Claims:WE CLAIM:

1. A system (100) for predicting erosion of a structure (104) located in a hostile environment (108), comprising:
atleast one sensor (112) positioned over the structure (104) to sense an optical signal (116) and transmit to and received by an optical device (120), the optical device (120) being communicatively coupled to the sensor(s) (112);
the optical device (120) being configured to transmit the optical signal (116) to and received by a processor (128), the processor (128) being communicatively coupled to the optical device (120); and
the processor (128) being configured to convert the optical signal (116) to a temperature data, and plot the temperature data on a corresponding erosion curve (136) of the sensor (112) to predict the erosion of the structure (104), the erosion curve (136) being function of temperature data and erosion of the structure (104).

2. The system (100) as claimed in claim 1, wherein the temperature data is an average temperature over a predetermined period.

3. The system (100) as claimed in claim 1, wherein the processor (128) being part of a computer related electronic device (132).

4. The system (100) as claimed in claim 1 further comprises a display unit (140) being communicatively coupled to the processor (128) to display erosion predicted.

5. The system (100) as claimed in claim 1, wherein the hostile environment being a blast furnace.

6. The system (100) as claimed in claim 1, wherein the structure (104) in the hostile environment being a tuyere (144).

7. The system (100) as claimed in claims 5 and 6, wherein the erosion being eroded length of the tuyere (144) from blast furnace.

8. The system (100) as claimed in claim 4, wherein the display unit (140) raise alarm if the erosion predicted is more than predetermined threshold level.
9. The system (100) as claimed in claim 6, wherein atleast one sensor(s) (112) being deployed in a thin passageway (148) of the tuyere (144).

10. The system (100) as claimed in claim 1, wherein the sensor(s) (112) is/are FBG.

11. The system (100) as claimed in claim 1, wherein the optical signal is optical ray radiation.

12. The system (100) as claimed in claim 1, wherein display being digital or analog.

13. The system (100) as claimed in claim 1, wherein the optical signal (116) being transmitted to the optical device (120) from the sensor (112) via an optical cable (124).

14. The system (100) as claimed in claim 1, wherein the erosion curve is formulated by historical data of temperature data and eroded length of the structure.

15. The system (100) as claimed in claim 1, wherein the erosion curve is simulated.

16. A method (600) for predicting erosion of a structure (104) in a hostile environment (108), comprising:
sensing an optical signal (116) by atleast one sensor (112) positioned on the structure (104) and transmitting;
receiving the optical signal (116) by an optical device (120) and transmitting; and
receiving the optical signal (116) and converting the optical signal (116) into a temperature data by a processor (128), and plotting the temperature data over a corresponding erosion curve of the sensor (112) and predicting the erosion of the structure (104), the erosion curve (136) being function of temperature data and erosion of the structure (104).

17. The method (600) as claimed in claim 16, wherein the predicted erosion is displayed over a display unit (140).

18. The method (600) as claimed in claim 17, wherein alarm is raised if the erosion predicted is more than predetermined threshold level.

19. The method (600) as claimed in claim 16, wherein plotting of the average temperature data over the erosion curve and prediction of the erosion is done in equal interval.

20. The method (600) as claimed in claim 16, wherein the optical signal is optical ray radiation.

21. The method (600) as claimed in claim 16, wherein the temperature data is an average temperature over a predetermined period.
, Description:TECHNICAL FIELD
[0001] The present invention relates to a hostile environment such as blast furnace. More particularly the invention relates to a system and method for determining health of a functional structure positioned in the hostile environment.

BACKGROUND
[0002] Blast furnace is a counter current metallurgical reactor in which hot air with enriched oxygen provided by tuyere, embedded circumferentially around the blast furnace, rises up to the top of the blast furnace and comes out in the form of different gases. Whereas granular iron bearing materials in the form agglomerate like sinter and pellet and raw iron ore with coke are charged from the top. Along with hot blast, different fuels like pulverized coal, plastics, charcoal are provided through tuyere to replace coke charged from the top. Iron bearing materials get reduced to liquid iron which is being drained periodically through tap hole from the blast furnace. Reduction of iron bearing materials to liquid iron happen in presence of reducing gases like carbon monoxide generated around the raceway zone of the blast furnace.

