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Washing Fingerprint

The ABB OPT800 Washing Fingerprint is a process diagnostic service that optimizes the brownstock washing process. It is a platform independent, non-invasive service that can be applied to any existing washing process where improved quality and productivity are desired.

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Overview
Key Performance Indicators
Scope of Supply
Delivery Schedule

The ABB OPT800 Washing Fingerprint identifies operation bottlenecks and opportunities for process improvements in the brownstock washing process. It provides unbiased insight into:

  • overall washing system performance based on the measures in key areas;
  • issues with all level 1 control loops in the washing area;
  • the readiness of the process for further optimization using advanced process control (APC).

Analysis of washing system performance and washing losses are used to establish performance benchmarks. The resulting diagnostic report provides improvement recommendations and associated estimated return on investment.

The Fingerprint gathers process and operational information through structured interviews with plant personnel and data gathered by ABB’s Data Logger (DL400) software tool to assess washing process performance.

Next, Key Performance Indicators (KPIs) that highlight operation bottlenecks are calculated. These KPIs are reviewed by ABB’s optimization experts and used to benchmark your process against industry standards. Areas of opportunity are identified and evaluated by these experts, who provide recommendations to implement and sustain performance of your washing process.

After verifying and collecting data, ABB determines KPIs for the following areas:

  • Washing Performance: The Washing Performance Index is a KPI representing the quality of the washing system performance. Washing Performance is measured in terms of washing process efficiency and washing losses. Areas measured are:

    • Liquor balance
    • Fiber balance
    • Washing efficiency
    • Washing losses
  • Loop Performance: Loop Performance Analysis gives the overall picture of the quality of the level 1 control loops in the brownstock washing area.

Reporting

After the evaluation, two reports are presented:

  1. Executive Report: summarizes the findings, benchmark results, financial impact of recommendations and an actionable improvement plan. ABB can assist in implementing this plan.

  2. Technical Report: provides detailed results of the Fingerprint along with data collected during the assessment.

Scope of Supply

Survey Areas

During the Fingerprint, the following broad areas will be assessed:

Washing Performance

The Washing Performance Index is a KPI that is a single number representing the quality of the washing process. The Washing Performance is measured in terms of the performance in key areas that determine washing efficiency and also chemical losses. These areas are:

  1. Liquor Balance
    • Dilution factor control
    • Liquor flows
    • Filtrate flows
    • Liquor tank farm
    • Liquor/wash water properties (temperature, pH etc.)
  2. Fiber Balance
    • Production rate
    • Pulp flow
    • Pulp consistency
    • Pulp properties (temperature, pH etc.)
  3. Washing Efficiency
    • Reduction in dissolved solids (overall & each stage, if data is available)
    • Pulp & liquor conductivities
    • Defoamer usage
  4. Washing Losses
    • Soda loss
    • COD, BOD etc.

Individual performance indices are computed for all the above controls/variables.  Each index represents the individual contribution of each area to washing process performance. The overall Washing Performance Index is calculated with the individual indices.

Loop Performance

Loop Performance Analysis gives the overall picture of the quality of the level 1 control loops.

APC Readiness Assessment

The readiness of the site and/or process for further optimization through advanced process control is assessed. Specifically, the following aspects are considered:

  1. Presence and operation of following controls
    • Liquor/dilution factor control
    • Production rate control
    • Defoamer control
  2. Presence and operation of following instrumentation/lab analysis
    • Pulp, liquor & filtrate flows
    • Dilution factor calculations
    • Consistency measurements
    • Pulp & liquor conductivity measurements
    • Dissolved solids
    • Washing losses

Delivery Schedule

The following is the Delivery Schedule for the Washing Fingerprint:

Day 1

  • Safety briefing
  • Kick-off meeting
  • Plant tour
  • Data collection setup

Day 2

  • Preliminary analysis of overnight data
  • Interview key plant personnel
  • Retrieval of long-term data for dissolved solids and washing losses
  • Check data and make configurations accordingly

Day 3

  • Loop Performance Analysis
  • Washing Performance Analysis
    • Liquor Balance
    • Fiber Balance

Day 4

  • Washing Performance Analysis:
    • Washing Efficiency
    • Washing Losses
  • APC Readiness Assessment

Day 5

  • Data analysis for Summary of Findings exit meeting presentation
  • Exit Meeting

A final Executive and Technical report will be issued approximately two weeks after the Exit Meeting.  ABB can usually deliver a Washing Fingerprint within two months of receipt of a purchase order.

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