Aug 2015 Thermography

PYROSCAN: A furnace camera that provides accurate temperature monitoring in extreme environments

The new PYROSCAN, from HGH Infrared Systems, is a High Dynamic Range (HDR) pyrometric camera with the highest resolution on the market. It has been designed to provide accurate temperature monitoring in extreme environments: with temperatures reaching higher than 1500°c and in very dusty and smoky atmospheres. It combines real-time high resolution imagery with temperature measurements at any point of the burning zone inside boilers, furnaces, kilns or incinerators.

Pyroscan software screenshot

For most industries using high temperature combustion chambers in their manufacturing processes, the shape, size, homogeneity and stability of the burner flame are critical parameters to be monitored in order to ensure a safe and efficient production. Thanks to the HDR and high-resolution images of the PYROSCAN, the operators in the control room can view the flame pattern in real time with astonishing detail in both the dark and bright areas of the combustion tube. In addition, each pixel of the image can be selected by the operator directly on the video image to gage temperatures, with reliable values, even through dusty atmospheres.

The combination of high quality imagery and an accurate thermal map, which can be transferred to the Distributed Control Systems (DCS ) via OPC protocol, provides insight into: the combustion efficiency, the fuel adjustment and flame geometry, the chamber refractories wear, the calcined material condition, and any energy lost.

With real time NIR video images of 1296 x 966 pixels, a 120 dB dynamic range, a powerful image analysis software providing temperature measurements over a large thermal range from 700°C to 1800°C, and for every pixel within the large field-of-view images: PYROSCAN is the perfect monitoring solution for cement, lime, and glass production processes as well as cokemaking, steelmaking, metal casting, waste incineration plants, and biomass heating systems.

Benefits :

  • View images of the clinker area and temperature measurements, inside a rotary cement kiln,
  • Detection of clinker avalanche, snowman or red rivers in a cement cooler,
  • Detection of changes in flame shape (flame length/width and black root length),
  • View images to see impacts on burner adjustments, variations in raw product composition or use of alternative fuels,
  • View images of non-uniform heating ,
  • View images of ring formations and blockages impeding product flow,
  • flame front monitoring in waste incineration plants,
  • Monitoring product ignition and leaks,
  • Reduction of downtime, maintenance costs and production losses.

PYROSCAN is a modular system for full adaptation to the application’s requirements. Do not hesitate to contact us to build the appropriate configuration fitting your needs. Below is a list of available options:

  • Uncooled NIR PYROSCAN camera and analysis software package. This configuration has previously been installed for flame front monitoring outside waste incinerators.
  • Visible or NIR PYROSCAN camera integrated into a borescope tube and analysis software package. This configuration is adapted to a metal casting application, for a 24/7 monitoring, in high temperatures and dusty environments.
  • Visible or NIR PYROSCAN camera at the end of a borescope tube with an automatic insertion and retraction mechanism and analysis software package. This configuration is common for many rotary kiln installations around the world.
  • Other options that can be included: Power over Ethernet module, optical fiber or ethernet cable connexion, air purge module, industrial PC, etc)

Kilnscan – beyond hotspot detection

With more than 1000 units sold worldwide, HGH Infrared Systems’ KILNSCAN thermal scanner works to ensure uninterrupted operation of the cement production line by avoiding unplanned shutdowns and kiln refractory failures, which can result in several days of lost production and impact operational costs.

KILNSCAN scans up to 25 lines per second along the entire length of the kiln. The infrared scanner displays a complete thermal map of the shell, which is continuously updated. Any thermal evolution will be easily detected and highlighted. No hot spot, even temporary, will go unnoticed. However, beyond alerting plant personnel to falling bricks in the kiln, the evolution of the general geometry of the kiln shell is also an important indicator to take into account. Shell distortion has implications on the resistance of refractory bricks and on the deformation of tyres and roller stations. It also highlights the global fatigue of the shell. KILNSCAN enables monitoring of the tyre slip, which must be greater than a few centimeters to avoid any constriction. In addition to this measurement, KILNSCAN provides a unique advanced feature: the calculation of thermal warp. This function shows the thermal axis distortion due to internal temperature gradients. The operator can receive information on mechanical stresses affecting the kiln shell, the tyres and the roller stations, and then try to minimize them by optimizing parameters such as the combustion flame adjustment. The thermal warp computation also provides information on the distribution of the clinker and the coating inside the kiln.

Kilnscan software screenshot

The user-friendly software for KILNSCAN enables the operator to set up alarm thresholds in the temperature profile, tyre slip and thermal warp values in order to anticipate medium-term kiln fatigue. Preventive actions such as changing flame intensity, using alternative fuel, or resurfacing tyres and rollers, can then be set up and their effectiveness assessed. The KILNSCAN software also includes the historical management of all measured data. The long term monitoring of each parameter, the comparison to reference level and the display of trend lines are functions that can be used to consolidate multi-year maintenance plans.