The grōCONTROL
system is designed to enhance the operation of the First Wave system by
automating the TSS (Total Suspended Solids) and pH readings of the process
liquids at specified time intervals. When grōCONTROL is activated, it will
automatically adjust the polymer dosing to maintain optimal operation with
minimal operator supervision or intervention.
The main functions
of the grōCONTROL system include:
1. Automated Readings:
The
system will automatically take TSS and pH readings of the process liquids at
predetermined time intervals. This ensures that the system constantly monitors
the quality of the liquid and makes necessary adjustments.
2. Optimal Polymer Dosing:
Based
on the readings obtained, the grōCONTROL system will adjust the polymer dosing
to maintain the desired TSS and pH levels. This helps in achieving efficient
and effective treatment of the liquid.
3. Operator Supervision:
The
grōCONTROL system reduces the need for continuous operator supervision by
automating the monitoring and adjustment process. Operators can rely on the
system to make appropriate decisions based on the collected data.
4. Intervention when Required:
In
cases where the system detects deviations from the desired TSS and pH levels,
it may trigger alarms or notifications to alert operators of the issue. This
allows for prompt intervention and corrective actions to be taken.
The grōCONTROL
system greatly enhances the efficiency and reliability of the treatment process
by automating critical monitoring and adjustment tasks. It reduces the reliance
on manual interventions, thereby improving operational stability and minimizing
the risk of human error.
Goals of chemical
treatment
| System | Microscreen
filtrate TSS | Size of
flocs on microscreen | Strength of
flocs on microscreen |
Goals | First Wave System | <15% of inlet liquid TSS | Large | Strong |
Goals | Plant system – Second Wave | <1.5% of Inlet Liquid TSS | Large | Strong |
LARGE
FLOCS
The purpose of the
Microscreen is to effectively remove solids, and therefore, it is important
that the size of the flocs exceeds the opening size of the microscreen (300
µm). This ensures that the flocs are retained by the microscreen and not passed
through, improving the overall solids removal efficiency.
STRONG
FLOCS
Strong flocs offer
two significant advantages in the treatment process. Firstly, they are less
likely to break apart when in contact with the Microscreen, reducing the
likelihood of increased filtrate Total Suspended Solids (TSS) levels. Secondly,
strong flocs enable the screw presses to produce drier solids and cleaner
liquids. To determine strong flocs, collect the flocs from a screen, typically
with a 300 µm opening, using one hand and squeeze gently. "Strong"
flocs should allow for easy liquid removal without excessive liquid passing
through your fingers, resulting in relatively dry solids.
By promoting the
formation of large flocs and ensuring their strength, the treatment process can
achieve improved solids removal and generate higher-quality solids and liquids.
Initial Chemistry Setting (LWR
model)
During the initial start-up of the
system, it is important to set the chemistry parameters manually before
allowing the grōCONTROL unit to take control. Follow the table below to set the initial
chemistry values. Once the grōCONTROL unit has taken its initial measurements, which
typically occurs after 20 minutes of running time, grōCONTROL can be placed back into AUTO mode to enable automatic control of polymer dosing.
First Wave
System | Plant System
– (includes the Second Wave) |
Manure TSS (ppm) | grō 17 (ppm) | Manure TSS (ppm) | grō 17 dosage(ppm) |
15,000 | 100 | 15,000 | 530 |
20,000 | 325 | 20,000 | 648 |
25,000 | 546 | 25,000 | 767 |
30,000 | 741 | 30,000 | 885 |
40,000 | 1095 | 35,000 | 1003 |
| | 40,000 | 1121 |
Chemistry Adjustment for Microscreen
The grōCONTROL
system is designed to continuously monitor the inlet and filtrate Total
Suspended Solids (TSS) levels in the process. It takes readings every 20
minutes and adjusts the polymer dosing rate based on the inlet TSS
concentration.
