An infrared thermal imager is a high-tech product used to detect the infrared radiation of a target object and convert the temperature distribution image of the target object into a video image by means of photoelectric conversion, electrical signal processing, and the like. Infrared thermal imagers have high military application value and civil value. In the military, infrared cameras can be used in military night vision surveillance, weapon sighting, night vision guidance, infrared search and tracking, satellite remote sensing, etc. In civil applications, thermal imaging cameras can be used for material defects. The detection and evaluation, building energy conservation evaluation, equipment status thermal diagnosis, production process monitoring, automatic testing, disaster reduction and prevention and other aspects.
I. Overview of the Development of the Infrared Thermal Imager Industry The infrared thermal imager industry is a new high-tech industry with a promising development prospect. Thermal imaging cameras are widely used in both military and civilian fields. Under the conditions of modern warfare, infrared thermal imaging cameras have been widely used in military weapons such as satellites, missiles, and aircraft; at the same time, with the development of uncooled infrared thermal imaging technology, especially with the production costs in the process of industrialization. With a drastic reduction, infrared thermal imagers have been widely used in various sectors of the national economy such as power, firefighting, industry, medical care, and security. In recent years, the development of the infrared thermal imager industry has exhibited the following characteristics:
(1) The international thermal imaging camera industry is ushering in a rapid development. The development of the infrared thermal imager industry began in the United States and was first applied in the military field. With the development of uncooled infrared technology, the infrared thermal imager industry is in civilian use. The field has been widely used and is showing a broader market demand. According to the infrared market report issued by Maxtech International in the United States in 2005, the output of civil infrared thermal imaging cameras and systems in 2004 was about 50,000 units. In 2006, only FILR Company obtained BMW in the automotive industry as its new 7-series sedan. It was equipped with an order of an infrared camera, and received an export permit application from the U.S. government of 350,000. With the promotion of infrared thermal imagers in firefighting, electric power, and construction industries, the international civil thermal imaging camera industry will usher in a period of rapid growth in market demand. In 2006, the sales volume of global civilian thermal imaging cameras was 1.63 billion U.S. dollars, a year-on-year increase of 17.35%, showing a rapid growth trend. The rapid increase in the sales of infrared thermal imaging cameras mainly came from the continuous expansion of new applications.
(2) The development space of China's infrared thermal imager industry is huge With the rapid development of China's economy and society, China's infrared thermal imager industry has a huge space for development.
1 The modernization of the army requires a large number of infrared thermal imaging cameras. In developed countries, infrared thermal imaging cameras have been deployed in various military, air, and naval services. In the Gulf War, each American soldier has an average of 1.7 infrared thermal imaging cameras. Compared with developed countries, the use of mid-infrared thermal imagers in China’s military is relatively small. According to the White Paper of China's National Defense 2006 issued by the Chinese government, the number of personnel in the Chinese military is 2.3 million, if the future of our military is 10%. The troops are equipped with an infrared thermal imager, and the market capacity of military infrared thermal imagers in China can reach 230,000 sets, at a cost of 100,000 yuan per set (at present, the actual selling price of most military thermal imaging cameras is far more than 100,000 yuan). According to the calculation, the market demand for the market can reach 23 billion yuan.
2 In the long run, the potential market demand in the civilian sector is very large. Infrared thermal imaging cameras are widely used in civil fields such as firefighting, electric power, construction, and security. The application of infrared thermal imaging cameras in these industries is still in its infancy, with huge development space. . The field of firefighting is the largest civilian market of infrared thermal imagers in developed countries in the world. Due to the smoke penetration and temperature measurement characteristics of infrared imaging, the infrared thermal imager can be used in fire-fighting fire-fighting rescue and detection equipment. According to statistics, there are currently approximately 5 million firefighters in the world. If each fire-fighting vehicle is equipped with a thermal imager, the total market will reach 200,000. China's fire engines are still equipped with infrared thermal imagers. According to the statistics of the Ministry of Public Security's Fire Department's equipment department, the current number of fire engines in China is about 23,000, which is revised by the Ministry of Public Security, the National Development and Reform Commission, and the Ministry of Construction. The "Standard for the Construction of Urban Fire Stations" requires that by 2008, the number of fire trucks in each fire station will increase from the current 3.2 to five; the number of fire stations will increase by 500, and the total number of fire engines in the country will increase by nearly 8,000. Vehicle. With the development of our country's economy and society, fire-fighting vehicles equipped with infrared thermal imager will become a trend. If each fire-fighting vehicle is equipped with an infrared thermal imager, the infrared thermal imager market of the fire protection industry in China will reach around 30,000 units. According to the calculation of 40,000 yuan, the total market demand will reach 1.2 billion yuan.
