ACKNOWLEDGEMENT

We sincerely thank our honourable Founder and Chairman,

Dr. JEPPIAAR M.A., B.L., Ph.D.,for his endeavour in educating us in his premier
institution.

We would like to express our deep gratitude to our beloved Secretary and
Correspondent, Thiru. Dr. P. CHINNADURAI, M.A., Ph.D., for his kind wordsand
enthusiastic motivation which inspired us a lot in completing this project and we
express our sincere thanks to our dynamic directors Tmt.C.VIJAYARAJESWARI and
Mr. SAKTHIKUMAR, M.E, M. Phil, for providing us with the necessary facilities
for completion of this project.

We also express our gratitude to our principal, Dr. K. MANI, M.E, Ph.D., for his
moral support.We wish to convey our thanks and gratitude to
Dr.C.ESAKKIAPPAN,M.E.,Ph.D., Head of the Department, Electronics and
instrumentation engineering for his support and providing us ample time to complete
our project.We express our indebtedness to our internal guide,
Ms.S.SUKAMBIKA,M.E, Department of Electronics& instrumentation for his
guidance throughout the course of our project.

We express our thanks to TAMILNADU NEWSPRINT AND PAPERS

LIMITED,KARUR and their management for providing us with necessary facilities
and guiding us on completing our project .

We express our indebtedness and gratitude to Our project guide,

Mr.R.RAJALINGAM, B.Tech, MBA., Senior Manager of TNPL, Karur for his
valuable guidance throughout the course of our project.We take this opportunity to
thank our beloved parents, friends and teachers for their constant support and
encouragement.

1
 ABSTRACT
De-inking process is the one in which the ink from the office waste and

news-papers are removed in order to prevent it from dispersing into the pulp.Sodium

soap is used for removing the ink.This sodium soap is processed in a container.The

existing method has level controllers for controlling the level.But our proposed

method has “load cell” for measuring and controlling the level.In this method the

level is measured by measuring the weight of the sodium soap inside the container.

Pulp is a cellular fiber which is made from wood / Bagasse. The Paper is

being made with different kinds of Pulp. Bagasse is the main raw softwood,

Hardwood, Chemical, Mechanical and Imported Pulp are mixed with some

proportionate ratio to produce different varieties of Papers like Cream wove, Copier,

Radiant, Maplitho and etc material for making Paper in TNPL. TNPL is

commissioning a new De-Inking Pulp (DIP) for making pulp from waste / Recycle

Paper. In addition to the above Pulp, TNPL indented to go for Waste paper Pulp as

the existing Pulp Mill are not able to cater the need of Pulp demand from paper

Machine area.

2
 ABOUT TNPL

TNPL(Tamil Nadu Newsprint and Papers Limited) was established

with a capital outlay of 240 crores by the Government of Tamil Nadu
specifically to meet the nation’s increasing demand of both Newsprint and
Writing & Printing paper.

TNPL unit is situated in Pugalur, an industrially backward area in

Karur, covering over an area of 780 acres. This unit commenced it’s trial
production in September 1984 and commercial production in October
1985.Recognizing the relevance of the project to the Indian Pulp and Paper
industry and the sugarcane producing countries, the World Bank rendered a
loan assistance of US $100 million to finance the major portion of the project
cost.

This unit was designed to produce 50,000 tpa of Newsprint and 40,000
tpa of Writing & Printing paper. Conventional method of paper production
involves cutting of trees, affecting the ecosystem.

In this context, TNPL is playing a unique role by producing paper out

of Bagasse,a waste product in sugar refining mills. Bagasse is supplied by 5
sugar mills, which are situated nearby to the plant. Bagasse consumption is
nearly 4,00,000 tpa. Usage of wood (Eucalyptus hybrid wood) is very low i.e.,
nearly 70,000 tpa which constitutes only 15% of the total raw material.

3
 Eucalyptus hybrid wood is procured from Government/TAFCORN
forests.In order to meet the power requirements, TNPL has erected 5 boilers
and 4 turbine generators for its own use and also for exporting power to TNEB
(Tamil Nadu Electricity Board).

Other utility is the Effluent treatment plant. In this plant, water is

treated and sent to Pugalur channel. While the treated water is free from
irrigation hazards it is providing an additional source for irrigation, increasing
the cultivation area.TNPL’s permanent workers constitute 1441, including
engineers and workmen whereas contract workers has a count of 5000.

TNPL has setup a colony with quarters for about 500 employees along
with infrastructure facilities like school, hospital, bank, cooperative stores,
recreation club, etc., for its employees. TNPL has evoked considerable interest
among the various State Government and Industrialists.

Some State Governments are also planning to setup plants of this kind
in the sugarcane rich areas. In that sense TNPL is really a harbinger of new
technology for the country and the third world as well

4
Table of Contents
CHAPTER NO TITLE PAGE NO

ACKNOWLEDGEMENT 1
ABSTRACT 2
ABOUT TNPL 3
1 10

1. INTRODUCTION 10
1.1. INTRODUCTION TO DCS 10
1.2. DCS VS PLC 12
1.3. DCS APPLICATION 12
1.4. DCS HARDWARE OVERVIEW 13
1.4.1. BASIC CONFIGURATION OF DCS SYSTEM 13
1.4.2. FIELD CONTROL STATION (FCS) 13
1.4.3. OPERATOR STATION 13
1.4.4. ENGINEERING STATION 13
1.5. GENERAL DCS ARCHITECTURE 14
1.6. BASIC ELEMENTS OF DCS 14
1.7. SYSTEM ANALYSIS 16
1.7.1. EXISTING SYSTEM 16
2 17

2. LITERATURE SURVEY 17
3 20

3. PROJECT DETAIL 20
3.1. OBJECTIVE 20
3.2. PROCESS 20
3.3. NA – SOAP PREPARATION 21
3.4. PROCESS DIAGRAM 32
4 33

4. SYSTEM ANALYSIS 33
4.1. PROPOSED SYSTEM 33
4.2. INSTRUMENT DETAILS 35
4.2.1. LEVEL TRANSMITTER 35
4.2.2. ELECTROMAGNETIC FLOW METER 37
4.2.3. CONSISTENCY METER 39
4.3. APPLICATION 40
4.4. Advantages 41
5
5 42

