Honeywell Pulp, Paper and Power Summit EMEA 2009
Hilton Helsinki Kalastajatorppa, Finland
30. September / 01. October
Lean
Times Demand Faster Results
Abstracts
To view abstracts for the breakout sessions please
click:
Keynotes
Pulp, Paper, Printing and Continuous Web
Solutions
OptiVision/MES
Power and
Alternative Fuels
Keynotes
Applications for Biomass
Combustion and Gasification
Presenter: Timo Kauranen, Andritz Oy
With the increasing number of new economic drivers for
biomass use in many countries, applications for energy
production are becoming attractive.
This presentation will introduce a number of different
applications for biomass combustion and gasification including
both traditional and innovative solutions:
-Steam/power plants with biomass boiler
-Fuel gas plants for kilns and for boilers (co-firing)
-Combined Heat and Power (CHP) plant with biomass gasifier and
boiler for district heating + motor for electricity production
-Integrated Gasification Combined Cycle (IGCC) power plant
-Syngas plants for natural gas substitution or for liquid motor
fuel production
Suitability of various kinds of biomass qualities for each
application will also be covered. As the selection of the most
feasible application is dependant on so many case specific
factors (existing infrastructure, biomass quality/fuel mixture,
legislation, taxation and other green drivers etc.), it is not
possible to give good general quidance for application
selection. However, knowing the portfolio of possibilities and
some presented "can/can't-do's" will help to focus evaluation
and speed up case development.
Innovative Technology Solutions and Services Ensure Reliable
Pulp Mill Automation – First Experiences from Botnia, Uruguay
Pulp Mill
Presenter: Jouko Kotilainen, Botnia S.A. Fray Bentos, Uruguay
Finland’s leading forest industry company, Oy Metsä-Botnia Ab
(Botnia), started up a million-ton-per-year pulp mill at Fray
Bentos in western Uruguay. The new mill, which began production
in November 2007, produces high quality bleached eucalyptus pulp
for the paper, paperboard and tissue markets. Botnia’s decision
to construct a cellulose processing facility in Uruguay marked a
major step forward in its global expansion strategy. In order to
maximize mill efficiency and profitability, and meet strict
environmental standards, Botnia needed to equip the Fray Bentos
operation with the very latest automation technology. This
included an advanced control system platform, asset management
tools, pulp machine quality controls and business optimization
solutions. The presentation will discusses the development of
Botnia’s Greenfield pulp mill, including challenges and
achievements, innovative technologies that optimized pulping
operations, as well as the international project team effort
that helped to ensure a smooth startup. Furthermore the
presentation will share the experiences from their first two
years of operation.
Innovation Needs of and Opportunities in the Forest Sector for
2010 and Beyond
Presenter: Jukka Kilpeläinen, Stora Enso Oyj
The driving factors of long term competitiveness for the
forestry sector to be focused on are
1. Stopping Climate Change and assuring availability of good
water. We have to use bio-based fuels, chemicals, plastics,
district heating, and electricity with the highest possible
efficiency when producing fibres, pulp and paper products. This
means an obligation to make our mills and their processes, as
well as all our products, sustainable.
2. Stop the explosive growth of the human population. “Education
for everybody, particularly women in developing countries as
they are the most critical target group. Good quality paper
products are a key element in education.
3. Give all nations of the world a fair chance to develop via
better trade agreements.This means more transportation packaging
needs.
Our sector, the whole cluster, has to build its future on
innovation. This means that we have to invest systematically in
sustainability, new business creation, technology development
and cross-disciplinary research. Within our network of partner
universities and institutes we have the capability to implement
very challenging cross-disciplinary research programmes. We have
to join EU Frame programmes for sector-specific research. A
critical success factor is to make the “Holy Triangle” work for
us – research, education and top talent availability. This
challenge we face equally seriously everywhere, on every
continent.
Our customers are experiencing major cost pressure. This is why
all manufacturing industry companies have to invest in
cost-effective and efficient solutions during all phases in our
operations. We have to be able to address issues both in the
short and the long term. A strategic development based on
sustainability must not rule out tactical challenges such as
considering trends and fashions in paper, new media consumption
patterns or adapting to new printing technologies. For us as
paper manufacturers it is crucially important to remember that
our most valuable innovations have their roots in the needs of
our customers.
Helping EMEA papermakers and printers survive the recession
and adapt to longer term global market changes
Presenter: Andrew Hird, Honeywell
This presentation will discuss some of the many challenges
facing current Pulp, Paper, Printing and flat sheet customers.
