Glass Furnace heat-up.

A new application note from LAND® demonstrates how thermal imaging manages the heat-up process in glass furnaces to achieve the optimum temperature while ensuring long-term performance and maintenance are achieved. Efficient and controlled heat-up in glass furnaces is critical to ensuring the longevity of the furnace and maintaining structural integrity while enhancing operational safety.

Philippe Kerbois, Global Industry Manager LAND said: “Our thermal imagers ensure you stay in control during the heat-up process, as well as the post-heat-up process, safeguarding the furnace and optimising the production for a more stable and fast production with higher quality glass”.

This application note highlights the complete process of achieving full-spectrum furnace monitoring through the use of thermal imaging cameras such as LAND’s NIR-b-2K-Glass and the MWIR-b-640, which work together to provide full-spectrum thermal coverage, from early ramp-up to steady-state operation.

There are numerous benefits to using thermal imaging cameras, including detecting wear or damage to refractories during charging, such as hot spots or cracks, which allows for planned maintenance and reduces the risk of unplanned shutdowns, which can be costly. Improved energy efficiency through optimal heat management, along with the prevention of crown overheating and structural damage, can also be achieved.

Designed for lower temperatures, the MWIR-b-640 is ideal for monitoring the efficiency of the furnace heat-up phase. At the same time, the NIR-b-2K-Glass measures the temperature of both the melting glass and the furnace structure at 1000+ °C temperatures and optimises charging to avoid piles that are difficult to melt.

The NIR-b-2K-Glass helps to achieve efficient heat transfer to the batch while avoiding overheating or skewed temperature profiles. The camera observes the flame and temperature profile, which allows the operator to fine-tune the flame length and direction and balance burner power levels. This results in even melting across the batch while protecting the refractory lining from localised overheating.

This system offers flexibility for operators, deploying a NIR-b-2K-Glass camera allows for seamless switching from the MWIR-b-640 camera, as both systems share identical mechanical assemblies. This offers comprehensive monitoring beyond heat-up, improving product quality, and reducing potential downtime. Operators can alternate between the two types of cameras as needed, without requiring significant modifications or additional training.

By using thermal imaging cameras from LAND®, glass manufacturers can maintain full visibility and control during heat-up in the furnace, which can lead to faster revenue generation, reduced disruptions, and a more efficient production ramp-up.

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Liquid Aluminium temperature control.

Next generation of Thermal Imaging Technology solves Aluminium temperature control challenges for operators.

Liquid Aluminium

Ametek LAND® highlights the increasing numbers of furnace operators who are achieving a competitive advantage by switching to the latest thermal imaging systems to overcome the difficulties of remote measurement of liquid aluminium. This is an advance from traditional single-spot temperature measurement methods used for many years, the new generation of borescope furnace technology enables an unparalleled view inside melt furnaces to accurately and continuously profile the temperatures within the furnace without disturbing the process.

Operators in the aluminium sector can benefit from optimised processes, enhanced efficiency and quality, and improved safety after implementing thermal imagers into automated process control systems. This generates extensive amounts of crucial thermal behavioural data that was not previously available to them.

Aluminium is a challenging material for measurement instruments to achieve accurate readings due to several characteristics, including a low emissivity which varies in value depending on oxide layers and type of alloy, preventing direct correlation of the Infrared radiation intensity emitted by the metal with its temperature.

LAND’s advanced radiometric infrared borescope MWIR-b-640 thermal imager with spectral filtering uses a mid-range wavelength of 3.9 μm to achieve a clear, continuous view through heavy smoke and hot furnace atmospheres, overcoming the difficulties caused by reflections from the hotter walls, fumes and particulates, dross build-up and surface materials which impact the measured signal.

With a wide-angle field of view, the LAND camera allows multiple areas to be imaged and measured simultaneously, enabling high-resolution furnace measurement image data to be taken, stored and trended over the lifetime of the furnace to facilitate the early detection of leaks and temperature variations helping to optimise processes.

Additionally, accurate temperature measurement of liquid aluminium is essential for process efficiency to ensure the integrity of the finished product. If the temperature is too hot, this will alter the chemical and physical properties and the casting will not meet the required specifications. If the temperature is too low, the molten metal will not flow into all the cavities and apertures of the casting due to solidification.

