Classifications

• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
  • C10B45/00—Other details
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U20/00—Constructional aspects of UAVs
  • B64U20/80—Arrangement of on-board electronics, e.g. avionics systems or wiring
  • B64U20/87—Mounting of imaging devices, e.g. mounting of gimbals
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U10/00—Type of UAV
  • B64U10/10—Rotorcrafts
  • B64U10/13—Flying platforms
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
  • G01B11/00—Measuring arrangements characterised by the use of optical techniques
  • G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
  • G01B11/00—Measuring arrangements characterised by the use of optical techniques
  • G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T7/00—Image analysis
  • G06T7/0002—Inspection of images, e.g. flaw detection
  • G06T7/0004—Industrial image inspection
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U2101/00—UAVs specially adapted for particular uses or applications
  • B64U2101/30—UAVs specially adapted for particular uses or applications for imaging, photography or videography
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U2101/00—UAVs specially adapted for particular uses or applications
  • B64U2101/30—UAVs specially adapted for particular uses or applications for imaging, photography or videography
  • B64U2101/31—UAVs specially adapted for particular uses or applications for imaging, photography or videography for surveillance
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U30/00—Means for producing lift; Empennages; Arrangements thereof
  • B64U30/20—Rotors; Rotor supports
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
  • B64U50/00—Propulsion; Power supply
  • B64U50/10—Propulsion
  • B64U50/19—Propulsion using electrically powered motors
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T2207/00—Indexing scheme for image analysis or image enhancement
  • G06T2207/10—Image acquisition modality
  • G06T2207/10024—Color image
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T2207/00—Indexing scheme for image analysis or image enhancement
  • G06T2207/10—Image acquisition modality
  • G06T2207/10048—Infrared image
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T2207/00—Indexing scheme for image analysis or image enhancement
  • G06T2207/20—Special algorithmic details
  • G06T2207/20084—Artificial neural networks [ANN]
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T2207/00—Indexing scheme for image analysis or image enhancement
  • G06T2207/20—Special algorithmic details
  • G06T2207/20172—Image enhancement details
  • G06T2207/20182—Noise reduction or smoothing in the temporal domain; Spatio-temporal filtering
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
  • G06T2207/00—Indexing scheme for image analysis or image enhancement
  • G06T2207/30—Subject of image; Context of image processing
  • G06T2207/30248—Vehicle exterior or interior
  • G06T2207/30252—Vehicle exterior; Vicinity of vehicle

Definitions

• the present invention relates to an aircraft for inspecting equipment in coking plants to detect sources of error and a corresponding method using the aircraft.
• coke oven batteries consist of up to 90 coke oven chambers coupled to one another in the longitudinal direction, with each of these coke oven chambers being framed on both sides by a heating wall. Viewed in the transverse direction, this heating wall consists of up to 44 individual hollow channels lined up next to one another, which are also referred to as heating flues. In these heating flues of the heating walls, heat is generated by burning fuel gases to heat the neighboring coke oven chambers filled with coal. This means that the heating of a single coke oven battery from individual combustion processes is guaranteed in up to approx. 3800 heating flues.
• the alternating arrangement of oven chamber and heating wall mentioned above produces coke oven batteries with a respective length of up to 140m and depths of up to 25m and heights of up to 20m.
• each heating flue viewed in the transverse direction of the coke oven battery, requires an individual heating setting, whereby the heating must be set in such a way that the stringent emission requirements are met. This means that, as is known, temperature peaks should be avoided and thermal nitrogen oxide formation should be minimized.
• the resulting temperature conditions within the heating flues can only be determined by time-consuming manual measurements by the staff using pyrometers through openings in the horizontal coke oven roof of the coke oven battery.
• only a small number of heating flues can be evaluated per work shift and day, so that it can take several weeks until all heating flues have been evaluated and a first overall thermal picture of the coke oven battery is available.
• this thermal overall picture is already to be regarded as outdated and therefore obsolete.
• the overall assessment of the coke oven battery leads to temporary misjudgments, is lengthy and costly.
• the inconsistent thermal heating setting of the coke oven battery which is not adapted to the coke oven battery cone and is consequently incorrect, is associated with a high emission load.
• the temperature-dependent nitrogen oxide emission load is of great importance, which is always linked to stringent limit values by local environmental authorities.
• the coke oven battery is exposed to high temperatures, which results in an essentially constant deformation of the coke oven battery, in particular its components and attachments.
• This deformation is also caused, for example, by an increase in the refractory lining of the coke oven battery as a result of temperature-related expansion processes in the material. Deformations of several centimeters per year can occur, for example in the area of the rails, the filling holes formed on the coke oven roof, the transverse and longitudinal anchors and the coke oven doors on the coke and machine side.
• the object of the present invention is to overcome the above-described disadvantages in the detection of error sources in a coke oven battery, in particular a coke remedial system at least partially.
• the object of the present invention is to create an aircraft and a method for inspecting equipment in coking plants to detect sources of error, which reliably detect sources of error in a simple and cost-effective manner and predict possible maintenance that may be required.
• an aircraft for inspecting facilities of coking plants to detect sources of error has at least one propeller (whereby two or more propellers can also be arranged) with at least one electric motor to enable the aircraft to fly, at least one accumulator to provide electrical energy, a flight controller to control the electric motor, sensors at least to determine the flight altitude or the angular velocity or obstacles on the flight path, as well as a satellite-controlled position detection module, such as a GPS or GPS-like module for determining the position.
• a satellite-controlled position detection module such as a GPS or GPS-like module for determining the position.
• the aircraft additionally has at least one inspection device for inspecting surfaces of the facilities to be inspected and an airspace at a distance from the surfaces to be inspected, as well as at least one transmitting and receiving device for data communication with at least other aircraft or at least one external analysis device for detecting the sources of errors on.
