Bionic µAI

How AI Transforms the Process Control of Bionic µFuel Systems

Microwave conversion is one of the most demanding areas in modern process engineering. Different biomass types, fluctuating moisture levels and spontaneous reaction dynamics make precise control challenging. This is exactly where Bionic’s AI-supported process management comes into play – making µFuel systems more stable, efficient and scalable for industrial use.

Why Conventional Control Systems Fall Short

Rule-based systems only react once thresholds are exceeded. But in microwave conversion, problems arise much earlier:

• Hotspots can form within seconds,
• Material properties change during the reaction,
• Moisture and density influence gas quality in real time,
• Every batch behaves differently.

AI detects these changes long before they become critical – and adjusts the process dynamically.

The Bionic Approach: A Learning, Predictive Control System

The AI combines real-time data with historical patterns:

• Microwave power
• Temperature profiles
• Process gas spectra
• Moisture & density parameters
• Torque, motor and conveying data

A digital twin in the background defines physical boundaries and stabilizes the AI model. The system does not simply react – it anticipates. It provides operators with optimized control suggestions that require only confirmation and simultaneously checks the plausibility of manual inputs.

Optimization of Bio-Oil and Biochar

Depending on the production goals, the AI can steer the µFuel system toward:

• maximum bio-oil yield and quality
• reproducible bio-oil and gas quality
• especially stable, high-grade biochar

This turns every µFuel installation into a flexible production platform for a wide range of markets.

Predictive Maintenance: Detecting Issues Before They Occur

The AI identifies patterns typical of:

• early-stage coking,
• material blockages,
• bearing or motor wear,
• valve irregularities,
• thermal overload zones,
• increased power consumption.

These anomalies are often detected days or even weeks before an actual failure would occur. This prevents costly downtime – a decisive advantage for industrial operators.

Remote Monitoring: Industry-4.0-Ready Plant Operation

All relevant operating data is continuously recorded and can be:

• visualized live in control rooms,
• automatically evaluated,
• compared across multiple locations,
• and used for remote operation.

This makes µFuel systems fully "Industry 4.0-ready":

• remote maintenance,
• centralized process optimization.

Conclusion

AI transforms Bionic µFuel plants into true high-performance reactors:

• more stable processes
• higher product quality
• optimized bio-oil and biochar production
• predictive maintenance
• improved energy efficiency
• centrally operable systems requiring fewer personnel

This makes microwave conversion not only more efficient – but scalable, robust and ready for industrial deployment.