Continuous temperature allows aluminium operators to closely control the process to better plan tapping and pouring operations and to ensure the metal is heated using a minimal amount of energy. Changes over the melt objects can be analysed to predict melt rates and process transitions, while dross formation can also be monitored.

James Cross, Head of Industry Management at LAND, said “The traditionally difficult process of continuous non-contact measurement of liquid aluminium in pouring processes can now be solved with LAND’s technology. The benefits for aluminium operators are significant, ranging from high-quality casting, reduced product variation, improved process control and quicker development of new recipes and products, to enhanced capabilities to answer demand for high-quality aluminium products while limiting emissions and reducing energy use.

“With increasing quality requirements, we are seeing more companies switch to process thermal imaging systems to provide accurate temperature measurements of the entire metal stock and the furnace interior. As we look to the future, the implementation of thermal imagers into process control systems will be a key factor in enabling a more efficient, optimised and automated operation.”

The MWIR-b-640 is supported by the advanced ImagePro thermal imaging and data processing software. Operators have a clear view of the critical areas within the furnace with more than 300,000 image pixels measuring in the range of 300–1200 °C or 500–1800 °C.

Through ImagePro, the performance of the furnace can be monitored to easily identify hot and cold areas, and any uneven heating can be viewed in real time from the safety of the control room.

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Advanced fixed thermal imaging.

Addresses the increasing risk of fires and explosions in battery storage facilities

The AMETEK Land LWIR-640 thermal image provides continuous, real-time monitoring of battery installations. By capturing detailed thermal images of battery modules and racks, the LWIR-640 identifies abnormal heat distributions, hot spots and temperature differentials indicative of potential issues.

Thermal runaway, a self-accelerating and uncontrollable rise in temperature that could lead to fires or explosions, is a potential threat in lithium-ion batteries. It can be triggered by overcharging, physical damage, overheating or short-circuiting but with early detection and intervention the risks are reduced.

James Cross, Head of Industry Management at AMETEK Land said: “With the growing prevalence and energy density of lithium-ion batteries, safety concerns are paramount. Our latest innovation, the LWIR-640 smart radiometric thermal imager offers an advanced solution for the early detection and prevention of thermal runaway in battery storage systems.”

The LWIR-640 thermal imager has been designed and developed by experts over 20 years, resulting in a highly accurate continuous monitoring solution for battery storage. Available in multiple models with a full temperature measurement range of -20 to 1000°C, the LWIR-640 provides versatile solutions that meet the diverse needs of battery storage facilities.

They have published an informative Application Note.

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Automatic retraction system animnated!

Latest animation to help furnace operators ensure the safe installation and accurate operation of a borescope.

AMETEK Land's NIR-B LPAR system is a failsafe system designed to automatically remove the borescope camera from a furnace when the temperature of the probe becomes too high. Competent installation is key to the LPAR working correctly in industries that have become increasingly reliant on continuous process data from their thermal imagers.

This new video demonstrates the key elements of the LPAR and how they work together, including the fittings to connect water and air to the PCU and media bar. A Pneumatic Control Unit controls the retraction mechanism and is typically installed around 15m from the furnace, away from the high temperatures.

James Cross, Head of Industry Management said: “This video is highly valuable to anyone looking to install a retraction system on their furnace, whether it’s a glass melt tank or reheat furnace. Our LPAR is a robust, tried and tested design that must be carefully and competently installed for a safe and secure operation. Video guides and animations are a key part of our marketing and training strategy and we’re looking forward to releasing similar content in the coming weeks and months.”

Watch the video!

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Non-contact temperature measurement strengthens US support.

AMETEK Land, has strengthened its support for customers in the US with a new appointment to its sales team.

Ryan Silkworth

Ryan Silkworth has been appointed as Regional Sales Manager for the Western US, where he will work directly with representatives and distributors for all AMETEK Land products.
Holding a Bachelor’s Degree in Mechanical Engineering from Colorado State University, he previously worked for Teledyne Monitor Labs (TML) as a Sales Manager/Application Engineer.

Larry Smith, AMETEK Land’s Director of Sales – Americas, said: “I’m delighted to welcome Ryan to the team. Our business is continuing to grow in the US, so Ryan’s primary responsibilities will be to manage and support our existing customers in the region while supporting our channel partners to bring LAND’s industry-leading products and services to this underserved region of the US market.”

