Simulation and optimisation of the controls of the stock preparation area of a paper machine.

Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2004.At Mondi Paper Ltd, Merebank, South of Durban, Paper Machine 2 has recently been transferred onto a Distributed Control System (DCS). This was seen as a good opportunity to enhance the control of the pulp feed to the machine. A prime concern in operating a paper machine is to ensure consistent set-point paper properties in the Cross-Direction (CD: ie. across the paper width) and in the Machine-Direction (MD: ie. along the paper length). Sophisticated adjustments are available to ensure an even feed of the stock (consistencies around 2% m/m wood fibres in water) from the head-box across the receiving width of the paper machine. The properties of prime interest as the pulp is pumped through the head-box distributor onto the receiving belt of the machine are the basis weight (fibre mass per unit area) and moisture content (per unit area). However, the distribution system is highly dependent on the properties of the stock as it arrives at the head-box. Variations in upstream chest levels, the supplied pressure, flow-rate and fibre/water ratio, all cause MD and even CD variations. The problems of maintaining steady conditions at the head-box are well known, and are understood to arise from sub-optimal control in the preceding section involving a blend chest and machine chest, amongst other items, where several pulp streams and dilution water are combined. A number of control loops are involved, but appear to require different tuning for different paper grades. Often individual loops are taken off-line. In this study, an understanding of the controller interactions in the stock preparation section has been developed by detailed dynamic modelling, including all of the existing control loops. The model is built up in a modular fashion using a basic element, having one input (which can collect multiple streams originating elsewhere) and four outputs, linked through a vessel of variable volume. Several basic elements are linked together to form the overall system. All of the necessary properties can be defined so that the model allows the simulation of all features of the network: vessels, pipes, junctions, valves, levels and consistencies. A set of first order differential equations is solved which includes total water balance, species mass balances, derivatives of flow controller action, and derivatives of supervisory controller action. Supervisory controllers for consistency or level cascade onto flow controllers. Flow controllers manipulate valves which give a first-order dynamic response of actual flow. Where valves are manipulated directly by the supervisory level, the flow controller is effectively bypassed. This study involves a constraint problem around the blend chest, resulting in a loss of specification at the paper machine. This was solved by the implementation of a static optimiser. Its objective function penalizes deviations from setpoint of five parameters (ratios, consistency and level) using respective weight factors. Both the model and its optimiser were included in a simulator designed with the graphical user interface (GUI) of Matlab. The simulator has then been used to explore control performance over the operating range, by means of a set of scenarios

Characterization of Paper Dusting

Dusting of paper in various printing and processing operations is a common problem. The dusting tendency of a paper is difficult to characterize with standard laboratory methods; there is currently no standard test available. As the trend to create grades with high filler content continues, the issue of dusting will remain important. The goal of this thesis was to explore various methods to characterize the dusting and linting in a laboratory environment with limited samples and time. Techniques to cause and collect dust are compared that include a tape pull test, a bending test, and an abrasion test. Methods to collect dust are also compared that involve gravity settling of particles, electrostatic collection, and filter methods. The collected samples are imaged using an optical microscope and a flat bed scanner and analyzed using image analysis software. Six grades of commercial paper and three grades of handsheets with various filler loadings are compared and dust is collected from an industrial test and a laser printer. In comparison with using gravity and electrostatic attraction, air filtration is found to be the best solution for collecting dust. The abrasion of paper against a rod gave the best repeatable results. The bending test measuring edge effects gives results that are significantly different between methods of cutting. The tests using the handsheets are conclusive in that increasing filler loading increases the dusting: all three methods agree with this expected result. Dust collected from the back panel of a laser printer reveals that one commercial sample had low dusting and two samples had high dusting, compared to the other samples. Scanning electron microscope (SEM) and optical microscope images shows that both fibers and filler particles are present in the dust from the laser printer. No other tests found significant differences between the commercial samples. An increase in dust is found near the outer edges of the laser printer’s guide rail. A test to measure edge effects showed an increase of dusting when paper is cut using the initial factory cut edges versus the edges of paper when cut by a standard benchtop paper cutter. The bending and abrasive test relates to industrial dust test results for particles over 40µm

Neural network modelling and prediction of the flotation deinking behaviour of complex recycled paper mixes.

