BLOWTANK CONSISTENCY CONTROL OPTIMISATION

SPEARHEADING SUSTAINABLE PRODUCTION IN SOUTH AFRICA

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.“

LIQUOR COOLER CONTROL ENHANCEMENT

A SUSTAINABLE INITIATIVE IN SOUTH AFRICA

Water, energy, and environmental conservation are three key pillars that drive modern industrial processes. In this context, a significant initiative was undertaken in South Africa to enhance the control of liquor coolers. The primary objective? Decrease SO2 emission in the MgO#2 blow tank stack, ensuring a sustainable and environmentally friendly operation.

Project Overview

  • Focus Areas: Water, Energy, Environment
  • Country: South Africa
  • Description: Liquor Cooler Control Enhancement
  • Status: Completed
  • Timeline: August 26, 2022 – September 26, 2022

The Challenge

The MgO#2 blow tank stack had been identified as a significant source of SO2 emissions. With environmental sustainability at the forefront, Anssum undertook a root cause analysis to pinpoint the underlying issues. The findings? The control system surrounding the liquor cooler was underperforming. This inefficiency resulted in hot quench liquor being directed to the digesters and subsequent over-pressurisation of these digesters during the pulp discharge phase.

The Initiative

Armed with this knowledge, Anssum’s approach was twofold:

  • Focus on Control: The initiative emphasised enhancing the control mechanisms around the liquor coolers. This involved an in-depth look at the tuning parameters and the overall layout of the control system. By understanding the current limitations and inefficiencies, a tailored solution could be proposed.
  • Leveraging Unutilised Equipment: A critical observation was the presence of equipment that was not being utilised to its full potential. By tapping into these resources, the project aimed to achieve its environmental goals without incurring additional hardware costs.

Outcome and Challenges

The project served as a proof of concept, showcasing the potential to significantly reduce blow tank emissions. However, like many transformative initiatives, there were hurdles along the way. Change management emerged as a primary challenge. Adapting to new processes and systems requires a shift in mindset, and the team had to navigate these waters with tact and patience.

Concluding Thoughts

The Liquor Cooler Control Enhancement initiative stands as a testament to the power of proactive analysis and innovative thinking. By identifying underutilised resources and optimising existing systems, Anssum has once again demonstrated its commitment to sustainable and efficient solutions. As industries worldwide strive for eco-friendly operations, such projects serve as a beacon, highlighting the path forward.

“Through initiatives like these, Anssum continues to lead the way in sustainable industrial practices, showcasing the perfect blend of technology and environmental consciousness.“

ASSET MANAGEMENT INSIGHT

COMPRESSOR DAMAGE INVESTIGATION IN SOUTH AFRICA

In the realm of asset management, ensuring the optimal operation and longevity of key machinery is paramount. One such instance necessitating intricate scrutiny was the damage to the compressor of the MgO#1 pre-evaporator in South Africa. This article delves into the investigation, its findings, and the consequential recommendations put forth by Anssum.

Project Overview

  • Focus Area: Asset Management
  • Country: South Africa
  • Description: Compressor Damage Investigation
  • Status: Completed
  • Timeline: April 20, 2022 – May 5, 2022

The Investigation

Anssum initiated a thorough examination to decipher the underlying causes contributing to the damage of the compressor. The investigative process highlighted a key issue: the malfunctioning of the demister was a primary factor aggravating the compressor’s damage.

Anssum's Recommendations

The study culminated in the following salient recommendations:

  • Demister Spray Alignment: The demister sprays were identified to be prone to misalignment. This misalignment resulted in water being sprayed directly into the compressor’s feed, leading to operational discrepancies.
  • Operational Procedures: Concerns were raised about the operational procedures associated with the compressor. Notably, the practice of washing the compressor with water during its operation, primarily due to the accumulation of black liquor on its blades. This issue was further linked to the underperformance of the demisters in the MVR (Mechanical Vapor Recompression).
  • Design Specifications: It was observed that the compressor was frequently operating outside its design specifications. This deviation not only exacerbated the damage but also ushered in production and asset management challenges. It was emphasised that such concerns went beyond the current scope of supply and warranted immediate attention.

