procsim gmbh · ditp 41st international annual symposium 19-20 11. 2014 bled slovenia possibilities...

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DITP 41st International Annual Symposium 19-20 11. 2014 Bled Slovenia www.procsim.eu

Possibilities of reducing energy

consumption at papermaking Process

Pulp and Paper Consulting

ProcSim GmbH

• Consulting in Areas of

- Pulp and paper technology

- CO2 emission in paper industry

- R&D for new technologies

• Realization and Support for

- Control of technological processes in production

- Optimizing of specific energy consumption

• Simulation of Technological Processes

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Energy to evaporate water cannot be saved!

1 kg / 2309 kJ (80°C)Modell

How to reduce?

1. Get more knowledge about the drying process in your machine!

2. Decrease energy lost (recuperation area) !

3. Maintain false air in machine hood (zero level) !

4. Decrease rewatering in Press Section (felt conditions)

5. Decrease broke (better process control decreases specific energy)

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Who has such paper machine energy diagram ?

lost energy

efficientDrying

Product 75- 80%

Broke 2 – 4 %

Recuperation Isolation

hot Airunproductive

Air heating

False Air

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Get more knowledge about the drying process

in your machine

Create your virtual machine

Let’s analyze your virtual drying process

and

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User Interface to virtual drying process

Modell

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Up to 4 % energy lost mostly in each

Recuperation area !

Modell1. Too much fresh air into machine hood

2. Hood air temperature many times too high

3. Fresh air volume not controlled according to the hood air moisture

4. Heat exchanger efficiency low because of dust and paper particle

5. Not controlled zero line negatively impacts energy balance

6. Waste energy from energy intensive equipments (IR, high efficiency

hoods) is not used or used in an infective way

Research project performed by TU Graz at 4 paper mills has

discovered energy saving potential up to 6% using virtual drying

process (see publications at www.procsim.eu)

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Always if we think: we are good, the work can

be done still better !

ModellThe „standard control“ of paper machines reacts too slowly on changes

in the production to avoid overreaction (long dwelling time and

enormous momentum). But the technical and technological parameters

enable significantly faster reactions.

Faster reaction = reducing broke, increasing production and decreasing

specific energy consumption.

Our control approach proves control steps using virtual machine and then

leads the process on the shortest way to the new target minimizing

unproductive time and saving energy costs.

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All control steps are optimized in the virtual future via

SIMULATION before activating controller in order to

avoid deviations in the real future

Modell

Model

Time

Speed (Dryness, BW)

classic control from the past

control from virtual future

Yankee Machine

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Simulation based multivariable control for paper machine

optimizes machine performance and minimizes energy

consumption

ModelVirtual machine „copies“ behaving of real

machine with high precision close to

instrumentation accuracy for all

production conditions

The simulated results are easy to

compare with results of real process

DCS is just ramping set point trajectories

derived by virtual dewatering and drying

processYankee Machine

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Basic equations of virtual drying process for pulp water mixture

Evaporation

Vapor diffusion

Sorption isotherms

Vapor partial pressure

Air density

Saturated steam pressure

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Comparing real / virtual Machines – for gas consumption

Gas consumption Sort 1 60 - gsm

80

100

120

140

160

180

200

220

240

153 169 171 181 198 217 237 247 247 247 247 247 249 249

Machine speed [m/min]

Gas F

low

[N

m3/h

]

20400

20600

20800

21000

21200

21400

21600

21800

22000

Ablu

ft [m

3/h

]

Gas consumption for gas burner 1 and 2 PLS Gas consumption for gas burner 1 and 2 Sim

Exhaust air flow PLS

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Comparing real / virtual Machines – for steam consumption

Steam Consumption Sort 1 - 60gsm

3,0

3,5

4,0

4,5

5,0

5,5

6,0

153 169 171 181 198 217 237 247 247 247 247 247 249 249

machine speed [m/min]

Ste

am

Flo

w [t/h

]

2,0

2,5

3,0

3,5

4,0

4,5

5,0

Ste

am

Pre

ssu

re [B

ar]

Steam flow total 4 + 12 Bar PLS Steam flow total 4+12 bar Sim

Steam pressure before cylinder PLS

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ModellResults:

1. Production increase about 2%

2. Halving of start up and boot time up to key performance

parameters

3. Reduction of gas consumption by 6%

4. Soft sensors are increasing process transparency

5. ROI below 1 year

Project: Simulation based multivariable controller for PM

drying process in paper mill Mondi Frantschach

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Modell

The control novelty is based on simulated future, which is

calculated in milliseconds using online process data and the

rigorous model (virtual process).

This control technology is quite new in this scope in the paper

industry. The results of these new set points before activation, will

be tested and tuned in the simulated future. There is no comparison

to „standard control“, where the results must by corrected only

after the processed processes.

This control technology enables to use completely available

capacity of the production lines in the paper industry without

additionally investments, Energy and CO2 emission will be reduced

and nonstandard production minimized.

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Thank You for Your Attention

visit us also on: www.procsim.eu

ProcSim GmbH

Dr. Fisera Peter

[email protected]

procsim gmbh · ditp 41st international annual symposium 19-20 11. 2014 bled slovenia possibilities...

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