BrainWave Control solutions for recycled paper - Andritz

BrainWave
Control solutions for recycled paper
www.andritz.com
We accept the challenge!

The challenge: To fi nd cost-effective
technologies to upgrade your paper mill
The solution: Advanced
control with BrainWave
Perhaps there is no upgrade that stabilizes
production and reduces costs like
BrainWave—without a large capital
investment. BrainWave is easy to install
and set up, can be retrofi tted to existing
processes, and delivers a quick return on
investment.
BrainWave is a patented controller, proven
since 1992, that can be installed as an upgrade
to any DCS or PLC system. It outperforms
traditional PID control because it controls
long dead-time processes, reacts before
being pushed off-target, handles nonlinear
responses and is both an adaptive and predictive
controller. It builds its own live models
during normal operations and accurately
forecasts the process responses to changes
in production rates or set points. BrainWave
Success story:
Multi-stage bleaching
In this mill, BrainWave measures the incoming
brightness from the thickening and fl otation
processes and brightness after the bleaching
tower. Based upon the deviation of incoming
brightness and the delay time, BrainWave calculates
the chemical dosage required ahead
of the pulp (feedforward principle) in order to
keep the fi nal brightness set point. This ability
to model and forecast the process is a huge
advantage over traditional PID and manual
controls which cannot cope with continuously
changing process parameters.
As a result, BrainWave minimizes the chemical
dosage required to obtain the fi nal brightness
target and stabilizes the overall quality
Page 2
takes corrective action before you produce
off-spec product to keep your process stable.
Return on investment is measured in
months, not years. BrainWave is controlling
over a thousand loops in factories around the
world and saving customers millions of US
dollars per year. In combination with other
ANDRITZ technologies, such as DotScan and
FiberVision, BrainWave delivers chemical and
energy savings—and improved quality.
of the bleached pulp. There has been a noticeable
reduction in COD discharge to the
effl uent system.
BrainWave control also delivers several signifi
cant side benefi ts. In addition to chemicals
savings, the mill has documented notable
BrainWave can be applied to virtually any
pulp or paper production process. It comes
with its own server that can be easily linked
to existing DCS or PLC systems through
a standard OPC connection, acting as an
overlay to the existing control. Once in operation,
it can control several process groups
without new investments in hardware.
Set point 1 BrainWave
Set point 2
BrainWave model 1 BrainWave model 2
production increases and yield improvements
(as a result of using less NaOH, minimizing
silicate, and obtaining stable control of the
process). The reduction in NaOH also lowers
the COD load in the effl uent— providing relief
for the water treatment plant, with signifi cant
improvement in environmental impact.

Success story: Bleaching
of deinked pulp
Before: This DIP line in China has a capacity
of 1,200 bdmt/d. Before installing BrainWave,
the mill controlled brightness by applying
bleaching chemicals in a ratio tied to production
rate. Operators tried to manually compensate
for variations in furnish brightness
and process disturbances in real time. This
became a time-consuming task: monitoring
brightness readings around the clock and
modifying chemical dosing to try to keep to the
targeted brightness. Most of the time, the operators
overshot the brightness target to be
on the safe side, and there was high consumption
of costly bleaching chemicals.
After: Within a very short time after installing
the BrainWave controller, the bleaching process
stabilized and the results were signifi -
Brightness % ISO
1,2
1
0,8
0,6
0,4
0,2
0
64
63
62
61
60
59
58
57
56
55
55,3
55
241
236
231
226
221
216
211
206
201
196
191
186
181
176
171
166
161
156
151
146
141
136
131
126
121
116
111
106
101
96
91
86
81
76
71
66
61
56
51
46
41
36
31
26
21
16
11
6
55,9
55,6
56,5
56,2
56,8
BrainWave
57,4
57,1
58
57,7
58,6
58,3
Operator control
LAB Brightness Line 1
May 5 May 8 May 11 May 14 May 17
58,9
59,5
59,2
60,1
59,8
Results
n Reduction in fi nal brightness
deviation = 71%
n Increase in overall
brightness = 1 pt Iso
n Reduction in bleaching
chemicals = $1/t (annual
savings ~ 400,000 USD)
n Return on investment in
just a few weeks
cant (see sidebar). In addition, the DIP plant
operators were now freed up to monitor the
overall process and ensure the proper performance
of the equipment.
60,7
60,4
Figure 1: Normal distribution, operator versus BrainWave (final LAB brightness)
BrainWave control
LAB Brightness Line 2
Standard Deviation = 1.4 Standard Deviation = 0.41
Figure 2: Lab brightness data (May 5 to June 1, 2010)
61
Mean St.Dev
-------------------------------------------------
Operator 59.65 1.42
BrainWave 58.2 0.41
------------------------------------------------
Improvement 2.28% 70.94%
(1.3 ISO)
61,6
61,3
Operator
62,2
61,9
62,8
62,5
63,1
63,7
63,4
64,3
64
Results, May 2010: Achieved in a
1,200 bdmt/d Chinese DIP line
When BrainWave was first installed, a short
time was needed for the controller to collect
process data and create a control model.
Figure 2 shows the immediate impact after
just a few hours of BrainWave being activated.
After a few weeks for optimization and
model refinement, BrainWave demonstrated
its full capabilities to minimize process
disturbances, save chemicals, and reduce
operating costs.
Paper machine operators noted that the final
product quality is more uniform due to
fewer variations. The lower consumption of
bleaching chemicals also contributed to less
COD load in the DIP water circuits—which
positively impacted the water treatment and
environmental aspects of the mill.
Benefi ts
n Stable process—on-spec
production
n Signifi cant reduction in
chemical, energy, and raw
materials costs
n Quality improvements
n Easy implementation, with
fast payback
Page 3