In the electric power industry, although this industry is currently the most widely used industry for civil infrared thermal imaging cameras, it is limited to Guangdong, Zhejiang, Jiangsu, Shandong and other coastal economically developed regions, and the current ownership of these developed regions is only the demand. 20%. As the most mature and effective means of power online detection, infrared thermal imaging cameras can greatly improve the reliability of power supply equipment operation, greatly reducing the equipment maintenance time. Therefore, with the development of our economy, the power of other inland provinces The industry will also use infrared thermal imaging cameras, which provide a huge space for the development of the infrared thermal imager industry. According to statistics, the total demand for thermal imaging cameras in China's power industry is about 25,000 units, which is calculated at an average price of 80,000 yuan (currently priced at 100,000 yuan). The total market demand is about 2 billion yuan.
In the construction industry, on November 1, 2006, the China Engineering Construction Standardization Association approved the implementation of the "Infrared thermal imaging method for the detection of debonding defects in the decorative exterior wall decorative layer", and applied the infrared thermal imager to the construction industry. specification. At present, there are about 100,000 construction companies in China. If each one is equipped with an infrared thermal imager, the total market demand can reach 100,000 units, and the average market price can reach 20,000 yuan. The market demand can reach 20. 100 million yuan. In addition, as of 2006, there are 1.32 million companies in the manufacturing industry in China, such as: 15,000 metallurgical enterprises, more than 300,000 food manufacturing companies, 70,000 electronic manufacturing companies, and 36,800 machinery and equipment manufacturing industries. Manufacturing companies that use infrared thermal imaging cameras for process control can greatly improve their product quality. For example, 10% of large companies in the manufacturing industry are equipped with infrared thermal imaging cameras, and each company is equipped with an infrared thermal imager to calculate. The total market demand will reach 132,000 units, and the market demand will reach 13.2 billion yuan at a price of 100,000 yuan each (the current sale price is 150,000 yuan).
In the medical industry, the human body is a source of natural infrared radiation. The infrared radiation of human skin is 3-50um. When the human body is sick, the human body's thermal balance is destroyed. Therefore, measuring changes in human body temperature is an important indicator of clinical medical diagnosis. The thermal imager can display and record the temperature distribution of the human body. By comparing the human thermal image at the time of the lesion with the human thermal image under normal physiological conditions, the pathological state can be judged by whether or not there is a difference in the thermal image.
Medical imager technology has been used in clinical diagnosis for decades and is now available for the diagnosis of many diseases. Medical thermal imager has become an effective tool for the diagnosis of superficial tumors, vascular diseases and skin disorders. In medical disciplines research, the application of thermal imaging cameras in medicine has become a special research topic.
In the petrochemical industry, many important equipments in petrochemical production work under high temperature and high pressure conditions, and there are some flammable and explosive dangers. They require strict online monitoring of the production process to eliminate hidden dangers in time. The use of a thermal imager to detect product transport and piping, fire, and thermal insulation materials, corrosion, cracking, thinning, plugging, and leaking of various reaction furnaces can quickly and accurately obtain two-dimensional temperature distributions of equipment and material surfaces. Refineries use thermal imaging cameras to detect catalytic cracking units, reactor off-gas equipment and furnaces, leakage of safety valves and traps, and leakage of underground pipelines. They can quickly and accurately identify hot-leakage points. Inspection of the loss, cracks and wear of refractories in the shaft, gas and dust ducts, reactor tanks and transfer lines is very effective in preventing accidents and reducing energy consumption.
1 Detection of the coke at the bottom of the cracking and fractionation tower: The bottom of the cracking tower is the key to affecting the long-term operation of the Eureka device. The use of a thermal imager to measure the thermal image of the outer wall at the bottom of the tower can determine the degree of coke accumulation in the tower, and guide the process adjustment according to the results to determine the best operating scheme. Practice shows that after the detection method is combined with the process, the operating cycle of cracking and fractionation is extended from the original average of 30 days to 268 days, and obvious economic benefits are obtained.
2 Assess the lining damage of the acetaldehyde acetal device: In the petrochemical equipment, the key equipment (catalytic regenerator, reactor, demister, etc.) of the acetaldehyde acetate device has multiple layers of lining material inside. The use of a thermal imager to measure the temperature field of its outer wall, combined with heat transfer theory to calculate the thickness of its internal insulation layer, can understand the degree of lining damage under the operating conditions of the device, so as to provide reference for the development of maintenance program.
3 Detection cracking furnace tube local "hot spot": cracking furnace is the heart of ethylene production, coke formation within the furnace tube hot spots will seriously affect the service life. The use of an infrared thermal imager to peer through the borehole to inspect the furnace tubes in the furnace can provide the thermal image characteristics of the hot spots and provide a basis for the implementation of the furnace tubes.
