Real-Time Flame Quality Control via Multi-Camera Image Analysis
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Solution Overview
Problem
Current methods for monitoring and controlling gas flare combustion efficiency are manual and prone to delays, leading to potential over-steaming and the release of volatile organic compounds (VOCs, as they rely on operator intervention to maintain efficient combustion and prevent black smoke production.
Innovation Solution
A system utilizing multiple cameras with different optical filters and sensors to acquire and process flame images from distinct fields of view, determining an overall flame quality parameter in real-time and adjusting steam injection accordingly to maintain efficient combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual monitoring by operator is used, then operational simplicity is maintained, but response time is delayed and over-steaming occurs
Solution Approach 1:
The patent replaces the manual mechanical monitoring system with an automated optical detection system using cameras and image processing algorithms. The system captures flame images, processes them to determine flame quality parameters, and triggers steam valve control automatically, eliminating the need for manual operator intervention and significantly reducing response time.
Solution Approach 2:
The system enables self-service by automatically monitoring flame quality and controlling steam injection without human intervention. The flame quality assessment and control decisions are made autonomously by the system based on real-time image analysis, allowing the flare system to self-regulate combustion efficiency.
2Reliability
If steam injection is increased to prevent black smoke, then combustion efficiency is improved, but over-steaming occurs and VOCs are released
Solution Approach 1:
The patent implements a feedback control system where flame images are continuously captured and analyzed to determine flame quality parameters. Based on the assessed flame quality, the system automatically adjusts steam valve position to maintain optimal combustion efficiency. This closed-loop feedback prevents both insufficient steaming (black smoke) and over-steaming (VOCs release) by continuously adapting steam injection to actual flame conditions.
Solution Approach 2:
The system dynamically changes the steam injection parameter based on real-time flame quality assessment. By continuously monitoring flame characteristics through image analysis and adjusting steam flow rate accordingly, the system optimizes combustion efficiency while preventing harmful VOC emissions that occur with excessive steam injection.
3Productivity
If real-time automated control is implemented, then response time is reduced and over-steaming is prevented, but system complexity increases
Solution Approach 1:
The patent replaces manual monitoring and control operations with an automated system comprising cameras, image processing units, and electronic valve control. This substitution enables real-time automated decision-making for steam injection, significantly improving combustion control efficiency while managing system complexity through integration of standard commercial components.
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
Enables real-time measurement and control of flame quality, preventing over-steaming and VOC release by optimizing steam injection based on continuous, automated assessment of combustion efficiency.
Implementation Method 1
The first camera may include a first filter and a first sensor. Similarly, the second camera may include a second filter and a second sensor. In one embodiment, the first and second sensors may be infrared sensors
Implementation Method 2
The injection of steam allows surrounding air to be intermixed with the interior of the flame resulting in a more complete combustion
Implementation Method 3
One purpose of gas flares is to safely and cleanly dispose of gases arising from sudden and abnormal process conditions
Data Source
AI summary
A method for measuring and controlling flame quality in real-time, the method comprising the steps of: acquiring a plurality of flame images in a first field of view; acquiring a plurality of flame images in a second field of view; processing the acquired plurality of flame images of said first and second fields of view to determine an overall flame quality parameter; and comparing the overall flame quality parameter to a tolerance range. In other aspects, a system for measuring and controlling flame quality in real-time and a non-transitory computer readable medium (CRM) storing instructions configured to cause a computing system to measure and control flame quality in real-time are provided.