Nalco Water – Tissue Intelligence 3D TRASAR™ for …...– 3 yrs. Process Engineer & Production...
Transcript of Nalco Water – Tissue Intelligence 3D TRASAR™ for …...– 3 yrs. Process Engineer & Production...
Nalco Water – Tissue Intelligence 3D TRASAR™ for Yankee Dryers
Bruce BarkerOctober 3rd, 2019
Biography
Bruce Barker: Director of Technical Consulting – Board, Specialty, Utilities, AutomationEducation• BS Chemical Engineering – University of Washington• BA English Literature – University of WashingtonIndustry Experience• 18 yrs. Nalco Company
– 11 yrs. District Sales Manager – Dallas / Shreveport Area– 6 yrs. District Representative to Area Manager – Board and Packaging
• 9 yrs. Paper Industry Manufacturing– 3 yrs. Process Engineer & Production Engineer– 6 yrs. RDF Chemical Sales Representative
Expertise• Wet End Chemistry, RDF, Sizing, Dry Strength, Wet Strength, Contaminant Control, Filler Loading,
Application Best Practices, Sole Source Transitions, Data Analysis
2
Introduction• What is TRASAR™?
– Chemistry– History / Evolution of 3D TRASAR™
• Yankee Dryer – Symptoms of Poor Performance– Deposit, Chemical and Monitoring components
• Methods for Monitoring and Treatment• Case Study - 3D TRASAR™ for Yankee Dryers• Nalco Water - Digital Solutions Vision
3
Emission
Excitation
Program overview – Nalco Water Trasar™WHAT IS TRASAR™
– TRASAR™ is a Nalco Water patented, tracer material developed in the 1980’s
– Non-reactive chemical species• Totally inert, non-volatile, thermally stable
molecules– Precisely measurable based on its
fluorescence• Can accurately measure the tracer element to
the ppb level• Measurement is based entirely upon
concentration of chemical, and not on the mass balance of chemical
TRASAR™ is like having a bar code on a molecule
5
Cooling Water TRASARAutomatic Dosage Control
Boiler TRASARAutomatic Dosage Control
3D TRASAR TechnologyPerformance Monitoring & Advanced ControlCharting, Reporting, & Web Alarms
System Assurance Center24/7 Remote Monitoring & Alarm Response
3D TRASAR Technology for DAF AutomationPerformance Monitoring & Advanced Control
Plant Resource OptimizerSystem Flow Diagrams (Web)
Nalco enVisionDashboards, charting, & reporting (Web)
Next Generation of Cooling WaterInformatics – ID Benchmark Opportunity
3D TRASAR Solid Cooling Water TechnologyAutomatic Dosage Control
3D TRASAR Technology for MembranesPerformance Monitoring & Advanced Control
3D TRASAR Boiler TechnologyPerformance Monitoring & Advanced Control
1988 1991 2004 2007 2008 2011 2012 2014 2016 2018
3D TRASAR Boiler - Hardness Response ProgramFully automated hardness monitoring and corrective action & communication
3D TRASAR Technology for High Pressure BoilersHigh purity systems including pH / PO4 programs
Commitment to Innovation
Nalco Water BioAssuranceMake sure biocide feeds are never missed
3D TRASAR Solid Cooling Water Technology: Advanced Biocide ProgramNon-pressurized solid biocide dispenser system
41,000 Total Shipped Globally
3D TRASAR™ – LATEST GENERATION• 4th generation Fluorometers & Controllers• TRASAR Excitation Advancements
• Fluorescent bulbs to LEDs• Additional sensors
• NCSM• pH• Conductivity
• Advanced software for automated boiler treatment and control• CoPhos Control algorithms• Front End or Back End Control
• Communication capabilities• Alarms – enVision – ECOLAB3D
• CASSADY Boiler Controller in development
• Innovative ways to use TRASAR in mills
Nalco Water Corrosion Stress Monitor Cond
pH
FluorometerController
What are the Consequences of Poor Water Treatment?
• Survey of 20 Boiler Repair Companies indicates that 82% of Boiler Repairs are related to poor water treatment.
7
Nalco Corrosion Stress Monitor™
What is the Nalco Corrosion Stress Monitor? The Corrosion Stress Monitor, in conjunction with 3D
TRASAR Boiler Automation, measures and controls boiler feedwater corrosivity
How is this unique? Direct Measurement of Corrosivity - Direct measure of
feedwater system corrosivity at operating temperature and pressure
Corrosion Protection - Maximize corrosion protection with continuous monitoring and corrective response to system stress
Real Time Visibility - Provides Real Time visibility of oxygen scavenger performance and corrosion protection
Immediate and Accurate - Controlled and precise treatment based on feedwater system demand.