The full Regional Sales Manager team for the US now consists of:

• Dennis Delmastro – Eastern US and Canada, based in Pittsburgh, PA
• Michael Mackin – Central and Upper Midwest US, based in Cleveland, OH
• Martin Handy – Southwestern US and Latin America, based in Houston, TX
• Ryan Silkworth – Western US, based in Denver, CO

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Pneumatic auto-retraction system.

A retraction system for thermal imagers has been launched by Ametek. This will safeguard the instrument and preventing overheating or damage in the event of loss of power, purge flow loss or cooling. It complements the thermal imager range, adding another level of safety and damage prevention.

Their Land Pneumatic Auto-Retraction System (LPAR) is ideal for a wide range of furnaces and other applications due to its seamless integration with both water-cooled and air-cooled furnace camera systems.

Developed for use with the NIR-B-656, NIR-B-2K, NIR-B-640 and the MWIR-B-640, the LPAR is supplied as part of a complete furnace camera systems or as an upgrade to existing systems.

Manfred Hayk, Head of Product Management at AMETEK Land, said “The LPAR is a highly engineered system, operating reliably 24/7 in the most challenging industrial environments. It’s the preferred system of choice for all applications as it operates using pressured air and electricity alone.”

The LPAR system will remove the instrument from the process if air pressure to the cylinder is lost, the cooling or purge flow drops below requirements or exceeds media temperature limits. It will also activate if the NIR-B lens system temperature reaches its alarm level, mains power is lost or the camera temperature exceeds the limit (NIR-B 656 & NIR-B 2K only).

Ametek Land has developed a range of thermal camera systems with advanced spectral responses and temperature ranges from 300 to 2000 °C (572 to 3632 °F). These systems can be equipped with either water cooling and air purging or air cooling and air purging, tailored to suit specific application requirements.

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Ethylene producer's furnace operations.

A large US ethylene producer has been provided with 28 thermal imagers by Ametek Land. This is to provide continuous, highly precise, temperature measurements for optimum process control in its four cracking furnaces*.

Ethylene is a key element in a range of everyday items from plastics to polymers and is produced by cracking hydrocarbon feedstocks at high temperatures with steam.

The furnace must be kept at a consistently high temperature to avoid inefficiencies and be effective. LAND’s high-definition NIR-B-2K thermal imaging camera delivers non-contact measurements with outstanding accuracy to help optimise furnace performance, extend tube life, and improve safety.

The NIR-B-2K is a high-resolution short-wavelength radiometric infrared thermal imaging camera, and provides improved definition at a distance, measuring temperatures in the range of 600-1800 °C (1112 to 3272 °F). It provides a cutting-edge clear thermal image unaffected by the furnace's hot atmosphere and allows operators to measure from any of the 2,904,768 pixels.

Jason Rushton, Application Engineer, Ametek Land commented: “The thermal imager is ideal for applications such as ethylene production, where furnaces require optimum process control while maintaining high temperatures. With the NIR-B-2K, plant operators can rest assured as it helps improve process control through continuous furnace monitoring and highly accurate temperature readings in the furnace.”

Ametek Land is renowned globally for its highly accurate measurement solutions used in a wide range of industrial processes and covering a broad temperature range.

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* Read the latest case study here: Thermal Imagers on Steam Crackers.

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Temperature measurement solutions in metal mining and processing.

Advanced solutions for metal ore extraction

AMETEK Land provides advanced solutions to meet the intricate demands of ore extraction applications. Precise furnace temperature measurements using instruments such as AMETEK Land’s thermal imagers are essential to support safety, effective process efficiency and superior product quality in platinum and nickel ore extraction.

Non-contact infra-red thermal imagers provide critical temperature data which is used to produce consistent, high-quality products and inspect the condition and integrity of high-value assets, without putting operators at risk.

Madeleine Lake, Global Industry Manager - Energy & Minerals, said: “Metal ore extraction requires advanced process control and precise furnace temperature measurements for a superior end product. Our accurate, non-contact solutions deliver this and more, including emissions and safety monitoring in the mineral plant.”

For a continuous and clear view through heavy smoke and hot furnace atmospheres, the MWIR-Borescope-640 is a highly accurate radiometric infrared imaging camera with spectral filtering for continuous temperature measurement and furnace profiling applications. 