5. SOFTWARE TOOLS 42
5.1. 800 XA Control Software 42
5.2. PROGRAM STRUCTURE 45
6 52

6. DE-INKING 52
6.1. Deinking chemistry 52
6.1.1. Traditional deinking chemistry 52
6.1.2. Neutral and low alkali deinking 53
6.1.3. Surfactants 53
6.1.4. Fatty acids 54
6.1.5. Synthetic surfactants 55
6.1.6. Blends 55
6.2. Other deinking aids 56
6.2.1. “Emulsions” 56
6.2.2. Modified Inorganic Particle (MIP) 56
6.2.3. Enzymes 56
6.3. Factors to consider when choosing deinking chemistry 57
6.4. Recovered paper furnish 57
6.5. Wood-free papers 58
7 59

7. CONCLUSION AND FUTURE ENHANCEMENT 59

6
Table of Figures

Figure 1.1 IMAGE OF DCS HARDWARE................................................................................................11

Figure 1.2 DCS STRUCTURE....................................................................................................................11

Figure 1.3 Basic configuration of DCS........................................................................................................13

Figure 1.4 General DCS architecture...........................................................................................................14

Figure 1.5 The elements of a commercial DCS network.............................................................................14

Figure 3.1Process diagram...........................................................................................................................33

Figure 4.1Flexmount model 0958...............................................................................................................34

Figure 4.2Construction................................................................................................................................35

Figure 4.3Level transmitter..........................................................................................................................36

Figure 4.4Electromagnetic flowmeter.........................................................................................................39

Figure 4.5Consistency meter.......................................................................................................................40

Figure 5.1Control builder-step 1.................................................................................................................45

Figure 5.2Control builder- step 2.................................................................................................................46

Figure 5.3Control builder-step 3..................................................................................................................46

Figure 5.4Control builder program logic 1..................................................................................................47

Figure 5.5Control builder program logic 2..................................................................................................47

Figure 5.6SOAP_COOKING - Program - CAP_Application.NA_SOAP..................................................48

Figure 5.7SOAP_COOKING - Program - CAP_Application.NA_SOAP..................................................49

Figure 5.8SOAP_COOKING - Program - CAP_Application.NA_SOAP..................................................50

Figure 5.9SOAP_COOKING - Program - CAP_Application.NA_SOAP..................................................51

Figure 6.1Layout of de-inking process........................................................................................................52

Figure 8.1PIDs - Program - CAP_Application.NA_SOAP.........................................................................60

7
 LIST OF ABBREVIATIONS
ABB -- ASEA BROWN BOVERI
DCS -- DISRIBUTED CONTROL SYSTEM
PID -- PROPORTIONAL INTEGRAL
DERIVATIVE
PLC -- PROGRAMMABLE LOGIC CONTROL
DP -- DIFFERENTIAL PRESSURE
FE -- FINITE ELEMENTS
RF -- RADIO FREQUENCY
AC -- ALTERNATING CURRENT
IL -- INSTRUCTION LIST
SFC -- SEQUENTIAL FUNCTION CHART
LD -- LADDER DIAGRAM
ST -- STRUCTURED TEXT
FBD -- FUNCTION BLOCK DIAGRAM
RAM -- RANDOM ACCESS MEMORY
MOW -- MIXED OFFICE WASTE
MIP -- MODIFIED INORGANIC PARTICLE

8
LIST OF TABLES

TABLE No. TITLE PAGE No.

6.1 Structure of some fatty acids in 55

de-inking acids

9
CHAPTER 1
1. INTRODUCTION

1.1. INTRODUCTION TO DCS

A distributed control system (DCS) refers to a control system usually of
a manufacturing system, process or any kind of dynamic system, in which the
controller elements are not central in location (like the brain) but are distributed
throughout the system with each component sub-system controlled by one or
more controllers. The entire system of controllers is connected by networks for
communication and monitoring. DCS is a very broad term used in a variety of
industries, to monitor and control distributed equipment. Before the beginning
of the DCS era there were pneumatic devices that controlled process and
engineers manually turned valves on the site. Modeling of the systems was
made possible by DCS as it allowed the ability to record and manages process
from comfort of a computer screen. Because of DCS we are able to control
processes remotely and gain a better understanding of how the process operate
and how they can be improved to both increase safety and increase profit
possibilities.
The input modules receive information from input instruments in the
process (or field) and transmit instructions to the output instruments in the field.
Computer buses or electrical buses connect the processor and modules through
multiplexer or demultiplexers. Buses also connect the distributed controllers
with the central controller and finally to the Human–machine interface (HMI)
or control consoles.

10
Figure 1.1 IMAGE OF DCS HARDWARE

Figure 1.2 DCS STRUCTURE

11
1.2. DCS VS PLC
DCS systems are deployed in operations where downtime due to a
malfunction may cause material and personnel losses. To prevent them it’s
possible to include redundant solutions, with in turn are increasing the investments
to the control system. Redundancy and sophisticated diagnostics are nowadays
standard built-in options for DCS and it’s not necessary for them to write a custom
program. Downtime is related with online and offline application changes. A
typical DCS runs non-stop for years.

In the case of DCS, the center for control is HMI because for the continuous
control it’s not possible to see the product (it’s located in enclosed tangs, pipelines,
…). On the other hand in PLC control used for discrete control, the operator can
see the product. Therefore, the operator must have as much information about the
process on the screens to know to monitor and control it.

1.3. DCS APPLICATION

Distributed control systems (DCSs) are dedicated systems used to
control manufacturing processes that are continuous or batch-oriented, such as
oil refining, petrochemicals, central station power generation, fertilizers,
pharmaceuticals, food and beverage manufacturing, cement production,
steelmaking, and papermaking. DCSs are connected to sensors and actuators
and use setpoint control to control the flow of material through the plant.
The most common example is a setpoint control loop consisting of a
pressure sensor, controller, and control valve. Pressure or flow measurements
are transmitted to the controller, usually through the aid of a signal conditioning
input/output (I/O) device. Large oil refineries have many thousands of I/O
points and employ very large DCSs.

12
1.4. DCS HARDWARE OVERVIEW

1.4.1. BASIC CONFIGURATION OF DCS SYSTEM

Figure 1.3 Basic configuration of DCS

1.4.2. FIELD CONTROL STATION (FCS)

It consists of input/output modules, CPU and Communication bus.

1.4.3. OPERATOR STATION

It is basically human interface machine with monitor, the operator
man can view the process in the plant and check if any alarm is presents and
he can change any setting, print reports..etc.

