The paper and pulp industry is highly competitive and must meet ever-changing market needs. Yokogawa helps realize energy-efficient plants which are globally sustainable. The demanding applications and severe process conditions in pulp mills pose challenges for accurate, repeatable, and reliable liquid analysis measurements.
By combining the field-proven superior design of application-specific technology, Yokogawa’s solutions provide the functionality and the flexibility to adapt quickly to the changing industry requirements; while guaranteeing performance throughout the lifecycle of the process measurement even for the dirtiest applications lies in your hands.
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Dedicated support staff and regional support specialists are available to help you tailor the appropriate products to your application needs. |
Yokogawa delivers measurement and instrumentation devices that offer extreme precision with dependable measurement accuracy, application flexibility, reliability, and serviceability. Creating value for you in both time and money savings.
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Verified Performance“Unnoticed problems upstream can cause irreversible problems for me downstream.” “Failure with instruments in service can cause loss of product or quality problems for me.” |
Designed to Last“I just need to keep the instrument running. I worry about unplanned outages.” “I worry about plant obsolescence and the costs of keeping plant instrumentation and control systems current.” "We use old technology because we can't seem to justify the upgrade." |
Plant Wide Integration“I worry about plant obsolescence and the costs of keeping plant instrumentation and control systems current.” "I am concerned with the plant engineering resources utilized to make modifications or maintain the systems. There just is not enough people." |
Total Insight is a Yokogawa concept for optimizing operations and reducing maintenance costs through every phase of the product lifecycle. The real-time diagnostics and sensor wellness for early detection of sensor failure and replacement enable you to have a more pro-active maintenance schedule. No more unplanned outages.
Yokogawa’s field-proven instrument can withstand the severe process conditions like high temperatures and abrasive slurries pose, without reducing the accuracy, repeatability, and reliability for the most critical measurements. Dedicated support staff and regional support specialists are available to help you tailor the appropriate products to your toughest application needs.
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Field Instrumentation Maximize your plant’s profitability through digitized process measurement solutions that alleviate cost pressures, increase availability and reliability, and improve safety. Learn more |
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Process Analyzers and Integrated Analyzer Systems Yokogawa’s analyzers and systems ensure accurate, repeatable measurements for asset management, process optimization, and regulation compliance. Learn more |
It is a well-known fact that plant data is the basis for all solutions in the process industry. As such, data must be easily captured and accessible to ensure long-term improvement opportunities. Based on open standards, Yokogawa's data historian and PIMS solution capture data easily to provide a valuable bedrock. Our solution is especially unique in that implementation costs are significantly reduced when compared to the alternatives. |
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This is the important step of all cellulose processes, as the better the chips are cooked in the process, the less lignin in the pulp. This results in more efficiency in the final steps of the process, which will save money and customer operation time. Many measurements are used in the digester such as pressure, temperature, and conductivity, but the most problematic for operators are the flow measurements. Challenges |
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Taking flow measurements often becomes very complicated due to:
Talking conductivity measurements often becomes very complicated due to:
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Earth Rings Minimizes lining abrasion from a slurry fluid
Welded Punch Plate Prevents lining deforming at high temperature |
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PFA Lining, Electrode Maintains sealing performance when the lining encounters abrasion from a slurry fluid
Epoxy Potting Increases heat dissipation for high-temperature fluid measurement. Prevents the outflow of fluid when fluid leaks from the electrode. |
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ChallengesTaking flow measurements often becomes very complicated due to:
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SolutionIn a lime kiln, the control can be complicated as several elements need to be maintained to provide the proper and efficient drying. As the size of the kiln increases the more critical the items are. The control of the burner is paramount. It has to be hot enough to ensure that the lime mud is dry by the time it reaches the end of the kiln but not too hot that refractory damage could occur and poor product quality. The length of the flame in the cylinder directly affects these issues. There are two considerations in managing flame length, the amount for fuel supplied to the burner and the amount of air generated by the primary air and induced draft fans. These fans together control the total production capacity of the kiln, how far the flame is thrown into the kiln, and its shape. |