Traditional markets for these customers have been changing
significantly over the past decade, more rapidly in the past 12
months than ever before. Some of the key drivers for this change
are:
- technology revolutions changing the grades of paper our
customers buy,
- growing middle classes in the developing world driving changes
in consumption,
- significant supply/demand imbalances resulting in capacity
curtailments,
- major investments in China, India, Russia and Brazil changing
production bases,
We will look at the effects these changes are having on European
production competitiveness. Most international paper companies
are looking at evolving their business models to adapt to these
changed economic conditions – those that learn to adapt most
quickly will survive the current recession and improve their
profitability.
One area of particular, recent interest to all global P3
customers is the inherent potential of BioMass as a fuel
substitute, energy source and carbon sink. We will discuss:
- Government regulations adding further spark to the BioFuels
market
- An introduction to Alternative Fuels Markets and Technology
options
- A Canadian case study on – Municipal Waste to Energy
- A US case study on – Biomass to Transportation Fuels
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Pulp, Paper, Printing and
Continuous Web Solutions
Challenges and Lessons Learned in Greenfield Ahlstrom Glass
Fibre Tissue Mill Tver, Russia
Presenter: Pekka Helynranta, Ahlstrom
Ahlstrom built a new state-of-the-art mill in Tver, Russia. The
mill, which commenced operations last year, produces glass fibre
tissue for the Russian industrial consumer.
Glass fibre tissue is a paper-like material, which is mainly
used in buildings as well as by automotive and electrical
endusers. The tissue is produced on wet-laid nonwovens machine.
Tver line is 4,3 m wide and uses Ahlstrom’s proprietary
Dispro-technology in wet end and web forming. The line is a
“sister” line of a glass fibre tissue line used by Ahlstrom
Karhula, Finland. The process is very similar to the paper
production process with pulpers, dilution head box, forming
wire, curtain coater, binder wire and through-air dryer. The
line also consists of a metering size press and flotation dryer
to give tissue web added properties. To control and develop the
process and product properties, advanced process and quality
control systems were naturally needed on our line. After a long
history of good co-operation and partnership with Honeywell on a
similar line/process in Karhula, we were more than happy to
select the Honeywell solutions over those of others.
Honeywell installed its Experion® Process Knowledge System (PKS)
with PMD Controller with integrated Machine Control System (MCS)
and line drives control to efficiently manage key production
processes at the mill. In addition, Honeywell implemented its
MXProLine™ Quality Control System (QCS), which provides
measurement capabilities designed to improve information flow to
plant operators, thereby increasing plant efficiency. Finally,
Honeywell installed its Web Inspection System (WIS) for the
online detection, identification and visualization of paper
defects. Honeywell also provided services for engineering,
configuration and start-up of the system. Collectively,
Honeywell’s technology should maximize efficiency at the mill,
and in doing so, result in higher quality products.
This presentation shows challenges Ahlstrom faced in this
Greenfield project and also highlights lessons learned that have
the potential to add value by highlighting the importance of
co-operation as well as longstanding relationship between
purchaser and supplier.
Experion PKS integrated DCS:
Sectional Drives and Electrification Offering
Presenter: Arto Iivanainen, Vaasa Engineering & Markku
Lehtoviita, Honeywell
Honeywell’s Experion Process Knowledge System (PKS) and Vaasa
Engineering (VEO) jointly provide a single supply solution for
process, machinery, drives and electrification offerings.
Honeywell and VEO offer pre-engineered and standardized
solutions for greenfield and upgrade/replacement investments
including: pre-studies/mill surveys of existing drives and
control systems, electrical facilities and power distribution,
new or retrofit options for drives, converters, motors and gears
with new drive control algorithms.
Integrated process, machinery, drives and electrification
implementation offers single window User Interface to control an
entire production line enabling also common alarming and event
logging. Substantial capital investment savings in hardware and
software commissioning costs can be achieved using common system
components and engineering tools.
Honeywell and VEO have now delivered 40+ drive solutions on
Machines, Board machines, Off Machine Coaters, Supercalenders
and other Continuous Web Processes (CWS).
On the web tension formation in
rotary offset printing press
Presenter: Markku Parola, VTT
On the web tension formation in rotary offset printing press
The competitiveness of printed media requires better
productivity of printing presses while production without
runnability disturbances is a goal for every printer.
