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Energy Conservation through Automation of Processes in Pulp and Paper industry

Applicability of Energy Conservation Act 2001 to Pulp and Paper industry


Pulp and Paper industry is one of the designated consumers as per EA Act, Paper industry is the six largest consumer of commercial energy in the country Energy cost accounts for 25% of the total manufacturing cost in paper industry Specific energy consumption in India is high in comparison of developed countries

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

Paper industry: the manufacturing process


Active alkali

Wood Yard
Wood From Different sources

Debarking

Chipping

Screening

FEED PREPARATION
White liquor Sawdust to hog boiler

Pulping
Digestion

Steam

Oxy delignification Fuel Recausticizing Lime stone


Kiln

oxygen

White liquor storage

Water Washing

Recovery Section
steam Refining Chemicals Multiple effect Evaporation WBL Bleaching

Filtration Mud Green liquor Makup salt cake Recovery Boiler

HBL

Steam Water

Final product Paper

Paper Making Machine


Rewinder/ Sheeter Reeling Calandar Press size Drier Press Wire Flow box

Fillers

Steam

Power

Pulp & paper making Challenges

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

Pulp & paper making Looking for


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

Energy Consumption in Pulp & paper industry


Steam: 8.00 tons/ton of finished paper

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%

Energy Consumption in Pulp & paper industry


Power: 1300 KWh/ton of finished paper

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%

Lighting and w orkshop etc.

What is APC?

A process control solution that Overcomes shortcomings of conventional single-loop control systems

Multivariable interaction Plant constraints Dead-times Lack of measurements

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)

Requires no additional Hardware. Leverages existing process instrumentation.

Plant Automation Solutions - Focus


Integration to ERP

Information flow to ensure synchronized supply chain, production plans linked to plants, shortened order-dispatch cycles.

Integration with Planning Layer, Industry Standards MESA, ISA95

Level 3 - MES

Control of the entire production process ensuring optimum utilization of available resources.

Plant systems & process mapping, MES architecture design, implementation.

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,

Level 1- Basic Control


PLCs, DCS, PID and On-Off control, Recipes PLC/ DCS Programming and commissioning, System Integration with Field instruments, PID Tuning

Level 0 - Sensors and Actuators


All the field equipment like motors, transducers, solenoids, drives Commissioning of H/W, Solenoids, valves, motors, drives and their interfacing

APCs position in automation hierarchy APC


L3
Knowledge Base Simulation, Monitoring & Diagnostics (plant wide)

L2

Supervisory Multiloop control (Optimization)

L2

Cascade Indirect control (single variable)

L1

L1

L1

Loop Local control (single variable)

DCS/PLC Level

Process

What does APC offer?

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: Measure the unmeasured

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

Stabilize and Optimize

105

S pec ific ation lim it


100

L im it/%

95

90

85

Reduc ed S tandard Deviations

80
Be fore AP C AP C On line Ta rge t M ove d

APC & optimization opportunities in pulp & paper industry

Optimization in pulp & paper making

APC solutions in the following areas Continuous and Batch Digester Recovery section
Recovery boiler Rotary lime kiln Evaporation section

Re-causticization Bleaching section Paper machines optimization Hog Fuel boiler

Optimization solutions Deckle matching & optimization Digester scheduling & optimization

Examples of opportunities for reduction in energy consumption by implementing APC in Paper and Pulp Industry

Recovery section: needs and challenges


Wood Yard
Wood From Different sources

Sawdust to hog boiler

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

Final product Paper

-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

Recovery section : Multiple effect Evaporation APC


Wood Yard
Wood From Different sources Debarking Chipping Screening Active alkali

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

Filtration Desired output Mud

Optimizer

Green liquor Makup salt cake

Recovery Boiler

Process HBL Multiple Process WBL output effect Evaporation Model

Controlled Variables Bleaching


Solids Concentration Temperature profile Vapor separator levels Solids throughput

Steam Water
Soft-sensor

Final product Paper

Paper Making Machine


Rewinder/ Sheeter

Reeling

Calandar

Press size

Drier

Press

Wire

Flow box

TYPICAL CONTROL STRATERGY FOR EVAPORATRS


Fillers Steam Power

What does APC offer?

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

Lime kiln APC Solutions

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!

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