Digitalized State-of-the-Art Short-Circuit Detection (ESCD) for Increased Tankhouse Efficiency

In copper refining tankhouses, short circuits can decrease current efficiency by up to 10%, creating operational inefficiencies that require timely and accurate intervention. Traditional methods, such as manual inspections and static thermal imaging, often fall short in addressing these challenges due to limited coverage and high personnel demands. This study presents an innovative short-circuit detection solution using thermal cameras equipped with rotational heads that monitor the cell surfaces from oblique angles, providing comprehensive, real-time coverage of the entire tankhouse. By implementing cameras with rotational capabilities, this system significantly reduces the number of cameras needed, compared to crane-mounted or drone-based monitoring solutions, while achieving superior area coverage. The cameras’ oblique perspective captures extensive sections of the tankhouse, allowing for a detailed temperature profile of anodes and cathodes across the hall. A key technical challenge was converting these angled captures into top-down thermal images that could be accurately mapped to cell locations. Additionally, individual camera feeds are integrated into a unified thermal map, providing operators with a complete overview in real time. This approach offers substantial advantages, including immediate short-circuit detection, optimized current efficiency, and enhanced stability in electrolyte quality. The automated detection system continuously updates and transmits data to a central server, facilitating rapid analysis and targeted interventions without interrupting operations. By reducing the number of required cameras and minimizing manual oversight, this technology supports more efficient resource allocation and improved tankhouse stability. Overall, the integration of rotational thermal imaging represents a cost-effective, high-precision alternative for monitoring large refining facilities, enabling sustainable improvements in energy consumption and refining efficiency through real-time, hall-wide short-circuit detection.