manu kettunen – abb-kpm...1 manu kettunen – abb-kpm experiencia 2018- a la fecha gerente de...

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Manu Kettunen – ABB-KPM

Experiencia2018- a la Fecha

Gerente de Producto • ABBpara: Sensores de consistencia opticos y de microondas. Ventas

globales y soporte de servicio de red de distribución a clientes.2007–2018 Especialista de Producto • Valmet/Metso Automatización

especialista de producto incluyendo Pulpa, papel y sensores de agua, soporte técnico, mantenimiento, arranque y entrenamiento.

2005-2006 Ing. de Pruebas • StaffPointPruebas de analizadores de pulpa y papel, pruebas y Soporte técnico

2005-2005 Laboratorista • UPM, KajaaniLaboratorio de análisis de Freeness y consistencia.

EducaciónIngeniería en Tecnología de Pulpa y Papel, 2005

Universidad Tampere de Ciencias Aplicadas, Finlandia

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© Copyright ABB. All rights reserved. Rev.:Document ID.:

ALBANY PANEL TISSUE6-8, November 2019, Acapulco

2019

Comparison of consistency measurement technologies at tissue machine stock preparation and wet end.

ABB Oy, KPM - Manu Kettunen

—ABB Ltd, KPM

November 11, 2019

- Kajaani Process Measurements Ltd. (KPM) was

established 2001

- KPM were acquired by ABB on 2011

- ABB Ltd, KPM is the third biggest Consistency

Transmitter Supplier in the World

3

—Product Offering

KPM KC3 Blade Type Consistency Transmitter KPM KC5 Rotating Type Consistency Transmitter

November 11, 2019 4

—Product Offering

KPM KC7 Microwave Consistency Transmitter KPM KC9 Optical Consistency Transmitters

November 11, 2019 5

—Product Offering

KPM KRA and KPM KRT Retention Measurement

November 11, 2019 6

—Product Offering

KPM KS2, KPM KS4, KPM KS6 Samplers KPM KB2 Sheet Break Detector

November 11, 2019 7

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Brazil

Argentina

GermanyFrance

Mexico

Chile

India

South Africa

Spain

Singapore

Thailand

South Korea

Indonesia

Philippines

China

Taiwan

Italy

Benelux

Peru

ABB KPM Headquarters

Kajaani, Finland

Sweden

Pakistan

Portugal

Finland

Denmark

Russia

Colombia Vietnam

Austria

Venezuela

Australia

New Zealand

Canada

USA

Norway

Turkey

UK

Poland

Switzerland

Syria

Egypt

Czech Reb.

Slovakia

Hungary

Ukraine

Ecuador

BangladeshSaudi Arabia

Sri Lanka

MalaysiaNepal

United Arab Emirates

Baltic Countries

Japan

Magreb countries

Worldwide Sales and Service Network

Uruguay

November 11, 2019 8

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Comparison of consistency measurement technologies at

tissue machine stock preparation and wet end

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Shear force consistency transmitters

– Rotary type

– Blade type

• Static

• Active

Optical

– Reflection, scattering

– Transmission

• Direct light

• Polarized light

Microwave

– Velocity of microwaves

CCD-camera image, Ultrasonic, Nuclear...very rarely used

• All technologies are indirect

measurements

• Not measuring dry weight of

material in g/l or Cs% as done in

laboratory

• Need to be calibrated

Technologies

November 11, 2019 10

—Operating Range of Consistency Transmitters

8 106 14 16122 40

Optical

Blade

Rotating

Consistency-%

Transmitter type:

Microwave

1,5-16 % (SW > 0,8%, HW > 1,2%)

0-5 Transmission

2-8 %

6-16 %

Limitations:

- needs laminar

flow, sensitive for

grade changes

- sensitive for grade

changes

- black liquor and

air

- conductivity

- air1 – 50 %

- sensitive for grade

changes

0.5-14 % Scattering


—Cost Range of Consistency Transmitters

8 106 14 16122 40

Optical

Blade

Rotating

1000 USD

Transmitter type:

Microwave

From 15 - Depends on installation configuration

4.5

16

9-20


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Consistency Transmitter Selection

—Process and installation conditions


—Optical Consistency Transmitters

– Total consistency measurement

– Ash consistency measurement

– Bypass/Flow-through sensors

– Inline sensors

– Retention measurement


—KPM KC9 Optical Bypass and Inline Cs Transmitters

– Measurement principles: Light transmission, depolarisation and/or

scattering/reflection

– Opticals are best choice for low consistency applications, below 2%Cs

– Screening, cyclones, deinking

flotation, Save-all filter inlet and outlets

– No wearing parts

– Maintenance possible during process running


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– Total Consistency and Ash Consistency measurement of

headbox and white water

– Control and stabilization of wet end and retention

– Improves machine runnability and increases production

– Chemical optimization

– Reduced downtime due to less sheet breaks

KPM KRA/KRT Retention Measurement and Control

Headbox

Pulp Paper

White Water

Retention is the Yield of Paper Machine wire section


—Retention System Monitoring and Control

November 11, 2019

Total Retention % =Tot Cs HB – Tot Cs WW

Tot Cs HB

*100 % Ash Retention % =Ash Cs HB – Ash Cs WW

Ash Cs HB

*100 %

18

– Retention calculation and control are configured in DCS,

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– Low consistency applications 0-2% Cs (0-20g/l)

