Reducing Energy Consumption & CO2 Emissions by using Continuous Furnace Outside Shell Monitoring with Stationary Industrial Thermal Imaging
Decarbonisation is becoming more important for industrial furnace operators in applications such as reheat furnaces, glass melt tanks, rotary kilns, and annealing furnaces.
While a breakthrough of such a furnace poses great dangers, the thermal inspection of the outside shell of industrial furnaces is often carried out only rarely and sporadically, so that trends and signs of increasing leaks or damage to the refractory are either not recognised or are recognised too late.
Likewise, undetected defects or leaks not only consume unnecessary energy and costs but penetrating gases, for example, can have a negative impact on the process and emissions from the furnace.
The solution: LWIR-640 smart thermal imaging system for 24/7 furnace monitoring
AMETEK Land provides advanced LWIR-640 thermal imagers, together with a choice of industrial cooling and protection enclosures, for continuous inside or outside monitoring of the external shell temperature of industrial furnaces. Even for hot, cold or wet environmental conditions, specifically designed enclosures enable safe 24/7 monitoring, providing a high level of furnace security and protection.
Depending on the furnace design, the camera positions and choice of fields of view are selected to monitor most of the critical outside shell of a furnace to detect evolving hot spots at an early stage.
The online camera images can be monitored, and pre- and high alarms are clearly reported to the control system and the furnace operator.
Using AMETEK Land’s IMAGEPro-AM asset monitoring software, alarms and change rates are logged in the integrated database and monitored in the trend view function. The camera’s onboard alarming and I/O functions can be used for stand-alone furnace monitoring applications, too.
Examples of furnace shell monitoring:
- Detection of critical hot spots at an early stage – early repairs can be carried out on identified areas
- Reduced energy costs – effectively reduce consumption of waste energy and associated costs
- Reduce emissions and CO2 –supporting the decarbonisation process
- Improved Safety – minimised risk of breakouts, damage to the furnace and fire protection
- Early leak detection – liquids or gas leak detection at a very early stage
- Evaluation of different refractories – assessment of the effectiveness of different refractories