Technology

SmartMelter® is a cutting-edge solution that is built on advanced radar technology. We have customized the application of radar imaging and computer tomography to detect areas of erosion in furnace walls. Our patented sensors launch radar waves into refractory walls to collect erosion data and refractory thickness measurements. This information from the SmartMelter® sensors is integrated with our proprietary software platform, XSight, for clear insight into the health of your furnace.

Refractory Thickness Sensor (RTS)

The Refractory Thickness Sensor (RTS) measures the residual refractory thickness to the glass interface. The RTS sensor operates in direct contact with refractories such as fused-cast AZS.

Furnace Tomography Sensor (FTS)

The Furnace Tomography Sensor (FTS) is used to map early-stage glass penetration into insulation layers and measure residual insulation thickness. It is used on the sidewall insulation and furnace bottoms.

SAFE TO USE

SmartMelter® sensors are safe to use, compatible with electric boosting, and built to withstand high temperatures.

Safer than a Cell-Phone

SmartMelter® sensors are safer to use than your mobile phone. Our sensors use the same radio waves that your phone uses, but with significantly less power (about one million times less).

Measures without Interference

Because of its low-power operation, you can have confidence that our sensors will not interfere with other plant instruments. Even if your furnace uses electric boosting, it will not interfere with our sensors. Our sensors have been used on furnace walls while the boosting is on. However, you should never use our sensors on boosting blocks while the boosting is on for safety reasons.

Operates Well in High Temperatures

We developed SmartMelter® sensors to withstand high-temperature environments. Our sensors have touched surfaces as high as 1000C (1832F) without incurring any damage. A protective measure warns the user and shuts down the sensor when the internal sensor temperature reaches an unsafe level.

EASY TO OPERATE

Your plant personnel can easily be trained to take measurements.

Intuitive Design

To use a SmartMelter® sensor, simply touch the sensor to the wall and press a button. Our sensors are:

self-calibrated

self-diagnostic

maintenance-free

Plug the sensor into the handheld computer and you are ready to inspect your walls. If a repair to the sensor is needed, the sensor will indicate this with a warning to the user.

Placement of the RTS Sensor

The Refractory Thickness Sensor (RTS) should be placed in direct contact with the AZS wall to work properly. The wall should be regular air-cooled as many critical wear areas already are.

Placement of the FTS Sensor

The Furnace Tomography Sensor (FTS) should be placed directly on the insulation wall to detect the presence of glass infiltration and measure residual insulation thickness.

MEASUREMENT

Accessibility around the furnace is what determines the total time it takes to map an entire furnace wall thickness. Mapping sidewall and insulation thickness of a typical 400 ton/day furnace takes 0.5 to 2 days. Most can be done in 1 day. Our RTS (Refractory Thickness Sensor) takes less than 2 seconds to do one measurement. Our FTS sensor takes less than 2 seconds to measure.

Tight Spaces

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.

Temperature Mapping

Our sensors do not use temperature information to measure wall thickness because they are based on radar measurements, independent of the wall temperature. However, they do record wall temperature for temperature mapping. The accompanying XSight software allows for both thickness and temperature mapping of the entire furnace walls.

SMARTMELTER® DATA

SmartMelter® is accompanied by our powerful XSight Software. With XSight, you can visualize SmartMelter inspection data, furnace health and store all maintenance and furnace records in an electronic environment.

Data Storage

SmartMelter® data is stored in PaneraTech’s secure server. In the near future, you will have the option to store data on your own server. View your furnace records on-site through internal XSight software, or access them globally using our web access platform. This makes it easy to enforce standard inspection policies across multiple plants.