Case Studies

Focus-1 at Returkraft

Achieving innovation in waste incineration for Returkraft

In this case study we will explore the traditional waste incineration process, the inherent challenges, and how FOCUS-ON’s innovative smart meter valves have revolutionized operations at the Kristiansand plant. By introducing FOCUS-ON’s smart meter valves, the plant has achieved significant advancements in efficiency and control, overcoming previous limitations.

LEVEL CONTROL SUPPLYING WATER TO ELEVATED TANK

A municipal utility in eastern Germany operates two water towers for the drinking water supply of adjacent communities. The long-distance pipeline (DN300) is operated at a pressure of 10…13 bar / 145…188.5 psi. The operator must regulate the supply to the elevated tanks to achieve the desired tank level setpoint and the pressure at the inlet must be carefully controlled so that no damage occurs to the components due to excessive differential pressures. In this application FOCUS-1 reliably controls the level as an external control variable according to the desired setpoint.

Optimization of hydrogen alkaline electrolysers with FOCUS-1

FOCUS-1 combines flow, temperature, and pressure sensors with controls for optimal alkaline electrolyser performance. Simplifying KOH concentration measurement and flow control, it enhances efficiency, reduces complexity, and lowers costs in hydrogen generation through electrolysis. Precise measurement ensures ideal electrolyser operation during the energy transition to renewable hydrogen sources, aiding the shift from fossil fuels.

CONDENSATE RETURN: MAINTAIN SAFE OPERATING CONDITIONS

An essential aspect of the biorefinery process involves steam production. Their careful regulation of water and steam production is geared towards reducing energy consumption and ensuring a responsible carbon footprint. A crucial element of achieving this lies in the efficient management of condensate return lines, which transport condensate back to the boiler. A important factor for this process is its safety aspects. FOCUS-1 ensures that the boiler feed water tank with the correct amount of water to maintain safe operating conditions.

THERMAL OIL COOLING: EFFICIENT & RELIABLE COOLING

Thermal oil is commonly used in steel mills, including the hot strip mill, to transfer heat efficiently. It helps maintain the correct temperature in rolling mills and continuous casting machines, which generate significant heat during steel production. Cooling the thermal oil prevents overheating and equipment damage. By replacing the traditional valve with a FOCUS-1, the process operator maintains all required control & monitoring capabilities with additional insights into the efficiency of the heat exchanger.

RELIABLE DOSING OF WASTEWATER: BALANCING MICRO ORGANISMS

Maintaining a proper balance between the volume of water and the microorganism colony is crucial for effective operation. Accurate dosing is essential to prevent the death of microorganisms, which can lead to process delays while the colony is reestablished. By implementing FOCUS-1, Heros achieves the integration of a flowmeter and valve into a single device, eliminating the need for separate components. The integrated flowmeter ensures exceptional accuracy, with only a 0.5% level of inaccuracy, enabling precise flow control into the basins.

BOILER FEEDWATER: CONTROLLING OF ENERGY EFFICIENCY

An important part of the adhesives production at Dynea is the steam production. By carefully regulating water and steam production Dynea strives to lower their energy consumption which adds to a responsible carbon footprint. By replacing the existing control valve with FOCUS-1, Dynea does not only gain comprehensive control and monitoring capabilities, but also a significant amount of insights into the boiler operation. By now having additional data such as: flow, pressure, and temperature, Dynea can effectively monitor feedwater usage, enhance energy efficiency resulting in a better Carbon Footprint.

SOYA OIL BAG LOADING: ENSURING EFFICIENT AND SAFE OPERATIONS

In the past a separate flowmeter and valve system for filling soy oil into trucks was used. However, for this specific application, there is an increased need for efficient and accurate flow control. To guarantee a safe and efficient bag loading process, preventing bag rupture, spills, and leaks, precise flow control is crucial. By implementing FOCUS-1 in this application the process achieves a inaccuracy of only 0.3% when loading the truck, enabling precise flow control and ensuring safety with the inclusion of an integrated pressure sensor.

BOILER FEED WATER: OPTIMIZATION OF FLOW CONTROL

At Ardo in the Netherlands, steam produced in a boiler is used to cook spinach before its frozen, this to maintain the quality and extend shelf life. During operations an optimal control and monitoring of the boiler feed water is crucial for several reasons. By replacing the existing control valve with FOCUS-1, Ardo gains comprehensive control and monitoring capabilities, offering valuable insights into the boiler operation.

Articles

November 13, 2023

Envision a typical weekday, where one of our valued customers urgently contacted us, alarmed by a high-stakes problem they are facingTheir situation is on the edge of a potential unplanned stop. FOCUS-1, the controller of their system, exhibited signs of instabilityputting the smooth operation of their boiler at risk. Despite FOCUS-1’s throttle set wide open at 100%, it was barely delivering 65 m3/h instead of its usual robust range of 100 m3/h. The customer pointed towards FOCUS-1 as the problem maker but less seemed to be true when the information of FOCUS-1 pointed out the real issue.