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Anthony RossInfrared Imaging of Black Liquor Droplets
Team Members:Aaron Brandt
Will Carter
Brent Illingworth
Matt Travis
Academic Advisor:Dr. David Sailor
Industry Advisor:Dan Higgins, P.E.
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Background
• Kraft paper pulping process schematic
White Liquor
Steam
Smelt
Weak Liquor
concentratedBlack Liquor
E-1
E-2
E-3
E-4 E-5E-6
P-1 P-2 P-3 P-4
P-5P-6
Pulp Digester
Evaporator Evaporator Evaporator
Recovery Boiler
Causticizer
P-7
Air
Combustion consumessolids
Sodium returned to NaOH and NaS
Schematic of Pulping Process
E-7
P-8
P-9
Turbine
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Mission
• Design an optical assembly • Images are used to generate data• Data is used to improve boiler model
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Project timeline
ID Task Name Start Finish DurationJan 2005 Feb 2005 Mar 2005 Apr 2005 May 2005
1/2 1/9 1/16 1/23 1/30 2/6 2/13 2/20 2/27 3/6 3/13 3/20 3/27 4/3 4/10 4/17 4/24 5/1 5/8 5/15 5/22 5/29 6/5
1 4w1/28/20051/3/2005PROJECT DESIGN SPECS.
2 3.2w2/18/20051/28/2005INTERNAL / EXTERNALSEARCH
3 5w3/11/20052/7/2005CONCEPT GENERATION
4 7.2w3/28/20052/7/2005OPTICS DESIGN
5 2.8w2/24/20052/7/2005ACTUATION DESIGN
6 5w3/28/20052/22/2005HOUSING DESIGN
7 6.8w4/8/20052/22/2005SELECTION & EVALUATIONOF FINAL DESIGN
8 1.2w3/1/20052/22/2005WINTER QUARTER REVIEW
9 4.4w5/9/20054/8/2005PROTOTYPING
10 2.2w5/23/20055/9/2005TESTING & VERIFICATION
11 2.2w6/6/20055/23/2005FINAL REVIEW &OPTIMIZATION
12 2w6/10/20055/30/2005FINAL PROJECTPRESENTATION
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Existing sizing techniques
Laser – Detector Systems
• Laser passes through spray
• Photodetectors gather scattered light
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Existing sizing techniques cont’
Imaging systems
• Light focused onto CCD to produce digital image
• Software analyzes images and outputs size
• Distance to droplets must be known
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Sizing technique to be used
Infrared imaging system
• Other systems infeasible
• Camera currently used for maintenance
• High contrast due to temperature difference
• Additional marketability of IR camera
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Major requirements
• Depth of focus must be short enough
• Focal length must be adjustable and known
• Viewing angle must be adjustable
• Adequate cooling and cleaning
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Depth of focus must be short enough
• Software will only measure droplets that are in focus• Focal length can accurately be used as the distance to
droplets• Optics aperture affects depth of focus
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Focal length must be adjustable and known
• Exact measurement region is unknown
• Needs to adapt to different boiler configurations
• Must be known to scale droplet image size to actual size
• Affects depth of focus & magnification
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Focal length adjustment
• Dual lens system allows for focus adjustment
• Fine adjustment of rear lens necessary
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Viewing angle must be adjustable
• Optics system will be inserted above spray
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Viewing angle must be adjustable
• Mirror based system
• Fiber optics based system
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Fiber optic imaging
Fiber bundles• Flexible• Coherent• Light entering and exiting must be parallel• Many components available
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Viewing Angle Adjustment
• Bracket assembly
• Planetary gear assembly
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Cooling/Cleaning
• Compressed air on sight
• Safe to use in boiler
• Air purge system for lens cleaning
• Air flow limited by compressed air pressure
• One or two air ports could be used
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Decision Matrix
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Future considerations
• Optics system– Dimensions– Calibration– Depth of focus– Utilize manufacturer expertise
• Cooling system– Detailed analysis
• Thermal expansion– Material selection
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Conclusion
• Existing sizing methods analyzed
• Infrared imaging confirmed as most feasible
• Major requirements established
• Possible solutions compared
• Overall concept decided
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Complete Concept
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Questions?