impingement, hot spots/band, and catalyst damage.
Figure 5: Thermal images showing reformer issues, including refractory damage and flame imp Figure 5 Thermal images showing reformer issues, including refractory damage and flame impingement
Thermal imaging for steam cracker and SMR optimisation Both portable and fixed thermal imaging systems produce high-resolution images/videos and extensive temperature data. Fixed systems employ automated image analysis, continuously monitor and alarm on TMTs and phenomena such as potential coking on steam crackers. On SMRs, they can identify insulation, burner tip/tile condition (see Figure 1 ), and potential hot bands or catalyst issues. The remaining tube lifetime can be calculated from real, continuous surface temperature data. Portable borescope systems are ideal for inspections and can see parts of the steam cracker or SMR that operators may not be able to see with the naked eye through peep-doors. The AMETEK Land portable furnace thermal imaging system (with optional air cooling) enables regular, easy, quick inspections whilst also providing thorough temperature data that can be analysed and archived. Multiple wavelengths, borescope lengths, and field of views (FoV) are available to ensure suitability for a large range of petrochemical processes. The wavelength should be suitable for the gas atmosphere; the borescope length should be long enough to extend through the peep-door comfortably, and the FoV should be suitable for the peep-door design and tube layout. A careful analysis of the thermal image and
temperature data in Figure 4 identified a significant air leak and tube surface temperatures far below design limits, resulting in highly inefficient combustion and a poor catalytic reaction. Profile lines were used to identify the maximum, mean, and minimum temperatures across multiple gradients. Advanced software allows emissivity and background temperature adjustments to be made on each tube to ensure correct compensation. The thermal images in Figure 5 show images collected from portable borescopes and issues relating to reformer temperature balance, flame impingement, hot spots/band, and catalyst damage. Reference measurements to verify accuracy Whilst handheld pyrometers and thermal imaging systems provide repeatable data, reference measurements are required to verify the accuracy of the temperature data produced. The AMETEK Land Gold Cup is a water-cooled 3m-long probe that creates near black body conditions at the measurement point to deliver repeatable, reliable reference temperatures. Non-contact infrared measurements require compensation for surface emissivity and incident radiation if the environment has a hotter background, especially in a steam cracker and SMR. By using a hemispherical reflector (the ‘gold cup’ which gives the instrument its name), a measurement is produced which is independent
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