阳极炉作为铜冶炼核心设备，炉膛温度常达1350-1450℃，需持续监控熔液温度以优化重油消耗。传统定氧枪测温存在三大痛点：

1.间歇性测量：无法实时调控工艺参数

2.高耗材成本：年消耗量达200-300支

3.数据断层：缺失连续温度曲线记录

2、Infrared Thermography智能测温系统核心优势

1.技术创新亮点

• 精准成像：短波红外传感器+自研算法，误差<±1%
• 极端耐受：IP66防护等级，2000℃测温上限
• 智能分析：支持GB28181协议，数据云端存储
• 

2. System architecture

炉内溶液采用短波红外作为传感器，分别搭配高性能镜头，性能优异的成像处理电路，并嵌入先进的图像处理算法，噪点低，具备防护等级高、环境适应性强、功耗低、启动快速、成像质量优异、测温范围宽、测温精准的特点，非常适合高温测温现场应用。

短波红外热像仪具体参数如下：

三、安装方案对比

方案一（炉外固定）
✓ 即装即用
✗ 监测范围仅30%熔池

方案二（摆臂式）
✓ 覆盖80%熔池区域
✓ 延长设备寿命2-3倍

四、行业应用价值

1.节能降耗：精确控温降低15-20%重油消耗

2.品质提升：温度波动减少50%以上

3.数字转型：建立完整的工艺数据库

为助力企业快速验证红外热成像方案的价值，华景康面向有色冶炼相关企业开放免费设备试用与方案定制服务，欢迎大家留言咨询！

红外热像仪的应用：应用多台红外热像仪，划分5大区域进行监测，基本覆盖目前热风炉区域监测的重点区域。该系统具备24小时全方位监测功能，能实时监控设备表面温度，超温时精确定位并实时预警，实现自动预警、截屏、图表生成及云台控制。通过数据分析预警，有效预防事故，直观判断设备运转。系统支持多预置位、多监测区域设定，图形标识重点监测区，滤除干扰。可根据部件属性单独设置测温报警参数，实时计算温度变化，提高测温分析准确度。

系统功能：

1.可实时监测区域范围内每个坐标点的温度，并支持鼠标点选查看。可圈定区域监测温度范围。

2.自动预警，自定义温度预警设置，超限温度报警。

3.自动保存温度数据和视频，支持超分辨率回放及高低温追踪报警，一键生成报告。

现场安装图：

整个窑炉的温度分布监控对于水泥质量至关重要。它还可以通过在早期阶段检测耐火材料或未充分淬火的熟料来帮助延长窑炉的使用寿命——如果不加以控制，可能会导致生产停顿。

窑炉内的条件使得温度分布监控变得困难。窑炉旋转、高温以及烧结材料沿窑炉的移动使得热电偶和其他接触式温度传感器不太好用。非接触式温度测量方式就显得非常有价值。

HJK-FBTS-XC在线式防爆红外热成像监控系统（非接触式温度测量方式）位于燃烧器下方和侧面的窑头罩的观察口可以最好地测量熟料温度，这个位置温度高，粉尘大，设备配套水冷装置，以防止损坏设备。

HJK-FBTS-XC在线式防爆红外热成像监控系统功能特性：

1. 采用非制冷焦平面探测器、高性能红外镜头、信号处理电路、并嵌入先进的图像处理算法，具备功耗低、启动快速、成像质量优异、测温精准等特点；
2. It has all-weather passive thermal imaging function, has strong smoke penetration performance, and can be used in a wide range of ambient temperatures;
3. Adopt self-developed temperature measurement correction algorithm to realize accurate temperature measurement;
4. 防护罩采用耐高温合金材料制成，具有耐腐蚀、耐高温性能。窥孔直径2mm，在冷却介质及风吹扫后，在耐高温、防粉尘等性能方面更为优良，大大提高使用寿命；
5. 在镜头前采用多道风屏，既可以起到降温的作用，更重要的作用是挡去了窑内的飞砂、熔融物等，使镜头不受污染和侵蚀，保持图象永久清晰；
6. 对压缩空气采用空气净化器，始终保持镜头无污，保证图像清晰；
7. 具有断水、断气、断电、温度高自动退出功能；
8. 全自动进入功能，气压压力、水流量高于设定值，温度低于设定值，探头自动伸进窑炉监测炉内情况。

