In the realm of water conservation, energy efficiency, and optimised production, the right control mechanisms are paramount. Anssum, with its unwavering commitment to these pillars, embarked on a project in South Africa to optimise the consistency control of blowtanks, paving the way for a more efficient and environmentally-friendly production process.

Project Overview

  • Focus Areas: Water, Production, Energy
  • Country: South Africa
  • Description: Blowtank Consistency Control Optimisation
  • Status: Completed
  • Timeline: September 14, 2022 – October 30, 2022

The Challenge

Consistency control within the blowtank discharge process was identified as an area ripe for enhancement. Achieving optimal pulp consistency is crucial for effective brown stock washing. However, the existing system required frequent manual intervention, leading to inefficiencies and increased operational complexities.

The Initiative

Anssum proposed a revamped control structure for the blowtank discharge process. The new design incorporated:

  • Feedforward Control: Anticipating future changes by using current measurements.
  • Feedback Control: Adjusting the process based on the difference between the desired and measured values.
  • Cascade Control: Using multiple controllers to manage a single control loop, enhancing the accuracy.
  • PID Logic Infrastructure: This infrastructure is straightforward to implement and offers a balance of proportional, integral, and derivative actions, ensuring smooth and precise control.

The goal was to regulate pulp consistency using only two control valves supplying hot liquor as manipulated variables, the pulp discharge valve positions as disturbance variables, and the blow effluent pulp consistency as the controlled variable.

Outcome and Challenges

The results were compelling. The Mean Absolute Error (MAE) of consistency was reduced by a notable 17%. Furthermore, the need for manual intervention to control blowtank consistency was eliminated, streamlining the process and ensuring consistent, high-quality output.

Concluding Thoughts

The Blowtank Consistency Control Optimisation project exemplifies Anssum’s dedication to sustainable and efficient solutions. By integrating advanced control mechanisms into the production process, Anssum has not only enhanced the quality of the output but has also underscored the importance of automation and precision in modern industrial operations.

As industries face increasing pressures to conserve resources and enhance production efficiency, initiatives like this one by Anssum provide a roadmap for sustainable and optimised operations in the future.