2007年3月 紙パ技協誌

On the Occasion of the Manufacturer's Presentation (Maker's Lecture), the 30 Years of History for Instrumentation

Process Control and Automation Committee, JAPAN TAPPI

 As a memorial to the 30th anniversary of instrument show, we have planned a manufacturer's presentation. "The History and Future" of instrument system are presented by various manufacturers. At the same time, we made the chronology of "The instrument technology of pulp and paper" and insert them.

Innovation of Technology, History and Future Technology for QCS

Satoshi Nakamura
Process Solution Pulp & Paper, Honeywell Japan Co., Ltd.

 Fundamental technology of basis weight sensor was funded in ‘40s and it was used for survey meter for radiation. Since first QCS was introduced in '50s to the paper market, technologies for QCS were dramatically changed. Recently, Honeywell introduced new and unique technologies as SpectraFoil, Express Moisture sensor, GalView, Laser caliper sensor and Multi variable controls for Supercalender. And advanced camera technologies are used for new generation's sensors as formation and fiber orientation. We believe those technologies are going to contribute making better paper in terms of quality and productivity.

Innovating Distributed Control System
- The Past and the Future -

Masatoshi Nakahara
PA Solution Dept., YOKOGAWA Electric Corporation

 Distributed Control System (DCS) appears on the market as a substitution of a panel instrument or a distributed system of Direct Digital Controller. At the beginning stage DCS was growing based on the severe evaluation and the feedback from the customers of all process industries and finally DCS established the firm position as one of the indispensable equipments in the process industry. During this period the technical development of computers was remarkable and our office environment changed drastically however the basic architecture of DCS has not changed. This proves that DCS abstracted the necessary functions highly and integrated them from the beginning. Currently the production activity of the company regarded as one system. All the function in the company evaluated as the contribution of the profits of the company as a whole. Naturally, the expected role for DCS exceeds a limit as merely a distributed control system and it should be innovated as an important platform to operate the plant.

The WIS of Evolution and its History and Future

Masahiro Nakata
W.I.S. Group, IT Solution Division, Omron Corporation

 Now, the demand to the improvement in quality from a market increases further, and especially the quality demand of the surface defect of the packing material of food and medicine is remarkable. Each packing material maker planned the performance rise of surface defective inspection equipment more often, in order to respond to it. On the other hand, low cost and rationalization are advanced for company survival. OMRON had about 2500 sets of the history of the enterprise of about 30 years. The delivery track records, expectation and a demand to the domestic maker from a user also had a severe thing especially. Positioning in the field of WIS is also severe and the equipment trouble has become a situation of carrying out a line stop and making it restore. Therefore, the demand of reliability to 24-hour operation is high. Also in order to answer to the expectation and the demand patronage-obtained for years from a user, in OMRON, it supposes that a model change is undergone as inspection equipment of the 7th generation, and came to develop "Super NASP". "Super NASP" is used as the indicator which respects and develops the opinion of a user, specification is determined as the basis of cooperation of a user. The viewpoint of its history, present, and future of WIS has described the text.

About the History and the Future of the Evolving MES

Yasuki Nagai
Industrial Systems Solutions Department
Industrial Systems Division

 In this paper, we introduce MES (Manufacturing execution System). We first describe the history, and, next, explain the system that applies the Web applications as one of the latest technologies of MES.
 As a merit of the system that applies this technology, the long-term use for the application software, and the extendibility of the system are shown. It explains the function of the information system in the future at the end.

Technology Innovations of Field Instruments
- Technology Innovations of Flow Measurement -

Fumitaka Nozawa
Yamatake Corporation, Advanced Automation Company
Industrial Products Marketing Department

 The customers utilize the differential pressure flowmeters and electromagnetic flowmeters on their sites to measure steams and pulp slurries. However these flowmeters have some issues to measure them stably. Especially the differential pressure flowmeters have clogging problems in the lead pipe, and the electromagnetic flowmeters have adhesive problems on the lining by pulp slurries. In this writing , I will propose the solutions for steams applications, and for black liquor and green liquor applications.

A Multivariable Brightness Control of Bleaching Process by Model Predictive Control

Masahiro Kawakita
Kasugai Mill, Oji Paper Co., Ltd.
Yoshitatsu Mori
Pulp and Paper Research Laboratory, Oji Paper Co., Ltd.
Jun Nishimura
Industrial Solutions Business Headquarters, Yokogawa Electric Corporation

 The needs of the optimal control for paper mills are increasing. The optimal control can reduce the cost and increase the productivity. MPC (Model Predictive Control) is a controller which can control the multivariable and long delay time system optimally, so the MPC is suitable for the optimal control of the paper plant.
 We applied the MPC system to the soft wood bleaching process of the KASUGAI Mill for the brightness control. The purpose of the brightness control is to stabilize the discharged final pulp brightness and to decrease the chemical cost.
 The sequence flow of the target bleaching process consists of [D1-E/O-P-D2] stages. At first, we applied this MPC system to the D2 stage of the bleaching process to verify the controllability of MPC to bleach process. As the result, we could see the contribution effect of the MPC system to stabilize the final brightness. The next target is to expand and to improve the MPC system to cover the whole process of the bleach plant.

Example of Waste Water pH Control by Fuzzy

Takayuki Ohkura
Saga Mill, Oji Paperboard Co., Ltd.