The NIR-Borescope-656 is a high-resolution short wavelength full radiometric infrared borescope imaging camera designed to produce continuous live high-definition thermal images. Measuring temperatures in the range of 600-1800C, it is suitable for a wide range of continuous process monitoring and control applications, providing high-resolution images and temperature readings in large furnaces.

Benefits of using the NIR-B-656 include optimised furnace temperatures leading to energy savings, increased efficiency and reduced emissions.

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Supporting metal quality and reducing costs.

LADA Foundry is focused on delivering top-quality products from its SG/ductile iron plant, which requires accurate measurements of the liquid metal during the casting process. Traditionally the foundry used dip thermocouple tips in combination with a pyrometer which takes longer and increases operator risk and cost. AMETEK Land’s Cyclops 055L portable pyrometer can address all these issues.

Capable of taking a non-contact measurement in under two seconds, the Cyclops improves operator safety with its point-and-shoot function, allowing the operator to be positioned several metres away from the molten metal.

It also significantly reduces the use and cost of disposable dip-type thermometers and improves measurement accuracy with its clear, wide-angle field of view and clearly defined measurement area for precision sighting.

After implementing the Cyclops into its process, LADA Foundry stopped using thermocouple tips completely, resulting in a cost savings of approximately INR 7,000,000.

LADA Foundry Plant Head, Mr. Yuvraj Patil, said: “The Cyclops 055L provides us with a safe, accurate and fast temperature measurement, and is helping us to improve production at our facility. Because the Cyclops is portable, we can measure each mould pouring temperature, and at the furnace, which helps to avoid super-heating.”

Its rugged instrument casing means the Cyclops 055L is used by foundry operators worldwide and in a wide range of applications including melting furnaces, ladle treatment locations, pouring sectors, blast furnace runners and liquid metal transfers. 

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Appointments at pyrometer leader.

AMETEK Land has introduced a new industry team structure to transform its approach to its customers, products, and solutions. The changes will mean a continued focus on global industrial solutions, and a drive to help customers meet their industry challenges.

James Cross

James Cross has been promoted to Head of Industry Management following five years as Regional Sales Manager in the Middle East as then Global Industry Manager for Hydrocarbon Processing industries. This new position will see James working with partners and customers to demonstrate where LAND’s technology is solving their most complex challenges. Commenting on the changes, he said: “This new role will allow me to highlight to our partners and customers where our technology is solving their most complex challenges. This is particularly important with the shift in industry towards safer, more intelligent, more sustainable manufacturing processes.
“I love having the strategic freedom to focus on solving serious challenges that can be replicated globally and across multiple industries. This means I’m constantly learning about new processes and how we can contribute to a more sustainable industry.
“AMETEK Land has seen the industrial landscape change and evolve dramatically, from its primary focus towards digitalisation to decarbonisation, and now to an equal focus on both. This is underlined by a demand to make more from less, with a reduced risk to human operators and engineers in the plant.”

Manfred Hayk

In addition, Manfred Hayk has taken on the role of Head of Product Management. This role will be focused on developing high-quality, accurate products in line with the wider team to support all industrial applications. He said: “I’m pleased to be working in this important role, which will see LAND develop new products and software to meet our customers’ process challenges and innovate with new algorithms to improve accuracy, save time, and increase safety.
“But it’s not an individual role – I look forward to the collaboration and teamwork across the whole AMETEK Land team to continue the market-leading product and application support we are known for.”

These team changes are key to AMETEK Land’s ongoing development towards greater digitalisation and decarbonisation, which balances between reacting to customer process challenges and innovating based on an expert understanding of what can be done with its technology.

These developments include building algorithms built into the company’s smart pyrometers to improve accuracy while saving operators significant amounts of time, and software development kits (SDKs) supplied with camera technology to allow developers the freedom to produce features using the accurate temperature data output by AMETEK Land instruments. The company is also building closer partnerships with industry-leading manufacturers, producing case studies and evidence showing the value of investing in advanced instrumentation

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Application note on temperature monitoring in steel.

Helping the steel industry meet global decarbonisation challenges with a range of solutions.

With the steel industry responsible for approximately 7% of global man-made CO₂ emissions, finding a way to meet the ongoing demand for steel while reducing and eventually eliminating carbon emissions, is a major challenge.

