Real-time Monitoring of Furnace Refractory Linings

Theme: Smelting and Power

Expected Pilot Duration - 6 Months

Challenge Summary

Lack of a real time monitoring system for the refractory furnace linings has led to reduced reliability and production from the equipment. Also, unoptimized preemptive maintenance has led to increased maintenance cycles and lower than rated furnace lining lifecycles. A real-time monitoring system for the refractory furnace lining is required.

Challenge Scenario

Monitoring of Straight Induction Furnace Refractory Lining is a challenging task. Refractories have their own life cycle. Deviation of refractory failure before design parameters i.e. time, poses significant safety threats and causes significant losses. These losses include higher maintenance and unpredictable production losses. Currently at Balco, Korba the refractory linings are rated for 300 hours of operation based on past performance but only 200 hrs is being realised. The furnaces with capacities of 2.5 Ton/hour operate at atmospheric pressure (open furnace) with max critical temperature of 1550oC.

Benefits to be realised : Safety benefits , Operational performance optimization and reduction in cost of maintenance.

Profile of the end users

Operation Team

Responsible for running the system in an optimised way by checking all critical parameters including site safety condition.

Maintenance Team

Responsible for maintaining all design parameters during maintenance activity and completion of job within time-period with Zero Loss Time Injury(LTI)/ Full Time Injury(FTI)

Solution Requirements

Real Time tracking of Life Span of Refractory lining.

Indicate Quality of refractory procurement and other procurement parameters.

Heat Map Analysis.

Improve shutdown planning and maintenance schedules.

Monitoring, tracking & reduction of heat losses in the system.

Monitor the health of the refractory on a real time basis.

Different Zone Temperature to be measured in real time.

Predictive analysis for maintenance planning and improve asset lifetime.

Integration with existing PLC & Historian system with a user friendly data interface.

Installation/Integration: Solution should be easily integrated to the existing systems, without any major modifications.

Data Interface and connectivity: To integrate with the current running PLC and Historian system.

Security: Industry standard security licences should be available for cloud based solutions.

Expected Outcomes

1. Quantified Metrics & Outcomes:

Operational KPIs/Metrics	Current Value	Expected Target Value
Performance & Asset reliability	5304 hrs/annum	>6456 hrs/annum 22% improvement
Relining Maintenance schedules	54 per annum	<36 per annum
Refractory Lifetime (300 hrs based on past performance)	200 hrs	300 hrs
Relining Cost	NA	50% decrease

2. Qualified Outcomes:

Current State	Target State (Expected)
Safety concerns due to failure of furnace (Failing of furnace linings have led to blasts in the past)	Improved safety by reducing chances of furnace failures/blasts

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