1.4.4. ENGINEERING STATION

It is used to configure all input & output and drawing and anything
required to be monitored on Operator station monitor.

13
1.5. GENERAL DCS ARCHITECTURE

Figure 1.4 General DCS architecture

1.6. BASIC ELEMENTS OF DCS

Figure 1.5 The elements of a commercial DCS network

14
 Local Control Unit (LCU). This is denoted as local computer in Figure 3.
This unit can handle 8 to 16 individual PID loops, with 16 to 32 analog input
lines, 8 to 16 analog output signals and some a limited number of digital inputs
and outputs.

 Data Acquisition Unit. This unit may contain 2 to 16 times as many analog
input/output channels as the LCU. Digital (discrete) and analog I/O can be
handled. Typically, no control functions are available.

 Batch Sequencing Unit. Typically, this unit contains a number of external

events, timing counters, arbitrary function generators, and internal logic.

 Local Display. This device usually provides analog display stations, analog
trend recorder, and sometime video display for readout.

 Bulk Memory Unit. This unit is used to store and recall process data. Usually
mass storage disks or magnetic tape are used.

 General Purpose Computer. This unit is programmed by a customer or third

party to perform sophisticated functions such as optimization, advance control,
expert system, etc.

 Central Operator Display. This unit typically will contain one or more
consoles for operator communication with the system, and multiple video color
graphics display units.

 Data Highway. A serial digital data transmission link connecting all other
components in the system may consist of coaxial cable. Most commercial DCS
allow for redundant data highway to reduce the risk of data loss.

15
 Local area Network (LAN). Many manufacturers supply a port device to
allow connection to remote devices through a standard local area network

1.7. SYSTEM ANALYSIS

1.7.1. EXISTING SYSTEM

 The existing system has level transmitters inside this container.
 Level transmitters are very sensitive to corrosion and will get
damaged easier.
 The outputs from level transmitters are inaccurate.

DISADVANTAGE
 Change in density affects the measurement and hence less accurate
 Prone to abrasion and corrosion
 Coating of sodium soap damages the sensor
 Needs periodic maintanance

16
CHAPTER 2

2. LITERATURE SURVEY

Jacob L. Johansen has proposed about quantifying Water Flow within Aquatic
Ecosystems Using Load Cell Sensors. Current velocity in aquatic environments has
major implications for the diversity, abundance and ecology of aquatic organisms, but
quantifying these currents has proven difficult. This study utilises a simple and
inexpensive instrument to provide a detailed current velocity profile of the coral-reef
system. The instrument uses load-cell sensors to provide a correlation between sensor
output and ambient current velocity of 99%. Each instrument is able to continuously
record current velocities to >500 cms−1 and wave frequency to >100 Hz over several
weeks.

I. Muller , R. M. de Brito and R. J. Bender used load cells in force sensing analysis.
Load cells have long been used to sense and measure force and torque. When properly
designed and used, they are very accurate and reliable sensors. Load cells are applied in
several different fields, usually for weighing measurements. Among many other things,
food, vehicles, and animals are weighed daily with load cells. The gripper of a robotic
arm that picks up an object can be equipped with load cells in order to provide
compression force feedback to the control system to prevent the object from being
damaged or released too early. Also, load cells can be used to sense the compression
forces during a robot's walk to provide data for the equilibrium-controlling system. In
industrial machinery, rods, beams, wheels and bars are instrumented in order to check
the forces exerted on them. The volume or level of a tank can be measured indirectly by
means of a load cell that monitors the total weight. Lift units can also have a load's total
weight measured to prevent overload. Because of such a variety of possible
applications, load cells are very important.

17
Professor P. Babu , Department of Electronics and Communication Engineering, K. S.
Rangasamy College of Technology presented a paper about automatic bridge control
system. Bridge vibration control is an important issue whose purpose is to extend the
structural service life of bridges. Normally, the bridge is modeled as an elastic beam or
plate subject to a moving vehicle. However, the moving truck on a bridge is a
complicated problem that must still be researched. In this paper, we propose a new
method, to overcome the huge load in the bridge a load cell is used at the entry which
will monitor the load continuously at both ends. To escape from the heavy water flow
bridge vibrations alarm is used and it is connected with the water over flow sensor
which will convert the heavy water flow signal into electrical signal and this electrical
signal will make an alarm and close the gate of the bridge. When both the problem
occurs at same time or at different time an alarm is generated and the bridges will
automatically closed.In this work, we proposed two approaches. The first approach is
used to indicate heavy weight on the bridge through the load cell. The second approach
is used to indicate the water flow over the bridge through the float sensor. By using our
concepts we can use the older bridges efficiently and safely too. There is no need for
constructing the new bridges when the old bridges already existing.

J.G. Rocha, C. Couto, J.H. Correia had presented a paper about smart load

cells. This paper presents a data acquisition solution using a RISC type

microcontroller with very few components around, taking advantage of the

ratiometric functioning of the load cells. The need of thermally stable circuits is

minimized through the use of the same amplification chain for both signal and

reference. The amplification and filtering are done trough switched-capacitor

techniques controlled by the microcontroller. This option allows the choice of the
18
proper scale according to the platform and permits the auto calibration of the system.

The weighing tests show errors below 100 g in 400 kg for an industrial platform of

eight smart load cells. The paper also describes an example of software calibration

of a multi load cell weigh-bridge using one processor per smart load cell.

Tan.Y.M, Sch. of Electrical & Electronics Engineering, University of

Manchester, United Kingdom .Yin. W.Peyton, A.J published about Non-
contact measurement of water surface level from phase values of inductive
measurements. Measurement of water surface level is important in many
applications, including geophysics, ocean engineering, and various industrial
processes. This paper describes a method for level measurement from phase
values of inductive measurements. A modular inductive measurement system is
developed based on a NI-PXI instrument. A linear array of inductive sensors is
designed to investigate the sensitive range for different coil pair combinations.
It is found that the phase values of inductive measurements are related to water
surface level and the effects of conductivity can be eliminated. Finite Elements
(FE) simulations and experimental results have confirmed the system
performance and the validity of the proposed method.