• a 3-dimensional overall image of the plant or the coking plant can be generated to determine thermal, deformation and emission-related changes in the plant.
• a short-term assessment for example of the heating setting and the external emission load of the coke oven battery of the coke oven, can be reliably carried out during the commissioning of the coke oven or also during a later inspection.
• heating flues in which temperature peaks lead to an undesirably high formation of nitrogen oxides can be identified in a short time and readjusted in terms of heating technology, which in turn ensures sufficient coke quality.
• Readjustment is understood to mean, for example, the readjustment of the springs of the anchorages or of deformed anchor stands that exceed limit values calculated according to (coke oven)-specific algorithms. The readjustment itself can be carried out as part of regular maintenance work.
• the ongoing operation of the plant such as the coke oven battery, is hardly disturbed and the plant capacity and the quality of the plant product generated (here, for example, the coke quality) remain at a high nominal level.
• Coke ovens are facilities for the pyrolysis of coal or biological raw materials into coke, such as horizontal chamber systems operating in bulk or ramming mode with downstream chemical secondary recovery equipment, horizontal chamber coke oven batteries with downstream thermal flue gas heat recovery (“heat recovery”) and vertical chamber systems, each with over Coal pre- and coke post-treatment facilities.
• Directional terminology is determined by the direction in which the coke product is pushed out of the oven chambers.
• coal is converted into coke in a rotary kiln.
• the aircraft according to the invention is advantageously a spatially mobile aircraft, such as a drone.
• the aircraft can advantageously (fully) automatically fly to or from previously defined areas of the coking plant, such as a coke oven battery, in order to carry out measurements and take pictures of different areas of the coking plant, such as horizontal outer surfaces or laterally adjacent vertical surfaces of a coke oven battery.
• the flight device is not only useful for the use of coking plants, but can also be used in other (chemical) plants. Accordingly, the general term “plant” is used below.
• the aircraft according to the invention also enables the inspection of impassable containers and pipelines of the plant, in particular the coking plant.
• the aircraft according to the invention also serves particularly advantageously for inspecting sub-devices of a plant, in particular a coking plant, such as a coal tower, a coke ramp, a quenching tower, a sewage treatment plant, a secondary recovery plant, a cooling tower, a tar cutter, a Claus plant, etc
• a coking plant such as a coal tower, a coke ramp, a quenching tower, a sewage treatment plant, a secondary recovery plant, a cooling tower, a tar cutter, a Claus plant, etc
• An electrical energy supplier such as an accumulator/a battery, is advantageously used to drive the aircraft, which not only enables the aircraft to be driven (supplying the electric motor with electrical energy) but also the energy supply for the inspection device.
• the aircraft it would also be conceivable for the aircraft to have an internal combustion engine and/or a compressed air drive in addition to the electrical energy supplier, in particular to enable movement/flying of the aircraft.
• the aircraft is controlled by an operator who can control sections/areas relevant for measurements, in particular objects/structures of the system, in order to carry out targeted measurements. Accordingly, it is also conceivable that the aircraft essentially (fully) automatically carries out measurements and image generation according to predetermined, in particular time-interval-controlled maintenance flights, with an operator being able to intervene at any time and take over the operation of the aircraft. Accordingly, the aircraft can be switched between fully automatic, semi-automatic or manual modes at any time. Within the scope of the invention, the fully automatic mode is understood to mean time-controlled flying of the aircraft with predetermined measurement intervals and image recordings, in which mode no operator intervenes and no operator has to be present during the activity of the aircraft.
• an automatic approach or departure is provided within the scope of the invention.
• defined areas (objects/structures) of the system whereby an operator can change, cancel or supplement measurements or image generation at any time.
• the operator flies to areas of the system that are relevant to him and the aircraft automatically decides, for example based on previously recorded values, which additional measurements must be taken at this point in the system (since there may not be sufficient data for this) or which image data from this section of the system must be generated in order to be able to map the system completely.
• the manual mode is understood to mean an operator mode in which the operator independently decides, without influencing the aircraft, which section, in particular which objects/structures of the system to be examined or observed, he would like to fly to with the aircraft and which measurements or which image generations he wants to carry out there.
• the inspection device is constructed in one piece or in several pieces.
• the inspection device advantageously has at least one measuring device.
• the inspection device can have a large number of measuring devices, in which case these measuring devices can be arranged at different positions/sections or areas of the aircraft.
• the positioning of the at least one measuring device, in particular the large number of measuring devices is determined by their functionality and the associated required alignment.
• the inspection device and in particular its at least one measuring device can advantageously be exchanged.
• this means that the measuring devices can be easily exchanged and the measuring devices can be individually configured as needed.
• the aircraft prefferably has a memory unit for at least temporarily storing the data recorded by the inspection device.
• This recorded data is then advantageously transmitted or sent to an analysis device via Bluetooth, radio, WLan or other wireless forms of transmission.
• a transmitting and receiving device which is also part of the aircraft, is advantageously used for this purpose.
• the recorded data is also forwarded to other aircraft. This makes sense in particular when a number of aircraft, in particular two or more aircraft, are used in one system. It is conceivable that each of the aircraft has the same inspection device with the same measuring directions (type and number) or each of the aircraft has a mutually different inspection device with a mutually different number of measuring devices or mutually different types of measuring devices.
• An aircraft can also use a measurement result to instruct another aircraft to carry out a comparison measurement in order to generate an exact (verified) measurement value.
• the aircraft can record measurement data from non-mobile measurement devices in the area of the coke oven battery or the system, in particular the coke oven system, and feed them to an evaluation unit.
• a non-mobile measuring device in particular a stationary measuring device, a pressure sensor is located, for example, in the oven roof of a heat recovery coke oven battery.
• Temperatures, gas compositions and volume flows can also be recorded or measured by at least one permanently or temporarily installed measuring device in the coking plant and sent to the aircraft or a large number of aircraft.
