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Juha KortelainenUPM R&D, Paper and Pulp
Finland
Avogadro Scale Engineering November 18-19, 2003The Bartos Theater, MIT
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Contents
● UPM overview● Jämsänkoski Paper Mill● Paper quality and data analysis
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UPM Key Figures, 2002
● One of the world's largest paper producers
Turnover, EUR million 10,475
Personnel at 31 December 35,579
Paper production, t/a 10E6
● Yearly production corresponds to 170,000 km2 area covered by paper! (land area of Massachutes is 20,000 km2)
● Mills mainly in Europe, North America and China
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From the Forest to the Customer
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Jämsänkoski – Finland, year 2002Products: - PM5&6: uncoated magazine 570 000 t/a- PM4: coated magazine 125 000 t/a- PM3: label paper 110 000 t/a
Founded: 1888Capacity: 815.000 t/aPersonnel: 940
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Jämsänkoski SC PM6● 325 000 t/a, 39 … 56 g/m², 9.30 m width, 25 m/s speed
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Automation Hierarchy, open systems
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Paper Formation● micrometer range variations, fibre level
− paper surface structure, small defects− optical and printing properties
● several meters range, CD and MD profiles− paper web brakes ~ up to 100 km range
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Paper Web Break Camera Monitoring
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Image analysis
● Microscopic image analysis for fiber dimensions− fiber length ~2 mm, width ~40 um, cell wall ~ 2 um− automatic fibre analysers with 1,5 um pixel resolution− paper structure with SEM using 0,2 um pixel resolution
● Real-time image analysis for web defects and brakes− on-line camera scanner defects down to 0,5 mm size
● Real-time microscopic scale?− 20 um pixel resolution − 10 meter web width− 25 m/s speed
12500 images / second with 1 MPix image size
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On-line control
● Distributed Controls− thousands positions
● Supervisory Controls: Paper quality data with web scanner
− e.g. cross-direction profile control
− basis weight− moisture− caliper− colour
.:
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Time series data – Multivariate AutoRegressive analysis● Time dependent cross-correlation
disturbance sources● Numerically efficient method needed (FFT)
− e.g. 1000 channels, 10 s sample period, 8.6E6 samples/day
● Problems:− not efficient enough for long process delays− assumes stationary process state during analysis period− assumes linearity
needs data prehandling, about 80 % of manual work!
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Data Clustering
● Automatic clustering often ends up to distinct time periods, which are (more) stationary
− product grades, process states
● Principal Components, k-means● Neural networks: Self Organised Maps by T.Kohonen
− visualization!
● Problems:− poor numerical efficiency− does not practically help in data prehandling
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Modelling of paper quality
● Paper strength● Optical
properties● PM control
variables dominate
● some correlation from raw material disturbances
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Neural Networks: Self Organised Maps (T. Kohonen)
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Clustering of SOM by k-means
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Summary for data-amounts / hour
● DCS data− 5 Hz rate, 10,000 channels 2E8 samples / hour− multichannel: vibration, NIR spectra
● Paper web scanner− six channels, 1000 Hz 2E7 samples / hour− typically 5 scanners for one production line
● Camera systems− many fast speed camera applications in use
● off-line image analysis applications real time needs
− in future 20 um resolution? 5E13 pixels / hour