回转窑是水泥厂的核心设备；其工作状况直接影响水泥厂的生产效率和熟料质量。为了使回转窑保持良好的工作状态，我们必须学会在日常生产中如何正确维护回转窑。回转窑的维护有一些注意事项和说明。

水泥回转窑可能出现的故障有：

1. 窑筒在长期的过程中可能会出现径向摆动变大，导致窑尾漏料严重的情况；
2. 熟料生产过程中窑筒上下运动不受控制，会影响托辊、轮带的稳定性和使用寿命；
3. 大齿轮、托辊振动异常，窑轮传动频繁振动，影响正常生产；
4. 回转窑耐火衬砖经常开裂、脱落；
5. 熟料生产过程中，窑的传递扭矩和各轮带支撑轴的承载力发生意外变化。

西南国有大型钢厂石灰窑红外与视频监控项目。

之前工人是通过手拿面罩的方式在观察孔看窑内熟料情况，此方法有安全隐患且人工强度大，业主想通过7*24小时不间断的方式监测窑内情况，并且把所获取的温度数据和数字化系统对接。

窑侧视图

项目存在的问题

1、业主每8个月要大修，炉膛成像装置不能进入太深，以免维修的时候不好开门；

2、大修的时候周边会有小车还有耐火砖，可以选择安装的地方不多；

3、气管支撑架在进出的炉口，会妨碍人员流动；

4、人员通过观察孔观看，全凭经验，无法准确获得窑内的温度；

5、数据不好记录和上传。

远景图

Programme

通过在窑头罩右侧布置两台炉膛成像装置，装置进入深度不超过20cm，在氮气源下方安装接线箱把气源接入进来，从平台下方打孔，用波纹管从下方穿入再从另外一头穿出接入炉膛成像装置，通过7*24小时不间断的检测输出高清视频和红外视频到中控室。

安装位置侧视图

气源

方案特点

1、一体化方案：无需配置任何其他设备即可使用；

2、退出保护装置：在高温或者断气的情况下退出保护炉膛成像装置里面的设备；

3、大视场角镜头：在插入不深的情况下可以看清楚窑内情况；

4、网络机芯：压缩数据或者全码流可以传输给业主系统。

炉膛成像系统安装点

应用系统

在线式防爆红外热成像监控系统HJK-FBTS-XC

回转窑窑内视频监控HJK-FBTS-PG

带来的价值

7*24小时检测，将温度数据传至现场人员，有利于去判断石灰熟料烧成情况，将数据传至业主的数据化大平台，做到数据可以追源、记录、后期分析。

红外图

中控室

在冶金行业中，在线红外热成像诊断技术通常用于以下方面：

1、降低热损耗，节约能源；

2、通过状态的监控，合理安排检修，并提高设备寿命；

3、通过对热像图像的分析，对现有工艺进行改进。

一、高炉炉瘤的诊断

高炉炉瘤采用在线红外热像仪检测是比较简便的方法。首先将需要检测的表面划区域进行检测，记录炉皮每一小块的温度分布，通过分析各层低温区域，从而可初步诊断出是否结瘤以及结瘤的部位。

二、高炉内衬水冷壁缺陷的检测与诊断

在线红外热像仪可对高炉表面进行分区块的检测，对得到的红外热像图进行温度分布分析。对于没有冷却器存在的部位，通过炉表面温度的不同变化，可以直接判断有无内衬缺陷，若某部位拍摄的热图温度持续上升，可以认定炉内衬已有损坏侵蚀；对于有冷却器存在的部位，可以依据热图分析表面温度分布情况，找出相对温度升高的部位，判断冷却壁损坏或炉内衬缺陷。

