Predicting NOx emissions in Biochar Production Plants using Machine Learning

The global Biochar Industry has witnessed a surge in biochar production, with a total of 350k mt/year production in 2023. With the pressing climate goals set and the potential of Biochar Carbon Removal (BCR) as a climate-relevant technology, scaling up the number of new plants to over 1000 facilities per year by 2030 becomes imperative. However, such a massive scale-up presents not only technical challenges but also control and regulation issues, ensuring maximal output of plants while conforming to regulatory requirements. In this paper, we present a novel method of optimizing the process of a biochar plant based on machine learning methods. We show how a standard Random Forest Regressor can be used to model the states of the pyrolysis machine, the physics of which remains highly complex. This model then serves as a surrogate of the machine -- reproducing several key outcomes of the machine -- in a numerical optimization. This, in turn, could enable us to reduce NOx emissions -- a key regulatory goal in that industry -- while achieving maximal output still. In a preliminary test our approach shows remarkable results, proves to be applicable on two different machines from different manufacturers, and can be implemented on standard Internet of Things (IoT) devices more generally.