System and method for accretion detection

• US 10,444,079 B2
• Filed: 06/23/2017
• Issued: 10/15/2019
• Est. Priority Date: 10/13/2016
• Status: Active Grant

• Current Assignee: TATA Consultancy Services Limited (Tata Sons Pvt Ltd.)
• Original Assignee: TATA Consultancy Services Limited (Tata Sons Pvt Ltd.)
• Inventors: Singh, Bashisht Narayan
• Primary Examiner(s): Caputo, Lisa M
• Assistant Examiner(s): Cotey, Philip L
• Application Number:
  US15/631,455
• Publication Number:
  US 20180106683A1
• Time in Patent Office: 844 Days
• CPC Class Codes: F27B 7/42 Arrangement of controlling, monitoring, alarm or like devices
• CPC Class Codes: G01B 21/085 using thermal means
• CPC Class Codes: G01K 1/024 for remote indication
• CPC Class Codes: G01K 1/026 arrangements for monitoring a plurality of temperatures, e.g. by multiplexing
• CPC Class Codes: G01K 13/02 for measuring temperature of moving fluids or granular materials capable of flow
• CPC Class Codes: G01K 13/026 of moving liquids
• CPC Class Codes: G01K 2213/00 Temperature mapping
• CPC Class Codes: G01K 7/34 using capacitative elements capacitors per se H01G
• CPC Class Codes: G02F 2001/1635 the pixel comprises active switching elements, e.g. TFT
• CPC Class Codes: G09F 9/301 flexible foldable or roll-able electronic displays, e.g. thin LCD, OLED
• CPC Class Codes: G09G 3/3225 using an active matrix

Abstract

This disclosure relates generally to accretion detection, and more particularly to system and a method for accretion detection within an iron kiln. The iron kiln includes a cylindrical body for holding and processing molten iron ore. In one embodiment, method includes receiving, in real-time, a first plurality of temperature values from a plurality of sensors configured on distinct locations on the outer surface of the iron kiln and is associated with a distinct sensor ID. The plurality of temperature values are compared with a reference temperature value to identify deviation in temperature gradient associated with the outer surface. Subsequently on identifying the deviation corresponding to one or more sensors, a second plurality of temperature values of surrounding locations of the one or more sensors is recorded and the presence of the accretion in the iron kiln is determined based on the second plurality of temperature values.

Claims

1. A system for accretion detection within an iron kiln, the iron kiln comprising a cylindrical body for holding and processing molten iron ore, the system comprising:

a plurality of sensors configured on a plurality of distinct locations on an outer surface of the cylindrical body to measure temperature at the outer surface, the plurality of sensors associated with a distinct sensor ID;

one or more memories to store the plurality of distinct locations and respective sensor ID corresponding to the plurality of sensors, and a reference temperature value associated with the outer surface; and

one or more hardware processors, the one or more memories coupled to the one or more hardware processors, wherein the one or more hardware processors configured to execute programmed instructions stored in the one or more memories to;

receive, in real-time, a first plurality of temperature values of the plurality of distinct locations from the plurality of sensors;

compare the plurality of temperature values with the reference temperature value to identify deviation in temperature gradient associated with the outer surface;

on identifying the deviation corresponding to one or more sensors of the plurality of sensors, record a second plurality of temperature values of a plurality of surrounding locations of the one or more sensors; and

determine presence of the accretion in the iron kiln based on the second plurality of temperature values.

2. The system of claim 1, wherein the reference temperature value is an average maximum temperature of the outer surface of the iron kiln.

3. The system of claim 1, wherein the one or more hardware processors are configured to execute the programmed instructions to compute dimensions of the accretion based on the second plurality of temperature values.

4. The system of claim 3, wherein the one or more hardware processors are configured to execute the programmed instructions to compute the dimensions of the accretion based on the following equation:

5. The system of claim 4, wherein the one or more hardware processors are configured to execute the programmed instructions to plot a graph indicating dimensions and location of the accretion inside the cylindrical body of the iron kiln.

6. A processor-implemented method for accretion detection within an iron kiln, the iron kiln comprising a cylindrical body for holding and processing molten iron ore, the method comprising:

receiving, in real-time, a first plurality of temperature values of a plurality of distinct locations from a plurality of sensors via one or more hardware processors, each of the plurality of sensors configured on the plurality of distinct locations on an outer surface of the cylindrical body and associated with a distinct sensor ID;

comparing, via the one or more hardware processors, the plurality of temperature values with a reference temperature value to identify deviation in temperature gradient associated with the outer surface;

on identifying the deviation corresponding to one or more sensors of the plurality of sensors, recording via the one or more hardware processors, a second plurality of temperature values of a plurality of surrounding locations of the one or more sensors; and

determining presence of the accretion in the iron kiln based on the second plurality of temperature values, via the one or more hardware processors.

7. The method of claim 6, wherein the reference temperature value is an average maximum temperature of the outer surface of the iron kiln.

8. The method of claim 6, further comprising computing dimensions of the accretion based on the second plurality of temperature values.

9. The method of claim 8, wherein computing the dimensions of the accretion comprises computing thickness of the accretion based on the following equation:

10. The method of claim 9, further comprising plotting a graph indicating the dimensions and location of the accretion inside the cylindrical body of the iron kiln.

11. A non-transitory computer-readable medium having embodied thereon a computer program for executing a method for accretion detection within an iron kiln, the iron kiln comprising a cylindrical body for holding and processing molten iron ore, the method comprising:

receiving, in real-time, a first plurality of temperature values of a plurality of distinct locations from a plurality of sensors, each of the plurality of sensors configured on the plurality of distinct locations on an outer surface of the cylindrical body and associated with a distinct sensor ID;

comparing the plurality of temperature values with a reference temperature value to identify deviation in temperature gradient associated with the outer surface;

on identifying the deviation corresponding to one or more sensors of the plurality of sensors, recording a second plurality of temperature values of a plurality of surrounding locations of the one or more sensors; and

determining presence of the accretion in the iron kiln based on the second plurality of temperature values, via the one or more hardware processors.