Ultrasonic Thermometer Refractory Thickness Measurement
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Solution Overview
Problem
Existing technologies face challenges in reliably measuring refractory temperature and thickness in harsh coal gasification environments, leading to frequent refractory degradation and high replacement costs, with direct measurement sensors being insensitive to dynamic temperature changes and indirect measurements prone to modeling errors and uncertainties.
Innovation Solution
An ultrasonic thermometer with a continuous measurement pathway and backscatterers is used to measure temperature profiles and thickness, employing ultrasonic pulses and processing devices to determine instantaneous average temperatures and distances, providing non-invasive, real-time characterization of refractory conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct measurement sensors with heavy sheathing are used to withstand harsh gasification environment, then sensor durability is improved, but sensitivity to dynamic temperature changes deteriorates
Solution Approach 1:
The patent introduces an intermediary measurement approach using ultrasonic transducers that measure temperature indirectly through the speed of sound in the refractory material. This mediator (ultrasonic wave propagation) allows temperature measurement without direct sensor contact with the harsh environment, thus maintaining both durability and sensitivity. The ultrasonic transducer placed on the external surface acts as an intermediary that couples the measurement function with the refractory without requiring the sensor to withstand extreme conditions directly.
Solution Approach 2:
The patent replaces the mechanical direct-contact temperature sensing system (thermocouples with heavy sheathing) with an acoustic field-based measurement system. By substituting mechanical sensors with ultrasonic wave propagation measurements, the system achieves temperature measurement without mechanical sensors exposed to harsh environments, thereby maintaining sensitivity while improving reliability.
2Reliability
If indirect measurements with modeling are used to infer operating parameters, then measurement safety is improved, but measurement accuracy deteriorates due to modeling errors
Solution Approach 1:
The patent replaces indirect electrical/measurement modeling approaches with direct acoustic field measurements. By using ultrasonic wave propagation characteristics (speed of sound) that directly correlate with temperature, the system eliminates the need for complex thermal models and inference algorithms, thereby improving measurement accuracy while maintaining the safety benefits of indirect measurement.
3Ease of operation
If conventional sensors are used in harsh gasification environment, then initial measurement capability is achieved, but service life deteriorates due to chemical and physical degradation
Solution Approach 1:
The patent uses the refractory material itself as an intermediary medium for measurement. By measuring the speed of sound through the refractory from an external transducer, the system obtains temperature data without placing sensors inside the harsh environment. The refractory acts as a coupling medium that protects the measurement system while enabling continuous operation for extended periods.
Solution Approach 2:
The patent creates a copy of the temperature information through ultrasonic wave propagation characteristics. Instead of placing a physical sensor in the harsh environment, the system uses the acoustic properties of the refractory to copy and transmit temperature data to external measurement equipment, thereby extending service life while maintaining measurement capability.
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 ultrasonic thermometer enables extended refractory life, reduced maintenance costs, and improved process control by providing accurate, real-time temperature and thickness measurements, minimizing unnecessary replacements and maintaining operational safety and efficiency.
Implementation Method 1
An ultrasonic emitter positioned at the proximal end transmits at least one ultrasonic pulse through the solid structure along a measurement pathway
Implementation Method 2
An ultrasonic receiver adjacent the ultrasonic sound emitter receives pulse echoes reflected from the at least two backscatterers
Implementation Method 3
A processing device electronically coupled to the ultrasonic transducer and receiver determines at least one time interval between the pulse echoes; determines an instantaneous average temperature of the structure between the backscatterers based on the time interval
Implementation Method 4
at least two backscatterers formed in the solid structure transverse to the longitudinal axis and separated by a predetermined separation distance
Data Source
AI summary
An ultrasonic thermometer for measuring a temperature profile along a measurement axis of a structure, comprising a continuous measurement pathway of a structure (310) having a longitudinal measurement axis and proximal (202) and distal ends (204), and at least two backscatterers (332) formed therein transverse to the longitudinal axis and separated by a predetermined separation distance.