Automated vision refractory Monitoring
Predictive Refractory Monitoring to Extend Equipment Life
Reduce unexpected downtime, gradual wear, and degradation of refractory linings in ladles, furnaces, kilns, and boilers. Our patented algorithm combined with real-time IR camera technology ensures safe and uninterrupted production.
Problem Statement
The lifespan and efficiency of ladles, furnaces, kilns, and boilers are heavily impacted by refractory wear and hotspots, which can lead to costly downtime and repairs.
The refractory monitoring systems previously in place were inadequate for addressing the operational challenges faced in industrial environments. These systems relied heavily on manual observation, which often lacked the attentiveness and consistency required to detect early warning signs of wear or damage in refractory linings. As a result, maintenance practices were largely reactive rather than proactive, leading to increased instances of unplanned downtime and equipment damage. Additionally, outdated equipment did not support continuous monitoring of refractory linings, limiting the ability to take timely and informed corrective actions.
Missed Critical Issues
Missed critical issues can lead to severe equipment damage
Undetected problems lead to severe equipment damage, risking costly downtime and repairs. Early detection is essential to prevent catastrophic failures and maintain operational efficiency.
Ripik AI leverages Infrared monitoring uses thermal imaging to proactively detect refractory damage
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Real-Time Infrared Monitoring Real-time infrared monitoring utilizes infrared (IR) cameras to provide continuous and accurate detection of temperature variations and hidden hot-spots in refractory linings, enabling early detection of potential breakouts and alerting operators in advance to take corrective actions before serious issues develop.
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hotspots Detection Hotspot detection uses advanced thermal imaging technology to identify areas of excessive heat on refractory linings that are invisible to the naked eye. By spotting these critical zones early, it helps prevent refractory failure, extend equipment life, and reduce unexpected downtime.
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Automated Anomaly Detection & Instant alerts The vision refractory system leverages AI-powered algorithms to continuously analyze data, automatically identifying anomalies such as temperature spikes or structural weaknesses. It generates instant alerts to notify operators immediately, enabling swift corrective actions to prevent equipment damage.
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Historical video feeds & insightful report The system archives continuous video footage of refractory conditions, allowing operators to review past events and identify patterns over time. Detailed reports provide actionable insights that support data-driven maintenance decisions and improve overall operational efficiency.
Root Cause Analysis Conducted by Plant Team for Identified Hotspot: Circular Rib Plate
Impact and Accuracy Validation by End Users
50%+
Reduction in downtime
Manual inspections often missed early signs of refractory damage, causing unplanned downtime. With AI-driven monitoring, early wear is detected promptly, leading to a 50% reduction in downtime and improved operational reliability.