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How to Monitor Batch Coverage and Crown Temperatures in a Glass Melt Tank for Optimised Daily Operations in Glass Furnaces

Installed looking into a glass melt tank, our NIR-B-2K thermal imaging camera allows 24/7 monitoring of batch melting. When coupled with our IMAGEPro-Glass advanced thermal imaging software, we enable temperature measurements of the melt line combined with hot spots on thermal profiling, batch coverage and batch transit time for recording and comparison, and the crown as well.

The IMAGEPro-Glass batch coverage functionality maps batch coverage onto the generated thermal image as a grid with rows and columns for pinpointing exact spots. Then areas are added, and alarms applied on the cold batch for when it reaches certain points. 

Whenever an alarm is triggered, the image is recorded for quality assurance and troubleshooting purposes.

In utilising a specific thermal palette and adjusting temperature bands, it identifies which burner flames, at which blocks, are the most intense or hottest, and therefore which are generating the optimal flames pattern and heat transfers.

The most suitable location for installing the thermal imager is at the furnace's centreline to provide a good view of the refractories, including crown, sidewalls, burner blocks and batch line. The thermal imager's view is converted into a 2D birds-eye display of the melter to provide the grid where the batch distribution and coverage appear for batch analysis. The melter can be set up in a basic grid with rows and columns to analyse how the batch movement occurs during every reversal and how it can be best controlled.

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From this, and with some additional zones of interest added near the throat and the crown, it is possible to focus on a critical area identified by the operator which needs to be batch free at the throat in front of the furnace and to avoid large amounts of batch piles (generally below 15% of the batch). This zone is generally directly related to an increase in glass defect. The hot spots on the thermal profiling are also clearly displayed to show the batch line's alignment. The software can provide a complete batch analysis in this area where the zone of interest near the throat is controlled.

By monitoring the two zones near the throat and the crown's temperature, it is also possible to adjust the batch length manually to avoid glass defects.

The IMAGEPro software can provide multiple displays, including two different displays with two different colour palettes and, at the same time, the batch coverage display.

Accurate batch monitoring helps glass furnace operators follow the batch line and thermal profile to improve thermal distribution in the furnace and have beneficial savings on energy and emissions.

IMAGEPro-Glass software combined with the NIR-B-2K thermal imager helps producers get closer to Industry 4.0 standards that are supporting and reinforcing furnace efficiency in the glass industry.



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