Mill-wide optimization – taking your mill
profitability to the next level
Samuli Lehtonen
Director, Operations Performance Optimization
Valmet Industrial Internet
Valmet as a performance provider
Facilitated by Industrial Internet
Mill / Line optimization
Performance
Process Local & VPC
optimization service
Advanced control Local & VPC Mill wide optimization
optimization service
applications and
Advisory Local & VPC services
Process
applications service
recommendations,
Performance Local & VPC equipment and process
Closed loop
predictions service modifications
optimization of KPIs
Local & VPC Recommendations
service
Based on analytics
Quality visualization
Savings
Monitor and report Advise Control Optimize
2 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
APC, optimization, scheduling, planning
Satisfy orders
Advanced Planning and
Forecast at Max
weeks/months Scheduling
profit
Time horizon
Achieve plan
Advanced Planning
days/weeks at max profit
Short term Process Coordination &
hours/days mill profit Optimization
minutes/hours Area
APC and Optimization
profit
seconds PID Control
Scope
3 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
APC, optimization, scheduling, planning
Satisfy orders
Advanced planning and
Forecast at max
weeks/months scheduling
profit
Time horizon
Achieve plan
Advanced planning
days/weeks at max profit
Short term Process coordination &
hours/days mill profit optimization
minutes/hours Area Traditional offering
APC and optimization
profit
seconds PID Control
Scope
4 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
Advanced controls for the entire process
Debarking Optimizer Evaporation Optimizer RCF Optimizer
Continuous Cooking Optimizer Recovery Boiler Optimizer TMP/BCTMP Optimizer
Batch Cooking Optimizer Causticizing Optimizer Brightness Optimizer
Washing Line Optimizer Lime Kiln Optimizer Pulp to Paper and Blending Optimizer
Oxygen Stage Optimizer
Bleaching Optimizer
5 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
Benefits of APC and analyzers cascade forward
+ Higher/stable black liquor solids
+ Steam production + Throughput
− Plugging and washing stops − Steam
− Washing sequences
+ Higher/stable strength
+ Machine runnability
+ On target/stable brightness
Paper − Basis weight
Machine
+ Stronger/stable white liquor Stock
− Water in system + Higher/stable dry solids Preparation
Bleaching
Washing + Higher/stable pulp strength
+ Stable pulp properties
Cooking
+ Fiber fibrillation
+ Stable brightness
+ Lower final brightness
+ Chip quality
+ Optimum/stable Kappa
+ Optimum/stable residual alkali
+ Production/yield
6 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
APC, optimization, scheduling, planning
Satisfy orders
Advanced planning and
Forecast at max
weeks/months scheduling
profit
Time horizon
Achieve plan
Advanced planning
days/weeks at max profit
Short term Process coordination &
hours/days New development
mill profit optimization
minutes/hours Area
APC and optimization
profit
seconds PID Control
Scope
7 October, 2018 © Valmet | Customer Days 2018
Valmet as a performance provider
High level process coordination and optimization
Production planning
(planned/unplanned shutdowns)
Board quality
Paper models
Make-Up chemicals Machine
De-bottlenecking
Energy production Pulp quality
models
Mill-wide Stock
mass Preparation
balance
Bleaching
Optimization of:
Washing Pulp property targets
Cooking Pulp blending targets
Chemicals, PM variables
LCR spec energy targets
Optimization of:
Final Brightness target Fiber line real time optimization
Optimization of:
Kappa Kappa target Advanced planning and scheduling
Chip furnish ratios
models
8 October, 2018 © Valmet | Customer Days 2018
Valmet Mill Wide Optimization
Needs and Valmet solution – turning point of our industy
Typical needs and challenges Our solution:
Problems are complex to handle, lot of exceptions Process Flowsheet Simulation and
How to make decision in real time, 24/7. Optimization
Many mills use spreadsheets to generate the New Optimization technology combined with Valmet
production plan and schedule. Due to the DNA and ability to connect directly with Valmet APC
limitations of the spreadsheet tools, mills do not solutions
achieve their full potential. Ability to embed Valmet’s knowledge of
Experienced operators are getting aged things behavior/relationships into the flowsheet models
that have not been an issue earlier will become Quality Scheduling with
issue in the future
Optimization
Millennials (Gen Y)
Scheduling with
Operational targets between departments can spreadsheets
cause challenges
Quantity
Improvement
9 October, 2018 © Valmet | Customer Days 2018
Valmet Mill Wide Optimization
How it works and how it can be utilized?
Build flowsheet and models Set objectives Set process limits
Optimization
Multiple optimization
Steady state detection Data reconciliation Parameter estimation
algorithms
Use cases
Allocating CAPEX /
Open loop Process
Closed loop control Process studies OPEX on correct
advisory system simulations
actions
10 October, 2018 © Valmet | Customer Days 2018
Valmet Mill Wide Optimization
Recovery Line Manager
Orchestrating the
recovery area as whole
11 October, 2018 © Valmet | Customer Days 2018
Valmet Mill Wide Optimization
Recovery Line Manager
12 October, 2018 © Valmet | Customer Days 2018
“I want to push as much “How do I manage my “I want take my APC’s to next
production as I can, inventories to meet level - increased overall
taking into account the the production plan benefits compared to the more
restrictions I always most efficiently?” typical unit process based
have.” optimization approach”
“I want to optimize my
“I want to maximize raw material and furnish
my mill availability.” blends to achieve quality “How do I decide my
at lower cost” chemical makeup
requirements?”
“I want to stabilize the
production as much as
possible, even during “I want to coordinate my “I need facts and
unplanned process pulp mill quality control support when planning
disturbances.” targets with my paper CAPEX investments”
machine grade targets”
