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  • 专利说明
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    • 专利摘要:
    CONFIGURED APPARATUS, SYSTEM, AND METHOD FOR MONITORING THE INTEGRITY OF A CONTAINER Apparatus, systems, and methods for monitoring the integrity of a container protected by a refractory material are described having a first radiation detector to measure an external surface temperature of the container, a first radiation source for measuring a thickness of the refractory material, and a central controller configured to display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material.
    公开号:BR112014011750B1
    申请号:R112014011750-0
    申请日:2012-11-12
    公开日:2020-10-20
    发明作者:Michel Pierre Bonin；Thomas Lawrence Harvill；Jared Hubert Hoog
    申请人:Process Metrix；
    IPC主号:
    专利说明:

    FUNDAMENTALS TECHNICAL FIELD
    [0001] Modalities of the subject described here generally refer to the apparatus, methods and systems and, more particularly, to the mechanisms and techniques for monitoring vessels or containers configured to maintain materials having a high temperature. DISCUSSION OF THE BASIS
    [0002] Metal vases or containers of various sizes and shapes designed to keep materials at elevated temperatures are widely used in many industrial applications. Examples of these applications include, but are not limited to, gasification processes in the production of energy and chemistry, electric arc wafers (EAF), basic oxygen wafers (BOF), cookware, tall wafers, degassers, and oxygen decarburization wafers argon (AOD) in the manufacture of wheels. As known in the art, these containers are usually lined with refractory material installed in the form of brick or cast in monolithic blocks in order to protect the metallic part of the vessel from the high temperature contents positioned therein; however, due to normal wear and tearing of the refractory material through the combined effects of oxidation, corrosion and mechanical abrasion, some portion of the refractory surface in contact with the molten metal is lost during processing, thus requiring frequent inspection to ensure the extended use by performing localized repair in order to avoid catastrophic failures and unnecessary or premature remodeling of the entire refractory lining of the vessel.
    [0003] Before the advance of inspection techniques based on. optically, the inspection of ceramic coatings to detect unacceptable levels of coating thickness was performed visually by an experienced operator looking for dark spots in the coating indicating both high localized heat transfer rates for the refractory material and metal hull as possible excessive wear and the need for coating repair. Such an approach introduces a combination of technique and science, exposes the container operator to unnecessary industrial hazards, reduces the frequency of inspections, and feels a lack of desired accuracy. In addition, the costs associated with installing and repairing ceramic tiles have increased significantly over the past twenty years as refractory materials have been redesigned for specific application installations. In order to improve the efficient use of these more expensive refractory materials, several conventional techniques have been developed to minimize the risks summarized above including those configured to directly measure the wear on the refractory material and those adapted to measure the effect of the refractory wear on the metal vessel, such as, for example, indirect monitoring of heat transfer rates to the vessel. However, as summarized below, these conventional techniques have several limitations.
    [0004] As for conventional techniques configured to measure quantitative refractory wear directly through the use of a laser, for example, since the diameters of lasers are finite sizes (for example, approximately 40 to 60 mm in some applications), defects Potential refractories with characteristic dimensions smaller than the diameter of the laser beam, such as a small hole in the coating, are very difficult, if not impossible, to detect, making the missing piece of brick also difficult to detect. In addition, because of the large angle of incidence between the laser beam and the pan walls, the size of the hole, when one is detected, appears to the operator or laser scanner to be smaller than it actually is.
    [0005] In addition, localized accumulation of slag on the internal surfaces of the pan can make it difficult to detect areas that were coating repairs may be necessary. That is, as steel is drained from the pot, the small amount of slag loaded from the converter that hits or is introduced into the pot metallurgy oven can form a coating on the walls or bottom of the pot. Since much of the added slag dissolves for the next heating cycle of the pan, comparing heat to heat measurements can sometimes reveal the build up of slag in a previous measurement. However, for any single heat technique that uses lasers it is not able to resolve the difference between remaining refractory and slag build-up on the interior pan surfaces. In this way, in the presence of slag accumulation, the system will predict the coating thickness in excess or predict the amount of refractory loss little - both limitations are undesirable in practice.
    [0006] Finally, another potential problem that cannot be detected by the laser-based system is the result of tuning, which occurs when molten steel naturally enters small gaps (for example, small openings with a characteristic dimension of approximately 1 to 5 mm) that develop between the bricks in a refractory-lined vessel. As understood by those skilled in the art, tuning has the potential to eventually form a metal bond between the molten metal contained in the pan and the solid metallic outer hull. Less bloating only causes localized heating of the hull of the pan. However, over time, less swelling can then become severe and result in melting of the hull of the pan and subsequently casting of molten steel. Thus, while conventional contouring systems are a useful tool for characterizing the interior profile of the vessel, there are situations in which the apparent thickness measurement alone may not be sufficient to prevent leakage.
