BrainWave Control solutions for recycled paper - Andritz
BrainWave Control solutions for recycled paper - Andritz BrainWave Control solutions for recycled paper - Andritz
BrainWave Control solutions for recycled paper www.andritz.com We accept the challenge!
- Page 2 and 3: The challenge: To fi nd cost-effect
- Page 4: Automation Solutions To help you ac
<strong>BrainWave</strong><br />
<strong>Control</strong> <strong>solutions</strong> <strong>for</strong> <strong>recycled</strong> <strong>paper</strong><br />
www.andritz.com<br />
We accept the challenge!
The challenge: To fi nd cost-effective<br />
technologies to upgrade your <strong>paper</strong> mill<br />
The solution: Advanced<br />
control with <strong>BrainWave</strong><br />
Perhaps there is no upgrade that stabilizes<br />
production and reduces costs like<br />
<strong>BrainWave</strong>—without a large capital<br />
investment. <strong>BrainWave</strong> is easy to install<br />
and set up, can be retrofi tted to existing<br />
processes, and delivers a quick return on<br />
investment.<br />
<strong>BrainWave</strong> is a patented controller, proven<br />
since 1992, that can be installed as an upgrade<br />
to any DCS or PLC system. It outper<strong>for</strong>ms<br />
traditional PID control because it controls<br />
long dead-time processes, reacts be<strong>for</strong>e<br />
being pushed off-target, handles nonlinear<br />
responses and is both an adaptive and predictive<br />
controller. It builds its own live models<br />
during normal operations and accurately<br />
<strong>for</strong>ecasts the process responses to changes<br />
in production rates or set points. <strong>BrainWave</strong><br />
Success story:<br />
Multi-stage bleaching<br />
In this mill, <strong>BrainWave</strong> measures the incoming<br />
brightness from the thickening and fl otation<br />
processes and brightness after the bleaching<br />
tower. Based upon the deviation of incoming<br />
brightness and the delay time, <strong>BrainWave</strong> calculates<br />
the chemical dosage required ahead<br />
of the pulp (feed<strong>for</strong>ward principle) in order to<br />
keep the fi nal brightness set point. This ability<br />
to model and <strong>for</strong>ecast the process is a huge<br />
advantage over traditional PID and manual<br />
controls which cannot cope with continuously<br />
changing process parameters.<br />
As a result, <strong>BrainWave</strong> minimizes the chemical<br />
dosage required to obtain the fi nal brightness<br />
target and stabilizes the overall quality<br />
Page 2<br />
takes corrective action be<strong>for</strong>e you produce<br />
off-spec product to keep your process stable.<br />
Return on investment is measured in<br />
months, not years. <strong>BrainWave</strong> is controlling<br />
over a thousand loops in factories around the<br />
world and saving customers millions of US<br />
dollars per year. In combination with other<br />
ANDRITZ technologies, such as DotScan and<br />
FiberVision, <strong>BrainWave</strong> delivers chemical and<br />
energy savings—and improved quality.<br />
of the bleached pulp. There has been a noticeable<br />
reduction in COD discharge to the<br />
effl uent system.<br />
<strong>BrainWave</strong> control also delivers several signifi<br />
cant side benefi ts. In addition to chemicals<br />
savings, the mill has documented notable<br />
<strong>BrainWave</strong> can be applied to virtually any<br />
pulp or <strong>paper</strong> production process. It comes<br />
with its own server that can be easily linked<br />
to existing DCS or PLC systems through<br />
a standard OPC connection, acting as an<br />
overlay to the existing control. Once in operation,<br />
it can control several process groups<br />
without new investments in hardware.<br />
Set point 1 <strong>BrainWave</strong><br />
Set point 2<br />
<strong>BrainWave</strong> model 1 <strong>BrainWave</strong> model 2<br />
production increases and yield improvements<br />
(as a result of using less NaOH, minimizing<br />
silicate, and obtaining stable control of the<br />
process). The reduction in NaOH also lowers<br />
the COD load in the effl uent— providing relief<br />
<strong>for</strong> the water treatment plant, with signifi cant<br />
improvement in environmental impact.