4 Detection of Catalytic Cracking Unit: The catalytic cracking unit is an important device in the kerosene plant. Its core equipment (catalytic regenerator and settler) is directly related to the safety of the cylinder wall in the production operation, so it needs to be tested and diagnosed at any time. The thermal imager is used to perform regular wall temperature testing on them to analyze the condition of the lining and the location and extent of faults that may occur, as well as the development trend. The results are provided to the factory in a timely manner to provide a basis for the factory to perform maintenance.
5 The measurement of the temperature of the outer wall of thermal pipelines: steam thermal pipelines criss-cross the oil refinery and are widely distributed. The insulation material of the outer wall of the pipeline will be gradually damaged and dropped during the production process. The temperature of the outer wall of the pipeline will rise at any time, causing a lot of heat loss. The thermal imager of Maoming Petroleum Industry Company applied an imported thermal imager to scan the external wall temperature of a steam boiler to a catalytic, distillative, and low-pressure steam thermal line. Based on the measured data, the thermal losses of the external wall of the thermal pipeline were calculated. As the temperature analysis data provided was very accurate, the relevant department quickly replaced the insulation material. After running for a period of time, the external wall temperature was traced and scanned. It was found that the heat loss was greatly reduced, and a more significant economic benefit was achieved.
In the steel industry, thermal imaging cameras can be used for everything from smelting to rolling. Specific application examples are listed below:
1 Measurement of Large Blast Furnace Plane: Modern ironmaking blast furnaces require that raw materials added in the furnace are distributed evenly, and the distribution of raw materials can be measured from the distribution of the top surface temperature. Japan used a thermal imager to measure the temperature of the material in the furnace through a silicon glass port equipped with a furnace shell at the top of the blast furnace. After the image processing, the computer controlled the movement of the feeding equipment to adjust the flow of raw materials so that the charge distribution was reasonable. Reduce the role of coke ratio. Baosteel No. 1 BF in China uses real-time thermal imager to collect, calculate and display the material surface temperature in real time, which plays an important role in determining the quantitative delivery of raw materials, providing pig iron production and quality, prolonging the furnace life, and saving energy and reducing consumption.
2 Damage diagnosis and repair of hot blast stove: The lining of hot blast stove is easy to be burned in production, but because the furnace is closed, the burning position is not easy to find. Shanghai Meishan Iron and Steel Company applied a thermal imager to diagnose the damage location of the furnace and timely maintenance, which greatly extended the service life of the hot blast stove.
3 The determination of the position of the remnants of the blast furnace: Before the blast furnace overhaul, it is necessary to open the furnace to remove the residual iron in the furnace. In the past, the position of the opening was determined by experience, which was often inaccurate, resulting in an incomplete row of residual iron, which was difficult to remove. When the No. 5 blast furnace of Benxi Iron and Steel Company was overhauled, the temperature of the furnace shell was measured with a 481 thermal imager and the inflection point was measured under dead iron. After 25 minutes, the position of the lower surface of the molten iron and the position of the opening were determined. Exhausted.
4 Determination of temperature of steel ingots: The steel ingots poured from steel mills are very important in the temperature before entering the soaking furnace. Baoshan Iron and Steel Works applies a thermal imager to measure the surface temperature of the steel ingots before the furnace, so that the soaking furnace can optimize the heating of the ingots and save the gas consumption.
5 Determination of the temperature of the continuous casting slab: There is a certain relationship between the drawing of the slab and the amount of cooling water and the drawing speed in the continuous casting machine. Studying this quantitative relationship is extremely important for the production and quality of the slab and the safe production of the continuous casting machine. important. Wuhan Iron and Steel used the AGA780 thermal imager to set the temperature of the billet under different cooling water volumes and different casting speeds. A large amount of data was obtained to formulate production process rules that are compatible with the temperature of the billet so that the continuous casting machine can operate stably. .
6 Steel mold temperature measurement: In order to improve the service life of the ingot mold and reduce the consumption, the change law of the surface temperature field in the hot working state of the ingot mold needs to be determined. Wuhan Iron and Steel Corporation, Anshan Iron and Steel Technology and Dalian Institute of Technology jointly determined changes in the surface temperature field of the steel mold from pouring to stripping, obtained the variation of the temperature field, the maximum temperature of the ingot mold, its position and duration, and other data. These data successfully designed a high quality steel mold.
