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Application Straight from the lab to the plant through simulation The production of cellulosebased fibers, as performed by the world market leader Lenzing AG, involves a long chain of highly complex chemical processing equipment. Between development of an improved process in the laboratory and its implementation as a full-scale system, several months would traditionally be needed to test and optimize a pilot system and its control technology. Lenzing was able to skip this intermediate step by simulating the new system in MATLAB ® / Simulink ® and running real-time tests of the control software using the real B&R APROL process control system, which also shortened the commissioning time of the system from several weeks to just a few days. 52 <strong>automotion</strong> 07/2009 Increased awareness about global climate change has increasingly led environmentally and health conscious consumers to consider where their purchased products came from and what materials went into making them. Because clothing as well as non-woven products such as hygiene products and foodstuffs are products with direct physical contact, the clothing industry has responded by using ecological labeling and carbon labeling to communicate information such as a product's 'carbon footprint' or skin friendliness. the Lenzing group is a global leader in the marketing and manufacturing of man-made cellulose-based fibers. teNCeL®, Lenzing modal® and Lenzing Viscose® fibers are primarily used in the textile industry; special fibers from Lenzing are used in the area of hygiene as well as for technical applications. The fibers are then distributed to companies around the world for further processing, whereby Asia represents the largest market with over 50%. Nearly 6% remain in Austria, home to the largest single customer. The fibers are manufactured in several steps, beginning with the renewable resource wood. Approximately 800,000 solid cubic meters of beech wood are processed annually at the Lenzing location alone. New plants optimize production the wood is converted to natural fibers in expansive systems, which operate with a high degree of automation, the lowest possible environmental impact and the best possible utilization and recycling of energy and residual materials. Optimization in this area is the main motive behind the successive modernization
of individual plants throughout the entire complex. Dr. Bernhard Voglauer, managing control technician in the Lenzing Fibers technical planning department found himself confronted with just this back in 2006. In-house chemists developed and tested a completely new process in the laboratory, which proved to be effective. the goal now was to implement the results in a full-scale production system. Construction of the system was mostly finished and a general automation concept had already been created. even the decision for the process control technology which would be used had already been made. the automation engineers at Lenzing count on B&R's ApROL for this. Because the production processes in this sort of system are complex and are not entirely hazard-free due to the chemical processes used, it is common to build a so-called pilot system after lab testing and before construction of the full-scale system. the pilot system is used to test and optimize processes scaled down to kilograms, before they are applied to the full-scale system. It is not hard to see how this procedure can consume a good deal of investment, time and space. "this drove us to search for a solution that didn't require this cumbersome intermediate step," remembers Bernhard Vo- glauer. "It was clear that the unproductive time spent on optimization during the commissioning phase was not acceptable." Safety through simulation Bernhard Voglauer found the answer to this challenging task to be dynamic process simulation, in Application The production chain goes from the sustainable raw material wood to the finished fiber. which the entire production system, including all process data, is simulated as a computer model. In this way, optimization can be performed on a virtual system. Without production downtime, without substandard production and most importantly without endangering the workers, the machine or the environment. As a tool, mAtLAB ® /Simulink ® from the American manufacturer the mathWorks was an obvious choice. On the one hand, because it is a well-known simulation system used worldwide that, unlike the product used earlier by Lenzing Ag, can handle the required complexity. On the other hand, because code that is understood by B&R systems such as the ApROL process control system The savings achieved by shortening the commissioning time for large systems from weeks to days are enormous. can be generated directly from the simulation models. With respect to the expected benefits brought by dynamic simulation of production systems, Bernhard Voglauer says: "The economic benefits are a result of being able to start production at full capacity sooner, with “Through simulation with MATLAB ® /Simulink ® we were able to shorten the commissioning time of a new production system to a minimum. The time saved and the problems avoided through virtual commissioning convinced even the toughest critics.“ Dr. Bernhard Voglauer Managing Control Technician Faser Lenzing Technik Planung minimum time lost during commissioning." Predefined settings for PCS parameters such as operating points, limit values, closed loop control parameters, alarm limits, etc. also contribute to the control concept and operability as does the detection of errors/defects in the pCS programming. In addition, the plausibility of the process design can be checked, and acceptance by the system operators can be increased by providing training in advance and implementing impressive functionality, which is important for smooth operation. Over the course of three months and nearly 400 hours of work, a physical model and then the Simulink simulation model were created based on construction data, the process graphic, expert knowledge and the results of lab testing. the "hardware-in-the-loop" concept was used: the simulation model >> <strong>automotion</strong> 07/2009 53
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