三、转炉

转炉结构仅仅有炉皮和炉衬，没有冷却部分。用在线红外热像仪对转炉表皮拍摄热图后，通过分析其表面温度，可直接判断炉衬的侵蚀损坏程度。

四、钢水包、铁水包

可以使用在线红外热像仪拍摄热图像来诊断钢水包、铁水包内衬的腐蚀程度，还可通过在烤包过程中的状态来寻求合理的升温速度与烤包时间。

五、热风炉

使用在线红外热像仪对热风炉进行检测，一般分为二个部分，一个是炉身，另一个是炉顶，并注意检测球顶与柱体交接部位，拍摄的热图中高温过热部位即对应耐火内衬的缺陷。

六、回转窑

通过在线红外热像仪对回转窑窑体进行检测，根据在线红外热像图上高温异常部分，可以立即诊断该高温对应部分的内衬存在缺陷，温度越高，其对应的缺陷越严重。

除此之外，冶金业还可以采用在线热像仪对厂内用电设备，如变压器、变电室开关接点和电缆等电气设备连接点进行检测，对大量机械传动装置、风机马达轴承进行检测，对钢芯温度及验证钢锭液率情况进行检测，降低能源及材料的消耗，提高钢锭的质量。

1. Application status of thermal imaging technology in rotary kiln inspection

At present, rotary kiln is an important equipment in metallurgy, building materials, chemical plants and silicate industry in China. According to relevant statistics, more than 60% of the kiln stoppages are caused by the damage of the kiln lining. The lining of the rotary kiln is mainly composed of refractory bricks. The refractory bricks rub against the materials for a long time and are in a high temperature state, which will lead to the deformation, serious wear and tear of the refractory bricks and even the falling of the bricks. This not only affects normal production, but also wastes energy and increases production costs. The on-line monitoring technology of the surface temperature of the rotary kiln enables the on-site staff to timely understand the temperature in the kiln and the changes of refractory materials, and arrange maintenance personnel to repair according to the actual situation, which greatly improves the efficiency and accuracy of production equipment fault detection.

2. Application requirements of rotary kiln for thermal imaging technology

2.1 working characteristics of rotary kiln

The rotary kiln is composed of cylinder, transmission device, supporting device such as supporting wheel and runner, sealing device at kiln head and tail, kiln head cover and combustion device. The barrel of rotary kiln is a heated rotary part, and the barrel is equipped with temperature measurement and sampling hole devices. Some kilns also need to be specially equipped with infrared thermometer to monitor the temperature of the barrel surface. Infrared imaging technology has been applied to the temperature measurement of materials in rotary kiln and the surface temperature detection of rotary kiln.

2.2 Routine maintenance methods and means of rotary kiln

For the maintenance of rotary kiln, the current practice is to strictly implement the regular overhaul system. According to the operating regulations, the refractory bricks should be replaced every 150 days of operation, while the actual operation can reach about 210 days. For the inspection between the two intermediate repairs of the rotary kiln, the conventional method is that the inspection workers use the hand-held temperature measuring instrument, combined with their inspection experience, to measure the temperature of the part of the rotary kiln that may be damaged, and then record and repair the rotary kiln with abnormal temperature. This method mainly relies on the experience of the testing workers to measure the temperature at a limited point, rather than the overall measurement of the rotary kiln. Therefore, it has certain limitations, randomness and is easy to miss the inspection.

Maintenance difficulties

The volume of the rotary kiln is large and it is rotating all the time. Moreover, the inspection workload of maintenance workers is large, and the time of one inspection is also relatively long. Similarly, sometimes the failure to repair in time due to faults will also lead to accidents and serious consequences. In view of this situation, various online monitoring means are being strengthened, the regular overhaul system is being reformed, and the transition to predictive maintenance system is gradually underway. Infrared thermal imaging is one of the important online monitoring means.

