Modular and Cost-Effective Computed Tomography Design.

We present a modular and cost-effective gamma ray computed tomography system for multiphase flow investigations in industrial apparatuses. It mainly comprises a 137Cs isotopic source and an in-house-assembled detector arc, with a total of 16 scintillation detectors, offering a quantum efficiency of approximately 75% and an active area of 10 × 10 mm2 each. The detectors are operated in pulse mode to exclude scattered gamma photons from counting by using a dual-energy discrimination stage. Flexible application of the computed tomography system, i.e., for various object sizes and densities, is provided by an elaborated detector arc design, in combination with a scanning procedure that allows for simultaneous parallel beam projection acquisition. This allows the scan time to be scaled down with the number of individual detectors. Eventually, the developed scanner successfully upgrades the existing tomography setup in the industry. Here, single pencil beam gamma ray computed tomography is already used to study hydraulics in gas-liquid contactors, with inner diameters of up to 440 mm. We demonstrate the functionality of the new system for radiographic and computed tomographic scans of DN110 and DN440 columns that are operated at varying iso-hexane/nitrogen liquid-gas flow rates.

Towards Real-Time Analysis of Gas-Liquid Pipe Flow: A Wire-Mesh Sensor for Industrial Applications.

Real-time monitoring of gas-liquid pipe flow is highly demanded in industrial processes in the chemical and power engineering sectors. Therefore, the present contribution describes the novel design of a robust wire-mesh sensor with an integrated data processing unit. The developed device features a sensor body for industrial conditions of up to 400 °C and 135 bar as well as real-time processing of measured data, including phase fraction calculation, temperature compensation and flow pattern identification. Furthermore, user interfaces are included via a display and 4…20 mA connectivity for the integration into industrial process control systems. In the second part of the contribution, we describe the experimental verification of the main functionalities of the developed system. Firstly, the calculation of cross-sectionally averaged phase fractions along with temperature compensation was tested. Considering temperature drifts of up to 55 K, an average deviation of 3.9% across the full range of the phase fraction was found by comparison against image references from camera recordings. Secondly, the automatic flow pattern identification was tested in an air-water two-phase flow loop. The results reveal reasonable agreement with well-established flow pattern maps for both horizontal and vertical pipe orientations. The present results indicate that all prerequisites for an application in industrial environments in the near future are fulfilled.

Towards Tomography-Based Real-Time Control of Multiphase Flows: A Proof of Concept in Inline Fluid Separation.

The performance of multiphase flow processes is often determined by the distribution of phases inside the equipment. However, controllers in the field are typically implemented based on flow variables, which are simpler to measure, but indirectly connected to performance (e.g., pressure). Tomography has been used in the study of the distribution of phases of multiphase flows for decades, but only recently, the temporal resolution of the technique was sufficient for real-time reconstructions of the flow. Due to the strong connection between the performance and distribution of phases, it is expected that the introduction of tomography to the real-time control of multiphase flows will lead to substantial improvements in the system performance in relation to the current controllers in the field. This paper uses a gas-liquid inline swirl separator to analyze the possibilities and limitations of tomography-based real-time control of multiphase flow processes. Experiments were performed in the separator using a wire-mesh sensor (WMS) and a high-speed camera to show that multiphase flows have two components in their dynamics: one intrinsic to its nonlinear physics, occurring independent of external process disturbances, and one due to process disturbances (e.g., changes in the flow rates of the installation). Moreover, it is shown that the intrinsic dynamics propagate from upstream to inside the separator and can be used in predictive and feedforward control strategies. In addition to the WMS experiments, a proportional-integral feedback controller based on electrical resistance tomography (ERT) was implemented in the separator, with successful results in relation to the control of the distribution of phases and impact on the performance of the process: the capture of gas was increased from 76% to 93% of the total gas with the tomography-based controller. The results obtained with the inline swirl separator are extended in the perspective of the tomography-based control of quasi-1D multiphase flows.

A Review on Fast Tomographic Imaging Techniques and Their Potential Application in Industrial Process Control.

With the ongoing digitalization of industry, imaging sensors are becoming increasingly important for industrial process control. In addition to direct imaging techniques such as those provided by video or infrared cameras, tomographic sensors are of interest in the process industry where harsh process conditions and opaque fluids require non-intrusive and non-optical sensing techniques. Because most tomographic sensors rely on complex and often time-multiplexed excitation and measurement schemes and require computationally intensive image reconstruction, their application in the control of highly dynamic processes is often hindered. This article provides an overview of the current state of the art in fast process tomography and its potential for use in industry.