Maintaining sufficient tension levels and avoiding variations is
critical for ensuring good runnability in the press, which often
means less waste and smooth production. VTT together with
several printing related companies has carried out a project
where the tension formation and control in presses have been
studied in detail. VTT Technical Research Centre of Finland is
the biggest multi-technological applied research organisation in
Northern Europe. Companies participating the project were:
Honeywell, UPM, Stora Enso, MAN Roland, Goss International, KBA,
ContiTech, Aamulehti and Sanomapaino.
Extensive trials and measurements were performed on the printing
presses, on a pilot scale press and in the laboratory. In
addition, advanced modelling tools were used to simulate the
interaction between paper web and press.
Printing blankets are one of the first items in the
troubleshooting checklist for printers. Nowadays, blankets are
characterized as positive, neutral and negative, depending on
their feeding properties and their effect on web tension. In
this work, we used numerical tools together with well controlled
printing trials, in order to describe the effect of blankets on
the tensions between and after the printing units. We found that
blankets induce local straining at very high loading rates
inside the printing nip. Results showed that depending on the
combination of the blankets and nip loads in succeeding printing
units, the effect of an individual blanket on web tension can be
negative or positive. The web tension change introduced by the
nips is also affected by paper properties as well as the
geometrical configuration of the press.
Tension formation is the interplay between paper web properties
and printing parameters. In this presentation, we will introduce
new aspects of this interplay concerning the effect of blankets
and multiweb interaction.
Application of On-line Monitoring Systems for Paper and Tissue
Machines
Presenter: Ed Bondoc & André Smulders, SKF CMC Lulea
High efficiency has always been important in the paper industry
but more so in the current economic times when only the best run
operations will survive. Production capacity is now concentrated
on fewer machines, thus increasing the need for high reliability
and long operating life for critical components such as felts.
The key to ensuring that the right things are done at the right
time is good information, which in turn depends on systems that
reliably collect relevant data. Techniques and processes then
turn this data into useful information that has a direct impact
on how production assets are run and maintained.
For paper and tissue machines, many years of experience have
shown that the most effective way of gathering data reliably is
through the use of permanently installed on-line monitoring
systems. These systems not only operate automatically, they also
have the ability to adjust to the operating conditions of
machines and display “live” data and alarms so they are useful
to both operations as well as maintenance.
The use of dynamic analysis techniques (particularly vibration)
on paper machines has commonly been associated with detecting
mechanical problems that affect reliability (e.g. damaged
bearings, etc.). However in addition (and perhaps of greater
over-all value), these techniques can also be used for finding
problems for example on felts or nipped rolls, or anomalous
conditions such as head-box pulsations, all of which directly
affect the operation of the machine and quality of the product.
By correlating the variations in measured quality parameters
such as moisture, basis weight, and caliper to upstream sources
it is possible to get to the root of many operational problems
quickly and make the appropriate adjustments.
This presentation discusses the current systems and techniques
used for monitoring paper and tissue machines for increased
process and mechanical reliability. Several examples of the use
of the techniques based on real-life applications will be
presented.
Batch Digester Control Using An On Line Kappa Analyzer
Presenter: Tom Biazzo, BTG Instruments
This paper will discuss the implementation of batch digester
control after the installation of an on line kappa analyzer.
Implementation of the analyzer and digester control allowed the
mill to improve the wood yield (decrease amount of wood per ton
of pulp) by frequently sampling from the digester blow tank.
With more frequent pulp sampling and use of the on line kappa
analyzer the mill gained better control of the digester kappa.
They could decrease the standard deviation of the digester kappa
allowing them to increase the average kappa from the digester
and increase the wood yield. The result was a decrease in their
overall wood costs which paid for the project in less than 1
year.
The Benefits of Post Processing Control
Presenter: Jason Zyglis, Cognex Corporation
Honeywell’s Advanced Winder Advisor (AWA) control application
has been successfully installed on over 100 winders worldwide.
This new technology can provide absolute stopping accuracy of
5-10 centimeters and has enabled these facilities to effectively
address critical defects while optimizing winder throughput by
20-30%. By using visual marking codes applied on the paper
machine the Advanced Winder Advisor, supplied by Cognex, can
also calculate yield by accurately measuring slab loss and spool
loss. Furthermore, this patented code marking technology enables
the same stopping accuracy on any winder without modification to
the drive controller.
