Process Automation and Water Management Learning solutions for basic and advanced training
Table of contents Magazine Welcome M6 Current trend topics M8 Key challenges M10 Sustainability M12 Distributed control systems M14 IIoT devices M16 Water 4.0 M18 Water-energy nexus M20 Battery manufacturing M22 Mining M26 Green hydrogen M30 Bioreactors M32 Excellence in technical education M34 Learning through competition M50 Services M54 M2 Process automation I Learning solutions for education and training
Industrial control technology Data acquisition 110 Programmable logic controllers 112 Sensor technology 118 Cybersecurity 120 Foundational areas of expertise Industrial trades 124 Electrotechnology 134 Fluid power 144 Learning media Festo LX 148 Courseware 155 Software 169 Introduction and fundamentals EduKit PA 4 MPS PA Compact Workstation 8 MPS PA 204 Learning System 16 Process Control Learning System 28 Water technology EDS Water Management 44 Industrial instrumentation and process control Pressure, flow, level, temperature 76 pH and conductivity 86 Air pressure and flow 88 Distributed Control System Demonstrator 90 Three-Phase Separator 92 Table of contents Products M3 → festo.com/didactic
Magazine
Festo Didactic At your side to prepare a skilled workforce M6 Process automation I Learning solutions for education and training Magazine > Welcome
Dear educators and instructors, Thank you for your interest in our learning solutions and for considering Festo Didactic as a partner for your technical education and training projects. Your commitment to imparting knowledge and fostering skills in process automation is paramount, equipping the workforce of today and tomorrow with the expertise needed to thrive in the dynamic process industry. We strive to optimize your educational investments in vocational or technical schools, universities, and industrial training centers with world-class solutions and services. I encourage you to browse this catalog and explore the wealth of resources at your disposal to facilitate learning and teaching. It is divided into two sections: The “Magazine” section offers a collection of articles on current trend topics that influence skill requirements, along with details about the breadth of our services. The “Products” section introduces our extensive range of learning solutions encompassing ready-to-use learning content, training equipment, and software tools. Should you have any questions or require further assistance, simply reach out to us at services.didactic@festo.com. We are here to support you every step of the way. Wishing you a fruitful reading and many rewarding learning experiences ahead! Stéphane Casse, Professional Engineer Product Manager, Process Automation Learning Solutions Festo Didactic M7 → festo.com/didactic Magazine > Welcome
Current trend topics Impact on skills requirements M8 Process automation I Learning solutions for education and training Magazine > Current trend topics
01 „In the dynamic process industry, digitalization, technology, and sustainability drive demand for cuttingedge automation solutions and highly skilled workers. “ Alexander Vargas Head of Industry Segment and Key Account Process Industries, Festo SE M9 → festo.com/didactic Magazine > Current trend topics
Process industry Key challenges M10 Process automation I Learning solutions for education and training Magazine > Current trend topics
Safety: The high potential for accidents, leaks, and chemical hazards necessitates unwavering attention. Ensuring the well-being of employees, safeguarding the environment, and protecting local communities constitute an enduring challenge. Operational and energy efficiency: Achieving optimal operational efficiency involves streamlining production processes, minimizing waste, and maximizing resource utilization. Escalating energy costs and growing environmental consciousness underline the imperative for enhanced energy efficiency in production processes. Technological advancements: Staying attuned to rapid technological advancements, including automation, artificial intelligence, and data analytics, is an ongoing challenge. The integration of new technologies into existing systems presents complexities and necessitates a commitment to innovation. Cybersecurity: With increasing interconnectivity and reliance on IT, the industry confronts heightened cyber threats. Safeguarding critical infrastructure and sensitive data against cyberattacks represents a perpetual challenge. Talent acquisition and retention: Attracting and retaining skilled labor and experienced personnel with the necessary technical expertise and adaptability to navigate industry changes present a common industry-wide challenge. The demand for specialized knowledge accentuates skills gaps in the labor pool. Global competition: Intense competition from international companies necessitates continuous improvements in efficiency and quality to maintain competitiveness on a global scale. Market volatility: Fluctuations in demand, commodity prices, and economic conditions exert significant influence on the profitability and stability of process industry companies. Sustainability: Companies face increasing pressure to align with sustainability objectives and meet Environmental, Social, and Governance (ESG) criteria. Embracing cleaner and more sustainable practices to reduce emissions and waste and conserve resources is imperative. Regulatory compliance: Beyond environmental regulations, the industry contends with a diverse array of regulatory requirements encompassing safety, product quality, and more. Ensuring compliance across diverse regions and markets introduces intricate complexities. The process industry exhibits significant diversity. Companies within various segments of this industry are involved in unique activities and processes, yet they encounter common challenges. Understanding these challenges helps technical education teachers stay abreast of industrial realities and skill requirements. Improving technical education in process automation and related fields cultivates essential skills, both technical and transversal, necessary to meet the evolving demands of the industry. M11 → festo.com/didactic Magazine > Current trend topics
Essential tools for Sustainability Pneumatic automation Electric automation Digitization Artificial intelligence Biological transformation What Factory automation, process automation How Automation and technical education Focus planet Why Challenge: Climate change and limited resources Why Challenge: Growing population and demographic change Focus on people Industrial transformation Driving structural change Ecological innovations Save resources, protect nature Resilience in value chains Deglobalization, safeguard supply chains Assist people at work Human-machine collaboration Improve health Technologies for life sciences Lifelong learning Technical education M12 Process automation I Learning solutions for education and training Magazine > Current trend topics