    [0007] Examples of conventional techniques configured to measure the qualitative effect of refractory wear on the metal vessel are those adapted to estimate the temperature on the external surface of the vessel. As the internal refractory material wears out and becomes thin, the temperatures of the metal hull in the compromised areas increase due to increased heat transfer from the molten materials to the vessel. Such measurements are typically taken with the pan hanging from a winch, shortly after the pan leaves a plate launcher, and are used primarily to determine when the container should be removed from service. Qualitative measurement provides an indication of hot spots in the hull of the pan regardless of the cause (ie, imminent failures due to thinning of the coating, or tuning, or both) and thus are a direct measurement of the nominal health of the “containment. " However, experts in the applicable techniques will understand that these techniques provide only qualitative information and are not able to provide detailed information that characterizes the rate of wear of the coating itself. The local thickness of the refractory lining, the possible existence of thinning effects, the time that the molten metal was contained in the pan, the temperature history of the molten material while it was in the pan, the processing history (ie through pot metallurgy) of the molten material while in the pot, and the radioactive properties of the outer surface of the pots all contribute to the apparent temperature of the metal hull. Thus, external temperature measurements are only useful on a relative basis, and the lack of quantitative information in the data prevents the determination of wear rates and refractory optimization in the pan.
    [0008] Therefore, based on at least the challenges stated above of conventional techniques, what is needed are devices, systems, and methods that will minimize or eliminate inconsistencies in the measured data of refractory lining and external surface temperature of metal vessels configured for carry materials at temperatures above the metal's melting point. This will allow for early detection and creep inspection of molten metal or small holes in the coating - all of which can contribute to coating failures, thereby increasing operational safety while reducing operating costs associated with expensive cleaning operations and potential production downtime. SUMMARY
    [0009] According to an exemplary embodiment, an apparatus configured to monitor the integrity of a container protected by a refractory material is described that includes a first radiation detector configured to measure an external surface temperature of the container; a first radiation source configured to measure a thickness of the refractory material; and a central controller configured to display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material.
    [00010] According to an exemplary embodiment, a system for monitoring the integrity of a container protected by a refractory material is described that includes a thermographic device configured to measure an external surface temperature of the container; a refractory thickness measurement device configured to measure a thickness of the refractory material; and a central controller configured to display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material.
    [00011] According to an exemplary embodiment, a method for monitoring the integrity of a container having an internal layer of a refractory material is described that includes the steps of providing a first radiation detector configured to measure an external surface temperature of the container ; providing a first radiation source configured to measure a thickness of the refractory material; and providing a central controller configured to display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material. BRIEF DESCRIPTION OF THE DRAWINGS
    [00012] The attached drawings (which are not drawn to scale), which are incorporated and constitute a part of the specification, illustrate one or more modalities and, together with the description, explain these modalities. In the drawings: FIG. 1 illustrates a container configured to hold materials at elevated temperatures; FIG. 2 illustrates a schematic diagram of an apparatus or system configured to monitor the integrity of the container of FIG. 1 according to an exemplary embodiment of the subject described; FIG. 3 illustrates a schematic diagram of an apparatus or system configured to monitor the integrity of the container of FIG. 1 according to another exemplary modality of the subject described; FIG. 4 illustrates a simulated coating thickness profile and a simulated external surface temperature profile according to an exemplary embodiment; FIG. 5 illustrates an exemplary portion of a simulated coating thickness profile and a simulated outer surface temperature profile according to an exemplary embodiment; FIG. 6 illustrates a flow chart of a method for monitoring the integrity of a container having a protective refractory layer; FIG. 7 illustrates a flow chart of a method for monitoring the integrity of a container having a protective refractory layer; and FIG. 8 is a schematic diagram of a control device for a system or apparatus configured to identify potential fault locations in a vessel adapted to maintain materials at elevated temperatures according to an exemplary embodiment. DETAILED DESCRIPTION
    [00013] The following description of the exemplary modalities refers to the attached drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following modalities are discussed, for simplicity, with respect to the terminology and structure of the devices, systems, or methods capable of detecting potential fault locations in a container having a coating material to protect it from high temperatures in a manufacturing application. of steel. However, the modalities to be discussed below are not limited to these sets, but can be applied to other containers having a coating material exposed to an elevated temperature compared to the melting point of the material from which the container is made, the which coating integrity needs to be determined in order to avoid unexpected failures.
