THERMOCOUPLE PROCESSING

Table 3 lists typical failure rate data for a variety of types of process equipment. Large variations between these numbers and specific equipment can be expected. However, this table demonstrates a very fundamental principle the more compHcated the device, the higher the failure rate. Thus switches and thermocouples have low failure rates gas—Hquid chromatographs have high failure rates. 

Measurement of the hotness or coldness of a body or fluid is commonplace in the process industries. Temperature-measuring devices utilize systems with properties that vaiy with temperature in a simple, reproducible manner and thus can be cahbrated against known references (sometimes called secondaiy thermometers). The three dominant measurement devices used in automatic control are thermocouples, resistance thermometers, and pyrometers and are applicable over different temperature regimes. 

Low level. The most common low level signals are inputs from thermocouples. These inputs rarely exceed 30 millivolts, and could be zero or even negative. The conversion equipment must be bipolar (i.e., capable of processing positive and negative voltages). 

Because indirect-heat calciners frequently require close-fitting gas seals, it is customaiy to support aU parts on a selFcontained frame, for sizes up to approximately 2 m in diameter. The furnace can employ elec tric heating elements or oil and/or gas burners as the heat source for the process. The hardware would be zoned down the length of the furnace to match the heat requirements of the process. Process control is normaUy by shell temperature, measured by thermocouples or radiation pyrometers. When a special gas atmosphere must be maintained inside the cyhnder, positive rotaiy gas se s, with one or more pressurized and purged annular chambers, are employed. The diaphragm-type seal ABB Raymond (Bartlett-Snow TM) is suitable for pressures up to 5 cm of water, with no detectable leakage. 

Temperature Measurement shift. Measurement not representative of process. Indicator reading varies second to second. Ambient temperature change. Fast changing process temperature. Electrical power wires near thermocouple extension wires. Increase immersion length. Insulate surface. Use quick response or low thermal time constant device. Use shielded, twisted pair thermocouple extension wire, and/or install in conduit. 

LThe compensated flow transmitter determines the process flow it converts this quantity to a signal that is proportional to the process flow and sends it to the flow controller. The transmitter could be a pneumatic device using a venturi primary element, with compensation for pressure by a pressure element and compensation for tern perature by a thermocouple. The output would be a pneumatic sic nal that is proportional to weight flow. 

Fig. 4.61 illustrates that the mould temperature is quite different from the set oven temperature (330°C) or indeed the actual oven temperature, throughout the moulding cycle. An even more important observation is that in order to control the rotational moulding process it is desirable to monitor the temperature of the air inside the mould. This is possible because there is normally a vent tube through the mould wall in order to ensure equal pressures inside and outside the mould. This vent tube provides an easy access for a thermocouple to measure the internal air temperature. 

A detonation flame arrester with an integral thermocouple at the inlet to the process heater firebox to prevent backflash into the vacuum system. 

Couplings are handy to have on the process inlet and outlet nozzles on both the tube and shell sides. These may be used for flushing, sampling, or thermometer wells, thermocouple bulbs, or pressure gages. 

In the chemical process industry molybdenum has found use as washers and bolts to patch glass-lined vessels used in sulphuric acid and acid environments where nascent hydrogen is produced. Molybdenum thermocouples and valves have also been used in sulphuric acid applications, and molybdenum alloys have been used as reactor linings in plant used for the production of n-butyl chloride by reactions involving hydrochloric and sulphuric acids at temperatures in excess of 170°C. Miscellaneous applications where molybdenum has been used include the liquid phase Zircex hydrochlorination process, the Van Arkel Iodide process for zirconium production and the Metal Hydrides process for the production of super-pure thorium from thorium iodide. 

The reactants are loaded in a magnesia crucible and heated by a resistance furnace to 800°C (Figure 3). Once the CaCl2 is molten, a tantalum stirrer and a Ta-Ni thermocouple sheath are lowered into the melt. While stirring, the reaction is monitored with a thermocouple. Once the reaction is complete, the stirrer and thermocouple well are retracted and the melt is allowed to cool. Figure 4 shows a typical DOR product and salt/crucible residue. A typical product button weighs 600 g and the process yield is >99%. Essentially no purification takes place in the reduction step, meaning that the product button is no purer than the feed. 

Thermocouples were placed in the curing part so that the model could be compared to the actual process. The model accurately predicted the cure time and temperature curing profiles for several parts with different geometries and curing conditions. 

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