BIO ENERGY
TRANSFORMING WASTE INTO FUEL
Raven SR transforms waste – such as solid waste, organic waste and methane – into high-quality usable fuels. To streamline its energy transformation process, Watlow provided expertise in thermal system design and Industry 4.0 control
A
s a clean fuels company, Raven SR transforms municipal solid waste, organic
waste and methane into high-quality, clean hydrogen and synthetic fuels. These are Fischer- Tropsch synthetic fuels, meaning that they are produced from a gas-to-liquid polymerisation technique that converts carbon monoxide and hydrogen into liquid hydrocarbon fuels that can act as substitutes for petroleum products. At the heart of Raven SR’s processes is a
CO2 reforming process that changes mixed feedstock and organic waste into products in an
environmentally friendly way, without the need for combustion. As a result, no emissions are produced – only clean hydrogen and fuels as output. Raven SR’s work is a crucial step in achieving
clean energy and greater energy independence. Not only does its process create fuel from waste that would otherwise end up in a landfill, but its products can also be created locally and delivered directly to gas stations in the region without the need for long-distance transportation or pipelines.
THERMAL CONTROL Although combustion is not used as part of Raven SR’s technology, precise thermal control plays a huge part in driving an efficient and safe process. There is already a clear connection between the operational targets that Raven SR is putting forward and the thermal content of the system. At higher temperatures, it’s possible to achieve 99.9% target output, a level of efficiency that also makes the process more cost effective. Achieving the high temperature requires running heaters at their maximum capacity for extended periods of time. Those heaters, however, are difficult to replace if
something fails. So, not only is precise control of temperature needed, but the entire system also needs to be monitored for any signs of a problem, or for indications of degraded performance. To help, Watlow, has designed a comprehensive thermal system from start to finish. The full thermal system provides an extraordinary
range of temperature control through different components, including the high-temperature MULTICELL heater, which offers three major advantages over other insertion heaters. These are extreme process temperature capability, independent zone control for precise temperature uniformity, and loose fit design for easy insertion and removal. The proprietary design of MULTICELL heaters with integrated thermocouple sensors provides a ‘thoughtful’ zoning and control approach, delivering precise control within the three dimensions of the reactor. The company also connected the system to other sensors for gas composition, flow and pressure. Using the WATCONNECT control panels, comprising
INDUSTRY 4.0 AT WORK This particular project is a great demonstration of Industry 4.0 at work. At a minimum, Industry 4.0 involves a physical layer of interconnected devices, but advanced cases also use a simulation layer that models and predicts the behaviour of a system as it unfolds over time. The sensors, controllers and connectors lay
temperature and process controllers, it could monitor all thermal and electrical characteristics to ensure proper process stability for the application. Lastly, it’s the connected architecture that makes this system whole. The Internet of Thing (IoT) ‘box’ is at the heart of the system and includes hardware for connectivity, syncing data from eight F4T controllers with control loops across four WATCONNECT panels. Connectivity to the cloud via a cellular router
allows further routing of data to other applications and devices, while a human machine interface (HMI) screen displays the total state of the system at any time using a custom-designed dashboard. These features allow for near real-time data logging and monitoring of system output.
the groundwork for such a system, an important function of which provides a foundation for predictive and diagnostic analytics. One of the chief principles of Industry 4.0 systems is to gather granular data for better system operation while avoiding unnecessary maintenance cycles. For example, if a system can be monitored and studied in real time, it is possible to look for the indications of a potential part failure, allowing engineers to proactively fix or replace the part. Over time, this data can also be used to understand system wear and part longevity, allowing engineers to have better insight into maintenance cycles and system inefficiencies, prolonging system lifespan. Watlow’s sensors, control architecture and
dashboard all work together to allow Raven SR’s engineers to capture data and use it proactively to keep system efficiency and uptime as high as possible. Transforming waste into fuel is one of the most significant ways to become resource efficient and contribute to the Paris Agreement’s targets. Companies like Raven SR are key in driving this, but without thermal systems that encompass Industry 4.0 technology, the efficiency of these crucial processes becomes limited.
Watlow Raven SR
LIQUID BIO-METHANOL PILOT COULD REDUCE OFFSHORE CO2 EMISSIONS
N
et Zero Technology Centre (NZTC) and Siemens Energy have demonstrated the running of an aero-derived gas turbine
on green methanol. This world first pilot, at the RWG facility in Aberdeen, creates the potential for significant reductions in
offshore CO2 emissions. It is believed that the use of green methanol could cut carbon dioxide
emissions by up to 75% compared to conventional fuels across the UKCS. The pilot marks a key milestone in NZTC’s ETF Alternative Fuel for Gas Turbines project. It aims to develop a cost-effective, retrofittable solution for existing gas turbines to help decarbonise the power generation sector across Scotland’s oil and gas operations. This successful pilot paves the way for existing offshore assets to operate using low carbon fuels without extensive modifications. If adopted this approach will help the energy industry reach Net Zero targets and provide significant
domestic and export potential. Charlie Booth, project manager, from Net Zero Technology Centre said: “The ETF Alternative Fuels Gas Turbine project identified green methanol as a strong contender for a clean, low-carbon, transition fuel for offshore power generation. This pilot unit takes us one-step closer to proving the viability of green methanol as a fuel for aero-derived turbines to reduce offshore emissions and strengthen the UK’s position as a leader in low energy systems.”
Net Zero Technology Centre
www.netzerotc.com
www.watlow.com
www.ravensr.com
16 ENERGY & SUSTAINABILITY SOLUTIONS - Spring 2023
www.essmag.co.uk
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