19
CHAPTER 3

3. PROJECT DETAIL
TITLE: Measurement and control of level using load cell in a De-Inking
process

1.8. OBJECTIVE
 The main objective of this project is to improve the quality of level
measurement.
 Level measurement using level transmitter has many disadvantages
like less accuracy , corrosion .
 This drawback has been overcome by using load cell for measuring
the weight which in turn can be used to control the level.
1.9. PROCESS
 De-inking is a process of removing the ink from the pulp obtained
from the waste and newspapers.
 For this de-inking process, sodium soap is used for removing the ink.
 This sodium soap is processed in a container. Processing involves
mixing sodium powder with water and then heating
 A variety of deinking aids exist. In traditional alkaline deinking these
aids are often composed of fatty acids and/or non-ionic surfactants.

20
1.10. NA – SOAP PREPARATION
Main sequence (product)

Operator checking

 The operator must check

 The Hopper contains product ( over the low level) The cooker is
empty
 The valve is closed
 The manual valve between mixer and storage tank is opened .
Command

 The recipe is started by the push button « start ».

Initial interlock

 No cleaning sequence in run

 The valve is closed
 The call recipe is on
Process

 The recipe starts

 The valve opens
 The counters are reset
 The tare is made
 The water dosing starts.
 When the water dosing sequence is finished, the heating sequence
starts and the stirring starts.
 When the heating is finished ,the adjusting water sequence starts
 When the adjusting sequence is finished
 The valve closes during powder dosing
21
  The powder dosing sequence starts
 When the powder dosing sequence is finished the homogenisation
sequence starts.
 During homogenisation sequence if the stirring stops the sequence
and timer are hold.
 When the homogenisation sequence is finished, the discharge
sequence is started.
 When the level product is under the stirring level set point the
stirring stops.
 When the discharge sequence is finished, the main sequence is
finished
 . The stirring starts if the product level is over the stirring level set-
point.
Filling Hopper

Operator checking

 The operator must check

 The quantity of product in the hopper.
Command

 Local box
 Selector switch (0 1) to start Blower
 Lamp “Low level “ request filling
Initial interlock

 No

Process

22
  If the product level is under the low level
 The local lamp is on (control box). The operator must fill the hopper.
 The operator fills the hopper.
 The operator switches on the selector
 Motor blower starts
 At the end of filling the operator switches on
 Motor blower stops
 Vibrating sleeves starts during (30s) (Timer in dedusting plate)

TARE control

Operator checking

 No control
Command

 The sequence is started from the main sequences (preparation or

cleaning)
Initial interlock

 The valve is closed

Process

 The sequence starts

 The tare is launched
 If the weigh is over the set point tare (recipe set-point)
 The defect tare is on else the recipe goes to the next step
Water dosing

Operator checking
23
  The operator must check The manual valve is opened
Command

 The sequence is started from the main sequence (preparation)

Initial interlock

 The valve is closed

Process

 The sequence starts

 The tare is made. (load weigh in memo)
 When the tare is finished timer (2s)] the dosing starts.
 The valves open.
 Memo “request water for soap” is on
 The weigh is increasing.
 If the weigh does not increase the « evolution alarms »is on.
 Quantity= actual weigh – tare = Q
 When (Q + Dosing finition water) is over set-point value, the valve
closes
 When (Q + overshoot) is over set-point value
 The valve closes.
 Memo “request water for soap” is off A stability timer (10s) starts.
 At the end of the timer, the quantity is checked.
 If |Q-set point| is under the tolerance parameter the sequence is finished or if
it is not, the alarm « tolerance » is on and the sequence is stopped.

HEATING

24
Operator checking

 The operator must check

 The manual valve is closed
 The pressure steam is over 3 bars
Command

 The sequence is started from the main sequence(preparation)

Initial interlock

 The level product in the cooker is over the heating level Heat
 Mixer motor is running
Process

 The sequence starts

 The valve opens
 The fan starts
FIRST :

 The actual weigh is put in memory, Measure temperature is loaded

in new set-point)
 The valves open and the fan is started. The temperature is
increasing.
 Each minute, intermediate set point is compute (new set-point = old
set-point + Ramp) When temperature is over new set-point
 The valves close
 During the heating the water quantity added is displayed
 Weigh – tare= water quantity added
 If the temperature does not increase the « evolution alarms »is on.
 When the temperature measure is equal or over the final set-poin
25
  The valves close.
 The sequence is finished
Water adjust

Operator checking

 The operator must check The manual valve is opened

Command

 The sequence is started from the main sequence (preparation)

Initial interlock

 No
Process

 The sequence starts

 The tare is made.
 (Load weigh in memory) When the tare is finished timer (2s)] the
dosing starts.
 The valve opens. Memo “request water for soap” is on
 The weigh is increasing.
 If the weigh does not increase the « evolution alarms »is on.
 Quantity= (actual weigh – tare)+ water quantity added during
heating = Q
 When (Q + overshoot) is over set-point value,
 The valve closes.
 Memo “request water for soap” is off A stability timer (10s) starts.
 At the end of the timer, the quantity is checked.

26
  If |Q-set point| is under the tolerance parameter the sequence is
finished or if it is not, the alarm « tolerance » is on and the sequence
is stopped.
 Else the sequence is declared finished
Powder dosing

Operator checking

 The operator must check the hopper contains product.

Command

 The sequence is started from the main sequence (preparation)

Initial interlock

 The product is over the low level hopper Process

 The sequence starts
 The tare is made. (load weigh in memory)
 When the tare is finished, the dosing starts.
 The valve opens and the screw starts.
 If the vibrating hopper is selected the vibrator starts.
 Quantity = actual weigh – tare = Q
 When (Q+ Param Dosing finition) is over the set-point the screw
turns
 The weigh is increasing.
 If the weigh does not increase the « evolution alarms »is on.
 When (Q + overshoot) is over set-point value
 The screw stops
 The valve closes the vibrator stops.
 A stability timer (10s) starts.

27
  At the end of the timer, the quantity is checked.
 If |Q-set point| is under the tolerance parameter the sequence is
finished or if it is not, the alarm « tolerance » is on and the sequence
is stopped.
 Vibrating hopper During dosing if “VIBRATING” command is on
 The motor works in Flip Flop :
 Timer ON Vibrating : Motor works
 Timer OFF Vibrating : Motor is stopped
Homogenization

Operator checking

 The operator must check No control

Command

 The sequence is started from the main sequences (preparation or

cleaning)
Initial interlock

 No
Process

 The sequence starts

 The stirring is on
 If the stirring is running the timer decreases..
 If the stirring is not running the timer is hold
 When the timer is finished
 The main recipe goes to the next step.
Discharge to tank

Operator checking
28
  The operator must check
 The product level is under the set-point call level in the tank
 The manual valve is closed.
 The manual valve is opened (Storage tank)
Command

 The sequence is started automatically from the main sequence

Initial interlock

 The product level is under the set-point call level in the tank
Process

 The sequence starts

 The valves open.
 The weigh is decreasing.
 If the weigh does not decrease the «decreasing alarms » is on.
 When the actual level is under the stirring level
 The motor stirring stops.
 When the low level is reached the draining timer starts.
 At the end of the timer
 The valve closes.
 The sequence is finished.

