ePM solution – eMPC Paper strength control Smurfit

automatically better!
Reference Project
ePM solution – eMPC Paper strength control
Smurfit Kappa Roermond Papier B.V.
Starting Point
Approach
Key Benefits
Results
Paper strengths are the essential properties for packaging grades and a production close to specifications still consider
huge financial potentials. Especially for packaging grades using recovered papers a consequently control is essential to
avoid lower quality or even broke.
Model Predictive Control (MPC) has the right characteristics to establish an automatically control for strength properties
and the main production settings, as it was initial presented at Smurfit Kappa Roermond Papier PM3 (recycled linerboard, corrugating medium/fluting).
There are two main influences – the stock in the pulper and the production settings between pulper and pope reel. This
MPC is established for the main production settings (additives, starch) according the final strength (Berst strength, SCT,
CMT). As an extension the MPC also could provide a recommendation of the actually RCP composition.
For the permanently control of lab-measured properties (Berst strength, SCT, CMT) first Soft Sensors were established.
An Soft Sensor calculates continuously final strength by existing online measurements. The quality of this prediction is
the result of measurement quality and process stability. The model is static and has to be continuously adapted according the final lab-strength measurement, automatically transferred from automatic paper-lab or manual by operators.
The MPC can act online on nonlinear relations of changing broke/fiber ratios, measured ash content, retention, machine
speed changes/production …
The main actuators are additives (ash/sludge, chemicals, starch …). For the initial solution Smurfit Kappa Roermond
Papier decided to start with a starch control at sizing press. So the main manipulated actuator is the starch concentration
to sizing press.
Beside monetary savings due to reduced starch consumption, the system/mathematical model is more accuracy after
grade changes and meets required strength soon. Additional the operator is unburdened and strength control is done
automatically.
This leads also to smoother strength conditions and a positive effect on machine run.
Additional the MPC control and the calculated KPI values provide information for the continuous recipe optimization and
control of changing production conditions effecting in strength deviations. (RCP, starch, dewatering …)
By continuous control of the strength in the first phase we could reduce starch consumption by 5% and the standard deviation of the controlled strength properties by 26%. The economic benefit and the positive effect on the daily production
business will force the continuous improvement of multivariate models and Advanced Process Control solutions (Soft
Sensor, MPC, RTO) by Smurfit Kappa Roermond Papier in the next months.
eposC process optimization GmbH | Teslastrasse 8, 8074 Grambach bei Graz, Austria | Phone: +43 / 316 / 4000-500 | Fax: +43 / 316 / 4000-59 | Email: [email protected]
VAT number: ATU 60929277 | Commercial register no.: FN 211066t | www.eposC.com
Solution ePM Paper strength
Adaptive Model
Correction
DV: Furnish ratio, Ash to headbox,
Production, Speed, Retention, Draw, …
eSOFT
Stock Preparation
Paper Machine 3
Laboratory
CV & Soft Sensor:
SCT, CMT, Berst strength
eMPC
MV: Starch concentration
Project Size
< 100.000 € 100.000–250.000 € 250.000–500.000 € > 500.000 €
Benefits
Starch: > 5 %
Standard Deviation: > 26 %
Project Horizon
about 6 month
Pay Back
< 8 month
About Smurfit Kappa Roermond Papier B.V.
Smurfit Kappa Roermond Papier is part of the Smurfit Kappa Group, one of the leading producers of paper-based packaging in
the world. The Dutch paper mill produces more than 550,000 tons testliner and fluting per year.
eposC process optimization GmbH | Teslastrasse 8, 8074 Grambach bei Graz, Austria | Phone: +43 / 316 / 4000-500 | Fax: +43 / 316 / 4000-59 | Email: [email protected]
VAT number: ATU 60929277 | Commercial register no.: FN 211066t | www.eposC.com

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