Increasing biomass throughput at MVV’s Ridham Dock Facility with Valmet’s advanced process control and camera technology

Germany-based MVV operates a highly modern and efficient biomass power plant at Ridham in the UK to produce electrical energy. Built in 2015, the plant uses 165,000 tonnes of solid biomass per year to generate about 190 million kWh of electrical energy. The primary fuel is processed wood, including locally sourced chipboard, fiberboard, old furniture and wood from building sites and demolished buildings.

The Ridham plant is just one of MVV’s facilities that support the group’s strategy of enabling customers to take part in an energy transition that is viable both technically and economically.

MVV's Ridham biomass plant in the UK turns 165,000 tonnes of recycled wood into 190 million kWh of clean electricity annually.

Control system for measurable results

The Ridham plant had previously implemented the Valmet DNA Automation System, installed by a local integrator. During a routine service call, the customer mentioned to Valmet service technicians that they might be interested in improving and adding additional monitoring to their grate control.

As a natural evolution to the existing Valmet DNA control system, Valmet proposed advanced process control (APC) and a camera solution with the latest imaging technology to achieve measurable improvements with a quantifiable return on investment.

Valmet knew our plant already. They had been working with us for years. They had a good understanding of our requirements and what needed to be resolved – and that’s what they focused on.”

“Valmet knew our plant already,” says David Magrath, Maintenance Manager, MVV Environment Ridham Ltd. “They had been working with us for years. They had a good understanding of our requirements and what needed to be resolved – and that’s what they focused on.”

MVV upgraded its Valmet DNA system with advanced control and imaging to improve grate performance and achieve clear, measurable results.

Increased waste throughput

Valmet proposed the Valmet DNA Combustion Manager, an APC application based on fuzzy logic, which analyzes multiple variables to improve combustion. “It helps increase average boiler load, minimize O₂ levels and reduce chemical consumption – in this case, urea,” says Chris Heywood, Country Manager, UK and Ireland, Automation, Valmet. “These are the key performance indicators (KPIs) we set.”

The Valmet Visible Thermal Imaging System uses a visible light camera and unique optical filtering to provide a high-definition image of the process. Operators can see and set up to eight different temperature areas in the grate and can manually adjust the temperatures regions according to need.

“Our camera technology and Valmet Grate Combustion Vision software provides both flame parameters and temperature data to the APC to increase waste throughput with better combustion stability and load shifts,” says Jesús Nuncira Valencia, Product Manager, Boiler Diagnostics Systems at Valmet.

Valmet’s Visible Thermal Imaging System gives operators a clear HD view of the grate, allowing manual control of up to eight temperature zones for optimized performance.

Flexible payment options

Before Valmet could proceed, Ridham needed to be convinced they would get a good return on investment, and that the solution would add value to their operations.

Valmet first carried out a performance study on site in 2022 and provided Ridham with a report of the return on investment and outlined how the solution could be beneficial.

“We also offered them a ‘payment by results’ commercial arrangement. We would start with a short run. After making any necessary improvements, we would then enter a longer performance evaluation period, and MVV would pay us based on results. If they weren’t satisfied, they would stop using our system,” Chris Heywood says.

The camera system was installed at the end of April 2024, and the Valmet DNA Combustion Manager in June. Commissioning began at the start of August.

Improved combustion

According to the agreement, Valmet verifies the KPIs four times over a period of 12 months.

“This also includes verifying the ROI calculation that we made for the customer, which originally showed that they could increase their performance,” Chris Heywood says.

Within the first month of installing the system, the plant already started reaching its KPIs, and the ROI looks likely to meet MVV’s expectations.

The burn we get in our combustion chamber is now much better. You can see the difference. The ash at the end also has a much better consistency than what we used to get. In all, it improves the boiler’s maintenance and efficiency.”

“The burn we get in our combustion chamber is now much better,” Magrath says. “You can see the difference. The ash at the end also has a much better consistency than what we used to get. In all, it improves the boiler’s maintenance and efficiency.”

At MVV Ridham, enhanced combustion boosts efficiency, ensures smoother maintenance, and produces higher-quality ash, optimizing boiler performance.

Responsive teamwork

The advanced process control, including the visible thermal camera system, is Valmet’s first installation in the UK. Valmet has made a similar delivery to the Tammervoima waste-to-energy facility in Tampere, Finland. Ridham also signed a performance agreement, which will be handled by the local service team from Valmet’s Performance Center in the UK. Valmet supervised the installation and took responsibility for startup and commissioning.

“We had some challenges during the camera installation, but we were able to successfully overcome them by being proactive with Ridham team,” says Jesús Nuncira Valencia. “Still, we are especially proud of our delivery execution and all the efforts made by our Valmet team.” 

The entire Valmet team and product managers have been highly responsive and in constant contact to ensure the system performs correctly. We were really pleased with how Valmet worked with our operators, staying with them in the control room and explaining everything they were doing. The communication and openness made the transition easier for the operators, who don’t always welcome change. But Valmet made it as comfortable and smooth as possible.”

“The entire Valmet team and product managers have been highly responsive and in constant contact to ensure the system performs correctly. We were really pleased with how Valmet worked with our operators, staying with them in the control room and explaining everything they were doing. The communication and openness made the transition easier for the operators, who don’t always welcome change. But Valmet made it as comfortable and smooth as possible,” says Magrath. 

For further information, please contact:

Chris Heywood, Country Manager UK and Ireland, Automation
chris.heywood(at)valmet.com, tel. +44 7887 952 432

Jesús Nuncira Valencia, Product Manager, Boiler Diagnostics Systems
jesus.nunciravalencia(at)valmet.com, tel. +358 50 330 2869

Jyri Kaivosoja, Senior Product Manager, Performance Solutions
jyri.kaivosoja(at)valmet.com, tel. +358 50 385 1907