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Nissinen, A . *, Rantala, T.
H
, Huhtelin, T.**, Lautala, P.*, Nokclaineu, J . t
t Valinet Autofnation Kajaani Inc" P.O. BOX 177, FL"'r'-8710J K4J.4.t11\ll, Finland.
Ernail.jukka. nokelainen @ lla!rnef. COrn
6872
Copyright 1999 IFAC ISBN: 0 08 043248 4
NEW PROCESS CONTROL REQUIREMENTS AND SOLUTIONS FOR... 14th World Congress of IFAC
economically reasonable solution, brings new flows are composed from several components: fibers,
connections and dynanlics to the short circulation. fines~ filler and retention aid that is used to improve
Because of tightened control requirements more and the retention of components on the ~'ire~ The fiber
more control loops have been added into the process consistency of the dilution water is significantly
and interactions between control loops have lower than the riber consistency of the main flo\v.
increased_ At the same time the process itself is taken The material of the dilution \vater has already once
to its extremes by increasing the production. Custom mixed with retention aid and passed through the \vire,
orientated tlexible operation of papeJ machine leads and therefore~ it is having di fferent retention
to frequent grade changes. These trends have brought properties compared to the material in the main flow.
up interactions between subprocesses causing
runnabi)jty problems. Main and dilution tlO\VS are Inixed in Inixing blocks
that are located 60 nl01 apart frotH each other in CD.
This paper discusses expedences gained from the 1\1ixing valve~ have been designed in such a vvay that
dilution headbox process environment and describes the total tlov/ through the dilution block is nut
possible sources of disturbances and their dependent on the aITIOunt of dilution \-vater mixed
conseq uenccs. Paper also descri bes Kaj aani RIvli with the I11ain flow i.e. dilution t1o\v is displacing the
consisLency analyzer based control applications main fluv/. Flo\vs of different mixing blocks are
applied to the dilution headbox process. These slightly mixed in CD in the stilling chamber and in
cons istency control applications are well proven in the slice channel. The response of one dilution block
the traditional headbox environment and give to basis weight profile is close to the bell shape.
important benefits also in the dilution headbox Anlplitude of the response is dependent on the
environment. consistency difference between nlain and dilution
flows and the relention of individual components on
the wire. The retention mechanlsm is very complex
2. PROCESS DESCIRPTION and difficult to predict accurately beforehand. To
achieve good feedback control performance jn the
In the rnosl of dilution headbox processes 'h'hite v,.'ater
CD profile control the properties of the main and the
is llsed as dilution \vater v/hich is economically
dilution flo\v should be kept as constant as possible
preferred solution concerning fiber and filler losses.
i.c. consistencies of main and dilution flow and
Ho\vever ~ that will make the short circulation more
retention of different components on the \vire have to
cOluplicated to control because the dilution
circulation form~ another paraUel loop \vith the be as stable as possible.
Lraditiona) short circulation (figure 1). The
consistency of the 'vvhite water in the v.rire pit is 3. STABILIZATION OF THE SHORT
dependent on the consistency in the headbox and the CIRCULATION
retention on the "vire section. Dilution \vater is
usuaHy taken from the upper part and Inain f10\v from Today among paper makers the most important
the lov·/er part of the wire pit. Therefore, the time quality requirernent is a flat basis weight profile.
delay from the \-vire section to the inlet of circulations Dilution control headbox is able to produce required
is different and transport delays of circulations also quality level upon condition that the environment of
vary - That will lead to di fferent dynamics between the dilution headbox is stable enough. Stable
circulations. Filler is fed to control the ash content of properties of the main flo\~' and the diJution flo\v are
the paper and retention aid is used to control white prereq uisite for R stable retention on the forn1er
water consistency. Ash content and white water section~ Disturbances in the consistencies will cause
consistency have strong interactions. quality disturbances (basis \\leight~ ash content,
caliper etc_) in machine dircctlon (MD)~ and
In the dilution headbox 1\\'0 streams are mixed inside therefore~ changes e-g. in strength that \vill affect the
the headbox to create consistency profile in CD. Both runnability of the paper machine and printability
Air removal tar.k properties on the printing machine. In case of the
A'{~:~~I.:K;r~~~O:~:~':~~,~~e~~7_
dilution headbox consistency disturbances of the
main and the dilution t10\V will also cause CD
disturbance directly and indirectly. Direct effects can
be seen as unstability of the basis \"'eight profile due
to the varying gain of the dilution control (varying
retention) in the area of each dilution block.
~ i I header
Indirectly MD disturbances v\/ill distort the estinlation
L. __ -r-I-"~_.-- _: 'N1r·p.--"'t'"--~-~---'
6873
Copyright 1999 IFAC ISBN: 0 08 043248 4
NEW PROCESS CONTROL REQUIREMENTS AND SOLUTIONS FOR... 14th World Congress ofIFAC
2Bf---'-------;1 03~-'
Ash conten1 01 paper 2 sigma Y::llue of basis weight profile
adjust operation point according to different paper
{~ -- grades. Break time headbox ash consistency control
~v'\ ,""",1~"""; 1 ~~ ~
0'27, 025 I ,,' .' '. is used to stahilize the short circulation during a ·web
26-
o
~)
2
-
4
-
6
O.2~
0 2 4 6 break when no ash content information from paper
Flow 01 fresh filler Conditioned ba.sis weight {MD)
\veb is available. "fhick stock ash content control is
used to compensate ash disturbances entering from
the stock preparation to the short circulation which
are not seen in the total consistency measurement of
Hours Hours machine stock. Kajaanl RMi sensors :ue llsed to
Fig. 3. Broke flov,,' changes are causing ash measure the total and ash consistencies and level of
disturbances to the paper and short circulation. flocculation of stock on-line fronl a continuous
salnple tlo\\l.