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WashingAfter the screening process, the washing process uses chemicals to help reduce the lignin and substances (black liquor) in the pulp. This stage’s objective is to remove the maximum amount of black liquor dissolved solids from the pulp while using as little water as possible. The remaining solids and chemicals in the pulp will interfere with later bleaching and other steps, increasing the cost of the final process. Normally the process has 3 or 4 washing stages in series. The same washing process is located after the oxygen delignification process and after the bleaching stages, as well. The lignin in the pulp will result in a bad quality of paper (in the case of the final product), because the lignin over time will oxidize in contact with the air, and this is what makes the paper looks “yellowish”. Excellent paper quality will keep the bright and white aspect as a lower quantity of lignin remains in the final product. |
BleachingThe objective of the bleaching process is to remove only the chromophores (elements that provide color). This is possible because the structures responsible for color are also more susceptible to the oxidation and reduction process. In the bleaching process oxygen, hydrogen peroxide, ozone, and caustic Soda are used to reduce the lignin, but keep the integrity of cellulose fibers. The combination of these chemicals and the sequence of these steps will depend on each customer’s required level of brightness in the final product. Most facilities use the following process and wash with sodium hydroxide, then treated in sequence with alkaline peroxide and sodium dithionite. Many measurements are used to monitor the process such as pressure, temperature, and flow. However, the process of bleaching highly depends on accurate pH/ORP measurements. |
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ChallengesTaking pH/ORP measurements often becomes very complicated due to:
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SolutionThe best fit pH solution is not a one size fits all. Yokogawa’s experts work side-by-side with each plant operator to determine which solution best aligns with their goals and existing installation constraints. |
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Maintenance Manager > |
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< Process Guard |
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Immediately after the washing and bleaching section, the white pulp is further refined to specific specifications and consistencies in cleaning, storage, and blending chests before it is introduced to the headbox of the paper machine. During each of these operations, additives such as resins, paper sizing materials, and colorants are blended into the pulp to meet customer specifications for fiber binding, wet tensile strength characteristics, and color in the finish paper sheet. As the paper stocks consistency has been significantly reduced through dilution of the pulp prior to the headbox, significant amounts of white water are removed as the pulp is applied to the Fourdrinier (wire bed immediately after the headbox) and as the sheet moves towards the drying section of the paper machine. Flow is commonly measured on the pulp stock into the headbox and on the white water lines; while level and pressure transmitters are used in the paper machine. The most critical measurement depends on accurate pH/ORP measurements. |
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ChallengesTaking pH/ORP measurements often becomes very complicated due to:
Prior to the headbox, the tolerances allowed for pH can be relatively wide, in many cases +/- 1-2 pH units. However, at the headbox, the pH must be tightly controlled to typically within +/- 0.2-0.4 pH units. pH control at the headbox is normally achieved with the addition of alum or soda ash. Both are used to control the pH but they are also acting a flocculating agent to precipitate resins during the forming of the sheet of paper on the paper machines wire. The control of pH at this point in the process is critical to the proper formation of the paper and also to prevent excess wear on the paper machine. |
Solutions
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PT. Tanjung Enim Lestari Pulp and Paper (PT. TEL) operates a pulp mill in Muara Enim, which is 130 km west of Palembang, the capital of Indonesia's South Sumatra province. This is the only pulp mill in the world to produce high-quality, bleached-hardwood kraft pulp solely from plantation grown Acacia mangium trees.
A virtual network system that securely connects OT-IT built on existing network resources.
Yokogawa experts monitor the network remotely like customer's information system department.
To enable central control of the entire plant, all of its subsystems are integrated with Yokogawa's CENTUM VP DCS.
Steam is still one of the most popular methods of providing an energy source to a process and its associated operations. The more accurate and reliable measurements that are made, the more informed decisions can be taken that affect costs and product quality.
Drying is an important part of the papermaking process that evaporates the remaining water in the wet paper web. This is performed with a dryer, and the humidity control in this dryer is essential to maintaining high paper quality (e.g., strength, paper surface) and high heat energy efficiency.
Yokogawa's unique simultaneous, dual-frequency excitation method used in the ADMAG TI magnetic flowmeter can enable tighter control, faster response, larger quantity of end product per batch, reduced cost, and higher profitability.
Now that the Moore / Siemens 353 Process Automation Controller is obsolete, are you considering upgrading to a DCS? We have a better solution for you. Yokogawa's YS1000 Series PID loop controllers can directly replace the Siemens Process Automation Controllers.
With the high temperatures, pressures, and levels of dissolved organics that are encountered, the ADMAG AXF flow meter design is ideal for use in all phases of the chemical recovery process.
The pulp and paper industry has very aggressive and challenging applications for magmeters. There are corrosive Zone chemicals, high temperatures and pressures, and abrasive slurries. Yokogawa can provide the most reliable and accurate meters for each application.
The treatment of wastewater from pulp and paper plants is a serious environmental concern. Yokogawa's submersion holder with an ultrasonic+air-jet cleaner (customized product) can reduce the manual cleaning frequency to just once every one or two months.
