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Lot of scope for improving energy consumption by implementing energy efficient processes and equipments and thereby improving profitability
Advanced process control (APC) is one of the options for reducing process variability and specific energy consumption
Wood Yard
Wood From Different sources
Debarking
Chipping
Screening
FEED PREPARATION
White liquor Sawdust to hog boiler
Pulping
Digestion
Steam
oxygen
Water Washing
Recovery Section
steam Refining Chemicals Multiple effect Evaporation WBL Bleaching
HBL
Steam Water
Fillers
Steam
Power
Typical characteristics of this industry: Capital intensive industry needs huge investment Energy intensive industry Most of the operations are energy intensive Environmental non-friendliness Large quantity & high COD / BOD values
Characteristics of processing
Long process chain many unit operations Large lag times Uncertainty of raw material composition Interdependent operations Multivariable interactions in almost all the operations
Reduce specific raw material, energy usages Reduce production cost Reduce quality variability Maximum utilization of the assets/equipment Reduce wastage Comply the regulatory norms Complete information of the processes
Pulping & washing 0.2, 3% 1.4, 18% 0.9, 11% 0.3, 4% Bleaching Black Liquor Evaporation Chemical recovery boiler 2, 24% 1.9, 24% 0.8, 10% Recausticising & Lime kiln Paper machine Deaerator Miscellaneous 0.5, 6%
4% 5% 8% 8% 5% 1% 4% 8%
Chippers Digester house Washing and Screening Bleaching plant Stock preparation + Paper machine + Finishing Pow er boilers
13%
Intake w ell + Water treatment plant Recovery (Evaporate, recovery boiler, causticisers and lime kiln) Effluent treatment plant
44%
What is APC?
A process control solution that Overcomes shortcomings of conventional single-loop control systems
Maximizes process performance without addition of new capacity Takes control of the plant and directs level-1 system
A software solution that Communicates with level-1 system Comprises of high-end algorithms
Process models Optimization algorithms Process variable estimation (Soft-sensors)
Information flow to ensure synchronized supply chain, production plans linked to plants, shortened order-dispatch cycles.
Level 3 - MES
Control of the entire production process ensuring optimum utilization of available resources.
Automation Hierarchy
Optimizing Control
The control knowledge (Technology) is built into the system in the form of a model. The system is intelligent enough to effect control on its own.
Development and deployment of Advanced Control technologies, algorithms (like MPC, Fuzzy, Neural Networks)
Level 2
Supervisory Control
Operator control using technology as an enabler. The control knowledge rests with the Human (Operator) Development and deployment of Supervisory Control systems, Creating Process Graphics, Tag databases, Interfacing with PLCs,
L2
L2
L1
L1
L1
DCS/PLC Level
Process
Looks at entire process unit as single entity to be controlled Uses process models (knowledge) Models capture multivariable interactions Controls now and in future Uses predictive power of models Optimizes performance Achieves balance between throughput & quality Honors process constraints Reduces variability in operation Facilitates feedback control Soft-sensors can be used to estimate important unmeasured process variables
Soft-sensors Soft-sensing is prediction of output variables using instantaneous values and history of the input-output variables on a pre-defied horizon Soft-sensors have a mechanism to incorporate periodic correction in the predicted value
Availability of off-line measurement facility Possibility of adaptation of the sensor parameters for performance improvement
Crucial for situations where the control frequency is greater than the measurement frequency
105
L im it/%
95
90
85
80
Be fore AP C AP C On line Ta rge t M ove d
APC solutions in the following areas Continuous and Batch Digester Recovery section
Recovery boiler Rotary lime kiln Evaporation section
Optimization solutions Deckle matching & optimization Digester scheduling & optimization
Examples of opportunities for reduction in energy consumption by implementing APC in Paper and Pulp Industry
Fuel
Maximize through puts Improve Steam economy FEED PREPARATION Pulping White Reduce variability in HBL conc.liquor Digestion Optimum thermal and combustion efficiency Reduce down time Oxy delignification Minimize SEC in Kiln White Recover maximum amount of NaOH
Recausticizing liquor storage
Washing
Debarking
Chipping
Screening
Active alkali
Steam
oxygen
Water
Lime stone
Recovery Section
steam Refining Chemicals
-Un measured chemical concentrationsHBL Multiple WBL Recovery effect Green -HBLs scalingMud tendency reducesBoiler effective heat transfer the Evaporation liquor -Inorganic in HBL deposits at the surface of tubes causing Steam Water Makup ineffective heat transfer salt cake -Ring formation inside the kiln Paper Making Machine
Rewinder/ Sheeter
Filtration
Bleaching
Reeling
Calandar
Press size
Drier
Press
Wire
Flow box
Fillers
Steam
Power
Multiple effect evaporator FEED PREPARATION Consistent HBL concentration liquor Pulping White Digestion Improve steam economy/Minimize steam consumption Sawdust to hog boiler Maximize through put Decrease down time due to exchanger cleaning Oxy
delignification White Reliquor causticizing storage Disturbance Variables
Inlet Recovery concentration Section Steam header pressure
Steam
oxygen
Fuel
Water Washing
Lime stone
steam
+ Manipulated Variables
Feed flow rate Steam flow rate Vacuum
Refining Chemicals
Optimizer
Recovery Boiler
Steam Water
Soft-sensor
Reeling
Calandar
Press size
Drier
Press
Wire
Flow box
Improvements achievable due to APC depend on process conditions Process complexity, variability, raw material variations, low frequency of feedback implies scope of higher benefits Benefits Higher throughput: Increased throughput without addition of new capacities. Typical 2-10% throughput increase Minimize energy consumption: Reduced energy / fuel consumption. Typical 5-10% reduction Reduced raw material consumption: Typical reduction of fibre and additives 1-5% Consistent quality: Consistent & improved product quality. Typical variability reduction 20-50% Reduction in off-spec production during grade change: typical 10-20% Smooth operation Higher availability of plant (reduced downtime) Overall lower cost of production
Kiln Optimizer
Indias largest cement manufacturer
The Challenge
The Goal
Rapid stabilization Increased throughput Reduced specific fuel consumption Consistent clinker quality Smoother operation of key process units
The Solution
CemPac TCS proprietary multivariable controller (MPC) Online switching to heuristic controller for abnormality handling Unique softsensor for on-line prediction of free lime, liter weight Built on TCSs in-house Advanced Process Control (APC) Toolkit
Indias largest kiln: rated at 10,000 TPD Stabilization and complete automation of operations
The Benefits
Reduction in average specific fuel consumption by 6.5 kCal/kg Reduction in variation of clinker quality (free lime and liter weight) by ~60% Improved clinker grindablity in cement milling operation Zero operator intervention
Challenges
Increased productivity Increase use of alternative fuels Create a corporate culture of continuous improvement Consistently reduce operating costs significantly
Results Delivered
Increased use of alternative fuels Reduce use of lignite as much as 14% Increased productivity Achieve kiln run time of as much as 90% Fewer kiln trips due to high temperature Fewer fuel trips Reduce NOx Emissions Better temperature control Increase production by as much as 4.5% (if not trying to maximize alternative fuel use) Improved Free Lime Control
Thanks!