Left image: An overview of the Blue World approach from Festo Energy efficiency Precise control of equipment and processes through instrumentation helps optimize energy consumption, reducing waste and greenhouse gas emissions. Real-time monitoring and control allow operators to identify and rectify energy inefficiencies promptly. Safety enhancement Instrumentation and control systems play a crucial role in maintaining the safety of industrial operations, preventing accidents, and reducing the environmental impact of incidents. Early detection of safety issues allows for swift responses, minimizing damage and the associated environmental consequences. Data analytics and decision support Digitalization in the process industry means that advanced data analytics and artificial intelligence can be integrated into instrumentation and control systems to provide insights for optimizing processes further and identifying opportunities for sustainability improvements. Resource conservation Process control systems can help minimize raw material wastage and reduce resource consumption by ensuring that processes operate within specified limits. Monitoring and controlling equipment can extend their lifespan, reducing the need for frequent replacements and conserving resources. Water management Many process operations are water-intensive, need highly pure water, or produce gray water that needs to be treated. Precise control of water usage and treatment processes can reduce water wastage and pollution. Monitoring and control of wastewater treatment can help ensure compliance with environmental standards. Predictive maintenance Predictive maintenance, enabled by instrumentation and control systems, can help prevent equipment breakdowns and reduce unplanned downtime, minimizing resource wastage and energy consumption, while also extending the operational life of industrial systems and machinery. Product quality and yield improvement Process control ensures consistent product quality, reducing the likelihood of producing defective or substandard products that may lead to waste. Optimization of processes can increase product yield, reducing the need for additional resources and energy to produce the same quantity of output. Regulatory compliance Instrumentation and control systems help industries meet regulatory requirements related to environmental standards, emissions, and safety, avoiding fines and reputational damage, and minimizing companies’ environmental footprint. Continuous monitoring can detect and address leaks or emissions anomalies quickly. Process control systems can also optimize dosing and usage of chemicals. Raising awareness and expertise in process automation is crucial moving forward. A robust integration of these topics into education and industry training programs at all levels will empower workers, enabling them to lead sustainability efforts and foster a greener, more responsible industrial landscape. A significant contribution Process industries play an integral role in sustainability efforts, both through the products they produce and the technologies and operations they employ to reduce environmental impacts. Examples include hydrogen production, battery manufacturing, renewable energy generation, biofuels, water treatment, waste-to-energy, recycling, and more. Sensors, meters, transmitters, controllers, actuators, and more are essential tools for improving production efficiency, reducing waste, minimizing environmental impact, enhancing safety, and ensuring compliance with regulations. By continuously monitoring and optimizing processes, these technologies enable industries to operate more sustainably while also improving their economic performance. They contribute to sustainability in several key areas: M13 → festo.com/didactic Magazine > Current trend topics
A DCS for training purposes First-hand experience with a DCS is key for thorough understanding. How to provide such experimentation opportunities? Discover our DCS demonstrator: → Page 90 Understanding Distributed control systems M14 Process automation I Learning solutions for education and training Magazine > Current trend topics
New skills requirements Working with DCS requires a new set of skills that go beyond the traditional mechanical or electrical skills. These skills include computer literacy, knowledge of programming languages, data analysis, networking, cybersecurity, and a deeper understanding of process automation. Workers must be able to work with computers, software, and networks, and be able to diagnose and troubleshoot complex issues. In addition to these technical skills, workers using DCS must also have strong problem-solving and critical thinking abilities to make quick and accurate decisions in the event of a failure or emergency. Good communication skills enable effective collaboration with other departments for efficient operation. Relevant for many occupations DCS knowledge is becoming a necessary skill for all process industry workers. Process operators and technicians need a basic understanding of DCS software, alarm management, and control strategies for monitoring and controlling industrial processes, and for adjusting process variables as needed. Instrumentation and control technicians install, configure, and maintain DCS equipment and systems. They need in-depth knowledge of DCS hardware and software, as well as strong troubleshooting skills. Engineers and system integrators design and optimize industrial processes using DCS, thus requiring advanced knowledge of DCS software, control strategies, and data analysis to ensure processes run efficiently and meet performance objectives. A well-rounded foundation In an introductory course, the emphasis should be on building a solid knowledge base and practical skills to understand DCS and their applications. Here is a non-exhaustive list of foundational learning outcomes: • Understand the concept of a DCS and its role in industrial process control. • Explain the architecture and core components of a DCS. • Navigate a DCS software program and know its basic functions. • Define the concept of control loops. • Understand PID control in DCS. • Configure and tune controllers to monitor and adjust process variables using DCS. • Create simple control