PIONEERING PRODUCTION ENHANCEMENT

BATCH DIGESTER MODELLING IN SOUTH AFRICA

In the dynamic world of production, accurate prediction and control are paramount. Anssum’s recent project in South Africa, focusing on Batch Digester Modelling, exemplifies a groundbreaking approach to enhancing production efficiency and accuracy.

Project Overview

  • Category: Production
  • Location: South Africa
  • Project: Batch Digester Modelling
  • Status: Monitoring accuracy

Background

Batch digesters play a crucial role in processing raw materials. However, the inherent challenge lies in ensuring that each cook achieves the desired viscosity. A deviation from the targeted viscosity can result in an overcook or undercook, leading to wastage and inefficiencies.

The Challenge

Achieving consistent viscosity for each cook in batch digesters.

  • Minimising the occurrence of overcooks and undercooks, which can compromise product quality and lead to resource wastage.

Anssum's Ingenious Solution

To address the challenge head-on, Anssum employed advanced modelling techniques:

  • State Space Model: This mathematical model describes the dynamic behavior of the system and provides insights into how changes in inputs affect the system’s outputs.
  • Integration of Kalman Filter: A renowned algorithm, the Kalman filter estimates the variables of interest from indirect and noisy measurements. In this context, it was employed to predict the viscosity of each cook with high accuracy.
  • Viscosity Prediction for Process Adjustment: The viscosity prediction derived from the model and filter was then utilised to fine-tune the S-factor. By adjusting this factor, Anssum aimed to achieve optimal viscosity and significantly reduce the chances of overcooks and undercooks.

The Way Forward

Currently, the focus remains on monitoring the accuracy of the model and its predictions. This ongoing assessment will ensure that the model remains robust and continues to deliver optimal results, driving efficiency in batch digester operations.

Conclusion

The Batch Digester Modelling project in South Africa underscores Anssum’s commitment to leveraging cutting-edge technologies and methodologies to enhance production processes. By integrating state-of-the-art modelling techniques and predictive algorithms, Anssum is poised to redefine the standards of production efficiency and accuracy in the industry.

“Anssum’s drive to innovate and optimise sets a benchmark for the future of production, demonstrating a blend of technological prowess and industry expertise.“

ENHANCING EFFICIENCY

IN SOUTH AFRICA'S LIQUOR FILTERS CONTROL

In the quest for greater efficiency in the realms of chemicals, environment, and energy, Anssum’s project centred on the Liquor Filters Control Optimisation in South Africa offers a blueprint for enhanced process efficiency and sustainability.

Project Overview

  • Focus Areas: Chemicals, Environment, Energy
  • Location: South Africa
  • Project: Liquor Filters Control Optimisation
  • Status: Completed

Setting the Scene

Liquor filters play a pivotal role in the chemical process industry, particularly in the filtration of liquors. A pressing challenge was the inefficiency observed in the existing liquor filters, which were predominantly run in manual mode. This approach led to the passage of more fibres to the recovery circuit, resulting in fibre concentrations in the filtered liquor ranging from 300-400 ppm. Such high fibre concentrations directly contributed to fouling in the evaporators, a scenario further exacerbated by the addition of a third liquor filter.

The Challenge

The crux of the challenge revolved around:

  • The passage of high fibre concentrations, directly causing fouling in the evaporators.
  • The impending risk posed by the addition of a third liquor filter, which under the current operational paradigm, threatened to introduce even more fibrous liquor to the recovery circuit.

Anssum's Innovative Solution

Recognising the gravity of the challenge, Anssum proposed a solution rooted in control optimisation:

  • Transition from Manual to Automated Control: Anssum introduced a shift from the existing manual mode of operation to a more efficient control-based approach.
  • Optimising Liquor Filter Vat Level Control: The newly proposed control mechanism centered on managing the level of the liquor filters’ vat through the adjustment of the drum’s rotation speed.
  • Tangible Results: The success of the project was palpable, with initial results showing a commendable 25% reduction in fibre passage. This not only optimised the filtration process but also significantly reduced the risk of fouling in the evaporators.

Conclusion

The Liquor Filters Control Optimisation project in South Africa exemplifies Anssum’s dedication to innovation and sustainability. By embracing advanced control mechanisms and veering away from traditional manual modes of operation, Anssum continues to lead the way in process efficiency, championing a future where chemicals, energy, and environmental conservation are harmoniously balanced.

