This work presents an ultrasound tomography imaging system and method for quantitative mapping of the sound speed in liquid masses. It is highly desirable to be able to inspect vessel fluid mass distribution, notably in the chemical and food industrial operations. Optimization of industrial reactors has been crucial to the improvement of industrial processes. There is a great need to investigate how and if tomographic imaging sensors could aid the automatic control of these process tanks. Single-measurement ultrasound techniques and especially spectrometric methods have been a subject of study of industrial applications. Tomographic systems provide key multi-dimensional and spatial information when compared to the well-established single-channel measurement system. Recently, ultrasound tomography has attracted a great deal of interest in a wide spectrum of industrial applications. The system has been designed as 32 piezoelectric ring-array positioned in a 30 cm tank, with an excitation frequency of 40 kHz. Two-dimensional transmission travel-time tomography was developed to reconstruct the fluid mass distributions. Prior experiments are mainly based on inclusions of a few centimetres and on a liquid solution of different concentrations. They have been conducted to test the spatial and quantitative resolution of the ultrasound imaging device. Analysing the reconstructed images, it is possible to provide accurate spatial resolution with low position errors. The system also demonstrated inclusion movement with a temporal resolution of 4 frames per second (fps) in dynamical imaging sense. Sound velocity quantitative imaging was developed for the investigation of ultrasonic propagation in different liquids. This work, for the first time, shows how quantitative sound velocity imaging using transmission mode time of flight data could be used to characterize liquid density distribution of industrial reactors. The results suggest that ultrasound tomography can be used to quantitatively monitor important process parameters.

Ultrasound computed tomography (USCT) is gaining interests in many application areas in industrial processes. The recent scientific research focuses on the possible uses of USCT for varied fields of industry such as flow monitoring in pipes, non-destructive inspection, and monitoring of stirred tanks chemical processes. Until now, most transmission tomography (UTT) and reflection tomography (URT) have been demonstrated individually for these applications. A full waveform USCT contain large amount of information on process under evaluation. The developed approach in this paper is focusing on demonstration of a triple modality USCT. First, an optimised transmission image is formed by fusion of time-of-flight (TOF) and acoustic attenuation (AA) images. Secondly, a reflection image is being optimised by using the information from the transmission image. This triple modality method enables integration of a shape-based approach obtained by URT mode with the quantitative image-based approach UTT mode. A delicate combination of the different information provided by various features of the full-wave signal offers optimal and increased spatial resolution and provides complementary information. Verification tests have been implemented using experimental phantoms of different combinations, sizes, and shapes, to investigate the qualitative imaging features. Moreover, experiments with different concentrations solutions further validate the quantitative traits to benefit from both reflection and transmission modes. This work displays the potential of the full-waveform USCT for industrial applications.

In this work, an ultrasound computed tomography (USCT) system was employed to investigate the fast-kinetic reactive crystallization process of calcium carbonate. USCT measurements and reconstruction provided key insights into the bulk particle distribution inside the stirred tank reactor and could be used to estimate the settling rate and settling time of the particles. To establish the utility of the USCT system for dynamical crystallization processes, first, the experimental imaging tasks were carried out with the stirred solid beads, as well as the feeding and stirring of the CaCO3 crystals. The feeding region, the mixing process, and the particles settling time could be detected from USCT data. Reactive crystallization experiments for CO2 capture were then conducted. Moreover, there was further potential for quantitative characterization of the suspension density in this process. USCT-based reconstructions were investigated for several experimental scenarios and operating conditions. This study demonstrates a real-time monitoring and fault detection application of USCT for reactive crystallization processes. As a robust noninvasive and nonintrusive tool, real-time signal analysis and reconstruction can be beneficial in the development of monitoring and control systems with real-world applications for crystallization processes. A diverse range of experimental studies shown here demonstrate the versatility of the USCT system in process application, hoping to unlock the commercial and industrial utility of the USCT devices.

Crystallisation is a crucial step in many industrial processes. Many sensors are being investigated for monitoring such processes to enhance the efficiency of them. Ultrasound techniques have been used for particle sizing characterization of liquid suspensions, in crystallisation process. An ultrasound tomography system with an array of ultrasound sensors can provide spatial information inside the process when compared to single-measurement systems. In this study, the batch crystallisation experiments have been conducted in a lab-scale reactor in calcium carbonate crystallisation. Real-time ultrasound tomographic imaging is done via a contactless ultrasound tomography sensor array. The effect of the injection rate and the stirring speed was considered as two control parameters in these crystallisation functions. Transmission mode ultrasound tomography comprises 32 piezoelectric transducers with central frequency of 40 kHz has been used. The process-based experimental investigation shows the capability of the proposed ultrasound tomography system for crystallisation process monitoring. Information on process dynamics, as well as process malfunction, can be obtained via the ultrasound tomography system.

Three-phase material imaging such as oil, gas and water is a critical problem in many processes. Monitoring and separation of each phase before corresponding process can be a key to realise cost efficiency production. In the oil and gas industry such a tool can generate great environmental benefits. In recent years, several multi-modality imaging systems are being adapted for such an application. It is not possible to gain information on three phase flow using a single imaging modality that can be deployed in production field. For a three-phase flow dominated by water phase, this is more challenging. The capability of the majority of current dual-modality systems was only demonstrated under limited flow regime conditions. This paper presents a novel combined imaging system including electrical impedance tomography (EIT), and ultrasound transmission tomography (UTT) for mapping three-phase flow. In water dominate mode, the EIT is able to image the nonconductive phases of oil and gas in a water dominate background phase, but not able to separate oil and gas. The EIT two-phase imaging then complimented with the speed of sound imaging of the UTT, which can separate liquid (oil and water) and gas. A dual modality EIT-UTT system combining a 32-electrode EIT array and a 32-transducer UTT sensor array is developed to demonstrate this novel three-phase material imaging. The concept was demonstrated using simulation study and then shown with experimental lab tests. Measurement principles and method are described, experiment based on several three-phase flow scenarios are established, and the results show successful distinguishably for all three phases. INDEX TERMS Three phase flow, electrical impedance tomography, ultrasound travel time tomography.