Utilizing optical fibres to monitor the status of melting units

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Peter Schmidt

Knowing the status of a melting unit is essential for a safe operation especially if water-cooled parts are used. Explosion hazards and metal run-outs generate high costs for loss of production and repairs – not mentioning the possible loss of human life. The highly sensitive and accurate temperature measurement utilizing optical fibres (DTS – distributed temperature sensing) can be used to monitor the status of various types of melting units. But an application is not always reasonable – some features of this technology can be a benefit or a drawback always depending on the conditions of application. In this paper examples of applications of optical fibres currently used to monitor the status of melting units in industry are shown. For this occasion different methods of temperature measurements utilizing optical fibres are briefly introduced. Furthermore the extensive monitoring of large areas with mostly steady state temperature conditions (e.g. on the surface of spray-cooled side walls) as well as transient temperature conditions (sensors placed inside cooling elements, e.g. copper tap block, copper side wall coolers) are discussed. Considering the thermal conductivity of the materials used and taking into account the structure of the surroundings of the sensor the wear inside the monitored area can be derived in many cases in a satisfactory manner. Eventually practical results of pyrometallurgical smelters and the application of an embedding technology of optical fibres into precast copper coolers are presented. Temperature measurements utilizing optical fibres can offer an efficient and safe monitoring of different kinds of melting units. Especially the status of endangered water-cooled parts of pyrometallurgical smelters can be monitored efficiently.

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