This presentation shows the economic and process benefits
realized by customers using a vision based camera system that is
coupled with post processing tools. The final predicted payback
period is <6 months through increasing winder throughput,
reducing customer complaints and reduced web breaks at coaters
and other downstream processes. This presentation also
highlights similar opportunities to use code marking technology
to optimize other post processing applications.
Integrated Line Control for Biaxial Oriented Film Lines
Presenter: Ilkka Penttilä, Ab Rani Tervakoski Oy
Revamping a biaxial oriented film machine can be a very
expensive process. Often a 10 year old line can be considered by
machine builders as ‘past their best’, prompting discussions
about replacing it or a full scale refurbishment which can be
very expensive.
Rani Tervakoski needed to upgrade their lines to increase
production and improve quality. Their solution was to work with
a process vontrol company to revamp their line, where they could
have more influence on the design and achieve the results they
were looking for.
The presentation details the scope of supply undertaken by
Honeywell and the Integrated Line Control provided by the
Experion system.
Image Analysis Technology Brings New Opportunities for On-line
Measurements
Presenter: Antti Paavola, Honeywell
Camera technology and image analysis are developing at an
increasing rate, extending to numerous new areas of application.
The on-line imaging measurement of the paper web is a
significant solution that has evolved from this technology. The
challenge includes handling the extremely high paper web speeds
and the web’s varying optical transmittance and reflectance
properties. To make these measurements of value in the paper
industry, the technology must be able to obtain high-quality
images from all paper and board grades, under all circumstances.
This requires the use of state-of-the-art camera and
illumination technology.
Honeywell has seriously invested in this technology with the
outcome being a new family of camera-based, on-line sensors:
FotoForm for formation analysis, and FotoFiber for surface fiber
orientation and anisotropy measurement.
The presentation introduces this new image analysis technology,
explains operating principles of these on-line measurements, and
discusses results of field installations from various customer
processes.
Technology and Products update Roadmap 2009
Presenter: Harri Oksanen, Honeywell
Honeywell technology and products have been designed for
optimizing the total business instead of serving point
solutions. This provides best in class solutions with
operational integration supporting the goals of safe, reliable
and efficient plant operation. In the latest developments of
Experion Process Knowledge Systgem (PKS) industrial security,
safety and Fire&Gas applications are tightly integrated with the
DCS.,.
For the power and energy industry, Honeywell provides solutions
for alternative fuels and energy management by optimizing the
combustion processes and improving boiler load allocation.
For the Pulp and Paper industry, Honeywell technology supports
efficient production line optimization through tight integration
of quality measurement and control applications within Experion
PKS. Unique quality sensors and process optimization
applications save energy, steam and raw materials, and improve
operational efficiency contributing to the companies bottom
line.
Continuous evolution has always been part of Honeywell’s
strategy. Migration solutions from Total Distributed Control
(TDC), PMD (Process, Motors, Drives) and MxOpen platforms
provide greater ROI over lifecycle of the control system for
true investment protection.
This presentation shows how Honeywell technologies help
customers survive through lean times by enabling performance
improvement through situation matched strategies, and provide
bottom line economic benefits.
Printa Printing Simulator
Presenter: Santtu Mäki, Honeywell
The Printa Printing Simulator allows print operators to be
trained on printing press procedures without incurring the high
costs associated with using a normal press. The concept is
similar to flight simulators used for training airline pilots.
With this system, the use of expensive press time as well as
paper or ink can be minimized in the training of press operators
and other printing plant personnel. The user interface of the
Printa Printing Simulator is the same as the press operator’s
standard user interface, which makes it easy to transfer the
learning experience to live operation. The system provides
several standard exercises, but it also allows the definition of
new exercises to cover customized requirements.
Exercises cover managing press quality issues as well as coping
with other types of events occurring during a print run. The
system is also a good tool for easily disseminating best
practices within the printing plant.
The system is a joint development of Honeywell and Sinapse
Print.
The presentation will describe the key features of the system
and the Printa Printing Simulator will also be available for
live demonstration.
Life Cycle Management & Printa System Migrations
Presenter: Juha Kankainen, Honeywell
Computer-based distributed process controls (DCS) came to the
process industry in the 1970’s. In the printing industry the DCS
based press controls became common by the 1980’s. Honeywell
(Altim Control) installed in June 1984 the world’s first DCS for
a printing press, in the Savon Sanomat printing plant in
Kuopio-FIN. Since then, almost every new press has been equipped
with a DCS press control system.
