Background

SUCCESS STORIES

Around $78,000 in savings in the bioenergy sector with the Dynamox Solution

The solution for monitoring asset health and performance in the renewable energy industry Fueling Sustainability

Fueling Logo

$78,000

In savings

12h

Downtime prevented

48h

Reduced in Service Order time

4

Failures prevented

OVERVIEW

General context

FS is the first ethanol company in Brazil to use corn for 100% of its production. Today, with three plants in Mato Grosso (Lucas do Rio Verde, Sorriso and Primavera do Leste), the company has the capacity to produce more than 2.2 billion liters of ethanol a year. It also has state-of-the-art technology for manufacturing products for animal nutrition (DDG - Dried Distillers Grains), corn oil, bioelectricity and marketing corn and ethanol. FS prioritizes and invests in sustainability with the aim of consolidating the sustainable development agenda and strengthening its long-term commitments to society. The company is developing a set of actions around five long-term commitments (until 2030), created in line with the United Nations (UN) Sustainable Development Goals (SDGs) and the Paris Agreement.

Segment:

Biofuels

Sensors installed:

245

Assets monitored:

50

Website:

fs.agr.br

Fueling overview

Fueling Sustainability | Lucas do Rio Verde Plant.

Implementing the Dynamox Solution

Following its vocation to be at the forefront of technology, the FS maintenance team aimed to adopt Industry 4.0 solutions. Dynamox therefore drew up a project to install sensors and gateways at the Lucas do Rio Verde plant. In light of the positive results, there has been an expansion to Primavera do Leste and a project for Sorriso. The next steps will be to implement other Dynamox products such as automated detection, sensitive inspection route routines and visual management.

Solutions applied

Sensors

Gateways

Condition analysis

RESULTS

Proven results in just a few months

In just a few months of using the Dynamox solution, FS has already made considerable savings.

$78,000

Savings

48h

Reduced in Service Order time

12h

Downtime prevented

Profile Picture

The integration of Dynamox sensors into our monitoring systems allows us to accurately identify and anticipate potential failures in our equipment, enabling strategic maintenance planning.

Dynamox sensors play a key role in our plants predictive maintenance strategy, enabling us to maximize the reliability of equipment and the efficiency of industrial processes and increasing the availability of our plants.

Victor Emmanuel Martins Brandão

Predictive Maintenance Specialist, Fueling Sustainability

TIMELINE

The process of signing up to Dynamox's solution

For FS to continue to expand and achieve its goals, efficient asset management is seen as fundamental by the company, starting with equipment monitoring.

2022

2022

Mapping for the implementation of online monitoring begins

Predictive maintenance at FS consisted mainly of instrumented sensitive inspection.Already familiar with Dynamox, the Lucas do Rio Verde (MT) unit wanted to learn more about the solution and how it could be applied in their industrial plant. Dynamox then presented an implementation project based on the needs and objectives listed.

The project therefore provided for the installation of:

  • 95 HF+ sensors

  • 8 Gateways DUO

  • 120 assets - almost 60% of them at criticality A.

Goal:

Minimize unplanned downtime and maximize the useful life of assets by detecting faults early.

Industrial image

Fueling Sustainability | Storage tanks.

2023.1

2023.1

Installation of wireless sensors and automated collection

During 2023, at the Lucas do Rio Verde plant, the sensors and gateways were installed, the system was parameterized and the team was trained.

Among the assets listed for online monitoring are:

  • Agitator

  • Centrifugal Pump

  • Positive displacement pump

  • Cooling Tower

  • Compressor

  • Mixer

  • Fan

  • Screw Conveyor

  • Redler

  • Rotating press

  • Chiller

Applied sensors 01

Sensors applied to motors and reduction gearboxes

Applied sensors 02

Sensors applied to motors

Applied sensors 02

Sensor applied to bearing

2023.2

2023.2

Expansion to Primavera do Leste plant

After the positive experience at the Lucas do Rio Verde plant, the Primavera do Leste (MT) team also wanted to learn more about the Dynamox solution.

For this unit, the project provided for the installation of:

  • 50 HF+ sensors

  • 3 Gateways DUO

Among the assets listed for online monitoring are:

  • Agitator

  • Centrifugal Pump

  • Positive displacement pump

  • Cooling Tower

  • Compressor

  • Mixer

  • Fan

  • Screw Conveyor

  • Redler

  • Rotating press

  • Chiller

The year ended with the base system implemented and configured in both units, as well as online monitoring in progress.

2024

2024

Expanding the use of Dynamox

With the basis of the solution implemented in Lucas do Rio Verde and Primavera do Leste, the expansion was set up. Both units are in the process of acquiring new sensors to increase the number of assets monitored and also to improve their experience with the Dynamox solution.

Next steps:

Implementation of the automated detection tool (DynaDetect)

Application of the DynaNeo visual management tool (DynaNeo)

Digitalization of inspection routines (DynaSens)

Preparation of the project to implement the solution at the Sorriso unit

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