Development of Mathematical Model based ROI for Rotary kiln To Measure 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.