Thesis (Ph.D.)-University of KwaZulu-Natal, Durban, 2011.In the absence of any significant legislation, paper recycling in South Africa has grown to a respectable recovery rate of 43% in 2008, driven mainly by the major paper manufacturers. Recently introduced legislation will further boost the recovery rate of recycled paper. Domestic household waste represents the major remaining source of recycled paper. This source will introduce greater variability into the paper streams entering the recycling mills, which will result in greater process variability and operating difficulties. This process variability manifests itself as lower average brightness or increased bleaching costs. Deinking plants will require new techniques to adapt to the increasingly uncertain composition of incoming recycled paper streams. As a developing country, South Africa is still showing growth in the publication paper and hygiene paper markets, for which recycled fibre is an important source of raw material. General deinking conditions pertaining to the South African tissue and newsprint deinking industry were obtained through field surveys of the local industry and assessment of the current and future requirements for deinking of differing quality materials. A large number of operating parameters ranging from waste mixes, process variables and process chemical additions, typically affect the recycled paper deinking process. In this study, typical newsprint and fine paper deinking processes were investigated using the techniques of experimental design to determine the relative effects of process chemical additions, pH, pulping and flotation times, pulping and flotation consistencies and pulping and flotation temperatures on the final deinked pulp properties. Samples of recycled newsprint, magazines and fine papers were pulped and deinked by flotation in the laboratory. Handsheets were formed and the brightness, residual ink concentration and the yield were measured. It was determined that the type of recycled paper had the greatest influence on final brightness, followed by bleaching conditions, flotation cell residence time and flotation consistency. The residual ink concentration and yield were largely determined by residence time and consistency in the flotation cell. The laboratory data generated was used to train artificial neural networks which described the laboratory data as a multi-dimensional mathematical model. It was found that regressions of approximately 0.95, 0.84 and 0.72 were obtained for brightness, residual ink concentration and yield respectively. Actual process data from three different deinking plants manufacturing seven different grades of recycled pulp was gathered. The data was aligned to the laboratory conditions to take into account the different process layouts and efficiencies and to compensate for the differences between laboratory and plant performance. This data was used to validate the neural networks and select the models which best described the overall deinking performances across all of the plants. It was found that the brightness and residual ink concentration could be predicted in a commercial operation with correlations in excess of 0.9. Lower correlations of ca. 0.5 were obtained for yield. It is intended to use the data and models to develop a predictive model to facilitate the management and optimization of a commercial flotation deinking processes with respect to waste input and process conditions

It’s Not a Bug, It’s a Feature: Functional Materials in Insects

Over the course of their wildly successful proliferation across the earth, the insects as a taxon have evolved enviable adaptations to their diverse habitats, which include adhesives, locomotor systems, hydrophobic surfaces, and sensors and actuators that transduce mechanical, acoustic, optical, thermal, and chemical signals. Insect‐inspired designs currently appear in a range of contexts, including antireflective coatings, optical displays, and computing algorithms. However, as over one million distinct and highly specialized species of insects have colonized nearly all habitable regions on the planet, they still provide a largely untapped pool of unique problem‐solving strategies. With the intent of providing materials scientists and engineers with a muse for the next generation of bioinspired materials, here, a selection of some of the most spectacular adaptations that insects have evolved is assembled and organized by function. The insects presented display dazzling optical properties as a result of natural photonic crystals, precise hierarchical patterns that span length scales from nanometers to millimeters, and formidable defense mechanisms that deploy an arsenal of chemical weaponry. Successful mimicry of these adaptations may facilitate technological solutions to as wide a range of problems as they solve in the insects that originated them.Insects have evolved manifold optimized solutions to everyday problems. The diversity and precision of their hierarchical material adaptations often outsmart and outperform current man‐made approaches. These materials hence provide an excellent basis for the inspiration of new technological approaches by taking design cues from nature’s solutions.Peer Reviewedhttps://deepblue.lib.umich.edu/bitstream/2027.42/143760/1/adma201705322.pdfhttps://deepblue.lib.umich.edu/bitstream/2027.42/143760/2/adma201705322_am.pd

