Computer Controlled Bioethanol Process Unit

Product Overview

The Computer Controlled Bioethanol Process Unit has been designed to study and control the bioethanol production process on a laboratory scale.

Technical Specifications

ATENG 11551 � Computer Controlled Bioethanol Process Unit

(for main items)

• With this unit there are several options and possibilities:
• Main items: 1, 2, 3, 4, 5 and 6.
• Optional items: 7, 8, 9, 10 and 11.
• Let us describe first the main items (1 to 6):
• 1 ATENG 11551. Unit:

Anodized aluminum frame and panels made of painted

steel.

The unit includes wheels to facilitate its mobility.

Main metallic elements made of stainless steel.

Diagram in the front panel with distribution of the

elements similar to the real one.

All the vessels, valves and other accessories in contact

with process materials (except the distillation unit) are

made of stainless steel. The distillation unit is made of

borosilicate glass. Sight glasses are made of Neoceram

glass.

• The �ATENG 11551� unit mainly consists of:
• Mash tank:

Cylindrical vessel made of stainless steel, with

an inlet at the upper cover to load the water, raw

material and starch, jacket for process heating

computer controlled stirrer and sight glass made of

Neoceram.

The base of the vessel is inclined slightly towards a

port for draining the solution or pumping it into the

• fermentation tank. Unit: ATENG 11551
• Volume: 5 l.
• Fermentation tank:

Cylindrical vessel made of stainless steel with a jacket for process heating, computer controlled

stirrer and a sight glass made of Neoceram.

The vessel has a base inclined slightly towards a port for draining the solution or pumping it into

the distillation unit.

• Volume: 5 l.
• Distillation unit:

Different elements made of borosilicate glass of high thermal and mechanical resistance, as well

• as perfect chemical inertia. It includes:

Computer controlled heating mantle, 800 W.

• Reactor flask with discharge stopcock, volume: 5 l.

Reactor lid, with four inlets, especially designed for this system.

Vigreux type distillation column.

Computer controlled stirring rod with stirring lock that assures a perfect insulation of the system.

Cold finger (dephlegmator).

Liebig-West condenser with interchangeable fittings.

Decantation funnel of 500 ml.

Temperature tappings placed at key points of the system.

Two computer controlled diaphragm pumps to introduce the solution into the fermentation tank and

• the distillation unit, range: 0 � 3.8 l/min.
• Nine �J� type temperature sensors:

Two temperature sensors located at the mash tank to measure the temperature of the mash inside

the tank and the temperature at the outlet of the tank�s jacket.

Two temperature sensors located at the fermentation tank to measure the temperature of the

preparation inside the tank and the temperature at the outlet of the tank�s jacket.

Four temperature sensors located at different points of the distillation unit.

Temperature sensor located at the hot water circulation system.

The temperature sensors located at the outlet of the jacket of the mash and fermentation tanks work

with the PID controller to maintain the desired temperature inside.

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Complete Technical Specifications (for main items)

• pH sensor measures the pH of the mash inside the mash tank, range: 0 � 13.
• Hot water circulation system, including:

Computer controlled pump.

Thermostatic bath, with computer controlled heating element.

• Acid/base circuit system, including:

Two computer controlled peristaltic pumps to introduce an acid or base solution into the mash

• tank, max. flow: 0 � 13 ml/min.
• Two vessels to contain the acid and base solutions, volume: 1 l.
• Seven valves:

Two needle valves are used to divert the hot water between the jacket of the mash tank and the

jacket of the fermentation tank.

Two ball valves and two needle valves are used to drain the solution from the mash and fermentation

tank or pump it into the fermentation tank and distillation unit.

Ball valve is used to drain water from the hot water circulation system.

• The complete unit includes as well:

Advanced Real-Time SCADA and PID Control.

Open Control + Multicontrol + Real-Time Control.

Specialized Control Software based on LabVIEW.

National Instruments Data Acquisition board (250 KS/s, kilo samples per second).

Calibration exercises, which are included, teach the user how to calibrate a sensor and the

importance of checking the accuracy of the sensors before taking measurements.

Projector and/or electronic whiteboard compatibility allows the unit to be explained and

demonstrated to an entire class at one time.

Capable of doing applied research, real industrial simulation, training courses, etc.

Remote operation and control by the user and remote control for technical support

are always included.

Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).

Designed and manufactured under several quality standards.

Optional ICAI software to create, edit and carry out practical exercises, tests, exams

calculations, etc. Apart from monitoring user's knowledge and progress reached.

