Explosion-proof thermal cameras extend hazardous area surveillance beyond the visible spectrum, providing temperature measurement and heat detection capability in Zone 1 / Division 1 and Zone 2 / Division 2 classified locations where conventional optical cameras cannot detect early-stage equipment failures, hot spots, or combustion events. An explosion-proof thermal camera combines a certified flameproof (Ex d) enclosure with an uncooled thermal infrared detector to provide continuous temperature mapping in petrochemical, oil and gas, pharmaceutical, and power generation classified environments.

How Explosion-proof Thermal Cameras Work

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Thermal cameras detect infrared radiation emitted by objects based on their temperature, rather than reflected visible light. Key components of an explosion-proof thermal camera:

Uncooled microbolometer detector: The standard detector technology for industrial thermal cameras, offering 160×120 to 640×512 pixel resolution in formats suitable for integration into Ex d enclosures. No moving parts, no cryogenic cooling requirements, and long service life in industrial environments.
Germanium or chalcogenide optical window: Infrared-transparent windows replace the glass or sapphire optical windows used in visible-light explosion-proof cameras. Germanium transmits 8-14 micron long-wave IR (LWIR) radiation, the primary wavelength band for industrial temperature monitoring.
Radiometric capability: Advanced explosion-proof thermal cameras offer radiometric imaging—assigning a temperature value to every pixel in the image. This enables alarm thresholds (alert when any zone exceeds a set temperature), trend monitoring for predictive maintenance, and automated hot-spot detection.
Dual-channel configuration: Many explosion-proof thermal camera housings include both a thermal channel and a visible optical channel, allowing operators to view the same scene in visible light and thermal imaging simultaneously for precise alarm verification.

Applications for Explosion-proof Thermal Cameras in Hazardous Areas

Explosion-proof thermal cameras address monitoring requirements that visible-light cameras cannot fulfill:

Hot-spot detection and predictive maintenance: Overheating bearings, motor windings, electrical connections, and refractory failures in furnaces and boilers are detectable by thermal imaging before mechanical failure occurs. Installing explosion-proof thermal cameras on rotating equipment in classified areas enables continuous remote monitoring that reduces emergency shutdowns and unplanned maintenance in hazardous locations.
Fire detection in storage tank farms: Early fire detection in crude oil, refined products, and chemical storage tank farms using explosion-proof thermal cameras provides faster response than point-type flame detectors for ground-level fire propagation. Fixed thermal cameras on tank farm perimeters can detect the heat signature of a developing pool fire in its first seconds.
Flare stack and combustion monitoring: Thermal cameras directed at flare stacks detect combustion completeness—monitoring that the flare is burning efficiently and not releasing uncombusted hydrocarbons. Combined with visible-light cameras, thermal imaging confirms proper flare operation through smoke and heat distortion that obscures visible-light cameras.
Conveyor belt hot-spot monitoring: Coal conveyors, biomass handling systems, and chemical powder conveyors can develop hot spots from friction, mechanical failure, or smoldering material. Thermal cameras monitoring the material surface across the belt width detect temperature anomalies before they develop into fires.
Perimeter intrusion detection: Explosion-proof thermal cameras with IR range of 300-1000 m provide day/night perimeter detection capability at oil terminal fences, LNG plant boundaries, and critical infrastructure perimeters where conventional camera IR illuminators are ineffective at long range.

Radiometric vs Non-Radiometric Explosion-proof Thermal Cameras

Two classes of explosion-proof thermal camera are available depending on whether temperature measurement is required:

Non-radiometric (detection only): Provides thermal video for visual hot-spot identification and perimeter intrusion detection. No absolute temperature values. Lower cost. Suitable for fire detection, perimeter surveillance, and basic equipment monitoring where relative temperature contrast is sufficient.
Radiometric: Assigns calibrated temperature values to each pixel, enabling alarm thresholds, trend logging, and automated analytics. Required for predictive maintenance, flare monitoring, and applications where compliance documentation of temperature data is needed. Higher cost but provides quantitative evidence for maintenance decisions and insurance purposes.

