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BrainWave pulp dryer

The solution for stabilizing pulp dryer operation

Control stabilization with BrainWave

ANDRITZ BrainWave is a patented advanced controller that outperforms traditional Proportional-Integral-Derivative (PID) control because of its two main components: an adaptive model and a predictive controller. BrainWave builds its own live models during normal plant operations, a powerful feature not offered by traditional Model Predictive Control (MPC) systems.

BrainWave’s predictive controller accurately forecasts process responses and accounts for multiple objectives. It adapts to process conditions, such as changes in production rate, keeping the process on target. BrainWave can also accept measured disturbance inputs, like raw materials properties, and takes corrective action before the process is pushed off target (PID, by comparison, must wait for the error to occur and then react).

BrainWave easily integrates with existing control systems and its patented Laguerre technology means an average implementation time of just a few weeks. Best of all, the plant’s own staff can support and deploy BrainWave.

Control stabilization for pulp drying

BrainWave stabilizes the operation of pulp dryers, resulting in improved moisture control of the final product and reduced energy consumption. It regulates moisture in the pulp drying process and pulp grammage (mass of pulp per square meter). It achieves tight, stable control over moisture content and grammage by precisely adjusting the stock flow and steam supply.

BrainWave is ideally suited to control the drying process due to its ability to account for the long transport delay times as the product moves through the dryer to the moisture measurement sensor. Also, key process variables such as sheet speed, broke flow, and consistency may be used as feed-forward signals. BrainWave provides for excellent coordination between the feed-forward and feedback control; as a result, the controller compensates for changes in these variables, preventing disturbance to pulp quality and guaranteeing consistent pulp moisture and grammage.

The BrainWave pulp dryer solution is typically installed within a few weeks and the benefits are immediately obvious. Because BrainWave achieves low variability moisture control, there are much fewer process upsets, less pulp sent to recycle, and higher production. In addition, since moisture variability is lower, the average pulp moisture can be kept closer to maximum, leading to increased production and energy.

Pulp dryers at a pulp mill in Brazil

Pulp dryers at a pulp mill in Brazil

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