FEATURE
Accurate temperature measurement in high temperature furnaces
Real-time , Accurate , Continuous Monitoring for Improved Furnace Performance
Via the data , they gather through real-time , accurate continuous monitoring , thermal imaging cameras enable predictive maintenance of furnaces , ensuring long periods of availability and optimal performance .
By Nick Barnes
Optimal process monitoring and control is a tried and tested approach to increasing equipment output in mining . In the contemporary atmosphere , it could not have been more relevant – the cost of ore extraction is escalating , squeezing profit margins . And so , to offset this trend , it makes businesses sense for mine mining companies to invest in process monitoring and control techniques that will enable them get more value from their ore in mineral processing . This is most especially , in when it comes to monitoring systems for refractory-lined furnaces and rotary kilns , which always need high accuracy continuous temperature measurement .
Traditional techniques out of kilter Certainly , traditional processing monitoring and control techniques , inherent with their limitations , would be out of kilter with the current requirements . Conveniently , infrared thermal imaging camera systems , which have emerged as a practical alternative , are filling the void , based on ongoing trends .
Switching from traditional to thermal imaging monitoring One would ask : How has thermal imaging cameras entered a space where the primary choice has been traditional process monitoring and control techniques ? Specifically , why is industry jettisoning the ‘ tried and tested ’ method shifted to thermal imaging cameras ? Recently , when contacted , business development managers from some of the leading providers of thermal imaging cameras in the game , who count mining companies among their major clientele , were eager to share their insights on factors driving the increase in demand for their products . The
information they provided is compelling . While there are differences in wording , it points to common factors that render the thermal cameras preferable to traditional techniques with reference to contemporary demands . At least based on the client ’ s feedback , the thermal imaging cameras , they concur , improved furnace availability and output . The relevance and convenience of thermal imaging cameras can be appreciated better when first analysing the gaps in the traditional techniques and how capably thermal imaging cameras fills them .
Traditional approach The traditional approach of monitoring furnace process and control involves cutting open refractory-lined furnaces and kilns to view critical areas . Unfortunately , this method does not always produce the desired end . Most often , this results in significant heat loss , as well as the debris entering the opening . In addition , visual inspection using a camera can take hours to complete . Typically , the visual cameras used do not provide continuous temperature readings . Even more , instances of failure or loss of connection thermocouples cannot be ruled out .
Filling the gap As an alternative , thermal imaging , cameras fill the gap , addressing drawback of traditional methods by providing continuous high-accuracy temperature measurement for process monitoring and control applications in furnaces . With the camera , operators are able to measure inside high temperature furnaces and acquire high-definition images . The camera is installed through a hole bored in the outer refractory wall , which is then sealed .
Through a single high-resolution image , the camera provides real-time , accurate , temperature measurement and monitoring , which is delivered though a high-speed digital connection . It is able to measure product , refractory and heat transfer surfaces from temperature ranges 600 to 1800oc . Besides , there is no interference from the hot atmosphere and furnace gases . With the data gathered , streamed online , operators are able to optimise furnace temperature .
What is more , with advanced control software , simultaneous data acquisition from multiple thermal imaging cameras , additional analysis , archiving , or integrating with the plant ’ s local network can be done . Accurate data analysis , in addition to automated alarm outputs and control , alert the user in the event of any problem .
Valid business case Clearly , there is a valid business case supporting the deployment of thermal imaging cameras in the area of continuous monitoring inside furnaces .
This is especially in three areas :
1 . The impact of furnace failure , due
to inadequate monitoring , can be costly , prompting unbudgeted replacement and repair expenditure . This is without mentioning downtime
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