AI-Alt Fuel Cement

Real-time analyzer for alternative fuels

Real-time monitoring with state-of-the-art sensors and our AI platform.

The challenge

Case Study

01 Alternative fuel

The properties of different types of fuel (moisture content, particle size, calorific value) are constantly changing. These changes are not detected in real time, preventing timely decision-making.

02 Current limitations

The current monitoring system relies on small-scale analyses with delayed results.
There is a lack of visibility between the time the fuel is received and the time it enters the furnace.

03 Operational impact

Loss of thermal efficiency and combustion stability.
Reactive operation and increased consumption of premium coal/coke.

Advantages

Smart measurement, easy integration

An advanced visual AI system designed for continuous, real-time analysis of alternative fuels (CDR, shredded tires, biomass, animal meal, olive pomace, etc.), both at the truck receiving area and on the production line.


Variables measured in real time

Calorific value

Estimation of the lower calorific value- PCI (MJ/kg)

Humidity

Continuous measurement of the amount of water present.

Composition

Identification of materials and quantities: plastics, wood, paper, cardboard, organic matter, metals, plaster, and paint.

Particle size

Analysis of fuel particle size distribution.


Direct integration

Real-time data

Data delivery via standard process signals
(4–20 mA)

Easy integration

Native integration into existing DCS/SCADA systems

Visualization

Display and use like any other
plant sensor

Contaminants detection

The system is also designed to identify materials that could cause emissions or blockages due to the accumulation of certain elements, such as:

Improved boiler lifespan • Better environmental compliance

Chlorine

Chlorine producing contaminants detection

Sulphur

Plaster, plasterboard and construction waste.

Foreign Objects

Batteries, vapes, aerosols, gas canisters, paint tins…

AI-Alt Fuel Cement

Real-time and continuos monitoring of alternative fuels. Why now?

  • Higher Thermal Substitution Rate

    Cement and asphalt plants are increasingly burning alternative fuels due to regulations.

  • More variability

    Refuse Derived Fuels, Biomass, Tyre Derived Aggregate, Animal Derived Products… An increasing number of fuels make traceability harder.

  • New industrial technology

    • Hyperspectral vision
    • IA Visual algorithms

  • Same (or higher) performance requirements

    Burning alternative fuels does not allow a reduction in productive efficiency or production rates.

AI-ALT FUEL CEMENT

4 keys to optimize your operations

Optimize operations with continuous, reliable real-time fuel information, enabling improved efficiency, reduced variability, and data-driven decision making.

Enforce material quality standards

Reject non-compliant fuel in real time preventing operational complications and maintains the integrity of the combustion system.

Enhanced thermal efficiency

The information of humidity and calorific value enables the thermal efficiency of the process to be monitored and improved at all times, optimizing energy conversion.

Reduction of costs

Quality control minimizes downtime, machine breakdowns, and jams, consequently reduces repair and maintenance costs.

Operational improvement

Reduce the number of laboratory tests and obtain instant results, reducing the operational burden and the number of samples taken.

Frequently Asked Questions

  • How does the system maintain accuracy in demanding industrial environments?

    Pixelabs’ hardware is specifically designed for demanding industrial environments. AI algorithms are trained to filter out environmental visual interference, ensuring that the processed data corresponds exclusively to the fuel on the conveyor belt.

  • Which fuels can the system operate with?

    The system is designed to operate with a wide range of alternative fuels, including RDF, biomass, shredded tyres, sewage sludge, and meat and bone meal.

  • Does the system require a plant shutdown for installation?

    No. The support structure design is non-intrusive and is installed ‘on top’ of the existing conveyor belt. Mechanical assembly and wiring tasks are coordinated to be carried out during routine maintenance windows or scheduled technical shutdowns, with an intervention time on the line of less than 6 hours.

  • How does the Pixelabs signal integrate with our current control system (DCS/SCADA)?

    Integration is native and straightforward. The system delivers variables (humidity, volume, and PCI) via 4-20mA current loops or standard protocols such as Modbus. This allows the plant system to receive the information as if it were any other process sensor.

  • Does this system replace laboratory tests?

    No. The Pixelabs system acts as a real-time process control tool, analysing 100% of the fuel. Real-time measurement is highly accurate and correlates well with laboratory results, but it is not intended to replace detailed testing of small quantities of material using industry-standard analytical methods. Both systems provide positive feedback for improved plant performance.

  • What is the estimated service life of the system and its maintenance requirements?

    The system is built with highly durable industrial-grade components. Preventive maintenance is limited to cleaning the external protections of the equipment and optics, and replacing bulbs if they burn out. At the software level, the system evolves through remote updates included in the support plan, ensuring that the technology never becomes obsolete, as well as through periodic recalibrations described in a Technical Annex to the product.

Get a closer look and discover how AI-Alt Fuel Cement will improve your business

Still have questions about the product? Schedule your demo with our experts
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(1) The data reflects how our client currently uses the system. Keep in mind that this information is shared based on mutual understanding. We’ve also estimated potential cost savings using details from our clients, keeping everything within the agreed terms and conditions. We recommend contacting us for detailed information. (2) This is a simplified explanation of the product’s functionality and may not fully represent the complete process involved. These representations are intended for the purpose of clarity and ease of understanding. We recommend contacting us for detailed information. (3) All images used in this website are for illustrative purposes only.

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