The Flame Supervisor: A new standard in flame monitoring technology

Hamburg, 1 July 2025 – DURAG GROUP launches the Flame Supervisor, a next-generation optical flame scanner that redefines ease of use, safety, and flexibility in flame monitoring across all fuel types and industrial burner configurations. Engineered for universal deployment in thermal processes, it introduces an innovative blend of advanced features, intuitive control, and robust safety compliance – including SIL 3 certification. Whether in industrial furnaces, cement kilns, gas turbines, or waste incineration plants, the compact, versatile device is tailored for the most demanding combustion systems.

Simplified commissioning meets compliance and operational confidence

“The Flame Supervisor is not just another flame scanner, it is a comprehensive solution for modern combustion systems, with smart tools that simplify commissioning, ensure compliance, and deliver operational confidence in applications,” says Thomas Pniok, Product Manager at DURAG GROUP. Key features are:

• Dual-channel architecture for maximum safety and system availability. The safe-landing function enables redundant, continued safe operation for up to 22:50 hours in the event of an internal failure.
• Auto Learn function: With just two buttons, operators can configure the system in minutes, using guided self-learning for fast and accurate commissioning.
• Flame Companion (App/Software, Android & Windows): Allows USB as well as wireless configuration via Bluetooth and fine-tuning of settings for specific process needs.
• Fiber optics option: Enables reliable flame detection in high-temperature, high-vibration, or difficult-to-access burner areas.
• Flexible variants: Available for manual rotary switch set-up (D-LX 1100) and for advanced, app-supported configuration with multiple filter options (D-LX 2xxx).
• Certified for global use: Compliant with a broad range of international standards including ATEX, FM EX, and SIL 3, enabling use across global markets.

Benefits from maximum safety to versatility

It all starts with the effortless setup and operation of the Flame Supervisor. Quick commissioning using auto-learn simplifies the startup process and reduces human error – this is ideal for operators of all skill levels. They can then rely on maximum safety of the high-end device: Its redundant dual-channel design ensures uninterrupted operation in critical applications, aligning with the highest safety requirements. 

At the same time, the Flame Supervisor stands for universal compatibility, being suitable for a broad range of burner types, fuel sources, and control systems, across almost all industrial sectors including the naval sector. Another plus is the operational resilience: Designed for extended temperature ranges, no external insulation or climate conditioning is needed. This ensures reliability even in harsh environments. The intelligent adaptability of the device is particularly noteworthy. Four preconfigured operating modes simplify adaptation to different combustion scenarios and fuel types, thus rationalizing the configuration process. Overall, the Flame Supervisor stands out for its versatility and global applicability. It is a scalable solution for installations around the world. It eliminates the costly need for companies to stock or maintain multiple scanner types for different regions or standards. 

Built for a wide range of industries, burner types and applications

From power plant boilers to industrial furnaces, cement kilns, reformers, and incinerators, the compact Flame Supervisor ensures reliable flame presence detection in even the most extreme or variable combustion systems. It is essential in any industry that relies on thermal energy which involves the use of a flame as part of its production process. This includes systems where energy is used to generate steam, hot water, hot air, or to transform product states (e. g. solid to liquid or gas), as well as in thermal decomposition processes like steam cracking in the petrochemical industry.

In addition, the Flame Supervisor of the DURAG GROUP is ideally suited for a wide range of burners, regardless of the manufacturer. It is also the perfect solution for low-capacity combustion systems where ionization-based flame monitoring is not feasible due to challenging conditions or system design. Here are some application examples and the respective benefits.

• Cement and building materials
  • Monitors the startup combustion process for a wide range of fuels.
  • Helps maintain clinker quality and minimizes production downtime.
• Power generation and utilities
  • Ensures continuous flame detection in fossil and biomass boilers, heat recovery steam generators and gas turbines.
  • Supports safety interlocks and regulatory compliance.
• Metal and steel production
  • For safe and consistent combustion monitoring in reheat furnaces and ladle preheaters.
  • Enhances energy efficiency and prevents thermal process disruptions.
• Food and beverage processing
  • Ensures stable flame monitoring for an even and stable production process in industrial combustion systems for steam and hot water boilers, industrial ovens and dryers.
  • Supports strict safety and regulatory requirements.
• Petrochemical, refinery, and chemical plants
  • Safeguards process burners in high-risk zones with ATEX/EX and SIL 3 compliance.
  • Minimizes unplanned shutdowns and ensures safe startup and shutdown sequences.
• (Hazardous) Waste incineration
  • Provides flame supervision for start-up burners to ensure compliance with emissions regulations.
  • Enables efficient energy recovery from waste materials.
• Alternative fuels like biomass, RDF, SRF, etc.
  • Delivers robust detection even with wide range of flame characteristics.
  • Supports safer, cleaner operation in co-firing and WTE systems.

Find more information can be found on the Flame Supervisor product page.