Photonics sensing start-up Senergetics has taken the latest step on its mission to tackle energy spillage with the development of a new sensor system that can see corrosion under insulation (CUI).
By detecting corrosion of industrial piping – even if it’s buried under a thick layer of insulation – the technology can benefit chemical plant owners through cost savings, as well as the environment through the reduction of CO2 emissions.
Offering real-time, continuous monitoring
Recognising that current imaging solutions fall short of businesses’ needs, the deep-tech firm, only established in 2022, set out to offer an option where plant operators could ‘continuously’ monitor all their piping for CUI.
Senergetics claims its fibre-optic sensor system, which can be installed along the outside of pipe cladding, can detect CUI as well as leaks. It does this with a system that combines both hardware for monitoring, as well as a software subscription.
The hardware, developed in part by PhotonFirst, consists of optical fibres inscribed with microstructures called fibre Bragg gratings, which partially reflect light travelling through the fibre. When the fibre is subjected to a temperature change, the wavelength of the reflected light changes proportionally. By measuring this shift, temperature change can be quantified.
Senergetics CTO and co-founder, Anitha, commented: “We deploy hundreds or thousands of sensors to continuously gather data. By applying machine learning and AI to analyse this data, we can effectively detect corrosive environments.”
Anitha added: “Since our technology is based on tiny pulses of light, there aren’t any safety risks to speak of. We are compliant with the European ATEX directives for potentially explosive environments, for example.”
The firm has tested the technology’s performance at several trials at three different plants in the Netherlands and Germany, as well as a follow-up test at Unilever’s Ben & Jerry’s ice cream factory.
“In the first test, we managed to point out perfectly where CUI was happening, demonstrating the value of our technology in terms of maintenance and safety operations,” Anitha explained.
Outperforming existing solutions to benefit businesses and the environment
According to a recent trial at a real-world plant, installation of the technology could potentially help businesses to save up to 60% on maintenance costs.
The beginning Dutch company also points to the fact its system exceeds existing options to view through glass wool and jacketing of pipes, which can often only offer a snapshot of the situation at a particular spot at a particular time. Senergetics states that these traditional options are also typically too expensive to be used anywhere else than suspect locations.
Beyond cost savings, the imaging system doubles as an energy loss monitor, quantifying thermal inefficiencies from poor insulation. Senergetics believes that it can eliminate at least 10% of this spillage.
With the worldwide annual heat loss caused by poor industrial insulation estimated to be equivalent to 520 megatons of CO2, such technology could pivotally help companies reduce their CO2 emissions. This has seen Senergetics earmarked as one of the top European climate technology start-ups to watch by investors.
Senergetics has also installed a new testing set up on the roof of one of the buildings of the High Tech Campus Eindhoven, consisting of high temperature insulated pipes filled with steam where non-intrusive photonics sensing technology will be installed. The firm says this will support even higher accuracy, enhanced safety, and energy efficiency for its clients.
Next up for the firm is to start offering the technology on a commercial basis, with the aim to launch both the hardware and software offering by the end-of-the-year.