• the fill level of a liquid container or basin can be measured and sent to the aircraft.
• the inspection device has a temperature measuring device which determines a temperature field on a surface to be inspected without contact, in particular at least optically or thermographically.
• this temperature measuring device can also be understood as a thermographic device.
• the temperature measuring device can be, for example, an infrared temperature measuring device, in particular a laser infrared thermometer or a thermal camera.
• this allows temperature data to be determined contact-free and process-reliably even at high temperatures, without the aircraft having to be moved too close to the measuring point to be measured.
• the inspection device has a gas concentration measuring device, which detects gas concentrations in an air space that is at a distance from the surfaces to be inspected.
• the gas concentration measuring device which can also be referred to as an emission measuring device, is advantageously a chemically reactive device. Accordingly, it is possible a gas concentration, such as concentrations of nitrogen oxides, sulfur oxides, dust particles, higher hydrocarbons, carbon monoxide, benzo[a]pyrene, hydrogen sulfide, ammonia, etc. at a defined optimum distance (maximum/minimum distance) from the surface that is metrologically relevant for the gas concentration measuring device and safety-relevant for the aircraft.
• the gas concentration measuring device advantageously has analyzers and sensors or probes.
• the inspection device has a gas storage device operating in negative pressure, which preserves a gas sample taken in tightly, in particular airtight or gas-tight or fluid-tight, in order to supply the gas sample taken to an evaluation unit, in particular an analysis unit for later analysis.
• a suction device is also arranged on the aircraft, with which any emissions or Gases are sucked in and forwarded to the gas storage device.
• the gas storage device is, for example, also a storage bottle referred to as a “gas mouse” or some other tight, in particular fluid-tight container for at least temporarily storing/keeping the sucked-in gases/emissions.
• the gas storage device is then advantageously uncoupled from the aircraft and, for example, supplied to an external gas analysis laboratory for evaluation.
• the aircraft has any desired suppression and/or gas storage unit.
• the inspection device has a compressed air lance, which is used at least to remove superficial dirt on the surface to be inspected by means of compressed air.
• this compressed air lance can also be used in such a way that compressed air is blown into existing cracks, crevices, depressions, etc. in the masonry, doors, cladding, etc., in order to use a suitable sensor to measure the depth of these cracks, crevices, depressions, etc. to investigate. Consequently, the compressed air lance is advantageously a physically reactive device.
• the aircraft preferably also has a compressed air reservoir, from which compressed air for the compressed air lance is taken.
• the actual depth of unwanted masonry joints in a coke oven battery can advantageously be determined for the first time, so that a downstream analysis is advantageous for finding the local len position of unwanted gas leaks from the coke oven chamber into the atmosphere or raw gas transfers from the coke oven chamber into a heating flue.
• Similar masonry and construction analyzes can be carried out at any height, for example inside coke quenching towers or coal towers, which were previously completely inaccessible with construction heights of up to 70 m on the inner or outer surfaces. Consequently, it is possible for the first time to determine the level of contamination or blockage of the separation lamellae by coke particles whirled up in the upper interior area of a wet quenching tower.
• the inspection device has a distance measuring device that uses a laser (laser scanner) or ultrasound to detect distances, lengths, distances between solid elements, such as components/objects/structures of the system near or on the surfaces to be inspected.
• the distance measuring device is advantageously also a physically reactive device.
• distances between solid body elements that are the same or different from one another (components/objects/structures) on the surfaces to be inspected are measured multidimensionally.
• Solid elements can be spring elements, a pressure surface, anchor stands, risers, wall protection plates, a transverse or longitudinal anchor or anchor, rails, rail support chairs, doors, coke oven closures, a frame, etc.
• the inspection device has a leveling device which detects at least a vertical and/or a horizontal alignment of solid elements (components/objects/structures), in particular the solid elements mentioned above, near or on the surfaces to be inspected.
• the leveling device is also a physically reactive device.
• the inspection device has a photo-technical device, such as a camera, in particular a high-resolution photo camera, which at least visually detects damage to the surfaces to be inspected.
• the photo-technical device is also used for the systematic generation/recording of 2-dimensional images of the entire system or at least areas (components/objects/structures) of this system, which are later converted into photogrammetric 3-dimensional images in the analysis device.
• the photo technical device is a digital SLR camera.
• the photographic device also enables the refractory lining of the coke oven chamber of a coke oven battery to be detected when the coke oven door is open, for example.
• the photographic equipment also enables recordings of the systems from great heights, in particular from greater distances, even during system operation, as well as recordings of components/objects/structures that are difficult for the personnel to reach, which could also endanger the safety of the personnel, such as areas near the coke oven.
• the photo-technical device In cooperation with the satellite-controlled position recognition module of the aircraft, the photo-technical device enables the creation of geo-referenced recordings, in particular for a reproducible before/after comparison.
• the aircraft can operate in defined spatial areas/corridors above or next to the system, in particular a coke oven battery, and has automatic position recognition. Furthermore, it is considered advantageous that the aircraft has a cover that is resistant to high temperatures (heat-resistant), so that the aircraft can also pass through the coke oven chamber of the coke oven battery and enter the interior of the coke oven battery (at least in sections) or fly/inspect other hot areas of the system can. In this case, it is also conceivable that the cladding of the aircraft is also acid-resistant.
• the inspection device or at least heat-sensitive or acid-sensitive measuring devices of the inspection device via an advantageously automatically closable opening (hatch/flap) in the casing, into the interior of the Aircraft can/can be retracted.
• the photographic device has an at least partially transparent protective cover, which allows the generation of photographic recordings, but at the same time enables the photographic device to be adequately protected against heat and harmful fluids.
• This protective cover can be arranged on the fairing of the aircraft or be part of the fairing of the aircraft.
• a method for inspecting devices of coking plants to detect sources of error using an aforementioned aircraft is claimed, the aircraft using the inspection device to record data and using the transmitting and receiving device to at least one external analysis device for detecting the source of the error sent.
