Plant - Industry 4.0

PLANT 4.0 The 4.0 Industry promoting the 4th Industrial Revolution in the Sugar-Energy Sector

1 MÁRCIO VENTURELLI

e-Paper

Márcio Venturelli

PLANT 4.0

The 4.0 Industry promoting the 4th Industrial

Revolution in the Sugar-Energy Sector



We are living the transition from the 3rd to the 4th Industrial

Revolution. From the 70s on, the introduction of computers in the

production lines allowed an unprecedented economy,

standardization and high quality, reducing production costs.

From the 90s on, the massification of the Internet has

brought a new way to communicate, impacting the daily lives of

people, with everybody communicating on a single platform - using

online devices, allowing information exchange, research, data

analysis, decisions and actions in real time, anywhere.

The Sugar-Energy Sector has also evolved in the Industrial

Automation category. In the early 80s, the pneumatic control panels

have been replaced by electronic ones, then by industrial networks

in the 90s and in the early twenty-first century. Today, we have

power plants with operation centers commanding the entire plant, all

connected in information and control networks.

The new technologies that arise are already present; we are

living a transition and also new concepts: the Internet of Things

(IoT) and the database (Big Data), dictate a new scenario.

In practice today, the industrial plants are reactive in relation

to the production processes. Changes in the economic conditions,

consumers, maintenance and operating trends only appear to the

operator or the engineer when in fact they occur, most often

dragging losses in the production of all kinds, cost, safety and

quality.



The 4.0 plant will have all its production processes

connected, all the instruments and equipment in the industrial plant

and in the agricultural sector with machinery and equipment will be

connected to the GPS, exchanging information with the industry and

the parameters of the controllers. This will be allowed through the

Internet of Things (IoT), most with wireless networks. The entire

production process will be simulated through scenarios, both in the

market and the consumption, making the plant produce the exact

amount, in the best Input x Sale because the database (Big Data)

will receive all the information in the production chain, both internal -

the equipment and people we see, and external – from suppliers,

governments, climate, market - delivering information to the

decision-making, still being supported by the Cognitive Computing,

in which the systems will "learn" with the scenarios.

It is the evolution of the operating control that exists today in

the form of programmable and supervisory controllers, or even the

SDCD - Distributed Control Digital Systems, providing the operators

and the engineers the best options for their decision making by

analyzing the productive environment-with related variables such

as: should a truck breaks down, what would be the impact that the

grinding would suffer and at what time; an increase in the moisture

and the impact on the cogeneration and input consumption in the

Thermoelectric Unit; an specific demand to produce anhydrous

ethanol; what the best productive arrangement is; and at what is the

right time to get the best use.



The main benefits of this new concept are: cost reduction,

energy saving, increased security, environmental conservation,

error reduction, end of waste, business transparency, increase in

the quality of life, personalization and unprecedented scale.

The 4.0 Industry is a proposal that is already a reality,

although in initial and experimental stage in some plants. However,

it is a vector that points to a new way of dealing with the production

and, in this case, serving as an efficient tool in the production of

ethanol, sugar and electricity.



AUTHOR

MAR/2016 - R0

Márcio Venturelli, Brazilian,

Senior member ISA (International

Society of Automation), has worked in

the industrial automation market for 20

years and has gone through several

departments, such as technical

assistance, training, commissioning,

design, engineering, marketing and

business.

Has worked on several projects to

implement the automation system in

bioenergy plants, processing and

manufacturing, in Brazil and abroad.

Currently works with developing new

market and new technologies, with a

focus solutions architecture in industrial

automation, as main guideline, adding

value to the users, using tools to

increase production, reduce costs and

increase operational safety, also,

planner and project manager.

Is a postgraduate professor in industrial

automation and project management.

Graduate in Computer Science, Post

Graduate in Industrial Management,

Technology Oil and Gas and MBA in

Business Strategy.

E-mail: [email protected]

https://mhventurelli.wordpress.com/

mailto:[email protected]

https://mhventurelli.wordpress.com/