    [00014] Reference through the specification to "a modality" or "the modality" means that a particular functionality, particular structure, or particular characteristic described together with a modality is included in at least one modality of the subject described. Thus, the appearance of the phrases "in one modality" or "in modality" in various places throughout the specification is not necessarily referring to the same modality. In addition, particular functionalities, particular structures or particular characteristics can be combined in any suitable way in one or more modalities.
    [00015] FIG. 1 illustrates a container 2 configured to hold materials at elevated temperatures. As used here, the term “container” or “vase” is used interchangeably and widely, including reference to all types of metal or non-metallic vessels or containers of various sizes and shapes designed to hold materials at elevated temperatures that may be below , at or above the melting point of the material vessel. Examples of such containers or vases are those used in applications such as, but not limited to, gasification processes in energy and chemical production, We were electric arc (EAF), We were basic oxygen (BOF), pans, we were tall, degassers, and We have been decarburizing argon oxygen (AOD) in the manufacture of wheels. In addition, as used here, the term materials at elevated temperature is used to mean materials configured to be disposed within these containers having temperatures high enough to cause damage to the container since it is exposed to it when the integrity of the materials refractories that cover at least a portion of a container surface are somehow compromised in order to expose the container to materials at elevated temperatures. As shown, container 2 has a hull 4, an inner layer of refractory material 6, and an opening 8. Dotted line 7 in FIG. 1 illustrates the original refractory layer 6 before the container is put into use. In order to better explain the subject being described, container 2 was illustrated with two areas in which local wear and tear from use damaged the refractory material 6, as is further explained below.
    [00016] A first area 10 illustrates a location where a hole having a small opening 12 has developed in the refractory material 6. As understood by an expert in the applicable techniques, the first area 10 can also be illustrative of an area in the refractory material 6 where thinning has developed, that is, an area where, when in use, molten steel naturally enters small gaps (for example, small openings with a characteristic dimension of approximately, for example, 1 to 5 mm) that develop between the bricks in a refractory-lined vessel. A second area 14 is also illustrated in FIG. 1 in which a piece of the refractory material 6 was removed by use and accumulation of slag 16 inside the container 2 filled the void left by the refractory material that was removed. One of the advantageous features of the subject described is an improved ability to better identify areas 10 and 14 by a combination of coating thickness and external surface temperature measurements, as will be further explained below. It will be understood that areas 10 and 14 were shown as examples of problems that can develop during the use of container 2 and in no way limit the scope of the subject being described. That is to say, experts in the applicable techniques will understand that there may be other types of defects that can be detected by the subject described, thus, mentioning exemplary areas 10 and 14 should in no way limit the scope of the subject described. .
    [00017] FIG. 2 illustrates a schematic diagram of an apparatus (or system) 20 configured to monitor the integrity of the container 2 of FIG. 1 according to an exemplary embodiment of the subject described. As has been shown, apparatus 20 includes a thermographic system or apparatus 21 for monitoring the outer surface temperature of container 2 and a refractory thickness measurement system or apparatus 25 configured to monitor the thickness of refractory material 6 within container 2. O thermographic system 21 includes a first radiation detector 22 and a first controller 24 associated therewith. The refractory thickness measurement system 25 includes a first radiation source 26 and a second controller 28 associated therewith. As also shown in the exemplary embodiment of FIG. 2, both the thermographic system 21 and the refractory thickness measurement system 25 are in communication with a central controller 30. In FIG. 2, the first radiation detector 22 is shown connected to the first controller 24 by using a cable 32. Similarly, the first radiation source 26 is shown connected to the second controller 28 by a cable 34; and the first and second controllers 24 and 28 are shown connected to the central controller 30 by cables 36 and 38, respectively. However, experts will understand that these connections can be wireless in other modalities and controllers 24 and 26 can be provided individually as illustrated or combined in a single device with the central controller 30 or housed therein. That is, the interconnection and / or the arrangement of the devices illustrated in FIG. 2 do not limit the scope of the subject being described, but it is provided as an illustration of its modalities. In addition, the number of detectors and radiation sources is not limited to one of each. For example, in one embodiment, the first radiation detector 22 includes a plurality of infrared (IR) detectors (or cameras) configured to measure the outer surface temperature of container 2 by transferring radioactive heat from container 2 to the external detectors 22 and the first radiation source 26 is a light source used to scan the interior of the container 2 in order to allow measurement of the thickness of the refractory material in it. In another embodiment, the first radiation source 26 is a distance or range scanner configured to measure the distance from the location of the system 25 to interior points on the surface of the refractory material 6. In yet another embodiment, the first radiation source 26 may be one having a selected wavelength spectrum, said spectrum possibly being visible or invisible to the naked eye. In other exemplary embodiments, communications between the noted controllers and / or other components may occur via the internet, radio waves, microwaves, satellites or other means known in the art and connections between the controllers may be wired or wireless.