6874
Copyright 1999 IFAC ISBN: 0 08 043248 4
NEW PROCESS CONTROL REQUIREMENTS AND SOLUTIONS FOR... 14th World Congress ofIFAC
rCALC~LArE 4
UF.n·:Yl101\i
COl\TROL
Pe-rcent
c·nl~.\llC/~L
--..: Fl.R.2'Y.~SI.
I _. -,!t.,.)
~~
:.:.:._~I
,.,.,~
I~__
.
. 3.5
• . ......j
! ....., . Y, .
To Heaclbox ~ ~' . i I ~o dilution
,watel
3L...-~---'---....L-....:::%..-....I-.-._-----'-------'-----
2 4 6 8 10 "12 14
I'I"'C~~:tW!'~I:;e!~atal~~"'ig~n:~~.t~~~±J'_:~-~---~
Hours
Fig. 6. Operator can freely adjust the operation pojnt
of the short circulation by setting the setpoint of
che dilution \vater consistency controller in a
desired level.
Fig. 5. Configuration of the consistency control of the Total c::>nsistency of dil.JLoll '....aler
6875
Copyright 1999 IFAC ISBN: 0 08 043248 4
NEW PROCESS CONTROL REQUIREMENTS AND SOLUTIONS FOR... 14th World Congress of IFAC
'fable 1. Change 1n standard deviation, mean value Comparison results of the headbox ash consistency
controJ
and Inin-tnax range bet\veen manual and control
run ut' dilution \-vater consistency control. 1.B
g~ 0.8
values) 1
- -- '--. '.'- . . .-
\-\lET END
,S! C.6 i- -----
'------'~---"---'-~ J
5,4 effective as generally thought. This is especially true
0.5 1 1.5
1. 2
0 0_5 1 15
in older paper machines \vhere production rate, and
Hours Hours therefore, also flow rates through mixing tanks have
Fig. 9. Example of the operation of the hreaktime been increased over the years.
hcadbox ash consistency controller during a long
\veb break. These thick stock ash content disturbances can be
eliminated \vith a feedfor\\'ard control based on an
furnisb. Fresh filler llov~l i.s adjusted accordingly to ash content measurement. Figure 11 sho\\o's the basic
compensate disturbances in the headbox ash principle of this conlrol. Furnish ash content is
conslstency. Paper is back on the reel at the point at measured afte.r the machine chest and fresh filler is
the second vertical line. Headbox ash consistency added to the short circulation. Based on the change in
controller is kept active the holding period (to the 3 n{ the measured ash content a compensation is
calculated and added to paper ash controller's output.
6876
Copyright 1999 IFAC ISBN: 0 08 043248 4
NEW PROCESS CONTROL REQUIREMENTS AND SOLUTIONS FOR... 14th World Congress of IFAC
Broke 6. CONCLUSION
Requirements for the paper quality and espec.ially for
the CD profile variables have increased and at the
same time the speed of the tuachines have been
increased. Dilution technology and diJutjon
T\I1'lxlng
headhoxcs arc able lo respond to these requlrenlents.
puirlp chest chest
Ho\\rever~ the short circulation process is coming
Fig. 11. Principle of the thick stock ash content
more complicated and offers challenges especially for
feedforward control
the consistency control applications.
Stability of the short circulation is essential
Fresh fi lIer to wet en d, I/s concerning the perforlnance of the dilution headbox.
Stable consistencies are basis for stable retention of
:~f!~Fu rnis hash con lent, '%
different stock components in CD. Stable 1\1D profile
is also required to get fast and accurate estimate of
::IS;:;&~'~
C~D profile with traversing measurement. Sources of
disturbances are fairly common in differe.nt machines
Paper ash, %, and a list of common sources \-vas gi ven.
~~P?'?±tY4~j Three consistency control applications for the
stabiJization of the short circulation were presented.
Headbox filler CS t ~~
o7 J====:::;:===I==~==::::::;:======;======I
Dilution water consistency control stabilizes the
consIstencies in the short circulation and allows the
operator to set desired operation point of the short
Feed-forward control ON
circulation. Break time headhox ash controUer
Fig. 12 Furnish ash feedforward control eliminates minimizes changes in the operation point during the
ash disturbances in the short circulation. \veb break even if the portion of broke is increased in
The sutn is then given to the filler flo"\v control loop furnish. The control \'-'ill also ruinimize the time
as a setpoi Ilt. Pi gurc 12 sho\vs how thick stock ash needed to recover frOITI the web break and achieve
content control improves the stability of the short paper grade specifications. Thick stock fcedfon.vard
circuLation. 'Thick stock ash content variations are ash control Vv'ill attenuate ash variations entering the
decreased and the stability of paper ash content is short circulation from the stock preparation
in1proved significantly. Overflow of the wire pit is led
to a disktilter and the output of diskfilter is taken to 7. REFERENCES
the blending chest. Feedfofward control stabilizes a~h
conslstency of white water In the wire pit? which Dumdie, D.P. (1997). i\daptive methods can achieve
stabilized the operation of the diskfiher. 'Therefore~ maxirnum process efficiency. Part 2: A systenlS
also consistency variations of thick stock are approach using pulp consistency during
decreased. blending as an example. lnTech~ April 1997, p.
32-36.
6877
Copyright 1999 IFAC ISBN: 0 08 043248 4