Ametek Land offers steelmakers several temperature monitoring solutions, and the technology, to meet their challenges when transitioning to more sustainable methods of steelmaking, supporting decarbonisation in several ways.

A specially designed solution, the Slag Detection System (SDS) from LAND, leverages the capabilities of mid-wavelength thermal imaging to help deliver improved yields, higher quality steel, and reduce costly downstream processing for EAF steelmaking operations. It is specially designed to withstand the harsh conditions of continuous operation in a steel plant, with minimal maintenance requirements.

Other solutions from LAND that play a part to help improve product quality, efficiency and reduce emissions include:

• The MWIR-640 390, a mid-wavelength thermal imager that provides reliable, robust and real-time thermal imaging measurements and imagery
• The NIR-2K is a high-precision thermal imager capable of producing high temperature measurements. It combines high accurately with high resolution measurement temperature distributions to identify hot and cold spots for process optimization
• Offering a full temperature measurement range of -20 to 1000°C, the LWIR-640 long-wavelength thermal imager provides high-precision temperature measurements and thermal profiles to continuously control, document and visualise industrial processes.

Manfred Hayk, Head of Product Management at Ametek Land, said: “Process parameters are changing throughout the industry in a bid to bring down carbon emissions. We know that there is no single solution to carbon reduction in steelmaking. However, several changes to existing practices can each make a significant contribution to decarbonisation in the industry.
“We offer accurate, reliable, proven solutions for temperature measurements that support these changes. For example, switching to thermal imagers rather than dip thermocouples helps support decarbonisation efforts by reducing the use of consumables, and delivers more information to support process efficiency.”

A new application note looks at all these processes, and explains the importance of accurate temperature monitoring within each of them, along with expert advice on the best method to use.

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Service and calibration assistance.

A service solution to ensure customers benefit from peak product performance and maximum return on investment over the life of their equipment is now being provided by AMETEK Land.

All thermometers, regardless of manufacturer, are subject to damage and deterioration over time. However, this can be limited proactively through their service and calibration support, providing ongoing confidence in the measurement accuracy of the instruments.

Service support, delivered through LAND’s worldwide network of regional accredited service centres, helps to maintain peak operating performance over time, while on-site calibration conformance testing maintains the accuracy of the temperature measurement being made.

“Many instruments are operated continually with little or zero maintenance which can affect their performance," said Victoria Jones, Team Leader - Aftermarket at AMETEK Land. "Our service and calibration adjustments restore instruments to ‘as new’, thus limiting their deterioration. This not only provides customers with the assurance that their instrument is working as it should but also protects the investment they have made in that equipment. It’s a proactive solution that maximises the availability and uptime of your AMETEK Land products.”

In addition to its service centres, AMETEK Land also operates three accredited ISO 17025 laboratories which provide certification to endorse the accuracy of temperature measurements being made.

ISO 17025 certification provides additional confidence through traceable independent testing and allows the thermometer operator to distinguish shifts in calibration and correct for calibration errors over and above the specification, providing a useful audit trail.

These ISO 17025 certification laboratories can also certify non-AMETEK Land thermometers/pyrometers within the scope of their approval, subject to the provision of necessary power supplies and cables.

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Induction heating.

Induction heat treatment is a highly versatile technique widely used to alter the mechanical properties of materials including metals and alloys. However, accurate temperature control is crucial to achieve the desired temperature and material properties, and to control both the heating process and induction generator.

AMETEK Land supports industries including manufacturing, automotive, aerospace and construction with highly accurate and reliable temperature measurement solutions for induction and heat treating applications. The company offers a wide range of dedicated pyrometers, line scanners and thermal imagers to optimise these heating and processing applications*.

Manfred Hayk, Global Infrared (IR) Product Manager - Product and Application Support said: “It can be challenging to obtain accurate temperature measurements in industrial processes. Our wide range of dedicated solutions are chosen by customers around the globe because of our proven technology and infrared temperature measurement experience, helping to provide controlled and precise measurements while optimizing process efficiency and increasing product quality.”

One key solution is the SPOT+ range of pyrometers. These smart infrared pyrometers offer advanced industrial connectivity and visible light process video, making non-contact temperature measurements accurate and flexible, especially in the harshest of environmental conditions.

Thermal imaging cameras and systems also play an important role in industrial processing and furnace applications, forming a crucial component for visualising, controlling, and documenting the induction heating and heat treatment process.

