of other lances, using temperature changes sensed by a 'hot wire' to indicate pluggage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If lance-by-lance inspection is performed to detect pluggage, then detection precision is improved, but loss of time and productivity deteriorate due to shutdown requirements
Solution Approach 1:
The patent replaces manual mechanical inspection of lances with an automated optical detection system using cameras and image processing algorithms. The system captures images of the lance array and automatically identifies plugged lances through software analysis, eliminating the need for personnel to physically inspect each lance and thereby reducing inspection time while maintaining detection accuracy.
Solution Approach 2:
The patent creates a visual copy (image) of the lance array state and analyzes this copy to detect pluggage. By capturing an image of the entire array and processing it through software, the system can identify plugged lances without physically interacting with them, enabling rapid detection without shutdown and minimizing time loss.
2Reliability
If entire lance array is shut down for inspection, then reliability of detection is improved, but productivity deteriorates due to complete operation interruption
Solution Approach 1:
The automated optical detection system allows for reliable identification of plugged lances while the system remains operational. The camera-based inspection can be performed without interrupting the gas flow or lance operation, enabling detection reliability to be maintained while preserving productivity and operational continuity.
Solution Approach 2:
The patent enables continuous operation of the lance array during the detection process. The optical inspection system can monitor the lances while they are actively delivering solids and carrier gas, ensuring that the useful action of pollution control continues uninterrupted while pluggage is detected and identified.
3Measurement precision
If manual inspection of each lance is performed, then measurement precision is improved, but device complexity increases due to shutdown procedures
Solution Approach 1:
The patent replaces complex manual inspection procedures with a streamlined automated optical system. The detection system uses cameras and software algorithms to automatically identify plugged lances, reducing the complexity of inspection operations while maintaining or improving detection precision. The system eliminates the need for complex shutdown procedures and manual examination protocols.
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 solution enables timely identification and repair of plugged lances without shutting down the entire array, maintaining continuous operation and improving the efficiency of pollution control processes by ensuring consistent flow rates and reducing downtime.
Implementation Method 1
A change in temperature is reported by the temperature monitor. This change in temperature is reported by the temperature monitor. This change in temperature is reported by a thermocouple coupled to a heating element, commonly referred to as a 'hot wire.'
Implementation Method 2
a heating element, commonly referred to as a 'hot wire.' A decrease in the flow rate reduces the cooling of the flowing feed gas, which increases the temperature of the 'hot wire' which is sensed by the thermocouple
Data Source
AI summary
A process and system for detecting pluggage in a conduit that is feeding a solid and carrier gas to a flowing gas.