Enhance Gas Flow Measurements

Real-Time Flare Stack Monitoring for Enhanced Efficiency

Achieved 90%+ accuracy, 20% reduction in flare emissions, and improved operational efficiency with Vision AI and multi-IR camera integration.

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Flare Stack Monitoring

One of India's leading steel producers

Client Overview

India’s leading steel company, with a current production capacity of approximately 27.7 MTPA, is set to expand to ~37 MTPA by the end of 2025. Demonstrating its commitment to sustainability, the company aims to achieve a 42% reduction in CO2 emissions by 2030. With a strong focus on digitalization across the value chain and advanced steelmaking innovations, the company continues to drive progress through innovation and responsible manufacturing practices.

Problem Statement

Inaccurate gas flow measurements and inefficient monitoring in flare stacks often lead to increased emissions and energy waste.

The client faced significant challenges in accurately monitoring gas flow within their operations. The existing monitoring systems were inadequate, with tar deposition frequently causing equipment malfunctions and compromising measurement accuracy. Optical cameras struggled to reliably monitor flame size due to the flame’s transparency, while thermocouple readings often proved inaccurate in the plant's harsh operating conditions. These issues hindered effective process control and posed risks to both operational efficiency and safety.

inaccurate gas flow readings

Unreliable gas flow readings caused by faulty flow meters

Faulty flow meters caused inaccurate gas flow readings, leading to inconsistent data and compromising process control. This impacted operational efficiency and hindered effective decision-making.

unreliable optical camera feeds

Improper judgement of flare size through camera feed

Unreliable optical camera feeds caused inaccurate flare size assessments, impacting process control. Limited visibility due to flame transparency further compromised monitoring accuracy.

Safety risks

Inaccurate monitoring can pose safety hazards for plant operations

Inefficient gas monitoring hampers operational sustainability and poses safety risks due to inaccurate measurements, potentially endangering plant operations.

unmonitored burner shutdowns

Unexpected burner shutdowns remain unmonitored

Unmonitored burner shutdowns can result in increased downtime, posing significant risks to both safety and production efficiency. These incidents may lead to energy wastage, unplanned maintenance challenges, and potential equipment damage.

Solution​

Ripik AI's Flare Stack Monitoring System Delivers Real-Time, Accurate Gas Flow Measurements

  • Real-Time Flare Monitoring with multi-IR camera system Ripik.ai utilizes orthogonally placed IR cameras to accurately calculate the volume of gas flared in real-time, enabling improved monitoring and control.
  • Instant real-time Alerts With immediate alerts through the interface, including sound notifications, Ripik.ai’s system ensures prompt action and improved safety. These real-time insights help operators quickly address flare irregularities, minimizing environmental impact and enhancing operational efficiency.
  • Automated Anomaly Detection Ripik.ai’s system detects anomalies instantly and logs corrective actions, tracking adherence and response time to drive proactive decision-making and ensure efficient flare management.
Flare Stack Monitoring

Impact and Validation by End Users

delivered precise gas flow measurements with flare stack monitoring

The Flare Stack Monitoring System delivered over 90% measurement accuracy, replacing manual judgment with data-driven insights. By providing real-time alerts and actionable insights, it empowered faster decision-making. Generating 650+ alerts in one month, it achieved a 5-10% reduction in gas flaring, enhancing efficiency and environmental outcomes.

1000MT+

Expected reduction in GHG emissions annually

The implementation of a real-time flare stack monitoring system achieved an annual reduction of over 1000MT in GHG emissions. Timely alerts supported data-driven decisions, reducing coke-oven gas over-flaring and improving operational efficiency.

20%

Improvement in fuel gas utilization

By reducing excess coke-oven gas flaring from 0.5% to 0.4% of total production, the real-time flare stack monitoring system achieved a 20% improvement in fuel gas utilization, enhancing both energy efficiency and environmental sustainability.

50%

Reduction in time to adjust valve opening

The platform achieved a 50% reduction in time to action by transitioning from human judgment-based decision-making to data-driven insights, enabling faster and more effective responses.