PYROLYSIS CONTROL APPARATUS AND METHOD USING IMAGE INFORMATION OF RAW MATERIALS AND PRODUCTS

Abstract

Disclosed is a pyrolysis reaction method including a raw material input step of inputting a raw material and acquiring first data, a pyrolysis reaction step of pyrolyzing the input raw material, a reactant discharge step of discharging a pyrolyzed reactant and acquiring second data, an image sample collection step of additionally obtaining image samples, a DB storage step of normalizing the obtained image samples into time series data and storing RGB code values in a DB, a labeling step of assigning labels to the first data and the second data, a data processing step of comparing the first data and the second data with the data stored in the DB to generate third data and fourth data, and a control value deriving step of deriving control values of a pyrolysis temperature and a pyrolysis time based on the third data and the fourth data.

Claims

1. A pyrolysis reaction method comprising: a raw material input step of inputting a raw material and acquiring first data through a first monitoring means; a pyrolysis reaction step of pyrolyzing and moving the input raw material; a reactant discharge step of discharging a pyrolyzed reactant and acquiring second data through a second monitoring means; an image sample collection step of additionally obtaining image samples in order to improve accuracy of the first data and the second data; a DB storage step of normalizing the obtained image samples into time series data and storing RGB code values in a DB; a labeling step of assigning labels to the first data and the second data based on the stored DB values; a data processing step of assigning a water content evaluation value to the label of the first data to derive a correlation between the RGB value and the water content, assigning a heating value evaluation value to the label of the second data to derive a correlation between the RGB value and the heating value, and comparing the first data and the second data with the data stored in the DB through simulation to generate third data, which is an estimated water content, and fourth data, which is an estimated heating value; and a control value deriving step of deriving control values of a pyrolysis temperature and a pyrolysis time required to secure heating value-based quality of the pyrolyzed reactant based on the third data and the fourth data generated through the data processing step, wherein the pyrolysis reaction step is performed by a pyrolysis reaction means configured to perform at least one of torrefaction, biochar reaction, drying, activated carbon reaction, and carbonization.

2. The pyrolysis reaction method according to claim 1, wherein, in the control value deriving step, the pyrolysis temperature controls at least one of a rate of rotation of a raw material supply motor of a hot air furnace, a rate of rotation of an air supply motor of the hot air furnace, and a rate of rotation of a dilution air supply motor of a gas mixer.

3. The pyrolysis reaction method according to claim 1, wherein, in the control value deriving step, the pyrolysis time controls at least one of a rate of rotation of a driving motor of a rotary kiln and a rate of rotation of a raw material supply motor.

4. A pyrolysis reaction apparatus comprising: a raw material input means configured to input a raw material and to acquire first data through a first monitoring means; a pyrolysis reaction means configured to pyrolyze and move the input raw material; a reactant discharge means configured to discharge a pyrolyzed reactant and to acquire second data through a second monitoring means; an image sample collection means configured to additionally obtain image samples in order to improve accuracy of the first data and the second data; a DB storage means configured to normalize the obtained image samples into time series data and storing RGB code values in a DB; a labeling means configured to assign labels to the first data and the second data based on the stored DB values; a data processing means configured to assign a water content evaluation value to the label of the first data to derive a correlation between the RGB value and the water content, to assign a heating value evaluation value to the label of the second data to derive a correlation between the RGB value and the heating value, and to compare the first data and the second data with the data stored in the DB through simulation to generate third data, which is an estimated water content, and fourth data, which is an estimated heating value; and a control value deriving means configured to derive control values of a pyrolysis temperature and a pyrolysis time required to secure heating value-based quality of the pyrolyzed reactant based on the third data and the fourth data generated by the data processing means, wherein the pyrolysis reaction means performs at least one of torrefaction, biochar reaction, drying, activated carbon reaction, and carbonization.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0023] FIG. 1 shows a pyrolysis reaction apparatus according to an embodiment of the present invention;

[0024] FIG. 2 is a photograph showing the shape of a torrefied product, which is a reactant from an input raw material depending on the reaction temperature, during torrefaction according to an embodiment of the present invention;