2.2 Advantages of infrared thermography detection of rotary kiln

The infrared thermal imager can quickly and conveniently obtain the two-dimensional thermal image of the outer wall of the rotary kiln, that is, the surface temperature field of the outer wall. Due to the obvious difference in heat conduction between the outer metal and the inner non-metallic materials of the rotary kiln, the degree, type and distribution of lining damage are the direct reasons for the different distribution of temperature field on the outer wall surface of the rotary kiln. Therefore, the main defects of the inner lining can be reflected in different degrees in the infrared image.

The damage types of rotary kiln lining can be roughly divided into thinning, cracking, bulging and falling off. Although the strict theoretical relationship between each type of damage and infrared thermogram has not been established, through the analysis of infrared thermogram and the comparison of lining inspection, the infrared spectrum of each type of defect has its own characteristics. For example, in terms of shape, for the crack type damage corresponding to the general long strip or slender overtemperature zone, when the maximum temperature of the overtemperature zone is greater than a certain value, it can be diagnosed as through crack damage; When the temperature is moderate, it may be a general crack. If the average temperature in the overtemperature zone exceeds a certain value, it can generally be diagnosed as falling off damage; If the average temperature in the overtemperature zone is lower than a certain value and the temperature gradient is small, it can generally be diagnosed as thinning.

It is a scientific and effective means to analyze, judge and inspect the working state of the internal lining through the on-line non-contact infrared thermal image test of the temperature field on the outer surface of the rotary kiln by using the infrared thermal image, which can provide a practical basis for ensuring the long-term operation of the rotary kiln.

2、 Current situation of infrared thermography and temperature measurement of rotary kiln

1. Use the hand-held thermal imager to regularly detect the rotary kiln

At present, the handheld thermal imager has been widely used in the steel industry. For example, the hand-held thermal imager is used to identify the blockage of steam pipes and hot water pipes and find the blockage point; Conduct regular maintenance of high-voltage electrical equipment to detect whether the contacts of such equipment are overheated; It can also detect the parts of some rotating (moving) equipment that are heated due to friction. Production equipment in iron and steel enterprises, including blast furnaces, hot blast stoves, hot blast pipes, heating furnaces, soaking pits, various steel-making furnaces, etc., are high-temperature service equipment with refractory lining, just like rotary kilns. Handheld thermal imagers have also been widely used in the maintenance of such equipment to judge the damage degree of refractory materials and play the role of preventive maintenance.

The infrared and visible light pictures taken by the hand-held thermal imager use the hand-held infrared thermal imager to detect the rotary kiln, mainly for the regular maintenance of the rotary kiln. The maintenance personnel regularly go to the site to observe the rotary kiln. First, store the thermal image in the memory card of the thermal imager, and then use the computer to read and analyze the collected pictures to form a report. This report is also mainly used for auxiliary positioning during intermediate repair of rotary kiln. Therefore, it is limited to use the hand-held thermal imager to regularly detect the rotary kiln:

1) When analyzing the infrared thermal image of the rotary kiln, the general analysis software is used, which does not combine the infrared spectrum characteristics of the lining damage of the rotary kiln. The judgment of the defect points mainly depends on the experience of the maintenance personnel. Therefore, the defects that can be confirmed by the maintenance personnel are often more serious damage, and usually they cannot give more specific information about the type and degree of damage;

2) Because it is a periodic inspection, the discovery of defects also has a certain contingency, which can not completely avoid the occurrence of major accidents;

3) The work of manual maintenance is complex, and the workload of using infrared thermal imager to overhaul all rotary kilns in use is very large. If it is overhauled in stages and batches, the overhaul interval will be extended, which is not conducive to the timely treatment of major damage to the lining of the rotary kiln.