strategies for processes using DCS software. • Understand alarms and how to manage them effectively. • Diagnose and troubleshoot common issues in DCS systems. • Apply safety practices to prevent accidents and protect personnel. • Interpret process data and create trends, charts, and graphics. • Use DCS tools to improve process efficiency, reduce energy consumption, and minimize waste. • Explore communication protocols. • Know relevant industry standards and guidelines related to DCS. • Use condition monitoring techniques and data analytics for predictive maintenance. • Explore methods and protocols for integrating IIoT devices and sensors. • Implement strategies for asset lifecycle management, tracking, and monitoring. Other outcomes can be added, such as understanding how DCS can contribute to sustainability goals, or be aware of best practices for cybersecurity, including security protocols, risk management, and more. With a right balance between theory and practice, students will be well prepared for the workplace. Enterprise level Management level Supervisory level Control level Field level ERP MES Sensors, actuators, equipment PLC, PID controllers HMI, SCADA, DCS SCADA systems centrally monitor, control, and acquire data in large-scale industrial processes. DCS and SCADA systems collaborate, with DCS managing local control tasks while SCADA provides supervisory functions. DCS systems typically include built-in HMIs, but they can also integrate with standalone HMI software for enhanced visualization and control. Distributed Control Systems (DCS) are computer-based systems that enable real-time management and automation of processes. They consist of interconnected controllers, input/output devices, and operator stations, offering centralized control. From enhancing safety and efficiency, reducing waste, to enabling data-driven decision-making and integration with emerging technologies like the Industrial Internet of Things (IIoT), DCS systems are a critical tool for companies seeking to remain competitive and sustainable. M15 → festo.com/didactic Magazine > Current trend topics
The growing importance of intelligent field devices marks a turning point in the process industry: streamlined processes, informed datadriven decisions, improved efficiency and safety, and reduced operational disruption. This underscores the need for parallel investment in improving workforce skills to take full advantage of the benefits of smart and Industrial Internet of Things (IIoT) and smart field devices. How to address this new topic in training programs? We turned to our process automation specialists for insights. What’s the main difference between IoT and analog or basic electronic field devices? The difference lies in their connectivity, communication, and the advanced features they provide, aligning with the latest advancements in industrial automation and Industry 4.0. Overview of the technological progression of industrial devices: Functionality Communication Data processing Traditional devices Basic instruments that perform specific measurement or control functions. They typically provide analog signals, such as 4-20 mA signals. Limited communication capabilities. They may use simple protocols for basic two-way communication. Minimal or no data processing capabilities. They usually transmit raw data to a central control system for processing and decision-making. Smart devices They come with more advanced features beyond basic measurement and control. They often have built-in microprocessors, enabling them to perform local data processing and make decisions. Enhanced communication capabilities. Smart devices can communicate digitally using protocols like FOUNDATION Fieldbus, PROFIBUS PA, HART, PROFINET, or EtherNet/ IP, allowing for more efficient data exchange and diagnostics. Some level of data processing capabilities. They can perform local calculations and transmit processed information to the control system and provide diagnostic information. IIoT devices Part of the broader trend of Industry 4.0, where devices are highly interconnected and capable of sharing and utilizing data in realtime. They often have advanced sensors and may support multiple functionalities. Designed for seamless connectivity to the Internet and other devices. They use standard Internet protocols, such as MQTT or CoAP, for communication with other IoT devices and cloud platforms. Significant data processing and asset management capabilities. They can analyze data locally, make complex decisions, and send relevant information to the central control system or cloud platforms. Training shifts in the age of IIoT devices M16 Process automation I Learning solutions for education and training Magazine > Current trend topics
What new skills are required to effectively work with smart and IoT devices? Given their characteristics, advanced devices require a broader skill set that encompasses IT and analytical skills. In practical terms, workers should demonstrate proficiency in digital communication protocols and the utilization of software tools for configuration, monitoring, control, and troubleshooting. Additionally, they must address potential security risks, interpret maintenance alerts, and utilize data to optimize reliability, particularly with predictive maintenance features. Is it worth upgrading the training equipment in technical schools with IIoT devices? Absolutely, it is a strategic move with several benefits. Students will encounter these advanced technologies in the workplace, making the training environment more reflective of real-world scenarios. Starting small, such as replacing one or two traditional transmitters in a process loop with smart ones, provides a manageable entry point. Taking small initial steps allows teachers and instructors to become familiar with the technologies and progressively update course content. Are there “user-friendly” technologies for teachers and learners? Yes, there are user-friendly technologies and straightforward introduction setups. Take IO-Link, for instance, known for its simplicity in industrial automation. Teachers can opt for IO-Link ready sensors, which are simpler than transmitters. Choose a sensor for flow, level, temperature, or pressure, and install it in the process loop on the lab training equipment, along with an IO-Link master module. Then download free configuration software like PACTware. Students can integrate and configure the sensor into the communication network. Another uncomplicated option is to replace a transmitter with an equivalent one equipped with Bluetooth connectivity and use a free app for remote configuration, diagnosis, and maintenance. What should companies do to upskill their existing workforce? Our top recommendation is to familiarize workers with upcoming technologies and devices well in advance of their implementation. Offering hands-on training opportunities beforehand allows workers to experiment, make mistakes, and learn in a controlled environment, away from production systems. This was the approach adopted by one of our mining clients, who purchased one of our industrial process control learning systems and asked us to integrate specific IoT devices that would soon be implemented into their operations. What learning solutions can be used to introduce the industrial internet of things? • IoT Kit for MPS PA systems → Page 11 • New components for the industrial process learning systems → Page 73 • Smart sensors TP 1312 → Page 118 M17 → festo.com/didactic Magazine > Current trend topics
