Sugarcane Management Case Study For more information, and to discuss how FactoryStudio can help modernize your SCADA HMI application, please contact us at our website: www.tatsoft.com Sugarcane Industry Several Brazilian Sugarcane Industry are benefiting from the use of digital twin to anticipate problems and determine the best production routes with maximum performance. CHALLENGE SOLUTION RESULTS Pentagro PGDI, built on FactoryStudio Framework, integrates Process Modeling, Production Planning and Operations for higher performance and yields. • The SugarCane processing plant is subject to strong variability in the quality of the inputs (sugarcane) as well as in the market prices of the outputs (sugar, ethanol and electric power). • The challenge is to provide a simple to use and semi-automatic solution for guiding planners and operators to maximize the asset results, subject to the customer’s daily defined strategies. • Pentagro PGDI can be seen as a plant GPS with telemetry. It uses a Digital Twin that allows the definition of the best route to transform the sugar cane into its final products (sugar, ethanol and bioelectricity), with the best performance feasible for the existing assets of the sugarcane processing unit. • Pentagro customers have experienced earnings of up to USD 2.00 per ton of sugarcane by stabilizing production schedule, plant throughput, and improving the efficiency associated with operational procedures guided by the decision support tools.
Transcript
Sugarcane Management Case Study
For more information, and to discuss how FactoryStudio can help modernize your SCADA HMI application, please contact us at our website: www.tatsoft.com
Sugarcane Industry
Several Brazilian Sugarcane Industry are benefiting from the use of digital twin to anticipate problems and determine the best production routes with maximum performance.
CHALLENGE
SOLUTION
RESULTS
Pentagro PGDI, built on FactoryStudio Framework, integrates Process Modeling, Production Planning and Operations for higher performance and yields.
• The challenge is to provide a simple to use and semi-automatic solution for guiding planners andoperatorstomaximizetheassetresults,subjecttothecustomer’sdailydefinedstrategies.
For more information, and to discuss how FactoryStudio can help modernize your SCADA HMI application, please contact us at our website: www.tatsoft.com
Pentagro, created in 2006, with the objective ofdevelopinginnovativetechnologysolutionstomaximizethe performance of agro-industrial plants, developedthe Pentagro PGDI for the sugarcane processingunits, which transforms the complex Operation andProduction Performance Management tasks in simpleandprofessionalactivities.
For centuries this process remained empirical withvery lowconversionefficiencybut, recently, therehavebeen great changes to the industry that demanded areview in the process engineering: the use of Ethanolas automobile fuel; electricity sold to the utility grid;environmentalrestrictionstotheconsumptionofwateranddisposalofvinasse,tonameafew.
In this context, it became necessary for a strongerfocusonefficiencyandproductionmanagement,whichopenedthewindowofopportunityexploitedbyPentagrowithhelpfromFactoryStudio.
Integrating the Process Automation and Business perspectives
From the process automation perspective, thesugarcane processing industry changed, in the last30 years, from no instrumentation at all to islands ofautomation and, in some cases, centralized controlroomsutilizingPLCsandScadaHMI.
ThisarchitecturewithdisplaysmimickingtheP&IDs,plus some trends and alarms, are convenient foroperations but not enough for integrated productionmanagement,andevenwithaddedhistoriancapabilities,thatarchitecturestill lackedthetools foranalyticsandidentificationofprocessandoperationalimprovements.
Consideringthis,Pentagroinitiallyoffereredarigorousprocess simulator to support Process Engineeringactivities,andlaterofferedtheSales&OperationplanningtoolandtheDecisionSupportKPIinterface.
Pentagro selected FactoryStudio as the platform tosupports the integration of these three modules withthe existing Scada and Historian from the automationarchitectureplusotherdatabases from the ITbusinessarchitecture.
Pentagro PGDIPentagro PGDI is an online platform designed
to assure the sugarcane processing unit operatesas planned following the optimal production plandesignedinaccordancetothedailydefinedstrategy.TheFactoryStudioframeworkalsoshadesaccesstoPentagroproprietarycodeandIP.Somefunctionalitiesinclude:
Digital Twin: avirtualmodelwhichmimics theplantoperationanddefines thebestoperational conditions.The Process Engineers also use the “digital twin” tosimulate operational conditions, scenario analysis andeveninvestigatecostsandbenefitsofplantandprocessmodifications.
Avanced Planning: a tool that help planners identifythe best possible plan, compatible with the existingequipment design restrictions and the final products’(sugar,ethanolandKWh)marketprices.
KPI Management: a front end User Interface tocompareplannedvsexecutedparametersandallowforonlinesetupadjustmentsandcorrections.
The results for the platform include supportoperational decisions; viability and Capex evaluations;andallowingforaproductionlineascloseaspossibletoplanning,withhigherperformanceyields.
