Digital Refractive Index Measurement Principle and the Latest Generation of SAFE-DRIVe Process Refractometer Keijo Pyörälä, K-Patents Oy How to improve pulp mill fiberline efficiency using real time process measurements Brown Stock Washing Optimization Seminar Crowne Plaza Hotel, Helsinki, Finland June 2, 2014 ISO 9001 CERTIFIED COMPANY 1 Program Part 1 12.00-12.30 Welcome speech and keynote Esko Kamrat, K-Patents Oy, Vantaa 12.30-13.00 Digital refractive index measurement principle and the latest generation of SAFE-DRIVE® Process Refractometer Keijo Pyörälä, K-Patents Oy, Vantaa 13:00-13:15 The need in continuous measurements of material properties and process optimization in a pulp mill Olli Dahl, Aalto University, Espoo 13:05-13:30 From real-time process data to advanced optimization control and improved mass, material and energy balances Pekka Tervola, Andritz Oy, Helsinki 13.30-14.00 Results of the PhD Thesis on real time refractive index measurement in washing process optimization and control Riku Kopra, MAMK Fiberlaboratory, Savonlinna 14.00-14.30 Results of the MSc Thesis on brownstock washing control and optimization at UPM Kaukas pulp mill Kimmo Koivula, UPM Kaukas, Lappeenranta 14.30-14.45 Coffee break Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 2 1 Program Part 2 14.45-15.30 Panel discussion: The aim of the discussion is to reveal the challenges, opportunities and already existing practical solutions of pulp mill process control implementation, and discuss research, instrumentation, installation and process improvement solutions and readiness to develop new solutions. 15.30-16.00 Operation of multi-stage Drum Displacement (DD) washers and improved efficiency with continuous process measurements Pasi Immonen, Andritz Oy, Savonlinna 16.00-16.30 Advanced process control possibilities for washer efficiency optimization with ACE instrumentation. Tapio Jokinen, Andritz Oy, Lahti 16.30-17.00 Brown stock washing optimization using Advanced Process Control (APS) system Jarmo Kosunen, Honeywell Oy, Kuopio 17:00-17:30 Field experiences using in-line refractometer for online measuring and monitoring of the total dissolved solids (TDS) in brown stock washing at Iggesund Mill, Sweden Lars-Åke Hägglund, Omni Process Ab, Solna 17.30-18.00 Review of the further research possibilities and summary of brown stock washing optimization seminar Keijo Pyörälä, Esko Kamrat Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 3 Patented In-line Liquid Concentration Measurements Worldwide 30 Years of Experience in Supplying Digital In-line Process Refractometers ISO 9001 CERTIFIED COMPANY Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 4 2 CORE COMPETENCE: CONTINUOUS DEVELOPMENT OF REFRACTOMETER TECHNOLOGY • Understanding customers’ specific measuring needs • Developing innovative and high quality instruments to new measuring tasks Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 5 INDUSTRIES SERVED Sugar & Sweeteners Food & Beverage Pulp & Paper Pharmaceuticals & Biochemicals Chemicals & Allied Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 Semiconductors & Solar 6 3 WORLDWIDE SUPPORT K-Patents, Inc. Naperville, IL NORTH AMERICA K-Patents HQ K-Patents (Shanghai) Finland Shanghai EUROPE, SOUTH AMERICA, CHINA ASIA & PASIFIC, AFRICA 12 000 reference installations 100 representatives Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 7 K-PATENTS PROCESS REFRACTOMETER The best way to measure concentrations • Accurate • No calibration drift • Maintenance free Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 8 4 NEW BENEFITS OF THE SAFE-DRIVE™ DESIGN • Free interchangeability of sensors • Full range: 0-100 % b.w. • Safe insertion and retraction • Automatic prism cleaning with steam • Retractable steam wash nozzle • Easy installation • Ethernet and remote access • No sampling needed • Direct pulp line installation • No dampening or filtration needed Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 9 PRINCIPLE Refractive Index nD measurement The only true measurement of dissolved components No influence by particles or bubbles Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 10 5 CRITICAL ANGLE MEASUREMENT Light source Optical image Process medium Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 11 BORDERLINE MEASUREMENT Low concentration High concentration Optical images Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 12 6 DIGITAL CAMERA No drift possible Optical image CCD camera Digital image Refractive Index nD Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 13 NO MEASUREMENT ERROR Caused by: Light reflected from a bubble • Crystals • Particles • Bubbles • Colour Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 14 7 PATENTED CORE-OPTICS No influence by • Vibration • Temperature shocks • Pressure peaks Disc