7 Measurement and control of furnace slab temperature: The slab to be rolled out from the furnace requires uniform temperature distribution. Anshan Iron and Steel Co., Ltd. measured the temperature of the furnace slab with a 6T61 thermal imager and found that the temperature in the furnace width direction was not uniform. It also found that the slab had “black marksâ€. Based on this, the causes were analyzed, and corresponding measures were taken to eliminate these. Problems, thus ensuring the quality of the sheet.
8 Determination of the surface temperature of the hot roll: The hot roll works at high temperatures for a long time, and it is prone to thermal fatigue cracks. This is related to the temperature distribution and variation of the roll surface. Wuhan Iron and Steel used the 6T61 thermal imager to measure and found that the temperature distribution on the surface of the roller was uneven, which was related to the uneven distribution of the cooling water in the production and the unequal temperature of the steel slab. Therefore, corresponding measures were taken to reduce or eliminate the hot crack.
In addition, as of 2006, there are 1.32 million companies in the manufacturing industry in China, such as: 15,000 metallurgical enterprises, more than 300,000 food manufacturing companies, 70,000 electronic manufacturing companies, and 36,800 machinery and equipment manufacturing industries. If the manufacturing industry uses infrared thermal imager for process control, it can greatly improve the product quality of enterprises. For example, 10% of large-scale manufacturing companies in the manufacturing industry are equipped with infrared thermal imagers, and each company is equipped with an infrared thermal imager to calculate. The total market demand will reach 132,000 units, and the market demand will reach 13.2 billion yuan at a price of 100,000 yuan each (the current sale price is 150,000 yuan).
(3) The research and development capabilities of China's infrared thermal imager industry have greatly improved. The research and development of infrared thermal imagers involves many disciplines such as optics, electronics, computers, physics, image processing, new materials, and machinery. Development is very difficult. In recent years, the infrared thermal imager manufacturers headed by Dali Technology have adopted talents introduction, technological research and increased investment in the development of infrared thermal imager core components (such as detectors) and new products of infrared thermal imagers. The major breakthroughs in development made the research and development capabilities of China's infrared thermal imager greatly improved.
(4) The phenomenon of industrial agglomeration in the civil thermal imaging camera industry is becoming more and more prominent. International mergers and acquisitions in the infrared camera industry are very active. The FILR SYSTEM company, the leading company in the infrared thermal imaging industry in the US, has achieved market share through multiple acquisitions. Gradually, in the international civilian thermal imaging camera market, FILR SYSTEM’s market share has reached 35%, and the top ten companies’ market share has reached 71%.
In recent years, the good development prospects of China's infrared thermal imager industry have attracted many capitals to enter the industry. According to statistics, there are nearly ten suppliers of infrared thermal imaging cameras in China, but most of them have weak R&D strength and brand influence. With a small force, many companies are actually agents or assemblers of foreign products. In the civil infrared thermal imager industry, it has gradually formed a market pattern of 80% of the civilian market, such as Dali Technology, Guangzhou Shengte and Wuhan Gaode, and the phenomenon of industrial agglomeration is more obvious.
Changes in the market demand for international infrared cameras The infrared thermal imager is divided into two major categories, military and civilian. The trends in demand for these two types of markets are as follows:
The infrared thermal imaging system in the military field is the earliest application field of infrared technology. The products are mainly refrigerated thermal imaging cameras, which require high performance of the detectors and are relatively expensive. At present, the military market is still the largest market for infrared products.
The civilian field is mainly used in many fields such as prevention and inspection, firefighting, security, automobile night vision, and legal supervision. In recent years, the civil market of infrared thermal imaging cameras in the world has grown rapidly, and with the application of infrared thermal imager industry in new fields. The thermal imaging camera market may show explosive growth.
In the long run, whether it is military or civil thermal imaging cameras, the potential market demand worldwide is very large. In the military field, infrared cameras will be equipped with various modern weapons. Currently, the number of troops in the world is about 20 million. If 10% of the troops are equipped with an infrared camera for each soldier, each infrared camera Calculated according to 2000 US dollars (currently priced at about 10,000 US dollars), the global market demand for military thermal imaging cameras can reach 4 billion US dollars; in the civilian field, the global infrared thermal imaging camera market is as much as 100 billion US dollars.
However, the actual annual demand and potential demand of the infrared thermal image market are quite different. The main reasons for this difference are: First, the core component of the infrared thermal imager—the yield of the detector is not high. The cost and selling price of detectors and even thermal imaging cameras are still high, affecting the development of the potential demand of the infrared thermal imager market. Secondly, at present, the most widely used industries for infrared thermal imaging cameras are the military, electric power, and fire protection industries. The promotion of infrared thermal imaging applications in more fields requires a process.
