© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 2
Unique processes require unique solutions
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 3
How APC Improves Performance - Stabilize Then Optimize
reduce variance shift target
actual constraint before APC
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 11
Shankar Singh
Advanced Process Control and Process Optimization – Pulp & Paper Industry
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 1
3. Production Increase 3 - 5% (5-15% possible)

Production optimization

Recovery Boiler and Evaporators
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 16

Higher black liquor solids content
2. Chemical Savings 1- 3%

Increased reduction efficiencies Reduced emissions - air distribution control Dissolving tank TTA and level control
Rec boiler
Cooking
O2
Bleaching
Turbines
Evaps
Lime kiln and recaust
Instrumentation and sensors
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 5
IndustrialIT
Energy Management
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 17
Advanced Control and Optimization of Power Island
Operational Objectives:
Recovery Boiler Economic Objectives
1. Energy Savings

Sootblowing based on heat transfer coefficients 30-40% red. Reduced excess O2 combustion control (2 - 4% excess O2 red) Lower flue gas temperature Lower fan power 5-15% Lower auxiliary fuel usage
Dilution Factor
4.0
IndustrialIT
Recovery Department Management
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 14
Recovery Section Advanced Process Control
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 8
IndustrialIT
Fiberline Management
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 9
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 4
Automation hierarchy
Mill-wide
Fiberline
Power Island
Powerboiler Steam net
Recovery dept.
FCE: The final control element: Valve, motor, another controller, etc.
Disturbance: is something that changes the process other than the FCE Measurement Uncertainty: Causes of Measurement and process differences. Wrong sensor type, worn out sensor, calibration error, Sensor changes the process, Filters, sample time, A/D resolution, location, flow type.

Reduce process variability

Steam temperatures Steam pressures Boiler load

Maintain process variables within constraints
Agenda

Introduction and overview Strategy Methodology Process area optimization Fiberline, Recovery department, Power Island Mill-wide optimization Pulp Mill Optimizer
Bleach unit Control
Temp Control Chemicals Flow Control
Digester Control
Temp Control Chemicals Flow Control
O2 Delignification Control
Temp Control Chemicals Flow Control
Causticizing
Mud washing
Lime Kiln
Produce quality white liquor at minimum operating costs
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 15
t
Dilution Factor vs. Total Cost
Cost $/Ton Soda Loss
Total Cost
Cost Minimum
Steam Cost
0.0
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 13
Digester example: reduce costs due to poor control
Max Kappa
Before

Stabilization
t
Max Kappa
After
t Max Kappa
Even later
Increased yield
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 12
Aggressive tuning
© ABB Process Automation BU Pulp & Paper Unit May 14, 2011 | Slide 7
Control loop auditing is non-invasive!
KPI
Loop Sorting based on KPI type and severity
© ABB Group May 14, 2011 | Slide 6
Control performance: Tuniቤተ መጻሕፍቲ ባይዱg vs. auditing
Tuning – Design


Auditing
Well tuned regulator
?
Is this good control? If not: why?
Implement ABB presents a strategy for success using both technology and people
Support - for long-term success ABB’s approach involves a longterm approach not only delivering initial results but insuring that these results continue into the future
Coordinated Control & Optimization