[0003] Typically, pulverized coal in presence of hot blast of temperature over 1150oC, starts combusting with oxygen present in air and creates flame temperature over 2150oC just in front of the tuyere. Proximity to high temperature tuyeres are failed by erosion frequently leading to loss of opportunity.

[0004] Though the tuyeres are comprised with a cooling circuits to cool the body and nose but due to such a high temperature the erosion becomes inevitable. The cooling circuit is formed during casting process and a central aperture connected to a blow pipe through which hot blast is provided during operation.

[0005] The only way to anticipate tuyere failure priori is to monitor the condition continuously which is not an easy due to its harsh and hostile operating environment.

[0006] At the moment, there doesn’t seem to be established methodology available which can predict tuyere failure apriori.

[0007] The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

Objects:
[0008] An object of the invention is to predict health of a tuyere of a blast furnace.

SUMMARY
[0009] The present invention provides a system for predicting erosion of a structure located in a hostile environment, comprising:
atleast one sensor positioned over the structure to sense an optical signal and transmit to and received by an optical device, the optical device being communicatively coupled to the sensor(s);
the optical device being configured to transmit the optical signal to and received by a processor, the processor being communicatively coupled to the optical device; and
the processor being configured to convert the optical signal to a temperature data, and plot the temperature data over a corresponding erosion curve of the sensor to predict the erosion of the structure, the erosion curve being function of temperature data and erosion of the structure.

[0010] The provision of the sensor positioned over the structure with the optical device and the processor enables calculation of the temperature data. The temperature data being plotted over the erosion curve to predict the erosion or eroded length of the structure. The erosion curve being the function of temperature data and the erosion which is formulated taking into consideration the historical data of the two.

[0011] In an embodiment, the temperature data is an average temperature over a predetermined period and the processor being part of a computer related electronic device.

[0012] In another embodiment, the system further comprises a display unit being communicatively coupled to the processor to display erosion predicted.

[0013] In yet another embodiment, the hostile environment is a blast furnace, and the structure in the hostile environment is a tuyere.

[0014] In yet another embodiment, the erosion being eroded length of the tuyere from blast furnace and the display unit raise alarm if the erosion predicted is more than predetermined threshold level.
In yet another embodiment atleast one sensor(s) is deployed in a thin passageway of the tuyere and the sensor(s) (112) is/are FBG.
[0015] In yet another embodiment, the optical signal is optical ray radiation and the display is digital or analog.

[0016] In yet another embodiment, the optical signal (116) is transmitted to the optical device from the sensor via an optical cable.

[0017] In yet another embodiment, the erosion curve is formulated by historical data of temperature data and eroded length of the structure.
In yet another embodiment, the erosion curve is simulated.

[0018] The present invention also provides a method for predicting erosion of a structure in a hostile environment, comprising:
sensing an optical signal by atleast one sensor positioned on the structure and transmitting;
receiving the optical signal by an optical device and transmitting; and
receiving the optical signal and converting the optical signal into a temperature data by a processor, and plotting the temperature data over a corresponding erosion curve of the sensor and predicting the erosion of the structure, the erosion curve being function of temperature data and erosion of the structure.

[0019] In an embodiment, the predicted erosion is displayed over a display unit.

[0020] In another embodiment, the alarm is raised if the erosion predicted is more than predetermined threshold level.

[0021] In another embodiment, plotting of the average temperature data over the erosion curve and prediction of the erosion is done in equal interval.

[0022] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Fig. 1 illustrates a system for predicting erosion of a structure in a hostile environment in accordance with an embodiment of the invention.

[0024] Fig. 2a illustrates a preferred embodiment of the system of FIG. 1a.

[0025] Fig. 2b illustrates a cross sectional view of a passageway formed inside a tuyere of the Fig. 2a.

[0026] Figs. 3a-3d illustrates an erosion curves against a sensors 112 S-1, 112 S-2, 112 S-3 and 112 S-4 in accordance with an embodiment of the invention.