According to the prediction of Maxtech International, a well-known infrared imaging camera industry consulting company in the United States, the annual growth rate of the global civilian thermal imaging camera market will reach 15% in the next five years. By 2012, the market demand for global civil thermal imaging cameras will increase. Reached 3.812 billion U.S. dollars. However, if you consider the development of new application areas, the actual total market demand may exceed this forecast.
I. Overview of the Development of the Infrared Thermal Imager Industry The infrared thermal imager industry is a new high-tech industry with a promising development prospect. Thermal imaging cameras are widely used in both military and civilian fields. Under the conditions of modern warfare, infrared thermal imaging cameras have been widely used in military weapons such as satellites, missiles, and aircraft; at the same time, with the development of uncooled infrared thermal imaging technology, especially with the production costs in the process of industrialization. With a drastic reduction, infrared thermal imagers have been widely used in various sectors of the national economy such as power, firefighting, industry, medical care, and security. In recent years, the development of the infrared thermal imager industry has exhibited the following characteristics:
(1) The international thermal imaging camera industry is ushering in a rapid development. The development of the infrared thermal imager industry began in the United States and was first applied in the military field. With the development of uncooled infrared technology, the infrared thermal imager industry is in civilian use. The field has been widely used and is showing a broader market demand. According to the infrared market report issued by Maxtech International in the United States in 2005, the output of civil infrared thermal imaging cameras and systems in 2004 was about 50,000 units. In 2006, only FILR Company obtained BMW in the automotive industry as its new 7-series sedan. It was equipped with an order of an infrared camera, and received an export permit application from the U.S. government of 350,000. With the promotion of infrared thermal imagers in firefighting, electric power, and construction industries, the international civil thermal imaging camera industry will usher in a period of rapid growth in market demand. In 2006, the sales volume of global civilian thermal imaging cameras was 1.63 billion U.S. dollars, a year-on-year increase of 17.35%, showing a rapid growth trend. The rapid increase in the sales of infrared thermal imaging cameras mainly came from the continuous expansion of new applications.
(2) The development space of China's infrared thermal imager industry is huge With the rapid development of China's economy and society, China's infrared thermal imager industry has a huge space for development.
1 The modernization of the army requires a large number of infrared thermal imaging cameras. In developed countries, infrared thermal imaging cameras have been deployed in various military, air, and naval services. In the Gulf War, each American soldier has an average of 1.7 infrared thermal imaging cameras. Compared with developed countries, the use of mid-infrared thermal imagers in China’s military is relatively small. According to the White Paper of China's National Defense 2006 issued by the Chinese government, the number of personnel in the Chinese military is 2.3 million, if the future of our military is 10%. The troops are equipped with an infrared thermal imager, and the market capacity of military infrared thermal imagers in China can reach 230,000 sets, at a cost of 100,000 yuan per set (at present, the actual selling price of most military thermal imaging cameras is far more than 100,000 yuan). According to the calculation, the market demand for the market can reach 23 billion yuan.
2 In the long run, the potential market demand in the civilian sector is very large. Infrared thermal imaging cameras are widely used in civil fields such as firefighting, electric power, construction, and security. The application of infrared thermal imaging cameras in these industries is still in its infancy, with huge development space. . The field of firefighting is the largest civilian market of infrared thermal imagers in developed countries in the world. Due to the smoke penetration and temperature measurement characteristics of infrared imaging, the infrared thermal imager can be used in fire-fighting fire-fighting rescue and detection equipment. According to statistics, there are currently approximately 5 million firefighters in the world. If each fire-fighting vehicle is equipped with a thermal imager, the total market will reach 200,000. China's fire engines are still equipped with infrared thermal imagers. According to the statistics of the Ministry of Public Security's Fire Department's equipment department, the current number of fire engines in China is about 23,000, which is revised by the Ministry of Public Security, the National Development and Reform Commission, and the Ministry of Construction. The "Standard for the Construction of Urban Fire Stations" requires that by 2008, the number of fire trucks in each fire station will increase from the current 3.2 to five; the number of fire stations will increase by 500, and the total number of fire engines in the country will increase by nearly 8,000. Vehicle. With the development of our country's economy and society, fire-fighting vehicles equipped with infrared thermal imager will become a trend. If each fire-fighting vehicle is equipped with an infrared thermal imager, the infrared thermal imager market of the fire protection industry in China will reach around 30,000 units. According to the calculation of 40,000 yuan, the total market demand will reach 1.2 billion yuan.
