Closed Loop Sugar Processing

Increasing sugar consistency with NI Closed Loop System

Features

  • NI Proprietary IP in 3 stages
  • Stage 1 : Determining strategic data points
  • Stage 2 : Process control algorithm
  • Stage 3 : Closed loop production control system

NI Proprietary IP in 3 stages

Nutrition Innovation (NI) is responsible for the leadership and development of global proprietary patents that allow customers unique access to harness data from Schneider Electric sensors and monitors to increase yield and consistency on lower energy.
NI Proprietary IP in 3 stages
Strategic Partnership Project Review
  • Our approach is based on a three stage process:
      1. To review the production site and determine location for sensors to collect real time data on production parameters.
      2. Using this data algorithms are established to create process control systems to better automate production to improve consistency, to reduce and better manage energy, to maintain output and minimize waste.
      3. Continual monitoring and optimization so that the system can strengthen and improve across seasonality and crop variability.
  • Each site will have it's unique recommendation for sensors and integration to tackle the challenge that is defined in the review.The bespoke software and hardware package that allows the ability to collect sample data in upstream sources prior to sugar treatment combined with the ability to collect further data downstream after the treatment process.

    Location points can include:
      - Baggase
      - Sugar Cane Juice
      - Filter Cake
      - Syrup
      - Massequite
      - Magma
      - Molasses
      - Final Raw Sugar

    Location points are determined by the customer based on what is targeted to optimize.

Stage 1 : Determining strategic data points

This initial stage reviews the entire production site and determine strategic locations for sensors to collect crucial real-time data that impacts product quality as well as sustainability factors of the plant. The Nutrition Innovation Closed Loop system leverages real-time data from sensors that are strategically placed in the production site to generate the information required for process control algorithms to be established. As part of the development project an analysis and review of the production site, including existing installed sensors will be required. Following this there will be a recommendation for both the type and position of sensors required to achieve the consistency objective. The following Foss and Foxboro sensors are a guide for the type of sensors that may be required but the final recommendation will be part of a project proposal for consideration and review.
ProFoss delivers non-invasive real time data
  • ProFoss™ is a process analysis system based on high resolution diode array technology. It provides non destructive analysis of products within a sugar milling and refining operation that is directly in the process line without bypass – a true in-line system. The ProFoss™ analyser is available with dedicated interfaces based on reflectance or transmittance technology whichever is best suited for each application area. A high-intensity dual-lamp light source illuminates the sample directly or through an optical fiber. The light interacts with the sample and the reflected or transmitted light is measured by the diode array sensor. FOSS standard SW interface for integration to Schneider control systems enables automatic regulation of the process. It is a true online system providing results approximately every 20 seconds for process control-improve recovery, factory control and efficiency through availability of continuous data analysis.
Stage 1 : Determining strategic data points
Foxboro Process Liquid Analytical
  • The Foxboro range of contacting conductivity and resistivity products comprises sensors, analyzers and transmitters. Sensor types include the 871CC and 871CR, both of which are available in 0.1 and 10.0 cm cell constants. Sensors are characterized by their wide range of mounting accessories, precision construction for high accuracy, rugged design and ease of use.
  • Foxboro Coriolis Flow Transmitters handle measurements that cause other Coriolis meters to fail. Additionally, Foxboro Magnetic Flowmeters are a reliable flow measurement solution with a lower cost of ownership and maintenance, with field-proven stability to maximize the availability of flow measurement. Foxboro Vortex Flowmeters are the highest-performing vortex flowmeters on the market.

Stage 2 : Process control algorithm

Using continual data captured from stage 1 & by leveraging precise advance PLC technology like Eurotherm, the solution enables continual monitoring and optimization so that the system can strengthen and improve across seasonality and crop variability. Helping to control sugar processing more precisely, this reduces energy usage, shorten processing times, minimize waste, and improve final product quality, all of which can increase your overall profitability.
The Eurotherm Edge+PLC range combines core expertise in measurement accuracy, precision control and tamper resistant recording, together with proven PLC functionality. The range includes a single box solution for small machine applications, and a modular platform solution for larger machine processes. This system can be tailored and adapted into the Nutrition Innovation Closed Loop Automation system.
Stage 2 : Process control algorithm
E+PLC400 combination PLC
    1. - Provides advanced control, data management and visualization in a modular platform solution.
      - A flexible combination PLC with selectable base sizes to suit the Closed Loop Automation system.
      - Precise control, setpoint programmer and tamper resistant recording fully integrated within a PLC application.
      - Minimizes engineering and commissioning costs while maximizing process performance.
      - Inbuilt advanced PID and setpoint programmer functions.
      - Continuous and batch recording.
      - Visualization remotely browsable from multiple devices.
      - More processing power and I/O, make it suitable for larger machines with more complex functionality.
      - Larger memory allows more extensive use of ladder logic and sequencing programs.

Stage 3 : Closed loop production control system

Once data flow is fully governed by Eurotherm Advance PLC (programmable Logic Controller), this final stage are to establish a production control systems to better automate production to improve consistency, to reduce and better manage energy, to maintain output and minimize waste. EcoStruxure Hybrid DCS harnesses the power of the Industrial Internet of Things (IIoT) to bring a sugar milling and refining plant into the future. It delivers everything needed to run a sustainable, productive and market-agile plant, from full process traceability to embedded energy management. It integrates the real-time data from the ProFoss and Foxboro to enhance processing control and drive production consistency.
Stage 3 : Closed loop production control system
Next generation process automation system
  • EcoStruxure Hybrid DCS is the next generation process automation system for a digitized and energy-aware plant that meets the demands of modern day production. EcoStruxure Hybrid DCS is a single automation system to engineer, operate and maintain your entire plant. The system enables users to achieve operational profitability from design engineering through to plant operations.
Single integrated scaleable database
  • This single automation system combines the management of field buses, instrumentation, intelligent devices, control networks, controllers, operator stations, engineering stations, alarm management in a common and single database. EcoStruxure Hybrid DCS is an essential component of EcoStruxure for Industry, interconnecting and managing all the components of the automation architecture. EcoStruxure Hybrid DCS supports standard field buses, instrumentation and best-in-class, intelligent, connected devices and at the heart of the system is a scalable and powerful automation platform.
Built on a open system platform
  • EcoStruxure Hybrid DCS is based on open communication standards and system-wide Ethernet architecture, that interconnects the automation assets. It gives you access to all the data you need to optimize your business; in the form you need it. EcoStruxure Hybrid DCS harnesses the power of the Industrial Internet of Things to bring your plant into the future. It delivers everything you need to run a sustainable, productive and market-agile plant, from full process traceability to embedded energy management.
Develop and deploy with speed and agility
  • Engineers can develop and deploy configurations faster and more accurately; operators have the necessary data at their fingertips for better insight to optimize the process; maintenance teams are empowered with powerful native diagnostics to diagnose root cause of any issues and solve problems, thus reducing downtime. EcoStruxure Hybrid DCS helps you make the right decisions for your plant at the right time.
  • To learn more about the benefits and capabilities visit Schneider Electric EcoStruxure™ Hybrid DCS

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