Inspection and cleaning of high-rise chimneys in paint shops
High-rise chimneys carry fumes of burnt gases, paint fumes, and volatile organic compounds (VOCs). They require regular internal and external health assessments to prevent fire risks from exhaust particle deposits. We seek cost-effective, innovative solutions for real-time monitoring and cleaning of chimneys to enhance safety and operational efficiency.
attractive
Reward money is paid in exchange of legally acquiring the solution, implementing it to solve the problem and meeting the success criteria. Milestones for paying the reward money would depend upon the complexity of challenge and maturity of the proposed solution, which would be discussed with the solver as soon as the proposed solution is selected by us.
30 Jun 2025
Challenge details:
The exhausts from painting and baking processes are carried outside through high-rise chimneys, which contain fumes of burnt gases, paint fumes, and volatile organic compounds (VOCs). Additionally, exhaust particles deposit on the inner walls of the chimneys, forming a flammable layer that poses a fire risk and requires periodic cleaning. These high-rise chimneys are made of mild steel, ranging from 25 to 40 meters tall with a base diameter of 1 to 2 meters and a top diameter of 0.5 to 0.75 meters. Accessing these chimneys for inspection and internal cleaning (in case of deposition) is difficult and at times not possible.
Current methods, such as visual inspection have limitations due to inadequate camera resolution, narrow chimney diameters (limiting use of drones), and the risk of damage from exhaust fumes. Physical climbing for inspection involves high safety risks and does not allow for internal assessment. Deploying sensors that can withstand heat and gas exposure is essential, but the challenge remains in reaching the points inside the chimney to install these sensors due to height, confined space, and access issues.
We seek innovative solutions for measuring internal (material deposition and thickness) and external health (outer casing condition, rust, ladder condition, bolts condition, top canopy condition) of chimney surfaces enabling timely decision-making. Additionally, cleaning the inside of ducts as well as gas composition analysis is desirable.
Condition Monitoring for Kiln Support Rollers and Gearboxes
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Rotary kilns rely on gearboxes and support rollers for efficient rotation, but high temperatures and low RPM hinder effective condition monitoring. Current ultrasonic methods are inadequate due to the harsh environment, leading to increased bearing failures and production stoppages. A robust monitoring system is needed to withstand these conditions, providing accurate data for proactive maintenance and preventing downtime. Addressing this challenge is essential for maintaining kiln efficiency and reliability in the production process.
Long-Term Corrosion Protection Solutions for Coastal Industrial Structures
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are seeking for innovative, cost-effective, and sustainable solutions to protect from corrosion and extend the service life of both RCC and MS structures. The proposed solutions should aim to provide a minimum of 10 -15 years of protection under these challenging conditions.
Alternatives to Slag Blasting for Painting in Operational Plants
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are actively seeking for solutions that can eliminate the need for slag blasting altogether, especially in sensitive zones, while still achieving effective surface cleaning.
Optimizing scrap blending for reduced power consumption in Electric Arc Furnace
Rewards proportional to the value add! Few solutions could be available! Efforts might be needed to customize the solution.
Steel scrap is blended for desired density and composition before charging into an Electric Arc Furnace (EAF). Fluctuations in scrap density can cause inefficiencies and increased power consumption. An automated inspection system is needed for real-time scrap density detection
Automating Clamping and Routing Inspections at the End-of-Line and Pre-Delivery Inspection
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
This challenge focuses on detecting clamping and routing issues in chassis assembly during the End-of-Line (EOL) and Pre-Delivery Inspection (PDI) stages. The complexity of overlapping routing paths and reliance on manual inspection make it prone to errors, impacting vehicle safety and reliability.
A system for enabling multi-parts dispensing efficient for operators
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
The challenge addresses inefficiencies in dispensing multiple small components (e.g., clamps, nuts, bolts) for assembly, which often leads to incorrect counts and disrupts production. A scalable, cost-effective solution is sought to ensure accurate dispensing and enhance operational efficiency.
Real-time condition monitoring of equipment with continuously varying speed
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
This challenge involves real-time condition monitoring of critical components in Roller Brake Test (RBT) machines, which operate under variable speeds and dynamic conditions. The goal is to develop solutions for timely fault detection to prevent breakdowns and ensure reliability.
Reducing ageing time for high carbon wire rod
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are looking for a solution to enhance the ductility of high carbon wire rods within a span of 3 days as opposed to the current span of 10 to 21 days.
Condition Monitoring for Kiln Support Rollers and Gearboxes
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
Rotary kilns rely on gearboxes and support rollers for efficient rotation, but high temperatures and low RPM hinder effective condition monitoring. Current ultrasonic methods are inadequate due to the harsh environment, leading to increased bearing failures and production stoppages. A robust monitoring system is needed to withstand these conditions, providing accurate data for proactive maintenance and preventing downtime. Addressing this challenge is essential for maintaining kiln efficiency and reliability in the production process.
Long-Term Corrosion Protection Solutions for Coastal Industrial Structures
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are seeking for innovative, cost-effective, and sustainable solutions to protect from corrosion and extend the service life of both RCC and MS structures. The proposed solutions should aim to provide a minimum of 10 -15 years of protection under these challenging conditions.
Alternatives to Slag Blasting for Painting in Operational Plants
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are actively seeking for solutions that can eliminate the need for slag blasting altogether, especially in sensitive zones, while still achieving effective surface cleaning.
Optimizing scrap blending for reduced power consumption in Electric Arc Furnace
Rewards proportional to the value add! Few solutions could be available! Efforts might be needed to customize the solution.
Steel scrap is blended for desired density and composition before charging into an Electric Arc Furnace (EAF). Fluctuations in scrap density can cause inefficiencies and increased power consumption. An automated inspection system is needed for real-time scrap density detection
Automating Clamping and Routing Inspections at the End-of-Line and Pre-Delivery Inspection
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
This challenge focuses on detecting clamping and routing issues in chassis assembly during the End-of-Line (EOL) and Pre-Delivery Inspection (PDI) stages. The complexity of overlapping routing paths and reliance on manual inspection make it prone to errors, impacting vehicle safety and reliability.
A system for enabling multi-parts dispensing efficient for operators
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
The challenge addresses inefficiencies in dispensing multiple small components (e.g., clamps, nuts, bolts) for assembly, which often leads to incorrect counts and disrupts production. A scalable, cost-effective solution is sought to ensure accurate dispensing and enhance operational efficiency.
Real-time condition monitoring of equipment with continuously varying speed
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
This challenge involves real-time condition monitoring of critical components in Roller Brake Test (RBT) machines, which operate under variable speeds and dynamic conditions. The goal is to develop solutions for timely fault detection to prevent breakdowns and ensure reliability.
Reducing ageing time for high carbon wire rod
Rewards proportional to your differentiated solution! More than one solution is expected to exist. Solution may be implemented without customization.
We are looking for a solution to enhance the ductility of high carbon wire rods within a span of 3 days as opposed to the current span of 10 to 21 days.
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