Flare Video Analytics for Combustion Control
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Solution Overview
Problem
Current flare management systems face challenges in accurately measuring and controlling flare emissions due to high temperatures, irregular flame shapes, condensation, corrosion, and mechanical wear on sensors, as well as safety concerns that restrict instrumentation placement, leading to inefficient combustion and potential noise pollution.
Innovation Solution
A flare management system utilizing video capture and analysis with electro-optics and infrared information from cameras, combined with process control data, to automatically monitor and control flare characteristics, including volume and combustion efficiency, without operator intervention, using video analytics and machine learning for real-time optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed close to the flare stack for real-time monitoring, then measurement precision and response time are improved, but sensor reliability deteriorates due to high temperatures, condensation, corrosion, and mechanical wear
Solution Approach 1:
The patent introduces video cameras as an intermediary device that captures optical images of the flare from a safe distance. These images are then processed through image analysis algorithms to extract flare characteristics (flame height, volume, color, shape) without requiring physical sensors to be exposed to the harsh environment near the flare stack, thus resolving the contradiction between measurement precision and sensor reliability
Solution Approach 2:
The patent replaces traditional mechanical/physical sensors (thermocouples, pressure sensors, gas analyzers) that directly contact the flare environment with an optical-based video imaging system. This substitution eliminates the mechanical wear, thermal stress, and corrosion issues while maintaining the ability to monitor flare parameters through computer vision and image processing
2Loss of time
If instrumentation is placed inside the safety perimeter for direct control, then control response time is improved, but safety and ease of operation deteriorate due to restricted access and maintenance difficulties
Solution Approach 1:
The patent transitions the monitoring system from a spatial dimension (physical placement of sensors inside the safety perimeter) to a temporal dimension (real-time video capture and processing). By using high-speed cameras and real-time image analysis, the system achieves rapid control response without requiring physical proximity to the flare, allowing instrumentation to be positioned outside the safety perimeter where maintenance is accessible
3Reliability
If steam injection is increased to improve combustion efficiency, then combustion completeness is improved, but harmful factors increase due to noise pollution and potential flame extinction
Solution Approach 1:
The patent implements a closed-loop control system where video cameras continuously monitor flare characteristics (flame height, volume, color, shape) and provide real-time feedback to the control system. The image analysis algorithms process these visual parameters to determine combustion efficiency, and the control system automatically adjusts steam injection rates to optimize combustion while preventing excessive steam that would cause noise pollution or flame extinction
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 enables precise, automated flare management, reducing emissions and noise, improving combustion efficiency, and allowing for regulatory compliance by providing accurate, tamper-proof records of flare operations, thus enhancing operator effectiveness during plant upsets.
Implementation Method 1
the video analytics module may analyze color information in the video images to determine a combustion efficiency of the flare
Implementation Method 2
the video analytics module may estimate a three-dimensional (3D) volume of the flare based on the video images
Implementation Method 3
A frequently used method for disposing of these waste materials is to burn them in what is known as a flare system
Implementation Method 4
steam may reduce the flame temperatures to a point that provides optimal burning and assists with the conversion process of flammable hydrocarbons
Data Source
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AI summary
A video analytics system (10) for characterization of a flare (23). A video of a flare (23) may be taken for obtaining information so as to appropriately control the flare (23) in an interest of reducing emissions not necessarily favorable to the environment. The system (10) may incorporate a control scenario involving one or more parameters of a flare (23) which are to be controlled in view of a flare characterization from an algorithmic analysis of the video.