Solid Rod Wave Guide for Liquid Level Measurement in Urea Synthesis
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Solution Overview
Problem
Existing radar methods for measuring liquid levels in high-pressure vessels, such as those in urea synthesis plants, face challenges due to the presence of dense gaseous phases, supercritical fluids, and corrosive environments, leading to unsatisfactory signal-to-noise ratios and energy inefficiency.
Innovation Solution
A radar method using a solid rod wave guide to transmit and receive electromagnetic signals, which is less affected by mist, foam, and dense gaseous phases, and operates at lower frequencies to reduce energy dissipation and improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radar measurement is used to measure liquid level in high-pressure vessels, then non-contact measurement is achieved, but signal-to-noise ratio deteriorates due to dense gaseous phases and supercritical fluids
Solution Approach 1:
A probe transmitter is introduced as an intermediary device that extends into the dense gaseous phase or supercritical fluid above the liquid level. This transmitter serves as a mediator that can withstand the harsh environment while emitting and receiving radar signals, thereby improving measurement reliability without sacrificing signal-to-noise ratio
Solution Approach 2:
The radar system parameters are changed by using a probe transmitter that operates at specific frequencies and power levels suitable for high-pressure environments. The transmitter parameters are optimized to penetrate dense gaseous phases and supercritical fluids effectively, resolving the contradiction between measurement reliability and signal quality
2Reliability
If conventional radar methods are used in corrosive environments, then non-contact measurement is achieved, but measurement precision deteriorates due to energy dissipation in dense fluids
Solution Approach 1:
The probe transmitter acts as a protected intermediary that shields the radar measurement system from direct exposure to corrosive fluids. By placing the transmitter in a protected position while maintaining measurement capability, both reliability and precision are preserved in corrosive high-pressure environments
Solution Approach 2:
The conventional mechanical or contact-based measurement systems are replaced with a radar-based electromagnetic measurement system using a probe transmitter. This substitution eliminates mechanical wear and corrosion issues while maintaining measurement accuracy through optimized electromagnetic signal transmission
3Measurement precision
If probe transmitters are installed in direct contact with process fluid, then measurement capability is improved, but device reliability deteriorates due to corrosive attack
Solution Approach 1:
A protective barrier or diaphragm is introduced as an intermediary between the probe transmitter and the corrosive process fluid. This intermediary allows the transmitter to function close to the liquid level for accurate measurement while preventing direct corrosive attack on the transmitter components
Solution Approach 2:
A thin protective film or membrane is used to enclose the probe transmitter, allowing it to operate in close proximity to the corrosive fluid without direct contact. This flexible barrier maintains measurement capability while protecting the device, resolving the contradiction between measurement precision and device reliability
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
The method provides more accurate, efficient, and reliable liquid level measurements in harsh conditions, requiring less energy and avoiding the installation of large, costly hollow tubes.
Implementation Method 1
A radar method using a solid rod wave guide to transmit and receive electromagnetic signals
Implementation Method 2
emitting a first electromagnetic signal from above the liquid level and towards the liquid level, through a wave guide which is an elongate solid rod
Implementation Method 3
detecting a second electromagnetic signal which is generated by the first signal reflected by the surface of the liquid
Implementation Method 4
The radar method suffers the drawback of scattering induced by the fluid above the liquid level (so called Tyndall effect)
Data Source
AI summary
A method and system for measuring a liquid level in a pressure vessel, the method comprising: transmitting an electromagnetic signal through a wave guide in the form of an elongate solid rod (5) with bottom end immersed in the liquid and detecting a signal generated by the reflection on the surface of the liquid.