 Seven loops of pH control for wastewater treatment plant at Oji Paperboard Saga Mill, which used to be taken control of with conventional PID algorithm, did not totally satisfy with its control response.
 Generally, pH controls for neutralization process have non-linear characteristics. In addition, dead time would be long at the wastewater treatment plant because of limited installation location of pH meter and would vary depending upon discharge volume. Accordingly, time consuming fine tuning procedure for PID parameters just covers some specific conditions, but never represents satisfactorily entire status of the plant.
 In this article, introduction of fuzzy control system in two out of seven pH control loops which had worse performance and had been strongly claimed for modification, significant improvement in control response and reduction of neutralizing agent cost after installation as well as principle of two loops with fuzzy system are summarized.

About the Adoption Made of the Other Companies DCS in the DCS Superannuation Update

Hirokazu Tanaka
Soka Mill, Nippon Daisyowa Paperboard Kannto Co., Ltd.

 DCS introduced first in the grass processing place has passed 20 years since it operated, and has come to interfere from the production stoppage to the spending passing of time increase remodeling.
 In addition, the problem of the part supply and the maintenance time limit was instituted by the manufacturer, and the examination of the system update in parallel with the life prolongment measures started.
 It was judged that it was possible to change in a short time comparatively because the update by the migration method was proposed by another manufacturer, and the update of the entire system became possible without detaching external wiring and executed it though a phased partial update by the same manufacturer was examined from the relation between the budget and the construction period at first. It reports on the update case by the migration this time.

Improvement of DCS (Distributed Control System) Operation Under the Environmental Optimization of Industrial Conditions

Yasuhiro Miki
Mishima Mill, Daio Paper Corp.

 For the last 4 or 5 years, incidents of DCS failure had been increasing at our Mishima Mill. Due to the increasing downtime these events were causing, the company undertook an in-house project to identify the causes and develop methods of reducing such failures.
 We analyzed the system's environment and the hardware's susceptibility to a number of potential irritants such as dust, temperature, humidity levels and corrosive gases (like hydrogen sulfide(H2S), sulfur dioxide (SO2), etc.) to see if we could reveal an obvious culprit. Our team also focused on improving the general conditions in control rooms and computer areas to make them more machine-friendly.
 In this report we detail the processes we followed to isolate the control system's physical vulnerability vectors and the steps we've since taken which have resulted in a marked decrease in the number of hardware failures.

Installation of Next-generation Web-inspection-system and Verification of System Performance

Tomoyoshi Kudoh
Ishinomaki Mill, Nippon Paper Industries Co., Ltd.

 The web-inspection-system is one of the indispensable systems as a tool of a quality control and defective cause investigation for paper making.
Nowadays, reconversion of the system is achieved as full-digital system according to digital camera adoption. Nippon Paper Industries has been developed the next-generation web inspection system in collaboration with OMRON in earnest since March, 2005.
 In this paper, conquest of the weak point of an old Analog web-inspection-system and the circumstances of the improvement, the introduction details and quality assessment to the present stage of the system, and the future view are described.

Current State and Development in the Future of GelView Sensor on No.5 Coater

Yutaka Maemura
Maintenance and Engineering Dept., Mitsubishi Paper Engineering Co., Ltd.

 Old Honeywell QCS (MX-2002ET) on No.5 Coater in Hachinohe Mill was upgraded to new Honeywell QCS (DaVinci) on August 2005.
 DaVinci System can consolidate various Honeywell new sensors. The one of them is GelView sensors which are installed in the dryer to measure the coating surface quality directly after the coater head. GelView would make it possible to optimize the evaporation rate in MD position and coating speed, which lead to the improvement of the coating quality and the reduction of the energy of the dryer. GelView sensors were installed in June, 2006.
 In this article, the results of the introducing GelView and the future of GelView would be reported.

Report of 2006 TAPPI Engineering, Pulping & Environmental Conference

Koki Kisara
Oji Paper Co., Ltd.
Shinichi Onogi
Nippon Paper Industries Co., Ltd.

 2006 TAPPI Engineering, Pulping & Environmental Conference was held in Atlanta, GA, USA from November 6 to 8. This conference included 110 presentations, 5 Panel sessions and 4 Workshops. In this report, the review of the conference and some presentations are presented.

Development of Manufacturing Process for High Quality Calcium Carbonate by Causticizing Process in a Kraft Pulp Mill
- Part2: Controlling Factors for Precipitation of Aragonite -

Haruo Konno, Yasunori Nanri and Hideyuki Goto
Pulp and Paper Research Laboratory, Nippon Paper Industries Co., Ltd.
Kazuto Takahashi
Gotsu Mill, Nippon Paper Chemicals Co., Ltd.
Mitsutaka Kitamura
University of Hyogo, Graduate School of Engineering

 Precipitated calcium carbonate is produced as a by-product in the causticization step of the kraft pulping process. There are many advantages to use this by-product, causticizing calcium carbonate (CCC), as filler and coating pigment in paper. By using this CCC for paper materials, lime-kiln operation can be shortened or stopped, resulting in the reduction of fuel oil for calcination of calcium carbonate. Furthermore, accumulated impurities in the lime cycle can be removed constantly. In our previous reports, we showed that aragonite crystal with high quality performance was obtained in the causticizing reaction. However, it is not clear the reason why high quality aragonite crystal could be obtained by the causticizing reaction. In this paper, the effect of reaction conditions on the precipitation of aragonite was precisely investigated. The results showed that aragonite crystal could be obtained under the conditions at optimum temperatures with low CO concentration. In addition, the presence of NaOH in the mother liquor accelerated the precipitation of aragonite crystal. These favorable conditions to precipitate aragonite crystal can be easily formed in the causticizing reaction; therefore, causticizing reaction is suitable to produce aragonite crystal.

Keywords: Causticizing reaction, calcium carbonate, aragonite, crystallization