Main sequence (cleaning)

Operator checking

 The operator must check

29
  The cooker is empty.
 The manual valve between mixer and storage tank is closed
 The manual valve to drain is opened
Command

 The operator has selected the mode “cleaning”

 The recipe is started by the push button « start, stop » located on the
recipe display.
Initial interlock

 The valve is closed

Process

 The sequence starts

 The counters are reset
 The tare is made
 The water dosing sequence starts.
 When the water dosing sequence is finished.
 The stirring starts
 The homogenization sequence starts.
 During homogenization sequence if the stirring stops the sequence
and timer are hold.
 When the homogenisation sequence is finished, the discharge
sequence is started.
 When the level product is under the stirring level set point the
stirring stops.
 When the discharge sequence is finished, the main sequence is
declared finished. The stirring starts if the product level is over the
stirring level set-point.
Stirring Tank
30
Operator checking

 No
Command

 The stirring is started from the screen command

Initial interlock

 Stirring level

Process

 The stirring starts is the product is over the stirring level. Stirring
level
Recirculation pumps

Operator checking

 The operator must check Inlet and outlet valves of pump selected
are opened
 The cleaning water valve is closed
Command

 The selection of the pump is also made by the screen command

when the status recirculation is off .
 The pump selected is started from the screen commands “On” “Off”.
Initial interlock

 One of the two pumps is not in mode cleaning.

Process Instance1:

 The pipe is empty

 The sequence starts
31
  The valve opens
 The pump selected starts A time delay after
 The pipe is declared line full of product .
 The valve closes
 The valve opens (100%) Time delay after
 The valve opens (pressure regulation)
Instance2:

 The pipe is line full of product

 The sequence starts.
 The valve opens (100%)
 The pump selected starts Time delay after
 PID starts

Process

 The sequence starts

 The stirring is on
 If the stirring is running the timer decreases..
 If the stirring is not running the timer is hold
 When the timer is finished
 The main recipe goes to the next step.

1.11. PROCESS DIAGRAM

32
 Figure 3.6Process diagram

CHAPTER 4

4. SYSTEM ANALYSIS

1.12. PROPOSED SYSTEM

 Instead of level transmitter ,our proposed system has load cell for
controlling the level by measuring the wait of the container.
33
 Load cell eliminates the measurement error due to corrosion and
provides accurate output.
 From the load cell, the output is given to the controller for
controlling the level.

PROPOSED SYSTEM
Flexmount
MODEL 0958

Figure 4.7Flexmount model 0958

34
 Figure 4.8Construction

1.13. INSTRUMENT DETAILS

1.13.1. LEVEL TRANSMITTER

The level in the tank affects not only the quantity delivered but also the
pressure and rate of flow in and out of the container.
The substance to be measured can be inside a container or can be in its
natural form. The level measurement can be either continuous or point values.
Continuous level sensors measure the level to determine the exact amount of
substance in a continuous manner. Point-level sensors indicate whether the
substance is above or below the sensing point. This is essential to avoid
overflow or emptying of tanks and to protect pumps from dry run.
Level transmitter is used to measure the level of the tank, and convert
into 4-20mA signal that is accepted by the PLC. The level transmitter is

35
mounted in the bottom of tank as shown in the figure. The level in the tank is
calculated by finding the differential pressure in the tank
P=P1-P2
P1=Total Pressure in the tank ,P2=Atmospheric Pressure
By knowing the density of the liquid, level (height) of the tank is found
out
H=P/g
where, H - height of the liquid level in the tank.
p – Differential pressure and  - Density of the liquid.
The most commonly used level transmitter in industries is the
differential pressure (DP) based capacitive type. Capacitive level transducer is
an example of indirect measurement of level. They are used for wide variety of
solids, aqueous and organic liquids, and slurries.

Figure 4.9Level transmitter

The principle of differential pressure (DP) based capacitive level

measurement is based on change of capacitance present in the diaphragm of DP

36
sensor. The capacitance depends on the fluid level. An empty tank has a lower
capacitance which is the atmosphere pressure is 1bar.
The higher capacitance is calculated by adding the atmosphere pressure
with the height of tank is then multiplied with density of liquid present in tank.
The dielectric medium present in the differential pressure sensor is
silicon oil. The value of C depends on dielectric used, area of the plate and also
distance between the plates.

where,
C = capacitance in picofarads (pF)
= a constant known as the absolute permittivity of free space
K = relative dielectric constant of the insulating material
A = effective area of the conductors
d = distance between the conductors
This change in capacitance can be measured using AC Bridge.
The measurement is made by applying an RF signal between the conductive
probe and the vessel wall. The RF signal results in a very low current flow
through the dielectric process material in the tank from the probe to the vessel
wall. When the level in the tank drops. The dielectric constant drops causing a
drop in the capacitance reading and a minute drop in current flow. This change
is detected by the level switch's internal circuitry and translated into a change in
the relay state of the level switch in case of point level detection. In the case of
continuous level detectors, the output is not a relay state, but a scaled analog
signal.

