Preparing operators for biomass fast pyrolysis
In spring 2020, Mobatec delivered a high-fidelity operator training simulator (OTS) for BTG Bioliquids, a technology provider for the fast pyrolysis of biomass residues. This project story looks back at how the simulator was developed to help operators prepare for fast pyrolysis plant operations.
An OTS provides a virtual plant in which both new and experienced operators can practise plant operations without interfering with the actual installation. BTG Bioliquids invested in this approach to support training before plant start-up and throughout the plant’s lifecycle.
An Empyro plant model built with Mobatec Modeller
The blueprint was Empyro, the fast pyrolysis bio-oil (FPBO) production plant in Hengelo, the Netherlands, which began operating in 2015. The plant processes five tonnes of wood residues per hour. Its specialised equipment and materials, including biomass and pyrolysis oil, called for a model tailored to this process.
Mobatec developed the plant model using Mobatec Modeller. The software’s flexibility allowed the team to tailor the model to the plant’s process requirements and provided BTG Bioliquids engineers with a basis for later modifications or expansion of the OTS.
Close collaboration from scope to delivery
Development progressed from defining the scope during the mark-up phase to engineering the plant model and integrating the simulator. BTG Bioliquids shared technical and process information about Empyro as the model took shape.
Mobatec also gave BTG Bioliquids an interactive remote preview of the OTS during development. Before delivery, engineers from both companies spent several weeks testing and improving the simulator together. This collaboration continued through to delivery in spring 2020.
An exact copy of Emerson DeltaV on a portable setup
Mobatec linked the plant model to an exact copy of the Emerson DeltaV distributed control system (DCS). Together, they formed a digital twin for operator training, combining the simulated process with a copy of the plant’s control environment.
Both the plant model and the control system ran on laptops, making the training setup portable. Operators could work with the virtual plant and its controls away from the operating installation.
Green Fuel Nordic training in summer 2020
Green Fuel Nordic in Finland, a customer of BTG Bioliquids, was the first to use the OTS in summer 2020. Its operators trained in preparation for their newly built plant.
All operators completed a successful start-up of the virtual plant during the training. Green Fuel Nordic shared the following feedback on the training and its expectations for operating the actual plant:
Everybody on the team liked the training on the simulator very much. Within a short period, operators gained skills to run and operate the plant. Now that we understand the plant, we can proceed to run and operate our plant at a high capacity with minimal stops.
Discuss a simulator for your process
To discuss a process-specific operator training simulator, a model built with Mobatec Modeller or integration with your plant’s control system, contact the Mobatec team.