Certifications for Explosion-proof Thermal Cameras

Like all Ex equipment, explosion-proof thermal cameras must carry appropriate certifications:

ATEX Group II Category 2G, Ex d IIC T5 or T6 (the thermal detector generates internal heat; T5 may apply for high-power radiometric models)
IECEx Ex d IIC T5/T6 for international projects
UL Class I Division 1 Groups A-D for North American installations

Veilux Explosion-proof Thermal Cameras

Veilux explosion-proof cameras include thermal imaging options certified to ATEX/IECEx and UL Class I Division 1 standards for Zone 1 and Division 1 classified locations. Our thermal camera housings accommodate uncooled LWIR detectors with radiometric capability for predictive maintenance and fire detection applications in oil and gas, petrochemical, power generation, and military classified environments.

For sites requiring both thermal and visible surveillance, our dual-channel thermal plus optical explosion-proof camera solutions provide complete scene awareness in one Ex d enclosure. Pair with our explosion-proof PTZ cameras for wide-area visible surveillance alongside targeted thermal monitoring points. Contact us to discuss thermal camera specifications, detector resolution, and radiometric requirements for your classified area monitoring project.

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Explosion-Proof Thermal Camera FAQ

What temperature range can explosion-proof thermal cameras detect?

Veilux explosion-proof thermal cameras using uncooled microbolometer detectors provide temperature detection across a range of -20°C to +550°C for standard industrial monitoring applications. High-temperature variants for furnace and refractory monitoring extend the range to 1,500°C+. The measurement accuracy is typically ±2°C or ±2% of reading for radiometric models. Specific temperature range and accuracy are listed on each model’s data sheet.

What is the thermal image resolution of your cameras?

Veilux explosion-proof thermal cameras are available in 160×120, 320×240, and 640×512 pixel detector resolutions. Higher resolution detectors provide finer temperature mapping and earlier hot-spot detection at greater distances. For most industrial predictive maintenance and process monitoring applications, 320×240 provides sufficient resolution. 640×512 is specified for large area monitoring where long detection distances are required. Many models offer a dual-channel configuration combining thermal with a 2 MP visible-light sensor.

Can thermal cameras detect flammable gas leaks?

Optical gas imaging (OGI) cameras — a specialized type of thermal camera using cooled or tuned detectors — can visualize certain gas leaks. Standard uncooled thermal cameras detect gas leaks indirectly by visualizing temperature differences caused by evaporating cryogenic liquids or temperature-differentiating gas leaks, but cannot directly visualize vapor clouds of most hydrocarbon gases. Dedicated OGI thermal cameras with MWIR cooled detectors are required for direct VOC visualization — contact us if OGI capability is required for your application.

Are your thermal cameras radiometric?

Both radiometric and non-radiometric models are available. Radiometric thermal cameras assign a calibrated temperature value to every pixel, enabling alarm thresholds, trend logging, and automated hot-spot detection with absolute temperature readouts. Non-radiometric models provide thermal video for visual hot-spot detection and perimeter surveillance but without absolute temperature values. Radiometric models are required for predictive maintenance, regulatory compliance temperature documentation, and applications where quantitative evidence is needed.

Can a thermal camera and visible camera be combined in one explosion-proof housing?

Yes. Veilux offers dual-channel explosion-proof camera assemblies that integrate a thermal infrared detector and a visible-light (2 MP or 4 MP) camera sensor within a single Ex d certified enclosure. The dual-channel design provides simultaneous thermal and visible imagery, enabling operators to verify thermal alarms with the visible channel in the same camera field of view. This reduces the installation footprint compared to mounting two separate cameras at the same location in a classified area.

Related Resources

IEC 60079-1 (Ex d enclosures) and IEC 80079-34 (quality assurance for Ex products) apply to the manufacture and certification of explosion-proof thermal cameras. See IEC.ch for current standards.

For regulatory standards on explosion-proof, refer to the OSHA hazardous location standards and NFPA 70 National Electrical Code.

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Explosion-Proof Thermal Cameras