SmartMelter® Refractory Assessments give manufacturers deterministic data about the melter’s condition so that reliability can be assessed and overcoat recommendations can be made according to company plans and goals. We help glass manufacturers make decisions such as:
SmartMelter®:
Refractory Assessment
for the Glass Industry
SmartMelter® Radar Assessment Applications
● Is overcoating necessary?
● Is it safe to change the glass color?
● What is the scope of our next repair?
● Can we operate safely until our scheduled rebuild date?
Refractory Thickness Measurement
SmartMelter® can measure residual refractory thickness and make overcoat recommendations at the metal/flux line, throat, and electrode/bubbler blocks. Sensor range is up to 100mm on AZS and 150mm on High Zirconia (depending on material). We can measure select bonded Chrome-Alumina, such as SEFPRO wool.
Lower Sidewall Reliability
A SmartMelter® assessment can predict lower sidewall reliability for up to one year, depending on the sidewall configuration. Our sensor range is up to the tank block in most cases.
Furnace Bottom Reliability
A SmartMelter® assessment can predict furnace bottom reliability up to two years, depending on the bottom configuration. In some cases, our sensor range is up to the pavers.
Smartmelter Mapping of Glass Penetration Over Time
Regular furnace monitoring with SmartMelter® will show the change of glass penetration over time. This data can be used to evaluate the effectiveness of cooling techniques and other preventative measures.
SmartMelter®:
Technology, Data, and People
SmartMelter® refractory assessment is a process that employs advanced
technology, scientific data analysis, and review by furnace experts
Advanced Radar Technology
Our patented sensors launch radar waves into refractory walls to acquire a radar signal.
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.
The Furnace Tomography Sensor (FTS) is used to map residual insulation thickness. It is used on the sidewall insulation and furnace bottoms
Our grating sensor is small enough to fit many grating / grillage types to acquire radar signals without removal.
Data analysis
Radar signals from our sensors are analyzed and interpreted by our data analysis team, a group of furnace radar experts led by PhD Engineers.
Furnace Expert Review
When the data analysis is complete, our furnace experts review the refractory condition, assess reliability, and make recommendations. Our team has 58 years combined experience in furnace design, maintenance, and operations.
If you are using one of our Certified Partners, a detailed recommendation with accurate materials and labor can be presented
Steps to a SmartMelter® Assessment
The steps to a SmartMelter® Assessment include mapping your refractory into a digital model, collecting data from your furnace, data analysis, and review by furnace experts. A dedicated technician supports this process.
Learn More About the SmartMelter® Assessment Process
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