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

Carbon-Based Smart Materials

Presents technologies and key concepts to produce suitable smart materials and intelligent structures for sensing, information and communication technology, biomedical applications (drug delivery, hyperthermia therapy), self-healing, flexible memories and construction technologies. Novel developments of environmental friendly, cost-effective and scalable production processes are discussed by experts in the field

Carbon-Based Smart Materials

Presents technologies and key concepts to produce suitable smart materials and intelligent structures for sensing, information and communication technology, biomedical applications (drug delivery, hyperthermia therapy), self-healing, flexible memories and construction technologies. Novel developments of environmental friendly, cost-effective and scalable production processes are discussed by experts in the field

Forecasting of uv-vis spectrometry time series for online water quality monitoring in operating urban sewer systems

El monitoreo de contaminantes en sistemas de saneamiento urbano es generalmente realizado por medio de campañas de muestreo, las muestras deben ser transportadas, almacenadas y analizadas en laboratorio. Sin embargo, los desarrollos en óptica y electrónica han permitido su fusión y aplicación en la espectrometría UV-Vis. Los sensores UV-Vis tienen como propósito determinar la dinámica de las cargas de materia orgánica (Demanda Química de Oxigeno DQO y Demanda Bioquímica de Oxigeno DBO5), nitratos, nitritos y Sólidos Suspendidos Totales (SST). Adicionalmente a los métodos aplicados para la calibración de los sensores y el análisis las series de tiempo de los espectros de absorbancias UV-Vis, es necesario desarrollar métodos de pronóstico con el fin de ser utilizada en control de monitoreo en línea en tiempo real. La información proveniente de los datos recolectados puede ser utilizada para la toma de decisiones y en aplicaciones de control de tiempo real. Realizar pronósticos es importante en procesos de toma de decisiones. Por lo tanto, el objetivo de este trabajo de investigación fue desarrollar uno o varios métodos de pronóstico que puedan ser aplicados a series de tiempo de espectrometría UV-Vis para el monitoreo en línea de la calidad de agua en sistemas urbanos de saneamiento en operación. Cinco series de tiempo de absorbancia UV-Vis obtenidas en línea en diferentes sitios fueron utilizadas, con un total de 5705 espectros de absorbancia UV-Vis: cuatro sitios experimentales en Colombia (Planta de Tratamiento de Aguas Residuales (PTAR) El-Salitre, PTAR San Fernando, Estación Elevadora de Gibraltar y un Humedal Construido/Tanque de Almacenamiento) y un sitio en Austria (Graz-West R05 Catchment outlet). El proceso propuesto completo consta de etapas a ser aplicadas a las series de tiempo de absorbancia UV-Vis y son: (i) entradas, series de tiempo de absorbancia UV-Vis,(ii) pre-procesamiento de las series de tiempo, análisis de outliers, completar los valores ausentes y reducción de la dimensionalidad,y (iii) procedimientos de pronóstico y evaluación de los resultados. La metodología propuesta fue aplicada a la series de tiempo con diferentes características (absorbancia), esta consiste del enventaneo Winsorising como paso para la remoción de outliers y la aplicación de la transformada discreta de Fourier (DFT) para reemplazar valores ausentes. Los nuevos valores reemplazando o los outliers o los valores ausentes presentan la misma o al menos la misma forma de la serie de tiempo original, permitiendo una visión macro en la coherencia de la serie de tiempo. La reducción de la dimensionalidad en las series de tiempo de absorbancia multivariadas permite obtener menor número de variables a ser procesadas: el análisis por componentes principales (PCA) como transformación lineal captura más del 97% de la variabilidad en cada