Concluding Remarks

The compressor damage investigation underscores the importance of meticulous asset management and the need for proactive interventions. By identifying potential pitfalls and offering actionable recommendations, Anssum reaffirms its commitment to ensuring operational excellence and safeguarding assets.

“Anssum’s dedication to thorough investigations and informed recommendations solidifies its position as a trusted partner in asset management endeavors.“

ENHANCING WATER EFFICIENCY

HEAT EXCHANGER CONDENSATE RECOVERY IN SOUTH AFRICA

Water conservation is an integral component of sustainability strategies worldwide. Emphasising this priority, Anssum embarked on a venture in South Africa to refine the Heat Exchanger (HE) Condensate Recovery process. This article sheds light on the challenges, applied solutions, and the remarkable results of the project.

Project Overview

  • Focus Area: Water Conservation
  • Country: South Africa
  • Description: Heat Exchanger Condensate Recovery
  • Status: Completed
  • Timeline: August 13, 2022 – September 13, 2022

The Challenge

Preliminary evaluations indicated that the condensate recovery efficiency stood at 40%. While this benchmark was noteworthy, Anssum identified room for further enhancement and resolved to boost this recovery efficiency.

The Anssum Approach

To augment the condensate recovery efficiency, Anssum adopted a multifaceted strategy:

  • Needle Valve Addition: A needle valve was incorporated into the sample line, providing refined control and facilitating nuanced adjustments, both essential for optimal condensate recovery.
  • Counter-Current Configuration: Ensured the Heat Exchanger operated in a counter-current configuration across all digesters. This setup, known for its superior efficiency, was instrumental in optimising heat transfer and subsequently, condensate recovery.
  • Standardised Heat Exchangers: Established the use of identical annular Heat Exchangers on all digesters, promoting uniformity and streamlining the recovery process.
  • Sensor Calibration: Undertook meticulous calibration of the conductivity sensors. Accurate data from these sensors is crucial for monitoring system performance and making data-driven modifications.

Outcomes

Anssum’s systematic methodology yielded significant achievements:

  • Enhanced Condensate Recovery: The recovery efficiency saw a significant boost, with an increase of 20%, resulting in an impressive 60% recovery rate.
  • Improved Sensor Longevity: Strategic process alterations led to a decrease in the frequency of conductivity sensor replacements, ensuring longer operational life and reduced maintenance overheads.

In Conclusion

The Heat Exchanger Condensate Recovery initiative is a testament to Anssum’s dedication to water conservation and technical prowess. By leveraging innovative solutions and emphasising sustainability, Anssum continues to establish industry standards and champion a future of water efficiency.

“Anssum remains committed to devising solutions that not only address technical challenges but also contribute to global sustainability.”

WATER CONSERVATION

THROUGH DIGESTER HE CONDENSATE RECOVERY IN SOUTH AFRICA

In the journey towards sustainable water usage, every drop counts. With this ethos, Anssum embarked on an initiative in South Africa centered around the Digester Heat Exchanger (HE) Condensate Recovery system. This article delves into the project’s objectives, the measures employed, and the commendable outcomes achieved.

Project Overview

  • Focus Area: Water Conservation
  • Country: South Africa
  • Description: Digester HE Condensate Recovery
  • Status: Completed
  • Timeline: July 28, 2022 – August 23, 2022

The Objective

The primary goal was clear: optimise the Digester HE system to enhance condensate recovery rates. However, this broad objective was broken down into specific actionable measures, ensuring a structured approach to achieving the desired results.

The Anssum Strategy

To realise the project’s objectives, Anssum implemented the following measures:

  • Counter-Current Configuration: Ensured that the HE configuration was counter-current across all digesters. This configuration is known to enhance heat exchange efficiency, crucial for optimal condensate recovery.
  • Operational Excellence: Ensured the flawless operation of the sample coolers. These coolers play a pivotal role in maintaining system efficiency and ensuring condensate recovery.
  • Sensor Calibration: Undertook precise calibration of the conductivity sensors and the condensate collection tank level sensors. Accurate sensor readings are crucial for monitoring and optimising system performance.
  • Parallel Ball Valve Installation: Addressed the sample cooler challenges by installing a parallel ball valve. This strategic addition mitigated issues previously faced, enhancing system reliability.