“Anssum’s commitment to pushing the boundaries of what’s possible, while ensuring responsible and sustainable practices, sets the gold standard in the industry.“

MAXIMISING HEAT TRANSFER

IN SOUTH AFRICA'S BATCH DIGESTER LP GAS RELEASE

In a world where water, chemical, and environmental efficiency are imperative, Anssum’s innovative approach to the Batch Digester LP Gas Release project in South Africa stands out, illustrating the company’s dedication to enhancing process efficacy while prioritising sustainable practices.

Project Overview

  • Focus Areas: Water, Chemicals, Environment
  • Location: South Africa
  • Project: Batch Digester LP Gas Release
  • Status: Completed

Setting the Scene

Batch digesters are essential components in the chemical processing realm, with the Low Pressure (LP) gas release playing a pivotal role in the overall system performance. Recognising the potential for optimisation, Anssum embarked on an initiative to bolster heat transfer efficiency within the system.

The Challenge

The core challenge was maximising the heat transfer within the heat exchangers:

  • The aim was to harness the potential of the LP gas, capitalising on its pressure and density attributes to boost heat transfer.
  • Ensuring optimal temperature control was crucial for the successful execution of the project.

Anssum's Ingenious Solution

With a keen eye for detail and a forward-thinking approach, Anssum proposed a transformative strategy:

  • Relocation for Enhanced Control: The initiative pivoted on relocating the effective LP gas release pressure control downstream of the heat exchangers. This strategic move was designed to harness the maximal pressure of the LP gas, thus enhancing its density and, in turn, facilitating increased heat transfer within the heat exchangers.
  • Temperature Optimisation: As a testament to the success of the relocation strategy, the LP exit gas temperature observed a significant decrease – by 8°C in LP2 and a remarkable 15°C in LP3. Furthermore, the strengthening tank temperature was reduced by 2°C, further optimising the process.

Conclusion

The Batch Digester LP Gas Release project in South Africa underscores Anssum’s commitment to innovation, efficiency, and environmental responsibility. Through strategic re-evaluation and optimisation, Anssum continues to set industry standards, ensuring processes are not only efficient but also environmentally conscious.

“Anssum remains at the forefront of championing water, chemical, and environmental efficiency, pushing boundaries and shaping the future of the industry.“

OPTIMISING FLASH TANKS IN SOUTH AFRICA

A DIVE INTO WATER, CHEMICAL, AND ENVIRONMENTAL EFFICIENCY

In the intricate dance of water, chemicals, and environmental processes, achieving optimal performance is crucial. Anssum’s initiative on Flash Tanks Optimisation in South Africa serves as a testament to the company’s commitment to driving systems to their peak potential while ensuring environmental sustainability.

Project Overview

  • Focus Areas: Water, Chemicals, Environment
  • Location: South Africa
  • Project: Flash Tanks Optimisation
  • Status: Completed

Background

Flash tanks, pivotal in the separation of liquids and gases, play a critical role in the chemical processing industry. Over time, the complexity of systems can drift from their original design parameters. Recognising this, Anssum embarked on a mission to bring the flash tanks back to their optimal performance levels.

The Challenge

The control mechanisms surrounding the flash tanks needed a thorough examination:

  • The objective was to ensure that the units operated as per their original design, guaranteeing efficiency and sustainability.
  • The necessity to maintain balance and control, especially with increasing pressures and discharges, was paramount.

Anssum's Strategic Proposal

A deep dive into the system revealed a path to enhanced performance:

  • Revisiting Control Mechanisms: Anssum proposed a revamp of the control mechanisms, suggesting a transition back to simple yet effective PID controllers. This shift aimed at controlling variables within small base layer loops, ensuring precision and reliability.
  • Pressure Augmentation: A notable outcome of the optimisation was the increase in Flash Tank 1’s pressure by 300 kPa, enhancing the tank’s efficiency and throughput.
  • Minimising Variability: With the new control mechanism in place, the variability in liquor discharges was reduced by a significant 38%. This reduction translates to more consistent operations, reduced waste, and enhanced process efficiency.

In Conclusion

Anssum’s Flash Tanks Optimisation initiative in South Africa underscores the company’s dedication to excellence and innovation. By revisiting, re-evaluating, and revamping systems, Anssum ensures that every process not only meets but exceeds its designed potential.

