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An exclusive combination of equipment that combines high performance and competitiveness to overcome the challenges of Industry 4.0

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Sugar-Energy Plant

Automation of machines and processes

Altus technology was employed to modernize boilers and scrubbers used in the production process of a major company in Brazil’s sugar-energy sector.

Modernization of Sugarcane Plant

Sustainability is the buzzword of the moment and the guarantee of a better future. In the sugarcane and energy sector, generating food, fuel, and energy from renewable resources is already a reality. And there are companies specifically focused on this, such as a client from São Paulo who wanted to automate the production system for sugar, ethanol, and energy from sugarcane. Sugarcane, besides being Brazil’s oldest raw material, drives the national economy by supplying domestic consumption and exporting these products worldwide.

With the help of an integrator certified by Altus, the client used the NX Series of programmable controllers to optimize the operation of its machines and remain among the largest companies in the world in this sector.

High Availability

The system features NX3030 CPUs running in hot standby redundancy mode

Flexible development

Nexto System technology enables the development of customized programs for special use cases

Distributed system

The application is powered by robust Nexto CPUs acting as remote units, enhancing the system’s control capabilities

Multiprotocol application

The solution integrates different communication networks, such as Profibus and Modbus, for device command and data exchange

Redundant and Flexible System

The flexibility of Nexto CPUs allows for not only redundancy but also the option to develop local programming for special use cases. All CPUs feature a multitasking, preemptive operating system. Additionally, their 32-bit RISC PowerPC processor combines high performance with lower energy consumption. It is free of moving parts, contributing to a higher mean time between failures (MTBF).

Through its programming tool, the MasterTool IEC XE software, field networks like PROFIBUS can be integrated with communication protocols such as IEC 61131-3. This allows the user to configure all parameters in one place, accelerating development and reducing engineering costs. The MasterTool also enables the reuse of code developed in previous solutions, allowing users to convert applications between graphical languages and reuse them in other opportunities

Scope of services

The project to automate five boilers and two gas scrubbers, which are critical to both energy production and environmental protection, involves a redundant high-availability system with two NX3030 CPUs and six remotes: one NX3020 and five NX3010, communicating via Modbus TCP. The remotes are distributed among the boilers and scrubbers.

This application features 350 digital I/O points, approximately 240 analog points, and a control panel (CCM). In addition to Modbus TCP communication between the main control system (NX3030 CPUs) and the remotes (NX3010 and NX3020), a PROFIBUS network is used for interfacing with the CCM. This versatility and support for multiple protocols within the same project allow for rapid application development, meeting the client’s demands and enabling them to focus on other critical tasks at the plant.