How Entsorga uses data storage to improve plant efficiency and sustainability

Industrial machine builders are constantly looking for solutions to improve performance and reduce costs. In a context that demands the manufacturing sector to be increasingly resilient and sustainable, the IXON Cloud application developed by Entsorga represents a true virtuous circle.

Challenge

Italian company Entsorga is a leading designer and builder of plants for production of energy, materials and renewable fuels from waste. The company was looking for a solution that could combine remote access with data storage. So that both remote maintenance operations and the improvement of its maintenance service offering could be realised.

There were several objectives: 

• Equip Entsorga's technicians with the tools and information for proactive assistance
• Provide plant managers with an overview of operations
• Ensure optimal levels of biogas production, reducing the environmental impact of the plants

Solution

The IXON Cloud solution was chosen for the installation of lines to recover biogas from organic waste. The operation of a line involves an overhead crane for waste handling, and a plug-flow semi-dry anaerobic digester where biological fermentation takes place in the absence of oxygen. 

The waste in the digester is moved by an agitator, to facilitate the activity of the microorganisms, and maintained at a constant temperature of 40°C by a steam heating system. The biogas thus obtained is subsequently refined to obtain biomethane, which in turn is fed by a compressor into the Snam network (Italian energy infrastructure company).

In the absence of a control system, the downtime of one or more machines can compromise biological fermentation and cause a reduction in biogas production.

_{Andrea Rivetti Electrical and Automation Engineer at Entsorga}

IXON Cloud allows for remote monitoring of the entire line. The overhead crane, the plug and flow digester, the upgrading plant and the compressor are connected and active 24/7. Thanks to sensors installed along the line, data is collected using a PLC based system: PLCs are installed on individual machines and connected to a central PLC, which in turn is connected to an IXrouter. 

The IXrouter collects and transfers all data to the IXON Cloud platform, which Entsorga's technicians can access remotely at any time. They can connect directly to the plants located at the customer's premises. They can monitor their operation and set up real-time notifications when thresholds are reached (distance travelled by the crane, amount of waste fed into the digester, measurement of biogas flow rate in Nm3/h). This allows immediate intervention in the event of anomalies, guaranteeing an optimal level of biomethane production.

_{Real-time and historical data visualisation dashboard on IXON Cloud.}

With a remote access solution [...] you get a plant running 24/7, even if it’s not constantly manned by operators. That's why it’s essential to connect via the smartphone app and visualise the data in real time.

_{Andrea Rivetti Electrical and Automation Engineer at Entsorga}

In addition, the availability of data has enabled Entsorga to include regular reporting in its service model. The process engineers responsible for monitoring prepare reports on a monthly basis on the operation of each plant. This allows for additional mid-term control and the production of proven documentation to be shared with external regulators for compliance with operating criteria.

Conclusion

The application of IXON Cloud to Entsorga's technologies in the field of anaerobic digestion enables the control and optimisation of plants and production processes. The results? Reduced consumption of fossil fuels for processing, maximum energy efficiency, guaranteed optimum levels of biomethane supply, maximum treatment capacity per m² of soil, as well as a drastic reduction in on-site trips and incidents related to technical interventions.