Pneumatic conveying systems have become a standard technique for the transport of bulk materials such as powdery or granulates. The spatial dependence of the material density and the stream velocity in such transport systems require a volumetric measurement principle for flow measurement. In this paper we analyse the capability to estimate the volume fraction from capacitive sensing data using electrical capacitance tomography (ECT). In particular, we investigate the capability of back-projection type imaging algorithms. The ill-posed nature of the imaging problem of ECT require the incorporation of prior knowledge in the design of the estimator. We analyse the different flow profiles in pneumatic conveying in order to generate specific sample-based prior information to improve the estimation performance and robustness. We discuss the construction of different linear image reconstruction algorithms and present a framework, which allows a detailed statistical analysis of the estimator performance. Simulation studies show the estimation behaviour of different algorithms with respect to the incorporated prior information. We demonstrate, that the incorporation of specific prior knowledge leads to an improved estimator behaviour; for example, reduced variance and unbiased estimates. We implemented laboratory experiments in order to analyse the presented approach for the application in real pneumatic conveying processes. We demonstrate the improved robust estimation behaviour by means of comparative reconstruction results obtained with different algorithms and priors. Furthermore, the uncertainty of the estimated volume fraction is analysed in steady state conveying processes. Hereby, it is demonstrated, that appropriate prior information improves the estimation performance also for measurements coming from real pneumatic conveying processes, making ECT a suitable tool for the volume fraction estimation in such transport systems.

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Purpose Nonlinear solution approaches for inverse problems require fast simulation techniques for the underlying sensing problem. In this work, the authors investigate finite element (FE) based sensor simulations for the inverse problem of electrical capacitance tomography. Two known computational bottlenecks are the assembly of the FE equation system as well as the computation of the Jacobian. Here, existing computation techniques like adjoint field approaches require additional simulations. This paper aims to present fast numerical techniques for the sensor simulation and computations with the Jacobian matrix. Design/methodology/approach For the FE equation system, a solution strategy based on Green’s functions is derived. Its relation to the solution of a standard FE formulation is discussed. A fast stiffness matrix assembly based on an eigenvector decomposition is shown. Based on the properties of the Green’s functions, Jacobian operations are derived, which allow the computation of matrix vector products with the Jacobian for free, i.e. no additional solves are required. This is demonstrated by a Broyden–Fletcher–Goldfarb–Shanno-based image reconstruction algorithm. Findings MATLAB-based time measurements of the new methods show a significant acceleration for all calculation steps compared to reference implementations with standard methods. E.g. for the Jacobian operations, improvement factors of well over 100 could be found. Originality/value The paper shows new methods for solving known computational tasks for solving inverse problems. A particular advantage is the coherent derivation and elaboration of the results. The approaches can also be applicable to other inverse problems.

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