1.13.2. ELECTROMAGNETIC FLOW METER

A magnetic flow meter is a volumetric flow meter which does not have
any moving parts and is ideal for wastewater applications or any dirty liquid
37
 which is conductive or water based. Magnetic flow meters will generally not
work with hydrocarbons, distilled water and many non-aqueous solutions).
Magnetic flow meters are also ideal for applications where low pressure drop
and low maintenance are required.
PRINCIPLE OF OPERATION

The operation of a magnetic flowmeter or mag meter is based upon

Faraday's Law, which states that the voltage induced across any conductor as it
moves at right angles through a magnetic field is proportional to the velocity of
that conductor.
Faraday's Formula:

E is proportional to V x B x D.
WORKING

To apply this principle to flow measurement with a magnetic

flowmeter, it is necessary first to state that the fluid being measured must be
electrically conductive for the Faraday principle to apply. As applied to the
design of magnetic flowmeters, Faraday's Law indicates that signal voltage (E)
is dependent on the average liquid velocity (V) the magnetic field strength (B)
and the length of the conductor (D) (which in this instance is the distance
between the electrodes).In the case of wafer-style magnetic flowmeters, a
magnetic fieldis established throughout the entire cross-section of the flow tube.
If this magnetic field is considered as the measuring element of the magnetic
flowmeter, it can be seen that the measuring element is exposed to the hydraulic
conditions throughout the entire cross-section of the flowmeter. With insertion-
style flowmeters, the magnetic field radiates outward from the inserted
probe .When a conductive liquid flows through the magnetic field, a small
voltage (u) is induced.

38
 This voltage is proportional to the velocity of the flow and is accurately
measured by two stainless steel electrodes mounted opposite each other inside
the metering pipe. The two electrodes are connected to an advanced electronic
input circuitry which processes the signal and in turn feeds it to the
microprocessor inside the electronics module. The microprocessor then
calculates the volumetric flow and controls the various outputs on the terminal
board.

Figure 4.10Electromagnetic flowmeter

1.13.3. CONSISTENCY METER

Operating principle

The blade type consistency transmitter operates by measuring the shear

force of the pulp as it passes the sensor. Its patented seal-less transfer
mechanism makes the virtually unbreakable one. The sensor blade (located in
the process stream) measures the sum of shearing forces created by pulp
network shearing on the blade and dragging along the sides of the blade. The
friction between the fiber network and the blade surface is converted into a
output signalthat varies as the consistency varies. These forces tilt the blade and
move the diaphragm the blade is attached to on the transmitter body. The
39
diaphragm actually acts as a spring and transfers the blade movement to the
measuring arm. The displacement of the arm is measured by an electronic
displacement sensor (eddy probe) which converts the distance in the gap
between the arm and the sensor itself. The shear force value is transformed into
gap measurement, which is converted to a consistency value by calibration
based on laboratory verification.
An analog 4 - 20 mA output signal is based on consistency signal .The
process flow and the transmitter electronics are completely isolated from each
other by the titanium metal diaphragm without the use of seals. A change in
consistency affects shear force, which varies the deflection of the diaphragm
thereby altering the displacement of measuring arm. This change in the arm
position is sensed by the eddy probe and via the electronics is transformed to
current signal (4 -20 mA) which is proportional to consistency.

Figure 4.11Consistency meter

The transmitter is loop-powered (2-wire 4 - 20 mA). Correct calibration

for selected grade and proper sampling ensures the accuracy of the Consistency
measurement. The transmitter comes with seven pre-calibrated consistency
curves that fit most applications in the mill plus one user defined grade for
those special applications.

40
1.14. APPLICATION

Performance
 Unique System combining three module types provides:
 Top Plate Travel up to ± 4.6mm* for expansion/contraction
 Live checking
 OIML & NTEP approvals as standard
Installation
 Aligned in Shipping/Installation Mode
 Easy transition to weighing mode
 Self-jacking* & minimal lift for easy load cell Removal
Safety & Protection
 Anti-Lift screw to prevent tipping
 Self checking in horizontal plane
 IP68 welded stainless load cell
 Hazloc approvals as standard
1.15. Advantages
 Using non contact type load cell makes it free from abrasion
 Corrosion resistant
 Accurate in measurements
 Coating of sodium soap over the sensor is eliminated
 Density changes does not affect the measurements
 Long lasting and requires no maintenance after installation

41
CHAPTER 5

5. SOFTWARE TOOLS

1.16. 800 XA Control Software

AC 800M Engineering

AC 800M control applications can be created in any of the five IEC

61131-3 dialects by using Engineering workstation, and then be downloaded to
controllers using the Control Builder. Control applications can be distributed
and executed on several controllers and communicate with each other on
Control Network using named variable communication. Parts of the application
can be downloaded to different controllers .The functionality range for control
applications is wide, from binary control to closed loop control, with advanced
functions like auto tuning PIDs, fuzzy control, etc. Pre-defined process objects
like motor objects,valve objects, etc. are available. It is possible to build user-
defined function blocks, and also to hide its content in order to protect the
intellectual property. User-defined serial protocols can be developed in
structured text with the support of special functions needed, e.g. for checksum
calculation.Control Modules extend the IEC 61131-3 language to an object-
oriented configuration method. The Control Module concept raises the
abstraction level of engineering by hiding details in pre-defined control blocks.
This enables reuse to a higher degree, making repetitive engineering very
efficient.

42
The programming languages

Function Block Diagram

Function Block is a graphical language for depicting signal and data

flows by means of library-stored software elements and interconnecting signals.
Function block programs are easy to develop and, thanks to the resulting
graphical diagrams, also easy to read.
Structured Text

Structured text (ST) is a high-level programming language. It has a

comprehensive range of constructs for assignments, function calls, expressions,
conditional statements, iterations, etc. ST lends itself well to writing advanced,
compact - yet easily understandable - programs thanks to its logical and
structured layout.
Ladder Diagram

Ladder diagram (LD) is a graphical language based on relay ladder

logic. Hence it is suitable for those who prefer to define interlocks and control
actions in terms of relay contacts and coils, and other functions as "black
boxes".
Sequential Function Chart

Sequential function chart (SFC) is a graphical language for depicting

the sequential behavior of a control system. It is used for defining time- and
event-driven control sequences. A sequence is shown in flow-chart form, using
steps, transitions and selection nodes. The language is amply suited to the
handling of control tasks which are sequential in nature, i.e. consisting of a
number of distinct steps, each requiring a number of enabling inputs where the
completion of the previous step usually is one of them.
Instruction List
43
 Instruction list (IL) is a low-level, execution-efficient PLC language
where each statement corresponds to a single or only a few processor
instructions. It has a structure similar to Assembler.
Program Changes

Configuration and Downloading

Applications can either be loaded into the target controller(s) by non-

volatile Flash memory cards or over a serial link or Ethernet network into
battery backed-up RAM. The former approach is suitable for smaller and more
standardized duties where users can be spared involvement in the application
software development and handling process. The latter is intended for larger
and more unique applications where debugging and improvements can be
expected to become recurring engineering tasks.

