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Deep Learning Techniques for Enhanced Flame Monitoring in Cement Rotary Kilns Using Petcoke and Refuse-Derived Fuel (RDF)

Author

Listed:
  • Jorge Arroyo

    (CIRCE Technology Center, Parque Empresarial Dinamiza Avenida Ranillas, 3D 1st Floor, 50018 Zaragoza, Spain)

  • Christian Pillajo

    (CIRCE Technology Center, Parque Empresarial Dinamiza Avenida Ranillas, 3D 1st Floor, 50018 Zaragoza, Spain)

  • Jorge Barrio

    (CIRCE Technology Center, Parque Empresarial Dinamiza Avenida Ranillas, 3D 1st Floor, 50018 Zaragoza, Spain)

  • Pedro Compais

    (CIRCE Technology Center, Parque Empresarial Dinamiza Avenida Ranillas, 3D 1st Floor, 50018 Zaragoza, Spain)

  • Valter Domingos Tavares

    (SECIL S.A., Estrada do Outão, 2901-182 Setúbal, Portugal)

Abstract

The use of refuse-derived fuel (RDF) in cement kilns offers a multifaceted approach to sustainability, addressing environmental, economic, and social aspects. By converting waste into a valuable energy source, RDF reduces landfill use, conserves natural resources, lowers greenhouse gas emissions, and promotes a circular economy. This sustainable practice not only supports the cement industry in meeting regulatory requirements but also advances global efforts toward more sustainable waste management and energy production systems. This research promotes the integration of RDF as fuel in cement kilns to reduce the use of fossil fuels by improving the control of the combustion. Addressing the variable composition of RDF requires continuous monitoring to ensure operational stability and product quality, traditionally managed by operators through visual inspections. This study introduces a real-time, computer vision- and deep learning-based monitoring system to aid in decision-making, utilizing existing kiln imaging devices for a non-intrusive, cost-effective solution applicable across various facilities. The system generates two detailed datasets from the kiln environment, undergoing extensive preprocessing to enhance image quality. The YOLOv8 algorithm was chosen for its real-time accuracy, with the final model demonstrating strong performance and domain adaptation. In an industrial setting, the system identifies critical elements like flame and clinker with high precision, achieving 25 frames per second (FPS) and a mean average precision ( m A P 50 ) of 98.8%. The study also develops strategies to improve the adaptability of the model to changing operational conditions. This advancement marks a significant step towards more energy-efficient and quality-focused cement production practices. By leveraging technological innovations, this research contributes to the move of the industry towards sustainability and operational efficiency.

Suggested Citation

  • Jorge Arroyo & Christian Pillajo & Jorge Barrio & Pedro Compais & Valter Domingos Tavares, 2024. "Deep Learning Techniques for Enhanced Flame Monitoring in Cement Rotary Kilns Using Petcoke and Refuse-Derived Fuel (RDF)," Sustainability, MDPI, vol. 16(16), pages 1-25, August.
    • Handle: RePEc:gam:jsusta:v:16:y:2024:i:16:p:6862-:d:1453556
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    References listed on IDEAS

    as
    1. Essossinam Beguedou & Satyanarayana Narra & Ekua Afrakoma Armoo & Komi Agboka & Mani Kongnine Damgou, 2023. "Alternative Fuels Substitution in Cement Industries for Improved Energy Efficiency and Sustainability," Energies, MDPI, vol. 16(8), pages 1-29, April.
    2. Nikolaos Margaritis & Christos Evaggelou & Panagiotis Grammelis & Roberto Arévalo & Haris Yiannoulakis & Polykarpos Papageorgiou, 2023. "Application of Flexible Tools in Magnesia Sector: The Case of Grecian Magnesite," Sustainability, MDPI, vol. 15(16), pages 1-30, August.
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