LAND’s advanced cameras and systems, including the MWIR-640 and LWIR-640 imagers, and the NIR-2K, working with the IMAGEPro advanced processing and control software, help to meet the increasing demand for improved product quality, process efficiency, energy saving, predictive maintenance and emissions reduction.

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*See their Application Note: "TEMPERATURE MEASUREMENTS FOR INDUCTION HEATING AND HEAT TREATMENT PROCESSES ." 

 

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Slag detection.

The slag detection system (SDS) from AMETEK Land, has been enhanced,leading to improved yields, higher-quality end products and reduced costly downstream processing.

Prasath Venkatasamy - Global Industry Manager – Metals, from AMETEK Land, said: “The cost of additional downstream processing time and materials can be a significant burden on an operating plant. By controlling slag carry-over with the aid of the latest version of our SDS, this costly downstream processing can be reduced or eliminated, improving plant throughput, product quality and operating margins.”
 

The SDS V2 is ideal for use in a variety of applications across the steel-making process, including secondary steel-making vessels such as electric arc furnaces (EAF) and basic oxygen furnaces (BOF), argon oxygen decarburization (AOD) as well as specialty metals processes like stainless steel, copper, and platinum smelting.

The SDS uses an industrial high-resolution, medium-wavelength smart thermal imaging camera to detect the transition between steel and slag. This dedicated camera has been specifically designed to work in harsh operating conditions where smoke and fumes obscure vision, through utilising a particular wavelength path.

Real-time camera data allows operators to make informed decisions about the tapping process, with clear alarm notifications to stop the tap before slag is carried over.

The SDS has been shown to improve operator response time and consistency at the end of each tap. This typically results in a reduction in slag depths of up to 25% compared to traditional methods of stream monitoring.

Designed for automatic operation, the system helps to ensure accurate, real-time detection of steel and slag independent of charge weight and without operator intervention.

The SDS also assists the de-carbonisation process in steel production by supporting continuous process control and optimisation, energy savings and carbon emission reduction.

Slag detection is a critical process during the early stages of production, as slag can negatively affect steel quality and increase costs. Detecting and analysing the composition and amount of slag in the steel melt helps manufacturers take timely corrective actions to ensure the production of high-quality steel with minimal waste, contributing to more sustainable and efficient manufacturing processes.

The SDS is supported by AMETEK Land’s powerful IMAGEPro thermal imaging process monitoring and control software. This includes the IMAGEPro SDS application, which allows users with the optional multi-camera licence to seamlessly integrate additional imagers into the system, enabling them to operate independently from the camera and continuous slag detection system.

By using additional analysing features, such as regions of interest (ROI), together with a secondary thermal imaging camera integrated into the system, optional features such as stream position or freeboard height can provide advanced process monitoring and control.

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Thermal imaging in harsh conditions.

An industry-leading protection design for thermal imaging cameras without the compromise of a wire grid has been revealed by AMETEK Land. This new, proven, protective housing has been developed for thermal cameras in challenging installation conditions and offers many distinct benefits around optical clarity, temperature accuracy, improved efficiency and lower maintenance.

James Cross, AMETEK Land’s Global Industry Manager for Hydrocarbon Processing Industries, said: “By using the gridless concept on several installations, the AMETEK Land LWIR in EXSH housing has provided LAND’s famed crystal-clear images with highly accurate, sensitive, repeatable temperature data. End-users increasingly demand higher accuracy temperature values to achieve better yields, improved efficiency, and longer maintenance intervals, and we expect the demand for gridless housing designs to increase with it.”

Thermal imaging camera housings must meet impact test requirements, so a wire grid or mesh is typically installed in front of a germanium window, which acts as a protective layer to absorb and disperse impact energy.

Germanium windows are completely impermeable to ultraviolet and visible light, giving them a dark, metallic appearance to the naked eye. When it comes to the infrared range, it has an excellent, broad transmission range from 2-16 μm, making it an ideal candidate for mid-wave-infrared (MWIR) and long-wave-infrared (LWIR) applications.

LAND’s protective housing uses a germanium window, but without an additional wire grid, that still satisfies the Ex d impact test requirement. It also reduces exposure to high temperatures and corrosive, outdoor environments, and also ensures the thermal imaging camera is not a potential source of ignition.

