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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
1
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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
2
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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 (%)
5
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!
6
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 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
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Heating steam flow solution:old 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 afterΔ 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 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
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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
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.
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Simulation of technological
processes is the most
efficient way to the success
Thank you for your patience