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Sistema de control online de calidad de pellets de madera


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Presentación realizada por Martin Englisch, CEO de BEA Institut für Bioenergie, en el 11 Congreso Internacional de Bioenergía "Bioenergía 4.0: Retos y Oportunidades"

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Sistema de control online de calidad de pellets de madera

  1. 1. • BEA - About us 2 BEA – About us BEA offers technical services for production and combustion of solid biofuels. Quality control and fuel analysis  Experts with > 20 years experience  Contract with 80+ pellet production plants for ENplus/DINplus inspection  Accredited laboratory for fuel analysis Supply of lab equipment  for pellet plants  for fuel laboratories
  3. 3. 4 1.0 To get started – the most basic production Control water content of raw material to keep in defined range QUALITY CONTROL IN PELLET PRODUCTION
  4. 4. 5 1.0 To get started – the most basic production • No stable production, very low availability of plant • No Certification • High power consumption, high wear QUALITY CONTROL IN PELLET PRODUCTION
  5. 5. 6 2.0 simple quality control Simple instruments to check few product parameters • Results sometimes very wrong! • Not suitable to control and stabilize production • No Certification QUALITY CONTROL IN PELLET PRODUCTION
  6. 6. 7 QUALITY CONTROL IN PELLET PRODUCTION 3.0 minimum quality control according ENplus/DINplus Product control: Fines, Oversizes, Bulk density, Water content, Durability Sampling once per shift • Sufficient for Certification • Results sometimes wrong • Limited suitability for process control
  7. 7. 8 3.5 quality control exceeding ENplus/DINplus • Higher sampling and testing frequencies • Additional parameters like ash content • Checks along the production process e.g. online moisture control and manual sampling for calibrati • Investment in high quality instruments with improved precision QUALITY CONTROL IN PELLET PRODUCTION
  8. 8. 9  Reproducibility of test methods is (often) limited  High influence of staff  on test result  analytical skills and understanding may be limited  mistakes due to „boring“ routine (little validation)  motivation (decreases e.g. night shifts)  may get blamed when quality is out of specification  Limited staff resources  keeping production running first goal;  quality control reduced when plant does not operate well  Non-compliances may be very costly BUT STILL, CHALLENGES REMAIN
  9. 9. 10 Automatic analyzers 4.0 online quality control systems  Reduce human influence  May increase repeatability (quality of results)  May be used for plant control  Improved quality of product (incl. reduced losses due to fines)  Reduction of wear and energy consumption  Man-less operation (e.g. night-shift)  Types and principles  Automatic analysis  Automatic sampling and analysis (online)  Single parameters  Multiple parameters  Physical-mechanical methods  Spectroscopy
  10. 10. 11 System for durability:  Fully automatic sampling  Reproducible accuracy of ± 0.1% Advantage: fast Disadvantage: not according reference method online, physical-mechanical single parameter Source:
  11. 11. 12 online, physical-mechanical some parameters System for bulk density, moisture, temperature:  Fully automatic sampling and analysis  Output signals may be integrated in plant control Advantage: fast, reliable Disadvantage: complex system but still not all required parameters Source:
  12. 12. 13 System for moisture, foreign matter, fuel volume Real-time using X-ray technology  Designed for power plants, sawmills and bio-refinaries  Fully automatic on-line analysis  Measures whole amount of fuel Advantage: fast, whole amount of fuel Disadvantage: complex system but important pellet parameters missing online, spectrometry some parameters Source:
  13. 13. 14 online, spectrometry some parameters High end Real-time NIR - Technology  Highly developed systems from other industries (food, plastics, board and wood-panels, etc.)  Lab and on-line analysis systems  Many parameters possible: moisture, extractives, proteins, ash (density, durability, energy content) Source: Source:
  14. 14. 15 online, spectrometry some parameters Advantage: fast, broad information Disadvantage: • complex system needs high level of method development and calibration. • Parameters like durability determined indirectly – change of e.g. raw material or process need recalibration • Parameters missing e.g. length distribution Source:
  15. 15. 16 online, physical-mechanical all parameters BEA - Development 2013-2016 Developed only for pellet industry Only system worldwide using ISO methods First instrument installed December 2016 – in full commercial operation since start 2 systems are currently installed
  16. 16. 17  100% automatic, eliminating any staff influence  All ENplus quality requirements:  durability  moisture  bulk density  temperature  optional: length distribution  Documentation  within instrument  exchange with plant control  and remote access Key data
  17. 17. 18 r interlab. comp. STD BEA-PPA Bulk density 13 kg/m³ 3 kg/m³ Durability 0,17 % < 0,05 % Moisture 0,20 % < 0,15% Performance
  18. 18. 19 • • •