TiRO Pilot-Scale Production Plant

Background

The TiRO process is a new process for producing titanium metal. The traditional Kroll process is an energy-intensive batch process that produces bulk metal that must be melted and cast to create Titanium parts. Each cycle of melting and casting degrades a proportion of the titanium stock to unusable nitrides, which are lost to the process cycle.

TiRO is an advanced continuous feed process that uses a fluidised bed reactor and vacuum sublimation chamber to produce Titanium powder under an Argon atmosphere. The powder can be processed directly into titanium parts using standard powder metallurgy techniques with no loss of product to the processing cycle.

TiRO was initially developed by CSIRO and commercialised in partnership with Coogee Chemicals. The first step in this partnership was to migrate the lab-bench prototype to a multi-function pilot scale plant capable of producing product in commercially usable quantities.

The Challenge

The pilot plant had three objectives:

  • To continue to perform basic research on the TiRO process.
  • To test commercial-scale implementations of advanced manufacturing equipment and techniques.
  • To run as a 24/7 production facility capable of producing high-quality products in quantities suitable to supply to target customers

TiRO had to address the different, and often opposing, needs of two major stakeholder groups:

  • The research scientists and engineers that are investigating the process. This R&D function demands that the plant be flexible and easily reconfigured to meet changing R&D and test requirements. Operators need to access and modify the system configuration as required.
  • The process engineers that are charged with running a controlled commercial facility. The plant must be industrially robust and meet all appropriate workplace standards and engineering certifications, with an emphasis on safe, reliable, and predictable operation. Operationally, this means that system stability is prioritised over variation, and operators are typically isolated from changing, or even accessing, the low-level functionality of the system.

An additional technical challenge was maintaining the highly exothermic fluidised bed reaction within a narrow temperature range just below the 1,668 °C melting point of titanium metal. This required a dense network of high-speed temperature sensors feeding data to custom real-time control logic algorithms.

The Solution

Elevate Controls implemented a high-speed deterministic control system based on NI CompactRIO Programmable Automation Controllers and NI LabVIEW Real-Time and FPGA software that deliver low-latency precision control of the thermal, pressure, and motion subsystems.

The system included:

  • 12 distributed IO Chasses/Controllers,
  • Over 400 analog, digital, and motion IO points, and a mix of conventional PID and custom control logic.

It met the needs of both the research scientists for flexible data acquisition, data processing & control, and the process engineers for safe, robust 24/7 operation.

High-level NI software modules and frameworks ensured that software changes were implemented safely, robustly, and repeatably.

An extensive R&D program was executed in parallel with 24/7 production of high-quality titanium powder product for regular delivery to major customers worldwide.

The Outcome

The system was deployed on-time and on-budget. Its active lifetime was originally projected to be 1-2 years. However, it has remained in continuous operation for over 10 years, including relocation to a major new facility with a 50x increase in production volume.

This project was recognised as a Finalist at the PACE Zenith Awards 2013 in theMining, Minerals, and Exploration category.

Our Approach

Every control, monitoring, or test system project is unique. Elevate Controls follows a consistent development process that adapts to the unique requirements of your project and delivers a quality outcome every time. We use industry-standard tool chains that ensure consistent and efficient application of resources across every stage.

We offer a full-cycle development service from concept to deployment, and every stage in between. Whether you’re starting from a blank page or optimising an existing system, our team brings deep industrial experience, technical know-how, and a problem-solving mindset to every project.

Our Services

Elevate Controls offers full-cycle development of embedded controllers. Our consistent development process adapts to the unique requirements of your project and ensures a quality outcome every time. We use industry standard tool chains that ensure efficient use of resources, and design protect to allow for future variation and scalability.

We supply custom measurement and automation systems for application in technology-based industries including mining & materials handling, renewable energy & power, transport, and manufacturing.

Our systems deliver superior performance for demanding applications that push the limits of traditional data loggers and PC/PLC controllers.

We are expert integrators of the Mathworks MATLAB/Simulink software toolchain for system modelling, simulation and control design of complex engineering applications.

We design, develop, validate and certify high-volume Vehicle/Engine Control Units.

We are a proven partner for VCU/ECU development with over 100,000 units currently in service.

Elevate Controls can partner with you to develop your control, measurement, or automation product. We can manage the entire process to the point of handover or work as an embedded part of your product development team.

We develop products using fully documented industry-standard processes and toolsets that ensure that your product can be maintained, evolved, and supported for it’s projected commercial life.

We employ a consistent development methodology that delivers successful outcomes every time.

Elevate Controls develops custom test systems that are integral to every successful industrial or manufacturing business. Test guides and validates product development, tracks and maintains product quality, and is an essential element of post-production support and warranty management.

Elevate Controls specialises in custom solutions to industrial automation challenges that push the limits of traditional PLC/SCADA systems. We target challenging industrial R&D or test applications, specialised sub-systems within a traditional DCS, and process control for niche or pilot-scale manufacturing.

We have supplied systems to industries that include mining and materials handling, electrical power, transport, manufacturing, process industries, agribusiness, and engineering services.

We do not compete directly in the large-scale DCS or SCADA space.

Traditional data management lags behind the exponential growth in the volume and variety of data collected in modern engineering workplaces.

Elevate Controls’ Engineering Data Management Solution is designed to meet the needs of small to medium-sized engineering groups that must manage, analyse, and report large quantities of mixed-signal data.

Elevate Controls is an NI Systems Integration Partner with over 30 years’ experience deploying NI-based systems into Australian industry.

We are one of Australia’s most awarded integrators of NI systems at leading industry events.

We have hands-on experience with all NI’s current & legacy hardware lines, and all NI software applications & frameworks. We are one of Australia’s leading LabVIEW software development houses, having worked with every version of LabVIEW since its initial release.

Fibre Optic Measurement delivers some unique benefits that complement the functionality of traditional electro-mechanical sensing systems.

Elevate Controls can deliver measurement and automation systems that seamlessly integrate Fibre Optic Measurement into traditional electro-mechanical sensing systems. This can address issues that may be challenging or impossible to meet with electro-mechanical sensors alone.

Contact Us

Our solutions leverage industry-leading platforms, including National Instruments hardware and software, ensuring reliability, scalability, and faultless integration with your existing infrastructure.

We partner with clients throughout the entire project lifecycle—from proof of concept to system development, deployment, and long-term support— with the added flexibility to integrate at any phase of your project.

Elevate Controls helps businesses accelerate innovation while optimising performance and cost.

Contact us today to discuss your specific requirements and discover how Elevate Controls drives efficiency, accuracy, and competitive advantage in your operations.



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