furnish optimization - the key to raw material and energy savings in paper and board manufacturing
DESCRIPTION
Presentation of raw material and energy optimization tool SoftaCell for paper and board manufacturing.TRANSCRIPT
Furnish Optimization - The Key to Raw Material
and Energy Savings in Paper and Board
Manufacturing
9.9.2014 Copyright GloCell Oy 1
Juhani Lehtonen
GloCell Oy has started back in 2004 as fiber
and furnish consulting company for pulp and
papermakers, founded by brothers Lehtonen
(Ph.D. and M.sc). They had an idea, that
forest based industry can do things in a new
way and wanted to develop a new software to
help in that process. That is how SoftaCell™was created.
Since then, GloCell has become the best on
the market providing solutions for
multivariable cost and material optimization.
GloCell’s SoftaCell™ optimization program is
nowadays globally in use by forest based
industry companies.
GloCell Oy
GloCell is a specialized company working
with different multivariable models for
furnish mix optimization and evaluation
of their cost to quality ratios.
Core competences of our company are
extensive understanding about the fibres,
mathematical modelling skills and wide
experience from the pulp- and paper
industry
WHAT WE DO
History
Part 1: Scientific Background
3
Where do we come from?
• The functional behavior of paper is characterized using methods that directly measure certain physical properties that are often believed to correlate with the required functionality
• Although these properties may or may not describe the actual functionality requirements thoroughly, they are tools for the paper manufacturer to target production
• These measured physical properties are often very strongly correlated, and changing one without affecting others is impossible
• This is because many of these properties are governed by the same fundamental variables
Wood fiberproperties
Pulp fiberPulp fiberpropertiesproperties
Fiber networkFiber networkpropertiesproperties
PaperPaperpropertiesproperties
End useEnd userequirementsrequirementsTreeStandMacro
environment
Bonded areaBonded area
Unbonded area
Fiber strength
Spec. bond strength
Fiber length
Runnability
Printability
Softness
CWT
Fiber length
MFA
CW
Vessels
Parenchyma
ConformabilityConformability
Fibers/g
Fiber cutting
FibrillationFibrillation
Fiber damage
Tensile strengthTensile strength
Tear strengthTear strength
In plane tear
strength
DensityDensity
Bulk
SurfaceSurfacesmoohtnesssmoothness
Air resistanceAir resistanceAdditive retention
Growth rate
Age
Species
Competition
Habitat type
Geneticbackground
Rain
Temperature
Soil type
History
OpacityFiber length
CWT
MFA
What are the ecology and forestrybased issues affecting
fiber quality
How is fiber quality transposed into paper properties
How do paper properties provideproduct benefits
The correlations of properties through the value
chain
Example of fiber baskets SW
Relative fiber length
Relativecell wall thickness
Douglas fir
Loblollypine
strength
opacityrefinabilitysmoothness
bulk
formation
Western red cedarScotch pine
Norway spruce
Sitka spruce
White spruce
Engelmannspruce
Lodgepolepine
Ponderosapine
Grand fir
Westernlarch
Easternhemlock
Westernhemlock
Subalpinefir
Blackspruce
Redspruce
Redpine
Whitepine
Balsam fir
SlashpineLongleaf
pineShortleaf
pine
Radiata pine
Scandinavian and Russian
West Coast BC
Southern US
BC Interior
Maritime province and Quebec
Main range Rockies, Plains and Western Ontario
Chile, New Zealand
® GloCell
Jackpine
2.0-3.3mm 2.5-3.5mm >3.5mm
>8 μm
5-8 μm
3-5 μm
Virginiapine
Example of fibre baskets HW
Relative fiber length and fiber width
Relative
cell wall
thickness
Sugar maple
Red maple
Silver mapleBetula
pendula
Betula
pubescens
Trembling
aspen
Bigtooth
aspen
American
beech
Yellow
birch
White
birch
Paper
birch
River
birchWhite
oaks
Balsam
poplar
Southern red
oaks
Yellow
poplar
Sweetgum
True
hickories
White
ash
Green
ash
Sycamore
Magnolia
(Sweetbay)
Eucalyptus
grandis
Eucalyptus
urophylla
Eucalyptus
nitens
Eucalyptus
saligna
Eucalyptus
globulus
Eucalyptus
tereticornis
Acacia
mangium
Gmelina
arboreaeEastern
cottonwood
Acacia
grassicarpa
strength
opacity
refinability
smoothness
bulk
formation
Indonesia
Northern US,
Canada high
aspen pulps
Northern US
Northern US
High maple
pulps
Scandinavia
Brazil
Chile,
Portugal,
SpainDeep south
US
0.6-0.8mm
<20μm
0.8-1.0mm
20-30 μm
>1.0mm
>30 μm
MTH
Indonesia>6 μm
4-6 μm
2-4 μm
Mid south US
High oak
pulps
Global palette of fibers
The Use Of PCA
• Principal Component Analysis (PCA) has been shown to be a very useful tool in detecting fundamental variables that affect paper properties
• The main applications of PCA are to
• reduce the number of variables to a few underlying fundamental effects
• detect structure in the relationships between these variables, and ultimately to
• classify variables
Common Variance Explained By Various Factors In Mechanical And
Chemical Pulps
Principal
component
Mechanical pulp,
Strand et al.
Chemical pulp,
Howard et al.
Bonding 68% 42.4%-53.2%
Fiber length 24% 30.0%-40.3%Fiber strength 12.7%-17.7%
What Type Of Furnish Is Needed?
These targets can be achieved if one knows how to control the principal components (factors) contributing to these properties!
Process optimization Raw material control
Correct targeting (quality and cost)
High tensile?
High tear?Opacity?
Softness?
Porosity?
