by Gary Mintchell | Aug 9, 2022 | Automation, Capital Projects, Process Control
Sustainability continues its strong trend among industrial and manufacturing companies. This story concerns Emerson and Albioma regarding biomass.
Global technology and software company Emerson has been selected by Albioma, a French independent energy provider, to help transition its coal-fired Bois Rouge plant to 100% renewable energy. As part of Albioma’s wider mission to transition all of its existing fossil fuel plants to renewable energy, Emerson’s automation systems and software will enable the coal-fired power station to convert to biomass feedstock.
The multi-million-dollar project is the latest example of how Emerson technologies are helping customers accelerate their transition to more sustainable energy. The power plant, one of three that Albioma operates on Réunion Island in the Indian Ocean, will be converted to use 100% biomass wood pellets. The overhaul of the 108-megawatt facility will reduce greenhouse gas emissions by approximately 640,000 tons of CO2 equivalent per year, an 84% decrease in direct emissions compared to current operating levels.
The Bois Rouge plant consists of three generating units. Two units are already controlled by Emerson’s Ovation™ distributed control system, which will be modified for use with biomass feedstock, and the third unit will be replaced with a new Ovation system. The units will also be modernized with new turbine protection and health monitoring systems, safety systems for the boilers, and upgraded boiler control elements and instrumentation.
To ensure the project is completed within the available timeframe – a critical requirement of Albioma – Emerson will provide its Project Certainty methodologies, digital technologies and software expertise. In addition to delivering local engineering support for the project, Emerson will provide its Remote Virtual Office (RVO) collaboration platform – a secure virtual engineering and testing environment that will enable Albioma to access Emerson’s resources and ongoing support to reduce project risk and costs.
by Gary Mintchell | Jul 14, 2022 | Capital Projects, Commentary, News, Process Control, Technology
Technology pundits have extolled hydrogen as an energy source that makes sense from environmental and sustainable points-of-view for many years. Emerson recently hosted an online conference focused on what it is doing to help customers develop hydrogen production. We are finally on the cusp of a breakthrough. One problem hydrogen shares with electricity is dirty generation. Emerson and customers are working to solve the tech and economics of green hydrogen production.
While we are talking sustainability, please check out The Carbon Almanac. Hundreds of volunteers from around the world have worked on this practical guide to doing something about global warming and environmental dangers.
I’m going to summarize three sustainability initiatives from Emerson that I have collected for a few weeks.
- Toyota Hydrogen Production
- Green Hydrogen Production
- Biofuel Production in Finland
Automation Technology for Toyota Australia’s Hydrogen Production and Refueling Plant
Emerson and Toyota Australia have collaborated to transform part of Toyota Australia’s operations into a commercial-grade hydrogen production, storage and refueling plant. The project, supported by the Australian Renewable Energy Agency (ARENA), adopts Emerson’s automation expertise to provide the control system that helps Toyota Australia demonstrate the technical and economic feasibility of manufacturing hydrogen fuels, including the use of renewable solar energy.
- DeltaV distributed control system gathers data from the plant’s complex equipment
- DeltaV systems control operations and help ensure safe operations
- Edge control technology from PACSystems will further reduce cost and complexity of integrating third-party systems
- Rosemount flame detectors will help keep personnel and operations safe
Emerson to Help Accelerate Green Hydrogen Production
The PosHYdon project is a pilot that aims to validate the integration of offshore wind power and offshore natural gas and hydrogen production at sea—generating renewable fuels by harnessing a green energy source. The Neptune Energy-operated platform Q13a-A in the Dutch North Sea will host the project, which will provide insight into electrolyzer efficiency from a variable power supply and the cost of installing and maintaining a green hydrogen production plant on an offshore platform.
Green electricity will be used to simulate the fluctuating supply from wind turbines and power the production process, which will convert sea water into demineralized water and then safely produce hydrogen via electrolysis. The hydrogen is then blended with the natural gas and transported to the coast, via the existing gas pipeline, and fed into the national gas grid. The 1 MW electrolyzer is expected to produce up to three tons of hydrogen per week.
Emerson’s DeltaV distributed control system, DeltaV safety instrumented system and DeltaV Live operator interface software will manage the desalination and electrolyzer units, gas blending and balance of plant equipment.
