Can Camera-Based Image Processing Accurately Measure Furnace Flame Intensity?

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Discussion Overview

The discussion revolves around the feasibility of using camera-based image processing to measure the intensity of flames in a basic oxygen furnace. Participants explore the technical aspects of capturing images of the flame and analyzing them using programming languages like C# or MATLAB to derive intensity measurements.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant inquires whether capturing images of the furnace flame and analyzing the RGB values can provide a reliable indication of flame intensity.
  • Another participant suggests using a thick filter to reduce light intensity, noting that CCDs are linear and that the camera lens is designed to handle bright light, while also discussing the importance of heat absorption by the filter.
  • A different participant mentions that traditional flame detectors in oil/gas boilers used UV sensors to measure the flicker of the flame signal, implying that more sophisticated methods may exist today.
  • The original poster expresses gratitude for the suggestions and indicates a desire to pursue a cost-effective, homemade solution for measuring flame intensity.

Areas of Agreement / Disagreement

Participants have not reached a consensus on the effectiveness of the proposed camera-based method for measuring flame intensity, and multiple approaches and considerations are presented without resolution.

Contextual Notes

Participants mention various technical considerations, such as the need for filters and the potential for using existing flame detection technologies, but do not resolve the limitations or assumptions inherent in the proposed methods.

Who May Find This Useful

This discussion may be of interest to individuals involved in industrial processes, optical engineering, or those exploring innovative methods for flame detection and measurement.

Nicole04
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Hi Guys,

A basic oxygen furnace is very large 400 ton vessel that steel is refined in. during the refining process oxygen is blown into the steel. during this process there is a flame at the mouth of the furnace, this is what I am interesting in. during the process the flame changes in size and intensity. I want to be measure the intensity of the flame by using a camera to capture an image then use some c#/matlab code to calculate the intensity based on the RGB array of the image. will this work to give an indication of the relative intensity of the flames ? or have a missed the boat? can you clever people please help?
 
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You probably want to use a fairly thick filter. CCDs are fairly linear, and in a camera, the lens is usually sized so that other than aiming directly at the sun, the data can be handled. Technically, the light you are trying to measure is not quite as bright as the sun's surface. However the atmosphere knocks the solar intensity down a significant amount.

The best filter for your application is going to reduce the light by several orders of magnitude. You also need to consider the heat absorbed by the filter all up and down the spectrum. This is why I recommend a reflecting filter. The "extra" light from the mirror surface won't contaminate your reading all that much. (And if you care more for cheap than precision you can take almost any pocket mirror and remove the black paint on the back. ;-)
 
this is what I am interesting in. during the process the flame changes in size and intensity.

Interesting project.

the flame detectors in our oil/gas fired boilers used a UV sensor and measured the AC component or 'flicker' of the resulting signal.

But that was forty years ago. Surely they've become more sophisticated.

Same outfit is still in business. This instruction manual from them gives an intro to optical flame detection, see around page 14-15. Probably you're aware of them, though...
http://66.18.210.80/manuals/Fireye/SERVICE MANUAL.pdf
 
@ eachus - Thank you :) , Thats just the sort of thing I had no knowledge of. I am definitely going to give it a try, will let you know how it goes.

@jim- Thanks Jim, that would work, however cost is a factor, so I'm trying to get a cheap 'home-made' solution ;-)
 
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