Multi-Wavelength Pyrometer Furnace Refractory Temperature Measurement
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Solution Overview
Problem
Current temperature measurement methods in furnaces are inaccurate, leading to inefficient energy consumption, increased material oxidation, and emission of harmful gases like carbon monoxide, due to the lack of precise control over the refractory lining temperature during the heating process.
Innovation Solution
A system utilizing multi-wavelength pyrometers to accurately measure the refractory lining temperature inside the furnace, coupled with a heating control module that adjusts fuel and oxidant amounts based on real-time temperature readings to maintain optimal working temperatures and minimize carbon monoxide emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermocouples are attached to the outer surface of the vessel to measure temperature, then the measurement device is simple and easy to install, but the temperature measured is only an approximation and not the actual temperature inside the vessel
Solution Approach 1:
The patent uses the refractory lining as an intermediary medium. Instead of directly measuring the material temperature or drilling holes through the vessel wall, the system measures the temperature of the refractory lining which thermally couples with the material. This intermediary approach allows accurate temperature measurement without compromising the vessel structure or requiring direct penetration of the material being heated.
Solution Approach 2:
The patent replaces mechanical contact-based temperature measurement systems (thermocouples requiring physical attachment or drilling) with an optical measurement system. The multi-wavelength pyrometer uses optical radiation to measure the temperature of the refractory lining from outside the vessel, eliminating the need for mechanical penetration of the vessel wall or direct contact with the heated material.
2Measurement precision
If drilled holes are made in the vessel walls to insert temperature measuring devices, then the measurement device can be closer to the material, but the refractory lining is significantly weakened which may lead to catastrophic failures
Solution Approach 1:
The refractory lining serves as a thermal intermediary that transfers heat from the material to the measurement point. By measuring the temperature of this intermediary layer (refractory lining) which is thermally coupled with the material, the system obtains accurate temperature data without needing to drill holes through the vessel wall or compromise the structural integrity of the refractory lining.
Solution Approach 2:
The patent replaces mechanical insertion methods (drilling holes and inserting thermocouples) with non-contact optical measurement. The multi-wavelength pyrometer measures temperature through optical radiation from the refractory lining surface, completely avoiding mechanical penetration of the vessel wall and preserving the strength and reliability of the refractory lining structure.
3Measurement precision
If temperature measurements are carried out from the outside during downtime periods, then the refractory lining temperature can be measured, but the process becomes time consuming and productivity is reduced
Solution Approach 1:
The patent enables continuous temperature measurement during the furnace operation cycle. The multi-wavelength pyrometer provides real-time temperature data of the refractory lining while the material is being heated, eliminating the need to stop production for measurements. This continuous monitoring allows for real-time process control and optimization without interrupting productivity.
Solution Approach 2:
The replacement of mechanical contact-based measurement systems with optical radiation measurement enables non-intrusive, real-time temperature monitoring during operation. The pyrometer can measure temperature continuously from outside the vessel wall without requiring physical access or downtime, thereby maintaining productivity while providing accurate temperature data for process control.
4Measurement precision
If multi-wavelength pyrometers are used to measure refractory lining temperature during operation, then real-time temperature control is achieved, but the device complexity increases
Solution Approach 1:
The refractory lining acts as a thermal intermediary that simplifies the measurement system architecture. Instead of requiring direct measurement of the material or complex sensor arrays inside the vessel, the system uses the refractory lining temperature as a proxy that thermally represents the material temperature. This intermediary approach enables accurate measurement with relatively simple optical measurement equipment from outside the vessel.
Solution Approach 2:
The system measures temperature at a different location (refractory lining) than the target object (material being heated), using thermal conduction principles to infer the material temperature from the lining temperature. This parameter transfer approach allows accurate temperature control without requiring complex direct measurement systems inside the high-temperature environment, thereby reducing overall system complexity.
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 precise control of the heating process, optimizing energy consumption, reducing material oxidation, and minimizing harmful gas emissions, thereby improving product quality and production efficiency.
Implementation Method 1
Some other solutions carry out measures of the temperature of the refractory lining from the outside of the vessel and through its mouth during the downtime periods of the vessels
Implementation Method 2
the beams emitted by the multi-wavelength pyrometer are projected directly onto said portion of the refractory lining in the heating chamber
Data Source
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AI summary
The invention refers to a system for measuring the temperature inside a furnace and to a method for controlling the combustion in the furnace. The combustion comprises a vessel that defines a heating chamber in which a material is to be heated, an openable door, at least one burner configured to burn a fuel and a gaseous oxidant, each burner generating a flame inside the heating chamber that heats the material and a flue through which an exhaust flame extends out of the heating chamber. The system comprises at least one multi-wavelength pyrometer coupled to the furnace wherein the multi-wavelength pyrometer is oriented towards a portion of a refractory lining of the heating chamber not in direct contact with the heated material. The multi-wavelength pyrometer is configured to measure the temperature of the corresponding portion of the refractory lining during operation of the furnace.