Burner Flame Imaging Control for Variable Flow Combustion
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Solution Overview
Problem
Conventional burners used in well testing operations face challenges in maintaining efficient combustion due to large variations in flow rates and environmental factors, leading to 'fall out' conditions where hydrocarbon-containing waste effluent is not combusted, resulting in environmental and safety concerns.
Innovation Solution
A monitoring and control system that uses cameras to acquire and analyze image data of the flame, detecting features indicative of combustion, allowing for real-time adjustments to optimize burning operations and prevent 'fall out' conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operators use natural vision to observe and manually adjust burner parameters, then operational flexibility and experience-based control are maintained, but real-time monitoring precision and response speed are insufficient
Solution Approach 1:
The patent replaces the mechanical human visual system with an optical monitoring system comprising cameras, infrared sensors, and image processing algorithms. This substitution enables automated detection of flame characteristics, combustion efficiency, and abnormal conditions without requiring human operators to physically observe the burner, thereby improving measurement precision while reducing human exposure to hazardous environments.
Solution Approach 2:
The patent introduces an intermediary monitoring system that acts as a bridge between the burner and human operators. The system includes image processing algorithms and analysis software that interpret visual data from cameras and infrared sensors, converting raw optical information into actionable combustion diagnostics. This intermediary layer enables precise real-time monitoring without direct human intervention in the hazardous zone.
2Productivity
If burners are designed to handle maximum flow rates, then high productivity is achieved, but combustion efficiency deteriorates when flow rates drop below minimum thresholds
Solution Approach 1:
The patent implements dynamic monitoring and control of burner parameters based on real-time combustion conditions. The system continuously adjusts air-to-fuel ratios, burner ignition timing, and flow rate control in response to detected flame characteristics and combustion efficiency metrics. This dynamic adaptation enables the burner to maintain optimal combustion across varying flow rates, preventing fall-out conditions even when processing capacity fluctuates.
Solution Approach 2:
The patent establishes a feedback control loop where combustion parameters are continuously monitored through image analysis and sensor data, then fed back to adjust burner operation. The system detects flame color, temperature distribution, and combustion completeness, using this information to automatically correct suboptimal combustion conditions and prevent fall-out, thereby maintaining reliable combustion across the full range of waste effluent flow rates.
3Use of energy by moving object
If waste effluent pressure drops below minimum atomization pressure, then energy consumption is reduced, but combustion efficiency deteriorates causing fall-out conditions
Solution Approach 1:
The patent monitors and adjusts multiple combustion parameters in response to changing waste effluent conditions, including atomization pressure, air-to-fuel ratio, and burner ignition timing. When atomization pressure drops, the system compensates by adjusting other parameters such as increasing secondary air supply or modifying ignition sequence to maintain effective combustion. This multi-parameter control approach allows the system to maintain combustion reliability without requiring constant high atomization pressure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures efficient combustion by providing real-time data and control mechanisms to maintain optimal burning conditions, reducing environmental impact and improving safety by preventing the discharge of uncombusted hydrocarbons.
Implementation Method 1
acquiring image data for a flame of the burner via the camera
Implementation Method 2
igniting oil or gas with a burner during a burning operation
Implementation Method 3
combustion of the oil or gas via the burner
Data Source
AI summary
Systems and methods for monitoring and controlling burning operations are provided. A method of one embodiment includes igniting oil or gas with a burner (282) during a burning operation and monitoring the burning operation with a camera (290). This monitoring of the burning operation can include acquiring image data for a flame (290) of the burner via the camera and analyzing the acquired image data to detect image features indicative of combustion of the oil or gas via the burner. Additional systems, methods, and devices are also disclosed.