© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
Optimizing Energy and Water Usage at
Verso’s Androscoggin Mill
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
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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
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Optimizing Energy and Water Usage at
Verso’s Androscoggin Mill
© Copyright 2015 OSIsoft, LLC
• 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
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The PI System is Integral
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Verso Corporation
• 8 Mills
• Major Producer of Coated Paper in North America
• Opportunities to replicate savings achieved at Androscoggin mill across Verso Corporation
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• 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
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Verso Corporation – Androscoggin Mill
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Verso Corporation – Androscoggin Mill
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• 4 Paper Machines
• 1 Pulp Machine
• +2,000 tons/day
• Freesheet & Groundwood Coated Papers for Offset and Rotogravure Printing
• Pulp, Specialty, and Groundwood
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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
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Optimizing Energy and Water Usage at
Verso’s Androscoggin Mill
© Copyright 2015 OSIsoft, LLC
• 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
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Goal: Reduce Energy and Water Consumption
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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
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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
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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
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• 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
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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
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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
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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
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• 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
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Achieving Our Goal by Better Understanding of
the Entire Mill
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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
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Optimizing Water Usage
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Continuous Improvement
• Familiarity with the overall process led to development of additional
tools
= More water and energy savings opportunities!
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Optimizing Water Usage
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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
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• 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.
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Predicting Energy Usage by Grade and
Production Rate
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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
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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
• www.versoco.com
Verso Corporation
Androscoggin Mill
PO Box 20
Jay, ME 04239
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Questions
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Please wait for the microphone before asking your questions State your name & company
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