serie de tiempo (en un rango de una a seis, dependiendo del comportamiento de la series de tiempo absorbancia) y el proceso de Clustering (k-means) combinado con cadenas de Markov. Los procedimientos de pronóstico basados en señales periódicas como la DFT, Chebyshev, Legendre y Regresión Polinomial fueron aplicados y estos pueden capturar el comportamiento dinámico de las series de tiempo. Algunas técnicas de aprendizaje de máquina fueron probadas y fue posible capturar el comportamiento de las series de tiempo en la etapa de calibración, los valores de pronóstico pueden seguir el comportamiento general comparado con los valores observados (excepto ANFIS, GA y Filtro de Kalman). Por lo tanto, ANN y SVM tiene buen rendimiento de pronóstico para la primer parte del horizonte de pronóstico (2 horas). La evaluación de cada metodología de pronóstico fue realizada utilizando cuatro indicadores estadísticos tales como porcentaje absoluto de error (APE), incertidumbre extendida (EU), conjunto de valores dentro del intervalo de confianza (CI) y suma de valores de incertidumbre extendida más el conjunto de valores dentro del intervalo de confianza. El rendimiento de los indicadores provee información acerca de los resultados de pronóstico multivariado con el fin de estimar y evaluar los tiempos de pronóstico para cierta metodología de pronóstico y determinar cuál metodología de pronóstico es mejor adaptada a diferentes rangos de longitudes de onda (espectros de absorbancia) para cada serie de tiempo de absorbancia UV-Vis en cada sitio de estudio. Los resultados en la comparación de las diferentes metodologías de pronóstico, resaltan que no es posible obtener la mejor metodología de pronóstico, porque todas las metodologías de pronóstico propuestas podrían generar un amplio número de valores que permitirán complementar cada una con las otras para diferentes pasos de tiempo de pronóstico y en diferentes rangos del espectro (UV y/o Vis). Por lo tanto, es propuesto un sistema híbrido que es basado en siete metodologías de pronóstico. Así, los valores de los espectros de absorbancia pronosticados fueron transformados a los correspondientes indicadores de calidad de agua (WQI) para utilización en la práctica. Los resultados de pronóstico multivariado presentan valores bajos de APE comparados con los resultados de pronóstico univariado utilizando directamente los valores WQI observados. Estos resultados, probablemente, son obtenidos porque el pronóstico multivariado incluye la correlación presente en todo el rango de los espectros de absorbancia (se captura de forma completa o al menos gran parte de la variabilidad de las series de tiempo),una longitud de onda interfiere con otra u otras longitudes de onda. Finalmente, los resultados obtenidos para el humedal construido/tanque de almacenamiento presentan que es posible obtener apreciables resultados de pronóstico en términos de tiempos de detección para eventos de lluvia. Adicionalmente, la inclusión de variables como escorrentía (nivel de agua para este caso) mejora substancialmente los resultados de pronóstico de la calidad del agua. El monitoreo de contaminantes en sistemas de saneamiento urbano es generalmente realizado por medio de campañas de muestreo, las muestras deben ser transportadas, almacenadas y analizadas en laboratorio. Sin embargo, los desarrollos en óptica y electrónica han permitido su fusión y aplicación en la espectrometría UV-Vis. Los sensores UV-Vis tienen como propósito determinar la dinámica de las cargas de materia orgánica (Demanda Química de Oxigeno DQO y Demanda Bioquímica de Oxigeno DBO5), nitratos, nitritos y Sólidos Suspendidos Totales (SST). Adicionalmente a los métodos aplicados para la calibración de los sensores y el análisis las series de tiempo de los espectros de absorbancias UV-Vis, es necesario desarrollar métodos de pronóstico con el fin de ser utilizada en control de monitoreo en línea en