The SmartMelter® Solution

Optimal Furnace Life with Minimum Maintenance

The SmartMelter® solution has been proven as the most accurate method of refractory inspection and overall furnace health management. Using real data from sensors that measure actual wall thickness, our complete furnace management solution provides valuable insights for furnace life optimization.

SmartMelter®:

  • Maps wall thickness below the glass level
  • Detects glass infiltration into the insulation to eliminate glass leak risk
  • Determines the pace of erosion for optimal overcoat, minor, and major rebuilds
  • Keeps comprehensive furnace maintenance records including other inspection records, endoscopic images and pictures
  • Lowers insurance premiums
  • Enables implementation of standard inspection and furnace management policies across multiple plants

“With the SmartMelter® solution, you will safely extend the life of your furnace and bring stability to your production.”

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SmartMelter® is Easy to Use

You can protect your furnace without interruptions or expensive repairs. The SmartMelter® solution is a simple 3-step process: map, measure, and analyze.

Map

Once the furnace is signed up for SmartMelter®, our team will map each section of the furnace into SmartMelter® XSight software for accurate identification. Sidewall blocks are mapped as numbers 1, 2, 3, etc. The insulation is mapped as sections A, B, C, D, etc. This step is only done once to enable proper mapping and tracking of each refractory inspection.

Once the furnace is signed up for SmartMelter, our team will map each section of the furnace into SmartMelter® XSight software for accurate identification and mapping of each area. Sidewall blocks are mapped as numbers 1, 2, 3 etc. for each sidewall block. The insulation is mapped as sections A, B, C, D etc. between binding steels. This step is only done once to enable proper mapping and tracking of each furnace inspection.

Measure

Using SmartMelter® does not disrupt any ongoing operations. From the outside of the wall, our compact sensors measure wall thickness and identify glass penetration
into the insulation. Any trained member of plant personnel can take these measurements, which are recorded by the sensor for each section and transmitted to SmartMelter® XSight software for record keeping and analysis.

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Our sensors also come with many attachments that allow for accessing in front of the cooling pipes, behind the buckstays, and other tight, hard to reach areas.

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Analyze

Data from the sensors is displayed and stored in the XSight software for evaluation and analysis. XSight is a powerful software that organizes inspection data, visualizes potential glass penetration, and provides analytics on furnace degradation to optimize overcoats and rebuilds.

The Bottom Line

  • Save money by confidently delaying untimely overcoating or rebuilding.
  • Eliminate the risk of production disruption.
  • Negotiate better insurance rates by significantly lowering risk .
  • Produce more with your existing furnace with full knowledge of its health.
  • Improve operations planning with accurate refractory inspection and comprehensive reporting.

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