Using Innovative Automation Solutions in Biofuels – Technology Features, Applications and Economics

  Abstract

Since
decades biofuels plants are automated with programmable logic controllers (PLC)
or distributed control systems (DCS) and continuous improved by operational
excellence programs. However, highly automated plants are still small and the
authors observe that there is an ongoing drift between the advanced operation techniques
and practice.

Innovative
automation solutions, such as model predictive control (MPC), Smith Predictor
Control, Control Performance Monitoring (CPM), PID Analysis & Tuning and
Softsensors are promise increased plant throughput, improvements of operability
and energy efficiency, reduction of plant start-up time as well as reduced
engineering cost and standardization in biofuels plants.

Innovative
automation solutions could – in the opinion of the authors - be implemented
much more in practice and this contribution aims to show the possibilities from
an application point of view and stimulating a dialogue between academia,
suppliers and users.

Specialized
suppliers offer tools and support with sophisticated functionalities,
independently from the distributed control system (DCS). Furthermore DCS
suppliers offer separate solutions which can be linked via OPC to their own automation
system. Alternatives to the established separate solutions, several DCS
suppliers have developed integrated advanced process control solutions in the recent
years. This opens up potential new application fields.

General
aspects related to the selection of attractive applications in bioethanol
process units

(slurry
solids, fermentation, distillation, drying) are summarized. Actual status,
advantages and disadvantages of the different approaches are shown to provide
orientation and decision factors for user in the biofuels industry. The most
common used technology in industrial practice “Model Predictive Control” is illustrated
with respect to tools, suppliers, degree of utilization, hurdles for
implementation, engineering, standardization and cost-benefit in investment and
maintenance.