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1
Manu Kettunen – ABB-KPM
Experiencia2018- a la Fecha
Gerente de Producto • ABBpara: Sensores de consistencia opticos y de microondas. Ventas
globales y soporte de servicio de red de distribución a clientes.2007–2018 Especialista de Producto • Valmet/Metso Automatización
especialista de producto incluyendo Pulpa, papel y sensores de agua, soporte técnico, mantenimiento, arranque y entrenamiento.
2005-2006 Ing. de Pruebas • StaffPointPruebas de analizadores de pulpa y papel, pruebas y Soporte técnico
2005-2005 Laboratorista • UPM, KajaaniLaboratorio de análisis de Freeness y consistencia.
EducaciónIngeniería en Tecnología de Pulpa y Papel, 2005
Universidad Tampere de Ciencias Aplicadas, Finlandia
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© Copyright ABB. All rights reserved. Rev.:Document ID.:
ALBANY PANEL TISSUE6-8, November 2019, Acapulco
2019
Comparison of consistency measurement technologies at tissue machine stock preparation and wet end.
ABB Oy, KPM - Manu Kettunen
—ABB Ltd, KPM
November 11, 2019
- Kajaani Process Measurements Ltd. (KPM) was
established 2001
- KPM were acquired by ABB on 2011
- ABB Ltd, KPM is the third biggest Consistency
Transmitter Supplier in the World
3
—Product Offering
KPM KC3 Blade Type Consistency Transmitter KPM KC5 Rotating Type Consistency Transmitter
November 11, 2019 4
—Product Offering
KPM KC7 Microwave Consistency Transmitter KPM KC9 Optical Consistency Transmitters
November 11, 2019 5
—Product Offering
KPM KRA and KPM KRT Retention Measurement
November 11, 2019 6
—Product Offering
KPM KS2, KPM KS4, KPM KS6 Samplers KPM KB2 Sheet Break Detector
November 11, 2019 7
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Brazil
Argentina
GermanyFrance
Mexico
Chile
India
South Africa
Spain
Singapore
Thailand
South Korea
Indonesia
Philippines
China
Taiwan
Italy
Benelux
Peru
ABB KPM Headquarters
Kajaani, Finland
Sweden
Pakistan
Portugal
Finland
Denmark
Russia
Colombia Vietnam
Austria
Venezuela
Australia
New Zealand
Canada
USA
Norway
Turkey
UK
Poland
Switzerland
Syria
Egypt
Czech Reb.
Slovakia
Hungary
Ukraine
Ecuador
BangladeshSaudi Arabia
Sri Lanka
MalaysiaNepal
United Arab Emirates
Baltic Countries
Japan
Magreb countries
Worldwide Sales and Service Network
Uruguay
November 11, 2019 8
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Comparison of consistency measurement technologies at
tissue machine stock preparation and wet end
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Shear force consistency transmitters
– Rotary type
– Blade type
• Static
• Active
Optical
– Reflection, scattering
– Transmission
• Direct light
• Polarized light
Microwave
– Velocity of microwaves
CCD-camera image, Ultrasonic, Nuclear...very rarely used
• All technologies are indirect
measurements
• Not measuring dry weight of
material in g/l or Cs% as done in
laboratory
• Need to be calibrated
Technologies
November 11, 2019 10
—Operating Range of Consistency Transmitters
8 106 14 16122 40
Optical
Blade
Rotating
Consistency-%
Transmitter type:
Microwave
1,5-16 % (SW > 0,8%, HW > 1,2%)
0-5 Transmission
2-8 %
6-16 %
Limitations:
- needs laminar
flow, sensitive for
grade changes
- sensitive for grade
changes
- black liquor and
air
- conductivity
- air1 – 50 %
- sensitive for grade
changes
0.5-14 % Scattering
November 11, 2019 11
—Cost Range of Consistency Transmitters
8 106 14 16122 40
Optical
Blade
Rotating
1000 USD
Transmitter type:
Microwave
From 15 - Depends on installation configuration
4.5
16
9-20
November 11, 2019 12
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Consistency Transmitter Selection
—Process and installation conditions
November 11, 2019 14
—Optical Consistency Transmitters
– Total consistency measurement
– Ash consistency measurement
– Bypass/Flow-through sensors
– Inline sensors
– Retention measurement
November 11, 2019 15
—KPM KC9 Optical Bypass and Inline Cs Transmitters
– Measurement principles: Light transmission, depolarisation and/or
scattering/reflection
– Opticals are best choice for low consistency applications, below 2%Cs
– Screening, cyclones, deinking
flotation, Save-all filter inlet and outlets
– No wearing parts
– Maintenance possible during process running
November 11, 2019 16
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– Total Consistency and Ash Consistency measurement of
headbox and white water
– Control and stabilization of wet end and retention
– Improves machine runnability and increases production
– Chemical optimization
– Reduced downtime due to less sheet breaks
KPM KRA/KRT Retention Measurement and Control
Headbox
Pulp Paper
White Water
Retention is the Yield of Paper Machine wire section
November 11, 2019 17
—Retention System Monitoring and Control
November 11, 2019
Total Retention % =Tot Cs HB – Tot Cs WW
Tot Cs HB
*100 % Ash Retention % =Ash Cs HB – Ash Cs WW
Ash Cs HB
*100 %
18
– Retention calculation and control are configured in DCS,
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– Low consistency applications 0-2% Cs (0-20g/l)
– Ash consistency measurement 0-1% Cs (0-10g/l)
– Very low consistencies: 0-0,02%Cs (0-0,2g/l, 0-200mg/l )
• Save-all filters inlet, filtrate and superfiltrate
