ION Energia and DEIF deliver reliable hybrid power for large-scale irrigation in Brazil

Hybrid energy management helps reduce diesel dependence and secure irrigation operations

Reliable energy is critical for modern agriculture, especially when irrigation systems must operate for long hours in remote locations.

When a Brazilian farm needed a stable and cost-effective power supply for a large-scale irrigation project, system integrator ION Energia designed a hybrid solution combining solar power, battery energy storage, and grid power. At the heart of the system, DEIF's energy management controllers ensure that all energy assets work together as one coordinated system.

The result is a reliable energy supply for irrigation operations, reduced dependence on diesel generation, and expected annual savings of more than BRL 1.1 million compared to a combined diesel generator and solar solution.

A remote irrigation project with complex energy demands

The project serves a 300-hectare irrigation area equipped with two pivot irrigation systems and a deep-well pumping installation. Water must first be pumped from deep underground before being distributed across the irrigation area through the pivot systems. Supplying these large electrical loads for an average of 13 hours per day, and up to 14 hours per day, requires careful coordination of available energy resources while ensuring safe operation of critical pumping equipment.

According to Allan Silva, Project Manager at ION Energia, balancing the available energy sources was one of the project's main challenges.

“We had three different power sources to manage: solar, battery storage and the grid. At the same time, we needed to ensure safe operation of the pumping and irrigation equipment and make sure the whole system would respond correctly in every possible situation.”

The installation consists of:

• 800 kWp solar PV

• 600 kW AC inverter capacity

• 1,075 kWh battery energy storage system (BESS)

• Approximately 500 kW battery output power

• Grid connection for supplemental charging

• Diesel generators available only as backup

The project is currently operating as a pilot installation covering 300 hectares, with future plans to expand irrigation capacity significantly if the technology continues to perform as expected.

Bringing multiple technologies together

For ION Energia, the challenge was not only providing power but coordinating several technologies from different suppliers into one reliable energy system.

The hybrid solution had to manage solar generation, battery storage, grid availability, load control and charging schedules while ensuring that pumps and irrigation equipment operated within predefined parameters. The solution also prevents critical loads from operating simultaneously when system conditions do not allow it, helping protect both equipment and system performance. Communication between equipment across the site was particularly important, requiring fibre-optic communication links and contingency strategies for potential communication failures.

“We needed to make sure everything communicated correctly and, just as importantly, have a backup plan if something stopped communicating. If the battery failed, if the solar system failed, or if communication was lost, the system still needed to respond safely.”

Because battery energy storage is still a relatively new technology in many parts of Brazil, the project team invested significant time in simulation and testing before commissioning the site. Using DEIF’s Utility Software (USW), the team simulated both normal operation and emergency scenarios based on the variables and operating limits of the actual system.

The simulations covered automatic breaker operation, communication failures, grid overvoltage, low battery state of charge and the loss of individual components. They also allowed the team to verify safety functions, M-Logic programming, relay behaviour and transitions between operating modes. By testing how the system would respond if a breaker, controller, battery system or communication link failed, ION Energia could refine the control strategy with a focus on safety, reliability and customer value. Extensive field testing was then carried out to ensure reliable communication between the DEIF controllers and the other equipment in the system. According to Silva, this preparation was essential for ensuring a smooth commissioning process.

“We started simulating the application months before commissioning. The simulations allowed us to test different communication protocols and understand how the system would respond in different situations before going to the field.”

DEIF controllers coordinate the entire hybrid system

To manage the different energy assets, ION Energia selected DEIF's ASC 150 Solar, ASC 150 Storage and AGC 150 Extended.

The three controllers allow solar generation, battery storage and grid power to be controlled individually while also operating as a fully integrated energy management system. Silva highlights reliability as a key reason for selecting DEIF.

“DEIF is the most reliable EMS brand we have in Brazil today. We trust the company, the technology and the experience DEIF has from similar applications.”

Beyond reliability, the flexibility of the DEIF platform enabled ION Energia to implement the automation required by the project.

“DEIF gives us the opportunity to implement automation, monitoring and advanced control logic in one platform. We can monitor power, voltage, frequency and many other parameters while coordinating the entire hybrid system.”

The system controls load scheduling, battery charging, energy prioritisation and operational safeguards while continuously monitoring power flows and system conditions. This level of control was particularly important because the irrigation system operates according to strict daily schedules and changing grid availability.

Optimizing energy use throughout the day

The hybrid system is designed to maximize the use of solar energy while maintaining reliable irrigation operations.

Each morning, the irrigation load starts at 5 a.m. using battery energy. As solar production begins shortly after sunrise, PV generation gradually takes over the load and recharges the battery. By mid-morning, the battery is typically fully charged, allowing solar power to maintain irrigation operations throughout the day. Later in the afternoon, as solar production declines, the battery once again supports the load until operations stop in the evening.

To optimize operating costs, the system avoids battery charging during Brazil's peak electricity pricing period. Instead, available grid capacity is used later in the evening to recharge the battery whenever surplus grid power is available.

This intelligent energy management enables continuous irrigation while maximising the use of available solar and battery energy. By coordinating renewable generation, battery storage and available grid capacity, the DEIF energy management system helps deliver both operational reliability and cost-effective energy use.

Reliable power helps protect critical equipment

For agricultural operations, power quality can be just as important as power availability.

Traditionally, many farms rely on diesel generators for irrigation. However, voltage and frequency fluctuations can create risks for sensitive electrical equipment, including deep-well pumps and frequency inverters.

At this site, repairing a damaged pump can involve removing equipment installed more than 200 metres below ground, resulting in extended downtime and significant repair costs. The process can take weeks and requires specialised equipment to remove and reinstall the pump. The hybrid solution helps mitigate these risks by providing stable, high-quality power for irrigation operations.

Lower costs and a cleaner energy solution

The hybrid setup enables the irrigation system to operate without relying on diesel generators during normal operation.

According to ION Energia, the system is expected to save approximately BRL 1.1 million annually compared to supplying the same load with a combined diesel generator and solar solution. A diesel-only comparison would indicate even greater savings, but it is not considered a realistic reference case because comparable projects do not normally rely on diesel generation alone. In addition to reducing operating costs, the solution supports a more sustainable approach to agricultural production by increasing the use of renewable energy and reducing diesel consumption.

Building confidence for future expansion

Following the successful commissioning and operation of the pilot installation, ION Energia plans to apply the knowledge gained from this project to future hybrid energy systems.

The company expects future deployments to follow a similar technical approach while benefiting from the experience and lessons learned during planning, testing and commissioning.

Silva's advice to others considering similar projects is straightforward:

“Emulate and test everything before going to the field. Simulate communication failures, equipment faults and every operating scenario you can think of. It is much better to learn during simulation than during commissioning.”