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Model based Control and Diagnostics strategies for a Continuous Pulp Digester
Mälardalen University, School of Business, Society and Engineering, Future Energy Center. (SOFIA)ORCID iD: 0000-0003-3610-4680
Mälardalen University, School of Business, Society and Engineering, Future Energy Center. (SOFIA)ORCID iD: 0000-0001-8191-4901
Mälardalen University, School of Business, Society and Engineering, Future Energy Center.ORCID iD: 0000-0002-8466-356X
Billerud Korsnäs, Gävle, Sweden.
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2018 (English)In: Paper Conference and Trade Show, PaperCon 2018, 2018, Vol. 1, p. 136-147Conference paper, Published paper (Refereed)
Abstract [en]

Kappa number, which essentially indicates the amount of lignin left in the pulp after cooking, is the most important physical quantity linked to the quality and economics of a Kraft-pulp mill. Controlling the Kappa number is a difficult task mainly due to the naturally varying feedstock, significant residence time, insufficient measurements and complex nature of the delignification process. Moreover, faults such as screen clogging, hang-ups and channeling in the process often occur and increase the operational costs considerably. In this work, the possibility of feedforwarding the lignin content of incoming wood chips, by a near-infrared spectroscopic measurement of one of the major process disturbances, to a model predictive controller, is investigated by means of modeling and simulation studies. Additionally, a simple Bayesian network based diagnostics approach is proposed to detect the continuous digester faults.

Place, publisher, year, edition, pages
2018. Vol. 1, p. 136-147
National Category
Engineering and Technology Energy Engineering
Research subject
Energy- and Environmental Engineering
Identifiers
URN: urn:nbn:se:mdh:diva-41297DOI: 2-s2.0-85060374344Scopus ID: 2-s2.0-85060374344ISBN: 9781510871892 (print)OAI: oai:DiVA.org:mdh-41297DiVA, id: diva2:1261414
Conference
TAPPI Paper Conference and Trade Show, PaperCon 2018; Charlotte; United States; 15 April 2018 through 18 April 2018; Code 143482
Projects
FUDIPOAvailable from: 2018-11-07 Created: 2018-11-07 Last updated: 2019-10-01Bibliographically approved
In thesis
1. Towards a learning system for process and energy industry: Enabling optimal control, diagnostics and decision support
Open this publication in new window or tab >>Towards a learning system for process and energy industry: Enabling optimal control, diagnostics and decision support
2019 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Driven by intense competition, increasing operational cost and strict environmental regulations, the modern process and energy industry needs to find the best possible way to adapt to maintain profitability. Optimization of control and operation of the industrial systems is essential to satisfy the contradicting objectives of improving product quality and process efficiency while reducing production cost and plant downtime. Use of optimization not only improves the control and monitoring of assets but also offers better coordination among different assets. Thus, it can lead to considerable savings in energy and resource consumption, and consequently offer a reduction in operational costs, by offering better control, diagnostics and decision support. This is one of the main driving forces behind developing new methods, tools and frameworks that can be integrated with the existing industrial automation platforms to benefit from optimal control and operation. The main focus of this dissertation is the use of different process models, soft sensors and optimization techniques to improve the control, diagnostics and decision support for the process and energy industry. A generic architecture for an optimal control, diagnostics and decision support system, referred to here as a learning system, is proposed. The research is centred around an investigation of different components of the proposed learning system. Two very different case studies within the energy-intensive pulp and paper industry and the promising micro-combined heat and power (CHP) industry are selected to demonstrate the learning system. One of the main challenges in this research arises from the marked differences between the case studies in terms of size, functions, quantity and structure of the existing automation systems. Typically, only a few pulp digesters are found in a Kraft pulping mill, but there may be hundreds of units in a micro-CHP fleet. The main argument behind the selection of these two case studies is that if the proposed learning system architecture can be adapted for these significantly different cases, it can be adapted for many other energy and process industrial cases. Within the scope of this thesis, mathematical modelling, model adaptation, model predictive control and diagnostics methods are studied for continuous pulp digesters, whereas mathematical modelling, model adaptation and diagnostics techniques are explored for the micro-CHP fleet.

Place, publisher, year, edition, pages
Västerås: Mälardalen University, 2019. p. 178
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 282
Keywords
Learning system, Supervisory system, Pulp and paper, Micro gas turbine, Process modelling, Model-based control, Diagnostics, Decision support, Anomaly detection, Fault detection
National Category
Energy Engineering
Research subject
Energy- and Environmental Engineering
Identifiers
urn:nbn:se:mdh:diva-45219 (URN)978-91-7485-438-1 (ISBN)
Presentation
2019-10-30, Pi, Mälardalen University, Västerås, 13:00 (English)
Opponent
Supervisors
Projects
FUDIPO – FUture DIrections for Process industry Optimization
Funder
EU, Horizon 2020, 723523
Available from: 2019-09-16 Created: 2019-09-16 Last updated: 2019-09-24Bibliographically approved

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Rahman, MoksadurAvelin, AndersKyprianidis, KonstantinosDahlquist, Erik

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