Outer shell monitoring of POX-Gasifiers at Celanese

The LIOS PRE.VENT system was installed as a Skin Temperature Sensing System on two POX-gasifiers. The intent was to detect hot spots early enough to take corrective action and prevent total failure of the reactor.

During the commissioning of the first POX-reactor at Celanese in Oberhausen, Germany, an unexpected hot spot occurred at the dome of the gasifier due to an insufficient lining. Due to PRE.VENT’s fast detection of the hot spot, an immediate shut down of the reactor as well as serious damage of the apparatus were avoided.

The internal conditions in a gasifier are extreme. Temperatures are often above 1300°C with pressures of 300 bar.

The outer skin of a gasifier is made of a relatively thin layer of steel. It would melt instantly if exposed to the internal operating temperatures of the vessel. Inside the vessel, a protective lining shields the outer skin from the extreme heat.

It is crucial that the lining is intact. Deterioration leads to hot spots on the reactor skin, and then – if not detected in time – to catastrophic failure.

Monitoring the temperature of the reactor skin can give valuable information in due time to react.

Material needed:

  • 2 x OTS20P, 1 channel, full redundancy
  • 1580 m high-temperature sensor cable “reactor pp”
  • 200 m supply cable
  • RS232 to RS485 conversion
  • Charon_02 software used for visualization and data logging


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