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1-s2.0-S003039920500157X-main
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1-s2.0-S003039920500157X-main
Abstract
This paper describes the design, computer simulation and experimental evaluation of a novel measurement system that has been
recently developed for the measurement of mass flow rate of particles in a gravity chute convey pipeline. Comprehensive computer
simulation and numerical calculations show that the proposed method with laser-sensing array is theoretically correct and the
programmed algorithm is effective. This method has been characterized by dynamic testing, real time and continuous measurements.
The results of simulation and experiment have demonstrated that the multi-laser source fan-shaped geometry can be an effective
approach to interrogate the mass flow rate of particles over the pipe cross-section. The mass flow rate of particles derived from
extinction principle has shown a good agreement with the projection sum of light beams and the real mass flow rate.
r 2005 Elsevier Ltd. All rights reserved.
0030-3992/$ - see front matter r 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.optlastec.2005.07.012
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Y. Zheng et al. / Optics & Laser Technology 39 (2007) 298–305 299
iron-making production. They measured both volumetric laser beam and particles falling in the gas in the pipeline,
concentration and velocity using capacitance sensors [14]. when a beam from a laser source transmits via the cross-
Also CSIRO Division of Minerals has developed and section of the pipe. For a monodisperse system the
successfully plant-tested a commercial prototype pulver- extinction of the light can be described by [8]
ized fuel (PF) mass flow measurement system, which
I p
utilized measurements of the attenuation and velocity of ln ¼ LD2 Eðl; m; DÞN, (1)
I0 4
pulsed beams of 60 kHz ultrasound transmitted across
the boiler pipes to determine the PF mass flow in each where I0 and I are, respectively, the intensities of the
pipe [15]. Mass flow measurement of pneumatically incident and transmitted light, L the length of the light
conveyed solids using radiometric sensors has been path in measuring area, D and N the diameter and
developed by Barratt et al. [16]. And Sen et al. described number of particles per unit volume, respectively,
a gas–solid two-phase mass flow-meter for pneumatically Eðl; m; DÞ the extinction coefficient, which is in function
conveying systems using an integrated system of capaci- of the wavelength of the light l, the diameter D and the
tance sensor and electrodynamic sensor [17]. refractive index of the particle m. Eðl; m; DÞ can be
In spite of all of these efforts, few commercial mass flow exactly calculated from the classical Mie theory [18].
meters based on inferential technique are yet to receive When the concentration distribution of the particles
wide acceptance from industries. The main reason is that within the cross-section in the pipe is not uniform, the
many variables exist in industrial process, which may relationship between the incident and the transmitted
directly affect the response of a solids flow instrument in light intensity corresponding a light path L is given by
ill-defined ways [1]. These include inhomogeneous dis- Z
I p
tribution of solids over the pipe cross-section, irregular ln ¼ D2 Eðl; m; DÞNðx; yÞ dl, (2)
I0 4 L
velocity profiles, variations in particle size, moisture
content, and deposition of fine particles on the inner wall where N(x,y) is the concentration distribution of the
of the pipeline and so on. Moreover, some of them may be particles in the pipe. Once the particle size D and
impossible to be controlled or predicted. These no doubt number of particles N have been determined, the volume
make measurement of solids mass flow more difficult. concentration of the particles, Cv can be calculated
Therefore, there is a great need for accurate, reliable, on- by [8]
line, continuous and non-invasive measurement of solids p
C v ¼ D3 N. (3)
mass flow rate in industrial processes. 6
In this work, based on the extinction and optical The mass flow rate of particles can be deduced
tomography principle, a novel optical method is according to the following equation [1]:
presented, which is able to give the concentration
distribution of the particulate solids in an experimental M ¼ r A v Cv, (4)
scale gravity chute conveyor. The system is intended to where, r is the density of the particles material, A the
employ multi-laser-source array to create the optical- cross-section area of the pipe and v the mean particles
sensing field interrogating the entire cross-section in velocity, Cv the volume concentration of the particles.
testing pipe to obtain the projection data of particles. The main problem to measure the mass flow rate of
According to the extinction principle, the information of the particulate solids is then focused on how to
the spacial distribution of particles over the cross- determine the concentration distribution of the particles
section of the testing pipe can be acquired. At the same in the pipe N(x,y). A novel approach has recently been
time, the flow image over the cross-section in the pipe developed by means of optical tomogranogy technology
can be produced based on projection data by image based extinction principle.
reconstruction algorithms. Both of them will reflect
the concentration information of particulate solids in 2.2. Forward and inverse problems
the testing pipe. When the velocity of the particles is
determined, the mass flow rate of the particles can be Supposing X– Y is the Cartesian coordinates of the
procured. The measurements will be non-invasively and object field f(x,y), t– s the Radon coordinates which has
continuously implemented on real time. the same origin as X– Y and locates in an identical plane
with X– Y, and s axis direction is consistent with
the projection direction, y the projection angle, L the
2. Principle and method arbitrary straight line on the plane, the object field and
the coordinates system are shown in Fig. 1.