In the electric power industry, although this industry is currently the most widely used industry for civil infrared thermal imaging cameras, it is limited to Guangdong, Zhejiang, Jiangsu, Shandong and other coastal economically developed regions, and the current ownership of these developed regions is only the demand. 20%. As the most mature and effective means of power online detection, infrared thermal imaging cameras can greatly improve the reliability of power supply equipment operation, greatly reducing the equipment maintenance time. Therefore, with the development of our economy, the power of other inland provinces The industry will also use infrared thermal imaging cameras, which provide a huge space for the development of the infrared thermal imager industry. According to statistics, the total demand for thermal imaging cameras in China's power industry is about 25,000 units, which is calculated at an average price of 80,000 yuan (currently priced at 100,000 yuan). The total market demand is about 2 billion yuan.
In the construction industry, on November 1, 2006, the China Engineering Construction Standardization Association approved the implementation of the "Infrared thermal imaging method for the detection of debonding defects in the decorative exterior wall decorative layer", and applied the infrared thermal imager to the construction industry. specification. At present, there are about 100,000 construction companies in China. If each one is equipped with an infrared thermal imager, the total market demand can reach 100,000 units, and the average market price can reach 20,000 yuan. The market demand can reach 20. 100 million yuan. In addition, as of 2006, there are 1.32 million companies in the manufacturing industry in China, such as: 15,000 metallurgical enterprises, more than 300,000 food manufacturing companies, 70,000 electronic manufacturing companies, and 36,800 machinery and equipment manufacturing industries. Manufacturing companies that use infrared thermal imaging cameras for process control can greatly improve their product quality. For example, 10% of large companies in the manufacturing industry are equipped with infrared thermal imaging cameras, and each company is equipped with an infrared thermal imager to calculate. The total market demand will reach 132,000 units, and the market demand will reach 13.2 billion yuan at a price of 100,000 yuan each (the current sale price is 150,000 yuan).
In the medical industry, the human body is a source of natural infrared radiation. The infrared radiation of human skin is 3-50um. When the human body is sick, the human body's thermal balance is destroyed. Therefore, measuring changes in human body temperature is an important indicator of clinical medical diagnosis. The thermal imager can display and record the temperature distribution of the human body. By comparing the human thermal image at the time of the lesion with the human thermal image under normal physiological conditions, the pathological state can be judged by whether or not there is a difference in the thermal image.
Medical imager technology has been used in clinical diagnosis for decades and is now available for the diagnosis of many diseases. Medical thermal imager has become an effective tool for the diagnosis of superficial tumors, vascular diseases and skin disorders. In medical disciplines research, the application of thermal imaging cameras in medicine has become a special research topic.
In the petrochemical industry, many important equipments in petrochemical production work under high temperature and high pressure conditions, and there are some flammable and explosive dangers. They require strict online monitoring of the production process to eliminate hidden dangers in time. The use of a thermal imager to detect product transport and piping, fire, and thermal insulation materials, corrosion, cracking, thinning, plugging, and leaking of various reaction furnaces can quickly and accurately obtain two-dimensional temperature distributions of equipment and material surfaces. Refineries use thermal imaging cameras to detect catalytic cracking units, reactor off-gas equipment and furnaces, leakage of safety valves and traps, and leakage of underground pipelines. They can quickly and accurately identify hot-leakage points. Inspection of the loss, cracks and wear of refractories in the shaft, gas and dust ducts, reactor tanks and transfer lines is very effective in preventing accidents and reducing energy consumption.
1 Detection of the coke at the bottom of the cracking and fractionation tower: The bottom of the cracking tower is the key to affecting the long-term operation of the Eureka device. The use of a thermal imager to measure the thermal image of the outer wall at the bottom of the tower can determine the degree of coke accumulation in the tower, and guide the process adjustment according to the results to determine the best operating scheme. Practice shows that after the detection method is combined with the process, the operating cycle of cracking and fractionation is extended from the original average of 30 days to 268 days, and obvious economic benefits are obtained.
2 Assess the lining damage of the acetaldehyde acetal device: In the petrochemical equipment, the key equipment (catalytic regenerator, reactor, demister, etc.) of the acetaldehyde acetate device has multiple layers of lining material inside. The use of a thermal imager to measure the temperature field of its outer wall, combined with heat transfer theory to calculate the thickness of its internal insulation layer, can understand the degree of lining damage under the operating conditions of the device, so as to provide reference for the development of maintenance program.
3 Detection cracking furnace tube local "hot spot": cracking furnace is the heart of ethylene production, coke formation within the furnace tube hot spots will seriously affect the service life. The use of an infrared thermal imager to peer through the borehole to inspect the furnace tubes in the furnace can provide the thermal image characteristics of the hot spots and provide a basis for the implementation of the furnace tubes.