What is Water 4.0? Water 1.0 through 4.0 are conceptual frameworks used to delineate the historical and evolving paradigms within water management. These frameworks were initially articulated by David Sedlak, a professor of environmental engineering at the University 4.0: The Past, Present, and Future of the World’s Most Vital Resource,” first published in 2014. Water 1.0: The earliest and most basic form of water management focused on collecting, storing, and distributing water for fundamental human needs, such as drinking and sanitation, with limited water treatment. Water 2.0: With a focus on delivering safe and clean water to growing urban populations, this phase marks a significant advancement in water management with centralized, modern water treatment facilities. Water 3.0: This phase introduced concepts like wastewater treatment and recycling to preserve aquatic ecosystems and minimize the environmental impact of water use. Water 4.0: Echoing the concept of Industry 4.0, cyber-physical systems enable the networking of virtual and real water systems and users (agriculture, industry, and households) in a sustainable, efficient, and responsive water infrastructure through the seamless integration of digitalization, automation, and smart technologies. Digitalization Water 4.0 M18 Process automation I Learning solutions for education and training Magazine > Current trend topics
Characteristics of modern water operations • Real-time monitoring of water systems, facilitated by the deployment of sensors and monitoring devices, allows operators to receive instant updates on water quality, pressure, and distribution. This capability enhances proactive decision-making and enables a rapid response to emerging issues. • Automated control systems optimize various water treatment and distribution processes, overseeing tasks such as automated chemical dosing, pump control, and valve adjustments, ensuring precise and efficient operations while minimizing the need for manual intervention. • The analysis of data generated by sensors and monitoring systems provides valuable insights into performance trends, empowering operators to make data-driven, informed decisions regarding resource allocation, maintenance scheduling, and overall system optimization. • Continuous monitoring of equipment health and performance facilitates predictive maintenance, reducing downtime and enhancing operational efficiency. • Modern water operations integrate technologies like IoT devices and communication networks. This interconnected and smart infrastructure enables efficient asset management, allowing for remote monitoring and management of equipment and infrastructure components. • Many pumping, heating, and cooling systems and equipment are energy-intensive. Aeration stands out as the most energy-consuming process, as it facilitates the growth and activity of aerobic bacteria responsible for digesting organic matter in wastewater. Digitalization contributes to energy optimization in water operations by enabling the intelligent control of such equipment, thereby reducing energy consumption and operational costs. Additionally, integrating on-site renewable energy production helps offset energy costs and reduces the carbon footprint. • Water utilities can implement more sustainable practices, including optimizing chemical usage, minimizing water wastage, and adopting energy-efficient technologies. These efforts align with broader environmental conservation goals. Impacts on occupations Digitalization significantly impacts various occupations within the water industry. Plant operators utilize digital tools to adjust chemical dosages, monitor equipment performance, and respond promptly to alarms and alerts. Automation engineers are responsible for programming and maintaining PLCs and SCADA systems, optimizing processes in treatment plants and distribution networks. Remote monitoring and control technicians oversee operations and address issues from a centralized location. Digital, real-time instruments and automated sampling systems have revolutionized water quality analysis and chemistry. Maintenance technicians employ digital tools for predictive maintenance. Data analysts process and interpret data collected from sensors and systems to make informed decisions concerning water quality, distribution, and treatment. Digitalization has also heightened the demand for cybersecurity specialists. New skill requirements To prepare for their evolving roles, both current and future workers must enhance their digital literacy to properly use digital tools and understand how data is collected, processed, and utilized. Knowledge of programming languages and automation systems is essential to design and implement automated control solutions for water treatment processes. Proficiency in data analytics is critical to extract meaningful insights from vast datasets and optimize water treatment processes. A strong environmental awareness and understanding of environmental impact and conservation practices in water management are imperative. Additionally, workers need problem-solving skills and the ability to adapt to rapidly changing technology and environmental conditions. Given the complexity and interconnectivity of systems, workers should be prepared to collaborate within multidisciplinary teams. Digitalization serves as a powerful modernization driver for water and wastewater operations, revolutionizing traditional approaches to water management and treatment. In this context, digitalization involves integrating advanced technologies, data-driven strategies, and automation to enhance efficiency, sustainability, and overall effectiveness. The success of digitalization depends on qualified workers capable of optimizing and managing water resources diligently. Therefore, education and training in process automation play a key role. M19 → festo.com/didactic Magazine > Current trend topics