– Ash consistency measurement 0-1% Cs (0-10g/l)

– Very low consistencies: 0-0,02%Cs (0-0,2g/l, 0-200mg/l )

• Save-all filters inlet, filtrate and superfiltrate

– Tissue machine Retention Measurement (Headbox, White water)

Limitations

– Black liquor and air disturbs the measurement

– Grade (fiber lenght) sensitive, complex furnish mix may require extensive

calibration

Selection Criteria for Optical Consistency Transmitter


—KPM KC7 Microwave Consistency Transmitter

Latest microwave technology for total consistency control


—KPM KC7 – Models for All Pipe Sizes

– KPM KC7 Flow-through model

• Available on sizes 50…300 mm

(2”…12”)

– KPM KC7 Insertion type

• Fits process pipes bigger than

150 mm (6”)


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– Total consistency measurement

• Measures fibers and fillers

– Unaffected of wood species change

like pulp grade, fiber length, freeness, brightness, colour, shives

– Unaffected of process conditions change like

flow rate, pressure, temperature, turbulence

One calibration line for all kind of pulps

– No moving parts

• No preventive maintenance needed

– Air content affects to the measurement, need pressure over 1,5 bar = 150kPa = 15mH2O.

Microwave Consistency Transmitters


—KPM KC7 Measurement Principle

– Microwave is transmitted to pulp through ceramic antennas

– Microwave speed depends on media

• Measures organic or inorganic material mixed

with liquid

• Response is linear


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– Superior accuracy compared to shear force transmitters

• Needed minimum 1,5 bar pressure ( 150kPa, 15mH2O)

• High conductivity >20mS/cm prevents measurement

(pulp mill bleaching applications)

– Measures total consistency, fibers, fines and & fillers

– Not sensitive to variation in fiber mix, freeness or color

– High accuracy applications; Machine Chest and Blend Chest

– Recycled pulps, excellent for unscreened applications; after pulper

– Before de-inking

– Effluent plant sludges

Selection Criteria for KPM KC7 Microwave Transmitter


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– Pulper outlet

– Storage/Dump chest feed to HD cleaning/refiners

– Blend chest feed to refiner (if pressure over 22 psi/ 1.5 bar)

– Machine tank feed to fan pump (if pressure over 22 psi/ 1.5 bar)

– UTM pulper, Broke tank feed to screening, accept feed to blend tank Cs

Installation locations of KC7 at virgin fiber Tissue Mill


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– Less maintenance personnel - KC7 maintenance free

– Accuracy required with minimum calibration work - Microwave

– Customer willing to change process design to enable use of KC7

Trends Favoring Microwave Transmitters


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– Measurements with the latest technology

• True-phase method

• Excellent temperature compensation

• State-of-art microwave components

– Robust design

• Stainless steel body

• No moving parts

• Ceramic antennas

– Easy start-up

• Factory calibrated with water

• One point calibration

Summary of KC7


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• Majority of all transmitters in use are shear force type

• Measure fiber consistency, does not measure fines or fillers

• Different grades require different calibration recipe

Shear Force Transmitters

– Rotating type

– Blade type


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– Shear force principle; force-balance

– Good for difficult flow conditions because of Measurement Chamber

– Industry standard in many areas

– Measures fiber consistency

– Sensitive to grade variations

Rotaring Consistency Transmitters


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– Installed through gate valve,

removable from process while

process running

• Enables maintenance without process shutdown and pipe drainage

– Auto-reverse function, motor

rotates clockwise and ccw

• Automatic removal of foreign material

• Auto-zero function eliminates drift

– Wide measurement range

1,5-16%

New Generation Rotaring Cs Transmitter KPM KC5


—KPM KC5 - Removable Without Shutdown

– Rotating Type Consistency

Transmitter KC5

– PN16 and PN25 gate valves

– Sensor installation by one

person

– Adjustable insertion depth

– Flange installation available

without gate valve


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– Direct Drive Servo Motor

– Smaller size – Low weight

– Less Maintenance / repair

• No drive belt

• No wearing parts in motor

– No 3-phase power to sensor

KPM KC5 - Modern Design of Rotary Cs Transmitter


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– Large pipe (>DN400, 16” )

– Low flow rate (<1m/s)

– Consistency 2-3% (blade measures but signal noisy, rotary still gives accurate measurement )

