Efficiency Solutions: Increase production and quality, reduce costs

OnEfficiency.BreakProtect uses a unique AI algorithm to automatically define break segments (breaks having the same break root causes). For each segment, a solution can be defined – ranging from counter actions applied each time the risk for this break segment increases to one-time optimizations and small rebuilds.

OnEfficiency.Strength combines three modules to create a new generation of advanced process control (APC): virtual sensors (also called soft sensors), model predictive control (MPC), and a cost optimizer.

The virtual sensors accurately predict quality values that otherwise are only available at the end of each tambour as the result of destructive tests in the lab. This allows the MPC to control the process to continuously reach these values, while the cost optimizer makes sure this happens at the lowest possible cost.

Field results Ružomberok PM18​:
OnEfficiency.Strength lead to improved basis weight and ratio of fiber to ash.
2,800 tpy fiber savings in the first year, by​ ~ 0.5% basis weight reduction ​and ~ 0.3%-points ash increase.

Field results Fabriano PM3​: On Efficiency.Strength lead to significant cost savings that have convinced the customer to use Voith’s digitization expertise for further machines as well. 

OnEfficiency.DIP optimizes an existing DIP line to create constant DIP quality at minimum cost. The existing flotation is supplemented by additional actuators; new sensors are installed to monitor the quality parameters.
The DIP quality fluctuations created by incoming raw materials or production changes are reduced by dynamic adjustment of the losses at the washing/flotation as well as real-time optimization of the bleaching chemicals dosage.

• yield increase from 77.9 to 79.8%
• energy consumption reduced from 35 to 32 kWh/t
• hydrosulfite charge reduced from 0.04 to 0.02%
• primary ash addition reduced from 28 to 16 kg/t

Total savings achieved: 1.22 MEUR/year, equaling a cost reduction of 13% or 7.2 EUR/t

DIP line for newsprint with 350 ktpy

 

• yield increase from 85.7 to 88.1%
• energy consumption reduced from 42 to 27 kWh/t
• peroxide charge reduced from 0.99 to 0.78%
• hydrosulfite charge reduced from 0.12 to 0.06%
• primary ash addition reduced from 40 to 23 kg/t

Total savings achieved: 3.55 MEUR/year, equaling a cost reduction of 22% or 9 EUR/t

OnCumulus.Suite contains four apps: Analyzer, Cockpit, Events and Functions. 
Analyzer is used to monitor and evaluate historical and live data, e.g. to find the root cause for a problem.
Cockpit visualizes the current status of the process in a clear and easily understandable way. 
Events allows to displays and filter different types of events, e.g. for quick trouble shooting.
Functions allows customers to calculate new values based on existing data. The calculated values are then available for all other applications running on OnCumulus.

OnView.VirtualSensorBuilder lets you create virtual sensors (soft sensors) quickly and without data analysis skills and display them either immediately via OnCumulus.Suite or in your own visualization tool.

OnView.MassBalance allows the real-time visualization of all relevant losses. For each stream, the deviation from the standard operation range is visualized in an intuitive Sankey diagram. If losses rise above a warning threshold – which can be defined for each stream – the corresponding streams in the Sankey diagram will be marked and the operators will receive recommended countermeasures, which also can be individually defined. 

The diagram shows the results from Saica Venizel, with an OCC line with 250 ktpy. Optimization based on the monitoring by OnView.MassBalance lead to ~ 2% fiber (paper for recycling / raw material) savings on average. A “reset” to the initial settings clearly showed the importance and positive effect of continuous monitoring and optimization.