Now these first generation DCS systems – installed in the 80’s
and 90’s – have arrived the end of their lifecycle. There are no
spares available, knowhow to operate and repair them is becoming
scarce, the reliability is declining, and the newest features
are not available. However, the biggest question is,what is the
best strategy to update these systems? Replacing the entire
system at once means high cost and high risk. A better approach
is to create a migration plan where the costs are spread over a
longer time, and the risks are minimized. Honeywell’s Life Cycle
Management offers a systematic way to achieve this type of
migration.
As a leading vendor of process automation systems, Honeywell has
always put strong focus on helping customers protect their
investments by getting you started down the path to
modernization today and getting there incrementally as your
plant needs, budget and schedule dictates. Honeywell’s roadmap
for Printa includes Lifecycle Management for all customers who
want to modernize, but need to do it in a gradual, systematic
manner.
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OptiVision/MES
Logistics Service Center and eTerminal
Presenter: Peter Colpaert, Stora Enso
In 2005 Stora Enso and Honeywell started a joined development to
fully automate and optimize its transportation logistics
operations at the Langerbrugge mill in Belgium. In 2007 Stora
Enso decided to fully automate all in and out going truck
traffic for paper delivery to customers, again with help from
Honeywell. The solution is now installed in all Belgium mills
and distribution centres, and currently Stora Enso and Honeywell
are working on installing the solution in all StoraEnso
facilities. The Logistics Services Centre (LSC) solution not
only optimizes logistics and mill traffic, but also achieves
substantial cost savings in pay-loads and manpower. The
eTerminal solution is designed to work in more than 20 languages
and is perceived as extremely user friendly. It reduces waiting
and loading time of the trucks and is adds to the safety on the
mill property by controlling the number of trucks allowed on the
property at once. The system is designed to easily integrate
with different ERP and MES systems.
Advanced Production Monitoring
Presenter: William Smit, SCA Containerboard
Today’s paper business demands sharp and alert machine operation
to be as efficient and effective as possible. A fast overview on
the performance of recent events is essential. The combination
of OptiVision and PHD makes all the data (i.e. production, real
time process, quality and costing data) available for everything
you want to know. But what we need is an easy tool to provide a
comprehensive presentation of the right information out of this
massive amount of mill data. SCA Containerboard developed, in
partnership with Honeywell, a tool combining PHD with OptiVision
event monitoring, Quality OptiMiser, tracking, costing and
reporting: the Advanced Production Monitor (APM), an interactive
tool providing state of the art graphical presentation.
This presentation will talk about the development and
functionality of these tools and ends with a demonstration of
OptiVision APM.
OptiVision for Tissue
Presenter: David Wojciechowski & Vim Vranken, Honeywell
In today’s marketplace, you need systems that, in addition to
reporting your backlog and schedule accurately, allow you to
meet customer requirements with accuracy and achieve delivery
schedules at the maximum margin. You also need to be able to
manage and control production and quality. With OptiVision for
Tissue Business Logic, you have that capability. Your return on
investment is realized by factors such as agility to respond to
demand, greater operational efficiency, better managed
inventories, increased output per worker, as well as accurate,
on-time delivery. This special MES package will be discussed and
demonstrated in this session.
Sheeter Scheduling and GPlan
Presenter: Mats Edling (tbc), Grycksbo Paper and David
Wojciechowski, Honeywell
In today’s marketplace, you need systems that report your
sheeter backlog and schedule accurately allowing you to make
optimal use of your sheeters while meeting customer
requirements. Honeywell has significantly improved OptiVision’s
sheeter/converting related functionality and capability with
help from Grycksbo and other customers. More than 50 new
features provide additional value. This new functionality is now
running in production at Grycksbo and NewPage and will be
commercially available with OptiVision’s Release 530. Additional
features and advantages will be presented and demonstrated in
this session. Also, Grycksbo will present their tracking
procedure and real-time production status with GPlan
functionality.
OptiVision 530 and OptiVision
Roadmap
Presenter: David Moron & Vim Vranken, Honeywell
Honeywell will introduce OptiVision’s Release 530. Differences,
advantages, improvements and ROI between Release 520 and Release
530 will be discussed. This new Release will be commercially
available in late 2009. In this session Honeywell will also
present and discus OptiVision’s technical and functional road
map.