[0027] Fig. 4 illustrates temperature monitoring of the tuyere via the sensors positioned at different locations inside the tuyere as an experimental analysis.

[0028] Fig. 5 illustrates enhanced temperature monitored during operation for the sensor as an experimental analysis.

[0029] Fig. 6 illustrates a method for predicting erosion of the structure in the hostile environment in accordance with an embodiment of the invention.

DESCRIPTION OF PREFERRED EMBODIMENT
[0030] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

[0031] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.

[0032] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

[0033] The terms “includes”, “including”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “includes… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

[0034] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[0035] Referring to FIG. 1, a system (100) is being shown for predicting health /erosion of a structure (104) located in a hostile environment (108). The health can be ascertained to be sound if erosion of the structure is less than the threshold. If the erosion is above or inching the threshold one may assume the health to be unsound and the same need replacement.

[0036] The system (100) comprises at least one sensor (hereinafter the sensor (112)) positioned over the structure (104) configured to sense an optical signal (116) (temperature signal). The optical signal (116) is transmitted to and received by an optical device (120). The optical device (120) is communicatively coupled to the sensor(s) (112) via an optical cable (124) through which the optical signal is transmitted. The optical signal (116) from the optical device (120) is transmitted to and received by a processor (128).

[0037] The optical signal is optical ray radiation.

[0038] The optical cable (124) is laid out inside a G.I conduit pipe (126) for protection against mechanical damage, as well as high temperature and dust as shown in FIG. 2a.

[0039] Through the optical device (120) input broad-band light comes and the same optical cable carries the reflected signal from the sensor (112).

[0040] The optical device (120) in an embodiment can be interrogator.

[0041] The processor (128) is communicatively coupled to the optical device (120) and is a part of a computer related electronic device (132).

[0042] The computer related electronic device can be embedded computer, personal computer or a mobile device such as a tablet computer, laptop, smart phone, PDA, or other touch screen or television with one or more processors embedded therein or coupled thereto, or any other sort of computer-related electronic device.

[0043] The processor (128) is configured to convert the optical signal into a temperature data.

[0044] In an embodiment, the processor (128) further converts the temperature data into an average temperature over a predetermined period against the sensor’ (112 S1-112 S4) positioned at corresponding locations as shown in FIG. 2a.

[0045] The processor features a programmed script for such conversions into temperature data and average temperature. This average temperature is averaged over a predetermined time for ex- a day (24 hrs format) in some embodiment.
[0046] Shown in FIG. 1 is the processor (128) includes an erosion curve (136). The erosion curve (136) is function of erosion of the structure or eroded length and temperature data sensed by the sensor.

[0047] The erosion curve (136) is based on historical data of temperature data realized and the corresponding eroded length of the structure. Preferably the temperature data is averaged over a period for proper temperature data. The erosion curve can be developed over such data of one or more number of months and years. It can be simulated as well.

[0048] In one of the embodiment the erosion curve (136) for the sensor (112) at specific location over the structure is shown in Fig. 3a. The X axis represents eroded length and Y axis shows average temperature sensed. The experiments are done over the structure (104) with specific characterization and numerous data are recorded keeping the same in the hostile environment.

[0049] On the erosion curve (136) corresponding to the sensor, the temperature data or average temperature is plotted by the processor (128) to predict the remnant or eroded length or erosion of a subject structure. This plotting of the average temperature is a part of system and is done automatically after a predetermined averaging time. The prediction is displayed over a display unit (140), the display unit (140) is communicatively coupled with the processor (128) shown in FIGS. 1 and 2a.

[0050] In an embodiment, the display unit may be digital or analog based.

[0051] It is to be appreciated that erosion curve (136) is the characteristics of the sensor (112) positioned at a specific location of the structure (104). That is to say, if one wants to predict the eroded length (thereby health) of a subject structure, the erosion curve need to be based on the structure with similar characteristics as that of the subject structure. Also, the temperature data need to be taken from the sensor positioned at similar location of the subject structure from where the erosion curve is based at.

