Radiant Coil Temperature Estimation via Imaging Camera
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Solution Overview
Problem
In ethylene production cracking furnaces, coke accumulation is non-uniform, leading to local hotspots that are difficult to detect with traditional pyrometer-based temperature measurement methods, potentially causing overheating and inefficiencies in decoking processes.
Innovation Solution
A method and device utilizing an imaging camera and image analyzer to estimate the outer surface temperature of radiant coils, allowing for the identification and monitoring of hotspots across a larger region, thereby preventing overheating and facilitating timely decoking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pyrometer is used to measure temperature at a single point, then the measurement device is simple and easy to operate, but local hotspots are easily overlooked and temperature distribution cannot be comprehensively monitored
Solution Approach 1:
The patent transitions from one-dimensional point measurement (pyrometer) to two-dimensional area measurement (imaging camera). The imaging camera captures temperature information across the entire coil surface, enabling detection of local hotspots while maintaining operational simplicity through automated image analysis.
Solution Approach 2:
The imaging camera serves multiple functions: it monitors overall temperature distribution, detects local hotspots, and provides comprehensive thermal mapping of the coil surface. This multi-functional approach replaces the single-point measurement limitation of pyrometers while maintaining ease of operation through integrated software analysis.
2Reliability
If temperature monitoring covers only a single point, then the measurement system remains simple, but comprehensive temperature distribution and hotspot detection are compromised
Solution Approach 1:
The system expands from point-based to area-based temperature monitoring using imaging cameras. This dimensional transition enables comprehensive coverage of the coil surface, ensuring reliable hotspot detection while the automated image processing maintains system simplicity.
Solution Approach 2:
The image analyzer acts as an intermediary that processes complex imaging data and converts it into actionable temperature information. This mediator handles the computational complexity, allowing the physical measurement system to remain relatively simple while achieving high reliability in hotspot detection.
3Productivity
If manual temperature measurement is performed regularly, then equipment cost remains low, but time consumption increases and continuous monitoring is difficult
Solution Approach 1:
The imaging system with automated image analysis performs self-service continuous monitoring without requiring manual intervention. The system automatically captures images, processes them to extract temperature distribution, and provides real-time feedback, enabling continuous productivity monitoring and timely decoking decisions.
Solution Approach 2:
The patent replaces manual mechanical measurement operations with automated optical imaging and digital image processing. This substitution eliminates time-consuming manual measurements while maintaining low equipment costs through the use of standard imaging technology and software analysis.
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
Accurately detects hotspots and their positions, enabling informed decoking schedules and improving ethylene production efficiency by preventing overheating and extending the lifespan of radiant coils.
Implementation Method 1
an imaging camera that images a region to be imaged of the radiant coil; and an image analyzer that processes an output signal from the imaging camera and estimates an outer surface temperature of the radiant coil
Data Source
AI summary
A device for estimating an outer surface temperature of a radiant coil which is provided in an cracking furnace for ethylene production including a convection coil that preheats hydrocarbons as raw materials and steam, a radiant coil that thermally decomposes the preheated hydrocarbons and steam, and a housing for accommodating them, and which includes an imaging camera that images a region to be imaged of the radiant coil, and an image analyzer that processes an output signal from the imaging camera and estimates an outer surface temperature of the radiant coil.