PosHYdon is being developed by consortium partners Nexstep, TNO, Neptune Energy, Gasunie, Noordgastransport, NOGAT, DEME Offshore, TAQA, Eneco, Nel Hydrogen, InVesta, Hatenboer, Iv-Offshore & Energy and Emerson. The project has been awarded a €3.6 million grant from The Netherlands Enterprise Agency (RVO) under the agency’s Demonstration Energy and Climate Innovation scheme, which invests in renewable energy developments, including hydrogen pilots.
Animated video with English subtitles.
Optimize Fintoil Biorefinery Operations for More Efficient, Sustainable Production
Fintoil, together with Neste Engineering Solutions, has selected Emerson’s automation software and technologies to maximize the operational performance of its biorefinery being constructed in the port of Hamina-Kotka, Finland. The plant will be the third-largest crude tall oil (CTO) biorefinery in the world and produce advanced biofuel and biochemical feedstocks that help lower emissions and reduce reliance on fossil-based fuels.
The plant will refine CTO, a by-product of the wood pulping process, to produce a sustainable feedstock for renewable second-generation diesel, as well as rosin, sterol pitch and turpentine used in the chemicals, foodstuffs and pharmaceuticals industries. These CTO derivatives have a carbon footprint up to 90% smaller than their fossil-based equivalents.
Emerson will apply its Project Certainty methodology, which digitalizes project execution and uses practices such as remote testing of equipment. Emerson consultancy services will advise on the implementation of cybersecurity best practices.
Construction of the facility is expected to be completed in 2022. The expected annual capacity of 200,000 tons will create a 400,000-ton reduction in carbon dioxide emissions, which is roughly 1% of Finland’s total emissions.
by Gary Mintchell | May 20, 2022 | Automation, Business, Capital Projects
Seth Godin initiated a project that has enlisted many volunteers from many countries called The Carbon Almanac. You can get yours soon. I thought I could contribute from the point of view of manufacturing and industrial production. I couldn’t get any information in time to contribute. However, I have had a couple of sustainability reports in the past month. Here is one from Phoenix Contact which has installed a nearly 1-megawatt array that will produce 30% of facility’s energy needs.
“We estimate this solar power installation will reduce our electricity costs by approximately $150,000 per year. While a smart business choice for us, reducing our company’s carbon footprint is more important in the long term,” said Jack Nehlig, president of Phoenix Contact USA. “Sustainability and renewable power generation are at the heart of Phoenix Contact’s vision for an All Electric Society. This is one critical step on our journey to becoming a carbon-neutral company by 2030.”
Phoenix Contact partnered with Gatter & Diehl Consulting Engineers and Terrasol Energies, Inc. to design the rooftop solar array. Phoenix Contact designed and installed the monitoring portion of the system, which features numerous Phoenix Contact products.
Terrasol Energies, Inc. also installed the solar array on the roof of Phoenix Contact’s Logistics Center for the Americas last year. The solar array consists of 2,185 SunPower photovoltaic panels, which can generate up to 961 kilowatts. A $250,000 PEDA restart grant and a $270,000 grant from the PPL ACT 129 fund helped offset the $1.8 million investment into the solar array.
In 2014, Phoenix Contact installed a 1-megawatt Combined Cooling Heating and Power (CCHP) facility. The system provides 65 percent of the facility’s energy needs and saves the company more than $300,000 annually. With the CCHP and the solar array, Phoenix Contact will generate enough energy to go off the grid on sunny days during the shoulder seasons (spring and fall).
by Gary Mintchell | May 16, 2022 | Capital Projects
That 2,800th post was not supposed to be the last for a while. I had an attack of seasonal allergies that sapped all my energy for several days. Finally about back to normal. I know about wearing masks for Covid and flu prevention. Seasonal allergies (pollen) are another good reason to wear a mask.
Speaking of the environment (OK, this is bad segue) I have a news item that came a couple of weeks ago relative to the circular economy. That is, reusing products we’d otherwise dispose of in a toxic manner. Here is a company called Assurant that just acquired Hyla and its sustainability in manufacturing activities. It has several plants that refurbish mobile phones for trade-ins.
**I’d like to plug a project at this point that I thought I’d get involved in to write from a manufacturing point of view. The Carbon Almanac tells stories and gives tips for saving the planet. Check it out. Spread the word.**
More than ever, the output from our circular economy – a systems framework that addresses global environmental challenges including waste and pollution – continues to have a markedly positive effect on our planet. Within that, businesses who prioritize CSR by mitigating e-waste through responsible recycling of mobile devices have contributed a significant impact to this positive outcome.