Temperature Compensation for Conductivity-Based Phase Fraction Measurements with Wire-Mesh Sensors in Gas-Liquid Flows of Dilute Aqueous Solutions.

Wire-mesh sensors are well-established scientific instruments for measuring the spatio-temporal phase distribution of two-phase flows based on different electrical conductivities of the phases. Presently, these instruments are also applied in industrial processes and need to cope with dynamic operating conditions increasingly. However, since the quantification of phase fractions is achieved by normalizing signals with respect to a separately recorded reference measurement, the results are sensitive to temperature differences in any application. Therefore, the present study aims at proposing a method to compensate temperature effects in the data processing procedure. Firstly, a general approach is theoretically derived from the underlying measurement principle and compensation procedures for the electrical conductivity from literature models. Additionally, a novel semi-empirical model is developed on the basis of electrochemical fundamentals. Experimental investigations are performed using a single-phase water loop with adjustable fluid temperature in order to verify the theoretical approach for wire-mesh sensor applications and to compare the different compensation models by means of real data. Finally, the preferred model is used to demonstrate the effect of temperature compensation with selected sets of experimental two-phase data from a previous study. The results are discussed in detail and show that temperature effects need to be handled carefully-not merely in industrial applications, but particularly in laboratory experiments.

Thermal Anemometry Grid Sensor.

A novel thermal anemometry grid sensor was developed for the simultaneous measurement of cross-sectional temperature and axial velocity distribution in a fluid flow. The sensor consists of a set of platinum resistors arranged in a regular grid. Each platinum resistor allows the simultaneous measurement of fluid temperature via electrical resistance and flow velocity via constant voltage thermal anemometry. Cross-sectional measurement was enabled by applying a special multiplexing-excitation scheme. In this paper, we present the design and characterization of a prototypical sensor for measurements in a range of very low velocities.

Temperature control design for a high-resolution gamma-ray tomography detector.

In this paper, a thermal control design for a high-resolution gamma-ray computed tomography detector is presented. It accounts for the generation of heat produced by active electronic components as well as heat transfer from external heat sources. The development and implementation of this feature were motivated by stringent requirements for measurement accuracy at thermal hydraulic test facilities, where ambient thermal conditions are constantly changing. As a first step, the thermal behavior of the existing tomography detector was analyzed, critical components were identified, and different approaches for heat removal were tested. Eventually, an improved thermal detector design was elaborated and a controlled active cooling system was implemented. Performance tests proved its effectiveness and accuracy improvement.

Planar Array Sensor for High-speed Component Distribution Imaging in Fluid Flow Applications.

A novel planar array sensor based on electrical conductivity measurements ispresented which may be applied to visualize surface fluid distributions. The sensor ismanufactured using printed-circuit board fabrication technology and comprises of 64 x 64interdigital sensing structures. An associated electronics measures the electricalconductivity of the fluid over each individual sensing structure in a multiplexed manner byapplying a bipolar excitation voltage and by measuring the electrical current flowing from adriver electrode to a sensing electrode. After interrogating all sensing structures, a two-dimensional image of the conductivity distribution over a surface is obtained which in turnrepresents fluid distributions over sensor's surface. The employed electronics can acquire upto 2500 frames per second thus being able to monitor fast transient phenomena. The systemhas been evaluated regarding measurement accuracy and depth sensitivity. Furthermore, theapplication of the sensor in the investigation of two different flow applications is presented.

Volume image reconstruction for diffuse optical tomography.

Optical tomography is a potential diagnostic method for visualizing optical properties of tissues in vivo. We present an optical tomography method that has been designed for imaging of the human testes, particularly for spectroscopic tumor differentiation. In this application we need to compute three-dimensional distributions of the optical contrast (absorption coefficient) in the tissue in real time. Thus we have given special care to elaborate an efficient inverse algorithm that takes the limitations of spatial resolution and data space point density into account. Our inverse solution is based on a linearization approach and a dedicated object space discretization. Furthermore, we introduce the concept of fuzzy voxels, which enables a reconstruction-inherent image smoothing.