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HOT METAL TEMPERATURE VALIDATION

Ensure thermal accuracy. Prevent overheating. Maintain metallurgical precision in every pour.

Hot Metal Temperature

THERMAL ACCURACY ISN’T A GUESS, IT’S A NECESSITY.

Steel-8

In the steel industry, even a few degrees can determine the success or failure of casting, rolling, or quenching. Manual temperature checks using handheld pyrometers or spot sensors are often delayed, inaccurate, or dangerously close to molten zones.Hot Metal Temperature Validation uses non-contact thermal imaging and AI analysis to provide continuous, real-time monitoring of molten metal and hot surfaces, ensuring exact thermal thresholds are maintained at each critical step, from ladle to line.

OUR HOLISTIC VIEW TO CHALLENGES & FEATURES

Challenges

Inaccurate Temperature Readings

Inaccurate Temperature Readings

Handheld devices offer point readings that don’t reflect true thermal spread or gradient.

Operator Safety Risks

Operator Safety Risks

Close-proximity measurements expose workers to extreme heat and radiant zones.

Thermal Overshoot or Undershoot

Thermal Overshoot or Undershoot

Failure to maintain optimal temperatures leads to poor grain structure or unwanted defects.

Lack of Real-Time Visibility

Lack of Real-Time Visibility

Temperature anomalies are often detected too late, after casting or forming errors have occurred.

Features

Non-Contact Thermal Monitoring

Non-Contact Thermal Monitoring

Monitors temperature across entire metal surfaces using AI-enabled thermal cameras.

Real-Time Thermal Threshold Alerts

Real-Time Thermal Threshold Alerts

Alerts operators instantly when metal temperatures move beyond safe ranges.

Thermal Mapping & Visualization

Thermal Mapping & Visualization

Provides heat distribution maps to detect hotspots, cold zones, and uneven thermal flows.

Integration with Process Control Systems

Integration with Process Control Systems

Syncs with casting or rolling controls to auto-adjust feed rates or cooling cycles.

WHO BENEFITS FROM HOT METAL TEMPERATURE VALIDATION?

Artboard 1 copy 7
  • Melt Shop Engineers – Maintain optimal pouring temperatures to avoid rejections or stress cracks.
  • Casting Supervisors – Ensure uniformity in billet/ingot quality through accurate thermal control.
  • Safety Teams – Reduce the need for manual heat readings near dangerous zones.
  • Process Engineers – Analyze historical thermal data to optimize heat transfer and energy usage.

BUILDING AND DEPLOYING PROCESS

Ladle Movement
Thermal Critical Point Audit

Thermal Critical Point Audit

We begin by identifying key stages where temperature accuracy is essential, such as ladle pouring, tundish levels, rolling exit, or pre-quench zones.

Sensor-Camera Calibration for High Heat

Sensor-Camera Calibration for High Heat

Thermal cameras are selected and calibrated for extreme heat ranges (800°C–1650°C) and placed at safe, shielded observation points using industrial-grade enclosures.

Dynamic Heat Model Training

Dynamic Heat Model Training

AI models are trained on visual + thermal data to correlate metal color, glow, and behavior with accurate temperature bands across steel grades and process variations.

Visual Dashboard & Alert Integration

Visual Dashboard & Alert Integration

Live thermal maps and status alerts are integrated with the control room interface. Auto-alerts are triggered for overheating, heat loss, or uneven flow, enabling timely intervention.

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