Real-Time Fault Detection and Diagnosis of CaCO3 Reactive Crystallization Process by Electrical Resistance Tomography Measurements

Abstract

In the present research work, an electrical resistance tomography (ERT) system is utilized as a means for real-time fault detection and diagnosis (FDD) during a reactive crystallization process. The calcium carbonate crystallization is part of the carbon capture and utilization scheme where process monitoring and malfunction diagnostics strategies are presented. The graphical logic representation of the fault tree analysis methodology is used to develop the system failure states. The measurement consistency due to the use of a single electrode from a set of ERT electrodes for malfunction identification is experimentally and quantitatively investigated based on the sensor sensitivity and standard deviation criteria. Electrical current measurements are employed to develop a LabVIEW-based process automation program by using the process-specific knowledge and historical process data. Averaged electrical current is correlated to the mechanical failure of the stirrer through standard deviation evaluation, and slopes of the measured data are used to monitor the pump and concentrations status. The performance of the implemented methodology for detecting the induced faults and abnormalities is tested at different operating conditions, and a basic signal-based alarming technique is developed.

Monitoring and Visualization of Crystallization Processes Using Electrical Resistance Tomography: CaCO3 and Sucrose Crystallization Case Studies

“…Using the ERT-Vis software, the detection and resolution of the issue of the noise in the reconstructed images were resolved swiftly, which optimized the overall time required for the experimentation. Quick analysis prior to the start of experiments provided us with an added advantage in performing closed-loop control experiments [27].…”

“…They provide an opportunity to the process engineer to observe the homogeneity degree and particulate suspension distribution inside the batch reactor. As a complementary technique, tomography can provide very useful information regarding qualitative determination of the spatial distribution, a quality assurance and monitoring tool , as well as in fault detection [25][26][27]. The complementary utilization of the single point or 1D measurement technologies and tomographic imaging technologies can achieve better control of the crystallization process.…”

Monitoring and Visualization of Crystallization Processes Using Electrical Resistance Tomography: CaCO3 and Sucrose Crystallization Case Studies

“…Using the ERT-Vis software, detection and resolution of the noise issue in reconstructed images were swiftly resolved, which optimized the overall time required for experimentation. Quick analysis prior to the start of the experiments provided us with an added advantage in performing closed-loop control experiments [26].…”

“…For instance, a reactive crystallization typically has fast kinetics in a high conductivity solution, while the sucrose crystallization by comparison has slow kinetics in a low conductivity medium. Hence, it is necessary to implement an ERT sensor which can provide resolution within the conductivity range of the given crystallization process [26].…”

Study of Fruit Waste as Bio-battery Materials for Alternative Electricity

“…The current transmission, or conductivity, may occur due to the ion breakdown when ionic substances dissolve. Nevertheless, in this scenario, CaCO 3 , an ionic molecule that is not soluble, can conduct an electrical current (conductivity) even in a liquid form [14,15].…”