Evaluation of the Long-Term Utilization of the Internet of Things in a Batch-Type Ceramics Kiln

Abstract

Batch-type ceramic kilning is an energy-intensive process whose primary expense is fuel consumption. This work demonstrates the incorporation of the Internet of Things (IoT) into an existing ceramic furnace to achieve more precise temperature profile control and lower fuel consumption. A long-term analysis of the kiln owner’s continuous utilization and adoption of the technology was performed. A total of 20 kilns in northern Thailand’s factories have been selected for implementation. The owner of the facility, who is also the operator of the kiln, can monitor and modify the kiln’s settings online using near-real-time information. The sensors, wireless connection devices, a cloud server, and mobile applications that comprise the IoT are tailored to achieve these goals. The kiln has been outfitted with sensors such as a gas flow meter, a gas pressure sensor, and kilning room temperature, wall temperature, and ambient temperature sensors. Using the narrowband-IoT (NB-IoT) network provided by a local communication company, continuous monitoring data, consisting of 8 to 10 hours of kilning time and 2-3 batches per week, have been sent to a cloud server every minute. On a smartphone, online information with alerts can be displayed. The study’s outcomes indicate that a kiln operator can consistently control the kiln from batch to batch, resulting in minimal fuel consumption. Compared to before the installation of IoT, data collected over three years indicates a 5.6% improvement in energy efficiency. Total annual petroleum savings amount to $59,787 for the 20 kilns. The straightforward repayment period is 4.7 years. According to a field investigation, IoT technology has an approval rating of nearly 9 out of 10.