Particle Extraction Sensor for Corrosive Flue Gas
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Solution Overview
Problem
Existing devices for continuous measurement of particles in corrosive and hot flue gases are extremely costly due to the need for temperature and corrosion-resistant sensors, limiting their widespread use in industry.
Innovation Solution
A device that separates particles from the gas stream before measurement, using phase separation techniques like centrifugal separators and dilutes them with ambient air to reduce aggressiveness, allowing for the use of cost-effective, non-corrosion-resistant sensors for precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature and corrosion-resistant sensors are used to measure particles in flue gas, then measurement reliability in corrosive environments is improved, but device cost increases significantly
Solution Approach 1:
The measurement system is divided into two functional segments: a sampling/protection unit that interfaces with the corrosive flue gas environment, and a sensor unit that operates in a protected, non-corrosive atmosphere. This segmentation allows the sensor to avoid direct exposure to corrosive conditions while still measuring flue gas particles, thereby maintaining measurement reliability without requiring expensive corrosion-resistant sensors.
Solution Approach 2:
A protective sampling system acts as an intermediary between the corrosive flue gas and the measurement sensor. This intermediary structure includes a sampling probe and measurement chamber that physically isolate the sensor from direct contact with corrosive flue gas components, enabling the use of standard, cost-effective sensors while maintaining measurement accuracy in industrial applications.
2Duration of action of stationary object
If corrosion-resistant and heat-insensitive sensors are used, then sensor durability in hot flue gas is improved, but manufacturing cost increases
Solution Approach 1:
The sensor is extracted from the hot, corrosive flue gas environment and placed in a protected measurement chamber. By taking the sensor out of the harsh environment and only exposing it to diluted particle samples, the system achieves sensor durability without requiring expensive heat-resistant materials, thereby reducing manufacturing costs.
Solution Approach 2:
The flue gas sample is pre-treated through cooling and dilution before reaching the sensor. This preliminary action removes the thermal and corrosive stressors that would otherwise require expensive specialized sensors, allowing standard sensors to operate within their normal temperature and chemical resistance specifications while still providing durable, long-term operation.
3Measurement precision
If flue gas is directly supplied to the sensor, then measurement representativeness is improved, but sensor exposure to corrosive components increases
Solution Approach 1:
A sampling probe and measurement chamber serve as intermediaries that allow representative particle sampling while protecting the sensor from corrosive exposure. The system maintains measurement representativeness by preserving particle characteristics during sampling, while the physical barrier prevents direct contact between corrosive flue gas and the sensor.
Solution Approach 2:
The harmful corrosive components are extracted or separated from the measurement path by directing only particle-laden portions of the flue gas through the measurement chamber, while the bulk corrosive gas flows separately. This extraction approach maintains measurement accuracy for particles while minimizing sensor exposure to corrosive substances.
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
Significantly reduces the cost of monitoring technology by 90% and minimizes maintenance, enabling affordable and accurate dust concentration measurements in industrial settings with reduced corrosion and heat stress on equipment.
Implementation Method 1
means for phase separation in order to separate the particles from the gas stream
Implementation Method 2
means for diluting the separated particles
Data Source
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AI summary
The present invention relates to a device (100) for the continuous measurement of particles in a corrosive and/or hot gas stream, in particular for measuring the dust particle concentration in smoke or exhaust gases. According to the invention, phase separation means are provided to separate the particles from the gas stream. This eliminates the need for heat- and corrosion-resistant sensors, making the device (100) according to the invention significantly more cost-effective than previous devices. Furthermore, maintenance requirements are reduced because the corrosion- and heat-related stress on the measuring technology (122) is lower. Operators of combustion plants (105) therefore have access to emission measurement technology at a more affordable price and with lower maintenance requirements, thus enabling widespread use.