• the method according to the invention summarizes at least the following steps:
• the method according to the invention advantageously detects and predicts sources of error, such as deformations on components/objects/structures of a plant, such as a coking plant, in particular a coke oven battery, which enables an optimized repair forecast and consequently reduces, in particular minimizes, downtimes of the plant.
• the aforementioned method advantageously enables automatic and regular monitoring of the components/objects/structures, with the exact position being output directly if anomalies are detected and a detailed investigation being initiated, for example with the aid of the aircraft named in the first aspect of the invention.
• the analysis device is a computer or server, for example, which includes a large number of programs for evaluating, comparing and/or analyzing the data sent by the aircraft.
• the analysis device has a large number of units, in particular self-contained programs, having system-specific algorithms, which are described in more detail below.
• the analysis device can also process data from more than one aircraft, in particular two or more aircraft (a large number of aircraft).
• the analysis device is also provided with operating and process data relating to the system and/or its environment for the detection of error sources or is already stored in a memory unit of the analysis device.
• the operating and process data are data regarding the operating status of the plant, such as throughput, material flow, pressure or gas composition, or data regarding the temperature sensors, the filling levels of the furnaces and containers or environmental conditions, such as the outside temperature humidity etc.
• the data recorded by the aircraft and the operating and process data are advantageously made available to the analysis device on a regular or continuous basis.
• the data generated by the aircraft according to the invention while flying over the system is advantageously processed into a 3D thermal point cloud, so that a point cloud is calculated from a series of georeferenced and overlapping (aerial) images of the system using a known stitching algorithm.
• the spatial position and the 3-dimensional form (3D form) of the system or its components (components/objects/structures) are then determined from this calculated point cloud. This results in distortion-free and true-to-scale images such as orthophotos, surface textures and/or 3D models.
• Image processing algorithms and/or machine learning algorithms are used to evaluate 2D images, 3D point cloud data, thermal data, operating and process data, more precisely all available relevant and recorded data. This evaluation advantageously includes the steps described below.
• a first step is the detection and localization of (known) components and structures of the plant whose monitoring is of interest. These are, for example, filling holes, (coke) oven doors, refractory linings in the area of the open coke oven door, rails, anchor stands, risers or the cooling tower, etc.
• Orthophotos are a preferred data basis for locating the plant and its sections or components and Structures, especially since exact coordinates and distances can be determined through the use of orthophotos and their perspective rectification.
• the orthophotos or surface textures or 3D model data are pre-processed in such a way that at least noise is suppressed and contrast and brightness are adjusted in such a way that, on the one hand, a normalization for the comparability of different images and, on the other hand, highlighting of distinctive and characteristic components/objects / Structures is made possible.
• Characteristic image features are, for example, certain color values, edges or textures.
• Various image analysis methods are then advantageously used in order to detect objects/structures of interest in the orthophotos and to distinguish them from the background and other irrelevant structures.
• At least the Hough transformation or the template matching method or deep learning models based on convolutional neural networks are advantageously used to identify relevant components/objects/structures, in particular depending on their shape, property and frequency.
• This process is also called classifying the point cloud.
• Each point with its coordinates and its color is assigned to an object class, such as the object class "coal filling hole cover".
• object class such as the object class "coal filling hole cover”.
• components/objects/structures that have shapes that cannot be parameterized but are known and are very reproducible, such as a cooling tower are advantageously identified by the template matching method, in particular with predefined references.
• An image section of the component/object sought or the structure sought serves as a reference, or else a synthetic image which depicts the structure of the component/object sought.
• Deep learning models based on convolutional neural networks (CNN) are advantageously used to identify components/objects/structures with complex or even variable shapes and textures, such as zones through which gas flows.
• CNN convolutional neural networks
• a priori knowledge is used, particularly in the form of plant-specific know-how, such as a reference image or a process scheme.
• Known shapes, microstructures or textures are adapted through transfer learning of the Depp Learning Neural Network.
• a combination of the aforementioned applications/methods can advantageously be used to automatically and specifically identify all common plant and machine components from image recordings.
• various features for defining the components/objects/structures can be extracted from the data regarding the identified relevant components/objects/structures, with these features being used at least for regular comparison.
• these features relate, for example, to the position, in particular the location and the height of the components/objects/structures, both in absolute terms and in relation to a reference structure.
• the size and the shape, especially the radius, the center and/or edge smoothness are essential features to be extracted.
• Other features include, for example, the periodicity and the distances between the components/objects/structures, such as the distances between the filling holes, etc. This means that if these features are recorded continuously or periodically and are superimposed on one another, changes such as displacements can result , deformations, etc., on the components/objects/structures are detected and monitored.
• the data is segmented from the rest of the data record area with regard to the identified relevant components/objects/structures.
• thermal hotspots and local temperature fluctuations are an indication of internal deformation or wear of components such as the lining, the masonry, the doors or openings.
• the thermal data obtained are advantageously segmented with the previously detected components/objects/structures, in particular in order to examine the temperature distribution of these components/objects/structures.
• the following characteristics are extracted for each component/object or each structure, such as each (coke) oven: Mean value, median, min, max, hour and distribution of the temperature.
• these features are additionally aggregated for each structure class, i.e. for example for all (coke) ovens.
• all relevant components/objects/structures are advantageously automatically examined for critical or abnormal areas.
• Critical or abnormal areas can be defined as follows,
• historical values are values or data which are determined and processed in advance on the same structure (component/object) and are advantageously stored at least briefly in the analysis device, in particular in the storage unit of the analysis device.
• data is overlaid with the data regarding the identified relevant components/objects/structures in such a way that a temperature distribution becomes visible and thermal deviation data is determined.
