Typical recoverable heat losses from furnace walls, ladle insulation, and refractory-lined equipment in metals facilities.
Full refractory condition mapping using infrared thermography to detect thin spots, hot zones, and erosion patterns.
Average payback period for refractory repairs and insulation upgrades on high-temperature steelworks equipment.
Steel & Metals
Heat Loss Audit
Steel and metals facilities operate furnaces, ladles, and refractory-lined equipment at extreme temperatures — all critical sources of thermal loss. Our specialised heat loss audits for the metals sector use advanced infrared and drone-based thermography to identify insulation failures, refractory degradation, and thermal inefficiencies, delivering a clear roadmap to cut costs and reduce emissions.
The Heat Loss Challenges
Facing Steel & Metals
From furnace walls to ladle insulation and refractory linings, every high-temperature asset holds untapped savings potential.
Furnace Wall Heat Loss
Arc furnaces, reheat furnaces, and annealing furnaces lose significant energy through refractory wear, hot spots, and insulation degradation — reducing thermal efficiency and increasing fuel costs.
Ladle Insulation Failures
Steel ladles and tundishes suffer from refractory erosion, skull buildup, and insulation breakdown, leading to excessive heat loss during metal transport and holding.
Refractory Monitoring
Refractory linings deteriorate over time, creating thin spots and hot zones that waste energy, reduce equipment life, and pose safety risks if not detected early.
Emissions & Carbon Costs
Steel production is highly carbon-intensive. Every unit of wasted thermal energy translates directly into unnecessary fuel consumption, CO₂ emissions, and rising carbon costs.
Our 4-Stage
Methodology
A structured approach tailored to steel and metals environments, combining drone thermography with on-site assessment.
Comprehensive Heat Loss Audit
Thorough evaluation of your facility combining advanced infrared thermography, environmental data logging, and hands-on on-site inspections to pinpoint every source of thermal loss.
Our engineers deploy drone-based infrared thermography for elevated or hard-to-reach assets such as rooftops, flue stacks, and overhead pipework, while ground-level inspections use calibrated IR cameras to capture surface emissivity variations. The resulting thermal profile is cross-referenced with ambient temperature, wind speed, and process data to quantify real-world heat dissipation rates.
Detailed Reporting & Analysis
Comprehensive deliverables including annotated thermal images, calibrated heat maps, and quantitative data that clearly highlight priority areas of concern.
Each report includes high-resolution thermograms with temperature gradients, a ranked deficiency register prioritised by energy impact, and projected annual savings in both kWh and cost. Where applicable, we benchmark your facility against industry norms so you can measure performance relative to best practice.
Insulation & Mitigation Solutions
Tailored engineering recommendations covering insulation thickness calculations, material selection, and installation techniques suited to your operating environment.
We specify insulation systems based on operating temperature, pipe diameter, and ambient conditions, selecting from mineral wool, calcium silicate, cellular glass, and flexible elastomeric foams. Every recommendation addresses condensation prevention, safe-to-touch surface temperatures, and corrosion under insulation (CUI) risk, supported by a full cost-benefit analysis that includes projected CO₂ reduction and payback period.
Partnership with AAI Drones
Strategic partnership with AAI Drones delivering drone-based infrared thermography that safely surveys hard-to-reach, elevated, or hazardous areas without scaffolding or shutdowns.
Drone surveys eliminate the need for costly access equipment and reduce on-site safety risk, while covering large roof areas, storage tanks, and elevated pipework in a fraction of the time of conventional methods. High-resolution radiometric sensors capture pixel-level temperature data, enabling our engineers to detect insulation voids, moisture ingress, and thermal bridging with pinpoint accuracy.
What You
Receive
Actionable intelligence, not just a report — everything you need to make investment decisions.
Thermal Survey Report
Comprehensive infrared thermographic survey of all furnaces, ladles, kilns, and refractory-lined equipment with annotated thermal images.
Heat Loss Quantification
Precise calculation of heat loss rates across all surveyed assets with comparison to design specifications and industry benchmarks.
Refractory Condition Assessment
Detailed mapping of refractory lining condition, identifying thin spots, hot zones, and areas requiring relining or repair.
Furnace Efficiency Analysis
Assessment of furnace insulation, door seals, flue gas losses, and combustion efficiency with specific improvement recommendations.
Carbon Reduction Roadmap
Phased plan showing CO₂ reduction trajectory from thermal improvements aligned with industry decarbonisation targets.
ROI & Investment Case
Board-ready financial analysis with NPV, IRR, and payback calculations for each recommended improvement measure.
Proven Results
in Steel & Metals
Based on completed heat loss audits across steel mills, foundries, and metals processing facilities.
Steel & Metals
Audit Questions
Common questions from steel and metals manufacturers about our heat loss audit service.
Ready to Reduce
Heat Loss?
Our steel & metals sector specialists are ready to identify thermal savings across your facility.
- Advanced infrared & drone-based thermography
- Steel & Metals-specific thermal benchmarking
- Detailed insulation & CO₂ impact report