Korea Zinc Introduces Four-Legged Robot Spot, First Among Global Smelters

Spot deployed for inspection and blind spot patrols at Onsan Smelter
Aiming to establish an integrated inspection system based on AI and robotics

Korea Zinc announced on August 5 that it has introduced Boston Dynamics' four-legged robot "Spot" to enhance on-site safety and management efficiency at the Onsan Smelter. The Onsan Smelter is the first smelter in the world to adopt Spot. With the introduction of Spot, the world's largest Onsan Smelter is now closer than ever to achieving its goal of becoming a "smart smelter."

Spot is a state-of-the-art industrial robot that can access hazardous and hard-to-reach areas instead of humans, collecting real-time information using a variety of sensors. Spot is currently being used by leading institutions, universities, and companies worldwide, including NASA, Brown University, BMW, Michelin Tire, Cargill (the world's largest grain trading company), GlobalFoundries (a semiconductor manufacturer), and Simmering Power Plant (Austria's largest power plant).

Korea Zinc has assigned Spot to site management duties. Equipped with high-performance sensors such as ultrasonic sensors, infrared cameras, toxic gas detectors, and acoustic sensors, Spot patrols 466 inspection points and hard-to-access blind spots within the Onsan Smelter. Its tasks include: inspecting for hazards such as equipment temperature measurement and gas leaks or liquid leaks; preventing collisions in areas with frequent vehicle movement; and sharing real-time information and issuing alerts.

Because Spot can operate continuously, it is able to monitor and supervise high-risk areas even during vulnerable times such as nights, weekends, and holidays when equipment inspections are typically less frequent. With the introduction of Spot, an autonomous inspection system has been established, strengthening both on-site safety and management efficiency. In addition, the information Spot collects throughout the smelter will be used to improve maintenance systems.

Korea Zinc plans to evaluate the effectiveness of Spot and expand its role to include inspecting areas at risk of gas poisoning and suffocation by the end of this year. Considering the frequent process changes characteristic of smelters, the company is also considering equipping Spot with a 360-degree rotating camera to visually track and manage changes in equipment structure or piping environments. This is expected to improve the accuracy of equipment management.

Furthermore, Korea Zinc is working to integrate Spot with a real-time data-linked control system by adding a thermal imaging camera and gas quantification sensors. This will enable accurate prediction of equipment failures and rapid early warnings in case of anomalies, advancing the smelter toward its goal of becoming an artificial intelligence (AI)-based "smart smelter." In the long term, the company aims to establish an integrated inspection system based on AI and robotics, combining Spot with drones and autonomous vehicles.

This content was produced with the assistance of AI translation services.