44
1.17. PROGRAM STRUCTURE

Figure 5.12Control builder-step 1

45
Figure 5.13Control builder- step 2

Figure 5.14Control builder-step 3

46
Figure 5.15Control builder program logic 1

Figure 5.16Control builder program logic 2

47
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Figure 5.17SOAP_COOKING - Program - CAP_Application.NA_SOAP

48
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Figure 5.18SOAP_COOKING - Program - CAP_Application.NA_SOAP

49
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50
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Figure 5.20SOAP_COOKING - Program - CAP_Application.NA_SOAP

51
CHAPTER 6

6. DE-INKING

1.18. Deinking chemistry

1.18.1. Traditional deinking chemistry

Deinking chemicals are generally added to the pulper (Lassus 2000).
During pulping the recovered paper is slushed into a pulp at high consistency.
The combination of chemical and mechanical action is favourable.
Additionally, by dosing early in the process to the pulper the reaction time is
increased as well as the more effective dosage of some chemicals as the result
of a high consistency. Figure shows a schematic layout of a typical deinking
process for the production of pulp for graphical grade paper. Often all deinking
chemicals are added to the pulper, but sometimes some or all of the deinking
aid can also be added to the flotation cell.Schematic layout of a deinking
process for the production of deinked pulp for graphical grades showing
possible addition places for deinking and bleaching chemicals.

Figure 6.21Layout of de-inking process

52
 A variety of deinking aids exist. In traditional alkaline deinking these
aids are often composed of fatty acids and/or non-ionic surfactants. Sodium
hydroxide (NaOH) is also added for reasons such as ink detachment and ink
dispersion. It is commonly believed that ink detachment is improved using
sodium hydroxide both because of fibre swelling effects as well as chemical
hydrolysis of some bonds between the substrate and some ink species. The pH
at the exit of the pulper is often between 8.5-10.5 when deinking a
newspaper/magazine furnish.

1.18.2. Neutral and low alkali deinking

A new trend for certain processes and mills in the deinking of
newspaper and magazine based raw materials is to move away from traditional
alkaline deinking and towards lower pH levels which are commonly referred to
as “true neutral” deinking (pH about 6.8-7.2) and “reduced or low alkali”
deinking (pH about 7.2-8.8). Often these desires are driven by chemical cost
savings and/or environmental factors. In true neutral deinking only surfactant,
usually a blend of different synthetic surfactants, is added to the pulper.

1.18.3. Surfactants
Surfactants are surface active agents. This chemically unique species
have a dual character. This character consists of hydrophilic and hydrophobic
portions of the chemical structure. In an aqueous environment, the hydrophilic
portion is water loving and relatively polar while the hydrophobic part of the
surfactant is water hating and relatively non-polar (Figure 2). Surfactants can be
non-ionic, anionic, or cationic. For the anionic and cationic species the
hydrophobic part normally includes a hydrocarbon chain (-CH2-CH2-) and the
hydrophilic part includes a variety of chemical functionalities. These can
include entities such as an amine group (-NH3), a carboxyl (-COOH),
53
sulphonate (-SO3), or sulphate (-SO4) group among others. Non-ionic synthetic
surfactants generally contain blocks or units of various alkoxylates, most
commonly derived from either ethylene or propylene oxides.

1.18.4. Fatty acids

Fatty acids have been used to produce fatty acid salts (soaps) for
centuries. These soaps have been used to remove dirt from different surfaces.
Fatty acids consist of a long hydrocarbon chain (-CH2-CH2-) with a carboxyl
group, typically at the terminus of the molecule. The hydrocarbon chain can be
saturated or unsaturated (containing double bonds) depending on the origin of
the fatty acid. Saturated fatty acids, such as stearic acid (18 carbons) or palmitic
acid (16 carbons) are solid at room temperature while unsaturated fatty acids,
like linoleic acid (18 carbons with two double bonds at the 9 and 12 positions)
can be liquid . Fatty acid products are normally mixtures of several fatty acids
with different structures.

Table 6.1 Structure of some fatty acids in de-inking acids

FATTY STRUCTURE SHORT MELTING
ACID NAME POINT
Palmitic acid 3 (CH2)14CO2H C16:0 63ºC
Stearic acid CH3(CH2)16CO2H C18:0 69 ºC
Palmitoleic CH3(CH2)5CH=CH(CH2)7CO2H C16:1 0 ºC
acid
Oleic acid CH3(CH2)7CH=CH(CH2)7CO2H C18:1 13 ºC
Linoleic acid CH3(CH2)4CH=CHCH2CH=CH C18:2 -5 ºC
Linolenic (CH2)7CO2H C18:3 -11 ºC
acid

54
 Fatty acid soaps are often formed by pre-neutralisation of the fatty acid
in the presence of alkalinity prior to introduction into the repulping system. It is
important to also evaluate the entire pulping and papermaking process to ensure
that no unfavourable metal soaps, such as calcium fatty acid soap, are
contributing to deposit problems. Fatty acid dosages to the pulper normally
range between 3-7 kg/t or 2-4 kg/t to the flotation cell. In processes where high
amounts of newspaper are used, like in the US, mills tend to use more synthetic
surfactants or blends rather than pure fatty acids.

1.18.5. Synthetic surfactants

Normally non-ionic synthetic surfactants are used directly or often can
be part of a multi-component deinking aids or blend. The most common
synthetic surfactants in deinking are ethoxylated (EO) and/or propoxylated (PO)
fatty acids or fatty alcohols. These are non-ionic surfactants. Figure 4 shows the
structure of some alkoxylated surfactants. The number and distribution (block
or random) of EO and PO units determines the properties of the surfactant.

1.18.6. Blends
As mentioned above, there is not one universal surfactant that would
perform optimally in all processes and under all conditions. Each process step
requires differentphysico-chemical conditions. In the pulper, ink detachment
and ink dispersion is crucial. In flotation again ink hydrophobisation,
aggregation and collection is important as well as good foam properties.
Deinking chemicals should optimally contain chemicals for each of these
micro-processes. Fatty acid-synthetic surfactant blends can combine the best
properties of both systems into one chemical blend. The dosage of blends
depends naturally on their chemical composition but is normally somewhere
between 1-3 kg/t. Alternatively, the dosage can also be split with one blend

55
 optimised for the pulper and another for the flotation cell. Liquid blends are
most common.

