Project A

Project Report: Full System Upgrade and Control Integration

1. Project Overview  

This project represents one of our earliest major installations, completed over 15 years ago, and marks a significant milestone in our company’s history. It involved the design, development, and commissioning of a large-scale Gas Bio Plant constructed entirely from the ground up.

Our team delivered the complete electrical, automation, and control system scope, establishing the foundation for our long-standing expertise in renewable energy and process automation. 

2. Project Objectives 

• Design, manufacture, and install custom-built control panels for plant operation. 
• Provide comprehensive wiring, installation, and commissioning on-site. 
• Develop and deliver detailed schematic drawings, including electrical and control documentation. 
• Design and program a SCADA system for centralized monitoring and control. 
• Integrate a Huning/Rotacut liquid feed system with an inline hammer mill to improve processing efficiency. 
• Enhance plant performance, reliability, and energy efficiency through optimized automation.

3. System Design and Engineering 

3.1 Electrical and Control Systems 

The electrical and automation systems were fully designed and built in-house. This included: 

• Custom fabrication of industrial control panels tailored to site requirements. 
• Complete field wiring and installation of control and power systems. 
• Production of comprehensive schematic documentation, including PLC layouts, wiring diagrams, and instrumentation drawings. 

All work was carried out to ensure compliance with safety standards and long-term maintainability. 

3.2 SCADA System Development 

A SCADA (Supervisory Control and Data Acquisition) platform was designed and programmed to enable real-time monitoring and control of all plant processes from the site office.

Through this interface, operators can: 

• Manage and adjust feeding cycles. 
• Monitor system performance and process parameters. 
• Identify and respond to operational issues promptly. 

The SCADA system provides a user-friendly, visual interface that enhances operational efficiency and simplifies plant management. 

4. Process Integration 

4.1 Huning/Rotacut Liquid Feed System & Hammer Mill 

As part of the upgrade, the plant was equipped with a Huning/Rotacut liquid feed system incorporating an integrated hammer mill. This addition significantly improved substrate processing by crushing and homogenizing feed materials, thereby enhancing digestibility and reducing handling challenges.

The Huning system was seamlessly integrated into the existing conveyor path via a bypass, allowing for efficient and flexible feeding of solid materials into the biogas process. 

5. Key Advantages and Performance Improvements 

The system upgrade delivered measurable performance and efficiency gains, including: 

• Increased plant performance using the same digester volume through reduced average retention time. 
• Higher gas yield from improved disintegration of fibrous materials such as grass silage, clover-grass, and solid manure. 
• Reduced risk of floating layer formation within the digester. 
• Improved fermentation residue structure, optimizing post-digestion handling. 
• Lower energy consumption through reduced mechanical load on pumps and agitators. 
• Extended equipment lifespan as a result of decreased wear and mechanical strain. 

6. Outcomes and Benefits 

The Full System Upgrade and Control Integration successfully delivered a robust, efficient, and scalable automation solution for biogas production. Key outcomes include: 

• A fully automated, reliable control system providing real-time supervision and process optimization. 
• Enhanced feedstock processing efficiency through integrated mechanical and automation systems. 
• Long-term operational stability and maintainability. 
• A proven design foundation that has influenced numerous subsequent biogas projects. 

7. Conclusion

This project served as a cornerstone in our company’s development, demonstrating our capability to deliver end-to-end automation, electrical design, and process integration for complex biogas facilities.

The successful completion of this early system established the engineering and control standards that continue to guide our approach to renewable energy projects today.