This unit has been designed for future expansion and integration. A common expansion is

the Scada-Net (ESN) System which enables multiple students to simultaneously

operate many units in a network.

• EBEC/CIB. Control Interface Box:

The Control Interface Box is part of the SCADA system.

Control interface box with process diagram in the front panel and with the same distribution that

the different elements located in the unit, for an easy understanding by the student.

• All sensors, with their respective signals, are properly manipulated from -10V. to +10V. computer output.

Sensors connectors in the interface have different pines numbers (from 2 to 16), to avoid

connection errors.

Single cable between the control interface box and computer.

The unit control elements are permanently computer controlled, without necessity of

changes or connections during the whole process test procedure.

Simultaneous visualization in the computer of all parameters involved in the process.

Calibration of all sensors involved in the process.

Real time curves representation about system responses.

Storage of all the process data and results in a file.

Graphic representation, in real time, of all the process/system responses.

All the actuators� values can be changed at any time from the keyboard allowing the

analysis about curves and responses of the whole process.

All the actuators and sensors values and their responses are displayed on only one screen in the

computer.

Shield and filtered signals to avoid external interferences.

Real time PID control with flexibility of modifications from the computer keyboard of

the PID parameters, at any moment during the process.

EBEC/CIB

Real time PID and on/off control for pumps, compressors, heating elements, control valves, etc.

Real time PID control for parameters involved in the process simultaneously.

Proportional control, integral control and derivative control, based on the real PID mathematical

formula, by changing the values, at any time, of the three control constants (proportional, integral

and derivative constants).

Open control allowing modifications, at any moment and in real time, of parameters involved in the

process simultaneously.

Possibility of automatization of the actuators involved in the process.

Three safety levels, one mechanical in the unit, another electronic in the control interface and

the third one in the control software.

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Complete Technical Specifications (for main items)

• 3 DAB. Data Acquisition Board:

The Data Acquisition board is part of the SCADA system.

PCI Express Data acquisition board (National Instruments) to be placed in a computer slot. Bus

PCI Express.

• Analog input:

Number of channels= 16 single-ended or 8 differential. Resolution=16 bits, 1 in 65536.

• Sampling rate up to: 250 KS/s (kilo samples per second).
• Input range (V)=�10 V. Data transfers=DMA, interrupts, programmed I/0. DMA channels=6.
• Analog output:

Number of channels=2. Resolution=16 bits, 1 in 65536.

• Maximum output rate up to: 900 KS/s.
• Output range (V)=�10 V. Data transfers=DMA, interrupts, programmed I/0. DAB
• Digital Input/Output:
• Number of channels=24 inputs/outputs. D0 or DI Sample Clock frequency: 0 to 100 MHz.
• Timing: Number of Counter/timers=4. Resolution: Counter/timers: 32 bits.

The Data Acquisition board model may change at any moment, providing the same or better

features than those required for the unit.

4 EBEC/CCSOF. PID Computer Control + Data Acquisition + Data Management

• Software:

The three softwares are part of the SCADA system.

Compatible with actual Windows operating systems. Graphic and intuitive simulation of the

process in screen. Compatible with the industry standards.

Registration and visualization of all process variables in an automatic and simultaneous way.

Flexible, open and multicontrol software, developed with actual windows graphic systems

acting simultaneously on all process parameters.

Analog and digital PID control.

PID menu and set point selection required in the whole work range.

Management, processing, comparison and storage of data.

Sampling velocity up to 250 KS/s (kilo samples per second).

Calibration system for the sensors involved in the process.

It allows the registration of the alarms state and the graphic representation in real time.

Comparative analysis of the obtained data, after the process and modification of the conditions

during the process. EBEC/CCSOF

Open software, allowing the teacher to modify texts, instructions. Teacher�s and student�s

passwords to facilitate the teacher�s control on the student, and allowing the access to different work

levels.

This unit allows the 30 students of the classroom to visualize simultaneously all the results

and the manipulation of the unit, during the process, by using a projector or an electronic

whiteboard.

5 Cables and Accessories, for normal operation.

• 6Manuals:
• This unit is supplied with 8 manuals: Required services, Assembly and Installation, Interface and

Control software, Starting-up, Safety, Maintenance, Calibration & Practices manuals.

• References 1 to 6 are the main items: ATENG 11551 + EBEC/CIB + DAB + EBEC/CCSOF + Cables and Accessories + Manuals are included

in the minimum supply for enabling normal and full operation.

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