ACOSENSE: The first Acoustic online instrument for intelligent fluids analysis

Project Information

ACOSENSE

Grant agreement ID: 880935

DOI

10.3030/880935

Project closed

EC signature date 6 September 2019

Start date 1 October 2019

End date 31 March 2022

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 1 959 003,75

EU contribution

€ 1 371 302,63

Coordinated by

ACOSENSE AB
Sweden

Periodic Reporting for period 2 - ACOSENSE (ACOSENSE: The first Acoustic online instrument for intelligent fluids analysis)

Reporting period: 2020-10-01 to 2022-03-31

Summary of the context and overall objectives of the project

The production in the pulp, paper and chemical industries requires constant and real-time information for process optimization. The industry is constantly seeking ways to reduce costs, save energy, develop its products, as well as decrease environmental impact.

In the process industry it is crucial to continuously analyze various parameters and states, online and in real-time. However, existing systems fail to meet these needs due to being hard to install, lack of accuracy and being maintenance intensive. Therefore, currently the optimization of the process links to a high market potential which remains untapped. ACOSENSE technology uniquely meets these needs. Our process monitoring system is installed on the outside of the process pipe and uses acoustic signals to analyze fluid properties and process states. Our technology digitizes the process and enables continuous and real-time monitoring, in a truly non-invasive way enabling analysis in positions previously thought impossible.

ACOSENSE enables a better process for producing high quality fibers from wood chips. This unlocks tremendous value for our customers, who constantly search for cost savings by optimizing their production and thus saving energy, chemicals, and raw materials. At the same time, our technology translates to huge economic and environmental benefits, as more pulp is produced from the same number of trees.

Our acoustic spectroscopy technology is a game changing innovation in process control with infinite applications in every industry segment. ACOSENSE project aims to carefully optimize our existing platform to meet the requirements of our customers in the Pulp&Paper and the Chemical industry, on our targeted markets Europe, Latin, North and South America. By doing so, we strengthen Acosense platform as well as our customers competitiveness and the need for careful use of natural resources

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project has had a tremendous impact on the markets knowledge of the brand Acosense as well as on the technology development. Even though Covid-19 has had big effects on the progress, primarily from a customer site perspective, it has also given Acosense the opportunity to shift the focus inwards in order to further evolve the technology.

From an application perspective Acosense has developed new applications and now has a much broader portfolio. Examples of new applications that are a result of the project are applications on heavy oil, quality indicators at the board machine as well as detecting mixed pulp.

The fact that Acosense can now install the instrument on the above applications is a result of a number of interesting things, that have all happened within the project time. Below are some of them.

Acosense has for example developed a high temperature approach where Acosense removed a technical feature called the backing (black plastic cover around the actuator/speaker) in order to provide more freedom of movement when developing e.g. the ATEX-variant (installment in explosive environment).

Acosense has also made several evaluations and conducted experiments about the so called stiffening rings, where the result was that Acosense, by using stiffening rings, where able to create a system resonant enough to obtain a clear interference pattern. What the stiffening rings does is that by installing these on the pipes on both sides of the instrument the acoustic environment could be improved (by for example greatly reduce the acoustic effect from surroundings pumps). The rings are now standard in all newly installed systems.

Acosense has also performed a theoretical study on frequency tracking using Finnveden mobility model to understand how frequency tracking can improve the results of the density estimates. As density is the base line for many of the analyses this is of great value in order for Acosense to further increase the number of applications in the portfolio. This technology will most likely be part of the next generation of instruments.

A lot of emphasis has also been put on simplifying the installation process with the ambition that any partner can do the installation. This is mostly improvements in the mechanical hardware, procedures and checklists.

From a dissemination perspective Acosense has, like the rest of the world, been forced to re-think the strategy of how to spread the word of the new innovative technology that Acosense has available. This has not been all bad as Acosense has been able to find completely new ways of digital dissemination. During the period of the pandemic several different ways of increase the knowledge of the brand Acosense was tested (as digital fairs, directed marketing material, use of external firms to create digital marketing content as video and text material, to mention a few) and positive insight has been concluded from all these activities. As a result of this, Acosense now has a good understanding of which digital dissemination activities have a good effect. Hence, Acosense can use the knowledge regarding digital activities as a complement to the physical activities going forward

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

ACOSENSE product aims to improve the production within three markets: paper board, pulp and petrochemical producers.

For paper board producers, main needs are to improve their production and reduce production related waste. Our ACOSENSE Coating analysis product provides them with continuous and real-time information of coating color quality. This allows our customers to produce only premium board which could generate additional revenues of up to €6 million per year by avoiding board that otherwise would be downgraded or going to waste. For a 300,000 tons/year paperboard mill, 3 ACOSENSE systems are needed at a total of €99,000. To recoup ACOSENSE investment, our customers will have to avoid only 7 hours of non-premium production. Also, by monitoring coating color quality during circulation, ACOSENSE reduces risk of coating color going to waste. 1,500 liters of coating color translates into cost savings of €90,000 if not even more so doing to the effects large amounts of coating color has on the wastewater treatment.

In the case of the pulp producers, main needs are reducing the energy consumption and the evaporation and increase the pulp yield. For an average pulp digester producing 55 tons of pulp/hour, 3 ACOSENSE instruments are needed at a total selling price of €115,500. This investment results in a total cost of €221,520/year in energy cost savings. Also, an increase in pulp yield by 1% for this typical mill (500,000 ton/year) would bring €390,000/year in additional revenues from just the pulp (€770 euro/ton pulp).

Main benefit in the case of the Petrochemical manufacturers comes in the safety of the workers. Our ACOSENSE product is a non-intrusive system which reduces the in-person interactions with fluids having this a direct impact in a drastic reduction of accidents in the facilities.

In addition, we foresee a direct impact in our own company when the effect of the pandemic is starting to wear-off. ACOSENSE project have been vital in order to prepare for the goal of growing our workforce by 10 new FTEs within a three year period, to facilitate for 500 units to be processed through Acosense AB, as a result of the improvements and market awareness that have been achieved during the project.

Acosense in coating colour installation provides process,colour,solid and viscosity info

Acosense at the blowline of a digester. Acosense actuator highlighted and signal unit on the right