• the aforementioned data recording and the analysis steps are advantageously carried out regularly, particularly advantageously in a predetermined interval cycle. From this, the changes over time in the local components/objects/structures, such as the distances, sizes, positions, etc. already mentioned, and their temperature properties can be advantageously documented and visualized over time.
• At least the data regarding the identified relevant components/objects/structures as well as the data from chemically reactive, physically reactive and thermographic devices and the deviation data as well as the operating data, which were recorded and evaluated, are stored in a memory unit of the analysis device as historical Data (values) are stored, with the aid of the historical data being used to train a model, in particular a correlation model, with which error sources can be forecast. More specifically, it is possible to use the trained model to predict changes such as deformations, displacements and temperature hotspots.
• a correlation model can be trained that shows the connection between the plant's operating mode and the structural, thermal or chemical changes important components/objects/structures. This advantageously results in a prediction/prognosis of the changes in the installation based on past data (historical data) including the data/information from the thermographic, chemically reactive or physically reactive (measuring) devices. From the prediction/prognosis of the changes to the system, necessary maintenance can advantageously be optimally planned before critical damage occurs to the system. In addition, the maintenance team and the additional helpful and important information such as the exact position and the degree of change (displacement) during maintenance.
• the named correlation model also advantageously enables a data-based, predictive operation of the system, in which positive system operating modes can be recommended in order to avoid the occurrence of sources of error, such as thermal hotspots or shifts, etc., as far as possible, or at least to postpone it in such a way that the longest possible maintenance-free operation of the system is made possible.
• FIG. 1 shows a side view of an embodiment of a coke oven of a coking plant and embodiments of the aircraft according to the invention during the inspection of facilities of the coke oven,
• FIG. 2 shows a side view of an embodiment of a coke oven of a coking plant and other embodiments of the aircraft according to the invention during the inspection of coke oven facilities
• FIG. 3 in a side view, embodiments of devices of the coke oven and their inspection by means of an embodiment of the aircraft according to the invention
• FIG. 4 in a perspective view a transverse anchoring system of a coke oven and its inspection by means of an embodiment of the aircraft according to the invention
• FIG. 5 the inspection of distances on a coke oven roof of the coke oven by embodiments of the aircraft according to the invention
• FIG. 6 the inspection of heating flue closures on a coke oven roof of the coke oven by an embodiment of the aircraft according to the invention
• FIG. 7 shows a flowchart with regard to an embodiment of the method according to the invention.
• FIG. 8 shows a line diagram to show manually measured temperatures on the bottom of the individual heating shafts and to visualize deviations/outliers in comparison to temperature measurements by an embodiment of the flying device according to the invention on the covers of the coke oven.
• FIG. 1 an embodiment of a coke oven 101 of a coking plant and embodiments of the aircraft 1, 2, 3 according to the invention during the inspection of facilities of the coke oven 101 of a coking plant 100 are shown schematically in a side view.
• the coke oven 101 has a multiplicity of twin flues 102 which extend in the vertical direction inside the coke oven 101 .
• the coke oven 101 has an approximate height of 20m.
• the operators 50 or the specialist personnel 50 who are responsible for firing the coke oven 101 can consequently only inspect limited areas of the coke oven 101, even using appropriate coke oven service platforms 105.
• the (lateral) coke oven ceiling 111 is not for the operator 50 reachable or difficult to assess and with an increased security risk.
• each aircraft 1, 2, 3 has a propeller 20 with a corresponding electric motor and an accumulator/battery 21 for supplying the electric motor and advantageously the inspection device 10 with electrical energy, a flight controller 22, sensors 23 for flight monitoring and satellite-controlled position detection module 24 on.
• each aircraft 1, 2, 3 also has a transmitting and receiving device 25 integrated, at least for sending the recorded data, and particularly advantageously also a storage device 26, at least for temporarily storing the recorded data.
• the first aircraft 1 has an inspection device 10 comprising a temperature measuring device 12, a distance measuring device 13 and a gas concentration measuring device 11 (also called an emission measuring device).
• the second aircraft 2 has an inspection device 10 also comprising a temperature measuring device 12 , a gas concentration measuring device 11 (also called an emission measuring device) and a distance measuring device 13 .
• the third aircraft 3 has an inspection device 10 that is constructed differently, which includes a temperature measuring device 12 , a gas concentration measuring device 11 (also called an emission measuring device) and a gas storage device 17 as well as an intake device 18 .
• the inspection devices 10 can be individually adapted with regard to their measuring devices or measuring attachments and the aircraft 1, 2, 3 can consequently be equipped individually. This means that the measuring attachments can be exchanged at any time.
• the number of measuring attachments or measuring devices is only limited by the dimensions of the aircraft 1, 2, 3 itself.
• the first aircraft 1 primarily serves to carry out an inspection of the coke oven ceiling 111, in particular the coke oven surface 111 (also called the coke oven masonry surface) of the coke oven 101.
• the first aircraft 1 flies the entire length of the coke oven ceiling 111, which can essentially be between 10 and 30 m, and its entire width. Based on the composition of the inspection device 10, it is possible to examine the coke oven ceiling 111 with regard to thermal, emission-related and/or distance-related error sources.
• a coke oven surface monitoring takes place, in which the heating manhole cover 107, the coal filling hole cover 106, the tube gas riser cover 108, the raw gas riser 109, the raw gas riser sleeve 110, the masonry areas located between these elements and ultimately the entire coke oven surface 111 is inspected and examined for the presence of sources of error.
• a thermal image of the coke oven surface 111 is generated using the temperature measuring device 12, the temperatures of the specific objects/structures of the coke oven surface 111, such as the coal filling hole cover 106, being checked with regard to their temperature level.
• Typical temperatures of the charcoal filling hole cover 106, in particular their frames, are approximately 100-350°C. A permissible deviation from the target value is approx.
• the typical temperatures at the heating shaft covers 106 are approximately 50-300°C. A permissible deviation from the target value is approx. +10K.