2. Scanning rotary kiln infrared thermal image detection system

The infrared thermal imager is installed on the tracks on both sides of the rotary kiln, and the infrared scanner reciprocates in the x-axis direction at the same time during the scanning process. From the working principle of scanning imaging, it can be seen that the infrared scanner needs to move back and forth before the system can detect the complete imaging of the rotary kiln. Moreover, when the rotary kiln and infrared scanner move at a uniform speed as far as possible, the proportion of the infrared thermal image obtained is consistent with the physical proportion of the rotary kiln, that is, the imaging does not deform.

From this, we can see the limitations of scanning imaging. Without the intuition and reality of focal plane imaging, the image details are not clear enough, that is, the resolution of temperature is not enough.

Infrared thermographic detection system for rotary kiln

After site measurement, the site dimensions are as follows:

Rotary kiln size: 70000 ×Φ 4200mm；

Site installation distance: 15000mm;

Parameters of infrared thermal imager are as follows:

It is calculated that the maximum length of the observation object of the infrared thermal imager is 17000mm, and the length of the rotary kiln to be monitored is about 62000mm. To monitor the whole rotary kiln, it is necessary to take periodic infrared photos of the rotary kiln at least at four preset positions. The detection system has two schemes, which are introduced in detail below.

Programme1 Install an infrared thermal imager, configure the track for the infrared thermal imager, and use the track control system to stop the infrared thermal imager at the specified position and take photos periodically. The site installation diagram and system structure diagram are shown in the following pages.

Installation diagram

System structure diagram

If this scheme is adopted, the whole system is composed of infrared image acquisition system, slide motion control system and infrared back-end analysis system. The infrared image acquisition system is composed of an infrared thermal imager and a network access system to realize the infrared image acquisition and transmission function of the rotary kiln; The slide rail motion control system is composed of motor, motor driver, sensor, slide rail and motion controller to realize the positioning function of the rail car; The infrared back-end analysis system is composed of server and analysis software to complete the storage and analysis of surface temperature field data of rotary kiln.

Programme2Three infrared thermal imagers with pan tilt are installed. Each infrared thermal imager is equipped with three prefabrication positions, and the three infrared thermal imagers monitor the surface of the whole rotary kiln. The site installation diagram and system structure diagram are as follows.

If this scheme is adopted, the whole system is composed of infrared image acquisition system, pan tilt control system and infrared back-end analysis system. The infrared image acquisition system is composed of three infrared thermal imagers, PTZ and network access system. The infrared image acquisition system and the infrared back-end analysis system have the same functions and scheme I.

The thermal imagers of the two schemes are installed on the side of the rotary kiln. Since the rotary kiln itself rotates continuously (generally, the rotation speed is 0.5~2 RPM), the thermal imager can collect the temperature field data of the rotary kiln regularly (such as every 5~10 seconds), which can cover all areas of the rotary kiln.

In addition, the infrared thermal imager is installed near the rotary kiln, which has to withstand the test of wind, rain, snow and other adverse weather, as well as high temperature and dust. Therefore, the protective shell of the infrared thermal imager must have the ability to prevent dust and rain. When the ambient temperature is high, it must be able to cool the thermal imager to ensure the reliability of work. Additional lens protection components, detector protection components and dust protection devices are provided.

Scheme 1 is difficult to install on site, which requires a new slide rail. In addition, the railcar runs for a long time, and its service life is limited, so it needs regular maintenance. In addition, the stability of the slide rail will also affect the accuracy of the rotary kiln infrared monitoring system; Scheme 2 can use the existing supports around the rotary kiln for fixed installation, which is convenient and reliable for construction and installation. The communication control technology between the rotary kiln and the pan tilt is also relatively mature, so we recommend scheme 2.

