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Combining a Transportable NIR-B-2K & Lancom 4 for Thermal Surveys & Combustion Optimisation

In this blog, we are going to explain what the benefits are of combining thermal surveys with the transportable NIR-B-2K (Near-Infrared Borescope) and Lancom 4 gas analyser.

Using a Transportable NIR-B-2K for Thermal Surveys Combining Lancom 4 and Combustion Optimisation to Reduce Energy and EmissionThis technology can help identify temperature distribution, optimize combustion efficiency, and reduce energy consumption.

Combining the NIR-B-2K technology with the Lancom 4 combustion analyzer can provide real-time data on combustion parameters such as oxygen, carbon monoxide, and carbon dioxide levels. The combination of these two technologies can help identify areas of inefficient combustion and provide data for adjustments to improve combustion efficiency, reducing energy consumption and emissions, particularly NOx.

This can lead to cost savings and lower emissions, as well as improved equipment performance and longevity improving the global life expectations of the furnace.

How to use transportable NIR-B-2K for in-furnace thermal surveys

The NIR-B-2K is a borescope-based thermal imaging system designed by AMETEK Land. It is used to provide real-time temperature imaging of various industrial applications, including furnaces, boilers, and kilns.

The NIR-B-2K uses near-infrared technology to capture thermal images, allowing for the identification of hotspots and temperature variations in the process being monitored. The device is designed for portability and ease of use, with a compact design and an intuitive user interface.

In order to use a transportable NIR-B-2K for an in-furnace thermal survey, follow these steps:

  • Install the NIR-B-2K borescope in the furnace: 
    • The NIR-B-2K is a portable device that can be installed in the furnace by inserting it through a small access peephole or port. It should be positioned in a location that allows for the best view of the area of interest.
    • Power on the NIR-B-2K and connect it to a laptop or computer: The NIR-B-2K is typically powered by a provided PSU cabinet and can be connected to a laptop or computer for real-time data analysis and monitoring.
  • Check the NIR-B-2K  temperature measurements:
    • Before use, the NIR-B-2K should be checked vs the existing Cyclops measurement (through peephole and/or TCs ) to ensure accurate temperature measurements. This can be done by placing the NIR-B-2K in a known temperature environment and comparing the readings with a thermocouple or other calibrated temperature measurement device.
  • Use the NIR-B-2K to capture thermal images: 
    • Once the NIR-B-2K is installed and calibrated, it can be used to capture thermal images of the furnace and focus on the flame pattern, peak flame location and thermal NOx production-related hottest part of the flames. These images can provide information about the temperature distribution and heat transfer in the furnace.
  • Analyze the data:
    • The thermal images captured by the NIR-B-2K can be analyzed by using the IMAGEPro V2 software to identify hotspots, areas of inefficient combustion, and other potential issues.
    • This data can be used to make adjustments to the combustion process to improve efficiency and reduce energy consumption.
The use of transportable NIR-B-2K for thermal surveys in combination with the Lancom 4 gas analyser, can provide valuable insights and data for optimizing combustion processes and reducing energy consumption.

The Lancom 4 is a portable combustion gas analyzer produced by AMETEK Land. It is used to measure the levels of combustion gases in various industrial applications, including boilers, furnaces, and engines.

The Lancom 4 can measure up to eight different gases, including oxygen (O2), carbon monoxide (CO), carbon dioxide (CO2), sulfur dioxide (SO2), and nitrogen oxides (NOx). It can also measure combustion efficiency and excess air, providing valuable information for optimizing combustion processes and reducing energy consumption. 

The Lancom 4 is designed for ease of use and portability, with a compact design and intuitive user interface. It features a built-in printer for on-site documentation and a USB port for data transfer. The device is also equipped with a rechargeable battery for extended use in the field.

Improving energy efficiency in a glass furnace can be achieved by implementing various strategies where the NIR-B-2K is a good starter for the decarbonisation of fired furnaces.

Some general steps that can help improve energy efficiency include:
  • Conduct an energy audit: 
    • Start by conducting an energy audit to identify areas of inefficiency in the glass furnace. This can help identify the most significant energy consumers and prioritize efforts for improvement. The NIR-B-2K could be the starter point to support.
  • Insulate the furnace: 
    • Insulating the furnace can help reduce heat loss, which can lead to significant energy savings. Insulation can be added to the furnace walls, doors, and roof to help retain heat.
  • Optimise combustion: 
    • Improving combustion efficiency can also lead to significant energy savings. One way to optimize combustion is by adjusting the air-to-fuel ratio to ensure complete combustion. This can be done using a gas analyzer like the Lancom 4 to measure combustion gases at the right location near the ports and make adjustments as needed. The NIR-B-2K can help to look at flames and then optimize the peak flames and patterns.
  • Use waste heat recovery systems:
    • Waste heat recovery systems can capture and reuse heat that would otherwise be lost. For example, waste heat can be captured from the furnace exhaust and used to preheat combustion air or other process materials.
  • Upgrade to more efficient equipment:
    • Upgrading to more energy-efficient equipment can also help reduce energy consumption in the glass furnace. For example, using high-efficiency burners or using advanced control systems with Oxygen to optimize furnace operation.
    • Fixed installation of a NIR-B-2K could support better control and monitoring of hot spots on thermal profiles, which is the very beginning of having the right energy balance.
  • Use advanced process control systems:
    • Advanced process control systems as predictive software or CFD modelling, or EBM can help optimize the glass furnace operation and reduce energy consumption. These systems use real-time data to make adjustments to the furnace operation and optimize combustion efficiency.
By implementing these strategies, it is possible to significantly reduce energy consumption and improve the energy efficiency and emission of a fired glass furnace. However, it is important to note that the specific strategies used will depend on the furnace's operating conditions, and it may be necessary to consult with a specialist to develop an effective energy efficiency plan.

Click here to learn more about the NIR-B-2K
Click here to learn more about the Lancom 4


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