When delving into water management within industrial operations, it is essential to recognize the inseparable connection with energy. Addressing the so-called “water-energy nexus” in technical education helps to prepare students to be conscientious, adaptable, and innovative professionals who can contribute to sustainable and responsible technological advancements. Water for energy, energy for water The intricate interplay between energy and water forms a multifaceted relationship that underscores the interdependence of these two critical resources. Energy choices impact water resource quality and availability, and vice versa. Energy production relies heavily on water resources, as various methods such as hydropower, nuclear, and thermal power generation require substantial water inputs. Conversely, water treatment and distribution necessitate significant energy inputs. This intricate nexus becomes even more pronounced in the face of climate change, as altered precipitation patterns and rising temperatures impact both water availability and energy demand. Striking a delicate balance between these two vital elements is imperative for sustainable development and social acceptability. Renewable energy availability There is growing interest in integrating renewable energy sources into water tech operations to reduce reliance on fossil fuels and decrease greenhouse gas emissions. Solar, wind, and hydroelectric power can be used to power water treatment and distribution facilities, making them more sustainable and resilient. However, decarbonizing electricity generation with renewables presents the challenge of energy storage during periods of low wind and sunlight. A solution involves utilizing surplus renewable electricity to pump water into reservoirs, enabling indirect energy storage through a smart grid. Students should be empowered or sensitized directly at school to identify these interconnections and develop innovative solutions. 1 2 3 1 2 3 1 10 9 8 7 6 5 4 3 2 1 1 2 3 1 2 3 PGM EXIT CAL The EDS Water Management helps to explore the water-energy nexus. → Page 44 Optimization of the Water-energy nexus M20 Process automation I Learning solutions for education and training Magazine > Current trend topics
Cross-disciplinary skills To optimize the energy-water nexus, individuals need a diverse set of skills spanning technical knowledge, analytical prowess, interdisciplinary understanding, environmental awareness, policy and regulatory insight, effective communication, collaboration, project management proficiency, innovation, adaptability, and system thinking. Optimization tools Instrumentation and process control, in conjunction with automation technologies, plays a vital role in improving the efficiency of the energy-water relationship in industrial operations. Various instruments and control systems are used to monitor and manage water and energy consumption efficiently: Differential pressure meters, electromagnetic flow meters, ultrasonic flow meters measure the rate of water flow in pipes or channels. They monitor water consumption, detect leaks, and optimize water usage in processes. Piezoelectric, strain gauge, and capacitance pressure sensors measure the pressure of fluids in pipes or vessels. They optimize pump efficiency, detect leaks, and ensure proper pressure in water distribution systems. Ultrasonic level sensors, radar level sensors, float level sensors measure the level of liquids in tanks or containers. They control water levels, prevent overflow, and manage storage in water treatment facilities. Thermocouples, resistance temperature detectors (RTDs), infrared temperature sensors measure the temperature of water or other fluids. They optimize energy consumption in heating and cooling processes, monitor water quality. Analytical instruments (pH/conductivity/ turbidity/dissolved oxygen meters) measure and analyze the composition of water and wastewater. They monitor water quality and ensure compliance with regulatory standards. Programmable logic controllers (PLCs) control and automate various processes based on programmed logic. They are key to sequence control, data acquisition, and process automation in water and energy management. Supervisory control and data acquisition (SCADA) Systems and distributed control systems (DCS) monitor, control, and gather data from industrial processes. Cloud data offer centralized control of water treatment plants, energy management, remote monitoring, and transparent communication with stakeholders. Variable frequency drives (VFDs) control the speed and power consumption of electric motors to optimize pump and fan operations, and overall energy efficiency. Smart sensors and IoT devices provide real-time data and enable communication between devices, enabling continuous monitoring, predictive maintenance, and datadriven decision-making. Energy management systems monitor and manage energy consumption in industrial processes to identify energy-saving opportunities and track energy usage patterns. The mastery of these technologies enables real-time monitoring, control, and optimization of processes, contributing to increased efficiency, reduced resource consumption, and overall sustainability in industrial operations. M21 → festo.com/didactic Magazine > Current trend topics
Battery manufacturing plants are mushrooming to support the acceleration of electric mobility and the expansion of renewable energy storage options. What characterizes battery manufacturing facilities? What skills are required? How can students be prepared to onboard the industry and how to enhance workers’ productivity? What is the contribution of process automation to operations? Let’s find out. Advanced manufacturing skills Battery manufacturing plants are modern, high-volume facilities that seamlessly integrate factory and process automation. Automation ensures precision, uniformity, and stability, meeting stringent safety and performance requirements. However, the introduction of innovative technologies impacts skills requirements, leading to skills deficits among workers. To thrive in an Industry 4.0 environment, workers need a broader range of skills, including digital literacy, troubleshooting, critical thinking, communication, collaboration, and creativity. Lifelong learning skills are also essential due to rapid changes in the industry. Therefore, teachers and industry training managers must invest in adapting or creating training