Outcomes

Anssum’s meticulous approach yielded noteworthy results:

  • Condensate Recovery Boost: Achieved an impressive 10% improvement in condensate recovery rates.
  • Sensor Longevity: Process changes were implemented ensuring that the conductivity sensor replacements were not affected, thereby increasing their operational lifespan.

In Conclusion

The Digester HE Condensate Recovery project exemplifies Anssum’s dedication to efficient water usage and conservation. Through detailed planning, technical expertise, and a commitment to excellence, Anssum continues to lead the way in water conservation efforts, ensuring a more sustainable future.

“In every project, Anssum aims to combine technical expertise with a deep commitment to environmental sustainability, setting benchmarks for industries worldwide.“

WATER CONSERVATION IN ACTION

BLOWTANK SCRUBBER ATTENUATION IN SOUTH AFRICA

Water is a precious resource, and its judicious use is the need of the hour. Anssum, committed to sustainable solutions, undertook an initiative in South Africa focusing on the Blowtank Scrubber system. This article highlights the innovative measures adopted and the tangible benefits reaped from the project.

Project Overview

  • Focus Area: Water Conservation
  • Country: South Africa
  • Description: Blowtank Scrubber Attenuation
  • Status: Completed
  • Timeline: May 15, 2022 – May 29, 2022

The Challenge

The Blowtank Scrubber, a critical component in the water treatment process, had a key issue: the existing control mechanism maintained a static flow rate setpoint for each discharge. This one-sise-fits-all approach didn’t consider specific process parameters that affect the scrubber’s absorption capacity. As a result, excessive SO2 landed in the cool acid tank, leading to wastage as it was eventually disposed of.

The Anssum Approach

Understanding the criticality of the issue, Anssum proposed a more sophisticated control mechanism for the chilled water flow into the absorber. The solution was grounded in adapting the water flow based on specific, real-time process parameters. These parameters included:

  • Blowtank Pressure: Recognising that variations in blowtank pressure could influence the scrubber’s efficiency, it was incorporated as a primary control parameter.
  • Venturi 6 pH: The pH level in Venturi 6 serves as a critical indicator of the absorption process’s effectiveness. By monitoring and responding to this parameter, the system could dynamically adjust water flow.

Outcomes

Anssum’s intelligent approach bore fruit:

  • Water Conservation: There was a significant 10% reduction in water consumption. This not only translates to tangible savings but also underscores Anssum’s commitment to sustainability.

In Conclusion

The Blowtank Scrubber Attenuation project is a testament to Anssum’s prowess in identifying inefficiencies and crafting tailored solutions. In an era where water conservation is paramount, such initiatives play a pivotal role in setting industry standards and advocating for a more sustainable future.

“At Anssum, the mission is clear: to drive innovations that align with global sustainability goals, ensuring a brighter tomorrow for all.“

ADVANCING PH CONTROL

VENTURI BASE LAYER CONTROL OPTIMISATION IN SOUTH AFRICA

Environmental sustainability and efficient chemical processing are among the top priorities in today’s industrial sector. With a focus on these areas, Anssum embarked on an innovative initiative in South Africa, aiming to optimise Venturi Base Layer Control. This article delves into the project’s intricacies and its commendable contributions to improved pH control.

Project Overview

  • Focus Area: Chemicals & Environment
  • Country: South Africa
  • Description: Venturi Base Layer Control Optimisation
  • Status: Completed
  • Timeline: June 14, 2022 – July 15, 2022

The Challenge

In chemical processes, maintaining optimal pH levels is paramount. However, disturbances can affect this delicate balance, leading to inefficiencies and potential hazards. Responding proactively to these disturbances is essential to ensure safe and efficient operations.