• the typical temperature of the raw gas riser pipe 109, in particular its advantageously metallic protective jacket, is approximately 50-300° C., with a permissible deviation from the setpoint being approximately +10K.
• the gas concentration measuring device/emission measuring device 11 it is possible to detect gases (emissions) escaping unintentionally near the surface of the coke oven 101 .
• relevant objects/structures in particular their surroundings (atmosphere in the immediate vicinity of the relevant object) are examined, in which an undesired escape of corresponding gases can occur.
• Such objects/structures are, for example, the raw gas riser pipe cover 108 or the coal filling hole cover 106 or the raw gas riser pipe sleeve 110.
• the distance measuring device 13 it is possible to measure distances between relevant objects/structures or also components of the coke oven 101, such as distances between two coal filling hole covers 106 (AL2) or between a coal charging hole cover 106 and a wall of the coke oven 101 (ALI). These measured distances (data/values) are then stored in a memory device 26 of the aircraft 1 and sent to an external analysis device 40 by means of the transmitting and receiving device 25 .
• this data is stored as historical data in a corresponding storage unit (not shown here) and compared with incoming current data in a comparison unit (not shown here).
• a comparison unit not shown here
• the second aircraft 2 also has a distance measuring device 13 with which, for example, the length (and/or width) or also the deflection of the coke oven door 103 is measured.
• the Lateral distance monitoring takes place at heights inaccessible to the operator 50, with the following distances/distances being determined, for example: the distances between the force adjustment elements (springs) on the coke oven door 103, the force adjustment elements (springs) of the transverse anchoring springs of the anchor stand, gaps between the coke oven door sealing strip and the coke oven chamber frame contact surface and /or gaps between leveling door sealing strips and the coke oven chamber frame bearing surface.
• the second aircraft 2 advantageously also includes a compressed air lance 15, which can use compressed air to remove dirt on the surfaces of the coke oven 101 or its objects/structures and is also useful for this purpose by blowing the compressed air into cracks /Indentations in the masonry of the coke oven 101 or its objects/structures to determine their crack depths. Consequently, the second aircraft 2 advantageously also has a compressed air reservoir 27 which serves, for example, to make compressed air available for the compressed air lance 15 .
• the third aircraft 3 shown in FIG. 1 is meanwhile monitoring emissions from the side in a space (airspace L) which is inaccessible to the operator 50 . More specifically, the gas concentration measuring device 11 examines a space (atmospheric space/atmospheric air space L) formed outside the coke oven 101 in close proximity to an object of the coke oven 101, particularly in close proximity to a surface of the object.
• This object can be, for example, a leveling door 104 or a coke oven door 103 through which gases (emissions) can escape (even when the door is closed).
• gases/emissions are determined, for example: hydrogen sulphide, benzo[a]pyrene, nitrogen oxides, carbon monoxide and dust.
• the aircraft 1, 2, 3 communicate with one another and consequently exchange determined data/values directly or indirectly via the analysis device 40, for example in order to commission each other or to be commissioned by the analysis device 40 for certain objects/structures of the system 100 further/supplementary examinations or inspections to be carried out.
• This is necessary in particular if all of the aircraft 1, 2, 3 in use have inspection devices 10 that are equipped differently from one another and one of the aircraft 1, 2, 3 found a deviation from the target value during an examination, which was determined by measurements another aircraft 1, 2, 3 are to be verified or even completed or to determine what the cause (source of error) of this deviation is.
• the third aircraft 3 detects an increased and undesired escape of gas through the gas concentration measurement, one of the other aircraft 1, 2 are prompted, for example by measuring using the leveling device 16 or the distance measuring device 13, to determine displacements on the doors of the coke oven 101, which may be the cause of the escape of gases.
• the third aircraft 3 also has a gas storage device 17 for the at least temporary storage or fluid-tight storage of gases/emissions. It is therefore conceivable that, in addition to or as an alternative to the direct measurement of emissions by means of the gas concentration measuring device 11, the gases exiting the system 100 from the atmospheric air space L are sucked in, for example, by the intake device 18 and fed to the gas storage device 17.
• the suction device 18 can be a component of the inspection device 10 and consequently, like the other measuring devices or also the gas storage device 17, can be mounted on the aircraft 3 in an exchangeable manner. It is also conceivable that the intake device 18 is directly (immediately) functionally connected to the gas storage device 17 and is consequently arranged on or at least next to the gas storage device 17 on the aircraft 3 . Alternatively, it is also conceivable that the suction device 18 is indirectly (indirectly) operatively connected to the gas storage device 17 and is consequently arranged at any position on the aircraft 3 and connected to the gas storage device 17 via lines (hoses).
• each of the aircraft 1, 2, 3 includes a photographic device 14 for generating images, in particular 2-dimensional images.
• Figure 2 shows a side view of an embodiment of a coke oven 101 of a coke oven 100, in particular the coke oven 101 shown in Figure 1, as well as further embodiments of the aircraft 1, 2 according to the invention during the inspection of facilities (objects/structures) of the coke oven 101 shown.
• the first aircraft 1 has an inspection device 100 having a temperature measuring device 12 , a gas concentration measuring device 11 , a compressed air lance 15 and a distance measuring device 13 .
• a distance measuring device 13 With the help of the distance measuring device 13, a lateral distance monitoring of the coke oven 101 is possible for the operator 50 inaccessible heights. Accordingly, force adjustment elements (springs) of the transverse anchoring springs 67 for the horizontal prestressing of the anchor stand 60 are advantageously inspected.
• the anchor stand 60 of the transverse anchorage has a maximum of ten vertically arranged spring assemblies 61 above the lateral coke oven service platforms 105 and thus above a regenerator, as can also be seen in detail A of FIG. It is necessary here with the aid of the aircraft 1, 2, in particular, as shown in FIG. 2, with the aid of the first aircraft 1 at regular maintenance intervals to check the distance between the spring assembly 61 of the transverse anchorage and the base plate 63 (AL), so that up to 14 springs per coke oven side, up to 28 springs per coke oven 101 and up to 2550 springs per coke oven battery are to be checked regularly by the aircraft 1.
