Distributed Sensing for Early Detection of Water Leakages in the Burner Area of an Electric Arc Furnace Using Optical Fiber Sensors

• Published in: IEEE transactions on instrumentation and measurement 2024, Vol.73, p.1-12
• Main Authors: Inalegwu, Ogbole Collins, Saha, Rony Kumer, Pullagura, Manoj Kumar, Sander, Todd Pearson, Dey, Koustav, Smith, Jeffrey D., O'Malley, Ronald J., Gerald, Rex E., Huang, Jie
• Format: Article
• Language: English
• Subjects: Assembly; Bricks; Continuous fibers; Continuous furnaces; Distributed sensing; Electric arc furnaces; fiber Bragg grating (FBG); Fiber gratings; Furnaces; Leakage; Maintenance costs; optical fiber sensor (OFS); Optical fiber sensors; Optical fibers; optical frequency-domain reflectometer (OFDR); Rayleigh scattering; Real time; Refractory materials; Safety; Sensors; Steam explosions; Temperature measurement; thermal mapping
• ISSN: 0018-9456; 1557-9662
• DOI: 10.1109/TIM.2024.3460948

This study introduces an innovative approach to enhance safety in electric arc furnaces (EAFs) through the integration of optical fiber sensors (OFS) in the refractory lining bricks' assembly. By demonstrating the significant benefits of OFS, we showcase its effectiveness in continuous thermal monitoring and location profiling within the EAF refractory lining. The work focuses on detecting the onset of water leakage in the vicinity of the burner of an EAF, with thermal data resolution up to 1.3 mm. The instrumented OFS in this work were able to detect volumes of water leaks (from a controlled water drip pipe with flow rates \ge 2.3 cc/min) at temperatures \gt 500~^{\circ } C, indicating their potential for promptly identifying and informing maintenance actions. Prompt maintenance actions would help to mitigate catastrophic consequences of water leakages such as steam explosions. Furthermore, proactively addressing water leakage issues can extend furnace lifespan and the overall safety of EAF operations. Therefore, our work aims to enhance safety and minimize downtime and maintenance costs by providing distributed and real-time thermal profiling solutions to the water leakage concerns in the refractory lining bricks' assembly around the burner of an EAF.