Furnish Optimization - The Key to Raw Material and Energy Savings in Paper and Board Manufacturing
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Glocell Oy specializes in optimizing raw materials and energy in paper and board manufacturing through their software, SoftacellTM, which helps companies find optimal furnish mixes for various grades of paper. The document discusses the scientific background of fiber properties, the significance of multivariable modeling, and the application of principal component analysis to enhance product performance while reducing costs. Glocell¡¯s approach aims to ensure competitiveness in the industry by optimizing the quality and cost-effectiveness of paper production.
Furnish Optimization - The Key to Raw Material and Energy Savings in Paper and Board Manufacturing
- 1. Furnish Optimization -The Key to Raw Material and Energy Savings in Paper and Board Manufacturing 9.9.2014 Copyright GloCell Oy 1 Juhani Lehtonen
- 2. GloCellOyhasstartedbackin2004asfiberandfurnishconsultingcompanyforpulpandpapermakers,foundedbybrothersLehtonen(Ph.D.andM.sc).Theyhadanidea,thatforestbasedindustrycandothingsinanewwayandwantedtodevelopanewsoftwaretohelpinthatprocess.ThatishowSoftaCell? wascreated. Sincethen,GloCellhasbecomethebestonthemarketprovidingsolutionsformultivariablecostandmaterialoptimization. GloCell¡¯sSoftaCell?optimizationprogramisnowadaysgloballyinusebyforestbasedindustrycompanies. GloCell Oy GloCell is a specialized company working with different multivariable models for furnish mix optimization and evaluation of their cost to quality ratios. Core competences of our company are extensive understanding about the fibres, mathematical modelling skills and wide experience from the pulp-and paper industry WHAT WE DO History
- 3. Part 1: Scientific Background 3
- 4. Where do we come from? ?The functional behavior of paper is characterized using methods that directly measure certain physical properties that are often believed to correlate with the required functionality ?Although these properties may or may not describe the actual functionality requirements thoroughly, they are tools for the paper manufacturer to target production ?These measured physical properties are often very strongly correlated, and changing one without affecting others is impossible ?This is because many of these properties are governed by the same fundamental variables
- 5. Wood fiberpropertiesPulp fiberPulp fiberpropertiespropertiesFiber networkFiber networkpropertiespropertiesPaperPaperpropertiespropertiesEnd useEnd userequirementsrequirementsTreeStandMacroenvironmentBonded areaBonded areaUnbonded areaFiber strengthSpec. bond strengthFiber lengthRunnabilityPrintabilitySoftnessCWTFiber lengthMFACWVesselsParenchymaConformabilityConformabilityFibers/gFiber cuttingFibrillationFibrillationFiber damageTensile strengthTensile strengthTear strengthTear strengthIn plane tearstrengthDensityDensityBulkSurfaceSurfacesmoohtnesssmoothnessAir resistanceAir resistanceAdditive retentionGrowth rateAgeSpeciesCompetitionHabitat typeGeneticbackgroundRainTemperatureSoil typeHistoryOpacityFiber lengthCWTMFA What are the ecology and forestry based issues affecting fiber quality How is fiber quality transposed into paper properties How do paper properties provide product benefits The correlations of properties through the value chain
- 6. Example of fiber baskets SWRelative fiber lengthRelativecell wall thickness Douglas fir Loblolly pinestrengthopacityrefinabilitysmoothnessbulkformation Western red cedar Scotch pine Norway spruce Sitka spruce White spruce Engelmann spruce Lodgepole pine Ponderosa pine Grand fir Western larch Eastern hemlock Western hemlock Subalpine fir Black spruce Red spruce Red pine White pine Balsam fir Slash pine Longleaf pine Shortleaf pine Radiata pineScandinavian and RussianWest Coast BCSouthern USBC InteriorMaritime province and QuebecMain range Rockies, Plains and Western OntarioChile, New Zealand ? GloCell Jack pine2.0-3.3mm2.5-3.5mm>3.5mm>8 ¦Ìm5-8 ¦Ìm3-5 ¦Ìm Virginia pine