2.1. Principle The Radon transform is the projection of the object
field intensity along a radial line oriented at a specific
The attenuation of the light can be expressed by the angle. It defines the forward problem with optical
extinction principle due to the interaction between the attenuation. Hence, the projection data based on optical
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300 Y. Zheng et al. / Optics & Laser Technology 39 (2007) 298–305
3. Experimental set-up
3.1. Sensor array structure has indicated that the sensitivity level of the optical-
sensing field depends mainly on the number of the light
The spatial array design of the sensor should be sources and detectors, i.e., the number of the indepen-
sufficiently taken into account to match in the geometric dent light beams. On the other hand, the uniformity of
shape, mechanical and physical features of the solid the sensitivity distribution of the optical-sensing field
phase particles in the pipe together with reconstruction relies principally on the fan angle of the fan-shaped
algorithm to ensure that the optical PT measurement beams and the number of the light sources. Fig. 2(b) has
system does work in the optimum model. clearly shown that the sensitivity distribution of the
To interrogate the cross-section of the measured optical-sensing field is not uniform. The sensitivity of the
object field, the light source-detector array based on areas, where they are nearby the center of the pipe and
fan-shaped arrangements is designed to obtain a series adjacent the light sources, looks remarkably higher than
of fan projections (see Fig. 2(a)). In the case of Fig. 2(a), that of other areas, while the sensitivity distribution of
15 laser sources are used and each source supplies five those areas far from light sources looks more even. This
light beams which are spaced at 121 intervals with a fan behavior depends mainly on the fan-shaped structure of
angle of 481. The sensitivity distribution of the fan- laser-detector array. It is really different from the
shaped arrangement has been given in Fig. 2(b) with the perpendicular structure of optical sensor array.
pixel grids 43 43.
The optical-sensing field is formed within the cross- 3.2. Experimental rig
section of the testing pipe along the source-detector
path. Its characteristics and behavior will directly The experimental set-up shown schematically in
influence the measurement system. The simulation result Fig. 3, has been designed and developed to facilitate
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302 Y. Zheng et al. / Optics & Laser Technology 39 (2007) 298–305
the measurement of mass flow rate of the solid particles drop down steadily to ensure adjusted flow of solid in
in an experimental scale gravity chute convey pipeline. the system.
The system consists of array of laser diode sources,
detector array, signal conditioning, data acquisition unit
and main computer. The experimental rig is shown in 4. Experimental tests and results
Fig. 3.
The laser source array (15 laser diode modules) and A series of experimental tests were conducted on an
photodiode array (15 photodiodes) were arranged in the experimental scale gravity chute convey test facility to
way alternated between laser source and detector, investigate the ability of the system to measure the mass
surrounded the testing pipe, termed fan-shaped array flow rate of solids. The main aims are to reconstruct the
with 15 light sources, each source with five beams. The concentration distribution and validate the relationship
light from each laser source traverses the cross-section of between the optical attenuation (projection sum) and the
the testing pipe. And the transmitted light is received at mass flow rate of the dilute dispersed phase in vertical
same time by five photodiodes right opposite the laser pipeline, meanwhile to try to calibrate the measurement
source, where the light energy is converted into the coefficient Z at different screw feeder speed to examine
electrical signal. The projections available for imaging the dynamic working state of the whole measurement
construction are produced in a successive order by system.
