smartmelter sensors are safer to use than your …...furnace life optimization and management...
TRANSCRIPT
smartmelter.com
P +1 703.719.9666
4125 Lafayette Center Drive, Ste 200, Chantilly, VA 20151 USA
RTS FTSMeasures AZS
ThicknessMeasuresInsulationThickness
XSightFurnace Asset Management
Software
Melter Mapping and Tracking
System
Furnace LifeOptimization Solution
SIDEWALL THICKNESS VIEWLess than 2 inches (5 cm)2-4 inches (5-10 cm)Thicker than 4 inches (10 cm)
INSULATION THICKNESS VIEWGlass penetration to the 2nd insulation layerGlass penetration to the 1st insulation layerNo glass penetration
Furnace Life Optimization and Management
SmartMelter integrates refractory thickness sensors with powerful furnace asset management software to present you with a comprehensive view of the health of your furnace.
• Maps wall thickness below the glass level
• Detects glass infiltration into insulation
• Keeps comprehensive furnace maintenance records
• Enables standard inspection and furnace management policies across multiple plants
A Comprehensive Solution For
Is it Safe?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).
We developed SmartMelter sensors to withstand high-temperature environments. Our sensors have touched
surfaces as high as 1650 F (900 C) without incurring any damage. A protective measure warns the user and
shuts down the sensor when the internal sensor temperature reaches an unsafe level.
smartmelter.com
An Innovative PartnershipA partnership between PaneraTech and glass industry leaders has finally led to a breakthrough solution in
refractory thickness measurement. The research was funded by Libbey Glass, O-I, and the National Science
Foundation (NSF) Industrial Partnership Division. Libbey supplied the development furnaces, PaneraTech
supplied experienced engineers, and the teams worked closely together to develop a solution. The result
is a comprehensive furnace inspection and maintenance solution called SmartMelter. SmartMelter has been
validated in multiple blind trials to accurately measure the thickness of refractory walls, revolutionising
furnace maintenance.
— Terry Hartman Libbey Glass Vice President, Global Engineering and Manufacturing Support
“Our success to date with the SmartMelter is helping us to target best-in-class risk of furnace
operation, recognition from our risk underwriters for these investments and a new level of
technically-driven performance of our melter lifecycles.
Recently, for example, for one of our furnaces at the Shreveport plant, SmartMelter indicated
better than expected wall thickness, which resulted in delaying the overcoat for a year and also
extending the planned rebuild by 12 months.”
SmartMelter offers clear insight into the exact condition of your furnace
by measuring refractory thickness and identifying glass penetration
into insulation. This adds several benefits to your operations.
REDUCE COSTSConfidently delay untimely overcoating or rebuilding until it is actually
needed.
ELIMINATE RISKExtend furnace life without the risk of a leak, eliminating costly
disruptions.
REDUCE INSURANCE PREMIUMSLeverage your lower-risk operation to negotiate better insurance rates.
IMPROVE PLANNINGImprove operations planning with accurate refractory inspection and
comprehensive reporting.
MAPEach section of the furnace
is mapped and labelled for
identification in SmartMelter
XSight software. This is a
one-time step to enable all
future inspections.
MEASUREFrom the outside of the wall, our compact sensors measure refractory thickness and identify glass penetration
into the insulation.
What Can SmartMelter Do for Your Company? SmartMelter is Easy to Use
smartmelter.comsmartmelter.com
ANALYZEData from the sensors is displayed and stored in the SmartMelter XSight software for evaluation and analysis.
“SmartMelter
is one of the
most innovative
technologies
developed to
improve the life
expectancy and
operation of our
float furnaces.
Cardinal is using the system on our
floats for not only sidewall block
measurements but also furnace
bottom thickness measurements
allowing us to accurately predict hot
and cold repairs and safely operate
and extend the life of our furnaces”
— Kelly Busch Cardinal Flat Glass Vice President, Technology
SmartMelter offers clear insight into the exact condition of your furnace
by measuring refractory thickness and identifying glass penetration
into insulation. This adds several benefits to your operations.
REDUCE COSTSConfidently delay untimely overcoating or rebuilding until it is actually
needed.
ELIMINATE RISKExtend furnace life without the risk of a leak, eliminating costly
disruptions.
REDUCE INSURANCE PREMIUMSLeverage your lower-risk operation to negotiate better insurance rates.
IMPROVE PLANNINGImprove operations planning with accurate refractory inspection and
comprehensive reporting.
MAPEach section of the furnace
is mapped and labelled for
identification in SmartMelter
XSight software. This is a
one-time step to enable all
future inspections.
MEASUREFrom the outside of the wall, our compact sensors measure refractory thickness and identify glass penetration
into the insulation.
What Can SmartMelter Do for Your Company? SmartMelter is Easy to Use
smartmelter.comsmartmelter.com
ANALYZEData from the sensors is displayed and stored in the SmartMelter XSight software for evaluation and analysis.
“SmartMelter
is one of the
most innovative
technologies
developed to
improve the life
expectancy and
operation of our
float furnaces.
Cardinal is using the system on our
floats for not only sidewall block
measurements but also furnace
bottom thickness measurements
allowing us to accurately predict hot
and cold repairs and safely operate
and extend the life of our furnaces”
— Kelly Busch Cardinal Flat Glass Vice President, Technology
smartmelter.com
P +1 703.719.9666
4125 Lafayette Center Drive, Ste 200, Chantilly, VA 20151 USA
RTS FTSMeasures AZS
ThicknessMeasuresInsulationThickness
XSightFurnace Asset Management
Software
Melter Mapping and Tracking
System
Furnace LifeOptimization Solution
SIDEWALL THICKNESS VIEWLess than 2 inches (5 cm)2-4 inches (5-10 cm)Thicker than 4 inches (10 cm)
INSULATION THICKNESS VIEWGlass penetration to the 2nd insulation layerGlass penetration to the 1st insulation layerNo glass penetration
Furnace Life Optimization and Management
SmartMelter integrates refractory thickness sensors with powerful furnace asset management software to present you with a comprehensive view of the health of your furnace.
• Maps wall thickness below the glass level
• Detects glass infiltration into insulation
• Keeps comprehensive furnace maintenance records
• Enables standard inspection and furnace management policies across multiple plants
A Comprehensive Solution For
Is it Safe?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).
We developed SmartMelter sensors to withstand high-temperature environments. Our sensors have touched
surfaces as high as 1650 F (900 C) without incurring any damage. A protective measure warns the user and
shuts down the sensor when the internal sensor temperature reaches an unsafe level.
smartmelter.com
An Innovative PartnershipA partnership between PaneraTech and glass industry leaders has finally led to a breakthrough solution in
refractory thickness measurement. The research was funded by Libbey Glass, O-I, and the National Science
Foundation (NSF) Industrial Partnership Division. Libbey supplied the development furnaces, PaneraTech
supplied experienced engineers, and the teams worked closely together to develop a solution. The result
is a comprehensive furnace inspection and maintenance solution called SmartMelter. SmartMelter has been
validated in multiple blind trials to accurately measure the thickness of refractory walls, revolutionising
furnace maintenance.
— Terry Hartman Libbey Glass Vice President, Global Engineering and Manufacturing Support
“Our success to date with the SmartMelter is helping us to target best-in-class risk of furnace
operation, recognition from our risk underwriters for these investments and a new level of
technically-driven performance of our melter lifecycles.
Recently, for example, for one of our furnaces at the Shreveport plant, SmartMelter indicated
better than expected wall thickness, which resulted in delaying the overcoat for a year and also
extending the planned rebuild by 12 months.”