Automation Solutions
To help you achieve operational readiness
BrainWave is a patented advanced control
technology that outperforms conventional
PID controllers because of its two main components:
an adaptive model and a predictive
controller. BrainWave builds live adaptive
models for all potential interactions during
normal operations. Then, its predictive
controller accurately forecasts the process
response before making any adjustments.
It also has the ability to “learn” based upon
past performance. Just as your operators get
better with experience, so does BrainWave.
BrainWave process applications
¡ Bleaching and chemical control:
reduced brightness deviation and
chemical cost savings
¡ Stock refi ner control: optimization of
refi ner power and quality control
(based on freeness targets and dirt
speck measurements)
¡ TMP refi ner control: specifi c energy
and pulp quality control (in combination
with fi ber property analyzers)
¡ Disperser system control: disperser
performance and bleaching chemical
control
¡ DIP fl otation control: improved yield
and maximum brightness
ANDRITZ AUTOMATION Inc.
Atlanta, GA, USA
Phone: +1 (404) 370 1350
Call our sales staff today:
Steve Crotty (Global)
Mobile: +1 (404) 229 6349
Email: steve.crotty@andritz.com
Fax: +1 (404) 378 3813
Andrés Rojas G. (Latin America)
Mobile: +56 (9) 8230 8752
Email: andres.rojas@andritz.com
Fax: +56 (2) 462 4646
Marcos Freitas (Brazil)
Mobile: +55 (41) 9971 1546
Email: marcos.freitas@andritz.com
Fax: +55 (41) 2103 7550
Austria: Graz, Vienna | Canada: Nanaimo, Prince George, Richmond, Terrace | Brazil: Belo Horizonte, Curitiba
Chile: Santiago | Finland: Hollola, Kotka, Tampere, Varkaus | India: Bangalore | USA: Bellingham, Montoursville
Mikko Vaisanen (Northern Europe)
Mobile: +358 (40) 860 6866
Email: mikko.vaisanen@andritz.com
Fax: +358 (20) 450 6711
Siegfried Troppan (Central Europe)
Mobile: +43 (664) 961 4177
Email: siegfried.troppan@andritz.com
Fax: +43 (312) 453 6145
Allan Sycamore (Australia/New Zealand)
Mobile: +64 (21) 950 095
Email: allan.sycamore@andritz.com
Fax: +64 (9) 266 2645
www.andritz.com
automation-sales@andritz.com
All data, information, statements, photographs and graphic illustrations made in this leafl et are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ AG or any
affi liates for 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 form or by any
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 for any purpose is a violation of the relevant copyright
laws. ANDRITZ AG, Stattegger Strasse 18, A-8045 Graz, Austria. BrainWave is a registered trademark in Canada and the USA. AT.BW-rp.02.eng.05.12