Suspension Smelting Burner Monitoring via Cross-Section Imaging
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Solution Overview
Problem
Existing methods for monitoring the performance of burners in suspension smelting furnaces are limited, as they can only determine symmetry of the reaction gas outlet during shutdowns, leading to prolonged poor performance due to issues like asymmetry, build-up, increased slag loss, lower oxygen utilization, and higher magnetite ratios in slag.
Innovation Solution
The method involves using imaging and processing means to produce and compare images of the reaction gas channel cross-section, enabling online monitoring of symmetry and build-up, allowing for immediate reaction to performance issues, including the use of imaging means outside or inside the burner and laser rangefinders to measure channel widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If monitoring is performed only during shutdowns, then measurement precision is improved, but loss of time increases and productivity decreases
Solution Approach 1:
The patent replaces manual visual inspection during shutdowns with an automated imaging system using cameras and image processing algorithms. The imaging means captures images of the reaction gas channel cross-section, and computer processing determines symmetry automatically, eliminating the need for physical access and manual measurement during shutdowns.
Solution Approach 2:
The patent introduces an intermediary imaging system that can monitor the burner performance non-invasively from the outside. The imaging means acts as a mediator to capture visual information about the reaction gas channel without requiring shutdown or physical intrusion, enabling continuous remote monitoring.
2Device complexity
If monitoring is performed only during shutdowns, then device complexity is reduced, but productivity decreases due to prolonged poor performance
Solution Approach 1:
The patent enables continuous monitoring during operational shutdowns, eliminating the downtime between monthly or bimonthly shutdowns. The imaging system operates continuously or at frequent intervals, providing ongoing feedback on burner performance and allowing immediate response to symmetry deviations or build-up issues.
Solution Approach 2:
The patent implements a feedback loop where images are captured, processed to determine symmetry, and the results are used to trigger alerts or automatic adjustments. This closed-loop feedback system enables real-time detection of performance degradation and immediate corrective action, maintaining high productivity without requiring complex manual monitoring systems.
3Measurement precision
If imaging means are placed inside the burner, then measurement precision is improved, but device complexity and safety risks increase
Solution Approach 1:
The patent uses optical intermediaries such as mirrors, prisms, or transparent windows to transmit light from the reaction gas channel to the imaging means positioned outside the burner. This allows high-precision imaging of the channel cross-section without requiring physical placement of sensitive imaging equipment inside the harsh, high-temperature burner environment.
Solution Approach 2:
The patent divides the imaging system into separate functional components: the imaging means positioned outside for safe operation, optical intermediaries for light transmission, and image processing systems for analysis. This segmentation allows each component to be optimized independently and simplifies installation and maintenance while maintaining measurement precision.
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 approach enables continuous monitoring and quick response to performance issues, reducing slag loss, improving oxygen utilization, lowering magnetite ratios, and minimizing dust and build-up, thereby maintaining optimal burner performance without shutdowns.
Implementation Method 1
producing images representing the cross-section of the reaction gas channel by means of at least one imaging means
Implementation Method 2
at least two laser rangefinders for measuring width of the reaction gas channel
Data Source
AI summary
Provided are a method and an arrangement for monitoring performance of a burner of a suspension smelting furnace. The burner is arranged at the top structure of a reaction shaft of the suspension smelting furnace. The burner has a solids feeding channel that has a solids outlet opening up into the reaction shaft, and a reaction gas channel comprising a reaction gas channel a that has a reaction gas outlet opening up into the reaction shaft. The arrangement comprises at least one imaging means for producing images representing the cross-section of the reaction gas channel, and a processing means for receiving images of the cross-section of the reaction gas channel from the imaging means.