4 Detection of Catalytic Cracking Unit: The catalytic cracking unit is an important device in the kerosene plant. Its core equipment (catalytic regenerator and settler) is directly related to the safety of the cylinder wall in the production operation, so it needs to be tested and diagnosed at any time. The thermal imager is used to perform regular wall temperature testing on them to analyze the condition of the lining and the location and extent of faults that may occur, as well as the development trend. The results are provided to the factory in a timely manner to provide a basis for the factory to perform maintenance.
5 The measurement of the temperature of the outer wall of thermal pipelines: steam thermal pipelines criss-cross the oil refinery and are widely distributed. The insulation material of the outer wall of the pipeline will be gradually damaged and dropped during the production process. The temperature of the outer wall of the pipeline will rise at any time, causing a lot of heat loss. The thermal imager of Maoming Petroleum Industry Company applied an imported thermal imager to scan the external wall temperature of a steam boiler to a catalytic, distillative, and low-pressure steam thermal line. Based on the measured data, the thermal losses of the external wall of the thermal pipeline were calculated. As the temperature analysis data provided was very accurate, the relevant department quickly replaced the insulation material. After running for a period of time, the external wall temperature was traced and scanned. It was found that the heat loss was greatly reduced, and a more significant economic benefit was achieved.
In the steel industry, thermal imaging cameras can be used for everything from smelting to rolling. Specific application examples are listed below:
1 Measurement of Large Blast Furnace Plane: Modern ironmaking blast furnaces require that raw materials added in the furnace are distributed evenly, and the distribution of raw materials can be measured from the distribution of the top surface temperature. Japan used a thermal imager to measure the temperature of the material in the furnace through a silicon glass port equipped with a furnace shell at the top of the blast furnace. After the image processing, the computer controlled the movement of the feeding equipment to adjust the flow of raw materials so that the charge distribution was reasonable. Reduce the role of coke ratio. Baosteel No. 1 BF in China uses real-time thermal imager to collect, calculate and display the material surface temperature in real time, which plays an important role in determining the quantitative delivery of raw materials, providing pig iron production and quality, prolonging the furnace life, and saving energy and reducing consumption.
2 Damage diagnosis and repair of hot blast stove: The lining of hot blast stove is easy to be burned in production, but because the furnace is closed, the burning position is not easy to find. Shanghai Meishan Iron and Steel Company applied a thermal imager to diagnose the damage location of the furnace and timely maintenance, which greatly extended the service life of the hot blast stove.
3 The determination of the position of the remnants of the blast furnace: Before the blast furnace overhaul, it is necessary to open the furnace to remove the residual iron in the furnace. In the past, the position of the opening was determined by experience, which was often inaccurate, resulting in an incomplete row of residual iron, which was difficult to remove. When the No. 5 blast furnace of Benxi Iron and Steel Company was overhauled, the temperature of the furnace shell was measured with a 481 thermal imager and the inflection point was measured under dead iron. After 25 minutes, the position of the lower surface of the molten iron and the position of the opening were determined. Exhausted.
4 Determination of temperature of steel ingots: The steel ingots poured from steel mills are very important in the temperature before entering the soaking furnace. Baoshan Iron and Steel Works applies a thermal imager to measure the surface temperature of the steel ingots before the furnace, so that the soaking furnace can optimize the heating of the ingots and save the gas consumption.
5 Determination of the temperature of the continuous casting slab: There is a certain relationship between the drawing of the slab and the amount of cooling water and the drawing speed in the continuous casting machine. Studying this quantitative relationship is extremely important for the production and quality of the slab and the safe production of the continuous casting machine. important. Wuhan Iron and Steel used the AGA780 thermal imager to set the temperature of the billet under different cooling water volumes and different casting speeds. A large amount of data was obtained to formulate production process rules that are compatible with the temperature of the billet so that the continuous casting machine can operate stably. .
6 Steel mold temperature measurement: In order to improve the service life of the ingot mold and reduce the consumption, the change law of the surface temperature field in the hot working state of the ingot mold needs to be determined. Wuhan Iron and Steel Corporation, Anshan Iron and Steel Technology and Dalian Institute of Technology jointly determined changes in the surface temperature field of the steel mold from pouring to stripping, obtained the variation of the temperature field, the maximum temperature of the ingot mold, its position and duration, and other data. These data successfully designed a high quality steel mold.
7 Measurement and control of furnace slab temperature: The slab to be rolled out from the furnace requires uniform temperature distribution. Anshan Iron and Steel Co., Ltd. measured the temperature of the furnace slab with a 6T61 thermal imager and found that the temperature in the furnace width direction was not uniform. It also found that the slab had “black marksâ€. Based on this, the causes were analyzed, and corresponding measures were taken to eliminate these. Problems, thus ensuring the quality of the sheet.
