Korea Zinc has decided to deploy robots at the Onsan Refinery to enhance safety and management efficiency.

Korea Zinc announced on the 5th that it has deployed Boston Dynamics' four-legged robot ‘Spot’ at the Onsan Refinery site. This marks the first time in the industry that robots have been introduced on-site to realize a safe and efficient smart refinery.

Spot navigates areas that are dangerous or difficult for humans to access, using various sensors to collect and share information in real-time. It is currently utilized by leading companies and institutions worldwide, including NASA, BMW, Michelin, Cargill, GlobalFoundries, Simmering Power Plant, and Brown University. Domestically, GS Construction and POSCO are operating Spot at their work sites.

Korea Zinc has assigned Spot the role of site management. It patrols 466 inspection points and hard-to-reach blind spots within the Onsan Refinery using various sensors, including ultrasonic sensors, infrared cameras, hazardous gas detectors, and acoustic sensors. Its main tasks include measuring equipment temperature, detecting gas leaks and spills, preventing collisions in areas with frequent vehicle movement, and sharing real-time site information and alerts.

A Korea Zinc representative stated, “After comparing robots from various companies, we decided to adopt Boston Dynamics' Spot as it possesses all the necessary functions for managing the Onsan Refinery, such as temperature, noise, and vibration measurement.” They added, “Spot is currently learning routes in the refining process and moving autonomously, and we plan to deploy it in other plants in the future.” Spot can operate continuously, allowing for the management and supervision of high-risk areas even during vulnerable times such as nights, weekends, and holidays. Korea Zinc expects that the completion of an autonomous inspection system will significantly improve site safety and management efficiency. The information gathered from inspecting various parts of the refinery is anticipated to contribute to the improvement and optimization of maintenance systems.

Korea Zinc plans to expand Spot's primary tasks to include detecting and inspecting risks such as gas poisoning and suffocation after test operations. Considering the frequent process changes characteristic of refineries, they are also considering equipping Spot with a 360-degree rotating camera to visually track and manage changes in equipment structure or piping environments. They are also working on integrating a real-time data-linked control system by additionally equipping thermal imaging cameras and gas quantitative measurement sensors. Ultimately, they aim to establish an AI technology-based integrated inspection system utilizing robots, drones, and autonomous vehicles.

A Korea Zinc representative stated, “With the introduction of Spot, we expect to eliminate safety blind spots within the Onsan Refinery and enable proactive risk prevention.” They added, “We anticipate that the workload and fatigue of existing safety inspection personnel will decrease, and job satisfaction will improve.” The representative emphasized, “The introduction of Spot is the first step towards innovation in the field of on-site safety management, and we will continue to actively adopt the latest technologies and improve working conditions and environments to achieve a zero-accident, zero-injury site.”

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