Technical means and function realization

1. Infrared focal plane imaging technology

The infrared thermal imager adopts an advanced uncooled focal plane detector with 384 pixels × 288. Each time the thermal imager images the target, there are 110592 sampling points. Therefore, the thermal imager can form a plane image of the temperature characteristics of the whole rotary kiln surface. The detector has high sensitivity and temperature resolution of 0.12 ℃. Small temperature changes on the surface of the rotary kiln can also be reflected. In addition, with focal plane imaging, there is no distortion in the thermal image, and the proportion of the thermal image is completely consistent with that of the rotary kiln entity. The corresponding points on the rotary kiln body can be found directly according to the temperature abnormal points on the thermal image, which is convenient for the location of damage points.

1.1 Infrared real-time temperature measurement technology

Infrared thermography uses computer computing technology to calculate the temperature data of the object surface according to the original infrared data. And store the temperature data for statistical analysis.

2. Rotary kiln surface temperature analysis function

2.1 Statistics of surface temperature data of rotary kiln

Combined with the experience of Baosteel's ladle monitoring project, the following functions are set for the rotary kiln monitoring system: according to the statistical temperature field data, the maximum temperature trend analysis chart is established according to the zoning of the rotary kiln, and the alarm value threshold of different areas on the surface of the rotary kiln is established in combination with the maintenance experience. Through the pre alarm analysis, the service life of the rotary kiln is prolonged and the refractory is saved on the premise of safe use of the rotary kiln; Judge the cinder blockage fault according to the average temperature, and find the cinder blockage fault in time.

2.2 Rotary kiln lining damage alarm

The following figure shows the maximum temperature history curve of multiple surface temperature field data collection in a rotary block. Set a reasonable alarm value according to the statistical ladle surface temperature field data and empirical value. When the maximum temperature of the ladle surface reaches the alarm value, remind the staff to arrange maintenance work in real time, so that the rotary kiln can prolong its service life on the premise of ensuring safe production, so as to reduce production costs. The infrared imaging system itself adopts focal plane imaging technology. When a fault is found, the actual position of the fault point can be calculated according to the infrared picture of the alarm point.

2.3 Rotary kiln cinder blockage alarm

After long-term operation of the rotary kiln, there may be cinders attached to the inner wall in some areas, which may cause cinder blockage if not cleaned in time. The surface temperature of this area is different from that of other areas due to the different heat-resistant layer. Using this feature, we have measured the surface temperature of each block of the rotary kiln for many times during the trial operation, and recorded and counted the average temperature and maximum temperature of these temperature data. The average temperature alarm threshold of cinder blockage can be inferred from the statistics of this historical curve and experience. Then, the surface temperature of the rotary kiln is measured in real time and compared with the average temperature alarm threshold of cinder blockage, and then the cinder blockage fault in the rotary kiln can be judged.

3. Feasibility of rotary kiln infrared thermal image detection system scheme

Wuhan huajingkang Photoelectric Technology Co., Ltd. is a high-tech company specializing in providing infrared thermal imager products and industrial application solutions. At present, the company's infrared thermal imager product series mainly covers the fields of power system, iron and steel metallurgy, security monitoring and so on. Because the company's products have the characteristics of online real-time monitoring, high temperature measurement accuracy, customized customer application functions, etc., we successfully won the bid for the power monitoring system of a substation of the State Grid. In this system, we successfully used the PTZ control system, thermal imager imaging and accurate temperature measurement.

In the application of iron and steel metallurgy, our ladle infrared thermal image detection system has been successfully applied to an ironmaking plant of Baosteel. In this system, we have accumulated the infrared thermographic data of the ladle and improved the temperature measurement accuracy of high temperature metallurgy. In this system, we customized and developed rich functions for specific applications in the metallurgical industry, which is convenient for operators to use. The rotary kiln infrared thermal image detection system will integrate the user interface functions of the pan tilt control system, the thermal imager imaging system and the ladle infrared thermal image detection system in the substation power monitoring system. The main system components have been successfully applied and experienced by customers, so the scheme has high feasibility.

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