stimulating light emitters, i.e., all emitters are lighted in
serial pattern within this entire measuring period for one 4.1. Test conditions
frame image reconstructed. Signal conditioning provides
both I/V transform and an electrical signal which According to the relationship described by Eq. (11),
increases in amplitude as the solid particle concentration considering that the properties of particulate material
increases. In one scanning turn, there will be 15 5 ¼ 75 are invariable under certain conditions, extinction
projection data to be obtained by the photodiode array. coefficient E, density r and particle diameter D can be
The projection data are sampled by individual sample/ approximately regarded as constant. Meanwhile, cross-
hold circuits. After an analogue/digital conversion the section A and total light path L1 should be fixed
signals are recorded, stored and reconstructed by a quantities when the structure of the optical array sensor
computer system connected with scanning control has been designed and completed. Also, considering that
interface. Each data set is processed using appropriate the height h (h the distance from the exit of the screw
image reconstruction algorithm to generate a concentra- feeder to the sensing section) is much greater than the
tion profile on line. sensor-sensing space, the effect of particle acceleration
The screw feeder, via motor controlled by frequency on the measurement is p expected
ffiffiffiffiffiffiffiffi to be small. So the
conversion device, is used to make the particulate solids particulate velocity v ¼ 2gh (where g is the gravity
acceleration, h the distance from the exit of the screw
feeder to the sensing section), at which the particles drop
vertically downwards through the sensing section of the
Feeder hopper
testing pipe, is a constant when the distance h is
Screw feeder
determined. Hence, Eq. (11) can be written as
Controlling
Motor Interface 2 rAvD X X
M¼ py j ¼ Z py j , (12)
3 L1 Eðl; m; DÞ j j
Testing
Pipe
Signal Data Acquisition where
Conditioning Interface
2 rAvD
h
Z¼ ,
Scanning Signal Analysis 3 L1 Eðl; m; DÞ
A A Control and Image Reconstruction
Interface and Interpretation where Z approximately is a constant, which can be
calibrated in the experimental test process. As a result,
A-A
Laser
the mass flow rate ofPthe particles M is proportional to
the projection sum py .
Diode
Array
and 4.1.1. Experimental conditions
Detector
Array
Laser diode Detector Gravity chute conveyor in experimental scale.
Workstation
Diameter of testing pipe: +80 mm.
Fig. 3. The experimental rig of optical tomography system for Distance from the exit of the screw feeder to the light
gas–solid two-phase flow measurement. sensing section: 225 mm.
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Y. Zheng et al. / Optics & Laser Technology 39 (2007) 298–305 303
Free fall velocity of silica sand: 2.1 m/s. The fitted equation between the mass flow rate y and
Mean particle size of the silica sand: 500–1000 mm. the projection sum x can be obtained using least-squares
Speed range of screw feeder: 100–1250 rpm. fitting
Calibration range of the mass flow rate of particle:
6.10–34.20 g/s. y ¼ 0:9466x 0:0441, (13)
Sensor array structure: 15 light sources, each source
where the slope of the fitted curve is the calibration
with five beams.
coefficient Z ðZ ¼ 0:9466Þ. And the residual standard
Projection data: 15 5 ¼ 75.
deviation is given in Eq. (14)
Light sources: laser diode modules.
Wavelength of laser source: 650 nm. sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
PN
Output power of laser source: 4 mw. i ðyi y ^ i Þ2
s¼ ¼ 0:1843 ðg=sÞ, (14)
N 2
4.3. Calibration
Table 1
Relationship between the mass flow rate and the on-line projection sum of solids distribution
Spin speed of screw feeder (rpm) 100 200 300 400 500 600 750 1000 1250
Mass flow rate (g/s)
P 6.10 12.51 18.97 20.10 21.83 24.03 28.21 33.77 34.20
Projection sum ( py ) (non-dimension) 6.90 14.78 17.68 20.12 23.21 25.03 31.00 36.02 37.82
Calibration coefficient Z (g/s) 0.884 0.846 1.073 0.999 0.941 0.960 0.910 0.938 0.904
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Table 2
The comparison of the real weighing data and the estimated data of the mass flow rate ðZ ¼ 0:9466Þ
Spin speed of screw feeder (rpm) 300 400 500 600 750 1000 1250
Real weighing data (g/s) 19.098 20.105 21.833 24.025 28.215 33.770 34.200
Estimated data (g/s) 19.907 20.242 22.122 24.069 28.298 33.846 34.071
Error (%) 1.00 0.68 1.32 0.18 0.30 0.22 0.38
According to Eq. (12) and the calibration coefficient show that the proposed method with optical-sensing
Z, the estimated value of the mass flow rate can be array is theoretically correct and the programmed
calculated from the projection sum in the real measuring algorithm is effective. This method has been character-
process (see Table 2). ized by real time and continuous measurements. The
Table 2 gives real weighing data and the estimated experiment results have illustrated that the multi-sources
data of the mass flow rate as well as the percentage error fan-shaped geometry can be an effective approach to
over the measuring range. The largest and the second interrogate the mass flow rate of particles over the pipe
largest errors are, respectively, 1.00% and 1.32% versus cross-section. The mass flow rate of particles derived
real mass flow rate 19.098 and 21.833 g/s while the from extinction principle in some assumption circum-
measuring errors less than 1% can be gained in majority stances has shown good agreement with the projection
measuring spots. The test results have expressed that sum of total light beams and the real mass flow rate. The
there is good correlation between the real weighing data advantages of the proposed mass flow measurement
and the estimated data. system can be summarized as follows:
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