Computer Controlled Biogas Process Unit
The Computer Controlled Biogas Process Unit, "EBGC", is supplied with two packed anaerobic digesters. In this way, the user can work either in only one stage or in two stages, separating the different phases of the digestion process (the processes of hydrolysis, acidogenesis and acetogenesis would take place in the first digester, and the methanogenesis in the second digester).
Both digesters have a heating blanket that allows to regulate (PID Control) both the appropriate temperature for each part of the process and the operation with different ranges depending on the used microorganisms. Thus, it can operate at the psychrophilic range (room temperature), mesophilic range (temperatures around 35ºC) or thermophilic range (temperatures around 55ºC).
The unit has four computer controlled peristaltic pumps which enable the propelling of both the supply to be introduced in the digester and the acid and the base (introduced in two vessels located at the rear side) in order to adjust and control thoroughly the pH in each stage of the process. In case of working in an anaerobic digestion in two stages, one of the pumps carries the product from one of the digesters to the other, passing through a buffer tank which collects the excess of flow from the first reactor. The control of these pumps allows to know the different flows with which the unit is working.
Two volumetric tanks are also included for the storage and volume measurement of the generated biogas. The generated biogas flows through a pipe from the upper side of the digesters to these tanks, where the biogas volume is measured by means of a water displacement.
Such tanks have two parts: the upper side is where the generated biogas is collected and the second part, smaller than the first one and located below it, is used to collect the displaced water.
Each digester has a temperature sensor and a pH sensor. Their function is to follow the whole process and study the influence of the different controlling parameters in the anaerobic digestion.
Finally, the volumetric tanks, by their upper side, enable the flowing of the collected biogas through a pipe and its passing through a methane sensor (CH4) which allows to know the methane concentration in such current and this way, the biogas quality depending on four the physical-chemical conditions under which the anaerobic digestion is developed can be determined, as well as its value as a renewable energy source.
This Computer Controlled Unit is supplied with the EDIBON Computer Control System (SCADA), and includes: The unit itself + a Control Interface Box + a Data Acquisition Board + Computer Control, Data Acquisition and Data Management Software Packages, for controlling the process and all parameters involved in the process.
GUIDED PRACTICAL EXERCISES INCLUDED IN THE MANUAL
- Study of the stabilization process.
- Study of the effect of temperature in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the pH effect of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the influence of the feeding rate in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the influence of the type of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the concentration of nutrients influence of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the hydraulic load effect in the anaerobic digestion, purification and quality of the obtained biogas.
- Study of the inhibitors influence in the anaerobic digestion, purification and quality of the obtained biogas.
- Comparison between the mesophilic and thermophilic anaerobic digestion and their influence in the biogas obtention.
- Determination of the optimum operation temperature.
- Determination of the optimum feeding rate.
- Determination of the optimum solids/water relation.
- Determination of the optimum degradable/non degradable solids relation.
- Determination of the multistage nature in the anaerobic digestion.
- Determination of the kinetics.
- Carbon balance.
- Solids balance.
- Biogas balance.
- Sensors calibration.
- Many students view results simultaneously. To view all results in real time in the classroom by means of a projector or an electronic whiteboard.
- Open Control, Multicontrol and Real Time Control. This unit allows intrinsically and/or extrinsically to change the span, gains, proportional, integral, derivative parameters, etc, in real time.
- The Computer Control System with SCADA and PID Control allow a real industrial simulation.
- This unit is totally safe as uses mechanical, electrical and electronic, and software safety devices.
- This unit can be used for doing applied research.
- This unit can be used for giving training courses to Industries even to other Technical Education Institutions.
- Control of the EBGC unit process through the control interface box without the computer.
- Visualization of all the sensors values used in the EBGC unit process.
- By using PLC-PI additional 19 more exercises can be done.
- Several other exercises can be done and designed by the user.
TENDER SPECIFICATIONS (for main items)
1 EBGC. Unit:
Anodized aluminum frame and panels made of painted steel.
Main metallic elements made of stainless steel.
Diagram in the front panel with distribution of the elements similar to the real one.
Two packed anaerobic digesters of 5 l. Reactors packing: 25 mm diameter bactoballs.
