Digital control and monitoring of carbon nanofibers

Nanomate is a leading company in the research and development of advanced materials, with a primary focus on improving efficiency and sustainability in the manufacturing of batteries and supercapacitors.
In 2024, Galeo developed the CNF Digital Monitor System to modernize Nanomate’s carbon nanofiber production plant, integrating IoT technology and Cloud services into a traditional industrial environment. The plant operates ten reactor furnaces, capable of reaching temperatures of up to 1000°C, where materials are processed through controlled gas interactions. These reactors, originally designed with 1990s technology, have been upgraded to enhance efficiency and control through a cloud-based system that allows simultaneous and remote production management.
System Features:

• Centralized and remote control: A single monocore PLC manages the independent operation of the ten reactors, enabling reconfiguration as needed. The system handles reactor telemetry, including pressure, temperature, and gas flow rates, while also generating signal and communication alarms.
• Process automation: The planning and control system allows the creation, storage, and execution of custom recipes for each reactor. These recipes manage all operational parameters, such as timing, work phases, process conditions, and operational limits. This automation minimizes the need for manual intervention by on-site technicians.
• Integration with industrial systems: To ensure interoperability with existing equipment, the system utilizes industrial protocols such as Modbus RTU, TCP, EtherCAT, and more, facilitating communication between reactors and other plant machinery.
• Specialized software development: The system software is developed in TwinCAT3 and runs on a CP6606 PLC with a touchscreen HMI interface. This provides a seamless user experience, improving monitoring and control from a single screen while optimizing costs and ensuring efficient performance.
• Cloud-based telemetry and analysis: Galeo designed an AWS-based architecture that enables remote plant configuration, as well as the reception, storage, and analysis of process variables from each reactor. These data are directly integrated into Nanomate’s Datalake, enabling real-time, data-driven decision-making.
• Infrastructure improvements: A central control panel has been installed to integrate all operational components. Additionally, the electrical and Ethernet networks have been optimized, ensuring system scalability and reliability.

Key Project Benefits: