Slurry Solid Detection via Thermal Field Monitoring
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Solution Overview
Problem
Existing methods for detecting settled solids in conduits transporting slurries are either expensive, pose health risks due to radioactive materials, or increase energy costs, and lack accuracy in monitoring conditions to prevent solids settlement.
Innovation Solution
A device with a housing that includes a reference temperature sensor and heaters positioned inside the conduit to maintain a target temperature higher than the ambient slurry temperature, allowing for accurate monitoring of slurry flow conditions by measuring power consumption, which indicates the presence and depth of settled solids without compromising the conduit's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotating gamma gauge with radioactive source is used to detect settled solids, then detection capability is achieved, but health and safety concerns arise and equipment cost increases
Solution Approach 1:
The patent replaces expensive, hazardous radioactive sources with inexpensive, non-hazardous temperature sensors and heaters. The sensing elements are simple thermal devices that can be easily replaced if needed, eliminating the health and safety concerns associated with radioactive materials while maintaining detection functionality through thermal field measurements
Solution Approach 2:
The patent substitutes the mechanical/physical radioactive gamma radiation system with a thermal field-based sensing system. Instead of using radioactive isotopes that emit gamma rays, the invention uses electric heaters and temperature sensors to create and measure thermal fields, providing a safe alternative that achieves the same detection purpose without harmful radiation
2Reliability
If heaters and sensors are mounted on the outer wall of the pipe, then protection from abrasive damage is achieved, but measurement accuracy decreases due to thermal conduction through pipe walls
Solution Approach 1:
The patent inverts the mounting location of the sensing elements from the outer wall of the pipe to the inner wall, directly exposed to the slurry flow. This inversion sacrifices some protection from abrasive damage but dramatically improves measurement accuracy by eliminating thermal conduction delays through the pipe wall, allowing the sensors to directly measure slurry temperature
Solution Approach 2:
The patent applies a protective coating to the inner wall of the pipe housing before mounting the temperature sensors. This preliminary protective layer shields the sensors from direct abrasive contact with the slurry, allowing them to be mounted in the optimal position for measurement accuracy while still providing protection from damage
3Reliability
If conveying velocity is increased above minimum conveying velocity, then solids settlement is prevented, but energy requirements and costs increase
Solution Approach 1:
The patent implements a feedback control system where temperature sensors continuously monitor the slurry for signs of solids settlement (such as insulation effects from settled solids). When settlement is detected, the system signals the pump to increase conveying velocity only to the extent necessary to prevent further settlement, rather than maintaining a constantly high velocity. This feedback-based approach prevents solids settlement while minimizing energy consumption by adjusting velocity dynamically based on actual conditions
4Measurement precision
If multiple heaters are mounted circumferentially inside the conduit, then detection accuracy across various conduit geometries is improved, but device complexity increases
Solution Approach 1:
The patent divides the sensing system into multiple discrete heater-sensor assemblies positioned at different circumferential locations around the conduit. Each assembly independently monitors its local region for solids settlement. This segmentation allows the system to accurately detect settled solids across various conduit geometries and orientations, as at least one assembly will always be positioned where settled solids are most likely to form, while keeping each individual assembly relatively simple in design
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 reduces costs, improves safety by avoiding radioactive sources, and enhances accuracy in detecting settled solids across various conduit geometries, while dynamically adjusting the target temperature to conserve energy.
Implementation Method 1
a reference temperature sensor associated with an inside of the housing to measure an ambient temperature of the slurry
Implementation Method 2
a plurality of heaters spaced on at least part of a circumference of the inside of the housing that are maintained at a target temperature that is higher than the ambient temperature of the slurry
Implementation Method 3
heating the slurry monitoring of slurry temperatures which occurs through the pipe walls
Data Source
AI summary
A device (100) for detecting settled solids (300) in a conduit (200) for transporting slurry. The device (100) comprises a housing (110) positionable to define at least a segment of a flow path for the slurry. The device (100) comprises a reference temperature sensor (140) associated with the inside of the housing 110 in order to measure an ambient temperature of the slurry within the conduit. The device (100) further comprises a plurality of heaters (150) spaced around part of the inside circumference housing (110) that are maintained at a target temperature that is higher titan the ambient temperature of the slurry.