Two computer controlled heating blankets of 120 W, with PID control and with a thermostat. Temperature range: 0 – 90 °C.
Four computer controlled peristaltic pumps.
Feeding flows measurement by the pumps calibration.
Two volumetric tanks for the storage and volume measurement of the generated biogas.
Buffer vessel, of 1 l of capacity.
Two glass vessels, of 1 l of capacity, for the acid and the base.
Methane sensor to measure its concentration in the generated biogas, 0 – 100 %.
Two pH sensors.
Two “J” type temperature sensors.
The complete unit includes as well:
Advanced Real-Time SCADA and PID Control.
Open Control + Multicontrol + Real-Time Control.
Specialized EDIBON Control Software based on LabVIEW.
National Instruments Data Acquisition board (250 KS/s, kilo samples per second).
Calibration exercises, which are included, teach the user how to calibrate a sensor and the importance of checking the accuracy of the sensors before taking measurements.
Projector and/or electronic whiteboard compatibility allows the unit to be explained and demonstrated to an entire class at one time.
Capable of doing applied research, real industrial simulation, training courses, etc.
Remote operation and control by the user and remote control for EDIBON technical support, are always included.
Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).
Designed and manufactured under several quality standards.
Optional ICAI software to create, edit and carry out practical exercises, tests, exams, calculations, etc. Apart from monitoring user's knowledge and progress reached.
This unit has been designed for future expansion and integration. A common expansion is the EDIBON Scada-Net (ESN) System which enables multiple students to simultaneously operate many units in a network.
2 EBGC/CIB. Control Interface Box:
The Control Interface Box is part of the SCADA system.
Control interface box with process diagram in the front panel.
The unit control elements are permanently computer controlled.
Simultaneous visualization in the computer of all parameters involved in the process.
Calibration of all sensors involved in the process.
Real time curves representation about system responses.
All the actuators’ values can be changed at any time from the keyboard allowing the analysis about curves and responses of the whole process.
Shield and filtered signals to avoid external interferences.
Real time PID control with flexibility of modifications from the computer keyboard of the PID parameters, at any moment during the process.
Real time PID control for parameters involved in the process simultaneously.
Proportional control, integral control and derivative control, based on the real PID mathematical formula, by changing the values, at any time, of the three control constants (proportional, integral and derivative constants).
Open control allowing modifications, at any moment and in real time, of parameters involved in the process simultaneously.
Three safety levels, one mechanical in the unit, another electronic in the control interface and the third one in the control software.
3 DAB. Data Acquisition Board:
The Data Acquisition board is part of the SCADA system.
PCI Express Data acquisition board (National Instruments) to be placed in a computer slot.
Analog input: Channels= 16 single-ended or 8 differential. Resolution=16 bits, 1 in 65536. Sampling rate up to: 250 KS/s (kilo samples per second).
Analog output: Channels=2. Resolution=16 bits, 1 in 65536.
Digital Input/Output: Channels=24 inputs/outputs.
The Data Acquisition board model may change at any moment, providing the same or better features than those required for the unit.
4 EBGC/CCSOF. PID Computer Control +Data Acquisition+Data Management Software:
The three softwares are part of the SCADA system.
Compatible with the industry standards.
Flexible, open and multicontrol software, developed with actual windows graphic systems, acting simultaneously on all process parameters.
Analog and digital PID control. PID menu and set point selection required in the whole work range.
Management, processing, comparison and storage of data.
Sampling velocity up to 250 KS/s (kilo samples per second).
Calibration system for the sensors involved in the process.
It allows the registration of the alarms state and the graphic representation in real time.
Open software, allowing the teacher to modify texts, instructions. Teacher’s and student’s passwords to facilitate the teacher’s control on the student, and allowing the access to different work levels.
This unit allows the 30 students of the classroom to visualize simultaneously all the results and the manipulation of the unit, during the process, by using a projector or an electronic whiteboard.
5 Cables and Accessories, for normal operation.
This unit is supplied with 8 manuals: Required Services, Assembly and Installation, Interface and Control Software, Starting-up, Safety, Maintenance, Calibration & Practices Manuals.