programs aligned with industrial skills requirements. Process technology: a key expertise area The battery industry’s value chain spans from raw material extraction to battery cell assembly, distribution, integration, services, recycling, and research. Process technology integration ensures efficiency and quality throughout. Skilled production workers require expertise in process technology and automation for safety and productivity in manufacturing. To prepare skilled workers in process automation, a comprehensive training program covering flow, level, pressure, temperature, pH, and conductivity processes, as well as industrial control technologies like PLCs, SCADA, and DCS, is essential. This program should also include specific knowledge of battery processes and technologies. Essential battery fundamentals Technical workers require a solid understanding of fundamental battery principles to effectively contribute to the production process. Here are a few important areas of battery fundamental knowledge: • Battery chemistry (lithium-ion, lead-acid, nickel-metal hydride…) and materials (including electrodes, electrolytes, and separators). • Battery design principles (including cell arrangement, electrode configurations, and packaging considerations) and structural components of batteries and their functions (such as current collectors, terminals, and casing materials). • Electrochemical processes (charge/discharge reactions, ion migration, and electron flow) and electrochemical parameters (voltage, current, capacity, and energy density). • Battery testing methods and characterization techniques, including performance metrics such as capacity, voltage, cycle life, and impedance. • Safety protocols and hazard awareness (flammability, toxicity, and chemical reactivity). • Quality control measures and standards (ISO quality management systems, industry-specific regulations, and product certification requirements). • Batch processing techniques, production workflows, and optimization strategies. Learning solutions for battery and electric vehicle production We can assist schools and industrial companies in developing comprehensive learning environments and training programs to build skills that help onboard new hires and enhance expertise of current employees. → Click here or scan the code: Instrumentation and control for Battery manufacturing M22 Process automation I Learning solutions for education and training Magazine > Current trend topics
Process Description Controlled variables Field devices Mixing Blending materials to form a uniform mixture, including slurry production. Mixing speed, temperature, viscosity, concentration of materials Speed, torque, and temperature sensors, viscosity meters, concentration analyzers Coating Applying a thin layer of slurry onto current collectors to create battery electrodes. Coating thickness and uniformity, temperature, solvent concentration Thickness gauges, temperature sensors, gas analyzers Drying Removing solvents from coated electrodes to enhance structure and prevent defects. Temperature, humidity, residual solvent concentration Temperature and humidity sensors, gas analyzers, heaters and fans Calendering Compressing, shaping coated electrodes to improve density and mechanical properties. Thickness of coated materials, density of materials, temperature Thickness gauges, density meters, temperature sensors Filling Injecting electrolyte into battery cells for proper volume and concentration. Electrolyte volume, seal integrity, electrolyte concentration Level sensors, leak detection systems, electrolyte analyzers Aging Allowing batteries to stabilize and activate for optimal performance. Rest time, temperature, self-discharge rate Timers, temperature sensors, self-discharge measurement devices Degassing Removing gases enhances battery safety and longevity. Gas concentration, temperature, pressure Gas analyzers, temperature and pressure sensors Testing Evaluating capacity, voltage, resistance, and safety characteristics. Capacity degradation, thermal stability, voltage drop, internal resistance Battery testers, voltage and internal resistance meters, safety testing equipment M23 → festo.com/didactic Magazine > Current trend topics
Raw material handling Material preparation Electrode manufacturing Cell assembly Front end Cell assembly Back end Slitting Raw material distribution Mixing Notching Vacuum drying Coating Calendering Drying Cylindrical cell Stacked cell Wound cell Tab welding Z-folding Tab assembly Typical battery production process M24 Process automation I Learning solutions for education and training Magazine > Current trend topics
Filling Formation Module and pack assembly Assembled cell Cylindrical winding Tab welding Cylindrical cell Stacked cell Prismatic cell Cylindrical cell filling Pouch cell filling Prismatic cell filling Aging Degassing EOL testing Module assembly Pack assembly Canning M25 → festo.com/didactic Magazine > Current trend topics
Technical training for the mining and metals workforce Explore our learning solutions that prepare operators and technicians for the mining industry. Download our brochure. → Click here or scan the code: Process technology in Mining M26 Process automation I Learning solutions for education and training Magazine > Current trend topics
Process automation enhances safety by minimizing human exposure to hazardous conditions, improves efficiency by streamlining workflows and reducing downtime, and boosts productivity by maximizing resource utilization. Moreover, process automation facilitates real-time monitoring and control of critical parameters, ensuring optimal operation of equipment and processes. Additionally, automation contributes to environmental sustainability. The processing of tech minerals differs significantly from that of traditional minerals, primarily due to their unique properties and characteristics and the specific requirements of modern technological applications. Key skills areas for production workers: Instrumentation and process control Managing the efficiency of the wide and diverse range of mining processes can be challenging, especially due to the variety of equipment that often operates using different interfaces and formats. Instrumentation enables real-time equipment monitoring for numerous mining operation processes simultaneously, increasing efficiency through automation, improving quality control, reducing waste and contamination, and creating a safe work environment. Water technology Water serves various purposes throughout the production processes, including extraction and processing, dust suppression, cooling, transportation