External Furnace Thermal Mapping for Zone-Based Fault Control
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Solution Overview
Problem
Existing furnace monitoring technologies are limited in providing an overview of the entire furnace operation and fail to correlate process steps with performance, leading to inefficiencies, quality issues, and potential shutdowns due to failures like coking, overheating, and burner misalignment.
Innovation Solution
A thermal imaging system using infrared cameras positioned externally to the furnace generates field signals, which are processed to create a temperature map divided into zones, allowing for real-time monitoring and control of furnace components, with control algorithms optimizing furnace operation and preventing failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal imaging apparatus is positioned externally at a distance from the furnace, then operator safety is improved and equipment protection is enhanced, but measurement precision and temperature mapping accuracy deteriorate
Solution Approach 1:
The patent introduces an intermediary optical system comprising lenses and mirrors positioned between the external thermal imaging apparatus and the furnace. This optical system acts as a mediator to transmit and focus thermal radiation from the furnace interior to the detector, enabling accurate temperature measurement while maintaining the safety benefit of external positioning.
Solution Approach 2:
The patent replaces direct mechanical contact or close proximity measurement methods with remote thermal imaging technology. By using infrared radiation detection instead of physical sensors inside the furnace, the system achieves reliable monitoring from a safe external distance while maintaining measurement capability through optical signal transmission.
2Measurement precision
If multiple cameras and complex video analysis systems are used for fault diagnosis, then measurement precision and fault detection capability are improved, but device complexity increases
Solution Approach 1:
The patent divides the furnace exterior into multiple monitoring zones, each captured by dedicated thermal imaging channels. This segmentation allows focused analysis of specific components (burners, charging port, discharging port, flue gas channel) while using a simplified single-camera-per-zone approach rather than complex multi-camera systems with sophisticated video analysis.
Solution Approach 2:
The patent extracts and monitors only the critical thermal zones of the furnace exterior that are most indicative of operational faults. By focusing measurement resources on key areas (burner zones, port regions, flue gas channels) rather than attempting comprehensive full-furnace analysis, the system achieves high fault detection precision with reduced system complexity.
3Productivity
If comprehensive monitoring of entire furnace operation is implemented, then productivity and quality control are improved, but loss of information and data processing burden increase
Solution Approach 1:
The patent applies local quality monitoring by dividing the furnace exterior into distinct functional zones (burner zones, charging port, discharging port, flue gas channel) and assigning specific monitoring parameters to each zone. This localized approach provides comprehensive operational information while reducing data complexity through zone-specific analysis rather than uniform full-furnace monitoring.
Solution Approach 2:
The patent implements feedback control by continuously monitoring thermal zones and providing real-time information about furnace operation status. The system compares measured temperatures against expected operational ranges and provides immediate feedback on deviations, enabling quick corrective actions that improve productivity without requiring complex data processing or storage of historical information.
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 near real-time monitoring and control of furnace components, optimizing energy efficiency, reducing emissions, and preventing costly failures by providing a comprehensive view of furnace operation.
Implementation Method 1
a thermal imaging apparatus, said apparatus being disposed at a distance from the exterior of the furnace to generate field signals of the furnace
Implementation Method 2
a signal processing unit configured and programmed for receiving said field signals and for generating a temperature map of the exterior of the furnace
Data Source
AI summary
A furnace monitoring system for monitoring a furnace over a span of time during furnace operation, including a thermal imaging apparatus, the apparatus is disposed outside of the furnace and at a distance from the exterior of the furnace to generate field signals of the furnace; a signal processing unit configured and programmed for receiving the field signals and generating a temperature map of the exterior of the furnace; and a means for displaying the temperature map locally or remotely. Wherein in that the furnace monitoring system is a system for monitoring the furnace over a span of time during furnace operation and in that the generated temperature map is divided into several zones, which correspond to different components of the furnace selected from burner, viewing port for burner observation, charging port, discharging port and flue gas channel.