1.19. Other deinking aids

1.19.1. “Emulsions”
Due to the difficulty in handling some fatty acids which can be
solids/semi-solid at common atmospheric temperatures of interest formation of
liquid emulsions and/or dispersions are often made. In many cases the fatty acid
is saponified and in all cases the products contain at least one
emulsifying/dispersing agent. These agents are commonly non-ionic
surfactants. Fatty acid levels in these products can range from 10-50 wt%.
Emulsions/dispersions may be used in smaller deinking mills that do not have a
saponification unit.

1.19.2. Modified Inorganic Particle (MIP)

In order to improve the collection in flotation deinking systems a new
technology has been developed (Rosencranceet al. 2007). This is based on
introducing a hydrophobically modified inorganic particle (MIP) to the pulper.
The particle will collect hydrophobic substances like ink and not only improve
flotation deinking selectivity but also significantly reduce ink re-deposition.
This technology is new andhas shown very promising results in mill scale trials
where very low attached ink values have been observed.

1.19.3. Enzymes
In some mills an enzyme containing additive is introduced. The concept
is based on the possibility that some enzymes can efficiently facilitate
favourable chemical reactions. For instance, these species can assist in ink
detachment from fibre surfaces. Some propose that cellulases and
hemicellulases can alter the fibre surface and thus contribute to release of ink.

56
 Lipases are proposed to attack fatty acids and resinous substances from wood
and any fatty acid or oil related carriers in the ink while laccase is offered to
assist in modifying the lignin on the fibres.

1.20. Factors to consider when choosing deinking chemistry

As discussed above, selection of the appropriate deinking aid is based
on a multitude of factors. Below are some factors worth considering for the
production of deinked pulp destined for the manufacturing of graphically
printed paper or tissue. Recycling of board normally does not involve deinking.

1.21. Recovered paper furnish

The base paper quality and the printing method are well known to be
directly related to deinkability. Two of the most common printing methods are
offset and rotogravure printing. Utilisation of water-based flexographic printing
is getting more common in some geographic regions. These are conventional or
mechanical printing methods.
Different recovered paper furnishes demonstrate different issues. For
instance, offset inks are known to become more difficult to deink with the
combination of time and/or temperature or “age”. Alternatively, if the furnish
contains high levels of flexographically (water-soluble ink) or ink-jet (small
colour pigments) printed papers increased amounts of process washing and/or
lower pH is often beneficial.
As reproduced from previous work by Eklund and Lindström, shows
the composition of the base paper, coating and printing method used for
different paper grades as well as the most common deinking method and the use
as end product. The values in the table are generalisations and exceptions can
exist. Magazine paper is today also produced with increasing amounts of
deinked pulp which is not indicated in the table which originated in 1991.The

57
 base paper can be either uncoated, supercalandered (SC, smoothened under
high pressure) or coated.

1.22. Wood-free papers

Chemical pulp based paper, such as office waste paper, does not
demonstrate the alkaline yellowing and is normally not so much affected by
pulping pH. The main reason is that chemical pulp fibres are not sensitive to
alkali-induced yellowing.
Chemical pulp fibres have already been treated with alkali in the
pulping process which is why these fibres will not swell to the same extent any
more as mechanical pulp fibres, i.e. ink will not be released more through fibre
swelling which is why neutral deinking conditions are more favourable for
office waste paper deinking.
Reductive bleaching is furthermore normally more beneficial for office
waste paper compared to peroxide bleaching as the fibre brightness is high
(chemical pulp) but colour removal is necessary.
Laser printed papers or photocopied papers are, however, difficult to
deink as the toner has been melted, fused and bonded to the fibre surface. The
toner is generally detached as large flat flakes which are too large to be
removed by flotation or washing.
The flakes become visible dirt specks in the paper if not removed or
destroyed. The flakes are in fact usually destroyed in disperger or kneader units
in the process. It is difficult to improve the deinkiability of office paper by
chemical means. Sometimes enzymes are applied.

58
CHAPTER 7

7. CONCLUSION AND FUTURE ENHANCEMENT

The demand for recycled fibre is globally increasing by more than 4%

annually compared to around 2% for virgin fibres. This means that more paper
needs to be recovered and recycled. As most countries in Europe already collect
up to 63% (in 2006) of all consumed paper, this means that the raw material
quality will decrease in these regions as also lower quality paper has to be
recycled. At the same time higher quality of the final deinked pulp is demanded.
A higher proportion of deinked fibre will also be used in especially magazine
grade papers. Newsprint is already produced with 100% deinked pulp.
Another trend is the lower use of fresh water or higher closure of water circuits
in the mills which will also affect the deinking process (higher temperatures,
more dissolved and colloidal substances in the process waters, etc.). All these
trends signify that more deinking, bleaching and other recycling process
chemicals are required to reach the same quality target. This will as a result
require more work in order to find new chemicals and concepts that will help
recycling mills to save raw material, chemical or energy costs.

59
 APPENDIX
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Figure 8.22PIDs - Program - CAP_Application.NA_SOAP

60
MOTOR

Figure8.2Motors-Program- CAP Application Na-Soap

61
REFERENCE

1. Jacob L. Johansen, ARC Centre of Excellence for Coral Reef Studies, and School of
Marine and Tropical Biology, James Cook University, Townsville, Queensland,
Australia.

2. Muller , R. M. de Brito and R. J. Bender "Instrumented Sphere for Compression

Analysis", Proc. IEEE IIMTC 2008.

3. M. Niraimathi[1], S.Sivakumar [2], R.Vigneshwaran [3], R.Vinothkumar [4], P.Babu[5] . 1,2,3,4

U G Students, Department of ECE, K. S. Rangasamy College of Technology,
Tiruchengode, Tamilnadu, India. 5Associate Professor, Department of ECE, K. S.
Rangasamy College of Technology, Tiruchengode, Tamilnadu, India. Published in
"International Journal of Electronics and Computer Science Engineering".

4. J.G. Rocha, C. Couto, J.H. Correia. Department of Industrial Electronics, UniÍersity of

Minho, Campus de Azurem, 4800 Guimaraes, Portugal Received 14 September 1999;
received in revised form 8 February 2000; accepted 9 February 2000

5. Tan, Y.M. Sch. of Electr. & Electron. Eng., Univ. of Manchester, Manchester, UK .Yin,
W. ; Peyton, A.J. Published in "Instrumentation and Measurement Technology
Conference (I2MTC), 2012 IEEE International". Date of Conference13-16 May 2012

62