OptiVision for Pulp
Presenter: Jukka Henriksson, Sunila (tbc), David Wojciechowski,
Honeywell
Honeywell has designed a full scope MES solution to operate
in stand alone pulp facilities as well as in integrated pulp and
paper facilities. Some of the benefits this package includes
are: meet customer commitments 100% of the time; manage and
improve work-in progress and finished-goods inventory levels;
find hidden capacities in your operation; provide
up-to-the-minute information across your organization so the
right business decisions can be made. This solution is also
designed to seamlessly integrate with Honeywell’s Pulp Slurry
Production Tracker. This solution provides time-based or
sample-based material quality testing before being added to the
process. The pulp slurry can be tested at different places in
the process through tests associated with either a time, a
sample ID, or a grade. This solution also provides forward and
backwards traceability based on time. This special MES package
will be discussed and demonstrated in this session.
Actual Costing
Presenter: Mr. El-Zubair, Obeikan (tbc) and David Moron,
Honeywell
The OptiVision Actual Cost solution will permit cost
controllers and production managers to capture production
performance and costs based on actual consumption of raw
materials, production, prices of raw materials, GL spending,
finishing materials, and freight calculations. The resulting
information enables the facility to improve performance by
providing visibility of production costs. In addition, this
information can be used to ensure that targets and standards are
realistic, that cost deviations can be analyzed and decisions
are made on profitability. Production is recorded in OptiVision
and raw material consumption is also fed into the system so that
production costs can be calculated . By identifying data at the
inventory level, profitability can be analyzed by individual
order, customer and market. Costs can be accumulated by cost
centers, runs and grade specs. Production performance can be
determined by machine hours, by ton or by square area. Factors
such as machine downtimes (both scheduled and unscheduled),
downgrade of off quality production, management of broke
operations, etc will be taken into consideration to arrive at
cost data. Both manual and automatic data collection methods (by
shop floor interfaces to flow meters, etc) will be supported for
raw material consumptions.
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Power and Alternative
Fuels
UPM Caledonian Bio Boiler project
Presenter: Jorma Johannson, UPM Kymmene
At the end of 2006, UPM announced a 115M€+ million investment in
a new biomass Combined Heat and Power Plant (CHP) at its
Caledonian paper mill in Irvine, Scotland.
The new power plant will replace the current coal fired boiler.
This investment is part of a long term plan to reduce the
company’s fossil CO2 emissions from their production processes.
This investment will enable UPM Caledonian to generate the
entire process heat and most of the electrical power needed from
a renewable energy source which will lead to economic and
environmental benefits. The start-up of the new boiler is
scheduled for Q2 2009.
UPM Caledonian selected Honeywell as their automation supplier
for this project. The delivery includes the Experion PKS system,
project services and the mill steam network management.
This presentation introduces the bio boiler project and its
automation concept to the audience and highlights the reasons
why Honeywell and its use of cleaner and greener technologies
was selected as the automation supplier . This presentation also
highlights lessons learned that have the potential to add value
to any bio boiler project.
Fortum Inkoo Block Number 2 Automation Rebuild project
Presenter: Markus Pyykönen, Fortum
The Inkoo power plant is located on the coast of the Gulf of
Finland in Inkoo, around 60 km from Helsinki. The power plant’s
four blocks became operational in 1974, 1975, 1976 and 1978
respectively. The power plant’s combined output is 1,000
megawatts. Each of the four blocks operates independently.
The power plant was originally built with the aim of addressing
the constantly growing demand for electricity in Helsinki.
Recently, the plant has operated through high peak demand
periods and acted as a back-up power plant.
In mid-2008, Fortum announced an Automation Rebuild Project,
consisting the re-build of an old Siemens analog automation
system for block number 2. A decision was made to invest in
securing the plant’s operations for 25+ years to come by
improving the plant’s efficiency and productivity. Due to the
nature of the plant, its requirements for reliability,
automation and safety are very high.
Honeywell was selected as the supplier for this project. The
delivery includes the Experion PKS main automation system, the
Honeywell Safety Manager System (SMS), the Integrated Turbine
Control System, the Operator Training System (OTS) and project
services. The commissioning of the new automation system is
scheduled to be finished in late Q4 2009.
In addition to a description of the Automation Solution, the
presentation will address the key factors and challenges in this
type of automation project and the results to date.
The benefits of Integrated Turbine Controls within the
Honeywell Experion Environment
Presenter: Ian Stuart & Neil Adams, Wood Group Turbine System
Solutions
Wood Group Turbine System Solutions (WGTSS) is the Centre of
Excellence for controls related matters within Wood Group. For
five years, WGTSS has collaborated with Honeywell to develop and
apply rotating machinery solutions to meet client needs that can
be implemented within the Experion Platform so as to provide the
client with a fully integrated solution.