and slurry handling, washing and cleaning, mineral separation and concentration, and more. Water technology relies on automation and control systems to precisely manage and optimize water and wastewater treatment processes. Renewable energy production By transitioning to renewable energy sources, mining companies can reduce their energy costs, particularly in remote locations with limited grid access, while mitigating environmental impacts such as greenhouse gas emissions and pollution. Industrial trades Industrial trade skills, particularly in machine mechanics and industrial pumps maintenance, are vital to ensure machinery and equipment reliability, minimize downtime, and optimize productivity. Picture: Flotation cells in a mineral processing facility Tech minerals often occur in complex ore bodies containing multiple elements, necessitating specialized extraction and processing techniques such as hydrometallurgy, ion exchange, and solvent extraction. Moreover, tech minerals used in high-tech applications require high levels of purity, leading to additional purification steps not typically needed for traditional minerals. Additionally, the processing of tech minerals may involve environmentally sensitive processes, prompting heightened environmental regulations and sustainability considerations compared to traditional minerals. With the increasing demand for technology minerals essential for various applications in renewable energy, electric vehicles, electronics, and telecommunications, the mining industry once again holds a pivotal position in modern society. Industrial mining operations heavily rely on process technology to optimize extraction processes, improve efficiency, ensure safety standards, and minimize environmental impact. M27 → festo.com/didactic Magazine > Current trend topics
Mining With deep mining or open-pit mining, the rock is drilled and blasted and then transported or conveyed to the surface. Crushing • Breaker A breaker station crushes the rock, often to rock dust. • Ball mills The wet milling of minerals like copper ore crushes the material. • Screening plant Screening separates granulated ore material into different grades based on particle size. • Jigger The separating machine has a deep tank in which water is used to separate out the materials since they have a specific weight that is different to the gangue. • Hydrocyclone Cyclones are one of the most frequently used plant components for separating solid particles from the liquid flows. Processing and extraction • Flotation Froth flotation selectively separates highvalue, hydrophobic minerals from hydrophilic waste product. In its simplest form, the minerals are skimmed from the surface of a “slurry” of specific chemicals, water and air bubbles. • Leaching This is the process by which precious metals, copper and other compounds are extracted from ores. Because of the chemical reactions, certain materials are absorbed and then separated again from other earth materials. • Precipitation A precipitating agent is added to a batch of metal-containing solution, causing the target metal ions to form insoluble precipitates, which can be separated by filtration or sedimentation. Typical mining processes 1 2 3 1 2 3 M28 Process automation I Learning solutions for education and training Magazine > Current trend topics
Thickener and filtration • Thickener The froth concentrate from the flotation cells is pumped to the concentrate thickener. The gravitational force causes the particles to form a thick slurry, which contains most of the solids. The overflow consists of liquids and caustic solution. • Filtration Filter presses are used to dewater the concentrate and waste material. The minerals that are extracted from the sludge are processed further in follow-up processes and the water used is returned to the process. Onward transport The finished mineral concentrate is transported to primary production plants like smelting works or refineries. In fully integrated plants, the internal transport is handled by conveyors. • Smelting The process involves feeding a batch of ore or concentrate into a furnace or smelter, along with fluxes and reducing agents, and heating it to high temperatures to separate the metal from the gangue materials. The molten metal is then tapped off and further refined. • Electrorefining/Electrowinning In electrorefining, a batch of impure metal is used as the anode in an electrolytic cell, where it is dissolved and deposited onto a cathode, resulting in purified metal. In batch electrowinning, metal ions in solution are reduced and deposited onto an electrode to recover the metal in pure form. 4 5 4 5 M29 → festo.com/didactic Magazine > Current trend topics
Preparing for Green hydrogen Renewable energies Solar Wind Hydro Produciton of hydrogen Electrolysis Cryogenic liquefaction Compressor station Storage Transport Truck Ship Pipeline Bulidng services Mobility Industry Chemistry Steel Paper Cement M30 Process automation I Learning solutions for education and training Magazine > Current trend topics
Numerous uses Green hydrogen is primarily utilized as a clean energy source for transportation, industry, and power generation. It is a renewable alternative to fossil fuels, helping to reduce greenhouse gas emissions and mitigate climate change. It can also be used for energy storage and grid balancing, contributing to the integration of renewable energy sources. It also holds potential for applications in sectors requiring high-temperature heat. The colors of hydrogen • Grey hydrogen is produced from fossil fuels, usually through a process called steam methane reforming (SMR): methane is reacted with steam at high temperatures to produce hydrogen and carbon monoxide. It is the most common form of hydrogen produced today but is associated with significant greenhouse gas emissions. • Blue hydrogen is also produced from natural gas, but with the additional step of carbon capture and storage (CCS) to mitigate greenhouse gas emissions. • Turquoise hydrogen is produced using methane pyrolysis, a process that involves breaking down methane into hydrogen and solid carbon without producing CO2 emissions. • Green hydrogen is produced through the electrolysis of water using renewable energy sources. Electrolysis splits water molecules into hydrogen and oxygen, with the hydrogen collected as a clean fuel source. Its production is entirely emissions-free. Green hydrogen production is a burgeoning topic, yet still unfamiliar to many. As a technical education teacher specializing in process automation, instrumentation, and process control, it is crucial to