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 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 2 www.procsim.eu www.automationX.com
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 3 www.procsim.eu www.automationX.com
Data analyze: wood weight in digester (tons) Digester 1 2 3 4 5 6 Weight (tons) 39,24 41,61 39,30 39,68 40,06 39,78 4 www.procsim.eu www.automationX.com
Data analyze: wood moisture calculation (%) Simple moisture calculation from Calculation using hydro module chip volume and chip weight does with heating steam match with not match with sporadic laboratory laboratory values and can even values (cal -> 15%, lab -> 7%) substitute expensive measurement 5 www.procsim.eu www.automationX.com
Fast changes of heating steam flow is a serious problem in turbine house! Long response time makes serious difficulties of steam flow control 6 www.procsim.eu www.automationX.com
Fast changes of heating steam flow is a serious problem in turbine house! Old heating sequence was controlled by means of 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 of steam flow. 7 www.procsim.eu www.automationX.com
Heating steam flow solution: old temperature control new steam flow control 18 min 9 min Gradient of steam flow change before and after Δ 8 t/h in 18 min = 0,44 t/h/min Δ 10,4 t/h in 9 min = 1,15 t/h/min below demanding limit 0,5 t/h/min Serious difficulties for control of steam network pressure 8 www.procsim.eu www.automationX.com
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 9 www.procsim.eu www.automationX.com
Digitalization is mathematical algorithm of 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 Program Start 10 www.procsim.eu www.automationX.com
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 www.procsim.eu www.automationX.com
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! www.procsim.eu www.automationX.com
Virtual Digester House predicts steam consumption! • 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. www.procsim.eu www.automationX.com
Communication with existing control system www.procsim.eu www.automationX.com
Project results: - 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 of 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. 15 www.procsim.eu www.automationX.com
Simulation of technological processes is the most efficient way to the success Thank you for your patience 16 www.procsim.eu www.automationX.com
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