Skip to content

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.

IMAGEPro Glass Blog

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.



Skip Navigation Links.
Collapse 2022(21)2022(21)
Collapse August(2)August(2)
Thermal Imaging Accuracy for Furnace Applications
Should I Choose an Air-cooled or Water-cooled Thermal Imaging Camera for my Furnace?
Collapse July(3)July(3)
Complete Open Gateways with the NIR-B-2K-Glass Thermal Imager to Have Digital 4.0 Data Exchange and SCADA
How Do I Perform an Audit on my Opacity Monitor?
Why Should You Use AMETEK Land Application Support to Choose the Right Pyrometer Instead of Purchasing Directly From the Internet?
Collapse June(4)June(4)
What Makes Stored Biomass Self-Ignite?
Optimising Fired Heaters using Thermal Imaging Solutions
Can the LWIR-640 be Used to Monitor the Refractory Condition of a Ladle?
What Are The Key Benefits of Using a SPOT Pyrometer with a SPOT Actuator?
Collapse May(3)May(3)
Reducing Energy Consumption & CO2 Emissions by using Continuous Furnace Outside Shell Monitoring with Stationary Industrial Thermal Imaging
Take a Tour Around The IMAGEPro Version 2 Software Interface
How to Set Glass Leak Alarms with the LWIR-640 Thermal Imager and Its IMAGEPro Software?
Collapse April(2)April(2)
Will a 1 µm and 3.9 µm Pyrometer or Thermal Imager Read the Same Tube Wall Temperatures (TWTs)? If Not, Which Value is Correct?
Do I Need a NOx Converter On My Flue Gas Monitor?
Collapse March(2)March(2)
How to Use the NIR-Borescope-2K with IMAGEPro-Glass in Float Furnaces
How to Monitor the Outside Condition of a Glass Furnace?
Collapse February(4)February(4)
What Are NOx and SOx and Why Are They Important?
How to Spot Damage in Modern Lime Kilns Using Thermal Surveys
How can accurate temperature and emissions monitoring improve efficiency, quality and sustainability?
What non-contact temperature measurement technologies are being implemented into actual Industry 4.0 communications within heavy industries?
Collapse January(1)January(1)
Measuring Gas Temperatures in a Boiler with the CDA Pyrometer
Expand 2021(21)2021(21)
Expand 2020(14)2020(14)
Expand 2019(15)2019(15)
Expand 2018(10)2018(10)