* References 1 to 6 are the main items: EBGC + EBGC/CIB + DAB + EBGC/CCSOF + Cables and Accessories + Manuals are included in the minimum supply for enabling normal and full operation.
EXERCISES AND PRACTICAL POSSIBILITIES TO BE DONE WITH THE MAIN ITEMS
1.- Study of the stabilization process.
2.- Study of the effect of temperature in the anaerobic digestion, purification and quality of the obtained biogas.
3.- Study of the pH effect of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
4.- Study of the influence of the feeding rate in the anaerobic digestion, purification and quality of the obtained biogas.
5.- Study of the influence of the type of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
6.- Study of the concentration of nutrients influence of the feeding waste water in the anaerobic digestion, purification and quality of the obtained biogas.
7.- Study of the hydraulic load effect in the anaerobic digestion, purification and quality of the obtained biogas.
8.- Study of the inhibitors influence in the anaerobic digestion, purification and quality of the obtained biogas.
9.- Comparison between the mesophilic and thermophilic anaerobic digestion and their influence in the biogas obtention.
10.- Determination of the optimum operation temperature.
11.- Determination of the optimum feeding rate.
12.- Determination of the optimum solids/water relation.
13.- Determination of the optimum degradable/non degradable solids relation.
14.- Determination of the multistage nature in the anaerobic digestion.
15.- Determination of the kinetics.
16.- Carbon balance.
17.- Solids balance.
18.- Biogas balance.
Additional practical possibilities:
19.- Sensors calibration.
Other possibilities to be done with this Unit:
20.- Many students view results simultaneously.
To view all results in real time in the classroom by means of a projector or an electronic whiteboard.
21.- Open Control, Multicontrol and Real Time Control.
This unit allows intrinsically and/or extrinsically to change the span, gains; proportional, integral, derivative parameters; etc, in real time.
22.- The Computer Control System with SCADA and PID Control allow a real industrial simulation.
23.- This unit is totally safe as uses mechanical, electrical/electronic, and software safety devices.
24.- This unit can be used for doing applied research.
25.- This unit can be used for giving training courses to Industries even to other Technical Education Institutions.
26.- Control of the EBGC unit process through the control interface box without the computer.
27.- Visualization of all the sensors values used in the EBGC unit process.
- By using PLC-PI additional 19 more exercises can be done.
- Several other exercises can be done and designed by the user.
TENDER SPECIFICATIONS (for optional items)
a) Industrial configuration
7 PLC. Industrial Control using PLC (it includes PLC-PI Module plus PLC-SOF Control Software):
-PLC-PI. PLC Module:
Circuit diagram in the module front panel.
Digital inputs (X) and Digital outputs (Y) block: 16 Digital inputs. 14 Digital outputs.
Analog inputs block: 16 Analog inputs.
Analog outputs block: 4 Analog outputs.
High-speed scan of 0.32 µsec. Program capacity of 32 Ksteps. High-speed counter. Multi-point PID control.
Digital inputs/outputs and analog inputs/outputs Panasonic modules.
-EBGC/PLC-SOF. PLC Control Software:
For this particular unit, always included with PLC supply.
Practices to be done with PLC-PI:
1.- Control of the particular unit process through the control interface box without the computer.
2.- Visualization of all the sensors values used in the particular unit process.
3.- Calibration of all sensors included in the particular unit process.
4.- Hand on of all the actuators involved in the particular unit process.
5.- Realization of different experiments, in automatic way, without having in front the particular unit. (These experiments can be decided previously).
6.- Simulation of outside actions, in the cases do not exist hardware elements. (Example: test of complementary tanks, complementary industrialenvironment to the process to be studied, etc).
7.- PLC hardware general use.
8.- PLC process application for the particular unit.
9.- PLC structure.
10.-PLC inputs and outputs configuration.
11.-PLC configuration possibilities.
12.-PLC program languages.
13.-PLC different programming standard languages (ladder diagram (LD), structured text (ST), instructions list (IL), sequential function chart (SFC), function block diagram (FBD)).
14.-New configuration and development of new process.
15.-Hand on an established process.
16.-To visualize and see the results and to make comparisons with the particular unit process.
17.-Possibility of creating new process in relation with the particular unit.
18.-PLC Programming Exercises.
