Plant - Industry 4.0
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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
PLANT 4.0 The 4.0 Industry promoting the 4th Industrial Revolution in the Sugar-Energy Sector
2 MÁRCIO VENTURELLI
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have been replaced by electronic ones, then by industrial networks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.
PLANT 4.0 The 4.0 Industry promoting the 4th Industrial Revolution in the Sugar-Energy Sector
3 MÁRCIO VENTURELLI
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.
PLANT 4.0 The 4.0 Industry promoting the 4th Industrial Revolution in the Sugar-Energy Sector
4 MÁRCIO VENTURELLI
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.
PLANT 4.0 The 4.0 Industry promoting the 4th Industrial Revolution in the Sugar-Energy Sector
5 MÁRCIO VENTURELLI
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/