“Anssum’s commitment to water, chemical, and environmental efficiency continues to set benchmarks, paving the way for a more sustainable and efficient future in the industry.“

REFINING HP GAS RELEASE POST LIQUOR DISCHARGE UPGRADES IN SOUTH AFRICA

A CHEMICAL AND ENVIRONMENTAL PERSPECTIVE

In the realm of chemical processing and environmental conservation, every change, no matter how minute, can ripple through an entire system, impacting efficiency and sustainability. Anssum’s recent initiative, focusing on the Batch Digester HP Gas Release in South Africa, offers a deep dive into the intricacies of system interdependencies and the need for adaptive strategies.

Project Overview

  • Focus Areas: Chemicals, Environment
  • Location: South Africa
  • Project: Batch Digester HP Gas Release
  • Status: Completed
  • Timeline: 17/11/2022 – 28/11/2022

Background

The liquor discharge flash tanks underwent an upgrade, leading to a more efficient and consistent liquor discharge system. This upgrade, while effective in its primary goal, had a cascading effect on the digester’s pressure management post-cook.

The Challenge

Due to the enhanced liquor discharge system, the digester’s pressure, post-cook, was now released more effectively. This shift impacted the High Pressure (HP) gas releases:

  • The HP valve remained shut for extended durations before the digester’s pressure reached the set point, as the pressure was primarily reduced through the liquor discharge.
  • Consequently, traditional HP gas releases were no longer as effective.

Anssum's Insightful Recommendation

Understanding the system’s new dynamics, Anssum proposed an adaptive solution:

  • Time Efficiency: It was recommended to reduce the HP gas release phase time by 10 minutes. This reduction is not just a time-saving measure but a reflection of the system’s new capability to release gas more efficiently post the liquor discharge upgrade.
  • Safety and Consistency: The faster gas release doesn’t compromise on safety. The recommendation ensures that the gas release remains consistent and effective, aligning with the new pressure dynamics of the digester.

Key Outcome

The primary achievement post the recommendation’s implementation was the shift from a constant pressure release to a constant volume release, ensuring a more predictable and stable operation.

In Conclusion

Anssum’s approach to the Batch Digester HP Gas Release post the liquor discharge upgrades underscores the company’s holistic perspective. By understanding the interconnectedness of systems and foreseeing potential challenges, Anssum continues to lead with innovation, ensuring both chemical efficiency and environmental sustainability.

“Through initiatives like these, Anssum reiterates its commitment to pushing boundaries, adapting to changes, and ensuring that every process is optimised for the future.“

ENHANCING FLASH TANKS PERFORMANCE IN SOUTH AFRICA

A DIVE INTO ANSSUM'S OPTIMISATION STRATEGY

Water conservation, chemical processing, and environmental conservation are areas of critical importance in today’s world. Anssum, with its deep expertise and commitment to innovation, has once again demonstrated its ability to transform industrial processes. A recent initiative focused on Flash Tanks Optimisation in South Africa is a testament to this prowess.

Project Overview

  • Focus Areas: Water, Chemicals, Environment
  • Location: South Africa
  • Project: Flash Tanks Optimisation
  • Status: Completed
  • Timeline: 23/02/2022 – 23/03/2022

The Challenge

Flash tanks, vital in the separation and recovery processes, were not performing up to their original design specifications. This led to inefficiencies in the system, impacting downstream processes.

Anssum's Solution

Anssum identified the need to overhaul the control mechanisms surrounding the flash tanks. Their proposition was clear:

  • Reversion to Fundamentals: By reverting back to simple yet effective PID controllers, Anssum aimed to ensure precise control of variables within the base layer loops.
  • Ensuring Design Integrity: The overhaul was not just about introducing new controls but ensuring that the flash tanks performed as they were initially designed to.

Tangible Outcomes

Post-implementation of Anssum’s strategies, the results were commendable:

  • Pressure Boost: There was a significant increase in flash tank 1 pressure by 300 kPa, indicating better separation and recovery processes.
  • Enhanced SO2 Recovery: The absorption reliability in SO2 recovery improved by a remarkable 40%, showcasing the effectiveness of the initiative.
  • Stabilised Liquor Discharges: The overhaul reduced variability in liquor discharges, ensuring a more consistent process. Furthermore, the controllability of the liquor being discharged saw marked improvements, leading to enhanced system efficiency.

In Conclusion

With its strategic approach to the Flash Tanks Optimisation project, Anssum has once again showcased its ability to drive impactful change. The project underscores Anssum’s unwavering commitment to refining processes, conserving resources, and ensuring a sustainable future in the water, chemicals, and environmental sectors.