• AL base plate 63
• the second aircraft 2 shown in FIG. 2 has an inspection device 10 which includes a gas concentration measuring device 11 , a distance measuring device 13 and a leveling device 16 .
• the second aircraft 2 is advantageously used to monitor the coke oven surface 111, in particular the coke oven ceiling 111.
• the distance measuring device 13 is used to measure the distances between the individual coal filling hole covers 106 when the system 100 is in pouring mode or between the individual gas suction opening covers 112 when the system is ramming Plant 100 measured. The determined values/data are then sent to the analysis device 40 .
• the second aircraft 2 can in particular check the longitudinal alignment of the raw gas riser pipe 108 or the coke oven door 103 or an anchor stand (not shown here) or the coke oven chamber frame 114 in order to identify any deviations in the form of inclinations of the raw gas riser pipe 108 or the coke oven door 103 or the anchor stand or of the coke oven chamber frame 114 to be determined.
• the gas concentration measuring device 11 which can also be referred to as an emission measuring device, serves to determine escaping gases in the area of the coke oven surface 111, in particular in its atmospheric clearance space L, in particular above the openings (coal filling hole cover 106 or gas suction opening cover 112) of the coke oven 101.
• each of the aircraft 1, 2 has a photographic device 14 for generating images, in particular 2-dimensional images, a propeller 20 with a corresponding electric motor, and an accumulator/battery 21 for supplying the electric motor and advantageously the inspection device 10 with electrical energy, a flight controller 22, sensors 23 for flight monitoring and a satellite-controlled position detection module 24.
• each aircraft 1, 2 also has a transmitting and receiving device 25 integrated, at least for sending the recorded data, and particularly advantageously also a storage device 26, at least for temporarily storing the recorded data.
• FIGS. 1 and 2 it is noted that more or fewer than the measuring devices shown can also be used per aircraft 1, 2, 3. The selection of the type and number of measuring devices depends essentially on the system to be examined and on the number of aircraft 1, 2, 3 used.
• FIG. 3 shows, in a side view, embodiments of devices (objects/structures) of the coke oven 101 and their inspection by means of an embodiment of the aircraft 1, 2 according to the invention.
• two aircraft 1, 2 are used to monitor the objects/structures shown. Except for the inspection device 10, these aircraft 1, 2 are essentially constructed in the same way as the aircraft 1, 2, 3 described in FIGS. 1 and 2, so that full reference is made here to their description.
• the first aircraft 1 has an inspection device 10 which includes a gas concentration measuring device 11 and a temperature measuring device 12 . Consequently, with the aid of this first aircraft 1, undesired emissions occurring at the objects/structures of the system 100 and the heat development of the individual objects/structures are determined.
• the second aircraft 2 has an inspection device 10 which, in addition to a gas concentration measuring device 11 and a temperature measuring device 12 , also includes a distance measuring device 13 .
• a distance measuring device 13 In particular, with the help of this distance measuring device 13, it is possible to enable lateral distance monitoring at a height that is inaccessible to the operator (not shown here).
• the force adjustment elements (springs) of the transverse anchoring springs 67 for the horizontal prestressing of the anchor stand 60 are checked or measured.
• vertical deformations and/or thermally induced bending of the wall protection plate 117, the coke oven door 103, the anchor stand 60 or the coke oven chamber frame 114 are measured at different heights checked.
• FIG. 4 shows a perspective view of a transverse anchoring system of a coke oven 101 and its inspection by means of an embodiment of the aircraft 1 according to the invention.
• the aircraft 1 is used here, for example, for lateral distance monitoring at heights that are inaccessible to the operators of the system 100 .
• the aircraft 1 it is particularly advantageously possible for the aircraft 1 to have a photographic device 14, such as a camera, with the aid of which at least 2-dimensional images of the system 100 and/or objects/structures/components of the system 100 can be recorded.
• the aircraft 1 includes an inspection device 10 which has a gas concentration measuring device 11 , a temperature measuring device 12 and a distance measuring device 13 . With the help of these measuring devices, in particular the distance measuring device 13, it is possible to check vertical deformations, in particular thermally induced bending of objects and structures, such as the anchor stand 60.
• the distance measuring device 13 detects/measures different distances between the coke oven ceiling anchorage 118, the spring elements or the spring assembly 61 for fixing the wall protection plate 117, the spring elements or the spring assembly 61 for fixing the regenerator cover plates, the regenerator anchorage 119, the upper transverse anchor 120 and/or the lower transverse anchor 121, to name a few examples, which, however, are not to be regarded as exhaustive.
• Detail B shows a wall protection plate 117, the thermally induced deformation of which is now detected with the aid of the aircraft 1, in particular the inspection device 10 of the aircraft 1.
• FIG. 5 shows the inspection of distances on a coke oven roof 111 of the coke oven 101 by embodiments of the flying machine 1 according to the invention.
• the coke oven ceiling 111 is subject to thermal expansion displacements, which are to be detected.
• the aircraft 1 essentially has the same structure as that in Figure 4 said aircraft 1, so that the descriptions given for this figure 4 can also be used in full for the aircraft 1 of Figure 5.
• the aircraft 1 can measure the distances between the frames of the individual coal filling hole covers 106, ie ALI, and/or the distances between the longitudinal anchors 68, ie AL2. The aircraft 1 then sends these determined data/values by means of the transmitting and receiving device 25 to a corresponding analysis device 40 (not shown here), which compares the received data/values with already stored historical data/values from previous distance measurements of the coke oven ceiling 111 compares to determine discrepancies.