The Anssum Solution

Recognising the need for advanced regulatory mechanisms, Anssum proposed the integration of a state-of-the-art controller designed to proactively counteract disturbances influencing pH control. The approach involved:

  • Time-Series Modeling: Utilising Fast Fourier Transform techniques, a time-series model was developed to understand the interplay between disturbances and the venturis.
  • Feedforward Design: Based on the insights from the model, feedforward elements were meticulously designed to enhance pH control in V5 and V6.

Technical Achievements

The outcomes of this initiative were notably significant:

  • Enhanced Stability: There was a marked 5% improvement in stability across V3, V5, and V6.
  • Reduced Deviation: The Mean Absolute Error (MAE) from the Set Point (SP) in V3, V5, and V6 was reduced by 3%, ensuring closer adherence to desired pH levels.

In Conclusion

Anssum’s Venturi Base Layer Control Optimisation project in South Africa exemplifies the company’s commitment to pushing the boundaries of chemical processing and environmental stewardship. By leveraging advanced techniques and a proactive approach, Anssum continues to drive excellence and innovation in the industry.

“As global challenges in the chemical and environmental sectors intensify, Anssum remains at the forefront, championing solutions that address pressing needs and set new standards for the future.“

REVOLUTIONISING BOILER EFFICIENCY

WITH SMART SOOT BLOWING IN SOUTH AFRICA

In the relentless pursuit of enhanced energy efficiency, innovations in boiler maintenance and optimisation stand as cornerstones. Anssum, at the forefront of pioneering energy solutions, embarked on a transformative initiative in South Africa, focusing on Recovery Boiler Soot Blowing. This article provides insights into the project’s nuances and its profound impact on boiler thermal efficiency.

Project Overview

  • Focus Area: Energy
  • Country: South Africa
  • Description: Recovery Boiler Soot Blowing
  • Status: Completed
  • Timeline: October 13, 2022 – April 20, 2023

The Challenge

Recovery boilers play a pivotal role in various industries, particularly in processing Dry Black Liquor (DBL) — a byproduct of the kraft pulping process. However, these boilers often face efficiency challenges due to soot accumulation. If not addressed efficiently, this soot can significantly hamper the boiler’s thermal capabilities.

The Anssum Solution

To tackle this challenge, Anssum introduced “smart soot blowing,” a modern technique with several advantages:

  • Precision: It targets specific areas of soot accumulation that critically affect efficiency.
  • Adaptability: The technique adjusts the soot blowing frequency and intensity based on real-time data and feedback.
  • Optimisation: By concentrating on key problematic areas, it reduces wear and tear on boiler tubes, extending the boiler’s operational lifespan.

Technical Achievements

The initiative’s outcomes were notably impactful:

DBL Ratio Enhancement: The Dry Black Liquor to steam ratio, a crucial metric reflecting the efficiency of processing this substance, improved by a remarkable 4.24%. This indicates a more efficient conversion of DBL, leading to optimised energy utilisation.

In Conclusion

Anssum’s Recovery Boiler Soot Blowing project in South Africa underscores the transformative potential of innovative energy solutions. With the introduction of smart soot blowing, the standards of boiler maintenance and efficiency have been elevated.

“As the energy landscape continues to evolve, Anssum remains committed to championing initiatives that not only address immediate challenges but also pave the way for a more sustainable and efficient future.“

MEE CLEANING INITIATIVE

ENHANCING ENERGY EFFICIENCY IN SOUTH AFRICAN EVAPORATORS

The energy sector continually seeks innovative solutions to maximise efficiency and optimise processes. Anssum, in its unwavering commitment to energy conservation, embarked on an initiative in South Africa that centered on the MgO#2 evaporators. Let’s explore the nuances of this project and its profound implications for energy conservation.

Project Overview

  • Focus Area: Energy
  • Country: South Africa
  • Description: MEE Cleaning
  • Status: Completed
  • Timeline: September 2020 – May 2021

The Challenge

MgO#2 evaporators, crucial for various industrial processes, often necessitate frequent shutdowns for maintenance. These shutdowns can be disruptive and lead to inefficiencies in the overall process. The primary goal was to extend the mean time between these shuts, ensuring smoother operations and heightened efficiency.