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Pyrometer saves costs in iron foundry.

One of the leading foundries in Germany, Hundhausen Casting GmbH – a member of the Beinbauer group – specialises in the production of cast iron parts with nodular graphite. Its high-quality products and first-class service are designed to meet the demands of renowned customers from the automotive, mechanical engineering, railway technology, and hydraulics sectors.

The company was looking for a reliable temperature measurement solution to be installed at its Schwerte foundry to support high product quality while reducing lifetime costs. The automated mould tapping processes used at the foundry require accurate, consistent measurement of the temperature of each part tapped in moulds to ensure continuous quality control of the process and documentation for each casting part produced (reformatted).

Dipping thermocouples traditionally used for these measurements contributed significantly to ongoing operational costs, and do not take into account temperature variations during tapping, or time differences between the thermocouple measurements and the tapping. The thermocouple readings were accepted for several taps over longer time periods, not detecting any temperature differences during this time interval.

Additionally, the company was seeking a way to capture the continuous data that would allow it to optimise the automated process and further improve quality.

To address the needs of the Schwerte foundry, AMETEK Land supplied the SPOT+ MM Application Pyrometer, a smart, non-contact infrared thermometer specifically designed to measure liquid metal temperature in foundry tapping applications.*

With an intelligent integrated Meltmaster (MM) application mode and optimized signal processing functions, it provides a single-sensor solution for liquid metal and tapping stream temperature measurements, overcoming the challenges caused by the continuous surface and condition changes common to those applications.

The SPOT+ MM is easily integrated into new and existing process control systems, enabling the operator to monitor and control the tapping process in real time. Analog and digital communications can be used, including worldwide leading and essential cybersecurity features. By using the SPOT+ MM application pyrometer at their Schwerte foundry, Hundhausen saw a rapid return on investment.

Jonas Störmer, Electrical Engineer at Hundhausen Casting GmbH, said: “By purchasing the SPOT+ MM pyrometer, the liquid iron temperature measurements using dipping thermocouples can be mostly omitted, which results in cost savings.

“In addition, we now receive continuous casting temperatures in our casting process, building the basis for process optimisation and quality improvements.”

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* The Case study (pdf) maybe viewed and downloaded here!

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Aluminium temperature.

AMETEK Land has designed its integrated thermometer systems specifically for the temperature measurement of aluminum.

The new SPOT+ AL is an advanced infrared digital pyrometer, providing an all-in-one temperature measurement for aluminum. Covering a wide range of different temperature measurements, the SPOT+ AL pyrometer is a single product that can be used in every part of the aluminum production process including extrusion, quench, strip, forging and liquid aluminum applications.

Now available with Ethernet IP connectivity, the SPOT+ AL will enable plant operators to reduce costs, enhance integration and lower training requirements as separate instruments are not required across the plant.

Larry Smith, Director of Sales - Americas, said: “We provide established and time-proven systems that are used in aluminum plants worldwide. These products meet the highest standards of quality and reliability, to ensure accurate performance under plant operating conditions.”

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Advanced industrial temperature measurements.

The SPOT pyrometer range from Ametek Land, has been relaunched with enhanced features and benefits for a wide range of industrial applications.

The new SPOT+ family offers a wide range of temperature measurements from 50 to 3500 °C (122 to 6332 °F) and a choice of different wavelengths for applications including metals, glass, cement and lime kilns and foundries. The range includes monochromatic and ratio pyrometers, fibre optic heads and sophisticated algorithm pyrometers for complex materials such as aluminium and galvanized steel.

Dr Fiona Turner

Dr Fiona Turner, Head of Product Management said: “The principles of infra-red temperature measurement don’t change, but over the last 10 years, there have been significant advances in automation and industrial ethernet. Customer focus on product quality and process efficiency has driven an interest in big data – and a risk of cyberattacks.

“I’m excited about the potential from using SPOT+ instruments for background temperature and emissivity correction of thermal imaging systems in IMAGEPro software. SPOT+ pyrometers provide more than just temperature measurements – emissivity outputs are key indicators of product surface quality, and the facility to log visible light process images alongside infra-red temperature measurement provides new insights into process conditions and product quality.”

