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Industry 4.0
Mondi Stambolijski sets new standards with Virtual Digester House
Ninth National Conference on Chemistry - Sofia 9. 2016
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Batch Cooking Process
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Industry 4.0 Mondi Stambolijski sets new standards with Virtual - - PowerPoint PPT Presentation
Industry 4.0 Mondi Stambolijski sets new standards with Virtual - - PowerPoint PPT Presentation
Industry 4.0 Mondi Stambolijski sets new standards with Virtual Digester House Ninth National Conference on Chemistry - Sofia 9. 2016 Batch Cooking Process 1 www.procsim.eu www.automationX.com Wood cooking is well proved technology, is
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Wood cooking is well proved technology, is robust, but after charging of cooking chemicals it proceeds in blind flying till the end. Except time and temperature there is hardly any other process information available. Therefore the starting conditions must be known as precise as possible
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Basic starting conditions:
- wood weight in digester (tons)
- belt scale
- position of feeding belt
- chip distribution on belt during chip filling
- weather (rain, frost, ice)
- chip moisture (%)
- laboratory representative sampling (time for result)
- online measurement (weather)
- strength of cooking chemicals (g/l)
- representative sampling (sampling place)
- robust of laboratory procedures
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Data analyze: wood weight in digester (tons)
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Digester 1 2 3 4 5 6 Weight (tons) 39,24 41,61 39,30 39,68 40,06 39,78
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Data analyze: wood moisture calculation (%)
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Simple moisture calculation from chip volume and chip weight does not match with sporadic laboratory values (cal -> 15%, lab -> 7%) Calculation using hydro module with heating steam match with laboratory values and can even substitute expensive measurement
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Fast changes of heating steam flow is a serious problem in turbine house!
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Long response time makes serious difficulties of steam flow control
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Fast changes of heating steam flow is a serious problem in turbine house!
Old heating sequence was controlled by means
- f
temperature curve, which does not support required smooth changes of steam flow. New algorithm controls digester heating by means of digester specific heat derived during the first heating
- minutes. This algorithm calculates how much steam will
be needed for digester heating, which enables full control
- f steam flow.
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Heating steam flow solution:
- ld temperature control
new steam flow control
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Δ 10,4 t/h in 9 min = 1,15 t/h/min Serious difficulties for control of steam network pressure
Gradient of steam flow change before and after
Δ 8 t/h in 18 min = 0,44 t/h/min below demanding limit 0,5 t/h/min 9 min 18 min
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To improve process control efficiency additional process information is a must Measurement instrumentation is expensive
- Purchase
- Installation
- Maintenance
Digitalization of technological processes multiplies information flow
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Digitalization is mathematical algorithm
- f
physical functions and chemical reactions including technical and technological parameters of real equipment. The precision of such simulation is close to accuracy on installed instrumentation. The interface to the virtual equipment is similar to the real one
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Program Start
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Production control of Batch Digester House in connection of downstream continual paper machine
Production plan for the next 24 hours of cooking (red bars) is calculated according to the evaluation of stored pulp before PM (blue line) and PM production plan (yellow line). It ensures enough space for pulp from the digester in the case of the break and enough pulp for PM in the case of sequence disturbance in the digester house.
Program Start
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Operator Interface to Mill coordination program
The targeted use of pulp inventories in the major vessels reduces the inefficient time in Digester House to a minimum and thus maximizes production capacity of the paper machine!
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- A completely new feature in paper industry is the prediction of
the steam consumption from Digester House for the next 60 minutes.
- The virtual Digester House is regularly synchronized with the
real one and simulates the process flow trajectories one hour ahead.
- This online predictive function is unique in the pulp industry
and supports secure control of the steam production and increases the efficiency of the steam turbine.
Virtual Digester House predicts steam consumption!
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Communication with existing control system
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Project results:
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- Due to the new digester heating steam flow control, the
fluctuation in steam consumption has been reduced by 30%
- The predetermined turbine house maximum change in the
steam consumption in one minute was even reduced by 20%.
- The fluctuation of the kappa number was reduced by 15% which
brings in the range of lower Kappa (in the rules) an exploitation
- f up to 1.4% more pulp
- The forecasted information on steam consumption in the next
60 minutes has greatly enhanced the stabilization in the steam network.
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