Feed
Wat
er C
orro
sion
Stre
ss M
onito
r (m
V) +300
+200
+100
0
-100
-200
-300
-400
-500
-600
0.8 mpy
0.2 mpy
Pitting
Close to Pitting Zone High General Corrosion
Rate
Low General Corrosion Zone
Operating Range for Corrosion Protection *
* Refer to specific control ranges for operating conditions and oxygen scavenger type
Yankee Dryer Performance
9
Symptoms of Poor Yankee Performance• Wet streaks• Random coating patchiness• Chatter• Reduced drying capacity• Increased ∆P at constant blowthrough
10
When these symptoms become apparent, it is too late,Quality and production have already been affected!
Components of Yankee Performance
11
Yankee Dryer Performance
DepositComponent
ChemistryComponent
MonitoringComponent
Operational Consideration
• One ppm of CO2 dissolved in 140oF pure condensate will lower the pH from 6.5 to 5.5
• Oxygen dissolved in 140oF pure condensate is 6-10 times more corrosive to iron than its molar equivalent of CO2
• When both gases are present together, the resultant corrosion rate is 10-40 times greater than the sum of the corrosion rates of the two acting separately
12
Carbon Dioxide and Oxygen entering through the feedwateror as in-leakage are incredibly corrosive to the Yankee.
ChemistryComponent
Operational Consideration
13
The concentration of these components is dynamic sotreatment and control is paramount to preventing corrosion
ChemistryComponent
Operational Consideration
• The velocity of the condensate will be at it's highest and the relative pressure at the lowest in the Yankee Dryer soda straw
• The physics dictate this is where corrosion by-product deposition will occur
14
Soda Straw WallIron deposit
DepositComponent
Operational ConsiderationInstrument or Test Limitation
pH Indirect measurement of only one of the components of corrosion.
Dissolved Oxygen Oxygen stays with the steam, not the condensate.
Conductivity Single component measurement of boiler water carryover.
Particle Monitor Slow sample time that can not be used to control chemicalprogram.
Millipore Test Requires 5 fps sample flow to be accurate.
15
A comprehensive monitoring and control system is needed to manage the performance of this asset.
MonitoringComponent
Components of Yankee Performance
16
Yankee Dryer Performance
DepositComponent
ChemistryComponent
MonitoringComponent
Deposit Component
Chemistry Component
MonitoringComponent
Measures every component of corrosion• NCSM measures active corrosion
through at temperature ORP• pH• Conductivity• TRASAR
Corrosion inhibitor controlled by PID, chemistry fed according to conditions• PID control allows the dampening of
events• Alarms and data collection provide
diagnostics of the system
Through proper monitoring, program automation, and diagnostic evaluation; corrosion by-products are minimized eliminating the source of deposition
Components of Yankee Performance
Simplified Diagram: 3D TRASAR™ for Yankee
• Standard Boiler Treatment– Internal Treatment– Oxygen Scavenger– Condensate Treatment
• 3D TRASAR™ for Yankee– Satellite treatment of
condensate for Yankee, with controller
18
pH Control – Before and After
Manual Control
Control – NCSM™ Corrosivity
Why do you care?Time pH NCSM Reading Soluble Iron (Fe+2)
8:30 am 9.01 -702 0 ppbAmine Off 8:40 am 9.01 -702 0 ppb
9:40 am 6.95 -640 0 ppb10:45 am 6.64 -625 1 ppb11:45 am 6.54 -620 1 ppb1:00 pm 6.2 -590 3 ppb3:00 pm 6.01 -560 10 ppb
Amine On 3:15 pm5:00 pm 9.0 -702 0 ppb6:30 pm 8.9 -700 0 ppb
The passivated layer in a Yankee Dryer is not robust!
CASE STUDY
Tissue MachineMid-West USA
3D TRASARTM for Yankee Dryer
SITUATION:A Tissue Machine incurred 5 unscheduled maintenance outages over 7 months due to poor tissue quality created by Yankee dryer soda straw flow issues. In addition to downtime, quality of the tissue produced was being compromised.
SOLUTION:The mill implemented a local condensate treatment on the Yankee Dryer with Nalco Water 3D TRASAR™ for Boiler control logic. By maintaining accurate feed rate, pH and NCSM parameters, the corrosion and plugging issues were eliminated.
Overview of Yankee Intelligence
Yankee Operations SolutionOPTIMIZE TISSUE PRODUCT QUALITY, MAXIMIZE MACHINE EFFICIENCY & REDUCE COST OF OPERATION
MAXIMIZE PERFORMANCEDRIVE RESULTS
System Assurance
Center
System-Specific
Collected Data
Modeling Value
Calculations
OPTIMIZEDCOSTS
OPTIMIZED TISSUEQUALITY
ENHANCEDPRODUCTIVITY
Enterprise Metrics / Global Benchmarking
Mill Control
Nalco Water Rep Connectivity
Yankee Operation
• Nalco Water Data• Customer Yankee
Operation data• Customer Tissue product
Quality data• Wet End operation data
Predictive Analytics
Monitoring-Chatter
Prevention
Performance Dashboard
Insights into Controllable actionsOUR JOURNEY
Nalco Water – Tissue Intelligence 3D TRASAR™ for Yankee Dryers
Bruce BarkerOctober 3rd, 2019