Refractory Thickness Scanning for Hot Furnace and Ladle Walls
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Solution Overview
Problem
Current methods for determining the thickness of refractory material in manufacturing vessels, particularly glass furnaces, are inaccurate and impractical due to high operating temperatures and limited accessibility, leading to unnecessary maintenance and operational risks.
Innovation Solution
A system and method using a surface profile scanner and computational algorithm to determine refractory material thickness while the vessel is at operating temperatures, integrating sensors like laser scanners and LIDAR devices to collect data on surface roughness and reference positioning, processing it to assess gaps and bending for accurate thickness measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement techniques are used to determine refractory material thickness, then measurement can be performed, but measurement precision deteriorates due to high temperatures and material degradation
Solution Approach 1:
The system performs measurements before the refractory material degrades to the point of failure. By continuously monitoring thickness from the interior surface, the system detects changes in thickness trends over time and predicts remaining service life before critical degradation occurs, allowing preventive maintenance scheduling.
Solution Approach 2:
The patent replaces physical contact measurement methods with electromagnetic radiation-based measurement. Sensors mounted on the interior surface use electromagnetic waves to measure thickness through the refractory material, eliminating mechanical contact issues and enabling measurement in high-temperature environments without compromising the refractory structure.
2Reliability
If conservative maintenance scheduling is implemented to ensure vessel safety, then reliability improves, but productivity deteriorates due to increased unscheduled shutdowns
Solution Approach 1:
The system continuously monitors refractory material thickness from the interior surface and feeds this data back to predict remaining service life. By analyzing thickness reduction trends over time, the system provides feedback that enables data-driven maintenance scheduling, replacing refractory material based on actual condition rather than conservative time-based intervals.
Solution Approach 2:
The measurement system detects thickness changes and predicts failure before it occurs, allowing maintenance to be scheduled in advance during planned downtime rather than requiring unscheduled shutdowns. This preliminary detection enables proactive maintenance planning that optimizes the balance between safety and productivity.
3Speed
If laser scanning technology is used to map refractory surfaces, then measurement speed improves, but measurement precision deteriorates due to surface roughness and gaps
Solution Approach 1:
The system divides the measurement task into two segments: first, laser scanning rapidly maps the exterior surface geometry; second, sensors mounted on the interior surface measure the interior surface profile. By segmenting the measurement approach and combining both data sets, the system overcomes the limitation of laser scanning alone in detecting surface roughness and gaps that affect thickness accuracy.
Solution Approach 2:
The patent merges laser scanning technology with interior surface-mounted sensors to create a comprehensive measurement system. The laser provides rapid exterior mapping while the interior sensors capture surface profile data including roughness and gap information, combining the advantages of both methods to achieve high-speed and high-precision measurement.
4Loss of energy
If refractory material thickness is not accurately monitored, then operational costs decrease, but harmful factors increase due to potential vessel failure
Solution Approach 1:
The system performs preliminary detection of thickness changes and predicts remaining service life before critical failure occurs. By monitoring thickness trends from the interior surface and analyzing degradation rates, the system enables proactive maintenance scheduling that prevents catastrophic vessel failure, optimizing the balance between operational cost and safety.
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 safe and efficient maintenance planning by accurately estimating refractory material thickness, reducing unscheduled repairs, and extending operational life of manufacturing vessels.
Implementation Method 1
transmit a laser beam to a pre-defined area of an innermost surface of the refractory material and receive a reflected beam of light from that area
Implementation Method 2
transmitting a set of electromagnetic waves to a zone having a region of interest within a coverage area of the antenna
Data Source
AI summary
Disclosed is a system and a method for determining the thickness of a refractory material forming part of a manufacturing vessel, such as a furnace or ladle, using a surface profile scanning while the vessel is maintained at operating temperatures. The system and method are operative to determine the relative positionings of an internal surface and the corresponding external surface of such material, based on a plurality of surface profile data scans. Additionally, a computational algorithm can process these data and/or other data to determine certain flaws of the refractory material, including the presence of gaps within and bending or deformation of such material for a more accurate determination of its thickness. This provides a way to early warn a user of the risk of continuing operating the vessel, achieve a higher operational safety, and more accurately estimate both the remaining operational life and the maintenance plan of the vessel.