SIMATIC WinCC

Sugar and ethanol factory

Iaco Agrícola – Brazil

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Ethanol fuel in Brazil

Brazil is the world's second largest producer of ethanol fuel and the world's
largest exporter. Together, Brazil and the United States lead the industrial
production of ethanol fuel, accounting together for 89% of the world's production
in 2009.In 2009 Brazil produced 24.9 billion litres (6.57 billion U.S. liquid gallons),
representing 37.7% of the world's total ethanol used as fuel.
Brazil is considered to have the world's first sustainable biofuels economy and
the biofuel industry leader,a policy model for other countries; and its sugarcane
ethanol "the most successful alternative fuel to date.

From Wikipedia, encyclopedia

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Industry Sector
Challenge

To improve facility performance and to facilitate maintenance and

servicing, Iaco Agrícola contracted Siemens to implement a state-of-the-art
solution based on PROFINET communication.
A powerful SIMATIC S7-400 system controls the operations in the plant.
Management and operation of industrial production were centralized in a
single Integrated Operations Center (IOC).
The SIMATIC WinCC visualization system runs on the operator station in
the IOC, while the Web-based WinCC Webnavigator allows access to the
system from any point in the plant.
Via SIMATIC WinCC with Thin Client technology, field operators can also
use hand-held computers (PDAs) to control, open and close maintenance
orders while in the facility.

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Industry Sector
Solution

To improve facility performance and to facilitate maintenance and servicing, Iaco

Agrícola contracted Siemens to implement a state-of-the-art solution based on
PROFINET communication. A powerful SIMATIC S7-400 system controls the
operations in the plant. Management and operation of industrial production were
centralized in a single Integrated Operations Center (IOC).
The SIMATIC WinCC visualization system runs on the operator station in the
IOC, while the Web-based WinCC Web-Navigator allows access to the system
from any point in the plant. Via SIMATIC WinCC with Thin Client technology, field
operators can also use hand-held computers (PDAs) to control, open and close
maintenance orders while in the facility.

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Industry Sector
Benefit

The Integrated Operations Center combines maintenance, production and

operations management and enables the control of all stages of the process and
rapid intervention whenever needed. The asset management tool speeds up
diagnostics and plant maintenance. PROFINET ensures reliable communication
and effectively supports system diagnostics. The automation solution has proven
to be extremely robust even under the harsh conditions in the sugar industry: In
3,576 hours of operation, the plant had only 10 hours of downtime due to
automation problems.

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Industry Sector
References
IACO Agrícola bioethanol project
ƒ Investor group : Grendene ,
Irmãos Schmidt and private
capital
ƒ Plant location: Chapadão Sul /
Mato Grosso do Sul, 15 km to
railway FERRONORTE
ƒ Investment volume: R$ 450’
(approx. EUR 170’)
ƒ Plant Capacity :
ƒ 2 millions ton of sugar cane
ƒ 200 million liters of ethanol
ƒ 40 MW electric power
generation
R$ 12,7 million
project revenue
Solutions implemented from … until … include:
ƒ 1st supplier Pony Motor sold in Brazil
ƒ 1st Process Automation based on Profinet /S7 400 / Win CC Thin Client
ƒ 133 Cabinet s of Siplux and 18000HP of motor Siemens installed
ƒ 29 GeafolTransformer , 66 Cabinet 8BK20 13,8 KV
Siemens Divisions involved and Cross-Selling approach:
ƒ E D EA ; ED M ; ET TR ; I DT LD ; I IA CDDM ; I IA AS …
Project goal:
ƒ Built a modern installation with integrated communication and
efficient flow information
ƒ Respecting the Costs of the projects
Initial situation:
ƒ First Ethanol project from Grendene Group
ƒ Technical team oriented for new technologies
ƒ Siemens participation since the beginning of the project
Added Value for the customer:
ƒ Customer technology requisition supplied with our solution ,
ƒ just one Siemens interface focused on the project
ƒ Siemens Expertise was extremely important to the project
development
ƒ deliveries divided in different stages /packages according to the project
development
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Industry Sector
Start of operation in 10/11/09
Production Capacity – 2 million ton per year
Location : Chapadão Sul / Mato Grosso do Sul / Brazil

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Industry Sector
Operation station – WinCC Thin client

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Central Control Room – WinCC Thin Client Architeture

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Pictures from IACO Plant

Cabinet 8BK20/13,8 KV – Power House Cabinet SIPLUX – Power House

Energy Management with Sentron PAC 3200

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Industry Sector
Pictures from IACO Plant

Cutting Cane - Pony Motor 3500 HP Siemens Salles Team - Mils

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Industry Sector
 IACO – Chapadão do Sul – MS Automation Architecture
INTERNET

FIREWALL
SCALANCE S
1 2 .... 7

WEB ENGINERING REDUNDANT OPERATION STATIONS

STATION STATION SERVERS

1 3 HISTORIAN
2
Control room

REDUNDANT RING Profinet Gigabit

Milling , Water treatment , Pretreatment /
Cooling towers, Utilities Fermentation / Power house
Steam
generator Distillation 500 / 600

REDUNDANT RING Profinet Gigabit

IE/PB Link IE/PB Link IE/PB Link IE/PB Link

I/O I/O I/O I/O
IE/AS-I Link IE/AS-I Link IE/AS-I Link IE/AS-I Link
.. .. .. ET 200 M ..
. . . .
DP/PA LINK DP/PA LINK DP/PA LINK
DP/PA LINK

CCMi CCMi CCMi

CCMi HMI of steam
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turbine
Industry Sector