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/

http://www.innventia.com/en/


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



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


This is our pilot paper machine FEX, were we will try out our proposed measurement system which I describe in the following slides.


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


This is how we want to do it.

This is the way many measurements are collected today.


Up to 1 km2 produced area per hour!

Visual image

IR image


Yes, that is A LOT of paper…


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


This is what the paper and board industry tell us when we talk to them about the near future.


”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



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


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.


High resolution online IR measurements

IR to correlate temperature after dryer to

• grammage,

• material variations and

• dryness variations

6 m


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.


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


This is what we go for in this project idea


Measurement and analysis principle

IR data

QCS data

Grammage analysis


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.


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


We have already made a great deal of work in projects with these kind of measurements


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”


A proposed project road map for this project idea.


Thank you for listening!

Science

Zero tolerance against grammage variations in board production