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Monitoring Blast Furnaces and Other Process Vessels by Acoustic Emission (AE) Monitoring Technique

All metallurgical vessels encounter similar problems with their refractory linings: chemical attack, wear abrasion, cracking, metal penetration and spalling. Thermal cycling is a key factor contributing to the structural deterioration of furnaces. Some of these issues are progressive, others are abrupt changes which can cause safety hazards or vulnerable linings. Traditional industry practices rely on long-term continuous monitoring of temperatures by thermocouples, monitoring of cooling water temperatures and heat flux variation to provide lining condition information. Recant years, periodic refractory thickness measurements by Acousto Ultrasonic-Echo (AU-E) was developed to provide discrete snapshots of furnace conditions and pinpoint local problematic areas [1, 2]. Furthermore, a long-term continuous monitoring system known as the Furnace Integrity Monitoring System (FIMS) was developed for smelting furnaces, aiming to provide real-time furnace condition monitoring. Since damages such as cracking, refractory wear and metal infiltration, etc. produce transient elastic waves (i.e. an acoustic emission (AE) which can propagate from the initial location to the furnace shell, by installing an array of AE sensors/receivers on the furnace shell, one can record all the AE signals and correlate with the furnace condition to prevent furnace run-out.
Product:
2019 AISTech Conference Proceedings
PR-377-039
Winnie Ying, Afshin Sadri
May 01, 2019
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