– Production measurement (= Flow rate * Consistency)

– High accuracy applications, such as after the mixing chest and machine chest

– Not enough straight pipe section after the pump to install blade

– High amount of air in the process with low pressure (microwave technology cannot be used)

Selection Criteria for KPM KC5 Rotating Cs Transmitter


—Rotary signal vs. Blade signal


—Blade Consistency Transmitters

– Basic design of measurement

blade 50 years old

– 2 wire technology and smart

electronics +20 years ago

KPM KC3

– Static Blade

– Measures 2 - 16 % Consistency

– Minimum Process pipe diameter 100 mm (4”)


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– Shear force principle; motion-balance

– Requires laminar flow conditions, turbulence disturbs measurement

– Operates well on specified flow range

– Sensitive to grade variations

– Most economical transmitter

Blade Consistency Transmitters


—KC3 – Features of the ABB Design

One piece sensor body and diaphragm

– Diaphragm works as a spring

– No maintenance

(no O-ring, no seals no leaks)

Sensor blade

Diaphragm (2mm thick)

Measuring arm

Gap measurement probe

Probe protection

Flow

Flat bottom surface

– Fibers do not collect on the bottom of the sensor

– Measuring arm moves freely


– Fits to standard process coupling Sandvik NS70 saddle

—KC3 – Blade Consistency Transmitter

– Fits to standard process coupling Sandvik NS70 saddle

– Field repairable at site with standard tools

– Electronics can be changed without taking

transmitter off from process

– Patented, no-seal transfer mechanism,with 5 year warranty against leaks

– Wetted parts titanium or Super Duplex Stainless

– Excellent sensitivity: response is better than 0.01% Cs


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– Cheapest solution wanted (wrong selection criteria)

– If high precision is not required, early in process

– After MC-pump where Cs>10%, as good as rotary

– Flow relatively steady

– Consistency more than 3% up to 16% and same fiber mix

Selection Criteria for KPM KC3 Blade Transmitter


—Comparison of Shear Force Transmitters

– Blade type

+ Price

+ Reliable measurement if conditions

are suitable (process, installation)

+ No wearing parts (static blades)

+ Size

+ 2-wire transmitter

- Require laminar plug flow: Long straight pipes before and after

installation point

- Limited acceptable flow range

- Vulnerable to mechanical damages

because blade is in main stream

– Rotary type

+ Performance

+ Turbulent flow acceptable

+ Freedom of installation location

+ Wide flow range

+ Wide measurement range 1,5-16%

- Price

- Wearing parts; seals, bearings


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Consistency Transmitter Selection

—Contact Your Supplier and Fill the Questionnaire


We help to select the

correct measurement

technology

– Make sure supplier is able to provide all measurement technologies

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– Select Cs transmitter by application, not by price

– Proper tank agitation is critical

– Constant dilution water pressure

– Dilution valve dimensioning

– Dilution water injection point and correct velocity

– Representative sampling

– Tune control loop

General Recommendations for Good Consistency Measurement and Control


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– Ball Valves

• Dangerous

• Does not take representative consistency sample

– Piston type Samplers

• Safety

• Representative sample

• Repeatability (not depend on user)

Different Samplers and Needs


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KPM’s Sampling Device Family

– KPM KS2

• Screened pulps 0–8%, no shives or trash

– KPM KS4

• Unscreened pulps 0 – 8%, Shives and trash allowed, no knots

– KPM KS6

• Screened and unscreened pulps 0–18%, shives, knots, trash allowed


—KB2 Fiber Optic Sheet Break Detector


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Fiber optic cables

Sheet

RGB and IRTransmitter

Detector

KPM KB2 Measurement principle

Dual light source to cover any application

– RGB light source for colour measurement

– Infra-Red source (880 nm)

Fiber-optic transfers light from transmitter to sensor head.

Non-contact sensor head is 10–30 cm (4–12”) from sheet.


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– Sensor tube and flexible conduit protect fiber optic cable

– Air purge prevents sensor head becoming dirty

KPM KB2 System components


Thank You

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Retention Aids – A Versatile Tool for Tissue Manufacture

By G. Furman, C. Foss, C. Kaley, S. Archer, R. Phillips and H. Zha, NALCO Water – An Ecolab Company

https://www.tissuestory.com/2019/01/21/retention-aids-a-versatile-tool-for-tissue-manufacture/

Survey of Retention Aid Impacts at 10 Tissue Machines


The primary benefit associated with the increase in FPR was the potential to increase the fiber to paper

ratio, or process yield. Additionally, the increased fiber retained with the sheet resulted in a lower solids

load to the white water process clarifier (DAF) and a reduction in solid waste from this unit. Yield

improvements varied between 1-5% depending upon whether the process utilized fiber recovery

screens or recycled a portion of the DAF solids.

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