Date post: | 15-Apr-2017 |
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Technology |
Upload: | ate-private-limited |
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Smart Manufacturing Suitefor the Sugar Industry
At-a-glance information on PLF on any device, anytime, anywhere
Introduction
Sustainable use of agro-based renewable resources like sugar cane demands the establishment of a complete manufacturing value-chain comprising of sugar as well as other value-added by-products such as exportable power from bagasse, alcohol and ethanol from molasses, biogas and bio-fertilizers from spent wash.
In a typical multi-plant operation setup, controlling losses and ensuring increased productivity is possible for an enterprise only if relevant manufacturing information is available on any device, anytime, anywhere.
If you have a typical multi-plant sugar complex, EcoAxis' solution will help you control losses and ensure increased productivity by making manufacturing information available to you on any device, anytime, anywhere - at your fingertips.
Manual and conventional logging of data is difficult to compile owing to the massive scale of data involved in the operations of an integrated sugar complex. This calls for a Machine-to-Machine (M2M) based monitoring solution that tracks critical parameters of operations and production output on a minute-by-minute basis – or even faster. This compilation is followed by automated analytics and management of the plant through online reports, alerts – very much like internet banking.
How we can help you – EcoAxis solution
IoT based monitoring involves:
• Selecting parameters: Critical process parameters, equipment operations, run-hours, stoppages etc.Intermediate & final products of production: cane crushed, juice, molasses, spent wash and bagasse, sugar andpower – produced, consumed, exported, ethanol production, utilities consumption etc.
• Consolidate data from automation systems through UDAN (Unified Data Access Network): Acquiring & integrating data from DCS, PLC, instrumentation and sensors, etc.
• Configuring and deploying algorithms/alerts: Based on users’ roles & needs reports, dashboards, alerts etc. can be developed.
Do you face these challenges?
• Enhance production and PLF (Plant Load Factor) while reducing losses.
• Ensure high plant availability in a seasonal crushing scenario through reduced break-downs, enhanced productivity, reduced costs/losses, and improved quality.
• Optimize sugar recovery, water usage, power exports and energy usage.
• Limited access to top management for accessing shop floor data on any device, anytime, anywhere.
• Consolidate critical manufacturing data from a multitude of automation systems across the sugar complex (sugar, distillery, co-gen and bio-gas) in a unified manner, which is crucial for technicians and operation managers to provide effective interventions and support to avoid plant downtime.
• Linking agro-based information such as area under cane cultivation, area harvested and cane delivered, cane and sugar yields etc., with production scheduling and manufacturing data in order to operate an integrated sugar complex in an effective and efficient manner.
Solution architecture
KPIs & Advanced AnalyticsData Management
Define user roles
Create users
Functionality
a sxi EYE
a sxi EYE a sxi GURU
a sxi NOTIFYAlerts & Notifications
Application
Server
Database
Server
Configuration
Organisation Users Sites Equipments
• End User
• O & M
• OEM
• Operator
• Maintenance Team
• Management (KPIs)
OPC Client
AxislogData Logger
ERP
Data Acquisition
Weighing System
Milling Section
Boiling House
Boiler House
Energy Meters
Boilers
Energy Meters
Balance of Plant
Turbine
Su
gar
Pla
nt
Co
gen
Pla
nt
Dis
tillery
Rectified Spirit
Energy Meters
Ethanol
ENA
Energy Meters
Flow Meters
Plant
Customer Scope
Bio
gas
EcoAxis’ Solution
Trending Tabular
Data
Export
to Excel
Export
to PDF
What can you achieve with IoT based continuous monitoring system?
• Ability to do in-depth analysis of production, productivity, availability and losses
• Ensuring increased production with high crushing through high mill capacity utilization.
• Optimal balance of sugar rendement (recovery) and sugar production on one hand and better production of alcohol in distillery on another hand, by controlling imbibition water addition as per the business need.
• Better control over production cost by monitoring thermal energy and electrical energy consumption per ton of cane crushed.
• Improve efficiency of multiple equipment across the sugar complex and SMSs/alerts to be generated asneeded.
• Operational load patterns on mill electrical motors against cane preparation, imbibition water consumption pattern in the sugar plant, and steam consumption pattern across sugar and distillery plants, are recorded continuously.
• Improved availability and maintenance by controlling and effectively managing unscheduled stoppages.
• Other benefits ٥ Reduced travel to site ٥ Bringing in more accountability in operations ٥ Ability to analyze through year-on-year, month-on-month performance comparison
Enable quick communication from the dashboard interface through
email and SMS alerts
Identify & rectify any abnormalities in operating patterns such as sudden
increases in electrical load in milling section, sudden variations in steam
demand, irregularity in fuel supply, etc.
Access up-to-date data of production, plant availability, productivity and losses
A.T.E. ENTERPRISES PRIVATE LIMITED
T-126, T Block, MIDC, Bhosari, Pune 411 026T | +91 20 3088 1100 E | [email protected] | www.ecoaxisindia.com / www.ateindia.com
(Business Unit: ) EcoAxis
Waste watereffluent disposal
monitoring
Continuous Measurement &
Verification (CMV)
Analytics for renewable
energy
Discrete equipment monitoring
Facility monitoring
Utilities monitoring
Plant process monitoring
Understand your most critical challenges
Setup systems to collate the most pertinent data
Data acquisition & historization
Build advanced analytics
Generate insights for better decisions
Cloud based platform
EcoAxis Solution
Manual Entry
Trending Tabular
Data
Export
to Excel
Export
to Pdf
ax si EYE - Historian
EcoAxis Hardware
OPC Client
Process 1
Process 2
Process 3
Process n
Basic Functionality
Additional Information
Any device, Anytime, Anywhere
Alerts & NotificationsAnalytics
GURUax si NOTIFYax si
Your Scope Our Solution
Process 4
Data Acquisition Data Management Advanced Analytics