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Miyazaki Biomass Recycle, Miyazaki, Japan. The company built and operates a biomass waste-to-energy plant that helps to dispose of the poultry litter generated by the farms in the surrounding area. While it earlier had been possible to dispose of all this waste by using it as fertilizer, a significant increase in the amount of generated waste necessitated the construction of this facility.

This need was made more pressing by a law that requires livestock breeders to properly dispose of livestock waste. MBR's plant uses a stoker-type furnace to incinerate the poultry litter. Steam produced using the thermal energy from the incinerator drives a steam turbine and electricity generator with a maximum output of 11, kilowatts.

The plant is capable of incinerating tons per day of poultry litter. The electricity is sold to Kyushu Electric Power Company and the incinerator ash is sold to fertilizer companies. All operations at this biomass waste-to-energy facility are monitored and controlled using a Yokogawa solution consisting of the CENTUM CS production control system, Exaquantum plant information management system, field instruments, and analytical instruments.

Stable operation The moisture content of the poultry litter varies depending on how it has been stored, the type of poultry house that is used, and the season. The calorific value of the poultry litter depends mainly on the moisture content, and any variation in this leads to fluctuations in the amount of steam generated by the boiler system.

To help maintain a consistent moisture content, the poultry litter is mixed at the receiving point and when in storage. Any remaining variation in the moisture content is dealt with by adjusting the speed of the conveyers that feed the poultry litter to the furnace.

By these means, a constant steam flow rate is maintained. To further optimize the combustion process, a Yokogawa zirconia oxygen analyzer measures the oxygen content at the furnace outlet.

Poultry litter normally contains alkali elements such as sodium and potassium that have a lower melting point and which are likely to adhere to the furnace's inner walls and the boiler tubes if the temperature is allowed to go too high, which reduces combustion efficiency and necessitates frequent maintenance.

To keep the temperature within allowable limits, the temperature of the exhaust gases exiting the furnace must be measured and monitored. To help prevent melted soot from adhering to surfaces in the furnace and boiler tubes, many blowers have also been installed. Smooth startup This plant is shut down for maintenance approximately 35 days a year. For the cold startup of the boiler system, the furnace is initially heated up using burning A-type heavy oil. When the furnace reaches the desired temperature, the operators switch over to poultry litter fuel.

The automation and display of information on the boiler and turbine startup procedures reduces operator workload and helps to ensure a smooth and safe startup.

Odor control Odor is a significant issue at this biomass waste-to-energy plant. Countermeasures include the use of a forced draft fan to draw air from the poultry litter receiving area and storage silo into the furnace, where it is thermally cracked. Also, the air pressure inside the furnace is maintained at slightly less than atmospheric pressure by means of an induced draft fan, ensuring that no offensive odors are released from the furnace.

With the information provided on the system's graphic displays, operators can stay on top of the entire process and thus are able to see clearly, know in advance, and act with agility.

Comments from our customer on this solution: "Each day, we incinerate tons of poultry litter, which works out to , tons a year, and generate enough electricity for 17, homes. The ash is rich in phosphorus and potassium, and we sell it for use as fertilizer. We have collaborated with local farmers to solve the problems caused by poultry waste and are contributing to a sustainable society by converting this poultry litter into electricity and fertilizer.

This is a true eco-recycling system. With this system, we are able to run the plant with fewer operators while still being able to take quick action in any emergency. The plant has achieved uptime comparable to that of conventional fossil fuel power generation plants. Exaquantum can acquire data from all facets of a process and transform that data into easily usable, high-value, widely distributed information.

Exaquantum forms the basis of most Yokogawa OES. Our distributed control system DCS enables automation and control of industrial processes and enhanced business performance. Over 10, plants entrust Yokogawa DCS to deliver their production goals. Oxygen analyzers provide valuable measurements in combustion control, process quality, safety and environmental applications. The Challenges and the Solutions 1. Heat generation process flow by poultry litter 2.

Have Questions? Contact a Yokogawa Expert to learn how we can help you solve your challenges.


Yokogawa's CENTUM CS 3000 DCS Monitors and Controls Operations at Poultry Litter-to-energy Plant

High functionality and easy engineering has been realized through the implementation of the acknowledged control functions of the CENTUM CS and expanding the interoperability of communication functions with various field control equipment. Moreover, the efficiency of debugging large- scale applications has been greatly improved by expanding the "Virtual Test Function" originally developed for CS , which uses the FCS simulator of Windows NT. The trend of open system architecture is becoming an important issue with distributed control systems hereinafter abbreviated as DCSs. The control functions are no exception, either; they are required to be increasingly "open" so as to support various types of field communication. Efficient engineering and easy maintenance are also in demand in order to reduce the life-cycle costs of a plant. This demand has had a significant impact on the architecture of the control functions. This article describes the control functions of the CENTUM CS , focusing on the functions that have been newly developed to achieve interoperability and make engineering more efficient.


Operation And Monitoring Functions Of CENTUM CS 3000

The HIS, based on Windows NT 2 , features both the functionality provided by the human-machine interface of a conventional DCS and the usability demonstrated by Windows-based operation. With such functions as window hierarchy, graphic data binding and the restoration of message summary data, we are able to offer a very friendly operation and monitoring environment to users. In the field of hardware products, we have developed a console-type platform that is an operation and monitoring machine dedicated to the CENTUM CS The environment surrounding process control systems has changed dramatically as the performance of personal computers improves and the Windows 2 operating system advances, there has been a move towards the trend of open architecture.

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