WGTCS has carried out more than 15 projects directly contracted
to customers who own a Honeywell Distributed Control System
(DCS) and who wish to integrate the control of their turbines
within the DCS. These projects have been very successful,
allowing customers to save on training and spare parts. Last
year, Honeywell, supported by WGTSS, won the contract to provide
Fortum with a DCS upgrade at the Inkoo Power Plant, and WGTSS
was subcontracted to provide the turbine controls, based on
Experion C200; this system is currently being commissioned at
the site.
Honeywell, with technical assistance from Wood Group, is now
developing a version of the Experion C300 that can be applied to
real time, high speed, turbine control. This development offers
even greater integration, improved operational flexibility and
maintenance reporting.
This presentation provides insight into Wood Group, our services
and capabilities to support Honeywell and our customers for all
rotating machinery applications, providing a fully integrated,
seamless controls solution for all aspects of the plant.
Adding Value to Forest Residues:
Proven Second Generation Technology for Liquid Biofuels
Production
Presenter: Monique Streff, UOP Renewable Energy and Chemicals
The marketplace for renewable fuels has received significant
attention in recent years, with increased focus on technologies
that provide fuel flexibility and reduce greenhouse gas
emissions. Recent legislation in many parts of the world, most
notably the Renewable Energy Directive in the EU and the Energy
Independence and Security Act in the US have increased the level
of attention on new technologies to enable the sustainable
production of renewable fuels.
One such technology is the Rapid Thermal Processing (RTP)TM fast
pyrolysis technology offered by Envergent Technologies LLC,
which is a joint venture between Ensyn Corporation and UOP LLC.
RTP converts second-generation biomass into pyrolysis oil for
power generation, heating fuel and for conversion into
transportation fuels. Significant resources are being invested
in both the characterization of pyrolysis oil, as well as the
upgrading of the oil for use in the production of renewable
transportation fuels.
Pyrolysis of biomass has actually existed for many years, but it
is only in the last several years that a combination of high oil
prices, a recognition of the environmental consequences of
unfettered growth in fossil energy demand, and a need to
diversify sources of energy supply has propelled this technology
back into the limelight. Today, RTP is a commercially proven
technology that is more consistent, flexible, economical and
environmentally friendly than other biomass processing routes
such as direct combustion, gasification or Fischer Tropsch.
This presentation will describe the RTP pyrolysis technology and
the green energy applications for pyrolysis oil. In conclusion,
the discussion will provide a picture of the role of forest
residues and RTP in addressing growing renewable fuels needs
worldwide.
The UOP Selexol Process, a Proven CO2 Capture Technology
Presenter: Robin Matton, UOP
Recent European legislation requires operators of all new
combustion plants with a rated electrical output of 300 MW or
more ensure that their facilities can be fitted with CO2 capture
and that the transport and storage of the CO2 is technically and
economically feasible. The capture of CO2 from gas streams
produced by the gasification of fossil and biomass fuels,
whether for the production of hydrogen, chemicals or power
(either singly or in combination), can be relatively more
economic than its capture from gas streams from other combustion
technologies. The UOP Selexol™ process offers a proven route for
CO2 capture from gasification plants. UOP has developed, and is
in the course of engineering, several flow schemes that offer
phased investment for CO2 capture with relatively high
efficiency and the capability of meeting the required
performance standards. This presentation will describe the
characteristics of the flow schemes and give examples of their
commercial application.
Solutions for Industrial and Utility Power
Presenter: Pascal Stijns, Honeywell
Within the Europe, Middle East and Africa (EMEA) region there
are two major factors driving capital investment in the power
generation industry. For Western Europe, the regulatory
environment and government initiatives are fueling investments
in “green energy”. Energy efficiency technology and renewable
feedstocks to replace coal, oil and gas will be the required to
reduce emissions to acceptable levels in this region.
Honeywell has Energy Management Solutions that include the
Energy Dashboard to identify areas in which energy use and
emissions performance can be improved as well as several
advanced control and process optimization technologies that will
improve environmental performance at the same time as increase
asset availability and reliability and reduce operating costs.
Honeywell also has technologies utilizing alternative fuel
sources to improve regulatory compliance, and the engineering
expertise to help power generators transition to these new
feedstocks..
