AI-Powered Blast Furnace Intelligence
Real-time tuyere camera AI, process data fusion, and predictive models — from raw signal to actionable alert.
monitoring
accuracy
process phenomena detection
processing
Operators Can't See What's Happening Inside
Tuyere conditions change in seconds. Traditional approaches leave operators blind until it's too late.
Critical furnace decisions rely on operator intuition and shift-to-shift knowledge transfer, not data.
Manual tuyere inspection forces operators into the hot zone — molten metal, radiant heat, dust, gas. Continuous monitoring with automated anomaly detection avoids dangerous situations and keeps humans out of harm's way.
Manual tuyere inspection every 2 hours leaves large blind spots. Anomalies develop and escalate undetected.
The raw view, then what the AI extracts from it.
Left: the raw camera feed with no processing — dust, flames, coal injection. Right: the same feed augmented by Industream AI — segmentation, regions of interest, ISA-18.2 alarms.
Everything You Need for Furnace Intelligence
Tuyere Camera AI
24/7 automated monitoring of all tuyeres. AI detects anomalies, burn-backs, raceway irregularities, and evaluates coke size.
Process Data Correlation
Fuse camera insights with 1000+ process tags — hot blast pressure, flow rates, burden distribution — for root cause analysis.
Raceway Condition Prediction
Hybrid AI models predict raceway depth and symmetry up to 30 minutes ahead, giving operators time to act.
Safety Monitoring
Avoid dangerous situations by continuous monitoring and automated anomaly detection.
Built for the hot zone.
A self-contained industrial enclosure: passive cooling, quick alignment, dust- and water-proof local screen, energy harvesting. No maintenance in the hot zone.
Passive cooling
No-fan thermal design. Zero maintenance, no filters to change.
Easy alignment
Quick-fit mount with integrated aiming. Operational in 5 minutes.
Quick coupling
Single connector — power + data. Tool-less hot-swap.
Dust & water-proof local screen
Built-in IP65 touch screen. Live tuyere feed + alarms, even in aggressive atmospheres.
Energy harvesting
Self-powered from furnace heat. No more cable runs.
Motorised alignment
Remote pan/tilt adjustment. Re-calibrate without physical access to the tuyere.
Ambient noise analyser · NEW
Built-in industrial mic + acoustic AI: live sound signature per tuyere, early detection of knocks, leaks, abnormal fluidisation.
50-bar isolation glass. Any tuyere door.
Quick connection with isolation glass (50 bars), compatible with any type of tuyere-door ball valve. Blue-glass adapter available to blind off the line when the camera is removed — zero furnace pressure loss, zero operator exposure.
Isolation glass certified for actual running-BF pressures.
Fits every ball-valve tuyere door — no furnace retrofit required.
Blinds the line without de-pressurising the furnace when the camera is pulled.
Camera swapped in under 2 minutes, furnace running, operator at safe distance.
Tuyere thermal imaging + side-mounted mini IR cameras.
The thermal camera fuses with the visible feed to extract 4 key phenomena: ignition, nose puncture, tuyere burning, skulls. The side-mounted Industream mini IR cameras complete the view — rugged stainless-steel enclosure.
Industrial powder-coated casing, 50-bar isolation quick coupling, waterproof M12 connector, quick-release clamps. Side-mounted mini IR camera indexable left/right depending on BF geometry.
Combination with a wide infrared camera.
A wide infrared camera (Wide IR) can be combined with the tuyere setup to deliver a broader field of view than the side-mounted mini cameras: thermal panorama of the whole tuyere zone, hot-spot mapping, detection of slag/hot-metal leaks outside the standard field. Live data fusion with the tuyere cameras inside the Tuyere Monitoring System.
Ready to See Your Furnace Like Never Before?
Book a demo and see how InduStream transforms blast furnace operations in weeks.