Just a couple of years ago, the extent of the relationship consumers had with their carrier or retailer was limited to purchasing add-ons to their current service in the vein of an upsell model. But the consumer needs often ended there in terms of any additional requirements. Fast forward to 2022: now the consumer wants to know just where the phone goes when they’re done with it. 3G sunsetting is now shining a light on new opportunities for CSR when it comes to sustainability and if carriers and retailers do not take note, it is a missed opportunity. By the end of 2022, the majority of wireless carriers will either have already completed the process of shutting down, or sunsetting, of their 3G networks or will have started the process of doing so.
Technology and Processing (TaP) Center is the nucleus of its operations, as it is the place where pre-owned devices are received, graded and resold into the global secondary device market.
The TaP Center receives and processes over six million devices per year, and this figure is set to rise as continuous innovations and efficiency gains drive increased demand on the facility.
The TaP Center facilitates the end-to-end processing of pre-owned devices efficiently. These steps include:
- Device receipt and validation
- Device identification
- Data clearing
- Functional testing
- Cosmetic grading
- Repairs
- Parts salvaging
- Warehousing/inventory management
- Device resale
- Sustainability management
Furthermore, the secondary device market is one that continues to grow and has displayed its resilience even despite the COVID-19 pandemic. While IDC reports that the worldwide market for secondhand devices will be worth $65 million by 2024, with a compound annual growth rate of 11.2% over the next three years, Gartner found a 24% increase in refurbished phone sales during the first quarter of 2020.
The patent pending HYLA Vision Tunnel was developed for cosmetic grading. Unlike other grading and processing technology, it has been designed by those working in industrial and manufacturing environments, which means it has been built with speed and simplicity in mind, and adapted to the needs of this specific industry. Vision Tunnel is also designed with operational efficiency in mind with virtually no training required for in-warehouse personnel.
Vision Tunnel uses AI technology to evaluate and analyze each device. It will take up to seven images of each pre-owned device to determine its grade. This means HYLA has over 1,000,000 high quality 4K images that it uses to continuously train its AI technology, which ensures it grades devices with 99% accuracy.
The beauty of Vision Tunnel is that it simplifies and speeds up device processing. It minimizes manual labor, which means it is less prone to human error, while at the same time delivering consistent and reliable results
by Gary Mintchell | Aug 30, 2021 | Capital Projects, Leadership, Workforce
Working on the factory floor early in my career taught me how much typical manufacturing workers know and care about the company’s products. Consultants came from time to time, studied, rearranged, left. Not much useful happened. But the individual guys (in those days) on the line knew more about what was going on than most of the supervisors and all of management.
Therefore, an opportunity to talk with Paul Vragel, Founder and President of 4aBetterBusiness in Evanston, IL to discuss his experiences as a project engineer and integrator was too good to pass up. After all, the values he learned and still implements include these:
- Listen to people
- Engage employees
- Respect
- Ask everyone to look for problems with no fault issued
- Assume employees have needed knowledge
Vragel told me, “My initial education and experience is in Naval Architecture and Marine Engineering – that is, ship design and construction. Building a ship involves building a hotel, a restaurant, a huge warehouse and a power plant, putting them all together, putting a propeller on it and sending it out on the ocean where there are no service stations. Ship design and construction is essentially a demanding, large-scale systems engineering project.”
After graduation from Webb Institute of Naval Architecture, he worked at Newport News Shipbuilding. After a year, 2 prior graduates of Webb Institute, working for Amoco Corporation, hired him, at the age of 22, to manage ship construction programs in Spain. “A couple weeks after I was hired, I was on a plane to Spain with my instruction set being, essentially, ‘figure out what you’re supposed to do, and do that’ ”.
After a year, one of the earlier ships built in the series came in to Lisbon for its guarantee drydocking and inspection. When we opened one of the crankshaft bearings of the 30,000 hp main diesel engine, we saw the bearing material, which was supposed to be in the bearing, was lying on the crankshaft journal, in pieces.
Talk about a complex situation—the ship was built by a company controlled by the Spanish Government. They were the holder of the guarantee. The engine was built by a different company, also controlled by the Spanish Government. Amoco had a contract with the shipyard, not the engine builder. And the engine was built under license from a company in Denmark.