Success story: Bleaching<br />
of deinked pulp<br />
Be<strong>for</strong>e: This DIP line in China has a capacity<br />
of 1,200 bdmt/d. Be<strong>for</strong>e installing <strong>BrainWave</strong>,<br />
the mill controlled brightness by applying<br />
bleaching chemicals in a ratio tied to production<br />
rate. Operators tried to manually compensate<br />
<strong>for</strong> variations in furnish brightness<br />
and process disturbances in real time. This<br />
became a time-consuming task: monitoring<br />
brightness readings around the clock and<br />
modifying chemical dosing to try to keep to the<br />
targeted brightness. Most of the time, the operators<br />
overshot the brightness target to be<br />
on the safe side, and there was high consumption<br />
of costly bleaching chemicals.<br />
After: Within a very short time after installing<br />
the <strong>BrainWave</strong> controller, the bleaching process<br />
stabilized and the results were signifi -<br />
Brightness % ISO<br />
1,2<br />
1<br />
0,8<br />
0,6<br />
0,4<br />
0,2<br />
0<br />
64<br />
63<br />
62<br />
61<br />
60<br />
59<br />
58<br />
57<br />
56<br />
55<br />
55,3<br />
55<br />
241<br />
236<br />
231<br />
226<br />
221<br />
216<br />
211<br />
206<br />
201<br />
196<br />
191<br />
186<br />
181<br />
176<br />
171<br />
166<br />
161<br />
156<br />
151<br />
146<br />
141<br />
136<br />
131<br />
126<br />
121<br />
116<br />
111<br />
106<br />
101<br />
96<br />
91<br />
86<br />
81<br />
76<br />
71<br />
66<br />
61<br />
56<br />
51<br />
46<br />
41<br />
36<br />
31<br />
26<br />
21<br />
16<br />
11<br />
6<br />
55,9<br />
55,6<br />
56,5<br />
56,2<br />
56,8<br />
<strong>BrainWave</strong><br />
57,4<br />
57,1<br />
58<br />
57,7<br />
58,6<br />
58,3<br />
Operator control<br />
LAB Brightness Line 1<br />
May 5 May 8 May 11 May 14 May 17<br />
58,9<br />
59,5<br />
59,2<br />
60,1<br />
59,8<br />
Results<br />
n Reduction in fi nal brightness<br />
deviation = 71%<br />
n Increase in overall<br />
brightness = 1 pt Iso<br />
n Reduction in bleaching<br />
chemicals = $1/t (annual<br />
savings ~ 400,000 USD)<br />
n Return on investment in<br />
just a few weeks<br />
cant (see sidebar). In addition, the DIP plant<br />
operators were now freed up to monitor the<br />
overall process and ensure the proper per<strong>for</strong>mance<br />
of the equipment.<br />
60,7<br />
60,4<br />
Figure 1: Normal distribution, operator versus <strong>BrainWave</strong> (final LAB brightness)<br />
<strong>BrainWave</strong> control<br />
LAB Brightness Line 2<br />
Standard Deviation = 1.4 Standard Deviation = 0.41<br />
Figure 2: Lab brightness data (May 5 to June 1, 2010)<br />
61<br />
Mean St.Dev<br />
-------------------------------------------------<br />
Operator 59.65 1.42<br />
<strong>BrainWave</strong> 58.2 0.41<br />
------------------------------------------------<br />
Improvement 2.28% 70.94%<br />
(1.3 ISO)<br />
61,6<br />
61,3<br />
Operator<br />
62,2<br />
61,9<br />
62,8<br />
62,5<br />
63,1<br />
63,7<br />
63,4<br />
64,3<br />
64<br />
Results, May 2010: Achieved in a<br />
1,200 bdmt/d Chinese DIP line<br />
When <strong>BrainWave</strong> was first installed, a short<br />
time was needed <strong>for</strong> the controller to collect<br />
process data and create a control model.<br />
Figure 2 shows the immediate impact after<br />
just a few hours of <strong>BrainWave</strong> being activated.<br />
After a few weeks <strong>for</strong> optimization and<br />
model refinement, <strong>BrainWave</strong> demonstrated<br />
its full capabilities to minimize process<br />
disturbances, save chemicals, and reduce<br />
operating costs.<br />
Paper machine operators noted that the final<br />
product quality is more uni<strong>for</strong>m due to<br />
fewer variations. The lower consumption of<br />