    [00018] In one embodiment, the first radiation detector or detectors 22 can be installed in the mill where container 2 is located, around the pan, to produce a composite image of the entire pan system. In another embodiment, the first controller 24 can be a personal computer (PC) that reads the output from IR cameras and assembles a composite image from individual images together if multiple cameras are used. The thermographic data collected by the IR cameras can be acquired while the pan or container 2 is hung from a winch. Thus, in such modalities, the relative orientation of the IR cameras and the pan can be nominally constant from measurement to measurement. The post-processing of the composite image of the thermographic data in such modalities can produce a temperature profile spatially resolved in cylindrical coordinates, the independent coordinate variables being Z (pan edge distance) and theta (the azimuth position around the circumference of the pan). R (the radial distance from a center line of the pan) can be redundant since the IR data is obtained only from the outer surface of the container. In some modalities the operation of systems 21 and 25 occurs concurrently, that is, measurements of the external surface temperature and internal coating thickness are made substantially simultaneously during the same stop of the vessel operation and combined and displayed to the user for evaluation of vessel 2. In other modalities, systems 21 and 25 are operated separately or sequentially during different stops of vessel operation and their data subsequently combined.
    [00019] According to an exemplary modality, a typical configuration that can be used to measure the coating thickness in a pan used in the steel industry is with the pan positioned in an appropriate station (in this case the station can be configured to rotate through a given angular displacement, for example, 360 °) at a given distance (for example, approximately 3 to 5 m) in front of the laser scanner with measurements taken with the pan mouth tilted towards the scanner. In another embodiment, band points for the inside of the pan are measured as described in U.S. Patent No. 6,922,252 (hereinafter the '252 patent which is assigned to the Assignee of this document).
    [00020] In another embodiment, the laser system 25 can be installed in a station with a fixed position that is both kinematic and instrumented to determine the position of the pan relative to the laser head. As was understood by the experts, in a kinematic modality, the pan position is constructed in such a way that to position the pan in the same position each time it is positioned in the position. In an instrumented mode, single-point laser rangefinders are used to measure the position of the pan at the station. In such modalities, the spatial orientation of the laser data must be known for the measurement uncertainty, typically ± 5 mm. The laser data can also be given in cylindrical coordinates, with R representing the local coating thickness at any given point in the pan, as illustrated later. With both the laser and IR scanner data in the same coordinate representation, the central controller 30 combines an image that represents the outer surface temperature of container 2 (for example, using a false colored composite image of the IR scanner in one modality) with a numerical representation of the local coating thickness in an appropriate grid density in order to preserve the clarity of the numerical thickness data. As further explained below, several algorithms are contemplated to produce such a combination of internal and external measurements in an efficient manner in order to allow the user to quickly and accurately determine where inconsistencies in thickness and temperature measurements exist in order to allow for a improved ability to detect potential container failures. One of the advantageous features of the subject described here is the fact that the qualitative IR scanner information and the qualitative coating thickness data eliminate, or substantially reduce the limitations of each measurement operation independently. The thinning of the overall coating and the analysis of the wear rate can be completed with the coating thickness data from the laser scanner. Thinning is easily observed in areas where the coating thickness remains acceptably high, but high outer pan hull temperatures are noted. Confirmation of thin coatings, regardless of slag accumulation, can be seen in regions where the laser scanner suggests reduced coating thickness and the IR scanner shows high surface temperature.
    [00021] Thus, one of the advantageous features of the subject described is the combination of the coating thickness data obtained from the laser scan of the inner pan with thermographic IR measurements of the outer surface of the pan's hull. Those skilled in the art will understand that the correlation of the internal refractory thickness with the external temperature will assist in the verification of internal thickness measurements. When combined as proposed here, the measurements will complement each other, that is, the limitations of one compensate for the capabilities of the other. A laser scanner difficult to detect potential failures due to thinning can be complemented with a thermographic scanner capable of detecting an incipient rise in hull temperature. Conversely, IR scanner systems lack quantitative information that describes the coating thickness that is produced in the laser scanner data. However, by combining data from both systems, a comprehensive pan analysis tool is created that provides protection against breakage, as well as quantitative information that characterizes wear rates and local coating thickness. Such systems can be operated simultaneously or sequentially. In addition, inconsistencies in the data, for example areas showing high temperature and high coating thickness, can be quickly and efficiently detected and unexpected additionally to molten metal creep or small holes in the coating - all of which can contribute to the failure of the coating. In this way, the subject described improves operational safety. In addition, improved detection of impending pan failure leads to significant cost savings by preventing the loss of added product value, costly cleaning operations, and potential downtime. In addition, the automated nature of the implementation allows the system to acquire and present data to the user quickly, through a simplified interface.
