Steel Scale Composition Detection by Multi-Wavelength Emissivity
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Solution Overview
Problem
Existing methods for determining the composition of scales on steel materials during hot rolling are not accurate for real-time online analysis due to reliance on model equations and interference from water or water vapor, making it difficult to assess the composition of scales generated on steel surfaces during operation.
Innovation Solution
A scale composition determination system that detects spectral radiance and temperature of steel materials, derives spectral emissivity, and determines the presence of hematite (Fe2O3) in the outermost layer by comparing spectral emissivity values across multiple wavelengths, using predetermined ranges to differentiate between single-layer and multilayer scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple types of scales are analyzed using multiple types of spectrometers, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent employs multiple types of spectrometers (FT-IR, Raman, XRD, XRF, ICP-OES, ICP-MS) to analyze different aspects of scale composition simultaneously. Each spectrometer targets specific components: FT-IR for organic compounds, Raman for crystalline structures, XRD for mineral phases, XRF for elemental composition, and ICP for metal concentrations. This multi-functional approach enables comprehensive characterization of complex scale deposits without requiring separate analytical systems for each component type.
Solution Approach 2:
The analytical system is divided into specialized spectrometer modules, each optimized for detecting specific scale components. Rather than using a single complex instrument, the patent segments the analysis into multiple targeted measurements, where each spectrometer handles a particular aspect of scale composition (organic vs. inorganic, crystalline vs. amorphous, elemental vs. molecular). This segmentation maintains measurement precision while managing system complexity through modular architecture.
2Productivity
If scale deposits are removed more aggressively, then productivity is improved, but harmful factors increase due to damage to heat exchange tubes
Solution Approach 1:
The patent utilizes controlled parameter changes in electrochemical cleaning, where voltage, current density, and electrolyte composition are precisely adjusted to optimize scale removal while protecting the heat exchange tubes. By varying these parameters dynamically, the system achieves effective cleaning without exceeding the threshold that would cause tube damage, thus maintaining productivity while minimizing harmful effects.
Solution Approach 2:
The system incorporates real-time monitoring of cleaning effectiveness and tube condition, using sensors to detect scale removal progress and potential damage indicators. This feedback mechanism allows dynamic adjustment of cleaning intensity, ensuring that productivity goals are met while preventing harmful damage to the heat exchange tubes by reducing cleaning aggressiveness when approaching damage thresholds.
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 accurate, real-time determination of scale composition on steel surfaces, improving operational management by distinguishing between single-layer and multilayer scales regardless of thickness, thus ensuring effective scale removal and surface quality.
Implementation Method 1
a plurality of spectrometers including a first spectrometer that irradiates the first scale deposit with first electromagnetic radiation and detects the first scale deposit based on interaction between the first scale deposit and the first electromagnetic radiation
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A scale composition determination device (10) determines that Fe2O3 has been generated in the outermost layer of a scale (SC) in the case where at least one of spectral emissivities at one wavelength and the other wavelength that are measured by radiometers for spectral emissivity measurement (21a, 21b) is not within a predetermined range including spectral emissivities of FeO at one wavelength and the other wavelength, and determines that Fe2O3 has not been generated in the outermost layer of the scale (SC) in the case where all of the spectral emissivities at one wavelength and the other wavelength that are measured by the radiometers for spectral emissivity measurement (21a, 21b) is within the predetermined range including the spectral emissivities of FeO at one wavelength and the other wavelength.