grasp green hydrogen technology’s growing significance in sustainable energy systems. Let’s delve into a few fundamental aspects. Green ammonia Ammonia is a versatile compound primarily used in the production of fertilizers, but also in industrial processes, chemical synthesis, and more. Green ammonia is produced using green hydrogen as a primary feedstock. This is typically achieved through the Haber- Bosch process, where hydrogen is combined with nitrogen extracted from the air or from nitrogen-rich sources like biogas or wastewater treatment plants. Electrolysis technologies Electrolysis is a fundamental process for green hydrogen production. There are currently three main technologies: • Alkaline electrolysis: Uses alkaline electrolyte solution (e.g., KOH or NaOH) to split water into hydrogen and oxygen using direct current. Commercially available for decades, known for reliability and cost-effectiveness. Operates at higher temperatures and pressures, impacting energy efficiency and requiring additional heat management. • PEM electrolysis: Utilizes solid polymer electrolyte membrane (e.g., Nafion) to split water into hydrogen and oxygen with an electric current. Offers high efficiency, fast response times, and lower operating temperatures and pressures. • Solid Oxide Electrolysis Cells (SOECs): Operate at high temperatures (700900°C) using a solid ceramic electrolyte to split water vapor into hydrogen and oxygen. Offers high efficiency and potential for co-electrolysis of steam and carbon dioxide. Water-intensive process While electrolysis relies on water as a feedstock, actual water usage varies based on several factors. Efficiency in electrolysis technology plays a significant role. Water usage is influenced by the purity of the hydrogen output, as additional water may be needed for purification to meet specific quality standards. The source of water utilized also affects consumption, with freshwater sources posing environmental concerns compared to alternative sources like seawater or wastewater. Instrumentation for hydrogen production Instrumentation measures and monitors key process variables and ensuring operational efficiency and safety: • Pressure transmitters for various components of production system, flow meters (for gases and liquids), and sensors for monitoring electrolyte pH, temperature, pressure, gas purity, and levels. • Various electrical instruments, including voltmeters, ammeters, and power meters, measure electrical parameters such as voltage, current, power consumption, and electrical efficiency within electrolysis systems. • Safety instruments such as gas detectors, flame sensors, and pressure relief valves detect and mitigate potential safety hazards, including gas leaks, combustion risks, and overpressure situations. Hydrogen production provides interdisciplinary insights into energy, sustainability, technology, economics, and policy. Left image: An overview of the green hydrogen value chain M31 → festo.com/didactic Magazine > Current trend topics
New knowledge and skills requirements The introduction of these specialized chemical reactors necessitates process operators, technicians, and engineers to acquire a range of specialized competencies. These encompass an understanding of biology and microbiology, proficiency in aseptic techniques to ensure sterility, familiarity with bioreactor-specific instrumentation and control systems, knowledge of bioprocess engineering principles, and the ability to analyze and interpret data using analytical techniques. Increased complexity Standard reactors typically employ simpler control systems primarily geared toward ensuring the safety and basic stability of chemical reactions. In contrast, automation and control systems in bioreactors are notably more sophisticated and customized to meet the unique demands of biological processes. These systems prioritize the maintenance of precision and stability, with a strong emphasis on optimizing productivity through the application of advanced control strategies and data-driven decision-making. Typical field devices in bioreactors Various sensors and measurement devices monitor key parameters to ensure the proper functioning of the bioreactor and maintaining optimal conditions for the bioreaction. • Temperature sensors measure and maintain the temperature of the culture medium and provide feedback to the control system. • pH sensors continuously monitor the acidity or alkalinity of the culture medium, which can have a significant impact on cell growth and product formation. • Dissolved oxygen sensors measure the concentration of oxygen dissolved in the culture medium to ensure an adequate oxygen supply. • Pressure sensors ensure that the vessel operates within safe pressure limits and detect pressure fluctuations. • Level sensors monitor the liquid level in the bioreactor to ensure that the culture medium remains at the desired volume and prevent overflow or dry-out. • Biomass sensors measure the density or concentration of cells or microorganisms in the culture. • Gas sensors monitor the concentration of gases like oxygen, carbon dioxide, and other gases in the headspace or exhaust. • Conductivity sensors measure the electrical conductivity of the culture medium, which can be related to the concentration of ions and solutes in the medium. • Turbidity sensors measure the cloudiness or turbidity of the culture medium, which can indicate cell density or the presence of particles. • Redox potential (ORP) sensors measure the oxidation-reduction potential of the culture medium, an important parameter for some types of microbial processes. • Flow meters measure the flow rate of gases or liquids entering or exiting the bioreactor. They are important for controlling nutrient addition and waste removal. Essential input to the control systems Data is collected and processed by a data acquisition and control system (PLC, SCADA, DCS, or other) that allows workers to set and adjust parameters, receive real-time data, and make automated decisions to maintain optimal conditions, and troubleshoot any issues that may arise during the processes. Biologization Bioreactors Biologization harnesses the potential of biological processes and materials. As this trend continues to gain momentum, bioreactors are emerging as crucial enabling technologies in the process industry. They serve as essential tools for cultivating, controlling, and optimizing biological processes at a commercial and industrial scale. M32 Process automation I Learning solutions for education and training Magazine > Current trend topics
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