Eastern Europe, especially Russia, and Africa have capacity
issues to overcome, as their industrial landscape rapidly
develops. These countries have large untapped natural resources
for generating power such as hydro, coal and solar, but they
require proven solutions to bring new assets online to keep up
with the growth in demand.
Honeywell has global and local resources, expertise and
solutions for Greenfield power generation projects as well as
major plant upgrades in all types of power plant concepts
ranging from coal to hydro. Honeywell has more than 40 years of
experience and has worked together with major power customers to
develop a comprehensive portfolio of optimization products and
services.
This presentation shows Honeywell’s capability to maximize
business results in existing power plants as well as it’s strong
global engineering capabilities to guarantee high quality
project delivery for major Greenfield investments throughout the
entire EMEA region.
Power Generation and Forest Base Feedstock – promising for
the environment but commercially a long, challenging journey
Presenter: Timo Saarelainen, Honeywell
Globally, in the power generation industry there is a trend to
discover ways to save the environment, while meeting commitments
to deliver power to customers. There are many initiatives in
place to reduce greenhouse gas (GHG) emissions and reduce energy
use or change the way in which energy is used in the generation
of power. Many initiatives are in place that cover several
methods for accomplishing this; some using existing technology
and methodologies and some new ones. One approach is to deploy
energy optimization solutions, where much of the technology
already exists today. Another one is using renewable sources of
energy for power generation employing new technologies and
feedstocks.
When you think of renewable energy sources, you typically think
of hydro power, wind and solar power solutions, but smart
engineers are also looking at new technologies for utilizing
forest-based feedstock for power generation purposes. For the
European region, this is the most viable option for renewable
energy due to its availability and suitability for the large
scale needs of the population. Most other options need a lot
more research and development before they are ready for reliable
use in Europe.
Traditionally timber and other available raw material from
forests have been used in pulp, paper and mechanical wood
industry products. The entire business model globally has been
developed to optimize this supply chain channel starting from
forest owners through manufacturing plants up to consumers.
Today, the Pulp, paper and mechanical wood industry is going
through major restructuring programs globally at the same time
there is a macro trend to shift energy production towards
renewable energy sources like forests. Timing is great for both
initiatives. Finding new products for forest-based raw materials
and at the same time moving toward renewable energy production.
This presentation shows the opportunities and also the
challenges in the area of using forest-based feedstock for power
generation. It will concentrate on the commercial challenges in
finding a suitable and sustainable business model for the
future. The first obstacle will be to change the expectations of
forest owners who traditionally see their raw materials go into
producing high class timber or very glossy paper for magazines.
How difficult will it be for them to make the paradigm shift to
selling forest products as a energy source?
Advanced Energy Solutions for Circulating Fluidized Bed (CFB)
Boilers
Presenter: Keijo Manninen, Honeywell
A novel advanced control strategy has been implemented on
Circulating Fluidized Bed (CFB) boilers in world class
reference. The primary goals of the optimization project have
been to improve stability of key combustion process variables,
improve effectiveness of limestone use, and to improve boiler
combustion efficiency under tightening emissions limits.
The plant operates two Foster–Wheeler 310 t/h superheated steam
CFB boilers burning a mixture of coal and coke. The CFB boilers
were operated with a standard design PID control strategy in a
dDistributed control system. The fluidized bed combustion shows
strong interactions between process variables, and standard PID
control, did not fully meet operational requirements.
A model based predictive multivariable controller is robust
enough to handle complex processes with multiple interactions,
and it has been designed and installed on these boilers. The
advanced controller makes use of inferential sensor of
immeasurable char and lime inventory in the fluidized bed, which
essentially influence boiler released heat, bed temperature,
flue gas emissions, and efficiency of the limestone calcination.
The controller thus implements a novel CFB control strategy
based on utilization of accumulated bed char inventory. The bed
temperature was originally manually kept between 860 — 900 °C by
operators. Now it is automatically maintained with standard
deviation of less than 1 °C at a given reference value, optimal
for SO2 emissions removal. The SO2 emissions, originally only
monitored, are now controlled with standard deviation less than
25 mg/m3. These measured results indicate significant
improvements in stability of boiler operation. The boiler
thermal efficiency, fuel and limestone consumption are now being
further optimized respecting given emissions environmental
limits and plant dynamic response requirements. The operational
improvements have been achieved by software tools without major
boiler hardware refurbishment.
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