RIZAL TECHNOLOGICAL UNIVERSITY

COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

This chapter deals with the results and discussion done by the group during actual

experimentation.

Specific Objectives:

1.) To implement a temperature, pH, motor and level controls for a batch process.

a.) Temperature Control

Temperature is considered as the most critical parameter to maintain in digestion rate. This is

the reason why our group implemented a temperature control to the process. A thermo-well is

mounted inside the digester since RTD is not directly contacted in the process. If the measured

temperature of RTD at digester is below set point, heater will turn on. With the certain time,

the heated water will pump and flow to jacket to reach the set point of digester temperature.

The temperature in water storage is being controlled by heater while the temperature in jacket

is controlled by the pump connected to the water storage output.

b.) pH Control

Another parameter to be considered in this process is the pH. The set point should be near

neutral or near 7 otherwise there is a need for pH down solute on or pH up solution.

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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

c.) Motor Control

Furthermore, the group provided a motor to send heated water from the water tank to the

digester’s jacket. There is also another motor for the purpose of the agitation for the even

distribution of inputs in the digestor. These motors are 110 V / 25 W agitator and the other one

is ½ Hp / 220 W sunction pump.

d.) Level Control

Lastly, the level of the digester and heater is being controlled through a GWR level controller.

Once the level reach the total level setpoint of 20.17 liters of water, food waste and manure, if

the conditions of the level are met it will turn off all the feeds and the digestion process will

start. Level from the Digester tank measures the water, food waste and manure entering the

tank for the digestion process and the level of the water for the cleaning process. There is also a

level switch in the heater tank to measure if the water in the heating tank is low. It serves as a

safety function for the heaters in used. lastly, there are level switches that are used for

measuring the level of the acid and base tank.

2. To create a 3D and de-scaled representation of anaerobic digester.

The group were provide a 3D representation for the actual implementation of the study.

It gives the real picture of the proposed design.

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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

a.) Design and Fabrication of Digester Tank, Heater Tank, and Separator Tank

The Digester Tank was designed to handle the main process of digestion which

is the generation of methane. The Heater Tank served as a heating place of the

water to be circulated in the digester’s jacket. and lastly separator tank was

designed to separate solid manure and liquid manure that would be used as

fertilizers. A motor driven agitator is installed at the center of the digester tank.

The GWR Level sensor is installed inside of the digester tank to measure the

maximum and the minimum level of the tank. The heating tank uses level switch

to measure the minimum level of the tank. A thermocouple and RTD was

installed at the side of the digester tank just enough to monitor and control the

temperature of digestor and heating tank. Figure __, __, shows the actual image

of the tanks.

b.) Design and Fabrication of Pipes and Valves

The pipes were designed and installed for the inflow and outflow of the water

from the heating tank, inflow of the acid and base to the digestor from the acid

and base tank. The connection of inflow and outflow from the motor to the

digestor’s jacket. The hose were designed and installed for the inflow and outflow

of the product to the storage tanks and backup storage. The pipes connected to

the jacket were also installed in a way that the heating medium would be able to

circulate from heating tank to the jacket of the digestor. Each pipeline has their

respective valves to permit or restrict flow.

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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

c.) Design and Fabrication of Control Panel and its Components

The control panel was designed to ensure the electronic components are away from gas

holder to prevent spark when there is a gas leak. The construction of the control panel is

made for easy sighting of audience because when in the original position, the panel is

located at the side of the prototype. The panel was designed in such a way that it

permits ventilation and entry points for the gases to create hazard in the prototype. The

relays were used for control and interlocks of the field devices to the PLC. The circuit

breaker served as isolation of the supply to the whole components inside the panel. The

terminal blocks were used for the proper termination of the devices to the supply.

Pushbuttons and toggle switches were used for local user’s interface. For initial testing

of wiring, 24VDC 3A was supplied to trace the continuity of the loop. Tagging of wires

was used for efficient wire tracing and troubleshooting. Figure __ shows the actual

image of the layout of the control panel.

d.) Design of the PLC (S7200: CPU 224 XP)

The PLC was supplied with 220VAC power supply and executes the logic of the

program to the project.

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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

e.) Design of Temperature sensor Thermocouple type K

The temperature sensor, 2-wire thermocouple is made up of 316 grade stainless

steel stem used to measure temperature in the digester tank. This temperature

was connected to a temperature controller installed in the control panel. This

controller is connected to the PLC module to the CPU to indicate the reading of

temperature from the tank.

f.) Design of RTD

The temperature sensor, 2-wire RTD is made up of 316 grade stainless steel

stem used to measure temperature in the heater tank. This temperature was

connected to a temperature controller installed in the control panel. This

controller is connected to the PLC module to the CPU to indicate the reading and

control of temperature from the tank.

g.) Configuration of Temperature Controller

The temperature controller is used to control the ampere entering the heater in order

to control the temperature inside the digester tank and the flow of water coming from

the heater. The PID of the temperature controller is set to reverse action on/off control

with a hysteresis respectively in order to get a fine tuning with the least amount of

overshoot and undershoot and the shortest stabilization time with respect to the

process.
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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

h.) Configuration of Temperature Controller

The temperature controller is used to control the ampere entering the heater in

order to control the temperature inside the digester tank. TC1 controls the temperature

of digester and TC2 controls the temperature of heater. The temperature controlled to

get the least amount of overshoot and undershoot and the shortest stabilization time

with respect to the process.

3. To ensure reliable and uninterrupted operation for bacteria

The group constructed a prototype which ensures that the process operation is

uninterrupted with any unwanted threat by making a tank sealed to meet the target of

zero oxygen and through controls of pH and temperature from digester.