The Anssum Strategy

To address this challenge, Anssum conceptualised a two-pronged approach:

  • Development of KPIs: Two Key Performance Indicators (KPIs) were created using available equipment. The short-term KPI provides insights into the condition of each of the four effects. This KPI not only aids in immediate decision-making but can also be employed in a closed-loop manner to clean dirtier effects in the evaporator. This is achieved by adjusting the surge tank level set points. The long-term KPI, on the other hand, assists in optimising the cleaning schedule. It helps determine the ideal time to shut the MEEs, factoring in mill conditions.
  • Cleaning Schedule Optimisation: With the help of the long-term KPI, Anssum was able to devise a cleaning schedule that ensures the MEEs are shut at optimal times. This minimises disruptions and ensures maximum efficiency.

Technical Achievements

The MEE Cleaning initiative bore significant fruits:

  • Steam Usage Reduction: A commendable reduction of 7t/hr was achieved.
  • Efficiency Improvement: The overall efficiency of the process was enhanced by 5%.
  • Efficiency Variance Improvement: The efficiency variance saw a marked improvement, with a 13% uptick.

Conclusion

Anssum’s MEE Cleaning project in South Africa stands as a sterling example of the power of innovative solutions in the energy sector. By strategically employing KPIs and optimising cleaning schedules, the initiative not only extended the mean time between shuts for the MgO#2 evaporators but also significantly improved their efficiency.

“In the dynamic landscape of energy conservation, such initiatives underscore Anssum’s commitment to pioneering solutions that drive efficiency and sustainability. As we forge ahead, endeavors like these illuminate our path, showcasing the transformative potential of control engineering and process optimisation.“

SRP OPTIMISATION

STREAMLINING CHEMICAL USE FOR A GREENER SOUTH AFRICA

In the realm of chemical engineering and environmental conservation, the judicious use of raw materials is paramount. Anssum, in its pursuit of sustainable solutions, undertook an initiative in South Africa to optimise Slurry Response Processes (SRP). Let’s delve into the intricacies of this project and its commendable outcomes.

Project Overview

  • Focus Area: Chemicals & Environment
  • Country: South Africa
  • Description: SRP Optimisation
  • Status: Completed
  • Timeline: July 24, 2021 – August 4, 2021

The Objective

The primary challenge in many chemical processes is the efficient and precise control of pH levels. Mismanagement can lead to overutilisation of raw materials, resulting in increased costs and potential environmental hazards. Moreover, smoother slurry responses are essential for reducing slurry usage, which has direct implications for both cost and the environment.

The Anssum Approach

With the above challenges in mind, the SRP optimisation initiative was rolled out. The project focused on two main goals:

  • Achieving tighter control of pH levels using fewer raw materials.
  • Ensuring smoother slurry responses, leading to reduced slurry usage.

Using advanced monitoring tools and innovative process controls, Anssum was able to fine-tune the chemical reactions involved, ensuring minimal wastage and optimal results.

Technical Outcomes

The results of this initiative were both immediate and impactful:

  • Stability Enhancement: The processes became more stable, ensuring consistent and reliable results.
  • Reduced Raw Material Consumption: With the tighter control of pH levels, the use of raw materials significantly decreased.
  • Environmental Benefits: A direct consequence of using fewer raw materials was the reduction in emissions, further underlining Anssum’s commitment to environmental conservation.

Conclusion

Anssum’s SRP optimisation project in South Africa stands as a testament to the company’s dedication to sustainable chemical engineering practices. Through innovative techniques and a deep understanding of the processes involved, the project not only achieved its goals but also set a benchmark for future initiatives.

“In an era where sustainable practices are more crucial than ever, Anssum’s endeavors highlight the symbiotic relationship between industry and environment. As we continue our journey, projects like these pave the way for a more sustainable and eco-friendly future.“