– Tissue machine Retention Measurement (Headbox, White water)
Limitations
– Black liquor and air disturbs the measurement
– Grade (fiber lenght) sensitive, complex furnish mix may require extensive
calibration
Selection Criteria for Optical Consistency Transmitter
November 11, 2019 19
—KPM KC7 Microwave Consistency Transmitter
Latest microwave technology for total consistency control
November 11, 2019 20
—KPM KC7 – Models for All Pipe Sizes
– KPM KC7 Flow-through model
• Available on sizes 50…300 mm
(2”…12”)
– KPM KC7 Insertion type
• Fits process pipes bigger than
150 mm (6”)
November 11, 2019 21
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– Total consistency measurement
• Measures fibers and fillers
– Unaffected of wood species change
like pulp grade, fiber length, freeness, brightness, colour, shives
– Unaffected of process conditions change like
flow rate, pressure, temperature, turbulence
One calibration line for all kind of pulps
– No moving parts
• No preventive maintenance needed
– Air content affects to the measurement, need pressure over 1,5 bar = 150kPa = 15mH2O.
Microwave Consistency Transmitters
November 11, 2019 22
—KPM KC7 Measurement Principle
– Microwave is transmitted to pulp through ceramic antennas
– Microwave speed depends on media
• Measures organic or inorganic material mixed
with liquid
• Response is linear
November 11, 2019 23
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– Superior accuracy compared to shear force transmitters
• Needed minimum 1,5 bar pressure ( 150kPa, 15mH2O)
• High conductivity >20mS/cm prevents measurement
(pulp mill bleaching applications)
– Measures total consistency, fibers, fines and & fillers
– Not sensitive to variation in fiber mix, freeness or color
– High accuracy applications; Machine Chest and Blend Chest
– Recycled pulps, excellent for unscreened applications; after pulper
– Before de-inking
– Effluent plant sludges
Selection Criteria for KPM KC7 Microwave Transmitter
November 11, 2019 24
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– Pulper outlet
– Storage/Dump chest feed to HD cleaning/refiners
– Blend chest feed to refiner (if pressure over 22 psi/ 1.5 bar)
– Machine tank feed to fan pump (if pressure over 22 psi/ 1.5 bar)
– UTM pulper, Broke tank feed to screening, accept feed to blend tank Cs
Installation locations of KC7 at virgin fiber Tissue Mill
November 11, 2019 25
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– Less maintenance personnel - KC7 maintenance free
– Accuracy required with minimum calibration work - Microwave
– Customer willing to change process design to enable use of KC7
Trends Favoring Microwave Transmitters
November 11, 2019 26
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– Measurements with the latest technology
• True-phase method
• Excellent temperature compensation
• State-of-art microwave components
– Robust design
• Stainless steel body
• No moving parts
• Ceramic antennas
– Easy start-up
• Factory calibrated with water
• One point calibration
Summary of KC7
November 11, 2019 27
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• Majority of all transmitters in use are shear force type
• Measure fiber consistency, does not measure fines or fillers
• Different grades require different calibration recipe
Shear Force Transmitters
– Rotating type
– Blade type
November 11, 2019 28
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– Shear force principle; force-balance
– Good for difficult flow conditions because of Measurement Chamber
– Industry standard in many areas
– Measures fiber consistency
– Sensitive to grade variations
Rotaring Consistency Transmitters
November 11, 2019 29
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– Installed through gate valve,
removable from process while
process running
• Enables maintenance without process shutdown and pipe drainage
– Auto-reverse function, motor
rotates clockwise and ccw
• Automatic removal of foreign material
• Auto-zero function eliminates drift
– Wide measurement range
1,5-16%
New Generation Rotaring Cs Transmitter KPM KC5
November 11, 2019 30
—KPM KC5 - Removable Without Shutdown
– Rotating Type Consistency
Transmitter KC5
– PN16 and PN25 gate valves
– Sensor installation by one
person
– Adjustable insertion depth
– Flange installation available
without gate valve
November 11, 2019 31
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– Direct Drive Servo Motor
– Smaller size – Low weight
– Less Maintenance / repair
• No drive belt
• No wearing parts in motor
– No 3-phase power to sensor
KPM KC5 - Modern Design of Rotary Cs Transmitter
November 11, 2019 32
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– Large pipe (>DN400, 16” )
– Low flow rate (<1m/s)
– Consistency 2-3% (blade measures but signal noisy, rotary still gives accurate measurement )
– Production measurement (= Flow rate * Consistency)
– High accuracy applications, such as after the mixing chest and machine chest
– Not enough straight pipe section after the pump to install blade
– High amount of air in the process with low pressure (microwave technology cannot be used)
Selection Criteria for KPM KC5 Rotating Cs Transmitter
November 11, 2019 33
