RESUMO
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.
RESUMO
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.
RESUMO
Understanding of flow patterns and their transitions is significant to uncover the flow mechanics of two-phase flow. The local phase distribution and its fluctuations contain rich information regarding the flow structures. A wire-mesh sensor (WMS) was used to study the local phase fluctuations of horizontal gas-liquid two-phase flow, which was verified through comparing the reconstructed three-dimensional flow structure with photographs taken during the experiments. Each crossing point of the WMS is treated as a node, so the measurement on each node is the phase fraction in this local area. An undirected and unweighted flow pattern network was established based on connections that are formed by cross-correlating the time series of each node under different flow patterns. The structure of the flow pattern network reveals the relationship of the phase fluctuations at each node during flow pattern transition, which is then quantified by introducing the topological index of the complex network. The proposed analysis method using the WMS not only provides three-dimensional visualizations of the gas-liquid two-phase flow, but is also a thorough analysis for the structure of flow patterns and the characteristics of flow pattern transition. This article is part of the themed issue 'Supersensing through industrial process tomography'.
RESUMO
The liquid fraction of foam is an important quantity in engineering process control and essential to interpret foam rheology. Established measurement tools for the liquid fraction of foam, such as optical measurement or radiography techniques as well as weighing the foam, are mostly laboratory-based, whereas conductivity-based measurements are limited to the global measurement without detailed spatial information of liquid fraction. In this work, which combines both types of measurement techniques, the conductivity-based wire-mesh sensor is compared with neutron radiography. We found a linear dependency between the liquid fraction of the foam and the wire-mesh readings with a statistical deviation less than 15%. However, the wire-mesh sensor systematically overestimates the liquid fraction, which we attribute to liquid bridge formation between the wires.
RESUMO
The identification of the main flow regime boundaries in bubble columns is essential since the degrees of mixing and mass and heat transfer vary with the flow regime. In this work, a new statistical parameter was extracted from the time series of the cross-sectional averaged gas holdup. The measurements were performed in bubble columns by means of conductivity wire-mesh sensors at very high sampling frequency. The columns were operated with an air/deionized water system under ambient conditions. As a flow regime indicator, a new dimensionless statistical parameter called "relative maximum number of visits in a region" was introduced. This new parameter is a function of the difference between the maximum numbers of visits in a region, calculated from two different division schemes of the signal range.