- 7. Example of fibre baskets HWRelative fiber length and fiber widthRelativecell wall thickness Sugar maple Red maple Silver maple Betula pendula Betula pubescens Trembling aspen Bigtooth aspen American beech Yellow birch White birch Paper birch River birch White oaks Balsam poplar Southern red oaks Yellow poplar Sweetgum True hickories White ash Green ash Sycamore Magnolia (Sweetbay) Eucalyptus grandis Eucalyptus urophylla Eucalyptus nitens Eucalyptus saligna Eucalyptus globulus Eucalyptus tereticornis Acacia mangium Gmelina arboreae Eastern cottonwood Acacia grassicarpastrengthopacityrefinabilitysmoothnessbulkformationIndonesiaNorthern US, Canada high aspen pulpsNorthern USNorthern USHigh maple pulpsScandinaviaBrazilChile, Portugal, SpainDeep south US0.6-0.8mm <20¦Ìm0.8-1.0mm20-30¦Ìm>1.0mm>30¦Ìm MTHIndonesia>6 ¦Ìm4-6 ¦Ìm2-4 ¦ÌmMid south USHigh oak pulpsGlobal palette of fibers
- 8. The Use Of PCA ?Principal Component Analysis (PCA) has been shown to be a very useful tool in detecting fundamental variables that affect paper properties ?The main applications of PCA are to ?reducethe number of variables to a few underlying fundamental effects ?detect structurein the relationships between these variables, and ultimately to ?classify variables
- 9. Common Variance Explained By Various Factors In Mechanical And Chemical Pulps Principal componentMechanical pulp, Strand et al. Chemical pulp, Howard et al. Bonding68%42.4%-53.2% Fiber length24%30.0%-40.3% Fiber strength12.7%-17.7%
- 10. What Type Of Furnish Is Needed? These targets can be achieved if one knows how to control the principal components (factors) contributing to these properties! Process optimization Raw material control Correct targeting (quality and cost) High tensile? High tear? Opacity? Softness? Porosity?
- 11. 11 SoftaCell? Fiber Knowledge Multivariable modeling Monetary Tools GloCell¡¯s Approach The understanding of multivariable modelling in the context of paper and board making has enabled to development of the tool. The user does not have to know why it works and what the mathematics underneath is.
- 12. 12 ?SoftaCell? primary function is to find and simulate the optimum furnish mix for different paper or board grades based on the potential of the available pulps and fillers ?With the help of SoftaCell? optimal pulp combinations and refining ratios can be found in acknowledge of effect on final quality and cost efficiency of the mix changes ?In the program it¡¯s easy to set limits minimum and maximum values for all the necessary quality parameter ranges and optimize without loss of total performance How Softacell? Works
- 13. Part 2: Fiber Benchmarking 9.9.2014 J. Lehtonen GloCell Oy 13 Note: The parts 2-4 will be presented as a live case using the SoftaCellTMoptimization tool. These slides (12-26) give a framework to what will be shown and discussed.
- 14. 14 First you canstart with just benchmarking pulps You can selecteach of the pulps you have in the database for components to be benchmarked You canselect what ever refining level you wish You see all measured pulp parameterswith chosen refining levels
- 15. 15 You can use the graphs of any quality measurements in the database Easy zooming of graphs Pulp benchmarking is a great tool for users to do first sanity checks on which pulps could be used Pulps can be chemical, mechanical, DIP or BCTMP, no limits to that!
- 16. Benefits Of Fiber Behavior Information 16 In this graph is shown how much does five typical hardwood market pulps differ. They are all refined equally much (100kWh/ton). The comparison is made to find the pulp which enables the highest tear strength and opacity at the same time. Would the changing of pulp, shown by the arrow, effect on the quality of the final product, if the half of the furnish mix is HW based? What would you think would happen to softwood hardwood ratio optimum in a mix?
