Instrumentation on a Premier Gasification Project
Background
Process Instrument Solutions recently secured a major project to supply instrumentation for a large UK-based gasification plant utilising RDF (Refuse Derived Fuel). The project incorporated a comprehensive range of instrumentation and sensors from Siemens, Fox Thermal, and Thermo Electra.
Gasification is a thermo-chemical process that converts carbonaceous materials—such as biomass, RDF, plastics, or coal—into synthesis gas (syngas). By heating materials to high temperatures (typically above 700°C) in a controlled environment with limited oxygen or steam, the process produces hydrogen, carbon monoxide, and methane without full combustion. This offers a more sustainable route for generating electricity, liquid fuels, and chemical feedstocks while reducing waste.
Challenge
The application presented several demanding challenges. The syngas environment is both highly corrosive and operates at extreme temperatures, requiring instrumentation capable of withstanding harsh process conditions.
Key considerations included:
- High operating temperatures, with level switches required to perform reliably at temperatures exceeding 500°C
- Compliance with ATEX requirements for hazardous areas (Zone 21/22) and SIL safety standards
- The presence of tar within the gas stream, which posed a risk of build-up on sensors and potential performance degradation over time
Ensuring long-term reliability and accuracy in such conditions was critical to the plant’s operation.
Solution
Process Instrument Solutions conducted a detailed review of the plant specifications, working closely with the client and incorporating insights into the gas composition and process conditions.
A tailored instrumentation solution was developed, focusing on:
- Selecting robust materials of construction suited to high temperature and corrosive environments
- Optimising the positioning of instruments based on site-specific experience to maximise performance and minimise exposure to process-related damage
- Providing detailed technical proposals aligned with both operational requirements and compliance standards
This collaborative and consultative approach ensured that each instrument was carefully specified and installed for optimal reliability.
Result
The full instrumentation package was successfully installed and commissioned, with all systems performing reliably under operational conditions.
The plant has since been recognised as a significant advancement in the gasification sector, with the instrumentation playing a key role in enabling efficient and safe operation. The project has been widely regarded as a “game changer” within the industry.
