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

+ Chip quality
6 October, 2018
+ Stable brightness
+ Lower final brightness
+ Optimum/stable Kappa
+ Optimum/stable residual alkali
+ Production/yield
© 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
production as I can,
taking into account the
restrictions I always
have.”
“I want to maximize
my mill availability.”
“I want to stabilize the
production as much as
possible, even during
unplanned process
disturbances.”
“How do I manage my
inventories to meet
the production plan
most efficiently?”
“I want to optimize my
raw material and furnish
blends to achieve quality
at lower cost”
“I want to coordinate my
pulp mill quality control
targets with my paper
machine grade targets”
“I want take my APC’s to next
level - increased overall
benefits compared to the more
typical unit process based
optimization approach”
“How do I decide my
chemical makeup
requirements?”
“I need facts and
support when planning
CAPEX investments”