Ensuring clean gas in compliance with environmental regulations and health & safety requirements is crucial in the agriculture and food industries. This case study explores how a global leader in these sectors optimized their gas scrubber application using the FOCUS-1 smart metering valve, resulting in improved control, energy efficiency, and process continuity.
Overview of the Company
A global leader in the agriculture and food industries operates in over 70 countries. In their gas scrubber applications, maintaining clean gas is essential for adhering to environmental regulations and health & safety standards. Stable control and accurate measurement in the scrubber are vital for energy efficiency and process continuity.
Traditional Setup and Limitations
Control Requirements
In the gas scrubber, harmful gases are extracted and transported to the incinerator room. Water is injected into the scrubber to extract these gases effectively. The temperature of the scrubber is maintained at approximately 50 degrees Celsius using water from the river IJssel. This temperature is crucial for optimal gas extraction.
Limitations of the Traditional Setup
Currently, a temperature sensor on the scrubber outlet sends signals to the Designated Control System (DCS), which calculates the optimal valve position. The valve then adjusts accordingly. However, this setup lacks additional measurements for alarming or data insight purposes, limiting the operator’s ability to monitor and respond to process changes effectively.
Challenges Faced
Inadequate Monitoring
The traditional setup does not provide real-time data or additional measurements for alarming, which limits the operator’s ability to monitor and respond to changes in the process conditions effectively.
Control Delays
Relying on the DCS for control calculations introduces delays, reducing the responsiveness and efficiency of the system in adjusting to set-point changes or process parameter variations.
Risk of Pollution
Without additional data insights, the risk of unanticipated stops due to polluted water increases, impacting process continuity and efficiency.
Implementing the FOCUS-1 Solution
Integrated Control and Monitoring
By replacing the traditional valve with FOCUS-1, the process operator gains enhanced control and monitoring capabilities. FOCUS-1 integrates measurement and control components into one device, allowing the operator to make informed decisions based on real-time data, regardless of process condition changes.
Direct Temperature Control
Connecting the temperature sensor directly to FOCUS-1 using internal PID parameters bypasses the DCS, resulting in faster and more accurate control. This setup improves the efficiency of the gas scrubber by enabling quicker responses to set-point changes and process variations.
Comprehensive Data Insights
FOCUS-1 provides additional data, including temperature of the cooling water, flow velocity, and inlet pressure. This information helps the operator assess energy consumption, monitor the influx from the river Ijssel, and detect potential pollution risks, thereby reducing the likelihood of unanticipated stops.
FOCUS-1: The first smart meter valve. Replaces large traditional set ups and ensures more reliable measurements and reduced risk of downtime.](https://fon-p.com/wp-content/uploads/2024/08/FOCUS-1-1024x788.jpg)
Customer Benefits
Easy Installation
- Simplified Setup: FOCUS-1’s design allows for easy installation with minimal modifications required. The customer gains additional insights into various parameters with minimal effort.
Improved Efficiency
- Direct Control: Connecting the temperature sensor directly to FOCUS-1 and using its internal PID parameters bypasses the DCS, eliminating delays and enabling more responsive and efficient control.
- Energy Savings: The direct connection and improved control result in significant energy savings.
Risk Mitigation
- Enhanced Monitoring: FOCUS-1 provides detailed insights into water pollution levels and potential risks, enabling the operator to make informed decisions and mitigate risks effectively.
- Proactive Maintenance: Real-time data transmission and diagnostics facilitate condition-based maintenance, reducing the risk of unexpected downtime.
Watch videos about how the Focus-1 work on our YouTube channel.
Conclusion
Integrating the FOCUS-1 smart metering valve in gas scrubber applications has transformed the control and monitoring capabilities of this global agriculture and food industry leader. By enhancing control accuracy, providing real-time data, and improving energy efficiency, the utility achieved significant operational improvements and cost savings. For more insights on process optimization, explore our related blogs on process simplification and smart meter valves.
