Optimising Waste-to-Energy Processes with the MoistTech IR-3000 Moisture Analyser

In the evolving landscape of sustainable energy solutions, waste-to-energy (WTE) plants play a crucial role in reducing landfill waste while generating usable power. However, one of the significant challenges in these facilities is managing the ash byproduct efficiently. Excessive dust, moisture control, and environmental compliance are key concerns that require precision monitoring. This is where the MoistTech IR-3000 Moisture Analyzer steps in as a game-changer for optimizing WTE processes. 

Proven Design

Designed to provide accurate real-time moisture readings, the IR-3000 helps facilities regulate moisture levels to minimize dust emissions, improve handling efficiency, and reduce operational costs. Its durable construction and advanced sensor technology make it ideal for harsh environments, ensuring reliable performance even under extreme conditions. With its ability to integrate with automated control systems, the IR-3000 provides seamless data monitoring, allowing operators to make informed decisions. By addressing common challenges in moisture measurement, this analyser has proven to be an asset in the waste-to-energy sector.

The Role of the IR-3000 in Waste-to-Energy Plants

Waste-to-energy plants operate by incinerating municipal and industrial waste known as RDF (refuse derived fuel) to generate heat and electricity. This process produces ash as a byproduct, which must be carefully managed to prevent dust pollution, equipment damage, and regulatory non-compliance. Measuring and controlling the moisture content not only of the incoming material, but we can also measure the by-product of ash at the exit of the process is crucial for operational efficiency and environmental safety. 

Reliable and effective solution for RDF and Ask Moisture

The MoistTech IR-3000 Moisture Analyzer has been rigorously tested for this application, proving to be a reliable and effective solution. After extensive trials in collaboration with various customers, the sensor successfully demonstrated its ability to withstand the harsh environment of a WTE facility while delivering accurate moisture readings. The IR-3000 is designed for non-contact measurement, utilizing near-infrared (NIR) technology to provide instant, continuous readings. This capability allows operators to maintain optimal moisture levels without disrupting the process flow, ensuring consistent performance and regulatory compliance. By reducing the manual intervention required for moisture testing, the IR-3000 enhances overall plant efficiency and safety.

Challenges in Measuring Moisture in WTE Ash

Implementing a moisture measurement system in a waste-to-energy facility presents unique challenges, including excessive dust, fluctuating moisture levels, and variable material composition. One of the primary difficulties is excessive, corrosive dust, which can accumulate on sensors and impact accuracy. The IR-3000’s rugged design and protective coatings help it withstand such harsh conditions, ensuring long-term reliability. Another challenge is intermittent product flow, as variations in waste input and incineration efficiency can lead to inconsistent flow. The IR-3000’s real-time measurement capabilities enable it to adapt to these changes, providing continuous and accurate data. Temperature variations also pose a significant challenge, especially with ash exiting the combustion chamber can be extremely hot. The IR-3000 is built to withstand extreme temperatures, allowing it to function effectively in high-heat environments. Additionally, integrating the sensor with water spray control systems can be complex, but the IR-3000 facilitates seamless integration, helping to optimize water usage and prevent excessive wetting of the ash.

Technical Features of the IR-3000

The MoistTech IR-3000 is equipped with advanced features that make it an industry leader in moisture measurement. Its near-infrared (NIR) technology enables non-contact, high-speed moisture analysis, ensuring precise readings without direct material contact. The sensor operates in real-time, providing instant feedback to optimize process control. One of its key advantages is adjustable calibration, allowing operators to customize settings based on specific material characteristics and environmental conditions. The IR-3000 also features auto-ranging capabilities, adapting to different moisture levels and material types without requiring manual adjustments. With its compact and lightweight design, the sensor can be easily installed in various locations within the plant, including conveyor belts, chutes, and hoppers. The device is also resistant to vibration and mechanical shock, ensuring stable performance in dynamic industrial environments. Additionally, the IR-3000 supports Ethernet and analog communication protocols, making it compatible with modern industrial automation systems.

How the IR-3000 Addresses Moisture Control Challenges

After a year of development and refinement, the IR-3000 successfully meets these challenges, allowing customers to integrate moisture measurement with feed forward control to boilers or controlling water spray control system at the exit. As a result, plants experience significant improvements, including 100% reduction in airborne dust, improving air quality and workplace safety. Complete elimination of excess washdowns and water use led to substantial cost savings, as facilities no longer needed to overcompensate with additional water. 

Improved handling of Ash for Environmental Benefits

Implementing online moisture analysis helps Reduced employee time and effort required for cleaning and maintenance allowed for more efficient labor allocation. Easier compliance with environmental regulations was achieved through better dust control, helping the facility meet industry standards. Lower water usage prevented the formation of mud, making ash handling and transport more efficient. Minimized trucking costs resulted from optimized moisture levels, as properly managed ash required fewer trips for disposal. Reduced wear and tear on equipment was achieved by preventing dust buildup in conveyor systems and boilers. Prevention of conveyor blockages ensured uninterrupted plant operations, reducing downtime and maximizing energy production.

Key Findings from the Implementation

One of the most interesting observations from the project was the variability in ash composition and its exothermic properties, making absolute moisture calibration difficult. Instead, a set point for moisture control was established to maintain optimal conditions. 12-14% moisture content was determined to be the lowest threshold before excessive dust became an issue, indicating that higher moisture levels were necessary for dust suppression. 15-18% moisture content was identified as the ideal range for balancing dust control and material handling efficiency. Over 25% moisture resulted in wet ash that contained surface water, leading to handling difficulties and potential equipment issues. 

Analyser Long Term Stability and Reliability

Despite being exposed to a highly corrosive and dusty environment for over two years, the IR-3000 remained in perfect operational condition. While the exterior of the sensor accumulated dust, its internal components, electronics, and external connections were completely unaffected, proving its resilience in demanding industrial applications. The durability of the IR-3000 ensures long-term reliability, making it a cost-effective solution for waste-to-energy plants.

A Proven Success in Waste-to-Energy Applications

With its robust design and ability to deliver real-time, reliable moisture readings, the MoistTech IR-3000 has demonstrated its value in optimizing WTE plant operations. The success of these installations has paved the way for adoption in facilities worldwide. The IR-3000 not only improves efficiency but also enhances environmental compliance by helping control the boiler but by reducing dust emissions and optimizing water use. Its ability to seamlessly integrate with existing process control systems makes it an invaluable tool for modern waste-to-energy facilities. 

An Evolving Industry

As the industry continues to evolve, moisture management will remain a critical factor in maintaining operational efficiency and environmental sustainability. Investing in advanced moisture measurement technology like the IR-3000 ensures that plants can meet regulatory requirements while maximizing energy production. If you’re looking for an efficient solution to control ash moisture, reduce environmental impact, and enhance plant efficiency, the IR-3000 moisture analyser is a proven choice. For more information on how this technology can benefit your operations, visit JW Industrial Instruments or contact our team for expert guidance.