Zero tolerance against grammage variations in board production
-
Upload
rise-bioeconomy -
Category
Science
-
view
566 -
download
1
Transcript of Zero tolerance against grammage variations in board production
Zero tolerance against grammage variations in board productionCatherine ÖstlundInnventia
This is a copy of our presentation of a project idea at the Innovation track at FTP partnering event in Münich in October 2015. I have added speech bubbles to guide you through the slides.
Please feel free to contact me if you have questions and comments: [email protected]
www.innventia.com © 2015 2
Research Institute– Owners: direct and through associations:
Industry 71%, Government 29% – A no dividend organization
Commissioned Research:– Exploratory research often with governmental funding– Innventia Research Programme with several partners – multi client– Bilateral single client projects
In close collaboration with:– Other institutes– Universities– In EU funded projects
Innventia - Boosting business with science
Innventia provides innovative ideas and scientific research results focused on wood-based raw materials for clients along the entire value chain
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
First three slides describing our research institute, and parts of what we do.
More information about us can be found at http://www.innventia.com/en/
www.innventia.com © 2015 3
Our RD&I covers several value chains
Pulp, paper and board production
Printing and media
Packaging and the supply chain
Bioenergy, chemicals and biomaterials
Testing, optimising and prototyping
Sustainability, CSR and LCA-analyses
Grants office and Library services
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
www.innventia.com © 2015 4
Innventia develops and optimizes paper processesPaper processes
The FEX machine is developed with a flexible pulping system
Pilot paper machine FEX is to research tools that enable testing under realistic conditions of theories for materials and
process technology development
Innventia developedstratified forming which reduces energy
consumption and improves product features
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
This is our pilot paper machine FEX, were we will try out our proposed measurement system which I describe in the following slides.
www.innventia.com © 2015 5
Is there a need for more measurements?
Figiel, K. et al: Paper Machine Quality Control Systems (QCS), Vol1: Measurement systems and Products Variability, Tappi press
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
This is how we want to do it.
This is the way many measurements are collected today.
www.innventia.com © 2015 6
Up to 1 km2 produced area per hour!
Visual image
IR image
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
Yes, that is A LOT of paper…
www.innventia.com © 2015 7
What does the paper and board industry need in 5 to 10 years?
A product produced using less energy & less raw material Not necessarily always a better produced quality - but a more even quality A more flexible production – and the tools to achieve that
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
This is what the paper and board industry tell us when we talk to them about the near future.
www.innventia.com © 2015 8
”Total area in real time”: measure all produced area
”Measurement and analysis in multiple wavelengths, also outside the visible interval”:Multisensor/multispectral measurements and analysis to gain more information – Combination of different information IR to correlate drying process to grammage, material variations and dryness variations
NIR for material composition
Secondary properties like surface structure online
Soft sensors
”Platform”:Create a platform for integrating image based (2D) measurements methods in QCS
Ideas discussed at Innventia in workshops with industry, academia and instrument suppliers
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
www.innventia.com © 2015 9
High resolution online measurementsIR, NIR and visible wavelengths
- Online surface structure measurements (left) and trend (right) measured using online OptiTopo
- 5 min temperature variation on tambour induced by a moisture variation (IR)
- Classification of material composition in sheets (NIR scanner)
Change of coating blade
20 cm
6 m
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
At Innventia we have worked with and developed measurement techniques and analyses during many years, and these are some of them that are or can be applied online in a large scale.
www.innventia.com © 2015 10
High resolution online IR measurements
IR to correlate temperature after dryer to
• grammage,
• material variations and
• dryness variations
6 m
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
The IR camera technique has been studied and used during 6 years in different project at Innventia. The IR technique will be the main tool for measurements in this project.
www.innventia.com © 2015 11
Three levels of implementation
1. Expert system for troubleshooting/mappingIdentification of process variations in full scale; throughout paper machine
2. Alarm function: Automatic identification of extreme statistical outliers for a more even production; web breaks
3. Implementation in a QCS; optimisation of process.
Alternatives for implementation
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
This is what we go for in this project idea
www.innventia.com © 2015 12
Measurement and analysis principle
IR data
QCS data
Grammage analysis
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
A short description of the thought analysis: We collect IR data of all produced area. Additional data from QCS is used to calibrate the IR data. The output are maps, curves and trends that are fed back into the process
optimisation system to control the quality.
www.innventia.com © 2015 13
Licentiate thesis, “IR Emittance of Paper” Caroline Hyll, Royal Institute of Technology, KTH, Stockholm, Sweden, 2012
IR and NIR measurement case studies for different paper qualities in the previous Innventia Research Cluster program (2012-2014)
Large-scale and long-term studies of temperature variations on two machines during early 2015 (ÅForsk funding)
“Roadmap for implementation of multispectral quality control of the whole produced area in paper and board making” during first half of 2015. (Process Industry IT and Automation (PiiA) Strategic Innovation Programme, Vinnova funding)
“Evaluation of multispectral material analysis for online application in board making”, ongoing project. (PiiA Strategic Innovation Programme, Vinnova funding)
Projects at Innventia aiming at developing an online large-area analysis of process variations
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
We have already made a great deal of work in projects with these kind of measurements
www.innventia.com © 2015 14
Step 1Initiation Project goals
Step 2Pilot
implementation
Step 3Permanent
implementationProject goals
Industrial value, Effect goal VisionProject goals
A more sustainable society through a better use of
wood-based raw material with the help of a higher resource and process efficiency in industrial
board productionAnalysis of needs
for measurements of
grammage variations in paper and/or
board production made
Built a consortium
of relevant actors from complete
value chain
IPR regulated
Defined plan for implementation
of a measurement
concept
Accomplished total-area
measurements in pilot and
industrial scale over a long time
period
Total-area measurements of grammage
integrated in a board machine
The analysis of measurements
are used for optimisation of
the process
The system is marketed
internationally by a instrument
supplier
An increased process efficiency leads to an
increased competitiveness for the
board industry
A measurement system that can be marketed
internationally
A more even quality of the paper/board
products will lead to new product opportunities
Methods developed to handle and
analyse data, and implement it in
QCS
Tools developed to present the variations in a
operator-friendly way
” Zero tolerance against grammage variations in board production”
FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
A proposed project road map for this project idea.
www.innventia.com © 2015 15
Thank you for listening!