{"id":6744,"date":"2026-08-19T09:01:53","date_gmt":"2026-08-19T07:01:53","guid":{"rendered":"https:\/\/www.electroglobal.ro\/proiecte\/upgrade-sistemului-cuptoarelor-industriale-conversia-pe-biomasa-vegetala\/"},"modified":"2026-08-19T09:21:14","modified_gmt":"2026-08-19T07:21:14","slug":"upgrade-sistemului-cuptoarelor-industriale-conversia-pe-biomasa-vegetala","status":"publish","type":"wbg_projects","link":"https:\/\/www.electroglobal.ro\/en\/proiecte\/upgrade-sistemului-cuptoarelor-industriale-conversia-pe-biomasa-vegetala\/","title":{"rendered":"Industrial kiln system upgrade: conversion to plant biomass"},"content":{"rendered":"

Location:<\/b> Deva, Hunedoara County, Romania
\nIndustry:<\/b> Extractive industry and building materials
\nProject value:<\/b> EUR 1.6 Million
\nSolution:<\/b> Integrated turnkey system (detailed electrical engineering, distribution panel manufacturing, PLC\/SCADA software architecture, on-site installation, testing, and commissioning)<\/p>\n

\"\" \"\" \"\"<\/p>\n

1. Context and technical requirements<\/h5>\n

Within the client’s production facility, the thermal process in the calcination kilns utilized a mixed fuel regime based on natural gas and shredded waste fraction. To align with industrial energy efficiency standards, a complete technological conversion of the feeding and combustion line to plant biomass (shredded wood and agricultural waste) was required.<\/p>\n

Constraints and requirements:<\/b><\/p>\n

    \n
  • \n

    Transitioning from natural gas and waste to shredded plant biomass required reconfiguring the kilns’ feeding and combustion systems.<\/p>\n<\/li>\n

  • \n

    Replacing field instrumentation involved operating with electric motors of varying power ratings, requiring electrical panels adapted to the new technological specifications.<\/p>\n<\/li>\n

  • \n

    Connecting and integrating the new motors and valves into the centralized control system to ensure a stable technological flow.<\/p>\n<\/li>\n<\/ul>\n

    2. Project objective<\/h5>\n

    Implementing a comprehensive engineering, execution, and automation package for controlling and monitoring the biomass combustion process, including:<\/p>\n

      \n
    • \n

      Electrical engineering for the entire infrastructure;<\/p>\n<\/li>\n

    • \n

      Developing dedicated control software;<\/p>\n<\/li>\n

    • \n

      Manufacturing the new electrical panels;<\/p>\n<\/li>\n

    • \n

      Connecting field instrumentation (motors, valves);<\/p>\n<\/li>\n

    • \n

      Executing on-site installation;<\/p>\n<\/li>\n

    • \n

      Testing, commissioning, and specialized technical support.<\/p>\n<\/li>\n<\/ul>\n

      3. Solution architecture<\/h5>\n

      The technical solution consisted of replacing existing electrical panels with equipment sized for the new technology and developing the corresponding control logic.<\/p>\n

      Key equipment:<\/i><\/p>\n

        \n
      • \n

        Control:<\/b> Siemens industrial programmable logic controllers (PLC) (requested by the client);<\/p>\n<\/li>\n

      • \n

        Drives:<\/b> Siemens SINAMICS G120 variable frequency drives;<\/p>\n<\/li>\n

      • \n

        Switchgear:<\/b> Eaton low-voltage electrical switchgear;<\/p>\n<\/li>\n

      • \n

        Rittal industrial panels and enclosures;<\/p>\n<\/li>\n

      • \n

        Lapp Kabel industrial cables.<\/p>\n<\/li>\n<\/ul>\n

        \"\"\u00a0 \u00a0 \u00a0 \u00a0\"\"\u00a0 \u00a0 \u00a0 \u00a0 \u00a0\"\"\u00a0 \u00a0\u00a0 \u00a0 \"\"<\/p>\n

        Integration and automation:<\/b><\/p>\n

          \n
        • Establishing connections for variable-power motors and process valves across the plant;<\/li>\n
        • Developing the control software application to manage the biomass flow and incorporate modern safety standards.<\/li>\n
        • <\/li>\n<\/ul>\n
          4. Integrated technical services package<\/h5>\n
            \n
          • \n

            Electrical Engineering<\/b><\/p>\n

              \n
            • \n

              <\/b>Elaborating complete technical documentation required to adapt the electrical infrastructure to the new biomass operating technology.<\/span><\/p>\n<\/li>\n<\/ul>\n<\/li>\n

            • \n

              Electrical Panel Manufacturing<\/b><\/p>\n

                \n
              • \n

                <\/b>Assembling and equipping Rittal industrial electrical panels and enclosures, integrating Eaton low-voltage switchgear and Siemens SINAMICS G120 variable frequency drives.<\/p>\n<\/li>\n<\/ul>\n<\/li>\n

              • \n

                Software Development<\/b><\/p>\n

                  \n
                • \n

                  <\/b>Programming the dedicated control application on the Siemens PLC platform, configured to handle the facility’s new operating logic.<\/p>\n<\/li>\n<\/ul>\n<\/li>\n

                • \n

                  On-Site Installation<\/b><\/p>\n

                    \n
                  • \n

                    <\/b>Executing on-site installation work and performing all electrical terminations to field instrumentation, including valves and motors with varying power stages.<\/p>\n<\/li>\n<\/ul>\n<\/li>\n

                  • \n

                    Commissioning<\/b><\/p>\n

                      \n
                    • \n

                      <\/b>Providing specialized technical support during start-up, functional verification of all connections, and system calibration until reaching standard operating parameters.<\/p>\n<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n

                      5. Impact and results<\/h5>\n
                        \n
                      • \n
                          \n
                        • Industrial Decarbonization<\/b>\n
                            \n
                          • Transitioning to a carbon-neutral renewable thermal energy source, reducing the emission footprint associated with natural gas combustion.<\/li>\n<\/ul>\n<\/li>\n
                          • OPEX Efficiency<\/b>\n
                              \n
                            • Decreasing the specific cost per gigacalorie consumed by energetically utilizing local plant biomass.<\/li>\n<\/ul>\n<\/li>\n
                            • Hardware Reliability<\/b>\n
                                \n
                              • Infrastructure built on Tier-1 equipment (Siemens, Eaton, Rittal) ensures a high Mean Time Between Failures (MTBF) and readily available spare parts.<\/li>\n<\/ul>\n<\/li>\n
                              • Operational Safety<\/b>\n
                                  \n
                                • Integrated hardware and software safety functions prevent abnormal operating conditions and protect operational personnel.<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<\/li>\n<\/ul>\n

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