Full system integration for optimal production efficiency and quality

This project transformed a brownfield site into a state-of-the-art waste-to-energy plant for our client, a leading manufacturer of Pyrolysis machinery. Their innovative technology offered an on-site, turnkey solution for converting various waste materials into biochar, a valuable recycled product.

One of the key project challenges involved co-ordinating and integrating equipment from multiple manufacturers into a seamlessly functioning system.

 

Our Solution

Through our expertise in integration and automation, iconsys successfully coordinated and integrated equipment from various manufacturers with distinct communication protocols.

This collaborative system played a vital role in establishing a sustainable waste management solution for our client, while prioritising the safety of plant operations

iconsys designed the PLC software and SCADA systems, considering the diverse communication protocols of the equipment.  We manufactured bespoke control panels specifically designed to manage the entire waste-to-energy process effectively.

Streamlined the waste treatment process by integrating the following equipment:

• Conveyors
• Pyrolysis Kiln
• Burners
• Coolers
• Abatement Filter
• Continuous Emissions Monitoring Systems (CEMS)

iconsys prioritised plant safety by designing and installing functional safety systems based on a comprehensive risk assessment to include;

• Emergency stops for immediate process shutdown
• Safety-rated pressure, temperature, and level sensors for real-time monitoring of critical parameters
• Safety dump valves to prevent dangerous buildups of pressure or materials

 

Results

• Integration of multiple manufacturers equipment
• Functional safety system integrated into process
• Optimal production efficiency and output achieved

 

Customer Feedback

The complexity of this installation project undertaken by iconsys can’t be underestimated.  It involved several heavy-duty tasks as well as some very intricate wiring work, which was completed on time over several weeks.

I was very impressed with the iconsys from the start.

Their professionalism, preparation and attention to detail when integrating the new Kiln, coolers, panels and additional onsite equipment to enable cross communication throughout the facility was a complete success.

Accurate planning at the offset avoided any issues that would have resulted in the project being delayed.  The attitude and flexibility of your team to adapt to last minute changes and work around our team with minimum disruption was much appreciated.

The quality of workmanship was first class, each phase of the project was completed in a professional and timely manner.

A big thank you to the iconsys team.