[0025] FIG. 3 is an experimental result of the heating value, yield, and elemental composition of an empty fruit bunch (EFB) torrefied product depending on the reaction temperature according to an embodiment of the present invention;

[0026] FIG. 4 is an experimental result of the heating value, yield, and elemental composition of an empty fruit bunch (EFB) torrefied product depending on the reaction time according to an embodiment of the present invention;

[0027] FIG. 5 is an experimental result of the heating value of an empty fruit bunch (EFB) torrefied product depending on the reaction temperature and the reaction time according to an embodiment of the present invention;

[0028] FIG. 6 shows a step of segmenting first data and second data images, converting the image color of each cell to an RGB code value, and deriving an average value according to an embodiment of the present invention;

[0029] FIG. 7 shows a step of overlapping the first data and second data images to generate an image according to an embodiment of the present invention;

[0030] FIG. 8 shows a labeling step of grouping RGB data code values and assigning labels thereto; and

[0031] FIG. 9 shows a data processing step of deriving a correlation between an RGB value, water content, and a heating value and estimating the water content and the heating value corresponding to an arbitrary RFG value through simulation.

DESCRIPTION OF EMBODIMENTS

[0032] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings such that the preferred embodiments of the present invention can be easily implemented by a person having ordinary skill in the art to which the present invention pertains. In describing the principle of operation of the preferred embodiments of the present invention in detail, however, a detailed description of known functions and configurations incorporated herein will be omitted when the same may obscure the subject matter of the present invention.

[0033] In addition, the same reference numbers will be used throughout the drawings to refer to parts that perform similar functions or operations. In the case in which one part is said to be connected to another part throughout the specification, not only may the one part be directly connected to the other part, but also, the one part may be indirectly connected to the other part via a further part. In addition, that a certain element is included does not mean that other elements are excluded, but means that such elements may be further included unless mentioned otherwise.

[0034] In addition, any limitations or additions to any embodiment described herein are not limited to a specific embodiment but are equally applicable to all embodiments described herein.

[0035] Also, in the description of the invention and the claims of the present application, singular forms are intended to include plural forms unless mentioned otherwise.

[0036] FIG. 1 shows a pyrolysis reaction apparatus according to an embodiment of the present invention, FIG. 2 is a photograph showing the shape of a torrefied product, which is a reactant from an input raw material depending on the reaction temperature, during torrefaction according to an embodiment of the present invention, FIG. 3 is an experimental result of the heating value, yield, and elemental composition of an empty fruit bunch (EFB) torrefied product depending on the reaction temperature according to an embodiment of the present invention, FIG. 4 is an experimental result of the heating value, yield, and elemental composition of an empty fruit bunch (EFB) torrefied product depending on the reaction time according to an embodiment of the present invention, FIG. 5 is an experimental result of the heating value of an empty fruit bunch (EFB) torrefied product depending on the reaction temperature and the reaction time according to an embodiment of the present invention, FIG. 6 shows a step of segmenting each of first data and second data images, converting the image color of each cell to an RGB code value, and deriving an average value according to an embodiment of the present invention, FIG. 7 shows a step of overlapping the first data and second data images to generate an image according to an embodiment of the present invention, FIG. 8 shows a labeling step of grouping RGB data code values and assigning labels thereto, and FIG. 9 shows a data processing step of deriving a correlation between an RGB value, water content, and a heating value and estimating the water content and the heating value corresponding to an arbitrary RFG value through simulation.

[0037] In addition, FIG. 6 shows a step of evenly segmenting each of first data and the second data images into nine or more cells, converting the image color of each cell into an RGB (red, green, blue) code value, and deriving an average value thereof.

[0038] In addition, FIG. 7 shows acquiring first data and second data images four times every 2.5 seconds, overlapping the same in a ratio of 2:8 to create one image, and generating an image to be applied to FIG. 6.

[0039] In addition, FIG. 8 shows a step of classifying code values of each of RGB data into 16 groups and assigning a total of 4,069 labels through a combination of the classified R, G, and B groups.

