Case Study: Renewable Energy — Trash to Gas to Cash

???The Challenge

An operator of landfill gas-to-energy facilities faced significant challenges with their outdated systems, some of which had been in place for over 15 years. Manual data collection using physical chart recorders created inefficiencies and left room for errors. The lack of connectivity across their four remote sites and central hub limited their ability to scale operations. To address these issues, they needed a standardized, scalable control system that would enable seamless integration, improve network security, and support future growth.

???The Solution

EOSYS developed a comprehensive solution to meet these needs:

• Rockwell PlantPAx 5.0 Software: Provided an integrated distributed control system that supported multi-site operations and scalability.
• CompactLogix P Controllers: Ensured reliable, flexible performance to handle current and future demands.
• FactoryTalk View SE HMI: Modernized operator interfaces, enabling automated data collection and central monitoring.
• Network Infrastructure Upgrades: Improved communication between sites with added network switches, enhancing reliability and security.
• Remote Historian Framework: Established a centralized data collection system, enabling real-time insights and streamlined decision-making.

??The Result

The project delivered significant operational improvements:

• Manual data collection was replaced with automated systems, reducing errors and saving time.
• Connectivity across all sites enabled centralized monitoring, simplifying troubleshooting and improving response times.
• The scalable system provided a solid foundation for future expansion while minimizing downtime.
• Enhanced data visualization allowed them to make more informed decisions and optimize performance.

These upgrades also ensured they could effectively repurpose methane, a potent greenhouse gas, into a reliable energy source, reducing emissions and supporting their commitment to environmental sustainability.

This case study first appeared in Control Engineering magazine. You can find it here.