Vragel was there as an observer for the new construction department. The ship was under the control of the operations department. I had no authority and no staff reporting to me. “I had no technical knowledge of poured metal bearings in high-powered diesel engines, I didn’t speak Portuguese or Spanish, I was 23 years old, and the instruction from my boss was very simple: ‘Fix It!’ To add to the urgency of the ship being out of service, the shipyard in Lisbon, where the ship was located, was charging $30,000/day (about $250,000 in today’s dollars), just for being there.”
Vragel went to the engine builder in Spain who said, “We don’t think we have a problem – we think the Danes have a problem. They designed the engine, we just built it according to their instructions.”
Figuring that getting the Danish engineers down to Spain for a meeting wouldn’t be productive, he decided the only thing to do was to go into the plant and talk to the people who made the bearings. One problem – they only spoke Spanish, and he only spoke English. But there are lots of ways to communicate if you really want to. “I observed what they were doing, pointed, asked a lot of questions – they learned a little English, I learned a little Spanish – and we sketched out how the bearings were made.”
After a couple of days, he thought he had figured out the cause of the problem, but “I had the good sense to shut up. While our communication had become pretty good, I was sure that there were other parts of the process they knew about that we hadn’t touched on that might be part of the problem or solution. If I just told them what I thought, everything would stop there without awareness of those elements and we wouldn’t get an effective solution. But if I could work with them through the process so they saw the issues, the employees would bring those additional elements to the table. We would have a full understanding of the system, the employees would be part of the solution. In this way, employees would have ownership in the results.”
“And that’s exactly what happened. With a little more effort we found and fixed the causes of the problem (which was causing porosity in the bearing).”
I had no authority, no technical expertise, no staff, I was 23 years old, I didn’t speak Portuguese or Spanish, and in a few days, working cross language and cross culture in an overseas plant I had never seen in a technology in which I had no experience, we together achieved a solution that permanently raised their manufacturing capability – that they owned.
This key formative experience led to the beliefs on which 4aBetter Business was founded:
- We believe that employees are the world’s experts at knowing what they actually do every day – their local systems
- We believe that 90% of the issues in a company are embedded in the way these local systems work and work together
This lesson applies to 22-year-olds and 52-year-olds alike. Sometimes we get so wrapped up in our own ideas that we overlook an obvious source of great expertise.
by Gary Mintchell | May 28, 2021 | Business, Capital Projects, Technology
One of this week’s more intriguing conversations centered on solar power from your canopy, awning, or tent with Pvilion CEO Colin Touhey.
Maybe in these post-Covid days of rediscovered al fresco dining, you may be able to have a fine meal under a tent with lighting and outlets to charge your mobile device powered by solar cells in the fabric of the tent. Or perhaps thinking of work, you need temporary coverage of an area for work or storage. And electrical power is required. Maybe many volts and amps. Same scenario. Pvilion products, er, cover a fascinating range of use cases. I’ve included a general background of Pvilion and its technology plus use cases from the New York Botanical Garden and a Home Depot location.
What is Pvilion?
(from an essay by Director of Marketing Jill Gettinger) Pvilion integrates solar cells into fabric, producing products that when exposed to the sun, generate electricity. Pvilion can take any surface that receives sunlight, cover it with this fabric and produce electricity, providing flexible structures that can be powered independent from the electricity grid.
The more technical name for Pvilion’s offerings is flexible photovoltaic (PV) solar fabric products and structures and behind the simplicity is a 10-year-old partnership between Colin Touhey, an electrical engineer and CEO of Pvilion, and fabric industry veterans Todd Dalland, a pioneering designer and inventor in the field of lightweight structures, and Robert Lerner, AIA, an architect who has led new technology development programs involving lightweight, deployable structures for NASA, the U.S. Army and the U.S. Air Force. The three connected when they were working on integrating photovoltaic cells with fabric for the U.S. Department of Defense.
Pvilion’s roots go back more than 20 years when Dalland and Lerner developed the first photovoltaic tent. That the tent was easy to deploy, flexible and self-powered piqued the attention of the military, which led to research and development funding from the U.S. Army.
Military deployments during this time further increased product demand as forward operating bases needed to be setup quickly in places where there was no grid, and it was difficult to setup up traditional power generators.
At the same time, mobile device usage, cell phones, laptops, handheld computers, was taking off. The mobile purpose of these devices meant they often needed to be powered where access to a traditional grid source was not available. To meet this need, Pvilion developed the Solar Sail, a small solar canopy that resembles a sail, hence the name, which can be easily deployed in public spaces and at outdoor gatherings, e.g., sporting events, concerts, parks, weddings,et cetera. Once deployed and receiving sun light, it generates power that can be tapped into to charge mobile devices.
