Watch our webinar on-demand and learn how to optimize DRI production using thermal imaging and infrared pyrometry
Direct reduced iron and hot briquetted iron systems produce reducing gases in a fired heater (steam methane reformer) used to process iron ore, commonly achieved with shaft, rotary heath, or rotary kiln furnaces. High temperature fired heaters are amongst the most complex pieces of major equipment on industrial complexes - each posing unique challenges from a temperature measurement, reliability, and optimization perspective.
Our primary goal, when optimizing fired heaters, is to run the outlet temperatures close to design temperature limits while considering safety, minimizing energy costs and emissions. By using industry leading temperature and imaging technology, it is possible to operate with both higher yields and reliability.
Both portable and fixed thermal imagers provide accurate, repeatable tube metal temperature (TMT) and tube wall temperature (TWT) readings independent of operator expertise, which improves efficiency and minimizes the risk of catastrophic failure. Thermal imaging delivers a high-resolution image which identifies, in real-time, the temperature measurements of the tube skin and refractory surface. Portable thermal imaging systems, such as the air-cooled AMETEK Land portable borescope system, permit the benefits of regular and convenient inspections and provide comprehensive temperature data. When selecting a portable thermal imaging system, considerations include the borescope length and the camera’s Field of View (FoV). The borescope length should be long enough to comfortably extend through the peep-door, and the FoV must be wide enough to see all tubes in the furnace.
Captured images allow for easy identification of hot and cold spots in a fired heater with a high degree of accuracy, so that mitigation or process control decisions can be made and monitored., Advanced software enables sophisticated processing of the TWT and TMT profile data, allowing for emissivity and background temperature adjustments on each tube or zone.
An archive of thermal images shows issues relating to reformer temperature balance, flame impingement, hot spots/band, and catalyst damage, and with associated temperature data help inform maintenance decisions.
Key Takeaways:
- Learn about the types of fired heaters used in DRI production
- Increase understanding of infrared temperature technology
- Learn how a 3.9 µm system enables a clear and high-resolution view of the furnace stock and refractory though furnace gas, heavy smoke and particles.
- Improve process efficiency and reduce fuel consumption with practical advice based on decades of experience in temperature measurement and thermal imaging
Presenter:
James Cross, Global Industry Manager - Hydrocarbon Processing (HPI), AMETEK Land
James Cross works with end-users, OEMs, EPCs, technology licensors, and a network of global partners to ensure that AMETEK Land’s industry leading technology is implemented across the hydrocarbon and petrochemical industry, to make improvements to process quality, efficiency, and safety. He applies his 10 years of experience with high temperature furnace instrumentation to HPI processes such a hydrogen, ammonia, methanol production using steam methane reformer furnaces, ethylene production using steam cracking furnaces, and other process including flare monitoring, gasifying, sulfur recovery thermal reactors, and more refinery and petrochemical processes.
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