Optimizing Energy and Water Usage at - cdn.osisoft.com

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Presented by

Optimizing Energy and

Water Usage at

Verso’s Androscoggin Mill

Changing the Way We Look at Data

Frank Card and John Hume

Verso Corporation


Optimizing Energy and Water Usage at


About Your Presenters:

Frank Card

– 35 years at the Androscoggin Mill

– Manufacturing Production, Maintenance, Technical, Process

Control, and Energy & Water Conservation Management

John Hume

– 3 years at Measurex and 36 years at paper mills

– Process Control and IT

– Androscoggin Mill PI System Manager

3


1965 -1984

– IBM 1800 process control

computer developed with IBM

and International Paper Company

1984 - 1999

– DCS in each operating

department with real-time data

stored in the Data Archive

2007 - 2015

– Enterprise Agreement with

OSIsoft

4




• Need dependable and cost effective solution

• All PI Servers current and architecture streamlined – OSIsoft Center of Excellence, Enterprise Project Manager, and Field Service

– Network Operations Center for 24x7x365 health monitoring of PI System

• No data left behind – solution utilizes about 200,000 PI Points – Add 4,000 new PI Points per year

– Enterprise Agreement eliminates the cost of curiosity

• Integration - PI System data utilized in Minitab for statistical data analysis – OSIsoft Center of Excellence and PI Developers Club for advice

– OSIsoft training for administrators and operators alike

5

The PI System is Integral


Verso Corporation

• 8 Mills

• Major Producer of Coated Paper in North America

• Opportunities to replicate savings achieved at Androscoggin mill across Verso Corporation

6


• Located in Jay, Maine

• Started mill up in 1965 by

International Paper Company

• Mill constructed in three major

periods: 1965, 1967, 1977

• 1977 mill upgrade was International

Paper’s largest capital expansion in

the history of the company

7

Verso Corporation – Androscoggin Mill


Verso Corporation – Androscoggin Mill

8

• 4 Paper Machines

• 1 Pulp Machine

• +2,000 tons/day

• Freesheet & Groundwood Coated Papers for Offset and Rotogravure Printing

• Pulp, Specialty, and Groundwood


Problem:

• Widely varying energy and water requirements based on paper grades, production rates, and seasons

• In 1965 water and energy were low cost commodities

• The Androscoggin mill was designed by department without a holistic approach to overall mill operations efficiency

• Water and energy conservation is now a top priority

9




• Energy reduction target set below the level of requiring purchasing

energy

• Water reduction target set to a level for the mill to be in the top 2nd

quartile water usage in North America

10

Goal: Reduce Energy and Water Consumption


Energy

• Mill produces 80% of its power requirements

with renewal resources

– Spent Pulping Liquor

– Wood Waste

– 4 Hydro stations

• Natural gas cost is up to 4 times higher than it is

west of the Hudson River

11


Water

• Androscoggin River water temperature is 32F 6 months per year

• Average process temperatures are 120F to 140F, 180F to +300F

• 80 major heat exchangers

• Optimizing water usage is key to reducing mill energy requirements

12

30 40 50 60 70 80

River Water Temperature

30

32

34

36

38

40

42

44

46

48

400

600

800

1000

1200

1400

1600

1800

2000

2200

1965 1967 1977 1980 1996 2003 2010 2015

Production T/d water mmgpd


• Installed and upgraded measuring devices to monitor water and steam

• Connected meters to the DCS with real-time data stored in the Data Archive

• PI ProcessBook displays and PI DataLink reports to monitor water and steam consumption

13

Achieving our Goal through Improved Monitoring

Flash Tank

No. 1 SeparatorNo. 2 Separator No. 3 Separator No. 4 Separator

PM Dryer Condensate

Vaccum Reciever

Main Cond. Collection Tank

To Power House

To Sewer

VLV

MEAS

SP

11.46

50.00

50.08

VLV

MEAS

SP

49.91

50.00

50.16

50 % 49%

VLV

MEAS

SP

2.90

50.00

49.97

VLV

MEAS

SP

29.21

50.00

49.85

VLV

MEAS

SP

26.83

50.00

49.56

VLV

MEAS

SP

15.63

50.00

48.51

128 GPM

50 %50 %50 %

50 %

Heat Exchanger

LVL VLV

51%

VLV

MEAS

SP

46.62

50.00

50.90

20

100

Flash and Main Tank Lvls

100

280

Cond Flw to Pwr

97

105

PM4 Condensate Percent Return

Pump, Green=run

#2 Pmp

#1 Pmp

Mill Water

Hand VLV

To Trim Squirts

104 PCT


Overall Mill Water Balance using PI DataLink

• Green boxes

are daily

averages

• Orange boxes

are monthly

averages

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Daily Mill's water balance Today's date Key

Daily average PI A FSC energy calc

Monthly average PI

Calculated PI data

Input from model

Millwater from Mill warm water tank

Riley Pumping Station By-pass water

Process water

Back Flushing Raw water

Pulp Mill warm water to paper mill

Turbine Condenser discharge water

Raw WaterAdams Filter - to paper machines vacuum pumps

56

Purge

Water Treatment WFI Scrubber

Total Raw Water to mill

demin 5 & 6, 7&8 Hid Seal water To Paper Mill

Boiler feedwater A Digester seal water Warm Water Tanks

A Evap's A Pulp Mill

Surface condenser A Pulp Mill A Decker

A Warm water tank Warm water usage

A Pulp Mill

A Cool water tank

A Pulp Mill A Pulp Mill

Winter operation for weak wash cooler A Hot water tank A Bleach Plant

Hot water usage

Millwater A Pulp Mill-A digester

A Flash Steam Cond.