[0040] In addition, after image generation through FIG. 7 and labeling through FIG. 8, at least one of the heating value and the water content may be predicted through at least one of the steps of: [0041] 1) preparing labeled data to learn collected image data (this step may include data augmentation); [0042] 2) training a model to predict the heating value/water content; [0043] 3) adjusting the weight of the model and learning the relationship between the heating value, the water content, the image, and the label corresponding thereto; and [0044] 4) adjusting the hyper-parameter of the model or performing a tuning operation to improve the performance of the model through accumulated data.

[0045] The present invention provides a pyrolysis reaction method including a raw material input step of inputting a raw material and acquiring first data through a first monitoring means, a pyrolysis reaction step of pyrolyzing and moving the input raw material, a reactant discharge step of discharging a pyrolyzed reactant and acquiring second data through a second monitoring means, an image sample collection step of additionally obtaining image samples in order to improve accuracy of the first data and the second a data, DB storage step of normalizing the obtained image samples into time series data and storing RGB code values in a DB, a labeling step of assigning labels to the first data and the second data based on the stored DB values, a data processing step of assigning a water content evaluation value to the label of the first data to derive a correlation between the RGB value and the water content, assigning a heating value evaluation value to the label of the second data to derive a correlation between the RGB value and the heating value, and comparing the first data and the second data with the data stored in the DB through simulation to generate third data, which is an estimated water content, and fourth data, which is an estimated heating value, and a control value deriving step of deriving control values of the pyrolysis temperature and the pyrolysis time required to secure heating value-based quality of the pyrolyzed reactant based on the third data and the fourth data generated through the data processing step, wherein the pyrolysis reaction step is performed by a pyrolysis reaction means configured to perform at least one of torrefaction, biochar reaction, drying, activated carbon reaction, and carbonization.

[0046] Also, in the control value deriving step, the pyrolysis temperature may control at least one of the rate of rotation of a raw material supply motor of a hot air furnace, the rate of rotation of an air supply motor of the hot air furnace, and the rate of rotation of a dilution air supply motor of a gas mixer.

[0047] Also, in the control value deriving step, the pyrolysis time may control at least one of the rate of rotation of a driving motor of a rotary kiln and the rate of rotation of the raw material supply motor.

[0048] In addition, the first data and the second data may be visual information, and the visual information may be an image.

[0049] In addition, the first monitoring means may segment the image into a plurality of cells in order to acquire the first data.

[0050] In addition, the second monitoring means may segment the image into a plurality of cells in order to acquire the second data.

[0051] In addition, each of the first and second data images may be evenly segmented into nine or more cells.

[0052] In addition, the image color of each of the evenly segmented cells may be converted into an RGB code value and an average value thereof may be derived.

[0053] Also, in order to improve accuracy in the image sample collection step, image samples may be additionally obtained by applying an overlap of 80% based on 2.5 seconds.

[0054] The 2.5 seconds set in the image sample collection step may be appropriately applied depending on the circumstances, since the dwell time can be adjusted to analyze the images of the input raw material and the discharged reactant seconds through for 10 the relationship between the movement distance and the rate of rotation of a motor when a conveyor belt is used.

[0055] In addition, representative image generation and system accuracy may be improved by using an overlap method of overlapping a plurality of images.

[0056] In addition, the RGB code values may be classified into 16 groups, and 4,096 labels may be assigned through a combination of the classified R, G, and B groups.

(Example 1) Pyrolysis Temperature Control

[0057] A step of controlling an operating factor related to pyrolysis temperature to achieve a target heating value of 4,500 kcal/kg in an operating condition in which the heating value of the pyrolysis product derived from the fourth data is 4,150 kcal/kg

[0058] (1) The rate of rotation of the raw material supply motor of the hot air furnace was increased by 5%.

[0059] (2) The rate of rotation of the air supply motor of the hot air furnace was increased by 7%.

[0060] (3) The rate of rotation of the dilution air supply motor of the gas mixer was decreased by 3%.

(Example 2) Pyrolysis Time Control

[0061] A step of controlling an operating factor related to pyrolysis time to achieve a target heating value of 4,500 kcal/kg in an operating condition in which the heating value of the pyrolysis product derived from the fourth data is 4,950 kcal/kg

[0062] (1) The rate of rotation of the driving motor of the rotary kiln was increased by 8%.

[0063] (2) The rate of rotation of the raw material supply motor was increased by 5%.