spring Prism gasket Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 15 CORRECT TEMPERATURE MEASUREMENT Measured at the same temperature as the prism surface Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 16 8 DESIGN REFRACTIVE INDEX nD and TEMPERATURE T are measured Image detector Light source nD T Prism Temperature sensor Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 17 INDICATING TRANSMITTER • Measurement values • Diagnostic messages • Ethernet UDP/IP • Dual connectivity • Menu guided verification • IP65/Nema 4x enclosure Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 18 9 MAIN DISPLAY • Concentration • Process temperature • Refractive Index, nD • Sensor serial number Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 19 SENSOR STATUS DISPLAY • Optical image • Raw measurement data • Sensor diagnostics • Transmitter diagnostics Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 20 10 REMOTE FUNCTIONALITY Remote access to DTR with a web browser • Review measurement • Instrument diagnostics • Alter configuration and settings Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 21 EXACT CALIBRATION Refractive Index nD and Concentration Conversion matches exactly Standard black liquor tables Conc% nD 0 1.3300 10 1.3478 20 1.3639 100 1.5400 Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 22 11 SENSOR VERIFICATION (1) nD calibration is traceable to international standards Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 23 SENSOR VERIFICATION (2) Menu guided procedure Verification report Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 24 12 SAFE-DRIVE™ Process Refractometer Complete System PR-23-SD: 1. Retractable Sensor(s) 2. SAFE-DRIVE™ Isolation valve 3. SAFE-DRIVE™ Retractor 4. Steam wash system 5. Indicating transmitter 6. Interconnecting cable Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 25 SYSTEM COMPONENTS Shut-off valve Transmitter Power Air SAFE-DRIVE™ Sensor and Isolation valve Steam Power Complete System: 1. SAFE-DRIVE™ Sensor and Isolation valve with prism wash nozzle 2. Transmitter (with internal wash relay) 3. Interconnecting cable 4. Check valve 5. Shut-off valve with steam trap Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 26 13 SAFE-DRIVE™ ISOLATION VALVE O-ring Lip seals Isolation valve handle Scraper Safety lock Ball valve Prism Retractable wash nozzle Safety aspects : • Accidental opening or closing of ball valve is prevented • Scraper protects the lip seals. • Double sealing and an O-ring. • Prism wash nozzle can be safely retracted for a service-check Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 27 RETRACTING WASH NOZZLE See Manual for full instructions Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 28 14 RETRACTING SENSOR (1) 1. Mount the inner casing. 2. Lock the casing. See Manual for full instructions Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 29 RETRACTING SENSOR (2) 1. Mount the outer casing. 2. Lock the casing. 3. Open the sensor flange bolts and retract sensor by turning the hand-wheel. See Manual for full instructions Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 30 15 RETRACTING SENSOR (3) 1. Open the locking latch. 2. Turn the handwheel untill it stops. Safety aspects : • Retractor is easy-to-place and self-retaining • Casing keeps user safe from spills 3. Open the safety lock. Close the Isolation valve and open the sensor flange nuts. The Retractor and Sensor will come out. See Manual for full instructions Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 31 SENSOR MOUNTING • Easy to weld in vertical and horizontal 2-24 inch lines with the welding stencil • No need for spool pieces or pipe sections Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 32 16 IN OPERATION Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 33 APPLICATION CHECK LIST • Process medium Dissolved material only • Range and accuracy 0-100% / typical accuracy +/- 0.1% • Process temperature Standard up to 180°C (355°F) • Process pressure Static 40 bar (600 psi)/10 bar (150 psi) during insertion and retraction • Sensor process connection SAFE-DRIVE™ Isolation valve • Probe connection SAFE-DRIVE™ Flange 1.5” 150 lbs/DN40 PN16 • Probe wetted parts SAF 2205/Duplex steel SS 2377/Prism Spinel, Prism gaskets PTFE (Teflon®) • Isolation valve wetted parts SAF 2205/Duplex steel SS 2377/AISI 316L/Flange gasket Viton® /Lip seals Bronze Teflon® • Pipe diameter 2”- 24” (50 – 600 mm) • Ambient temperature Maximum 45°C (113°F) • Interconnecting cable Standard 10 m (32 ft) Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 34 17 TYPICAL APPLICATIONS Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 35 Thank you! Any questions? Brown Stock Washing Optimization Seminar, Helsinki, Finland, June 2, 2014 36 18
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