Development of Conventional Controller Based on Image Processing for Monitoring and Controlling Burning Zone Temperature in a Cement Plant in Rotary Kiln Process Through IOT

In the cement factories, a rotary kiln is a pyro-processing device that is used to raise the temperature of the materials in a continuous process. Temperature monitoring is an essential process in the rotary kiln to yield high quality clinker and it has been implemented using various image processing techniques. In this paper we are measuring and controlling the temperature of rotational kiln in cement industry to get proper clinker ouput. Burning zone flame images are captured using CCD(Charge Coupled Device) camera and are processed using image processing with PID(Proportion Integration and Derivative) controller and which are programmed on raspberry pi card with the help of python language, also the captured images and attributes are transferred to authorized mobile/pc through Raspberry PI by selecting the IP address of mobile or PC. All the attributes received in the mobile in the form of web page the according to the object following data temperature controlled and object is ceaselessly followed to get the proper clinker output. Picture handling calculation with Open cv, as indicated by the calculation the edge estimation of the camera is settled. The frame value of the camera is set. Conversion from RGB color space to HSV color space is achieved and the reference color threshold value is determined. The range esteem estimated by the camera is contrasted and the reference esteem. In this study temp of rotational kiln is measured effectively using PID controller, this controller continuously control the temperature of revolving kiln by varying the i/p images of burning zone at finally fix one flame which is giving 1400degc.

BROADLEAVED TREE TRUNKS CHARRING DURING FOREST FIRES WITHIN THE UKRAINIAN ROZTOCHYA

Introduction. On the territory of Ukrainian Roztochya and Male Polissya (Zhovkva part of Roztochya included) fires often occur in natural ecosystems – forest fires, meadow vegetation burning, stubble, landfills, and peatlands. Such fires, in addition to the destruction of property, cause significant emissions of incomplete combustion products and smoke into the air. Charring of broadleaved species, along with conifers, needs more detailed research, as the territory of the Ukrainian Roztochya is dominated by hornbeam-oak-pine, mixed oak, and beech forests.Aim. The object of the paper is to investigate the degree of tree trunks charring of the main forest-forming species in the Ukrainian Roztochya during forest fires based on experimental data.Research methods. Freshly cut trees were exposed to heating for 10 minutes, at periods of 1 minute, 3, and 5 minutes, checking the degree of damage to the trunk (charring, mm). Repeatability of the experiment – three times. Basing on received data the charring of broadleaved tree trunks in the Ukrainian Roztocze was determined. The flame temperature was measured by a GM1150A non-contact pyrometer. The level of burnout was measured by a ruler made following GOST 17435-72. A stopwatch was used to record the time of burning. Results and discussion. The experiments were performed in the fresh air under close-to-natural conditions. The fire source was an artificial open flame. Freshly cut tree trunks were installed vertically, right in the burning zone. Cutting residues, fallen dry leaves, straw, dry grass was used as flammable material. It was found that the lowest degree of charring is inherent to oak, which has burned by 38 mm during 10 minutes (with log thickness of 124 mm). Species such as hornbeam and maple completely burned out in 10 minutes (in diameters of 129 mm and 140 mm).Conclusions. Investigations of temperature effects on the main forest-forming species of the region have shown that they all differ in charring during forest fires. Three species grown in Ukrainian Roztochya were selected – hornbeam (Carpinus betulus), oak (Quercus robur), and maple (Acer platanoides). To prevent fires in forests, fire lanes should be planned with oak plantations on the edge of the forest.

Phase Transformations in Fly Ash-Based Solids

The presented article describes the phase transformations in solid bodies based on fluid fly ash (FFA) over eight years from the initial to the final phases. FFA has been selected as a type of industrial waste whose amount has been growing in recent years. This type of ash has self-hardening properties when watered because of the conditions of its origin. The specific temperature of fluid burning and the addition of calcium carbonate into the burning zone create a mixture of phases which are, even when solidified, ready to form new crystal phases, especially alumina-silicates, relicts of coal clay minerals. For experiments, bricks from the mixture of FFA and quartz sand were industrially produced and left outside. Subsequent mineralogical analyses of samples of various ages confirmed differences in phase compositions. It is supposed that the main role in the presented changes is played by the content of the roentgen-amorphous part of alumina-silicates because they are likely to be transformed into a stable form of feldspar. In addition to that, this article presents the hypothesis of a moving agent, which could explain the transformations in the final bodies.