[0064] In addition, the present invention provides a pyrolysis reaction apparatus including a raw material input means configured to input a raw material and to acquire first data through a first monitoring means, a pyrolysis reaction means configured to pyrolyze and move the input raw material, a reactant discharge means configured to discharge a pyrolyzed reactant and to acquire second data through a second monitoring means, an image sample collection means configured to additionally obtain image samples in order to improve accuracy of the first data and the second data, a DB storage means configured to normalize the obtained image samples into time series data and storing RGB code values in a DB, a labeling means configured to assign labels to the first data and the second data based on the stored DB values, a data processing means configured to assign a water content evaluation value to the label of the first data to derive a correlation between the RGB value and the water content, to assign a heating value evaluation value to the label of the second data to derive a correlation between the RGB value and the heating value, and to compare the first data and the second data with the data stored in the DB through simulation to generate third data, which is an estimated water content, and fourth data, which is an estimated heating value, and a control value deriving means configured to derive control values of the pyrolysis temperature and the pyrolysis time required to secure heating value-based quality of the pyrolyzed reactant based on the third data and the fourth data generated by the data processing means, wherein the pyrolysis reaction means performs least one of torrefaction, biochar reaction, drying, activated carbon reaction, and carbonization.

[0065] In addition, the present invention provides a rotary pyrolysis reaction apparatus 100 including a kiln type indirect pyrolysis reaction means constituted by an outer cylinder 200 configured to allow external hot air to be supplied thereinto and an inner cylinder 300 configured to allow a raw material to move therein, a pyrolysis reaction control means 900 configured to drive the pyrolysis reaction means, a raw material inlet 110 located at one side of the pyrolysis reaction means, the raw material inlet 110 being configured to allow a raw material to be input to the pyrolysis reaction means therethrough, a reactant outlet 120 located at the other side of the pyrolysis reaction means, which is opposite the raw material inlet 110, the reactant outlet 120 being configured to allow a pyrolysis reactant, which is the raw material that has been pyrolyzed, to be discharged therethrough, a hot air supply pipe 400 configured to supply hot air to the outer cylinder 200, a multipoint thermocouple 430 located at one side of the inner cylinder 300, the multipoint thermocouple 430 being configured to measure the temperature in the pyrolysis reaction means, a heat source supply quantity control means 440 connected to the multipoint thermocouple located at one side of the inner cylinder 300 and the hot air supply pipe 400, supply quantity control means 440 being configured to control hot air supplied to the outer cylinder 200, a generated gas discharge pipe 600 located at one side of the pyrolysis reaction means above the pyrolysis reaction means, the generated gas discharge pipe 600 being configured to discharge gas generated in the pyrolysis reaction means, a first monitoring means 700 installed in the vicinity of the raw material inlet 110, the first monitoring means 700 being configured to monitor a raw material input through the raw material inlet 110 and to transmit first data acquired through monitoring, a second monitoring means 710 installed in the vicinity of the reactant outlet 120, the second monitoring means 710 being configured to monitor a reactant discharged through the reactant outlet 120 and to transmit second data acquired through monitoring, and an AI analysis means 800 configured to receive the data transmitted by the first monitoring mean 700 and the second monitoring mean 710, to generate third data and fourth data based on the received first data and the received second data, to provide the third data to the heat source supply quantity control means 440, and to provide the fourth data to the pyrolysis reaction control means 900, wherein the outer cylinder 200 includes a partition plate 210 configured to divide the outer cylinder 200 into predetermined zones, and one side of the hot air supply pipe 400 and one side of the outer cylinder 200 are connected to each other via a hot air branch pipe 410 including a control valve 420.

[0066] The raw material may be a solid raw material that requires pyrolysis, such as drying, torrefaction, biochar reaction, and carbonization. For example, the raw material may include biomass (bagasse, EFB, woodchip, etc.), organic waste (animal manure, sewage sludge, food waste, etc.), and combustible waste (waste plastic, waste paper, waste rubber, etc.).

[0067] The outer cylinder 200 may be divided into two or more zones by the partition plate 210.

[0068] The multipoint thermocouple may be disposed to sense the temperature T1 to T6 in the inner cylinder 300 corresponding to the zones of the outer cylinder 200 divided by the partition plate 210.