“Anssum’s initiatives continue to set benchmarks in industry best practices, proving that with innovation and expertise, challenges can be transformed into opportunities for growth and sustainability.“

OPTIMISING BATCH DIGESTER HP GAS RELEASE

THE BERNOULLI PRINCIPLE ADVANTAGE IN SOUTH AFRICA

In the rapidly evolving sectors of chemicals and environmental conservation, Anssum consistently stands out, championing innovative solutions that drive meaningful impact. A prime example is their recent initiative focused on the Batch Digester HP (High Pressure) Gas Release in South Africa.

Project Overview

  • Focus Areas: Chemicals, Environment
  • Location: South Africa
  • Project: Batch Digester HP Gas Release
  • Status: Completed
  • Timeline: 14/06/2022 – 14/07/2022

The Challenge

The traditional approach to gas release from batch digesters was based on a linear decay set point. However, this method could lead to irregularities in the gas flow, posing challenges for downstream processes.

The Bernoulli Principle Solution

Anssum proposed a paradigm shift: using the Bernoulli set point for gas release. This method guarantees a more steady and constant flow of gas from the digester. The benefits of this refined approach include:

  • Consistent Gas Release: By transitioning from a constant pressure release system to a constant volume release, the gas flow becomes more predictable, allowing for better management and control.
  • Enhanced Absorption: The constant flow ensures that the pressure/strengthening tank absorbs the gas more effectively. This minimises sudden loads, leading to improved reliability in processes downstream.
  • Venturi System Protection: A steady flow of gas ensures that the venturi system, crucial for mixing and spraying, isn’t subjected to sudden surges, thus enhancing its longevity and performance.

Impactful Outcomes

Post-implementation of the Bernoulli approach, the initiative yielded commendable results:

  • A successful shift from constant pressure release to constant volume release.
  • An impressive 40% improvement in absorption reliability in SO2 recovery, showcasing the effectiveness of the initiative.

In Conclusion

Anssum’s forward-thinking approach to the Batch Digester HP Gas Release has set new standards in the fields of chemical processing and environmental conservation. By leveraging the Bernoulli set point, they’ve not only enhanced efficiency but also ensured that industries are better equipped to face future challenges.

“Anssum continues to be at the forefront of innovation, with projects like these underscoring their commitment to excellence and sustainability in the chemical and environmental sectors.“

BATCH DIGESTER HP GAS RELEASE

LEVERAGING BERNOULLI PRINCIPLE FOR ENHANCED ABSORPTION IN SOUTH AFRICA

In the dynamic field of chemical processing and environmental conservation, Anssum consistently showcases its prowess through innovative solutions. Their latest initiative, centred around the Batch Digester HP (High Pressure) Gas Release in South Africa, is a testament to this commitment.

Project Overview

  • Focus Areas: Chemicals, Environment
  • Country: South Africa
  • Description: Batch Digester HP Gas Release
  • Status: Completed
  • Duration: 14/06/2022 – 14/07/2022

The Innovation

Traditional methods of gas release from batch digesters often relied on a linear decay set point. Anssum, in its bid to optimise this process, proposed employing the Bernoulli set point for gas release. This approach ensures a more consistent and constant flow of gas from the digester, providing several tangible benefits.

Technical Details

Batch digesters play a critical role in chemical processes, and the manner in which they release gas can significantly impact other systems downstream. The Bernoulli set point for gas release results in a constant volume of gas being released, as opposed to the conventional constant pressure method. This uniformity in gas flow allows for:

  • Improved absorption in the pressure/strengthening tank: A steady flow ensures that the tank can absorb the gas efficiently, minimising sudden loads and potential inefficiencies.
  • Enhanced performance of the venturi system: A sudden surge of gas can strain the venturi system, but a consistent flow mitigates such challenges.

Outcome and Achievements

Post-implementation of the Bernoulli set point, the initiative recorded remarkable improvements:

  • A shift from constant pressure release to constant volume release, ensuring more predictable and manageable gas flows.
  • A significant 50% improvement in absorption stability in SO2 recovery, demonstrating the effectiveness of the new approach.
  • A whopping 500% increase in strengthening tank absorption, underlining the profound impact of consistent gas release on downstream processes.

Concluding Remarks

Anssum’s innovative approach to the Batch Digester HP Gas Release epitomises their forward-thinking approach to chemical processes and environmental conservation. By embracing the Bernoulli set point, they have ushered in a new era of efficiency and stability for the involved systems, reinforcing their reputation as leaders in the field.

