High-resolution infrared camera provided real-time thermographic images unaffected by noise from combustion gases to quickly detect hot spots in the tuyeres and optimize process conditions as needed |
Condition based monitoring for Tuyeres
Pilger mill in tube rolling mills - hot and cold pipe detection
Increased efficiency: Scans the entire tuyeres to check for any refractory break.
Improved safety level: Hot spot detection to avoid costly damage and subsequent downtime
Challenges
During the process of heating iron-ore to make iron, hot air is injected at high temperature at the bottom of the blast furnace by tuyeres. The heated air optimizes the process accelerating the burning of the coke and effectively reduces the coke consumption per ton of iron produced. As smelting temperatures of over 1600⁰C is produced, it becomes critical to carefully monitor refractory temperature for hot spots and blockages.
Thermocouples do survive the high heat and high-pressure environment but lifespan of the thermocouple is significantly reduced due to damage to its metal sheath. Furthermore, sudden change in temperature readings due to snorting can result in unreliable thermocouple signals.
Solution
A high-resolution infrared camera from Optris is ideal for this application. It provides pin-sharp infrared pictures and videos unaffected by noise from combustion gases.
The real-time thermographic images prove especially valuable to quickly detect hot spots and optimize process conditions as needed.
System features include
- Temperature range of 50⁰-600⁰C
- Wide optic lens
- Alarm and alert
- PTZ Housing: Pan- Tilt housing
Products and Accessories
Case Study Number
- TP3
Challenge
- The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity.
- In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C.
- After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter.
Previous solution / Competitor product
- N/A
Solution
- The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19.
- The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase.
- An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions.
- The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C.
- Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling.
Customer Benefits
- Maintenance-free
- High temperature stability
- Recognition of hot objects at big distances
- Self adjustment with Auto-Teach or step switch for the response temperature
Product Part number
- OKA 2038.38 G
Brand
- Proxitron
Accessories
- Piros swivel stand HM2
- Tube OL 19
- Pilot light unit (for alignment) DAK 308 + OL 26
- Different cable lengths (e.g. 15 m)
Customer Testimonial
compared to previous solution or competition
Case Studies
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