Rockwell Automation Assists in South African First
Rockwell Automation has entered into the local renewable energy market with a project win to supply its Integrated Architecture solution to a biodiesel project.
| Challenge At the first continuous, fully automated biodiesel plant in South Africa, the key challenge was to have complete visibility of the process plant froma central engineering station or remote location, at all times. Solutions An Integrated Architecture solution featuring an Allen-Bradley® ControlLogix® controller, RSLogix™ 5000 programming software, FactoryTalk View SCADA system, intelligent motor control, analogues featuring HART and numerous Allen-Bradley drives, including the PowerFlex® 40 and PowerFlex 700. Rockwell Automation was selected as the preferred automation vendor due to its range of solutions meeting the application and project requirements. Rockwell Automation CSM provided support in the formof an embedded engineer to optimise PID control loops and variable speed drive applications. These included advanced PID loops for temperature and pressure control. Results Rockwell Automation’s powerful control system and associated software allowed the plant to upgrade easily and seamlessly. Reduced engineering time, premier integration with the drives and vertical integration allows excellent visualisation from the office environment straight down to the drives. Single vendor responsibility for supply of all automation equipment. |
The solution was supplied to Bioneer, a multi-disciplinary engineering consultancy responsible for the engineering and technology for the first continuous, fully automated biodiesel plant in South Africa, located in Chamdor on the West Rand of Johannesburg.
The plant was constructed for GBC Organic Fuels and coverts used cooking oil, sourced from fast food chains, into biodiesel. This is accomplished through a double catalytic process using methanol, as well as a two-stage settling process.
According to Bioneer managing director, Gerrit Smith, Rockwell Automation was selected as the preferred automation vendor because its range of solutions suited the application, as well as the project requirements.
“In addition to the company’s excellent hardware and software solutions, its team of engineers showed complete commitment and gave us an incredible level of support.”
Integrated Architecture
“We selected this state-of-the-art software and hardware so that the plant would run smoothly and optimally. The use of Rockwell Automation’s powerful control system and associated software also allows us to upgrade the plant easily and seamlessly.We would even be able to add another line because we have the infrastructure to support it. There is also the potential for remote monitoring of operations which would be beneficial if there were more than one plant,” says Smith.
The Integrated Architecture solution features an Allen-Bradley ControlLogix controller, RSLogix 5000 programming software, FactoryTalkView SCADA system, intelligent motor control, analogues featuring HART, as well as numerous Allen-Bradley drives, including the PowerFlex 40 and PowerFlex 700.
One of the key challenges of the project was to have complete visibility of the process plant from a central engineering station or remote location at all times |
Maximising Efficiency
One of the key challenges of the project was to have complete visibility of the process plant from a central engineering station or remote location at all times. Based on these requirements, the ControlLogix solution included an L63 processor housed in a 17 slot chassis, Ethernet IP bridge module for communication to the engineering workstation and for remote programming. HART enabled analogues were added to provide the customer with a clear vision of plant process instrument health at all times.
The Rockwell Automation scope of delivery also included all motor protection circuit breakers, electronic overload relays, contactors, push buttons, control and load switches and related switchgear. While the solution was installed by Bioneer engineers, Rockwell Automation was on hand with advice and support, when needed.
Rockwell Automation Customer Service and Maintenance Group provided support in the form of an embedded engineer to optimise PID control loops and variable speed drive applications. These included advanced PID loops for temperature and pressure control.
According to Grant Watkins, Industry Manager, Rockwell Automation – the selected solution provided ensured that Bioneer was able to obtain single vendor responsibility for supply of all automation equipment. “Additional benefits for the project team include reduced engineering time, premier integration with the drives, and vertical integration that allows for excellent visualisation from the office environment straight down to the drives,” saysWatkins.
Construction on the plant began in January 2008 after an environmental impact assessment, and was fully commissioned in June. Smith notes that in addition to the plant being automated and continuous, it is also the first biodiesel plant in the country to use ultrasonic technology and solid esterification. “Esterification coverts the free fatty acids from the cooking oil straight into biodiesel, and is followed by trans-esterification where the oil reacts with methanol, is converted to biodiesel, and the resulting glycerol is settled.
“Bioneer engineered this process to provide maximum efficiency in regards to energy, methanol and catalyst consumption, as well as cooking oil conversion rate.We don’t use water in the process which means that the plant is more environmentally friendly. The biodiesel yielded is of an excellent quality and is even used in the plant’s boiler,” says Smith.
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Results
The plant meets environmental and safety standards and currently has a capacity of 100,000 litres per month, which will increase to approximately 500,000 litres per month once it is running at optimum levels.
GBC Organic Fuels sells the biodiesel to diesel distributors to be used as a 5 percent blend, while the logistic trucks servicing the fast food outlets that supply the used cooking oil run on a 20 percent blend.
For more information, please e-mail us at: info_at@ra.rockwell.com with ref: Bioneer
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