[0052] In an embodiment, the average temperature is calculated by collecting temperature data in every minute time stamp, then sum up and then divide by number of minutes in a day (24*60).

[0053] Also, the average temperature can be chosen as per the convenience. One may average the temperature “per day” or “per 12 hours” “per 6 hours” and so on.

[0054] It is also to be appreciated that for prediction of eroded length one may input the temperature data complementing the one in the erosion curve. That is to say if erosion curve has the temperature data averaged on day basis then the temperature data of the subject structure needs to be averaged per day only and plotted.

[0055] The system (100) is designed in such a way that during operation the temperature data is fed automatically after the averaging time to the erosion curve and the eroded length is provided. The operator is being conveyed the eroded length or remnant over a display unit (140). In case the predicted eroded length inches towards or crosses the predetermined threshold, the display unit (140) gives an alarm. The alarm signal can atleast one or combination(s) of visual, sound or beacon. The alarm may suggest the operator to replace the structure with fresh structure.

[0056] In accordance with one of the embodiment of the invention, the hostile environment is a blast furnace (not shown) and the structure is a tuyere (144) as shown in FIGS. 2a & 2b. The erosion in the tuyere is the eroded length of the tuyere (144) from blast furnace.

[0057] The sensor (112) in an embodiment is a Fiber Bragg Gratings (FBG) sensor. Shown in FIGS. 2a is the plurality of the sensors 112 S-1, 112 S-2, 112 S-3 and 112 S-4. A thin passageway (148) is formed in the tuyere (144) additionally during the casting to accommodate the sensors. The passageway (148) can be created by inserting a cupro-nickel tube to accommodate during casting. Though multiple sensors (112 S-1, 112 S-2, 112 S-3, 112 S-4) have been positioned in the passageway (148), but even one sensor can get the prediction of the erosion. More the sensors more it may add robustness in the system (100).

[0058] The benefit of deploying the FGB sensors is that it is thin and could be deployed easily over the passageway. Also with only one cable, sensing of temperatures across different locations is possible which may be clumsy using other temperature sensing instrument.

[0059] The thin passageway (148) is so carved that it does not affect the efficiency and working of the tuyere (144). The thin passageway (148) is extended only up to the portion of solid copper separating a nose cooling circuit (152) and a body cooling circuit (156). This is to avoid any damage in the critical nose zone of the tuyere so that it does not affect thermal performance of the tuyere. On the other hand; the location of a tip is positioned sensible enough to predict the change of thermal condition of tuyere during operation.

[0060] The sensors 112 S-1, 112 S-2, 112 S-3, 112 S-4, fabricated over the optical cable (124) shown in FIG. 2a, are mounted inside the thin passageway so that the sensors do not get affected by the mechanical handling while inserting inside the passageway.

[0061] In an embodiment, a copper tube (164) can be provided in the thin passageway (148) to house the sensors and the optical cable (124) to provide protection. The copper tube (164) has been chosen to match the thermal conductivity of base copper body.
[0062] Multiple sensors are placed in various axial locations. 112 S-1 sits near the tip of the copper tube facing the maximum temperature as it is located near the nose portion of the tuyere. 112 S-4 which is far away from the nose will experience very low temperature.

[0063] The erosion curve (136) (as shown in Fig. 3a) being the function of average temperature per day realized by the tuyere and the eroded length of the tuyere (144). The erosion determines the health of the tuyere (144). If the erosion at any point of the time is more or beyond the threshold the tuyere needs to be replaced else it can be kept in operation till it reaches the threshold.

[0064] During operation, the average temperature per day of particular location of the running tuyere is plotted over the erosion curve (136) of similar location to predict the eroded length.

[0065] As per FIG. 2a, during operation as tuyere (144) gets eroded and the sensor (112 S1-112 S4) seated closest to the nose part (S-1) experiences higher thermal load which will reflect with an increase in temperature. Over the period, as the erosion grows up and starts approach the threshold/critical eroded length plotting of the average temperature will be done over the erosion curve. This predicts the eroded length and subsequently guide the operator with remnant length of the tuyere.