[0069] The temperature in the inner cylinder 300, i.e. the reaction temperature, may be 100 C. to 500 C.

[0070] One or more multipoint thermocouples 430 may be located in the vicinity of the raw material inlet 110 or the reactant outlet 120 by insertion, or the multipoint thermocouple 430 may be installed in the vicinity of the raw material inlet 110 and the reactant outlet 120 by penetration.

[0071] The control valve 420 may adjust the amount of hot air that is supplied.

[0072] The outer cylinder 200 may be installed so as to surround the inner cylinder 300 while being spaced apart from the inner cylinder 300 by a predetermined distance such that a path configured to allow hot air to move therealong is defined between the outer cylinder 200 and the inner cylinder 300.

[0073] A hot air discharge pipe 500 configured to allow the hot air supplied to the outer cylinder 200 to be discharged therethrough may be further provided at one side of the outer cylinder 200.

[0074] The hot air discharge pipe 400 may be formed so as to have a double structure configured to surround the generated gas discharge pipe 600 in order to maintain the temperature of the generated gas discharge pipe 600 at a predetermined temperature or higher such that the generated gas can be used as fuel.

[0075] The hot air discharge pipe 400 may be formed so as to have a double structure such that the generated gas discharge pipe 600 is installed so as to extend in the hot air discharge pipe 400.

[0076] When the hot air discharge pipe 400 is located at a lower end of the pyrolysis reaction means, the hot air discharge pipe 400 may supply hot air to a lower part of the pyrolysis reaction means such that the most indirect contact between the hot air and the raw material occurs. In this case, heat source utilization efficiency may be slightly higher than when the hot air discharge pipe 400 is located at an upper end of the pyrolysis reaction means.

[0077] The pyrolysis reaction means may be used for at least one of torrefaction, drying, biochar reaction, activated carbon reaction, and carbonization.

[0078] At least one of the first data and the second data transmitted by the AI analysis means 800 may be based on visual information.

[0079] The first monitoring means 700 may acquire moisture content information from visual information of the input raw material.

[0080] The second monitoring means 710 may acquire heating value information from visual information of the discharged reactant.

[0081] Upon receiving the third data, the heat source supply quantity control means 440 may adjust the control valve 420 installed at the hot air branch pipe 410.

[0082] Upon receiving the fourth data, the pyrolysis reaction control means 900 may adjust the rate of rotation of the pyrolysis reaction means.

[0083] The hot air branch pipe 410 may be connected to the outer cylinder 200 so as to correspond to each of the zones of the outer cylinder 200 divided by the partition plate.

[0084] The present invention provides a pyrolysis reaction method using the pyrolysis reaction apparatus, the pyrolysis reaction method including a raw material input step of inputting a raw material and acquiring first data through the first monitoring means, a pyrolysis reaction step of pyrolyzing the input raw material and moving the pyrolyzed raw material, a reactant discharge step of discharging a reactant resulting from pyrolysis reaction and acquiring second data through the second monitoring means, a data processing step of generating third data and fourth data based on the first data and the second data, and a pyrolysis reaction apparatus control step of controlling the pyrolysis reaction apparatus based on the third data and the fourth data generated through the data processing step.

[0085] RGB refers to three primary colors of light, i.e. red, green, and blue, and an RGB color model is a way of representing colors using the three primary colors of light.

[0086] Those skilled in the art to which the present invention pertains will appreciate that various applications and modifications are possible within the category of the present invention based on the above description.

DESCRIPTION OF REFERENCE SYMBOLS

[0087] 100: Rotary pyrolysis reaction apparatus [0088] 110: Raw material inlet [0089] 120: Reactant outlet [0090] 200: Outer cylinder [0091] 210: Partition plate [0092] 300: Inner cylinder [0093] 400: Hot air supply pipe [0094] 410: Hot air branch pipe [0095] 420: Control valve [0096] 430: Multipoint thermocouple [0097] 440: Heat source supply quantity control means [0098] 500: Hot air discharge pipe [0099] 600: Generated gas discharge pipe [0100] 700: First monitoring mean [0101] 710: Second monitoring means [0102] 800: AI analysis means [0103] 900: Pyrolysis reaction control means