Current Value
149 °C
Range
0-500°C
Type
Temperature Indicator
Process Stage
Gasifier
Monitors the temperature at the Telegraf host connection point in the gasification reactor. Critical for tracking syngas quality and preventing thermal runaway conditions. This sensor provides real-time feedback for automatic temperature control systems.
Current Value
70 °C
Range
0-200°C
Type
Temperature Indicator
Process Stage
Particle Filter
Measures syngas temperature after the tar removal stage. Essential for verifying effective tar condensation and ensuring optimal conditions for downstream methanation. Low temperatures indicate successful tar removal; high temperatures may signal tar breakthrough.
Current Value
117 °C
Range
0-400°C
Type
Temperature Indicator
Process Stage
Water Gas Shift
Bartec-certified explosion-proof temperature sensor monitoring syngas temperature in the water gas shift reactor zone. Provides ATEX-compliant measurement in hazardous area classification Zone 1. Critical for CO-to-H₂ conversion efficiency monitoring.
Current Value
85 °C
Range
0-150°C
Type
Temperature Indicator
Process Stage
Dryer
Monitors feedstock temperature at dryer outlet to ensure moisture content targets are achieved. Optimal temperature range ensures feedstock moisture is reduced below 12% for efficient gasification while preventing thermal degradation of organic material.
Current Value
38 °C
Range
0-100°C
Type
Temperature Indicator
Process Stage
Methanation Reactor
Measures biological methanation reactor operating temperature. Maintains optimal conditions (35-40°C) for methanogenic archaea activity. Temperature control is critical for maximizing CH₄ yield and preventing microbial population die-off.
Current Value
-1.72 mbar
Range
-100 to 100 mbar
Type
Pressure Indicator/Controller
Process Stage
Gasifier
Monitors and controls gasifier operating pressure toward the gas analyzer (GA) sampling point. Maintains optimal gasification pressure (typically 1-3 bar) for maximum syngas yield. Integrated with pressure relief systems for overpressure protection per ASME BPVC Section VIII.
Current Value
2.5 bar
Range
0-10 bar
Type
Pressure Indicator
Process Stage
Methanation Reactor
Tracks biological methanation reactor pressure to ensure optimal gas-liquid contact and prevent pressure vessel overpressure events. Equipped with redundant pressure relief valves and ESD (Emergency Shutdown) interlocks rated to PLd per ISO 13849-1.
Current Value
85 mbar
Range
0-500 mbar
Type
Pressure Indicator
Process Stage
Particle Filter
Measures pressure drop across the particle filtration system. Rising differential pressure indicates filter cake buildup requiring cleaning or replacement. Critical for maintaining syngas flow rates and preventing backpressure-induced gasifier inefficiency.
Current Value
-0.343 %
Range
-5% to 25%
Type
Analytical Instrument
Process Stage
Gasifier
Continuous O₂ monitoring in syngas stream using electrochemical or paramagnetic sensor. Negative O₂ values indicate reducing atmosphere (desired). Positive values signal air ingress requiring immediate investigation to prevent combustion hazards and syngas quality degradation.
Current Value
64.3 ppm
Range
0-100 ppm
Type
Analytical Instrument
Process Stage
Water Gas Shift
Real-time H₂S concentration measurement using electrochemical or UV fluorescence detection. Critical contaminant monitoring for catalyst protection. Alarm setpoint at 15 ppmv triggers emergency Rectisol scrubbing activation. Target: <10 ppmv for methanation catalyst longevity.
Current Value
48.6 %
Range
0-100%
Type
Analytical Instrument
Process Stage
Gasifier
Measures moisture content in syngas using capacitive or infrared absorption sensors. High H₂O content (>50%) indicates effective steam gasification. Excessive moisture requires additional drying to prevent downstream condensation and equipment corrosion.
Current Value
39.9 %
Range
0-100%
Type
Analytical Instrument
Process Stage
Water Gas Shift
Thermal conductivity or gas chromatography-based H₂ measurement. Hydrogen concentration (typically 30-40%) is a key indicator of gasification efficiency and water gas shift reactor performance. High H₂ content enhances syngas LHV and methanation yield.
Current Value
45 %
Range
0-100%
Type
Analytical Instrument
Process Stage
Methanation Reactor
NDIR (Non-Dispersive Infrared) CO₂ sensor tracking carbon dioxide levels. CO₂ removal via biological methanation converts CO₂ + 4H₂ → CH₄ + 2H₂O. Decreasing CO₂ concentration indicates effective methanation; high CO₂ signals incomplete conversion or microbial inhibition.