4. To provide a wiring diagram of the controls and a P&ID for the actual

process of the proposed design

Wiring diagram represents the connection of wires from field devices to control

panel and to the controller. While the P&ID is a diagram that shows the interconnection

of process equipment and the instrumentation used to control the process.

5. To evaluate the functionality of the prototype and the control system

After the wiring diagram, testing the prototype will be conducted to observe if the

prototype is working based on the designed plan.

 RIZAL TECHNOLOGICAL UNIVERSITY
COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

Table 3. Actual Testing of Prototype Results

NOT
ACTIONS COMPLIED
COMPLIED

1. Manual and Automatic switching of process 

2. Solenoid valves (SVA, SVB, SVC, SVH) open and 

closes when triggered.

3. Agitator (M-001) turn ON when triggered in PLC 

4. Pump (P-001) start-up when triggered by temperature

controller in digester. 

5. Heater (H-001) turn ON when triggered by temperature 

setpoint inside the water tank.

6. Status of the equipment and sensors will be displayed in 

control panel using indicators

7. Status of the Temperature Controller will be displayed in 

control panel

8. No pipe, tank or valve leakage 

9. Push buttons does not stuck-up 

10. Indicator lamps are responsive 

11. Level sensor and temperature sensor are responsive 

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General Objective:

To construct a prototype model of an Automated Biogas and fertilizer Production,

a system that will convert food waste to biogas, solid and liquid fertilizer. And to

encourage communities to build stronger systems of organic recycling, renewable

energy and soil revitalization.

Upon completion of the specific objectives, the aim for the general objective has been

achieved. The prototype made is a representation of the proposed design. A digester tank,

Heater tank, Separator tank, motors, and pumps are prepared to visualize the actual

picture of the study. The size of the components of the prototype is not the actual size of

the plant because it is a scaled prototype. The prepared parts have indicator lamps

installed in front of the control panel. Every time the instrument is being used in the

process the indicator is lighted. The time on how long the indicator lamps will be ON is

based on the sequencing of the process. The supply voltage for the indicator lamps of

equipment is 220 volts while the supply voltage for the sequence of the process is 24

volts. The group also provide a control panel that holds the PLC (S7200: CPU 224 XP)

controllers, relays, switches, indicator lamps, terminal blocks, power supply, breakers and

temperature indicating controller.

 RIZAL TECHNOLOGICAL UNIVERSITY
COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

Experiment of pH according to different amount of Substrates

This experiment was conducted to observe the ratio of water and manure that can

give the near neutral amount of pH. Wherein near neutral pH helps to produce higher

methane.

Basis: 100 mL
Manure: Carabao manure
Table 4. Experiment for pH from carabao manure

Test Food Waste Water Manure Temperature pH

5
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COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

Testing of Manure

The data gathering of project was done by different ratios of food waste and

manure with different degrees of temperature. This is to observe the best amount of

substrate and amount of temperature that will give a higher production of biogas.

Table 8 below shows the results of the stated data with a 4 Day reference.

Table 6. Ratio Test: Manure with Specific Temperature

TEST MANURE TEMPERATURE pH BIOGAS SOLID LIQUID

4
 RIZAL TECHNOLOGICAL UNIVERSITY
COLLEGE OF ENGINEERING AND INDUSTRIAL TECHNOLOGY

CHAPTER V

SUMMARY OF FINDINGS, CONCLUSIONS

AND RECOMMENDATIONS

This chapter is the summarization of the results in the previous chapters and the

conclusion that can be derived from the gathered data. Recommendations as well as

further studies are included in this chapter for the enhancement of the study.

Summary of Findings

Based on the conducted simulation of the prototype, the program made can

function prior with the anticipated results by following the sequence of control of the

process.

 
 All control logic conditions listed in the truth table in Table 9 were satisfied.


All valves, motors
 and pump functions properly with respect to the sequence of
 the process.


All indicator lamps that represent the correspondingfinal control elements have
 successfully demonstrated the flow of the process.
 
 Temperature controller was properly configured within the process requirements.

 
Problem encountered during the testing of prototype:

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o Leaks from pipes and tanks occurred.

Conclusions

The study has generated some conclusions based on the findings that were

summarized in the previous section. These conclusions are as follows:


The Anaerobic Digester is a great proposal for farmers and those who has a big
 source of manure that do not have an idea to manage it. This could help improve

the waste mismanagement to generate additional income and/or fund for a good

purpose.


Based on the testing made on the prototype, the sequence of control were  all
 satisfied and the output expected were met therefore we conclude that the

proposed design will also work for the life sized digester.


Based on the different testing made, temperature has the
biggest impact since it affects the generated biogas a lot, therefore we
conclude that the proposed design can help fasten the generation and production of
biogas because of its uninterruptible operation and ensure safe system.
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
Proper/ fine PID tuning is necessary in order to achieve fine temperature control

 with minimal undershoot and overshoot and also a quick stabilization time.

Recommendations:



Insulation must
be provided to the jacketed vessel to maximize the efficiency of
 heat transfer.


Improvement
 in the design of the separator tank and additional relief valve for
tanks.


Based on research, it is suggested that anaerobic digestion of food waste to
recover energy depends on optimal conditions, temperature and methodology as
well the feedstock loading. More research shouldbe done to increase methane
 content in biogas and reduce costs of operation.


Have a complete package of the temperature controller with its output
 unit and
 communication accessory to take full advantage of the controller.

 The operator that will be in-charged in the process for the proposed design shall

undergo proper training in operating in the process.




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