Šaržno vodenje sistema rezervoarjev za pripravo brozge za oblivanje katalizatorjev

ŽABERL, MATEJ (author), Nedeljković, David (mentor)

V diplomskem delu predstavljam projekt priprave prevlečne brozge za premaz v enem izmed delov linijskega avtomatiziranega procesa izdelave katalizatorjev. Cilj je bil napisati program za PLK Allen Bradley, ki mora krmiliti proizvodni proces, v katerem se nahajajo: 36 osnovnih nepremičnih postaj in 29 mobilnih rezervoarjev, cevi z ventili in merilnimi senzorji za dovajanje tekočin ter mešala. V skupku osnovne postaje in mobilnega rezervoarja se izvajajo različni procesni postopki za pripravo prevlečne brozge, ki bo nato nanesena na keramične ali jeklene katalizatorje v postopku nanašanja. Osnovne suspenzije, narejene v rezervoarjih, so sestavljene iz kovinskih oksidov, zeolitov, kislin in baz, po potrebi pa še s kovinami platinske skupine (angl. platinum group metals) ali drugimi katalitskimi kovinami. Suspenzijo je treba neprestano mešati, saj bi v nasprotnem primeru prišlo do posedanja netopnih snovi in posledično do strjevanja, kar bi povzročilo uničenje rezervoarja. Dodajanje prašnatih snovi se izvaja ročno, saj je potreben nadzor prenosa materiala in tehtanje za vsako serijo priprave. Tekočine se iz skladiščnih v prenosne rezervoarje prenašajo s pomočjo črpalk v avtomatiziranem procesu serijske priprave brozge. Postopek krmili PLK Allen Bradley z oznako 1756-L82E, vhodno-izhodni signali pa so povezani v modul 1734-AENTR s komercialno oznako Point-IO. Ker vsak rezervoar predstavlja samostojno enoto, ima svojo elektro omaro z ventilatorjem za hlajenje; v njej so napajalni modul, varovalke, Point-IO modul, frekvenčni pretvornik za krmiljenje hitrosti motorja s potenciometrom, varnostni releji s stikalom za izklop v sili in omrežno stikalo. Na slednje so priključeni krmilnik, frekvenčni pretvornik, Point-IO in tehtnica za nadzor količine dodanih sestavin v cisterno. Program za uporabljeni krmilnik Allen-Bradley je napisan v razvojnem programskem okolju Studio 5000, operaterji pa spremljajo delovanje procesa preko HMI vmesnika, na katerem je SCADA, ki je narejena v programskem okolju Wonderware. S končnim izdelkom smo dosegli nižje produkcijske stroške, saj je delovanje sistema natančno, hitrejše in učinkovitejše. Vgrajene merilne naprave stranki omogočajo večji nadzor nad procesnimi podatki in končnimi rezultati. Zagotovljena je tudi boljša varnost operaterjev, saj niso izpostavljeni nevarnim kemikalijam.

• Language: Slovenian
• Keywords: avtomobilski katalizatorji, šaržni proces, PLK, S88, Allen Bradley, Studio 5000
• Work type: Bachelor thesis/paper
• Typology: 2.11 - Undergraduate Thesis
• Organization: FE - Faculty of Electrical Engineering
• Year: 2024
• PID: 20.500.12556/RUL-163023
• COBISS.SI-ID: 209879299
• Publication date in RUL: 01.10.2024

Secondary language

• Language: English
• Title: Batch control of a tank system for the preparation of slurry for catalyst coating

Abstract

In the thesis, I present a project focused on the coating slurry preparation for catalyst coating in one segment of an automated production process. The goal was to develop a program for the Allen Bradley PLC, which controls the production process involving 36 fixed stations and 29 mobile tanks, pipes with valves and measurement sensors for fluid supply and mixers. Various process operations for preparing the coating slurry are performed within the combination of a fixed station and a mobile tank, after which the slurry is applied to ceramic or steel catalysts during the coating process. The basic suspensions, prepared in the tanks, consist of metal oxides, zeolites, acids, and bases, with the potential addition of platinum group metals or other catalytic metals. Continuous mixing of the suspension is necessary to prevent sedimentation of insoluble substances and solidification, which would result in tank damage. The addition of powdered substances is carried out manually, as material transfer monitoring and weighing are required for each batch preparation. Liquids are transferred from storage tanks to mobile tanks using pumps in an automated batch slurry preparation process. The process is controlled by the Allen Bradley PLC, model 1756-L82E, with input-output signals connected to the 1734-AENTR module, commercially known as Point-IO. Since each tank operates as an independent unit, it has its own control cabinet with a cooling fan, containing the power module, fuses, Point-IO module, a frequency inverter for motor speed control using a potentiometer, safety relays with an emergency stop switch, and a network switch. The network switch connects the controller, frequency inverter, Point-IO module, and a scale for monitoring the amount of ingredients added to the tank. The program for the Allen-Bradley controller is written in the Studio 5000 development environment, and operators monitor the process through an HMI interface, which includes a SCADA system developed in Wonderware. The final product has resulted in lower production costs due to precise, faster, and more efficient system operation. The installed measuring devices provide the client with greater control over process data and final results. Enhanced safety for operators is also ensured, as they are not exposed to hazardous chemicals.

• Keywords: Catalyst, Batching system, PLC, S88, Allen Bradley, Studio 5000