Development and Evaluation of Mathematical Model based Region of Interest for Rotary kiln Burning Zone Temperature in Cement Industry by Digital Image Processing

Industrial processes particularly cement manufacturing unit consumes about 7% of total fuel used in the industry and hence there are strenuous efforts to reduce the fuels and lower the production costs by applying Optimal Control Algorithms. In order to achieve these parameters in the Rotary Kiln Plant, we need to continuously monitor the temperatures of the burning zone inside the rotary kiln at Regions of Interest (ROI) in real-time. In this image processing setup a thermal camera samples the temperatures inside the kiln at a rate of 5 frames per 2 seconds. The images which are highly sensitive to red and green wavelengths provide sufficient resolution to differentiate between various burning temperatures. The present burning zone temperature measurement obtained from the radiation pyrometer is not reliable on the one hand and indicates temperature information about particular point in the burning zone on the other hand. This is inadequate for optimizing the operation the kiln where a kiln furnace camera has been already installed at the plant for watching the burning status the inside the kiln. Software will be developed to determine the temperature T, for the video captured from the camera. Presently real time video from the camera is displayed in a computer monitor at kiln control room. We will tap the video signal from the setup and the calculate the burning zone temperature at the Region of Interest utilizing real time Image Processing Technologies. The temperature signal so estimated will be validated using the radiation pyrometer signal obtained from the field. The graphical tool developed in MATLAB automatically converts the receiving color images to temperature measure by proposed algorithms and also interactively analyzes the temperatures in a neat graphical user interface, in less than 2 seconds duration. ROI can be selected by a movable and re-sizable window which acts like a probe on the kiln temperatures at this instant, then displays the summary statistics of the temperatures. The tool is extended to provide a real-time graph of average temperature in the ROI over a long time when the probe is fixed at a particular region. However, the developed temperature tool and the point burning zone temperature measured by a proposed mathematical model as like thermocouple in the plant. The results are carried out by MATLAB software and benefits will be quantified in terms of enhancement in the Production efficiency, Energy efficiency, Pollution Control and clean environment.

ACOUSTICS OF PROCESS AS A FACTOR OF FORMING IN THE COMBUSTION ZONE OF FORMATIONS WITH EXCESS CHARGE

The nature and mechanism of formation and reproduction in time of macroscopic, fluctuational nature of formations with uncompensated electric charge (aquazineutral or AQN-formations) fixed by observations in the burning zone are investigated. With account of characteristic to combustion acoustic manifestations it is shown, that when burning in the reacting medium are necessarily developed instabilities in the distribution of electrical charge over the volume.It is substantiated, that the excitation conditions and the general features of charge instabilities in distribution of charge over volume really determine the mechanism under study as factor jointly providing of both the formation and continuous reproduction of AQN-formations in the combustion zone (in the pre-flame region, first of all).

NUMERICAL SIMULATION OF HEAT TRANSFER PROCESSES IN LINING AND OPTIMIZATION OF HEAT WORK OF THE UNIT

The features of heat and mass transfer inlining of high-temperature tunnel kiln for the burning of refractory materials are revealed by numerical simulation of heat transfer processes. Use of modern computer calculation programs permits to choose optimal constructions of trolley walls and heart lining. This ensures improved hermeticity of workspace and 15-20% reduction of heat loss. We studied the operation of a hightemperature of the unit with a combined system that ensured efficient burning of natural gas as well as regulation of temperature regime in the thermal aggregate workspace. A procedure was advanced to calculate consumption of fuel by gas burners and hot air over burning zone positions of high-temperature tunnel kilns when using a combined system of natural gas burning. The heat work of a tunnel kiln was optimized. This permitted to supply maximal quantity of hot air and natural gas into the initial positions of burning zone of tunnel kiln and to ensure technologically required temperatures of products burning (1780-1800ºС).