Concern for the environment also came into play as solar power’s proven advantage over fossil fuels is that its use leaves no carbon footprint. As a result, environmentally conscious corporations and public entities, like schools, began installing Pvilion’s solar power canopy structures to meet both short- and long-term needs while avoiding the costs, environmental damage, and time associated with erecting and running permanent structures tied into the local power grid.
What started out as a solar powered tent has evolved into a product range covering standalone USB charging stations and easy to erect temporary structures, including canopies and awnings, all solar powered.
The easiest way to understand what Pvilion does is to look at one of its signature products: The Solar Sail Canopy, a free-standing canopy that can be erected anywhere that receives sunlight: parks, university campuses, bus stands or in any public setting, and used to recharge mobile devices. The Solar Sail Canopy is available in (3) versions: a Single Pole Solar Sail, a Double Pole Solar Sail that can be used as a solar powered shelter, e.g., over a bus stop or bench, and a portable Four Pole Canopy for seasonal applications that can be customized to suit an individual space requirement.
Sustainability At New York Botanical Garden
Aesthetic appeal is very important to The New York Botanical Garden (NYBG), which is why the NYC Department of Citywide Administrative Services (DCAS) chose NYBG as the launch site for Pvilion’s Solar Powered Canopy structures.
Intended to provide NYBG visitors a place where they can seek shade, enjoy a beverage and recharge their mobile devices, the eight (8) solar canopies, designed, engineered and installed by Pvilion, provide ample space to relax while staying safely socially distanced.
Pvilion provides a fabric that incorporates photovoltaic cells, which generate electricity upon exposure to the sun. As part of New York City’s emission reduction efforts, seven (7) of the canopies contribute energy directly to the city’s power grid. One (1) structure powers a bank of batteries used by NYBG and by Botanical Garden visitors to charge their mobile phones and other cellular devices.
The solar canopies are a pilot project operated by Pvilion and the Innovative Demonstrations for Energy Adaptability (IDEA) Program, an initiative of the City of New York’s Division of Energy Management. The program encourages businesses, innovators and entrepreneurs to create transformative opportunities and to foster a culture of innovation. The goal is to find solutions to the challenges facing manufacturers and businesses through partnerships with private sector business entities, with emphasis placed on technology to help the City reduce carbon emissions.
Pvilion’s Solar-Powered Fabric Products are fully turn-key solutions that provide energy in any location where fabric is exposed to the sun. Pvilion integrates its fabric technology into a wide range of applications. The technology eliminates the need of having two (2) separate systems: fabric shade/shelter and solar panels. Instead, Pvilion integrates the solar power into its fabric to achieve one turn-key product that provides charging, lighting, ventilation, climate control all in an easy to install manner. Pvilion has delivered high quality products for customers like Google, Tommy Hilfiger, Carnegie Hall, Tishman, New York City, Yale Univ, the Florida Dept of Transportation, Bloomberg, The City of Miami, FL and more.
Home Depot Pilot Program to Achieve Sustainable Energy
The Home Depot Rental Center in Geismar, Louisiana, a large industrial building and parking area, serves as the rental equipment preparation and distribution center to surrounding Home Depot stores. Here, equipment is prepared before being sent to Home Depot Superstores upon being rented by customers. The first of over one hundred rental centers planned to be opened throughout the country, Geismar is also the initial location for a Home Depot green pilot energy sustainability program in which Pvilion Solar Canopies will be used to recharge rental equipment batteries.
Pvilion developed and installed its signature product, the Portable Solar Sail Tent, at the Geismar, LA Home Depot. Effectively, a relocatable canopy integrated with solar panels; the Solar Sail can provide sustainable power anywhere that receives sunlight. It lets Home Depot charge its electric rental equipment independently from the local electric grid, eliminating the environmental impact associated with traditional sources of energy and the need to create permanent infrastructure.
The implemented 20 ft x 24 ft structure provides two (2) bays under an angled roof for maximum sun exposure. It is designed to withstand extreme weather conditions yet is flexible for speedy assembly/disassembly. It can provide up to 5 kW of energy and storage for up to five (5) full operational days of energy without sun. In addition to charging rental equipment, the energy provided by the Solar Sail can also be used to power other devices such as cell phones, laptops and lighting.
