A complete soybean processing plant using PlantPAx ...€¢ Selecta developed the SIPP–Selecta...

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Rockwell Automation

Process Solutions User Group (PSUG)

November 14-15, 2011

Chicago, IL – McCormick Place West

Food Ingredients Industry

A complete soybean

processing plant using

PlantPAx (Greenfield)

Jales Junior – SELECTA

Rafael Pezzella Chiea – IASTECH/SP

Fabricio Hayashi – IASTECH/SP

Marcel Almeida – Rockwell Automation

Agenda

� Process Overview

� Soybean Market

� Selecta General Information

� Rockwell Solution Provider - IASTECH

� Automation Project and Asset Management

� Future Projects

� ScreenShots

� Conclusion

Overview Soybean Market

World Soybean Production (Millions of Tons)

• US is the first world soybean

producer – 2011: 91 Mtons.

• BRAZIL is the second one

producer – 2011: 75,0 Mtons.

• US+BRAZIL+ARGENTINA

represents 98% of world

soybean business.

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

General Information

• Selecta is a 100% Brazilian Company.

• Production site is located in Araguari - Minas

Gerais.

• Production/crushing capacity of 2,000 tons of

soybean a day.

• Main Products: soy concentrated with

different protein tenors (soybean meal), soy

molasses and degummed oil.

• The plant produce a high quality 60% protein

products (Soy protein concentrate).

• Self-energy generation and water reuse.

• Zero effluents and waste emission.

• Main Markets: Brazil, Europe and Asia.

• PDV/GMP B2+ certification.

• ANEC Member – non-acquisition of

soybeans produced in the Amazon biome.

• Selecta developed the SIPP – Selecta

Identify Preserved Program (audited by

independent certifier) to garantee the

traceabilty from acquisition of raw materials

to product deleivery to the final customer.

• Integrated Laboratory for raw materials,

production and finished product.

• Social projects – Boas Mãos, Plié, Bikila

and Retocar children educational projects.

General Information

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

About IASTECH

� Since 1990

� Rockwell Automation Solution

Provider

� Life Science, food and beverage

specialist

� ISO 9001:2008

� EPM e PMI

Rockwell Automation Solution Provider since the beginning of the program !

Rockwell Automation Process Solution Provider !

Rockwell Automation Information Solution !

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

Process Overview

SELECTA

Soybean Processing Plant

Reception Preparation Extraction SPC1 SPC2

Boiler1

Boiler2

Self-Generation

(turbines)

Soy Protein Concentrate Soy Protein Concentrate

Soybean meal

Soy molasses

Degummed Oil

BIOMASS

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

Automation Project

A complete soybean processing plant

using PlantPAx (Greenfield)

• 10 x ControlLogix CPUs;

• 1200 x I/O points (Redundant ControlNet);

• 800 x HART Instruments (Redundant ControlNet);

• 900 x Intelligent Motors Controls (DeviceNet);

• 2 x Redudant PASS;

• 10 x Operator Stations;

• 1 x Engineering Station;

• 2 x Local PanelView;

Selecta Automation Architecture

Boiler1

Boiler2

Co-generation

Ring-Ethernet Optical FiberRing-Ethernet Optical Fiber

PASSRedundant

AssetCentreServer

10 x OWS

Operator StationsDomainServers

Engineering Workstation

1200 x I/O Points - 800 x Hart Instruments - 900 x Motors/Pumps

Selecta Automation Architecture

Typical MCC Automation Architecture

DeviceNet

Redundant C

Ethernet

Industrial

Switch

To Fiber Optical Ring

VLAN Pass

PowerFlex PowerFlexE3+

HART Modules

Flex I/O

ControlLogix L62 Processors

Project Phases

Selecta - Main Project Phases

1. Hardware Design Specification;

2. Process Description;

3. Functional Specification including process;

4. Control Software Programming;

5. Operation Design;

6. Factory Acceptance Tests with process simulation - FAT;

7. Operator Training - Operation Tests using process simulation;

8. Commissioning and Start-up – Phase 1

11. Site Acceptance Tests – SAT;

12. Assisted Operation;

One year

Project

Selecta Asset Management

AssetCenter Server10+2000 = 2010

Assets

Disaster RecoveryProcess Device Configuration

Calibration ManagementOWS

AssetCentre AgentsEWS

AssetCentre Client

ControlLogix

Rede Automação Ethernet

ControlLogixControlLogix

1200 x I/O Points - 800 x Hart Instruments - 900 x Motors/Pumps

AssetCentre System Architecture

Selecta Asset Management

Process Device Configuration

Calibration Management

• Use Field Device Type Technology (FDT);

• Access the instruments, parameters and

configuration online or offline;

• Upload or download the configuration device

• Diagnostic;

• Paperless solution for

calibration management

• Manage calibration

requirements

• Schedule, Event History,

Reminders

• Calibration reports for audit

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

Selecta Future Projects and Investments

Boiler1

Boiler2

Co-generation

Ring-Ethernet Optical FiberRing-Ethernet Optical Fiber

PASSRedundant

AssetCentreServer

10 x OWS

Operator StationsDomainServers

Engineering Workstation

Corporate Network

FTVantgePoint

FTHistorian

WEB Reports

ProductionQualityAdministrationERP

Server

FTTransaction Manager

MSSQL Server

Mobile Access

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

System Screen Shots – Area 1

SCREENSHOT

will be presented

SCREENSHOT

will be presented

SCREENSHOT

will be presented

SCREENSHOT

will be presented

Agenda

� Soybean Market

� Future Projects

� ScreenShots

� Conclusion

Why PlantPAx System ?

Why have we chosen PlantPAx System ?

• Scalability – Plant start-up in phases;

• Capability - Process and Discrete Control;

• Technology – High performance processors and I/O modules;

• Reliability – High availability networks;

• Support – Rockwell Techsupport and Solution Providers;

• Asset Management;

• Production Management and Reporting;

• ERP Integration;

Questions ?

Rafael Pezzella Chiea, Eng.rafael@iastech.com

+55 11 8369 3384

QUESTIONS???

Jales Juniorjales@selecta.com.br

+55 34 2109 7300

Marcel Almeira, Eng.mralmeida@ra.rockwell.com

+55 11 8472 6222

Fabricio Hayashifabricio.hayashi@iastech.com

+55 11 8369 3389

A complete soybean processing plant using PlantPAx ...€¢ Selecta developed the SIPP–Selecta...

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