[0066] In case 112 S-1 fails somehow, other sensors (112 S-2, 112 S-3 and 112 S-4) are also positioned at various other locations of the tuyere. Correspondingly for 112 S-2, 112 S-3 and 112 S-4 there will be separate erosion curves as well in the processor (128) as shown in Figs. 3b-3d respectively. So, in case S-1 fails, the eroded length can be predicted through S-2, S-3 and S-4 and their corresponding erosion curves at similar locations. In an embodiment, even if S-1 is working other sensors can be brought into use simultaneously. More number of sensors can bring more sturdiness and robustness into the system.

[0067] FIG. 4 represents the day average temperature trend across the different sensors. 112 S-1 shows the maximum temperature while 112 S-4 shows the lowest of the lot. This signifies how the thermal load is being dissipated due to high thermal conductivity of copper. This can also be converted in the form of heat flux experienced by the copper body by calculating the temperature gradient.

[0068] FIG. 5 denotes the distribution of temperature for 112 S-1 sensor for three days, separated by 10 days interval from the installation day. While the spread of curve for each day shows the range of temperature observed during that day, the peak value of the curve represents the mean temperature of that day. As observed, the mean temperature is shifted to a higher value as the tuyere is being operated for days compared to its initial value measured during installation.

[0069] A method (600) for predicting erosion of the structure (104) in the hostile environment has been disclosed in FIG. 6. At step 604, sensing of the optical signal (116) by at least one sensor (112) positioned on the structure (104) and transmitting is done.

[0070] At step 608, receiving the optical signal (116) by the optical device (120) and transmitting is performed.

[0071] At step 612, receiving the optical signal (116) and converting the optical signal (116) into the temperature data is performed by the processor (128). In processor plotting of the temperature data over the corresponding erosion curve of the sensor (112) is done to predict the erosion of the structure (104), the erosion curve (136) is function of temperature data and erosion of the structure (104).

[0072] The predicted erosion of the structure is displayed over the display unit (140). Alarm is raised at the display unit if the erosion happens to be more than predetermined threshold level.

[0073] Method illustrated in FIG. 6 may include one or more blocks for predicting erosion of the structure (104) in the hostile environment. The method illustrated in FIG. 6 may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, and functions, which perform particular functions or implement particular abstract data types.

[0074] The order in which the method illustrated in FIG. 6 are described may not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.

[0075] Advantage:
This system helps to monitor real time temperature of the tuyere which is directly associated with the erosion pattern of the structure. Operators will get erosion pattern of tuyere over days of its operation and thereby plan the shutdowns accordingly to avoid production loss of blast furnace due to total failure of tuyere.

[0076] The system can be used to predict remnant thickness in any refractory liner say for example in Blast furnace hearth, Blast furnace trough etc.

[0077] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise.

[0078] The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise.

[0079] The enumerated listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise.

[0080] The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.

[0081] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.

[0082] When a single device or article is described herein, it will be readily apparent that more than one device/article (whether or not they cooperate) may be used in place of a single device/article. Similarly, where more than one device or article is described herein (whether or not they cooperate), it will be readily apparent that a single device/article may be used in place of the more than one device or article or a different number of devices/articles may be used instead of the shown number of devices or programs. The functionality and/or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality/features. Thus, other embodiments of the invention need not include the device itself.

[0083] The illustrated operations of FIG. 6 shows certain events occurring in a certain order. In alternative embodiments, certain operations may be performed in a different order, modified, or removed. Moreover, steps may be added to the above described logic and still conform to the described embodiments. Further, operations described herein may occur sequentially or certain operations may be processed in parallel. Yet further, operations may be performed by a single processing unit or by distributed processing units.

[0084] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.

[0085] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Reference Numerals
System 100
Structure 104
Hostile environment 108
Sensor 112
Temperature signal 116
Optical device 120
Optical cable 124
GI conduit 126
Processor 128
Computer related electronic device 132
Erosion curve 136
Display unit 140
Tuyere 144
Thin passageway 148
Cooling circuit nose 152
Body cooling circuit 156
Copper tube 164
Method 600