    [00022] In addition, the combined presentation produces an immediate correlation between hot spots and local reduction in coating thickness. Areas that show a thicker coating but high hull temperatures can be investigated immediately for both slag build-up and thinning, or small holes / bricks missing from the pan that were not detected by laser scanning. Areas that show low temperature but thin coating are unlikely to be affected by thinning, but should be addressed based on the limited coating life that remains alone.
    [00023] FIG. 3 illustrates a schematic diagram of an apparatus 40 configured to monitor the integrity of the container 2 of FIG. 1 according to another exemplary modality of the subject described. In this exemplary modality, five IR cameras 42A to 42E (cameras 42D and 42E are not shown for simplicity). Four of the cameras (42B to 42E) are used to monitor the outer surface of the container 2 in four quadrants of the side wall of the container and another camera (42A) monitors the bottom of the container. The measurement of refractory lining thickness is done in this modality by the use of a mobile trolley 44 that includes a tracking system 46 and a contour system 48 mounted on it as described in the '252 patent. However, it should be noted that the subject described here must be limited in any case by the use of the mobile cart 44 and / or the five IR cameras 42A to 42E. Different configurations of the invention are possible that will take into account the availability of space and particular requirements of a given application. For example, fixed position laser measuring devices can also be used for pan measurement. These devices can be positioned above a transfer car, or adjacent to a sliding portal maintenance station in other ways. Arrangements of the present invention, such as reference marks configured to assist in positioning the mobile cart 44 (not shown in FIG. 3) can be anchored to the floor, construction columns, or in the hood area are also possible. In both fixed or mobile position modes, the laser can be positioned as close to the mouth of the vessel as possible in order to maximize the field of view.
    [00024] As has been understood by those skilled in the art, modalities that use a mobile scanner can simplify the process of acquiring the refractory thickness date by eliminating the need to use fixation points in or near the high temperature container. In addition, if the system measurement is mobile and the terrain on which it moves is uneven, an accurate determination of the position of the system measurement in relation to the container is necessary. However, as understood by the experts, the positioning of the sensors is dependent on the nature of the application and the degrees of freedom in the installation of the container and should not limit the scope of the subject for which the patent protection is intended. For example, in modes configured to characterize a BOF, the only unknown degree of freedom may be the inclination of the oven. In pan applications that use fixed position instrumentation, the measurements described can be automated. In pan applications, the vessel can typically be brought into the described measuring system, while in BOF / converter applications the described measuring system can be brought into the vessel. For applications involving pots, one of the advantageous features of a particular mode may be a single button operation, that is, with the pot in the measurement position, an operator may only need to press a “measurement” button, and the system will automatically scan the pan and report the results. In other embodiments, single button operation can be implemented for the IR scanner, although control can typically be initiated from a winch cabin.
    [00025] In the illustrated modality, one of the components of the contour system 48 is a sensor that measures the range, that is, the distance from the contour system to a target, and the location of that target in relation to the range sensor. In operation, optical radiation 50 from an optical radiation source in the bypass system 48 is emitted into the container and the reflected optical radiation from inside the container is detected back by the bypass system. Based on the time taken between the emitted radiation and the reflected radiation to leave and reach the contour system, respectively, and the characteristics of the radiation source, the distance between the contour system and the surface of the container that causes the radiation reflected is measured. Typical range measurement systems use a scanned beam to quickly record multiple positions and tracks.
    [00026] Exemplary measurements using modalities of the subject described are illustrated in FIGS. 4 and 5. As understood by those skilled in the applicable techniques, the subject described here is in no way limited by the exemplary temperature scales depicted in FIGS. 4 and 5. FIG. 4 illustrates a refractory thickness profile represented by the spatially resolved quantitative values that correspond to the local thickness of the refractory material both as a function of vessel depth and angular position. The thickness, reported in both mm and inches, is reported in relation to a defined surface in the vessel. This defined surface may be the outer or inner metallic hull of the vessel, the inner surface of the safety liner (the supporting refractory brick that normally remains permanently installed in the vessel), or the inner surface of the working liner (the primary refractory brick that is replaced during a normal vessel reload). Surface temperature measurements are also illustrated in FIG. 4 by using contour lines that define areas having different gray scale colors that represent different temperature levels as shown in the legend of those figures. FIG. 5 illustrates similar results but for a smaller portion of the container.
