Short-wave thermal camera mounting for cracking coil temperature

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Solution Overview

Problem

The existing methods for determining the surface temperature of cracking coils in hydrocarbon cracking processes are unreliable and costly, leading to inefficient operation, premature aging of equipment, and unnecessary interruptions due to decoking.

Innovation Solution

A method using a short-wave thermal camera mounted in a fixed position on a mounting device attached to the outside of a thermal reactor, allowing for precise and reproducible temperature measurements of the cracking coil surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a hand-held portable pyrometer is used to measure the surface temperature of cracking coils, then the measurement can be performed manually, but the measurement reliability is poor due to varying distance and position

Engineering Contradiction:

Improvemanual measurement capabilityVSAvoidtemperature measurement reliability

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The measurement system is segmented into a fixed mounting device attached to the furnace and a movable pyrometer that can be positioned precisely within the mounting device. This allows the pyrometer to maintain a constant measurement position while still enabling manual operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A mounting device acts as an intermediary between the operator and the cracking coil. It provides a fixed reference frame with marked positions that ensure consistent measurement locations, eliminating the variability introduced by direct manual handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the temperature measurement is performed through an inspection window, then access to the cracking coil is enabled, but the measurement data becomes unreliable due to varying body heights and angles of the operator

Engineering Contradiction:

Improveaccess through inspection windowVSAvoidtemperature measurement consistency

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The mounting device is pre-positioned and fixed to the furnace structure before measurement takes place. It includes pre-marked positions that guide the pyrometer to the exact measurement location, eliminating the need for operators to judge positions during measurement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mounting device creates an equipotential measurement platform where all measurement positions are at the same distance and angle relative to the cracking coil surface, regardless of the operator's body height or standing position.

Inventive Principle:

Principle #12Equipotentiality

3Measurement precision

If pyrometers with special equipment requirements are used for high temperature measurements up to 900°C and more, then accurate temperature measurement is achieved, but the costs become rather high

Engineering Contradiction:

Improvehigh temperature measurement accuracyVSAvoidequipment cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces complex expensive pyrometer systems with special high-temperature components with a simpler system using a standard pyrometer combined with a fixed mounting device that maintains optimal measurement geometry, reducing equipment costs while preserving measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If the surface temperature of cracking coils is not accurately monitored, then production can continue without interruption, but the furnace may be decoked too early or left too long under increased temperatures which accelerates aging

Engineering Contradiction:

Improvecontinuous operationVSAvoidcoil lifespan

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fixed mounting device enables reliable temperature monitoring that provides accurate feedback on the actual thermal state of the cracking coil. This feedback allows operators to make informed decisions about when decoking is truly necessary, avoiding both premature interruptions and dangerous over-temperature operation.

Inventive Principle:

Principle #23Feedback

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

This method provides accurate, reliable, and cost-effective temperature monitoring, reducing the frequency of unnecessary decokings and extending the operational lifespan of the cracking coils.

Implementation Method 1

The surface temperature of an object, in particular of a cracking coil, is determined contactlessly by means of a short-wave thermal camera

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentEP3855140B1Method for determining the surface temperature of an object using a short-wave thermal camera

Publication Date: 2025.03.19 BASELL POLYOLEFINE GMBH

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AI summary

The present disclosure refers to a mounting device and a method for determining the surface temperature of an object located inside a thermal reactor using a short-wave thermal camera as well as an apparatus comprising said object and said short-wave thermal camera. The present disclosure further refers to a process for cracking hydrocarbons which employs the inventive method to determine and monitor the temperature of the surface of the cracking coil.