Zone-Separated Videoscope for In-Situ Explosion-Proof Process Control
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Solution Overview
Problem
Existing devices for observing and monitoring chemical processes in explosion-proof environments are not suitable for in-line or in-situ process control, as they either require large observation windows prone to wear and corrosion or are limited to offline analysis, and do not meet explosion protection regulations.
Innovation Solution
A zone-separated videoscope with a robust tube tip and protective housing, equipped with fiber optic cables and a flow-through design, allowing in-line observation and control of chemical processes in explosion-protected areas, meeting Zone 1/21 and 2/22 safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large observation windows are built into reactor vessels for direct optical observation, then direct process observation is enabled, but the windows are subject to wear, corrosion, leakage, or bursting under extreme loads
Solution Approach 1:
The observation system is segmented into a robust external housing and a separate observation tube with a small viewing window that projects into the reactor. This separates the large window function from the reactor vessel, protecting the main vessel from window-related damage while enabling observation.
Solution Approach 2:
An observation tube acts as an intermediary element between the reactor interior and the external housing. The tube transmits light and images while being robust enough to withstand reactor conditions, eliminating the need for large windows in the reactor vessel itself.
2Reliability
If endoscopic or videoscopic devices with small viewing windows are used, then robustness against wear and corrosion is improved, but electronic image analysis for process control is not enabled
Solution Approach 1:
The patent merges the robust endoscopic design with electronic imaging capabilities. The electro-optical camera integrated in the housing captures images through the observation tube, combining mechanical robustness with electronic analysis functionality.
Solution Approach 2:
The observation device serves multiple functions: it provides direct observation through the tube, captures electronic images for analysis, and maintains robustness against harsh conditions. This multi-functionality enables both manual viewing and automated process control.
3Ease of operation
If known process scopes are used in potentially explosive environments, then process monitoring is enabled, but they are not suitable due to explosion protection regulations
Solution Approach 1:
The housing is designed as an explosion-proof enclosure that maintains an inert internal environment. Electrical components are protected from explosive atmospheres, allowing safe operation in Zone 1/21 and Zone 2/22 areas while enabling process monitoring.
Solution Approach 2:
The observation tube serves as an intermediary that extends into explosive zones (Zone 0/20 or 1/21) while the main housing with electronic components remains in protected areas. This separation enables monitoring in hazardous environments while maintaining compliance with explosion protection regulations.
4Measurement precision
If offline analysis devices are used, then measurement capabilities are provided, but continuous in-line process control is not achieved
Solution Approach 1:
The system enables continuous in-line observation and electronic image capture during the polymerization process. Real-time monitoring allows continuous process control and optimization, eliminating the need for offline sampling and analysis.
Solution Approach 2:
The electro-optical camera provides continuous visual feedback on particle formation and reaction progress. This enables real-time process control adjustments to optimize polymerization, improving both measurement precision and productivity.
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 continuous, in-situ process monitoring and control in high-pressure and high-temperature environments, optimizing production processes by analyzing parameters like particle motion and size distribution without interrupting operations, while ensuring explosion safety.
Implementation Method 1
Optical cables or fiber optic cables are provided for the light transmission from the illumination device to the tube tip and for the image transmission from the tube tip to the electro-optical camera
Data Source
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AI summary
The invention relates to a device (1), especially a process scope, for the in-line or in-situ observation, monitoring, closed-loop and open-loop control of chemical and physical processes in the interior of explosion-proof containers and reactors, especially in large-scale industrial systems, during operation and without interruption of the production and/or development and research process. Said device (1) comprises an observation tube (3) having a tube tip (3'), an electro-optic or spectroscopic camera (6), a shock-proof housing (2) with an electronic protection circuit (5) and a lighting device (4), and image processing electronics (19). The tube tip (3') does not have any ignition sources and is suitable for use in danger zones 0/20 or 1/21 of an explosion-proof area. The housing (2) is explosion-proof and suitable for use in danger zones 1/21 or 2/22 of an explosion-proof area. The power supply unit (17) and the data acquisition, data analysis and data recording system (19) are provided for use in danger zone NH of an explosion-proof area. Optical waveguides, especially optical cables (21, 23) are provided for transferring light from the lighting device (4) to the tube tip (3') and for the image transfer from the tube tip (3') to the electro-optic or spectroscopic camera (6). A single- mode or multi-mode glass fiber data cable (18) is provided for the transmission of image data from the electro-optic or spectroscopic camera (6) to the data acquisition, data analysis and data recording system (19). By arranging the lighting and monitoring front windows laterally in the tube tip (3'), it is possible to carry out, for example, parallax distance measurements within the reaction vessel.