    [00027] As shown in FIG. 4, there are at least two regions (labeled 52 in FIG. 4) in which the external temperature has reached high values; however, the refractory thicknesses of the working coating in these regions are on average 49 mm or so in region 52 located on the left and around 76 mm for region 52 located on the right. For this vessel, the starting thickness values of the working lining were 110 mm and the pan will be removed from service when the lining thickness reaches 10 mm. As explained above, the two regions 52 in FIG. 4 are example regions where thinning most likely occurred (for example, area 10 shown in FIG. 1) and refractory thickness measurement did not detect this problem. In other words, steel melted from a previous melting cycle naturally entered the small gaps (for example, small openings related to the diameter of the radiation source) between the container bricks not detected by the refractory scanning system. In this way, using only the scanning system to detect such a problem can take longer before the thinning develops further such that the scanning system can detect these openings in the refractory material, or the probability can be high that the scanning system cannot detect the fading. The results of FIG. 5 illustrate measurements in a region of the vessel where the outer surface temperature is high and the refractory thickness is thin, suggesting that a hole in the vessel lining exists at that particular location (for example, the area 14 illustrated in FIG. 1).
    [00028] According to another exemplary embodiment, a process or method for monitoring the integrity of a container having an internal layer of a refractory material is described as illustrated in the flow chart shown in FIG. 6. In this process it is intended to be as complete as possible, it is noted that all interruptions need to be carried out to monitor the integrity of the container. In other words, some steps to be described below may be optional.
    [00029] As shown in FIG. 6, the method for monitoring the integrity of a container having an inner layer of a refractory material includes the steps of providing a first radiation detector configured to measure an outer surface temperature of the container at 62; provide a first radiation source configured to measure a refractory material thickness of 64; and, in 66, providing a central controller configured to display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material.
    [00030] According to another exemplary embodiment, a process or method for monitoring the integrity of a container having an internal layer of a refractory material is described as illustrated in the flow chart shown in FIG. 7. As this process is intended to be as complete as possible, note that not all steps need to be taken to monitor the integrity of the container. In other words, some steps to be described below may be optional. As shown in FIG. 7, the method for monitoring the integrity of a metal container having an internal layer of a refractory material includes the steps of measuring an external surface temperature of the container with a first radiation detector at 72; measure a thickness of the refractory material with a first radiation source at 74; and in 76, display to a user the measurement of the outer surface temperature of the container and the measurement of the thickness of the refractory material.
    [00031] Finally, an example of a representative control device or controller 100 capable of performing operations according to the exemplary modalities discussed above is illustrated in F1G. 8. Hardware, firmware, software or a combination of them can be used to perform the various steps and operations described here. In several examples of the subject described, the central controller 30, the first controller 24, and / or the second controller 28 of the F1G. 2 individually or in any combination are part of a system containing the control device or controller 100 in the form of a computing structure that can be used in conjunction with such a system.
    [00032] The exemplary central controller 100 suitable for carrying out the activities described in the exemplary embodiments can include a server 102, which can correspond to any of the controllers 24, 28, and / or 30 in FIG. 2. Such server 102 may include a central processor (CPU) 104 coupled to a random access memory (RAM) 106 and a read-only memory (ROM) 108. ROM 108 can also be of other types of media storage to store programs, such as programmable ROM (PROM), erasable PROM (EPROM), etc. Processor 104 can communicate with other internal and external components via input / output (I / O) circuits 110 and bus formation 112 to provide control signals and the like. Processor 104 performs a variety of functions as is known in the art, as dictated by software and / or firmware instructions.
    [00033] Server 102 may also include one or more data storage devices, including, for example, hard disk and floppy 114 drives, CD-ROM drives 116, and / or other hardware capable of reading and / or store information such as DVD, etc. In one embodiment, software to perform the steps discussed above can be stored and distributed on a CD-ROM 118, floppy disk 120 or other form of medium capable of storing information in a portable manner. These storage media can be inserted into, and read by, devices such as CD-ROM drive 116, disk drive 114, etc. Server 102 can be coupled to a display 122, which can be any type of known display or display screen, such as LCD displays, plasma displays, cathode ray tubes (CRT), etc. A user input interface 124 may be provided, including one or more user interface mechanisms such as a mouse, keyboard, microphone, touch panel, touch screen, voice recognition system, etc.
    [00034] Server 102 can be coupled to other computing devices, such as fixed and / or wireless telephone terminals and associated applications, over a network. The server can be part of a larger network configuration such as a global area network (GAN) such as the Internet 126, which allows the final connection to the various mobile and / or landline client devices.