—Rotary signal vs. Blade signal
November 11, 2019 34
—Blade Consistency Transmitters
– Basic design of measurement
blade 50 years old
– 2 wire technology and smart
electronics +20 years ago
KPM KC3
– Static Blade
– Measures 2 - 16 % Consistency
– Minimum Process pipe diameter 100 mm (4”)
November 11, 2019 35
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– Shear force principle; motion-balance
– Requires laminar flow conditions, turbulence disturbs measurement
– Operates well on specified flow range
– Sensitive to grade variations
– Most economical transmitter
Blade Consistency Transmitters
November 11, 2019 36
—KC3 – Features of the ABB Design
One piece sensor body and diaphragm
– Diaphragm works as a spring
– No maintenance
(no O-ring, no seals no leaks)
Sensor blade
Diaphragm (2mm thick)
Measuring arm
Gap measurement probe
Probe protection
Flow
Flat bottom surface
– Fibers do not collect on the bottom of the sensor
– Measuring arm moves freely
November 11, 2019 37
– Fits to standard process coupling Sandvik NS70 saddle
—KC3 – Blade Consistency Transmitter
– Fits to standard process coupling Sandvik NS70 saddle
– Field repairable at site with standard tools
– Electronics can be changed without taking
transmitter off from process
– Patented, no-seal transfer mechanism,with 5 year warranty against leaks
– Wetted parts titanium or Super Duplex Stainless
– Excellent sensitivity: response is better than 0.01% Cs
November 11, 2019 38
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– Cheapest solution wanted (wrong selection criteria)
– If high precision is not required, early in process
– After MC-pump where Cs>10%, as good as rotary
– Flow relatively steady
– Consistency more than 3% up to 16% and same fiber mix
Selection Criteria for KPM KC3 Blade Transmitter
November 11, 2019 39
—Comparison of Shear Force Transmitters
– Blade type
+ Price
+ Reliable measurement if conditions
are suitable (process, installation)
+ No wearing parts (static blades)
+ Size
+ 2-wire transmitter
- Require laminar plug flow: Long straight pipes before and after
installation point
- Limited acceptable flow range
- Vulnerable to mechanical damages
because blade is in main stream
– Rotary type
+ Performance
+ Turbulent flow acceptable
+ Freedom of installation location
+ Wide flow range
+ Wide measurement range 1,5-16%
- Price
- Wearing parts; seals, bearings
November 11, 2019 40
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Consistency Transmitter Selection
—Contact Your Supplier and Fill the Questionnaire
November 11, 2019 42
We help to select the
correct measurement
technology
– Make sure supplier is able to provide all measurement technologies
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– Select Cs transmitter by application, not by price
– Proper tank agitation is critical
– Constant dilution water pressure
– Dilution valve dimensioning
– Dilution water injection point and correct velocity
– Representative sampling
– Tune control loop
General Recommendations for Good Consistency Measurement and Control
November 11, 2019 43
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– Ball Valves
• Dangerous
• Does not take representative consistency sample
– Piston type Samplers
• Safety
• Representative sample
• Repeatability (not depend on user)
Different Samplers and Needs
November 11, 2019 44
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KPM’s Sampling Device Family
– KPM KS2
• Screened pulps 0–8%, no shives or trash
– KPM KS4
• Unscreened pulps 0 – 8%, Shives and trash allowed, no knots
– KPM KS6
• Screened and unscreened pulps 0–18%, shives, knots, trash allowed
November 11, 2019 45
—KB2 Fiber Optic Sheet Break Detector
November 11, 2019 46
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Fiber optic cables
Sheet
RGB and IRTransmitter
Detector
KPM KB2 Measurement principle
Dual light source to cover any application
– RGB light source for colour measurement
– Infra-Red source (880 nm)
Fiber-optic transfers light from transmitter to sensor head.
Non-contact sensor head is 10–30 cm (4–12”) from sheet.
November 11, 2019 47
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– Sensor tube and flexible conduit protect fiber optic cable
– Air purge prevents sensor head becoming dirty
KPM KB2 System components
November 11, 2019 48
Thank You
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Retention Aids – A Versatile Tool for Tissue Manufacture
By G. Furman, C. Foss, C. Kaley, S. Archer, R. Phillips and H. Zha, NALCO Water – An Ecolab Company
https://www.tissuestory.com/2019/01/21/retention-aids-a-versatile-tool-for-tissue-manufacture/
Survey of Retention Aid Impacts at 10 Tissue Machines
November 11, 2019 50
The primary benefit associated with the increase in FPR was the potential to increase the fiber to paper
ratio, or process yield. Additionally, the increased fiber retained with the sheet resulted in a lower solids
load to the white water process clarifier (DAF) and a reduction in solid waste from this unit. Yield
improvements varied between 1-5% depending upon whether the process utilized fiber recovery
screens or recycled a portion of the DAF solids.
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