1. Standards Certification Education & Training Publishing Conferences & Exhibits Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Addressing Cycling Problems in Pulp & Paper Processes

2. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Presenter – Steve Obermann A Chemical Engineer with emphasis in process automation. Expertise in advanced process control designs for refinery and petrochemical process units, process modeling, inferential properties, real time optimization and cost/benefit estimation. Metso ExperTune develops and markets pre-packaged industrial software for the processing and manufacturing industries which maximizes productivity, efficiency and reduces waste. 2

3. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Agenda Harmful effects of cycling Causes of cycling Detection Summary Questions & Answers 3

4. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Harmful effects of cycling Production impact –Mean value may satisfy needs –Peak values are opportunities –Valley is a loss –Presents uncertainty in capability 4 TC PC 97% design rate 102% design rate 90% design rate Boss, Can I take an order for xx tons/day?

5. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Harmful effects of cycling 5 Raw material consumption –Raw materials, chemicals, additives applied in ratio? –Recycle / reprocess –Increased cost per unit production –Reduces fresh feed capability –Disposal cost TC PC RC $$$ Conversion Un-converted! Recycle/disposal Some of this HERE

6. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Harmful effects of cycling Energy consumption –Linear with cycling variable? 6 Energy Moisture Energy Moisture

7. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Harmful effects of cycling Product quality –Downgrade (if different grades of product) –Re-process / recycle –Destroy (incinerate, fuel) –Dispose (landfill, deep well) –Uncertainty in capability 7

8. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Harmful effects of cycling Safety concerns –Production trips –Relief system vent / flare –Hazardous release 8

9. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Causes of cycling Self induced –Loop put in Manual –Poorly tuned controls 9

10. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Causes of cycling Valve Issues –Sizing –Malfunction 10

11. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Causes of cycling Process –Non-linear Design issues –Recycle loops –Heat integration 11 Cooking liquor Steam

12. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Causes of cycling Operational procedures –On this condition do this… –…and then automating it 12 … If valve opening > 85% then turn on pump2 ElseIf valve opening < 30% then turn off pump2 EndIf …

13. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Causes of cycling Environmental –Day to Night Cycles can be established with day to night temperature fluctuations. Controls need to prevent these swings from affecting critical process parameters. 13 24 hours

14. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Detection of cycling Is it Oscillating? –Appearance 14 Noise? OR Oscillation Just Sometimes?

15. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Detection of cycling Is it important? –What does it affect? –What is the variability? –Oscillation Significance 15

16. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Detection of cycling Is it related to… –Shape of the Oscillation? –Oscillation Period? 16 Valve Hardware Valve sticking, extra energy needed to move the valve due to friction. “Stiction”

17. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Summarizing Oscillations reduce production efficiency –Profitability, uncertainty Oscillation are caused by –Hardware problems –Poor Tuning –Process behavior –Other parts of the process/environment Oscillations can be detected and ranked for importance –Visually –Apply some math –Recognize patterns 17

18. Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA Process Control & Safety Symposium 2015 9-12 November Houston, Texas USA 18 Questions? Thank You