Design and Development of Real-Time Plant Process Control Monitoring System in Organic Fertilizer Production

Abstract

In this applied research, a plant controller with capacity of 300 litres has been developed. The system provides graphical user interface (graphics and tables) using Visual Basic program to show and monitor the fermentation process. Communication between the software and hardware is established through microcontroller’s interface. The microcontroller acts as the main controller which controls the humidity, temperature, pH, aerator, heater, exhaust fan, and the speed of the motor. Temperature and humidity sensor (DHT-22), Methane Gas sensor (CH), Carbon Gas sensor (MQ7), and Nitrogen Gas sensor (MiCS-2714) are used in this system. The domestic waste raw materials such as vegetables and sugar cane waste are thinly sliced while the fruits are grinded. Temperature, humidity, and pH readings are collected as reference parameters prior to the process starts. During the anaerobic digestion process, temperature is kept at 40°C ±1 while plant’s tube is maintained at 40°C. When the temperature falls to 39°C, the heater is switched on, when the temperature reach 40°C the heater is switched off. This research is carried on using two kind of mixture models which are: mixture model X (mixture of vegetables, fruits and sugar cane waste) and mixture model Y (same as X with additional rice husk). The mixture model X and Y C/N’s ratio is in compliance with SNI-7030-2004 standard. The real-time plant controller system proposed in this research is successfully.