Current Value
5.38 %
Range
0-100%
Type
Analytical Instrument
Process Stage
Gasifier
Electrochemical or NDIR CO sensor for syngas quality monitoring. CO concentration (15-25%) directly correlates with gasification efficiency. Also serves as toxic gas safety monitor with 50 ppm alarm for personnel protection per OSHA/EIGA standards.
Current Value
4.85 %
Range
0-100%
Type
Analytical Instrument
Process Stage
Methanation Reactor
FID (Flame Ionization Detector) or catalytic bead sensor measuring biomethane production. CH₄ concentration increase from <5% (raw syngas) to >90% (post-methanation) indicates successful biological methanation. Final product quality metric for SNG (Substitute Natural Gas) grid injection.
Current Value
75 kg/h
Range
0-200 kg/h
Type
Flow Indicator
Process Stage
Dryer
Gravimetric belt scale or loss-in-weight feeder measuring feedstock input rate (sewage sludge, horse manure, MSW). Maintains target throughput of 50-100 kg/h for pilot scale operation. Critical for calculating gasification efficiency and carbon conversion rates.
Current Value
22 kg/h
Range
0-100 kg/h
Type
Flow Indicator
Process Stage
Gasifier
Vortex or thermal mass flowmeter tracking steam injection rate. Steam-to-biomass ratio (SBR) control is critical for oxysteam gasification optimization. Target SBR: 0.3-0.5 kg steam/kg biomass. Adjusts automatically based on feedstock moisture and gasifier temperature.
Current Value
48 Nm³/h
Range
0-150 Nm³/h
Type
Flow Indicator
Process Stage
Particle Filter
Thermal mass or ultrasonic flowmeter measuring syngas production rate. Normalized to Nm³/h (Normal cubic meters per hour at 0°C, 1 atm). Key performance indicator for gasification efficiency. Typical range: 30-60 Nm³/h for 75 kg/h feedstock input.
Current Value
18.5 Nm³/h
Range
0-50 Nm³/h
Type
Flow Indicator
Process Stage
Methanation Reactor
Coriolis or thermal mass flowmeter measuring final biomethane (SNG) production rate. Corrected to energy content (kWh/h) based on measured CH₄ concentration and LHV. Target: 15-25 Nm³/h biomethane at >90% CH₄ purity for grid injection compliance.
Current Value
65 %
Range
0-100%
Type
Level Indicator
Process Stage
Dryer
Ultrasonic or radar level sensor monitoring feedstock inventory in feed hopper. Low-level alarm triggers feedstock replenishment to prevent gasifier starvation. High-level alarm prevents overfilling and material bridging. Target operating range: 30-80% capacity.
Current Value
55 %
Range
0-100%
Type
Level Indicator
Process Stage
Particle Filter
Capacitance or float-type level sensor in oil scrubber vessel. Maintains optimal liquid level for tar absorption efficiency. Low level reduces tar removal effectiveness; high level risks liquid carryover into downstream equipment. Automated makeup oil addition system.
Current Value
12 ppm
Range
0-500 ppm
Type
Gas Detector
Process Stage
All Stages
Fixed electrochemical CO detector for personnel safety monitoring. Alarm setpoints: 50 ppm (evacuation), 100 ppm (emergency ventilation activation). Compliant with EIGA/HAZOP requirements. Located in methanation reactor vicinity and enclosed process areas per NFPA 86 standards.
Current Value
8 % LEL
Range
0-100% LEL
Type
Gas Detector
Process Stage
Flare
Catalytic bead or infrared LEL (Lower Explosive Limit) sensor near flare system. Monitors combustible gas concentration to prevent explosive vapor cloud formation. Alarm at 20% LEL triggers area evacuation and inert gas purging. Portable detector backup required during maintenance.
Current Value
3 ppm
Range
0-100 ppm
Type
Gas Detector
Process Stage
All Stages
Electrochemical H₂S detector for toxic gas monitoring. Alarm setpoints: 10 ppm (warning), 15 ppm (evacuation). Hydrogen sulfide is acutely toxic and corrosive. Multiple detectors positioned at potential leak points (flanges, valves, sampling ports) per ATEX Zone 1 classification.
Current Value
45 %
Range
0-100%
Type
Control Valve
Process Stage
Gasifier
Pneumatic or electric actuated control valve regulating steam injection to gasifier. Modulates steam flow based on gasifier temperature and syngas composition feedback. Fail-safe design closes on air/power loss to prevent steam runaway. Characterized for linear flow control 10-100% opening.
Current Value
0 %
Range
0-100%
Type
Control Valve
Process Stage
Flare
On-off or modulating valve directing off-spec syngas to flare during startup, shutdown, or upset conditions. Interlocked with syngas quality analyzers (CO, H₂, CH₄). Opens automatically when syngas composition falls outside acceptable ranges for downstream processing.