Inteligência artificial aperfeiçoa manobras da produção de açúcar e etanol orgânico da Usina Goiasa

Goiás Case Presentation

Introduction to Goiás

• Alvimar Tavares introduces himself as the Industrial Production Manager at Goiás, expressing gratitude for the opportunity to present.

• Tavares highlights the significant results achieved in recent years, attributing them to the application of Industry 4.0 technologies.

Overview of Goiás

• Goiás is located in central-southern Brazil and has a production capacity of processing three million tons of sugarcane annually.

• The company employs over 3,000 people, making it one of the largest employers in the region and a key player in renewable sugar and alcohol production.

Mission and Values

• The mission emphasizes transforming energy sustainably while maintaining cost-effectiveness and community harmony.

• Goiás differentiates itself by producing organic sugar, which adds value but also presents significant challenges.

Certifications and Standards

• Tavares discusses various certifications that Goiás holds, including organic certifications for markets like Korea, Japan, Brazil, China, and the European Union.

Industry 4.0: A Necessity or Trend?

Importance of Technology Adoption

• The presentation addresses whether adopting Industry 4.0 is a necessity or merely a trend within competitive markets.

• Tavares notes that Brazil has only 69% of companies implementing some form of digital technology as of 2021—a figure lower than developed countries.

Competitive Market Dynamics

• He stresses that companies must adopt new technologies to remain competitive; otherwise, they risk obsolescence.

Revolutionizing Processes

• The goal is to revolutionize products and services through connected systems that optimize value chains using digital technology.

Automation and Data Management

Automation Concepts

• Automation involves coordinating functions such as measurement control and monitoring without human interference.

Big Data Integration

• Discussion on how modern automation incorporates Big Data analytics and IoT (Internet of Things), leading to smarter operational decisions.

Impact on Performance Metrics

• Emphasizes that even minor improvements can lead to substantial gains when scaled across large production volumes (e.g., millions of tons).

Evaluating Automation Investments

Measuring Success

• Tavares illustrates how investments in automation can be evaluated based on performance metrics before and after implementation.

Consistency in Production

Operational Challenges and Innovations in Plant Management

Key Objectives of AI in Plant Operations

• The speaker emphasizes three critical objectives for integrating artificial intelligence (AI) into plant operations: operational safety, consistency, and maximizing results. These are deemed essential for effective standardization.

• Achieving these objectives presents challenges, particularly the need for precision in process readings. A well-modeled plant or complex algorithm will not yield better outcomes if based on unreliable data.

Importance of Reliable Instrumentation

• The effectiveness of algorithms is contingent upon the reliability of input data from instruments. Poorly calibrated devices like thermocouples or flow meters can lead to inaccurate calculations and suboptimal results.

• Ensuring accurate instrument calibration requires technical expertise and adherence to maintenance protocols from reputable companies.

Engineering Considerations

• Proper placement of instruments is crucial; for instance, a thermometer positioned incorrectly may provide misleading temperature readings that do not reflect actual conditions.

• Addressing engineering issues before adopting advanced technologies is vital to avoid wasted resources and ensure successful implementation.

Operator Engagement and Paradigm Shift

• A significant challenge lies in changing operators' mindsets regarding automation. Operators may resist changes fearing job loss unless they understand the benefits of technology enhancing their roles rather than replacing them.

• To facilitate this transition, it’s important to elevate operators’ understanding through education about operational improvements brought by automation while ensuring job security remains intact.

Communication as a Tool for Change

• Effective communication between management and operators is essential. Clear messaging helps operators feel valued and understand their importance in achieving company goals alongside technological advancements.

• Establishing strong relationships between coordinators, managers, and operators fosters an environment where everyone collaborates towards maximizing operational efficiency without fear of obsolescence.

Implementation Timeline at Goiás Plant

• The Goiás plant began implementing its intelligent system (SPA) in 2018 with a focus on steam generation as a primary energy source to enhance overall productivity.

• By 2019, additional systems were integrated into the plant's operations following initial success with SPA, indicating positive project validation through improved processes.

Focus on Stabilization for Production Efficiency

• The main goal was stabilizing steam pressures across the facility since consistent operation directly impacts sugar and ethanol production—key outputs for Goiás's business model.

• Continuous monitoring led to adjustments that enhanced stability within production processes while optimizing resource utilization effectively over subsequent years.

Analysis of Energy Efficiency and Production in Ethanol Plants

Overview of System Performance

• Discussion on the stability of energy systems, emphasizing that fluctuations can lead to losses. The speaker mentions a closed-loop system similar to a tent structure.

• Introduction of data modeling from Douglas's work, showcasing how physical data informs operational efficiency in ethanol production.

Historical Data Comparison

• Analysis of energy consumption from 2019 onwards, noting that 2019 is not a valid baseline due to operational issues during the implementation of the spa cogeneration system.

• Highlighting an increase in monthly energy output from 10,000 Mega to 11,000 Mega over two years despite challenges faced by the plant.

Efficiency Metrics

• Presentation of specific efficiency metrics for different processes within the plant, indicating improvements in performance with increased output per ton processed.

• Emphasis on comparing internal results rather than against external benchmarks due to differing operational setups across plants.

Challenges in Fermentation Process

• Addressing fermentation as a critical and sensitive stage in ethanol production where organic alcohol must be produced without using certain chemicals or antibiotics.

• Discussion on historical performance metrics before implementing new technologies and their impact on overall production stability.

Technological Advancements and Results

• Examination of technological contributions leading to improved consistency in production metrics over time.

• Insights into how digital technology has enhanced process management and efficiency within the plant operations.

Management Strategies and Outcomes

• Reflection on management practices aimed at continuous improvement amidst competitive pressures within the industry.

Recuperação e Fermentação: Desafios e Estratégias

Reflexões sobre a Recuperação no Processo de Fermentação

• A recuperação no final da história é crucial, destacando que o somatório do todo deve ser considerado. O número dois é mencionado como um ponto preciso para entender os desafios enfrentados.

• É importante aprender com as experiências dos outros, evitando tropeços desnecessários. O palestrante expressa gratidão pela oportunidade de compartilhar seu conhecimento.

• A conexão entre os participantes é enfatizada, com agradecimentos à equipe presente e ao apoio recebido durante a apresentação.

Importância da Saúde da Levedura na Produção Orgânica

• Uma pergunta surge sobre a ausência de ácido e antibióticos na fermentação. O palestrante confirma essa prática, ressaltando que isso pode impactar a penetração do processo.

• Durante o período de produção orgânica (maio a novembro), o palestrante colhe cana orgânica e produz suco orgânico, mas enfrenta desafios na produção de álcool orgânico devido à saúde da levedura.

• A temperatura é utilizada como método para minimizar contaminações durante a fermentação. A levedura selvagem pode introduzir contaminações indesejadas.

Desafios e Limitações na Fermentação

• O palestrante discute as limitações na produção orgânica, mencionando que após um certo período, a levedura começa a falhar em sua função produtiva.

• Um participante questiona sobre eficiência e subprodutos gerados pela falta de ácido durante o processo. O palestrante reconhece que há limites para perdas aceitáveis sem comprometer a produção.

• Apesar das dificuldades financeiras relacionadas ao custo do ácido sulfúrico, o palestrante afirma que não se pode sacrificar eficiência por custos baixos; existe um limite para perdas toleráveis.

Conclusão da Apresentação

• O palestrante conclui sua fala reafirmando que cada etapa do processo deve ser monitorada cuidadosamente para garantir uma produção eficiente e sustentável.