• a laser measurement, a radar measurement and/or a photogrammetry, in particular an optical measurement, of the coke oven surface 111, in particular the coal charging hole cover 106 and its frame is carried out.
• the ascertained/measured two-dimensional or three-dimensional data/values are then made available (transmitted) in the form of a point cloud to the analysis device 40, which uses this to create a digital, precisely georeferenced representation of the system.
• distance measurements can be carried out there manually by the operator or also automatically with the aid of a corresponding calculation program of the analysis device 40
• FIG. 6 shows the inspection of heating flue closures 123 on a coke oven roof 111 of the coke oven 101 by an embodiment of the aircraft 1 according to the invention.
• the aircraft 1 essentially has the same structure as the aircraft 1 mentioned in FIG. 4, so that the descriptions given for the aircraft in FIG. 4 can also be used in full for the aircraft 1 in FIG.
• the temperature measuring device 12 of the inspection device 10 With the help of the temperature measuring device 12 of the inspection device 10, a temperature measurement takes place on the coke oven ceiling 111, in particular on the heating flue closures 123.
• this enables conclusions to be drawn about the heating system, in particular since uniformity of the temperatures is aimed for--particularly in bulk operation of the coke oven battery operated.
• a temperature measurement is advantageously carried out on the at least twenty to at most forty-four heating flue closures 123 of a heating wall.
• four heating flue connections are shown in FIG. Conclusions 123, namely the first heating flue closure 123, the nineteenth heating flue closure 123, the twentieth heating flue closure 123 and the forty-fourth heating flue closure 123 shown.
• thermal control of the heating flue closures 123 also detects cracks in the masonry, for example due to a conspicuous temperature coloration when operating an infrared camera as the temperature measuring device 13.
• FIG. 7 shows a flowchart with regard to an embodiment of the method according to the invention.
• step S1 data/values are collected by means of the inspection device of the aircraft, in particular by means of the photo-technical device, such as the camera of the system to be inspected, in particular its objects and structures, and sent to an analysis device 40 and in a subsequent step S2 by means of the analysis device 40 converted to orthophotos. These orthophotos are used to identify the system with its individual components/objects/structures in a subsequent step S3 and to localize individual (relevant) components/objects/structures.
• step S4 this data is then further processed accordingly in order to be able to determine individual features with regard to the position, location, size, etc. of the individual objects/structures more precisely.
• step S9 further data/values from the inspection device, in particular from the gas concentration measuring device, the distance measuring device, the compressed air lance and/or the leveling device, are advantageously collected in step S9 and forwarded (sent) to the analysis device 40 .
• step S10 From these data/values, corresponding characteristics with regard to the temperature of the objects/structures, the distances, distances, lengths and/or deflection, etc. are then determined in step S10 and, in a subsequent step Sil, are compared with target specifications or historical (older) data/ Values compared to identify anomalies/changes over time. This then takes place in particular in a subsequent step S5, in which the data/values for the system to be examined, i.e.
• step S12 operating data/process data from the system to be monitored are made available to the analysis device 40 and correlated with the data/values from step S5 in a step S7.
• step S6 a first all-encompassing prognosis takes place with regard to the changes in the system to be monitored.
• This data from step S6 and step D7 is then combined in a step S8 so that predictive maintenance of the system can be created.
• FIG. 8 shows a (first) line diagram D1 to show manually measured temperatures on the bottom of individual heating shafts and to visualize deviations/outliers compared to a (second) line diagram D2 to show temperature measurements, carried out by an embodiment of the aircraft according to the invention, shown on the covers of the coke oven, such as the coal filling hole covers and / or the heating shaft covers.
• the manual measurement of the temperature is carried out by an operator who, for example, measures a guide temperature at the bottom of the heating shaft, in particular the heating flue, by means of a pyrometer through the inspection hole cover.
• the measured temperature is then transmitted to the analysis device, which plots it accordingly using a line diagram.
• the dashed line shows the permissible tolerance limits, more precisely the upper temperature tolerance limit OT and the lower temperature tolerance limit UT.
• the measured temperature should range within these temperature tolerance limits (OT and UT), which are approx. +- 15K to the averaged actual measured value.
• the coke oven measured here has a coke oven battery with thirty-four heating shafts arranged between the coke side and the machine side. It can be seen from the first line diagram Dl that the temperature measured in shaft number twenty-six (26) exceeds the upper temperature tolerance limit OT and consequently deviates by more than 15K from the exemplary actual value tolerance +-15k and consequently forms a deviation/outlier Al. It is also conceivable that the typical tolerance limits are between 5-30K for the measured actual value.
• the temperature per heating shaft is plotted, the temperature being measured using an embodiment of the aircraft according to the invention, as described above.
• the aircraft as can be seen in Figure 1, for example (here in particular the first aircraft 1), uses a corresponding temperature measuring device 12 to measure the temperature of the coke oven ceiling 111, in particular at its openings or covers, such as the coal charging hole cover 106 and/or the heating shaft cover 107 and /or their framework.
• the measurement data recorded by the aircraft 1 are then also sent to an analysis device 40, for example via WiFi or Bluetooth.
• Analysis device 40 compares the data obtained with the data relating to the upper temperature tolerance limit OT and the lower temperature tolerance limit UT in order to identify deviations/outliers, such as in particular the outlier shown with the reference symbol A2, from the Recognize target value data and report this to specialist personnel (operators), for example.
• a visualization of the data can be done via a corresponding graphic unit, such as a monitor / screen, so that the results of the measurements, in particular the temperature measurements, can be visually clarified for the technical staff at an emission-safe location.
• an instruction is given to the specialist staff to assess the heating cross section of the heating shaft at which a deviation of the measured actual value from the specified setpoint has occurred, in particular to readjust the corresponding heating cross section or the media volume flows.

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• 2021
  • 2021-01-20 DE DE102021101102.7A patent/DE102021101102A1/de active Pending
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