The SmartAsset Intelligence platform, which incorporates AI, the Industrial Internet of Things (IIoT) and smart sensors for operational optimisation, offers a modern solution to customers, says industrial and furnace solutions provider Dickinson Group of Companies (DGC) Africa.

Adopting the platform benefits furnace and kiln operations in a variety of ways in industries such as manufacturing, metal and mineral processing, petrochemicals, cement and glass, states DGC Africa group commercial director Justin Nothnagel.

“Digital innovation is creating a paradigm shift in furnace and kiln operations. With advanced data collection and analytics, plant operators can now move from reactive to proactive maintenance models. Machine learning algorithms detect anomalies early, preventing costly failures.”

The platform enables operators to use solutions such as asset health monitoring for performance tracking, customised AI models to analyse root causes, digital twins for modelling and simulation, predictive analytics and maintenance forecasts, as well as smart sensors for monitoring temperature, vibration and/or structural integrity, he adds.

“Smart technologies, such as embedded sensors and edge computing, collect and process data from critical furnace components in real time. Paired with AI models, they identify performance deviations and predict potential breakdowns.”

This predictive capability ensures timely maintenance, minimises downtime and allows for condition-based repairs, which results in optimised furnace operations, increased uptime and improved asset life, he adds.

Digitalisation innovations also ensure optimised energy use, thereby facilitating the realisation of sustainability goals, helping to improve product quality and cost reduction, owing to their ability to provide real-time monitoring and performance benchmarking.

AI and the IIoT helps operators avert safety and operational risks through continuous monitoring of the environment and workers. They can also help to predetermine issues and reduce CO2 and nitrogen oxide emissions, which often affect high-temperature industrial environments.

“By detecting issues before they escalate, AI and smart monitoring systems facilitate timely interventions, preventing excessive wear and unplanned shutdowns. Through real-time analytics and control, furnaces can be tuned to operate at maximum efficiency, minimising fuel consumption,” says Nothnagel.

Amid challenges such as “unsound” infrastructure, high costs and return-on-investment concerns – in addition to a widening skills and training gap – DGC Africa equips organisations with solutions that help to mitigate or eliminate potential, controllable risks.

Nothnagel notes that the company offers cloud-based, cost-effective deployment models, integration support for legacy systems, knowledge transfer with local expertise, and training programmes to upskill industrial workforces responsible for furnace and kiln operations.

He suggests that the increased adoption of AI and IIoT solutions will continue, as automation has proven benefits associated with reducing environmental impact and enhancing worker safety.