033fi_005

A1 & A2 SVP ICC Water/millwater A Pulp Mill-A digester

A Black Liquor Cooler

CUB 4003 Millwater A Pulp Mill-A digester

bypass water booster A3 A Cold Blow Cooler

pump

Groundwood Mill &

Admin AC

F A Pulp Mill

SVP A O2 Filtrate

ICC and Eductor Cooler

A4 & A5

SVP

ClO2 Absorber

A warm and hot water tank return to power plant

022fi_a318 218 321 gpm

Chillers 0.3 0.5 mmd

bypass water booster Condenser water

pump-to chillers and abs in summer Outlet Water Temp of Chiller Condenser

% valve opening-Peter Lee Valve

Turbines inlet temp

F

Turbine Condensers RTO Heat Exchangers

2/24/15 3:47 PM

24 hours


• Mill water and energy systems are complex

• No one person knows the entire mill system

• Operators have became more familiar with the water and energy

systems inside and outside of their departments

• Operators now call me with questions instead of the reverse

• Operators suggest ideas of improvements in energy and

water conservation

15

Achieving Our Goal by Better Understanding of

the Entire Mill


How We Are Achieving Our Goal

• Managers, engineers, and operators better understand how different process areas impact each other

• Optimization of processes

• Instituted more cost saving projects to reduce mill water and energy consumption

• Water system is reconfigured to accomplish high energy savings

16

Optimizing Water Usage


Continuous Improvement

• Familiarity with the overall process led to development of additional

tools

= More water and energy savings opportunities!

17

Optimizing Water Usage


Predictor model looks at present and

past water consumption based on

– Production rate

– Temperature

– Flows

Shows which piece of equipment

(department) is using the proper

amount of water

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Predicting Mill Water Usage Predictive Water Model for the Androscoggin Mill

Date 3/5/15 2:16 PM

Today 3/5/15 4:16 PM

Area

Units for

production

production

rate

Predicted

water usage

Actual

water

Within

Limits?

mmgpd mmgpd 105%

A Digester T/day

A Bleach Plant T/day

B Digester T/day

B Bleach Plant T/day

Total Kraft Production T/day

-RTO Heat Exchangers gpm

-O2 Filtrate Cooler on bypass water gpm

SVP- Abs. T/day

SVP-ICC & Eductor T/day

Chillers-Condensers (0255) @84F gpm

Pulp Mill's bypass water usage less SVP abs.gpm

Groundwood Mill T/day

Recaust T/day

-Weak Wash Cooler-cooling water flow

Woodrooms est.

A Evaps - condenser water gpm

B Evaps - condenser water gpm

A1 & A2 Unfin. T/day

A3 Unfin. T/day

A4 & A5 Unfin. T/day

Total Paper Production Unfin. T/day

Paper Mill's bypass water usage gpm

Raw water to vacuum pumps gpm

Boiler Feed water make up k#/hr of steam

Regens flushing (estimated) gpm

Raw water to WFI scrubber gpm

SMI fresh water usage (estimated daily ave) gpm

Unmonitored Flows

Total mill water make up added (Millwide)

*Red indicates the department is using

more than predicted


• Paper machines grade runs

– Predict paper machine and total mill energy requirements

• As we predict energy requirements, we can plan for additional energy requirements

• This allows us to purchase energy at lower cost or avoid purchasing entirely

• Predict total mill energy usage into the future

• Look at entire mill consumption to foresee regularly what the required energy needs will be for the selected paper grades, equipment repair shutdowns, etc.

19

Predicting Energy Usage by Grade and

Production Rate


Progress to Date

Run at full production while other mills are

slowed back or shutdown completely

Water usage has been reduced by 20%

80% of mill energy requirements generated on

site with renewal resources. Goal is 100%

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1. Reduced Water Usage by 20% - 2nd Quartile

2. Reduced Energy consumption by 9%

3. Allowed the mill to operate at full production

4. More people are engaged in accomplishing the goal

Solution(s) Results and Benefits

Optimizing Energy and Water Usage at Verso’s Androscoggin Mill

Business Challenges

1. Reduce Energy Consumption below the level of requiring purchasing energy

2. Top 2nd quartile water usage for paper mills in North America

1. Predictor model to show where water usage is different than expected.

2. Predict paper machine and total mill energy requirements based on grade run schedule to minimize and manage energy purchases.

3. Predict future total mill energy usage for the selected paper grades, equipment repair shutdowns, etc.

4. Developed Millwide Process Screens that operators, engineers, and managers could use to understand, monitor and control the processes

Changing the Way We Look at Data

21


Next Steps

AF Templates and Asset Analytics

Notifications

Future Data from Predictor Models

Integrate mill production scheduling

Use similar approach to address other priorities such as ensuring environmental compliance

Implement learnings at other Verso Mills

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Presenter Contact Information

• [email protected]

• [email protected]

• www.versoco.com

Verso Corporation

Androscoggin Mill

PO Box 20

Jay, ME 04239

23

mailto:[email protected]

mailto:[email protected]

http://www.versoco.com/


Questions

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Optimizing Energy and Water Usage at - cdn.osisoft.com

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