“Anssum’s relentless pursuit of innovation and excellence ensures that industries evolve and adapt to the ever-changing landscape of chemical processing and environmental conservation. This project is yet another feather in their cap, setting a benchmark for future endeavours.“

FLASH TANKS UPGRADE AND OPTIMISATION

ENHANCING ENERGY AND ENVIRONMENTAL EFFICIENCY IN SOUTH AFRICA

In the intricate realm of energy conservation, chemical processes, and environmental preservation, ensuring the robustness and efficiency of industrial systems is paramount. Anssum, renowned for its expertise in these areas, took on the challenge of upgrading and optimising the MgO#3A flash tanks in South Africa.

Project Overview

  • Focus Areas: Energy, Chemicals, Environment
  • Country: South Africa
  • Description: Flash Tanks Upgrade and Optimisation
  • Status: Completed

The Collaboration

Anssum’s partnership with the projects team was rooted in a shared vision: to enhance the performance of the MgO#3A flash tanks. Leveraging their extensive experience with the control and operation of analogous systems in various production lines, Anssum became an invaluable collaborator. Their deep understanding of the intricacies of such systems ensured that the upgrade process was informed, effective, and geared towards optimal performance.

Technical Details

Flash tanks play a pivotal role in processes where pressure reduction is required. The MgO#3A flash tanks, in particular, are crucial for managing liquor discharge (LD) and low-pressure (LP) releases. Any inefficiency or instability in these releases can lead to operational challenges and environmental concerns.

Outcome and Achievements

Post collaboration, the flash tanks witnessed significant improvements, especially in terms of stability. Both the LD (liquor discharge) and LP (low-pressure) releases saw enhanced consistency and efficiency. Such optimisation not only augments the production process but also plays a vital role in conserving energy, reducing chemical wastage, and mitigating environmental impact.

Concluding Remarks

The success of the Flash Tanks Upgrade and Optimisation project exemplifies Anssum’s commitment to sustainable and efficient industrial solutions. By collaborating with the right partners and leveraging their deep-seated expertise, Anssum has once again underscored its position as a leader in the realms of energy conservation, chemical processes, and environmental preservation.

“With the global emphasis on sustainability and efficiency, initiatives like this highlight the significance of innovation, expertise, and collaboration in shaping a greener and more efficient future. Anssum’s endeavours serve as an inspiration for industries worldwide, propelling them towards more sustainable practices.“

MEE RECIRCULATION RATE IMPROVEMENTS

ENHANCING ENERGY EFFICIENCY IN SOUTH AFRICA

In the ever-evolving landscape of energy conservation and optimisation, ensuring the efficiency of industrial processes is crucial. Anssum, driven by its commitment to sustainable energy solutions, initiated a project in South Africa focused on improving the recirculation rates in Multiple Effect Evaporators (MEE).

Project Overview

  • Focus Area: Energy
  • Country: South Africa
  • Description: MEE Recirculation Rate Improvements
  • Status: Completed

The Challenge

Optimal recirculation rates in the evaporators are paramount to achieving energy efficiency. However, inconsistencies in these rates can lead to operational challenges such as pump vibrations, which can compromise the system’s effectiveness and longevity.

The Initiative

The core proposition was to provide new calibration and operating instructions to improve the recirculation rates in the evaporators. The strategic approach involved maintaining a steadier level at higher set points. This adjustment ensured that the recirculation pump was provided with a more significant suction head, optimising its operation and reducing vibration issues.

Additionally, a strong emphasis was placed on the maintenance of the level sensors of the effects. Proper maintenance and monitoring of these sensors are crucial to ensure that the desired levels are consistently achieved, leading to smoother operations and enhanced efficiency.

Outcome and Advantages

The project successfully eliminated the vibration issues associated with the recirculation pump, enhancing the overall efficiency and lifespan of the evaporator system. By maintaining steadier levels at higher set points, the recirculation pump could operate more effectively, reducing wear and tear and ensuring consistent performance.

Concluding Thoughts

The MEE Recirculation Rate Improvements project stands as a testament to Anssum’s dedication to energy-efficient solutions in industrial processes. Through meticulous calibration, operational adjustments, and a focus on maintenance, Anssum has once again showcased its expertise in providing sustainable solutions that not only conserve energy but also optimise industrial operations.

“As the global push for energy efficiency intensifies, projects like this underscore the importance of continual innovation and adaptation in industrial processes. Anssum’s approach offers a glimpse into the future of sustainable and efficient energy solutions.“