Intelligent control strategies in agro-industrial systems: real-time optimization at Iracema Mill

São Martinho S.A. is one of Brazil’s largest sugar-energy companies, operating four industrial units: São Martinho (Pradópolis, SP), Iracema (Iracemápolis, SP), Santa Cruz (Américo Brasiliense, SP), and Boa Vista (Quirinópolis, GO). The company specializes in the production of sugar, ethanol, and electricity derived from sugarcane and corn processing. With a milling capacity of approximately 24 mn t of sugarcane per harvest plus 2.5 mn t equivalent sugarcane milling from corn (0.5 mn t of corn), São Martinho stands out for its high level of mechanization and commitment to sustainability.

The Iracema unit, located in Iracemápolis, São Paulo, has over 80 years of experience in sugar and ethanol production. It processes approximately 3 mn t of sugarcane annually, sourced from about 30,000 ha of owned and partnered lands. The facility boasts a modern industrial plant and efficient agricultural management, enabling it to produce sugar and ethanol in line with market trends. The Iracema unit successfully implemented Real-Time Optimization (RTO) technology. This system utilizes real-time data from the plant’s operations to simulate and predict outcomes, providing optimized setpoints for process control. The implementation of RTO led to significant improvements in operational stability and efficiency.