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
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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
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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
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Patented In-line Liquid Concentration
Measurements Worldwide
30 Years of Experience in Supplying
Digital In-line Process Refractometers
ISO 9001
CERTIFIED
COMPANY
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CORE COMPETENCE:
CONTINUOUS DEVELOPMENT OF
REFRACTOMETER TECHNOLOGY
• Understanding customers’ specific
measuring needs
• Developing innovative and high
quality instruments to new
measuring tasks
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INDUSTRIES SERVED
Sugar &
Sweeteners
Food &
Beverage
Pulp &
Paper
Pharmaceuticals
& Biochemicals
Chemicals
& Allied
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Semiconductors
& Solar
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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
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K-PATENTS PROCESS REFRACTOMETER
The best way to measure concentrations
• Accurate
• No calibration drift
• Maintenance free
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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
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PRINCIPLE
Refractive Index nD measurement
The only true measurement
of dissolved components
No influence by particles
or bubbles
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CRITICAL ANGLE MEASUREMENT
Light source
Optical image
Process medium
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BORDERLINE MEASUREMENT
Low concentration
High concentration
Optical images
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DIGITAL CAMERA
No drift possible
Optical image
CCD camera
Digital image
Refractive
Index nD
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NO MEASUREMENT ERROR
Caused by:
Light reflected from a bubble
• Crystals
• Particles
• Bubbles
• Colour
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PATENTED CORE-OPTICS
No influence by
• Vibration
• Temperature shocks
• Pressure peaks
Disc spring
Prism gasket
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CORRECT TEMPERATURE MEASUREMENT
Measured at the same temperature
as the prism surface
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DESIGN
REFRACTIVE INDEX nD and TEMPERATURE T are measured
Image detector
Light source
nD
T
Prism
Temperature sensor
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INDICATING TRANSMITTER
• Measurement values
• Diagnostic messages
• Ethernet UDP/IP
• Dual connectivity
• Menu guided verification
• IP65/Nema 4x enclosure
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MAIN DISPLAY
• Concentration
• Process temperature
• Refractive Index, nD
• Sensor serial number
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SENSOR STATUS DISPLAY
• Optical image
• Raw measurement data
• Sensor diagnostics
• Transmitter diagnostics
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REMOTE FUNCTIONALITY
Remote access to DTR with a web browser
• Review measurement
• Instrument diagnostics
• Alter configuration and
settings
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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
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SENSOR VERIFICATION (1)
nD calibration is traceable to
international standards
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SENSOR VERIFICATION (2)
Menu guided procedure
Verification report
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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
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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
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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
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RETRACTING WASH NOZZLE
See Manual for full instructions
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RETRACTING SENSOR (1)
1. Mount the inner casing.
2. Lock the casing.
See Manual for full instructions
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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
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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
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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
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IN OPERATION
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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)
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TYPICAL APPLICATIONS
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Thank you!
Any questions?
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