bleaching chemicals also contributed to less<br />
COD load in the DIP water circuits—which<br />
positively impacted the water treatment and<br />
environmental aspects of the mill.<br />
Benefi ts<br />
n Stable process—on-spec<br />
production<br />
n Signifi cant reduction in<br />
chemical, energy, and raw<br />
materials costs<br />
n Quality improvements<br />
n Easy implementation, with<br />
fast payback<br />
Page 3
Automation Solutions<br />
To help you achieve operational readiness<br />
<strong>BrainWave</strong> is a patented advanced control<br />
technology that outper<strong>for</strong>ms conventional<br />
PID controllers because of its two main components:<br />
an adaptive model and a predictive<br />
controller. <strong>BrainWave</strong> builds live adaptive<br />
models <strong>for</strong> all potential interactions during<br />
normal operations. Then, its predictive<br />
controller accurately <strong>for</strong>ecasts the process<br />
response be<strong>for</strong>e making any adjustments.<br />
It also has the ability to “learn” based upon<br />
past per<strong>for</strong>mance. Just as your operators get<br />
better with experience, so does <strong>BrainWave</strong>.<br />
<strong>BrainWave</strong> process applications<br />
¡ Bleaching and chemical control:<br />
reduced brightness deviation and<br />
chemical cost savings<br />
¡ Stock refi ner control: optimization of<br />
refi ner power and quality control<br />
(based on freeness targets and dirt<br />
speck measurements)<br />
¡ TMP refi ner control: specifi c energy<br />
and pulp quality control (in combination<br />
with fi ber property analyzers)<br />
¡ Disperser system control: disperser<br />
per<strong>for</strong>mance and bleaching chemical<br />
control<br />
¡ DIP fl otation control: improved yield<br />
and maximum brightness<br />
ANDRITZ AUTOMATION Inc.<br />
Atlanta, GA, USA<br />
Phone: +1 (404) 370 1350<br />
Call our sales staff today:<br />
Steve Crotty (Global)<br />
Mobile: +1 (404) 229 6349<br />
Email: steve.crotty@andritz.com<br />
Fax: +1 (404) 378 3813<br />
Andrés Rojas G. (Latin America)<br />
Mobile: +56 (9) 8230 8752<br />
Email: andres.rojas@andritz.com<br />
Fax: +56 (2) 462 4646<br />
Marcos Freitas (Brazil)<br />
Mobile: +55 (41) 9971 1546<br />
Email: marcos.freitas@andritz.com<br />
Fax: +55 (41) 2103 7550<br />
Austria: Graz, Vienna | Canada: Nanaimo, Prince George, Richmond, Terrace | Brazil: Belo Horizonte, Curitiba<br />
Chile: Santiago | Finland: Hollola, Kotka, Tampere, Varkaus | India: Bangalore | USA: Bellingham, Montoursville<br />
Mikko Vaisanen (Northern Europe)<br />
Mobile: +358 (40) 860 6866<br />
Email: mikko.vaisanen@andritz.com<br />
Fax: +358 (20) 450 6711<br />
Siegfried Troppan (Central Europe)<br />
Mobile: +43 (664) 961 4177<br />
Email: siegfried.troppan@andritz.com<br />
Fax: +43 (312) 453 6145<br />
Allan Sycamore (Australia/New Zealand)<br />
Mobile: +64 (21) 950 095<br />
Email: allan.sycamore@andritz.com<br />
Fax: +64 (9) 266 2645<br />
www.andritz.com<br />
automation-sales@andritz.com<br />
All data, in<strong>for</strong>mation, statements, photographs and graphic illustrations made in this leafl et are without any obligation and raise no liabilities to or <strong>for</strong>m part of any sales contracts of ANDRITZ AG or any<br />
affi liates <strong>for</strong> equipment and/or systems referred to herein. © ANDRITZ AG 2012. All rights reserved. No part of this copyrighted work may be reproduced, modifi ed or distributed in any <strong>for</strong>m or by any<br />
means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ AG or its affi liates. Any such unauthorized use <strong>for</strong> any purpose is a violation of the relevant copyright<br />
laws. ANDRITZ AG, Stattegger Strasse 18, A-8045 Graz, Austria. <strong>BrainWave</strong> is a registered trademark in Canada and the USA. AT.BW-rp.02.eng.05.12