    [00035] In the detailed description of the exemplary modalities, several specific details are defined in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art can understand that various modalities can be practiced without such specific details.
    [00036] As will also be understood by a person skilled in the art, exemplary modalities can be incorporated into a wireless communication device, a telecommunication network, as a method or into a computer program product. Appropriately, exemplary modalities can take the form of an entirely hardware modality or a modality that combines aspects of hardware and software. In addition, exemplary embodiments can take the form of a computer program stored on a computer-readable storage medium having computer-readable instructions embedded in the medium. Any suitable computer-readable medium can be used including hard drives, CD-ROMs, digital versatile disc (DVD), optical storage devices, or magnetic storage devices such as a floppy disk or magnetic tape. Other non-limiting examples of computer-readable media include flash-type memories or other known types of memories.
    [00037] The exemplary modalities described provide an apparatus, a system and a method for identifying potential failure locations in a metal container configured to maintain materials at elevated temperatures. It will be understood that this description is not intended to limit the invention. On the contrary, the exemplary modalities are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims.
    [00038] Although the functionalities and elements of the present exemplary modalities are described in the modalities in particular combinations, each functionality or element can be used alone without the other functionalities and elements of the modalities or in various combinations with or without other functionalities and elements described on here.
    [00039] The written description uses examples of the subject described to allow any person skilled in the art to practice the same, including making and using any devices or systems and carrying out any built-in methods. The scope of protection of the subject of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
    权利要求:
    Claims (20)
    [0001]
    1. Apparatus (20) configured to monitor the integrity of a container (2) protected by a refractory material (6), the apparatus comprising: a thermographic system (21) with a first radiation detector (22), the thermographic system ( 21) being configured to perform spatially resolved temperature measurements of an external surface of the container (2); a refractory thickness measuring device (25) with a first radiation source (26), the refractory thickness measuring device (25) being configured to perform spatially resolved thickness measurements of the refractory material (6); and a central controller (30) configured to display to a user the spatially resolved temperature measurements of the outer surface of the container (2) and the spatially resolved thickness measurements of the refractory material (6); characterized by the fact that: a defect in the refractory material (6) is identified by a combination of spatially resolved temperature measurements of the outer surface of the container (2) and the spatially resolved thickness measurements of the refractory material (6).
    [0002]
    Apparatus (20) according to claim 1, characterized by the fact that the thermographic system (21) comprises a first controller (24), the first controller (24) being configured to communicate with the central controller (30).
    [0003]
    Apparatus (20) according to claim 1, characterized by the fact that the thermographic system (21) is a plurality of thermographic systems, each comprising a first controller (24), each of the first controllers (24) being configured to communicate with the central controller (30).
    [0004]
    Apparatus (20) according to claim 1, characterized by the fact that the spatially resolved temperature measurements of the outer surface of the container (2) and the spatially resolved thickness measurements of the refractory material (6) are made substantially simultaneously.
    [0005]
    5. Apparatus (20) according to claim 1, characterized by the fact that the monitoring is configured to be carried out with the container (2) positioned kinematically in a position, with the container (2) positioned substantially in a certain position before performing spatially resolved thickness measurements or determining the position of the container (2) at the station before performing spatially resolved thickness measurements.
    [0006]
    Apparatus (20) according to claim 1, characterized by the fact that the refractory thickness measuring system (25) comprises a second controller (28), and in which the refractory thickness measuring system (25) and the second controller (28) is arranged in a mobile unit, the second controller (28) being in communication with the central controller (30).
    [0007]
    Apparatus (20) according to claim 1, characterized by the fact that the thermographic system (21) comprises a first controller (24), in which the refractory thickness measurement system (25) comprises a second controller (28) and wherein the first controller (24) and the second controller (28) are in communication with the central controller (30).
    [0008]
    Apparatus (20) according to claim 1, characterized by the fact that a fin formation at a location within the container (2) is detected by a temperature measurement located on the outer surface of the container (2) with a value of high temperature and a corresponding measurement of the localized thickness of the refractory material (6) with a thickness value.
    [0009]
    Apparatus (20) according to claim 1, characterized by the fact that a molten metal creep or a small hole in the refractory material (6) at a location within the container (2) is detected by a localized temperature measurement of outer surface of the container (2) with a high temperature value and by a corresponding localized thickness measurement of the refractory material (6) with a thickness value.
    [0010]
    10. Apparatus (20) according to claim 1, characterized by the fact that the refractory thickness measurement system (25) is arranged on a mobile trolley (44) and further comprises a tracking system (46) and a tracking system contour (48) mounted on it.