Additionally,
grōCONTROL compares the filtrate TSS with the expected range. If the filtrate
TSS falls outside of the specified range, the system will make adjustments to
bring it back within the desired range. The dosing rate will be trimmed up or
down by 10 parts per million (ppm) to effectively control the TSS in the
filtrate.
This automatic
adjustment mechanism ensures that the microscreen filtration process remains
optimized and maintains the desired level of TSS removal efficiency. By
continuously monitoring and adjusting the dosing rate, grōCONTROL minimizes
operator intervention and ensures consistent and reliable performance of the
microscreen system.
grōCONTROL
OPERATION WITH THE FIRST WAVE SYSTEM
The operation of
grōCONTROL with the First Wave system is controlled through two buttons on the
P-150B HMI Popup screen. These buttons determine the mode of operation for the
grōCONTROL unit:
1. grōCONTROL Manual/AUTO
This
button allows the operator to switch between MANUAL and AUTO modes. In AUTO mode, the grōCONTROL system will automatically adjust the
dosing of grō17 polymer to maintain optimal system performance based on the TSS
measurements. It is recommended to keep this button in AUTO mode for the
best performance of the system.
2. PID AUTO/MANUAL
This
button controls the mode of the PID (Proportional-Integral-Derivative) control
algorithm used by the system.
In AUTO mode, the PLC (Programmable Logic Controller) will automatically
control the speed of the pump to achieve the desired dose in parts per million
(ppm) of gro17 polymer.
In MANUAL mode, the operator has the ability to manually control the pump
motor speed in Hertz (Hz). It is recommended to keep this button in AUTO mode to allow the system to automatically adjust the pump speed based on the
required dose.
By utilizing these
buttons and keeping the grōControl system in AUTO mode, operators can
ensure that the polymer dosing is automatically adjusted and maintained at
optimal levels for efficient system performance.
grōCONTROL
OPERATION WITH THE PLANT SYSTEM (INCLUDING THE SECOND WAVE)
The operation of
the grōCONTROL system in conjunction with the PLANT system, including the
Second Wave, is controlled through three buttons on the P-150B HMI Popup
screen. These buttons determine the mode of operation for grōCONTROL:
1. grōCONTROL Manual/AUTO
This
button allows the operator to switch between MANUAL and AUTO modes. In AUTO mode, the grōCONTROL system will automatically adjust the
dosing of grō17 polymer to maintain optimal system performance based on the TSS
measurements. When in MANUAL mode, the operator has the ability to
manually set the dose in parts per million (ppm) of gro17 polymer. It is
recommended to keep this button in AUTO mode for the best performance of
the system.
2. PID AUTO/MANUAL
This
button controls the mode of the PID (Proportional-Integral-Derivative) control
algorithm used by the system. In AUTO mode, the PLC (Programmable Logic
Controller) will automatically control the speed of the pump to achieve the
desired dose in ppm. When in MANUAL mode, the operator can manually
control the pump motor speed in Hertz (Hz). It is recommended to keep this
button in AUTO mode to allow the system to automatically adjust the pump
speed based on the required dose.
3. FIRST WAVE ONLY/SECOND WAVE
This
button allows the operator to select the operational mode of grōCONTROL. When
set to "FIRST WAVE ONLY," grōCONTROL will adjust the dosing to
maintain an 85% solids removal rate in the system. When set to "SECOND
WAVE," grōCONTROL will adjust the dosing to maintain a higher solids
removal rate of 98.5% in the Second Wave. It is important to note that if the
Second Wave is running, grōCONTROL MUST be set to "SECOND WAVE"
mode.
By utilizing these
buttons and keeping grōCONTROL in AUTO mode,
operators can ensure that the grō17 polymer dosing is automatically adjusted to maintain optimal system
performance. Additionally, selecting the appropriate operational mode (FIRST WAVE ONLY or SECOND WAVE) ensures that the grōCONTROL system is calibrated to achieve
the desired solids removal rate based on the specific stage of the PLANT system.