Industry:Pulp & Paper
Continuous technology improvement is ongoing in the pulp & paper industry to obtain the best possible performance. The improved plant performance translates to the higher quality improvement and lower cost, and simultaneously environmental friendly plant operation.
Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.
The discharge of improperly treated industrial chemicals and fuel gas can have a major impact on the environment, posing a serious threat to public health. Concurrent with the global growth of manufacturing operations to keep pace with market trends, many countries are taking measures to deal with environmental problems.
The new digester magmeter enabled accurate and stable flow measurement of the black liquor circulation line, helping the user to stabilize the cooking degree that determines the quality of the chip digesting process.
The kraft process, also known as kraft pulping or the sulfate process, is a technology for conversion of wood into wood pulp that consists of almost pure cellulose fibers. Today, the kraft process is used in approximately 80% of paper production.
To defray energy costs, many industrial plants have their own boilers to generate steam to produce a portion of their energy needs. In addition to generating power, the steam may also be used directly in plant processes or indirectly via heat exchangers or steam jacketed vessels.
Heat exchangers are devices that provide the flow of thermal energy between two or more fluids at different temperatures. Heat exchangers are used in a wide variety of applications. These include power production; process, chemical and food industries; electronics; environmental engineering; waste heat recovery; manufacturing industry; and air-conditioning, refrigeration, and space applications.
Ion Exchange is a method for the exchange of ions between two electrolytes or between an electrolyte solution and a complex molecule. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic ion exchangers.
Visual MESA© is a steam system optimization and management computer program that was originally developed at Chevron and now marketed by Nelson & Roseme, Inc. Visual MESA is currently used at refinery and chemical manufacturing sites to optimize the overall site steam system and the parts of the electrical system that economically trade off with the steam system.
This paper will explore significant optimization variables and constraints commonly encountered in refinery steam system optimization, the strategies Visual MESA uses to deal with them.
This paper will not describe just all the features of the software or fully explain on-line optimization technology. The objective of this work is to present some interesting facts and lessons from the experience of implementing a cost based optimization program at thirty oil refineries and petrochemical complexes, around the world, since 1997. This paper will focus on the key optimization variables and constraints in steam system optimization, how they should be handled and how the human and organizational aspects can be addressed.
The worlds of process automation and production management have been converging for some time. What once used to be islands of automation and production management functionality connected through highly proprietary integration schemes that were costly to maintain have developed into integrated platforms that provide seamless data exchange between the world of automation and the plant floor, the functions of production and operations management, and integration with business level systems.
The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.
The automation suppliers that will be successful in the long term will be those that effectively address application or industry specific problems for end users with a value proposition that cannot be ignored. These problems exist throughout the process industries today, and they won't be solved by simply offering a product, but through a combination of hardware, software, services, application expertise, and knowledge.
In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action.
Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.
Process automation end users are under more pressure than ever to do more with less. The current economic climate means that many automation capital projects are on hold. With capital budgets tighter than ever, users instead focus on operational budgets (where cost cutting is also a key concern), or on automation investments with a very rapid return on investment.
In today's dynamic industrial marketplace, the only constant is change. Raw material costs, energy costs, market demands, environmental and safety regulations, technology, and even the nature of the labor force itself are constantly changing, and not always in predictable directions.
Discovering your Baseline with OT Security Risk Assessment
Optimizing the maintenance cycle is not always straightforward. In some cases, cleaning once a week is sufficient and other processes may require every 8 hours.
Select the correct pH glass and reference type to improve your pH sensor lifetime and you can limit or even eliminate the effects of temperature and pressure on especially the reference sensor.
Learning these four lessons will help you improve your engineering skills and most importantly extend the life of your pH sensors.
The lifetime of a pH sensor has a significant impact on the overall annual costs of a pH measuring loop. Optimizing four key factors will decrease these costs and optimize process control and overall plant efficiency.
Kind of. Calibration itself will not extend the life of a sensor, however, a sensor that is not calibrated properly can cause unreliable measurements - that are often misdiagnosed leading to unnecessary replacements.
How much do you know about pressure transmitters? Are you accurately, quickly and reliably measuring pressure? Ultimately, the drive of any good pressure transmitter is to get an accurate, reliable pressure measurement to the data user quickly. This video gives you the answers to your basic questions about pressure and pressure transmitters.
Join this webinar to better understand which manifolds you should use for specific applications and conditions. You will learn:
- New maintenance and operations support function for the display of statistical information on the status of all plant devices -
- Optimizes the supply chain and operations by enabling plant personnel to work more efficiently -
- For improved agility in implementing control system projects -
- Ideal for construction of small-scale field wireless systems -