A wide range of new communications interfaces makes the SPOT+ ideal for Industrial Internet of Things (IIoT) factory automation applications in addition to traditional 4-20 mA signals. Ethernet/IP, REST API and Modbus TCP/IP are standard on SPOT+, and an integrated web server provides easy access for control and setup using a standard browser. Upgraded cybersecurity functions reduce the likelihood of unauthorized access to the instrument functions.

An integrated video camera provides a visible light process view alongside infrared temperature measurement, which allows sighting to be carried out safely and easily. As the video images are available via the webserver and AMETEK Land’s IMAGEPro software, alignment can be checked remotely and images logged for quality purposes.

The SPOT+ can be used in the harshest of environmental conditions, and in hazardous area zones 1, 2, 21 and 22 when mounted in LAND’s high-specification EXSH enclosure. With response times down to 1ms, SPOT+ pyrometers are also suitable for fast-moving processes.

AMETEK Land’s SPOT pyrometers are built on extensive research and development and have always been at the leading edge of measurement technology. The new SPOT+ enhancements offer improved connectivity for easy integration with control systems, and the confidence that data transmission is secure. Upgraded electronic and electromechanical components ensure highly reliable and accurate operations, all backed by our 36-month warranty and supported by a range of extensive accessories for installations in the most demanding applications.

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Supporting growth in energy & minerals sector.

AMETEK Land has appointed Madeleine Lake as Global Industry Manager - Energy and Minerals, to support the company’s growth strategy in this important industry.

Madeleine Lake

In this new role for AMETEK Land, Madeleine will be primarily responsible for driving growth in the energy and minerals market, with a particular focus on the clean energy transition.

Working closely with the global sales team, Madeleine will develop strategies and value propositions for AMETEK Land’s industry product solutions and their benefits. This will be in line with customer requirements which include meeting clean energy targets, and product quality and efficiency.

Commenting on the role, Madeleine said, “I’m excited to be taking on this new role, which demonstrates LAND’s commitment to driving innovative solutions for this important industry, particularly around clean energy, which is a serious issue that affects us all.”

With previous experience in various commercial and product management roles, including working for GEOSLAM Ltd, Madeleine is well-placed to drive new solutions in the energy and minerals market. This is backed by her experience as an exploration geologist in Australia, a BSc in Exploration and Resource Geology, and an MSc in Petroleum Geoscience.

David Primhak, DVP Business Manager added: “Our commitment to clean energy has led us to bring Madeleine on board in this new role. Her broad experience in geology and extensive qualifications will be a great addition to LAND and will complement our highly experienced team.”

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Mid-wavelength thermal imager.

AMETEK Land is helping meet the demand for improved product quality and efficiency in industrial processes with the launch of its new mid-wavelength thermal imager, the MWIR-640 390. With energy savings, predictive maintenance, and emissions reduction high on the industrial processing agenda, thermal imaging cameras and systems play an important role by providing reliable, robust, and real-time thermal imaging measurements and imagery.

Manfred Hayk, Global Infrared Product Manager said: “The new MWIR-640 390 thermal imager is part of LAND’s smart thermal imaging solutions for a range of industrial applications including automation, process control, slag detection, secondary steel-making vessels, and melting operations.

“With decades of experience, our thermal imaging and temperature measurement solutions and software deliver the measurements and data that operators need to meet the demands of high product quality, energy savings, reduced and predictive maintenance and emissions reduction.”

Designed for use in harsh industrial and environmental conditions, the new MWIR-640 390 provides clear images through smoke or particulates in high-temperature processes through its advanced spectral filtering, which shows every surface structure detail in heat treatment applications.

With a pixel resolution of 640 x 480 and high thermal resolution, uniquely clear and detailed thermal images and videos are created at up to a 60 Hz frame rate. This unmatched image quality supports highly accurate process visualisation and control.

A wide range of applications from melting to final processing are covered through two temperature measurement ranges – 500 °C to 1800 °C (932 to 3271 °F) and 300 °C to 1200 °C (572 to 2192 °F). This is supported by three lens options offering a choice of optical field of view, complete with motorised focus.

In addition, an integrated web server with multiple I/O options enables the camera to be used autonomously, or integrated easily into new or existing process control systems. Using a standard browser, the web server provides easy camera access, configuration, and remote control. The MWIR-640 390 utilises smart Industry 4.0 capabilities, bi-directional digital interfaces and an on-board I/O for real-time thermal imaging.

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