Development of AI-based systems for real-time optimization of thermal industrial processes using infrared technology
ci-tec GmbH
KarlsruheNew on Amplifa
About ci-tec
ci-tec GmbH, headquartered in Karlsruhe, is an engineering and automation company that optimizes thermal industrial processes in a data-driven manner. Its core product is the inspect pro control system, which uses infrared image data (infrared microbolometers at a 10.6 µm wavelength) and additional sensor data to capture the thermal process state in real time, filters out interference from flames and dust, and automatically adjusts process parameters such as process air supply via a control module. The application areas include zinc recycling from steel mill dusts in Waelz kiln plants (inspect pro control Z), cement production with sintering zone temperature control and an AI-based free lime estimator (inspect pro control C), and hazardous waste incineration in rotary kiln and afterburning chamber plants with deep learning image analysis (inspect pro control H). In addition, the company offers AI engineering for real-time estimation of process quality from sensor data as well as research-based consulting services for decarbonization, for example for the use of hydrogen and renewable energy sources. ci-tec GmbH sees itself as a partner for research and industry and serves industrial companies worldwide, including Holcim Germany at the Beckum site.
- Site
- Karlsruhe
- Processes
- Infrared thermography and sensor-based analysis methods (infrared microbolometer 10.6 µm), AI Engineering, Infrared thermography, Optimization of thermal processes, Machine learning methods, Sensor-based analysis methods, Decarbonization consulting, On-site test measurements
- Materials
- Zinc, Steel mill dusts, Cement/clinker, Hazardous waste (alternative fuels), Zinc / steel mill dusts, Cement/clinker, alternative fuels, Hydrogen / renewable energy sources
- Founded
- 2000
- Employees
- 11-50
- Industries
- Cement production, Zinc recycling / steel industry, Hazardous waste recycling, Silicon production
- 01
On-site test measurement
- 02
Infrared measurement data acquisition
- 03
Image evaluation and machine learning methods
- 04
Real-time calculation of process key figures
- 05
Real-time temperature control
- 06
Commissioning and continuous optimization
Processes and Application Materials
Zinc / steel mill dusts
Recycling of zinc from steel mill dusts in Waelz kiln plants with real-time temperature control of the slag temperature.
Cement/clinker, alternative fuels
Stabilization of the sintering zone temperature under fluctuating combustion behavior of alternative fuels with an AI-based free lime estimator.
Hazardous waste (alternative fuels)
Stable combustion of changing hazardous waste fractions in the rotary kiln and afterburning chamber using deep learning image analysis.
Hydrogen / renewable energy sources
Research-based services for adapting thermal processes to hydrogen and renewable energy sources as part of decarbonization.
Locations
Karlsruhe
DEHeadquarters and Development
- inspect pro control Z/C/H (infrared microbolometer 10.6 µm with image evaluation software and control module)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Engineering | – | – | – | – | Zinc, steel mill dusts |
| Engineering | – | – | – | – | cement/clinker, alternative fuels |
| Engineering | – | – | – | – | hazardous waste |
| Engineering | – | – | – | – | – |
| Infrared thermography and sensor-based analysis methods (infrared microbolometer 10.6 µm)Testing | – | – | – | – | – |
| Engineering | – | – | – | – | Hydrogen |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| – | ci-tec inspect pro control (Z/C/H) | – | – | – | Karlsruhe |
| Rotary kiln / Waelz kiln plant (monitoring at the customer) | – | – | – | – | Holcim Germany, Beckum |
Additional services
Reference customers
History
- 2000
Founding of ci-tec GmbH in Karlsruhe
- 2023
Award as winner of ALLIANZ Industrie 4.0 Baden-Württemberg
- 2025
Re-award as winner of ALLIANZ Industrie 4.0 Baden-Württemberg (2025/2026)
- 2026
Official dual partner of DHBW Karlsruhe; commissioning of inspect pro control C at Holcim Germany in Beckum with partner CMV Systems GmbH & Co. KG