Tuyere Camera AI at a Major European Steel Producer
28 AI cameras. 24/7 monitoring. Live edge processing. How InduStream transformed blast furnace operations from reactive to predictive.
Image Quality
See the Slag Rising in HD
Crisp imagery so detailed you can watch slag climb the tuyere in real time — the foundation that makes our AI detection so accurate.
AI in Action
Real-Time Region of Interest Detection
Watch the AI model analyze tuyere conditions live, highlighting anomalies and regions of interest as they appear.
The Challenge
Manual Inspection Every 2 Hours — Not Good Enough
The steel producer operated three blast furnaces with a combined 84 tuyeres. Inspection was manual, subjective, and limited to every 2 hours per shift.
Manual tuyere inspection every 2 hours left large blind spots
Subjective assessment varied between operators and shifts
Anomalies developed and escalated between inspection rounds
No correlation between visual observations and process data
Critical events discovered only after significant damage had occurred
The Solution
28 AI Cameras Monitoring All Tuyeres 24/7
InduStream deployed industrial Vision cameras at each tuyere position, connected to the AI Engine for real-time anomaly detection and the DataBridge for process data correlation.
What sets us apart
We Fixed the Main Flaws of Competitor Tuyere Cameras
Existing tuyere cameras suffer from well-known limitations. InduStream tackled them one by one.
Blurry, low-contrast images that miss subtle anomalies
Sharper, higher-contrast image quality — smaller defects detected earlier.
Image degradation in harsh environments
Reinforced protective housing — survives heat, dust, vibration, and steam without optical loss.
No on-board intelligence — depend on remote servers
Live AI runs directly on the edge computer — no network round-trip, no cloud dependency.
Closed protocols and vendor lock-in
Open standards: RTSP video streams, REST/MQTT for events. Plug into any system.
Single sensor — vision OR thermal
Combined tuyere camera + thermal add-on, fused in real time by the AI.
Manual recalibration after every campaign
Self-adapting models that retune as the furnace evolves.
Manual camera alignment after every reinstallation
Automatic camera alignment — no setup time after maintenance.
From Pilot to Full Deployment in 3 Months
Pilot — 4 Cameras
Installed 4 cameras on the first blast furnace. Trained initial AI models on baseline tuyere conditions.
Validation & Tuning
Validated detection accuracy with operators. Fine-tuned anomaly thresholds. Wired alert workflows.
Full Deployment — 28 Cameras
Rolled out to all three furnaces. Operators trained. Alert workflows configured and live.
Results
Measurable Impact Across All Three Furnaces
Within six months of full deployment, the steel producer reported a significant reduction in unplanned furnace stops and improved operator confidence in process decisions.
24/7
Automated monitoring
Live
Edge processing
95%
Anomaly accuracy
-40%
Unplanned stops
Technical Details
" InduStream's tuyere cameras transformed our blast furnace operations. Our operators now have a continuous, objective view of all tuyeres — something we couldn't imagine before. "
Head of Process Engineering
Major European Steel Producer
Ready to Transform Your Blast Furnace Operations?
Talk to our steel industry experts and see how InduStream can be deployed at your site.