ANDRITZ AUTOMATION

RECAUST AREA DIGITAL TWIN

PRODUCT OVERVIEW

18-05-2021
HOW - IDEAS ONLINE DIGITAL TWIN
MRI of the Process Plant

Plant/Asset-
Specific Data

IDEAS Process Simulation Model Digital Twin Dashboard with KPIs

2 IDEAS DIGITAL TWIN INTRODUCTION
DIGITAL TWIN – BENEFITS WLP AREA

Anomaly Detection
Data Validation & Reconciliation • Transmitter Drifts
• Model based DVR to detect faulty • KPIs away from normal operating
transmitters range

What-if Scenarios/Offline Study

KPIs • Scenario 1
• Lime Milk Quality Index • Scenario 2
• Over and under-liming predication • Scenario n
• Causticizing efficiency
• Kiln temperature profile
• Kiln Performance Index Optimized Supervisory Setpoints
• WL filter and LMD filter • Optimal Green Liq. to Lime Ratio
Performance Index • Optimal slaker Temp.
• Optimal CE%
• Optimal Excess O2
Virtual Transmitters
• Residual Carbonate
• Lime Kiln Production Operator Guidance- Dashboard
• Lime mud moisture • Warnings/Alarms/Advice
• Lime Mud Flow • Anomalies
• Green Liq. Density
• Lime Mud Flow
Mass and Energy Balance
3
ONLINE DIGITAL TWIN ARCHITECTURE

IDEAS Digital Twin y’ = Corrected measurements

Online DT Parallel Model

p’ = Updated model parameters

1 Optimizer 2 Model Adaptation 3

Online Mass and Data Validation and
Obj. Fun + Constraint + State and Parameter
Energy Balance Manipulated Variables Estimation Reconciliation (DVR)

KPI ,Virtual Transmitters, SP –Setpoints* y’ = Corrected

Guidance and Visibility measurements

Set Point Control

APC/Regulatory Level feedback
“IDEAS Optimizer is designed to
u= Control actions solve optimization problems
where the objective function
and constraints come from a
complex model which cannot be
Process Area
y = Plant measurements written down as a simple set of
*supervisory level setpoints analytical equations”

4 / ANDRITZ (BUSINESS AREA) / PRESENTATION NAME AND DATE / © COPYRIGHT (IF REQUIRED) – ARIAL BOLD, ALL CAPS, 8 PT, BLUE, ALIGN LEFT
ONLINE DIGITAL TWIN ARCHITECTURE
• Mass Balance • Optimal setpoints
• Performance (KPI’s) • Data Validation & Reconciliation
• • What-if scenarios
Virtual Transmitters Model • Advice & Alarms
• Current Plant operating conditions
• Equipment Efficiencies Adaptation • Predictions

Actual Plant Online DT Model Parallel Model

ONLINE MODEL: An Online DT model running with real time DCS data as input (Data frequency of per sec/per min)

PARELLEL MODEL: A copy of the model running within the online model, with select inputs manipulated by the optimiser to maximise/minimise the desired
objective function (Profit, inputs/outputs, losses etc.)
MODEL ADAPTATION: A regular/scheduled check of synchronization between the online model and the parallel model as per actuals to ensure model accuracy.

5 / IDEAS DIGITAL TWIN

 APPLICATION OF IDEAS OPTIMIZER

Maximizing Profit – For Recovery Boiler Area

INPUTS :
OUTPUTS :
• $$ 𝐹𝑒𝑒𝑑 𝑊𝑎𝑡𝑒𝑟
• $$ 𝑆𝑡𝑒𝑎𝑚 𝑡𝑜 𝑡𝑢𝑟𝑏𝑖𝑛𝑒
• $$ 𝑀𝑎𝑘𝑒 − 𝑢𝑝 𝑆𝑜𝑑𝑎
• $$ 𝑆𝑚𝑒𝑙𝑡 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝐶ℎ𝑒𝑚𝑖𝑐𝑎𝑙𝑠
• $$ Soot blowing Steam
• $$ Flue Gas Emissions