    [0011]
    11. Apparatus (20) according to claim 1, characterized by the fact that the refractory thickness measurement system (25) further comprises a contour system (48) configured to measure range data from the contour system (48 ) for an internal surface of the refractory material (6).
    [0012]
    12. Apparatus (20) according to claim 1, characterized by the fact that the container (2) is configured to be used in a gasification process in the production of energy and / or chemistry, in an electric arc furnace, in an basic oxygen oven, in a pan, in a blast furnace, in a degasser, or in an argon oxygen decarbonization oven.
    [0013]
    Apparatus according to claim 7, characterized in that the first controller (24), the second controller (28) and the central controller (30) are arranged in a single control unit.
    [0014]
    14. System according to claim 1, characterized by the fact that the refractory thickness measurement system (25) comprises a second controller (28), and in which the refractory thickness measurement system (25) and the second controller (28) are arranged in a fixed position; and the second controller (28) is in communication with the central controller (30).
    [0015]
    15. Method for monitoring the integrity of a container (2) having an internal layer of a refractory material (6), the method characterized by the fact that it comprises: performing spatially resolved temperature measurements of an external surface of the container (2) with a thermographic system (21); perform spatially resolved thickness measurements of the refractory material (6) with a refractory thickness measurement system (25); and displaying to a user, through a central controller (30), the spatially resolved temperature measurements of the outer surface of the container (2) and the spatially resolved thickness measurements of the refractory material (6); detecting a defect in the refractory material (6) by a combination of spatially resolved temperature measurements of the outer surface of the container (2) and the spatially resolved thickness measurements of the refractory material (6).
    [0016]
    16. Method according to claim 15, characterized in that the detection step additionally comprises: detecting a fin formation at a location within the container (2) identifying a temperature measurement located on the outer surface of the container (2) with a high temperature value and a corresponding localized thickness measurement of the refractory material (6) with a thickness value.
    [0017]
    17. Method according to claim 15, characterized in that the detection step additionally comprises: detecting a molten metal creep or a small hole in the refractory material (6) at a location within the container (2) by identifying a localized temperature measurement of the outer surface of the container (2) with a high temperature value and a corresponding localized thickness measurement of the refractory material (6) with a thickness value.
    [0018]
    18. Method according to claim 15, characterized by the fact that the step of performing spatially resolved thickness measurements of the refractory material (6) further comprises: positioning the container (2) in a position; and carrying out thickness measurements with the container (2) substantially held in a certain position; or determine the position of the container at the station before making thickness measurements.
    [0019]
    19. Method according to claim 15, characterized in that the refractory thickness measurement system (25) comprises a second controller (28) and the refractory thickness measurement system (25) and the second controller (28) are arranged in a fixed position post.
    [0020]
    20. Method according to claim 15, characterized in that the refractory thickness measurement system (25) comprises a second controller (28) and the refractory thickness measuring device system (25) and the second controller (28 ) are arranged in a mobile unit.
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    同族专利:
    公开号 | 公开日
    WO2013074464A3|2013-07-18|
    SI2780663T1|2018-08-31|
    AU2012339861A1|2014-06-05|
    CA2855892A1|2013-05-23|
    CA2855892C|2019-01-08|
    UA115658C2|2017-12-11|
    ZA201403518B|2015-07-29|
    NO2874857T3|2018-01-13|
    CL2014001264A1|2015-01-16|
    CN104081152B|2017-09-29|
    PL2780663T3|2018-08-31|
    KR101970035B1|2019-04-17|
    BR112014011750A2|2017-05-09|
    MY171543A|2019-10-17|
    US8958058B2|2015-02-17|
    EA201490785A1|2014-11-28|
    MX2014005907A|2014-11-12|
    WO2013074464A2|2013-05-23|
    EP2780663A2|2014-09-24|
    EP2780663A4|2015-06-24|
    ES2662906T3|2018-04-10|
    EA027851B1|2017-09-29|
    KR20140100522A|2014-08-14|
    JP6174594B2|2017-08-02|
    JP2015504153A|2015-02-05|
    CN104081152A|2014-10-01|
    EP2780663B1|2018-01-24|
    US20130120738A1|2013-05-16|
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-24| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-05-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-10-20| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/11/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/296,301|2011-11-15|
    US13/296,301|US8958058B2|2011-11-15|2011-11-15|Apparatus, process, and system for monitoring the integrity of containers|
    PCT/US2012/064727|WO2013074464A2|2011-11-15|2012-11-12|Apparatus, process, and system for monitoring the integrity of containers|
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