8 Determination of the surface temperature of the hot roll: The hot roll works at high temperatures for a long time, and it is prone to thermal fatigue cracks. This is related to the temperature distribution and variation of the roll surface. Wuhan Iron and Steel used the 6T61 thermal imager to measure and found that the temperature distribution on the surface of the roller was uneven, which was related to the uneven distribution of the cooling water in the production and the unequal temperature of the steel slab. Therefore, corresponding measures were taken to reduce or eliminate the hot crack.
In addition, as of 2006, there are 1.32 million companies in the manufacturing industry in China, such as: 15,000 metallurgical enterprises, more than 300,000 food manufacturing companies, 70,000 electronic manufacturing companies, and 36,800 machinery and equipment manufacturing industries. If the manufacturing industry uses infrared thermal imager for process control, it can greatly improve the product quality of enterprises. For example, 10% of large-scale manufacturing companies in the manufacturing industry are equipped with infrared thermal imagers, and each company is equipped with an infrared thermal imager to calculate. The total market demand will reach 132,000 units, and the market demand will reach 13.2 billion yuan at a price of 100,000 yuan each (the current sale price is 150,000 yuan).
(3) The research and development capabilities of China's infrared thermal imager industry have greatly improved. The research and development of infrared thermal imagers involves many disciplines such as optics, electronics, computers, physics, image processing, new materials, and machinery. Development is very difficult. In recent years, the infrared thermal imager manufacturers headed by Dali Technology have adopted talents introduction, technological research and increased investment in the development of infrared thermal imager core components (such as detectors) and new products of infrared thermal imagers. The major breakthroughs in development made the research and development capabilities of China's infrared thermal imager greatly improved.
(4) The phenomenon of industrial agglomeration in the civil thermal imaging camera industry is becoming more and more prominent. International mergers and acquisitions in the infrared camera industry are very active. The FILR SYSTEM company, the leading company in the infrared thermal imaging industry in the US, has achieved market share through multiple acquisitions. Gradually, in the international civilian thermal imaging camera market, FILR SYSTEM’s market share has reached 35%, and the top ten companies’ market share has reached 71%.
In recent years, the good development prospects of China's infrared thermal imager industry have attracted many capitals to enter the industry. According to statistics, there are nearly ten suppliers of infrared thermal imaging cameras in China, but most of them have weak R&D strength and brand influence. With a small force, many companies are actually agents or assemblers of foreign products. In the civil infrared thermal imager industry, it has gradually formed a market pattern of 80% of the civilian market, such as Dali Technology, Guangzhou Shengte and Wuhan Gaode, and the phenomenon of industrial agglomeration is more obvious.
Changes in the market demand for international infrared cameras The infrared thermal imager is divided into two major categories, military and civilian. The trends in demand for these two types of markets are as follows:
The infrared thermal imaging system in the military field is the earliest application field of infrared technology. The products are mainly refrigerated thermal imaging cameras, which require high performance of the detectors and are relatively expensive. At present, the military market is still the largest market for infrared products.
The civilian field is mainly used in many fields such as prevention and inspection, firefighting, security, automobile night vision, and legal supervision. In recent years, the civil market of infrared thermal imaging cameras in the world has grown rapidly, and with the application of infrared thermal imager industry in new fields. The thermal imaging camera market may show explosive growth.
In the long run, whether it is military or civil thermal imaging cameras, the potential market demand worldwide is very large. In the military field, infrared cameras will be equipped with various modern weapons. Currently, the number of troops in the world is about 20 million. If 10% of the troops are equipped with an infrared camera for each soldier, each infrared camera Calculated according to 2000 US dollars (currently priced at about 10,000 US dollars), the global market demand for military thermal imaging cameras can reach 4 billion US dollars; in the civilian field, the global infrared thermal imaging camera market is as much as 100 billion US dollars.
However, the actual annual demand and potential demand of the infrared thermal image market are quite different. The main reasons for this difference are: First, the core component of the infrared thermal imager—the yield of the detector is not high. The cost and selling price of detectors and even thermal imaging cameras are still high, affecting the development of the potential demand of the infrared thermal imager market. Secondly, at present, the most widely used industries for infrared thermal imaging cameras are the military, electric power, and fire protection industries. The promotion of infrared thermal imaging applications in more fields requires a process.
According to the prediction of Maxtech International, a well-known infrared imaging camera industry consulting company in the United States, the annual growth rate of the global civilian thermal imaging camera market will reach 15% in the next five years. By 2012, the market demand for global civil thermal imaging cameras will increase. Reached 3.812 billion U.S. dollars. However, if you consider the development of new application areas, the actual total market demand may exceed this forecast.
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