Smart Smelt Flow Measurement uses video analysis of smelt spout CCTV cameras to measure smelt flow velocity, volumetric flow rate, and spout fouling index in recovery boilers. Measurement values are shared via OPC UA and the fouling index can be used to trigger or control smelt spout cleaning robots.
The Challenge
Smelt spout performance is critical to recovery boiler safety and operational continuity. Fouled or partially blocked smelt spouts reduce smelt flow capacity, increase the risk of smelt-water contact, and complicate smelt dissolving operations. Monitoring smelt flow rates and spout fouling traditionally requires manual observation near high-temperature, high-hazard areas, limiting the frequency and objectivity of assessments.
The ANDRITZ Solution
Smart Smelt Flow Measurement is a video-based measurement system that continuously analyzes CCTV camera feeds from recovery boiler smelt spouts. It determines smelt flow velocity, volumetric flow rate, and a quantitative fouling index for each spout — providing objective, real-time data on smelt spout performance without requiring operators to approach the high-temperature smelt zone.
How It Works
CCTV cameras — at least one per smelt spout — capture video of the smelt flow. The system analyzes these feeds to calculate flow velocity and volumetric flow rate, and to detect fouling of smelt spouts and furnace smelt flashes. The resulting fouling index is a quantitative measure of spout condition that can be used to schedule or directly trigger a smelt spout cleaning robot. All measurement values are transmitted to the plant DCS via OPC UA for display and integration into process control.
Key Benefits
- Continuous, objective monitoring of smelt spout flow and fouling without operator proximity to hazardous areas
- Fouling index enables condition-based cleaning, replacing manual inspection schedules
- Cleaning robot integration automates response to spout fouling events
- OPC UA output ensures compatibility with standard DCS architectures
- Smelt flash detection provides additional furnace safety monitoring data
Integration & Compatibility
The system requires at least one CCTV camera per smelt spout and delivers measurement values via OPC UA to the plant DCS or process control system. Cleaning robot integration is supported through the fouling index output. Confirm camera specification requirements and robot interface protocols with ANDRITZ for a specific installation.
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