New guidance on thermal imaging systems for steam cracker furnaces

With hundreds of its imagers installed on furnaces across the world, LAND is sharing key findings drawn from years of extensive experience in developing dedicated infrared technology solutions for steam cracker measurement.

The new application note reveals the significant yield, safety, reliability and efficiency gains which can be achieved through automated temperature monitoring of critical Tube Metal Temperatures (TMTs).

Relevant for furnace operators in the ethylene industry who are planning to invest in real-time thermal analysis for process control, the LAND report also includes the latest thermal imaging technology and product updates, as well as camera installation advice.

Firstly, LAND explores the benefits of using thermal imaging in the petrochemical industry, using accurate temperature measurements to optimise the steam cracker process to its most efficient level – maximising output, extending equipment lifetime, reducing fuel consumption and minimising emissions.

Efficient steam cracking relies on the performance of the furnaces, which operate at extremely high temperatures. To monitor furnace temperature profiles, operators can use thermal imaging as a real-time, non-invasive method to provide detailed temperature information, enabling them to identify and address potential issues before they escalate.

By monitoring and controlling TMTs, operators can benefit from longer production runs and increased output. The enhanced insight helps achieve optimal decoking, reducing decoking time, minimising downtime and extending furnace run length. Overheating and thermal fatigue cracking is prevented, prolonging the life of the furnace coils.

Improved heat transfer uniformity and efficiency leads to fuel savings and reduced CO₂ emissions, which is vital for the environment, meeting regulations and reducing costs.

Also included in the guidance, LAND experts set out the steps required to calculate the number and positioning of cameras to determine the best locations for the largest coverage area while keeping hardware costs to a minimum. Factors to consider include field of view (FOV) analysis, accessibility, wall thickness, safety considerations, and the need for a reliable cooling medium, such as instrument air, nitrogen or cooling water.

For thermal imaging projects and the optimisation of camera quantities, LAND emphasises the need for “engineering judgement, historical data from tube failures and experience with furnace maintenance”.

For more information about the benefits of using thermal imaging to optimise steam cracker furnaces in the petrochemical industry, download the application note here.

Read the article online at: https://www.hydrocarbonengineering.com/petrochemicals/01042025/new-guidance-on-thermal-imaging-systems-for-steam-cracker-furnaces/