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FIBRESAVE project developed an on-line optimized management system for recovery of wasted fibres during Pulp & Paper production together with simultaneous recovery of energy.
In fact, based on the in-plant experience of the involved end-users (Stora Celbi and Portucel) and the available statistics at the start-up of the project, the estimated loss of fibres during processing was (at the start-up point of the project) about 10 kg per ton of pulp produced. For instance, at the start-up of the project the Setubal mill produced about 360,000 tons per year and there were about 48 such plants in the EU with a total pulp production of 29.5 million tons. The cumulative loss of fibre in all such plants then amounted to about 0.3 million tons per year. In case of paper industries, which process the pulp further, there is additional wastage, which is lower than in pulp mills
That led to a waste of raw material and consequently to a lower productivity, higher energy consumption and a higher environmental impact.
The principal theme of research within the proposed work was centred on a completely novel approach towards the optimization of the processes of pulp and paper production comprising fibre recovery and also integrating the environmental control of all operation.
The existing monitoring and control situation in the pulp and paper plants (Stora Celbi, Portucel and Thrace Paper Mill) was improved with an intelligent and automatic system supported by a knowledge base system (KBS) in terms of relevant parameters to be monitored, such parameters would be identified and defined.
This project started by first analyzing the existing systems already in operation on the three industrial plants, that resulted in identification of critical circuits and paths during process operation control.
By examining carefully these aspects it was possible to define a novel monitoring and control strategy and also the intelligent software modules that need to be developed.
The developed system allows an on-line optimized management for recovery of wasted fibres during Pulp & Paper production together with simultaneous recovery of energy.
Also, this system is an integrated monitoring overview of the manufacturing processes in the industries of pulp and paper, as well as a knowledge based system able to provide information on relevant aspects of mill operation such as: real-time monitoring, environmental protection, wastes recuperation and recycling, risk evaluation, energy savings and productivity increases. This system will reduce production costs in both pulp and paper production thus increasing the competitively of the European industry.
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