11
SoftaCell™
Fiber Knowledge Multivariable modeling
Monetary Tools
GloCell’s Approach
The understanding of multivariable modelling in the context of paper and board making has enabled to development of the tool. The user does not have to know
why it works and what the mathematics underneath is.
12
• SoftaCell™ primary function is to find and simulate the optimum furnish mix for different paper or board grades based on the potential of the available pulps and fillers
• With the help of SoftaCell™ optimal pulp combinations and refining ratios can be found in acknowledge of effect on final quality and cost efficiency of the mix changes
• In the program it’s easy to set limits minimum and maximum values for all the necessary quality parameter ranges and optimize without loss of total performance
How Softacell™ Works
Part 2: Fiber Benchmarking
9.9.2014 J. Lehtonen GloCell Oy 13
Note: The parts 2-4 will be presented as a live case using the SoftaCellTM optimization tool.
These slides (12-26) give a framework to what will be shown and discussed.
14
First you can start with just
benchmarking pulps
You can select each of the pulps you
have in the database for components to be benchmarked
You can select what ever refining level
you wish
You see all measured pulp
parameters with chosen refining
levels
15
You can use the graphs of any quality
measurements in the database
Easy zooming of graphs
Pulp benchmarking is a great tool for users to do first sanity checks on which pulps
could be used
Pulps can be chemical, mechanical, DIP or BCTMP, no limits to that!
Benefits Of Fiber Behavior Information
16
In this graph is shown how much does five typical hardwood market pulps differ. They are all refined equally much (100kWh/ton). The comparison is made to find the pulp which enables the highest tear strength and opacity at the same time. Would the changing of pulp, shown by the arrow, effect on the quality of the final product, if the half of the furnish mix is HW based? What would you think would happen to softwood hardwood ratio optimum in a mix?
Part 3: Furnish Mix Optimization
9.9.2014 17
Input Of End Quality Parameters
• It’s easy to enter all the needed quality
parameters into the software for the
end use requirements
• Optimization tools help to find the
most cost effective way to reach the
target quality in any properties
• The changed costs of raw materials
and energy influence and change the
optimum solution constantly
18
Creating the Furnish Mixture
19
Then you go to the real thing: Furnish mix
optimization
You usually have different types of machines and/or
grades in the database
Fillers and Chemicals Included
20
Here as an example of comparison between PCC and Kaolin. All other fiber mixes are the same!
Multivariable Optimization Button!
All quality parameters can be seen for the both mixtures in Table or Picture.
For optimization Min and Max accepted values can be entered
The Quality Comparisons
21
The Quality and Cost Optimization
In this case MIX #2 shows a significant 9,69 € / ton savings in raw materials
and energy!
22
Part 3: Board Optimization
9.9.2014 Juhani Lehtonen GloCell Oy 23
Creation of Board Layers
9.9.2014 Juhani Lehtonen GloCell Oy 24
Alternative mixes for all board layers can be created easily.
Board Optimization
• The board structure is created from furnish mixes
• In this case a 3-layer structure in presented
• Easy comparison• Grammages included
25
Alternative Board Recipes are Created
9.9.2014 Juhani Lehtonen GloCell Oy 26
Target here is to achieve the same bending stiffness with less raw material!
The Target Can Easily Be Met With This Approach
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Savings in raw material and energy are even 18,2 € per ton with the main
quality parameters remaining intact!
Part 4: Future Roadmap
9.9.2014 Copyright GloCell Oy 28
Future: Box Compression Modeling
• Fiber types
• Basis weight
• Bonding
• Fiber strength
• Orientation
• SCT (STFI) compression strength of the liners and medium
• Thickness of the board from the form of the medium (take up factor)
• Bending stiffness of the liners
Paper Board Box Functional use
ECT(Edgewise compression)
BCT(Box compression or
stacking strength)
Load demandSCT (STFI)Bending stiffness
• ECT of the board• Bending stiffness
of the board • Box dimensions
• Weight of single box?
• Printing properties?
• How high will it be stacked?
• What environmental conditions?
Box Compression Modeling Directly From Raw Materials
• Fiber types
• Basis weight
• Bonding
• Fiber strength
• Orientation
• SCT (STFI) compression strength of the liners and medium
• Thickness of the board from the form of the medium (take up factor)
• Bending stiffness of the liners
Paper Board Box Functional use
ECT(Edgewise compression)
BCT(Box compression or
stacking strength)
Load demandSCT (STFI)Bending stiffness
• ECT of the board• Bending stiffness
of the board • Box dimensions
• Weight of single box?
• How high will it be stacked?
• What environmental conditions?
You can run the board machine based on end use requirement optimum!
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Summary
Conclusion
• Principal component analysis is an efficient tool for analyzing the potential of mechanical and chemical pulps
• It can be used to explore the full design space for alternative furnish solutions
• When combined with economical evaluation it can serve as a valuable tool for altering the performance-to-cost ratio of any paper product
• GloCell approach for furnish optimization can thus serve as a strategic tool to ensure your competitiveness in the future
• SoftaCellTM – tool is used comprehensively today to optimize millions of tons of yearly production of paper and board with effective savings of tens of millions of euros per annum
33
Steering to use the best raw material combinations
available
Compare different options of raw materials easy and
fast
Cost efficient development and testing of new
products
Optimization of quality to customers
•Buy the right pulps
•Survey in which end products you can use same pulp grades.
•Channel right raw materials to right locations
•Find out technical potential in the end product
•Be able to see effects of material change fast on economical level
•Steering of R&D on higher business area level
•Point out the best and be able to forget the rest
•Be able solve customer problems
•Produce “quality good enough”
•Increase your pulp sales with SoftaCell™
SoftaCell™ can offer value for the whole corporation
Mill
level
Value Added By Softacell™