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"Kilns"
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Two Vignettes
Syz talks about Koichi who was telling him about various aspects of kilns and how the dating of this type of porcelain was being reconsidered in the latest scholarly debates and publications. There were many interesting technical details and lessons, which he always was ready to share. He also became quite animated with people who showed genuine interest in the art.
Journal Article
Deep Learning Techniques for Enhanced Flame Monitoring in Cement Rotary Kilns Using Petcoke and Refuse-Derived Fuel (RDF)
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 (mAP50) 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.
Journal Article
Evaluation of Four Types of Kilns Used to Produce Charcoal from Several Tree Species in Mexico
Charcoal production is an activity that dates back over the years. The objective of the study was to determine the temperature and heating ramp in industrial carbonization processes using different kiln types and to quantify its impact on yield and quality of charcoal from different firewood species. The selection of sites, kiln types, and species investigated was based on those with highest production in Mexico. Brazilian beehive kilns using Arbutus xalapensis, Quercus durifolia, and Quercus sideroxyla species were analyzed; modified Brazilian beehive kilns with Pithecellobium dulce and Tamarindus indica; Argentine half-orange kilns with Quercus magnoliifolia and Q. sideroxyla, industrial metal kilns with Brosimum alicastrum, Vitex gaumeri, Manilkara zapota, and Pouteria unilocularis. The process time, temperature, heating ramp, production yield, and quality of charcoal produced were determined. Data were analyzed in a completely random statistical design. The industrial type kilns showed the highest production yield (>35%), and the Brazilian beehive kilns obtained the longest carbonization time (>240 h). On the other hand, the modified Brazilian beehive kilns obtained the best energetic characteristics (>75% fixed carbon and <16% volatile material). A carbonization process with a slow heating ramp (<1 °C min−1) and temperatures of 500–600 °C can generate a charcoal with export quality.
Journal Article
Alternative Clinker Technologies for Reducing Carbon Emissions in Cement Industry: A Critical Review
Currently, the production of one ton of ordinary Portland cement (OPC) releases considerable amounts of CO2 into the atmosphere. As the need and demand for this material grows exponentially, it has become a challenge to increase its production at a time when climate-related problems represent a major global concern. The two main CO2 contributors in this process are fossil fuel combustion to heat the rotary kiln and the chemical reaction associated with the calcination process, in the production of the clinker, the main component of OPC. The current paper presents a critical review of the existent alternative clinker technologies (ACTs) that are under an investigation trial phase or under restricted use for niche applications and that lead to reduced emissions of CO2. Also, the possibility of transition of clinker production from traditional rotary kilns based on fuel combustion processes to electrification is discussed, since this may lead to the partial or even complete elimination of the CO2 combustion-related emissions, arising from the heating of the clinker kiln.
Journal Article
Rotary Kiln, a Unit on the Border of the Process and Energy Industry—Current State and Perspectives
A rotary kiln is a unique facility with widespread applications not only in the process industry, such as building-material production, but also in the energy sector. There is a lack of a more comprehensive review of this facility and its perspectives in the literature. This paper gives a semi-systematic review of current research. Main trends and solutions close to commercial applications are found and evaluated. The overlap between process and energy engineering brings the opportunity to find various uncommon applications. An example is a biogas plant digestate treatment using pyrolysis in the rotary kiln. Artificial intelligence also finds its role in rotary kiln control processes. The most significant trend within rotary kiln research is the waste-to-energy approach in terms of various waste utilization within the process industry or waste pyrolysis in terms of new alternative fuel production and material utilization. Results from this review could open new perspectives for further research, which should be focused on integrated solutions using a process approach. New, complex solutions consider both the operational (mass calculations) and the energy aspects (energy calculations) of the integration as a basis for the energy sustainability and low environmental impact of rotary kilns within industrial processes.
Journal Article
Centerline measurement of rotary kilns based on the free station method
The rotary kiln is an important production equipment in the building materials and metallurgy industry, and its operating conditions, safety, and efficiency largely determine the economic benefits of its users and the safety of workers on site. At present, the testing methods for each rotary kiln part are relatively mature and can be used to realize accurate measurements in a dynamic environment. However, the main means of measurement is limited by the site conditions, and the actual detection speed is slow; the preparation work is cumbersome and will be subject to the measurement of the site obstacles and other environmental factors constraints. In this paper, we propose and design an optimized rotary kiln centerline measurement method using the free station method and verify its feasibility with respect to the optimization of the centerline offset, which is an important measurement item in rotary kiln measurement.
Journal Article
Description of Bricks
[...]the gray stocks are an inferior kind. Pan tiles are about IS inches long, 8 inches broad, and about half an inch thick; their transverse section is a figure of contrary curvature, the form of the tile being two portions of cylindric surfaces on both sides; the part which is of the greatest radius serves as a channel for discharging the rain water, and the other part, which is of much less radius, serves to lap over the edge of the adjoining tile: at the upper end of the tile projects a knob from the under and convex side, for the purpose of hanging it to the laths. [...]the book covers many of the trades needed to build a house from start to finish.
Journal Article