MANIPULATED VARIABLES :
• 𝐵𝑙𝑎𝑐𝑘 𝐿𝑖𝑞𝑢𝑜𝑟 (𝑓𝑢𝑒𝑙) Optimization Objective = Maximize Objective function by changing
• 𝐶𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛 𝐴𝑖𝑟 Manipulated Variables within defined Constraints
• 𝑃𝑟𝑖𝑚𝑎𝑟𝑦, 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦, 𝑇𝑒𝑟𝑡𝑖𝑎𝑟𝑦
• Makeup Soda Objective Function = 𝑀𝑎𝑥 𝑃𝑟𝑜𝑓𝑖𝑡 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑣𝑒𝑛𝑢𝑒𝑠 $$ – 𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 $$
Total Revenues = 𝑓(Steam Production, Smelt Recovered Chemicals)
Total Cost = 𝑓(𝐹𝑒𝑒𝑑 𝑊𝑎𝑡𝑒𝑟, 𝑆𝐵 𝑆𝑡𝑒𝑎𝑚, 𝑀𝑎𝑘𝑒𝑢𝑝 𝑆𝑜𝑑𝑎, 𝑁𝑂𝑥 𝑎𝑛𝑑 𝑆𝑂𝑥 𝑃𝑒𝑛𝑎𝑙𝑡𝑦)
CONSTRAINTS :
• 𝐿𝑜𝑤 < 𝑀𝑎𝑖𝑛 𝑠𝑡𝑒𝑎𝑚 𝑡𝑒𝑚𝑝 < 𝐻𝑖𝑔ℎ
• 𝐿𝑜𝑤 < 𝐹𝐺 𝑇𝑒𝑚𝑝 < 𝐻𝑖𝑔ℎ
• Low < Excess O2 < High OPTIMAL Maximize
• Low < Reduction Efficiency < High SETPOINTS PROFIT = $$ - $$

6 / IDEAS DIGITAL TWIN

DATA VALIDATION AND RECONCILIATION (DVR)

Workflow : Process Data Validation and Reconciliation

Daily Reports
KPI Calculations
Optimization
Performance Monitoring
IDEAS Model

Raw Measurements Data Filtering Data Quality Checks Database

Every Sec/Min Pre-validation Reconciliation Chi Square Test Reconciled Data
screening ~Every 5 mins Each Variable Test for Storage

Error Analysis
Gross Error Detection
and Elimination

7 / IDEAS DIGITAL TWIN

DIGITAL DEVELOPMENT STEPS &TIMELINE

ANDRITZ experts work with customers all along to customize the application

Digital Twin Design and Offline Testing Deployment of Prediction and

• Asset specific simulation model Advisory Modules
• Data-Driven modules to complement • Anomaly Detector, Set Point Calculations
DT Scope and Objectives • What-if scenarios, operator guidance
• Production and Inventory Calc Module
• Define Objectives, KPIs, VT,
setpoint and advisory functions Deployment of Performance Info Modules
• DTwin connected to Online Plant Data
• Configuration of mass balance, KPIs, VT, and Data
Project Reconciliation modules
Start Date

3 Months

4 Months Remote
Monitoring
6 Months
5 Months

8 IDEAS DIGITAL TWIN

DIGITAL TWIN REFERENCES – PULP AND PAPER

No. Customer Name Application Status Year

1 Aanekoski, Finland Recausticizing Plant Operational 2019

2 Confidential Customer, USA Evaporation Plant Ongoing R&D, Major KPIs Configured 2018

3 Aanekoski, Finland DD Washer Test Velocity Operational 2019

4 Ust Ilimsk , Russia Recovery Boiler 3 PoC Ongoing 2020

9 IDEAS ONLINE DIGITAL TWIN

DIGITAL TWIN REFERENCES - MINING

No. Customer Name Applications Status Year

1 Virtual Instrument for Density -Thickener Underflow
Haile Gold, USA Virtual Instrument for Density - Cyclone Feed Operational 2018
2 Newmont Akyem Virtual Instrument for Density - Cyclone Feed Operational 2019
3 Minera Los Pelambres (MLP),
Chile Virtual Instrument for Density - Cyclone Feed Operational 2019
4 FMGL - Kings Valley, Australia Virtual Instrument for Density - Thickener Underflow Pump Operational 2019
5 Confidential Customer Overland Conveyor POC Completed 2019
6 MLP, Chile Grinding Circuit (SAG, BALL Mill and Hydro cyclones) Operational 2019
7 BHP, Olympic Dam, Australia Digital Twin for Feed Preparation process Operational 2020
8 BHP, Chile Primary Crusher and Conveying System Operational 2020
9 MLP, Chile Phase 2- Grinding Circuit (SAG, BALL Mill and Hydro cyclones) Ongoing 2020
10 FMGL – Christmas Creek,
Australia DT for Scrubber Operation Ongoing 2021
11 TECK - QB2, Chile DT for Pumping Station Optimization Ongoing 2021

10 IDEAS ONLINE DIGITAL TWIN