- 17. Part 3: Furnish Mix Optimization 9.9.2014 17
- 18. Input Of End Quality Parameters ?It¡¯s easy to enter all the needed quality parameters into the software for the end use requirements ?Optimization tools help to find the most cost effective way to reach the target quality in any properties ?The changed costs of raw materials and energy influence and change the optimum solution constantly 18
- 19. Creating the Furnish Mixture 19 Then you go to the real thing: Furnish mix optimization You usually have different types of machines and/or grades in the database
- 20. Fillers and Chemicals Included 20 Here as an example of comparison between PCC and Kaolin. All other fiber mixes are the same! Multivariable Optimization Button!
- 21. All quality parameters can be seen for the both mixtures in Table or Picture. For optimization Min and Max accepted values can be entered The Quality Comparisons 21
- 22. The Quality and Cost Optimization In this case MIX #2 shows a significant 9,69 €/ ton savings in raw materials and energy! 22
- 23. Part 3: Board Optimization 9.9.2014 Juhani Lehtonen GloCell Oy 23
- 24. Creation of Board Layers 9.9.2014 Juhani Lehtonen GloCell Oy 24 Alternative mixes for all board layers can be created easily.
- 25. Board Optimization ?The board structure is created from furnish mixes ?In this case a 3-layer structure in presented ?Easy comparison ?Grammagesincluded 25
- 26. Alternative Board Recipes are Created 9.9.2014 Juhani Lehtonen GloCell Oy 26 Target here is to achieve the same bending stiffness with less raw material!
- 27. The Target Can Easily Be Met With This Approach 9.9.2014 Juhani Lehtonen GloCell Oy 27 Savings in raw material and energy are even 18,2 €per ton with the main quality parameters remaining intact!
- 28. Part 4: Future Roadmap 9.9.2014 Copyright GloCell Oy 28
- 29. Future: Box Compression Modeling ? Fiber types ? Basis weight ? Bonding ? Fiber strength ? Orientation ? SCT (STFI) compression strength of the liners and medium ? Thickness of the board from the form of the medium (take up factor) ? Bending stiffness of the liners Paper Board Box Functional use ECT (Edgewise compression) BCT (Box compression or stacking strength) SCT (STFI) Load demand Bending stiffness ? ECT of the board ? Bending stiffness of the board ? Box dimensions ? Weight of single box? ? Printing properties? ? How high will it be stacked? ? What environmental conditions?
- 30. Box Compression Modeling Directly From Raw Materials ? Fiber types ? Basis weight ? Bonding ? Fiber strength ? Orientation ? SCT (STFI) compression strength of the liners and medium ? Thickness of the board from the form of the medium (take up factor) ? Bending stiffness of the liners Paper Board Box Functional use ECT (Edgewise compression) BCT (Box compression or stacking strength) SCT (STFI) Load demand Bending stiffness ? ECT of the board ? Bending stiffness of the board ? Box dimensions ? Weight of single box? ? How high will it be stacked? ? What environmental conditions? You can run the board machine based on end use requirement optimum!
- 31. 9.9.2014 Juhani Lehtonen GloCell Oy 31 Summary
- 32. Conclusion ?Principal component analysis is an efficient tool for analyzing the potential of mechanical and chemical pulps ?It can be used to explore the full design space for alternative furnish solutions ?When combined with economical evaluation it can serve as a valuable tool for altering the performance-to-cost ratio of any paper product ?GloCellapproach for furnish optimization can thus serve as a strategic tool to ensure your competitiveness in the future ?SoftaCellTM¨Ctool is used comprehensively today to optimize millions of tons of yearly production of paper and board with effective savings of tens of millions of euros per annum
- 33. 33 Steering to use the best raw material combinations available Compare different options of raw materials easy and fast Cost efficient development and testing of new products Optimization of quality to customers ?Buy the rightpulps ?Surveyin whichend products you can use same pulp grades. ?Channel right raw materials to right locations ?Find out technical potential in the end product ?Be able to see effects of material change fast on economical level ?Steering of R&D on higher business area level ?Point out the best and be able to forget the rest ?Be able solve customer problems ?Produce ¡°quality good enough¡± ?Increase your pulp sales with SoftaCell? SoftaCell? can offer value for the whole corporation Mill level Value Added By Softacell?