19.-Own PLC applications in accordance with teacher and student requirements.
b) Technical and Vocational Education configuration
8 EBGC/ICAI. Interactive Computer Aided Instruction Software.
This complete software package consists of an Instructor Software (EDIBON Classroom Manager - ECM-SOF) totally integrated with the Student Software (EDIBON Student Labsoft - ESL-SOF). Both are interconnected so that the teacher knows at any moment what is the theoretical and practical knowledge of the students.
- ECM-SOF. EDIBON Classroom Manager (Instructor Software).
ECM-SOF is the application that allows the Instructor to register students, manage and assign tasks for workgroups, create own content to carry out Practical Exercises, choose one of the evaluation methods to check the Student knowledge and monitor the progression related to the planned tasks for individual students, workgroups, units, etc...so the teacher can know in real time the level of understanding of any student in the classroom.
• User Data Base Management.
• Administration and assignment of Workgroup, Task and Training sessions.
• Creation and Integration of Practical Exercises and Multimedia Resources.
• Custom Design of Evaluation Methods.
• Creation and assignment of Formulas & Equations.
• Equation System Solver Engine.
• Updatable Contents.
• Report generation, User Progression Monitoring and Statistics.
- ESL-SOF. EDIBON Student Labsoft (Student Software).
ESL-SOF is the application addressed to the Students that helps them to understand theoretical concepts by means of practical exercises and to prove their knowledge and progression by performing tests and calculations in addition to Multimedia Resources. Default planned tasks and an Open workgroup are provided by EDIBON to allow the students start working from the first session. Reports and statistics are available to know their progression at any time, as well as explanations for every exercise to reinforce the theoretically acquired technical knowledge.
• Student Log-In & Self-Registration.
• Existing Tasks checking & Monitoring.
• Default contents & scheduled tasks available to be used from the first session.
• Practical Exercises accomplishment by following the Manual provided by EDIBON.
• Evaluation Methods to prove your knowledge and progression.
• Test self-correction.
• Calculations computing and plotting.
• Equation System Solver Engine.
• User Monitoring Learning & Printable Reports.
• Multimedia-Supported auxiliary resources.
9 EBGC/FSS. Faults Simulation System.
Faults Simulation System (FSS) is a Software package that simulates several faults in any EDIBON Computer Controlled Unit.
The "FAULTS" mode consists in causing several faults in the unit normal operation. The student must find them and solve them.
There are several kinds of faults that can be grouped in the following sections:
Faults affecting the sensors measurement:
- An incorrect calibration is applied to them.
Faults affecting the actuators:
- Actuators channels interchange at any time during the program execution.
- Response reduction of an actuator.
Faults in the controls execution:
- Inversion of the performance in ON/OFF controls.
- Reduction or increase of the calculated total response.
- The action of some controls is annulled.
- Several on/off faults can be included.
c) Multipost Expansions options
10 MINI ESN. EDIBON Mini Scada-Net System for being used with EDIBON Teaching Units.
MINI ESN. EDIBON Mini Scada-Net System allows up to 30 students to work with a Teaching Unit in any laboratory, simultaneously.
The MINI ESN system consists of the adaptation of any EDIBON Computer Controlled Unit with SCADA and PID Control integrated in a local network.
This system allows to view/control the unit remotely, from any computer integrated in the local net (in the classroom), through the main computer connected to the unit.
- It allows up to 30 students to work simultaneously with the EDIBON Computer Controlled Unit with SCADA and PID Control, connected in a local net.
- Open Control + Multicontrol + Real Time Control + Multi Student Post.
- Instructor controls and explains to all students at the same time.
- Any user/student can work doing "real time" control/multicontrol and visualisation.
- Instructor can see in the computer what any user/student is doing in the unit.
- Continuous communication between the instructor and all the users/students connected.
- It allows an easier and quicker understanding.
- This system allows you can save time and cost.
- Future expansions with more EDIBON Units.
The system basically will consist of:
This system is used with a Computer Controlled Unit.
- Instructor’s computer.
- Students’ computers.
- Local Network.
- Unit-Control Interface adaptation.
- Unit Software adaptation.
- MINI ESN Software to control the whole system.
- Cables and accessories required for a normal operation.