tiempo real. La información proveniente de los datos recolectados puede ser utilizada para la toma de decisiones y en aplicaciones de control de tiempo real. Realizar pronósticos es importante en procesos de toma de decisiones. Por lo tanto, el objetivo de este trabajo de investigación fue desarrollar uno o varios métodos de pronóstico que puedan ser aplicados a series de tiempo de espectrometría UV-Vis para el monitoreo en línea de la calidad de agua en sistemas urbanos de saneamiento en operación. Cinco series de tiempo de absorbancia UV-Vis obtenidas en línea en diferentes sitios fueron utilizadas, con un total de 5705 espectros de absorbancia UV-Vis: cuatro sitios experimentales en Colombia (Planta de Tratamiento de Aguas Residuales (PTAR) El-Salitre, PTAR San Fernando, Estación Elevadora de Gibraltar y un Humedal Construido/Tanque de Almacenamiento) y un sitio en Austria (Graz-West R05 Catchment outlet). El proceso propuesto completo consta de etapas a ser aplicadas a las series de tiempo de absorbancia UV-Vis y son: (i) entradas, series de tiempo de absorbancia UV-Vis,(ii) pre-procesamiento de las series de tiempo, análisis de outliers, completar los valores ausentes y reducción de la dimensionalidad,y (iii) procedimientos de pronóstico y evaluación de los resultados. La metodología propuesta fue aplicada a la series de tiempo con diferentes características (absorbancia), esta consiste del enventaneo Winsorising como paso para la remoción de outliers y la aplicación de la transformada discreta de Fourier (DFT) para reemplazar valores ausentes. Los nuevos valores reemplazando o los outliers o los valores ausentes presentan la misma o al menos la misma forma de la serie de tiempo original, permitiendo una visión macro en la coherencia de la serie de tiempo. La reducción de la dimensionalidad en las series de tiempo de absorbancia multivariadas permite obtener menor número de variables a ser procesadas: el análisis por componentes principales (PCA) como transformación lineal captura más del 97% de la variabilidad en cada serie de tiempo (en un rango de una a seis, dependiendo del comportamiento de la series de tiempo absorbancia) y el proceso de Clustering (k-means) combinado con cadenas de Markov. Los procedimientos de pronóstico basados en señales periódicas como la DFT, Chebyshev, Legendre y Regresión Polinomial fueron aplicados y estos pueden capturar el comportamiento dinámico de las series de tiempo. Algunas técnicas de aprendizaje de máquina fueron probadas y fue posible capturar el comportamiento de las series de tiempo en la etapa de calibración, los valores de pronóstico pueden seguir el comportamiento general comparado con los valores observados (excepto ANFIS, GA y Filtro de Kalman). Por lo tanto, ANN y SVM tiene buen rendimiento de pronóstico para la primer parte del horizonte de pronóstico (2 horas). La evaluación de cada metodología de pronóstico fue realizada utilizando cuatro indicadores estadísticos tales como porcentaje absoluto de error (APE), incertidumbre extendida (EU), conjunto de valores dentro del intervalo de confianza (CI) y suma de valores de incertidumbre extendida más el conjunto de valores dentro del intervalo de confianza. El rendimiento de los indicadores provee información acerca de los resultados de pronóstico multivariado con el fin de estimar y evaluar los tiempos de pronóstico para cierta metodología de pronóstico y determinar cuál metodología de pronóstico es mejor adaptada a diferentes rangos de longitudes de onda (espectros de absorbancia) para cada serie de tiempo de absorbancia UV-Vis en cada sitio de estudio. Los resultados en la comparación de las diferentes metodologías de pronóstico, resaltan que no es posible obtener la mejor metodología de pronóstico, porque todas las metodologías de pronóstico propuestas podrían generar un amplio número de valores que permitirán complementar cada una con las otras para diferentes pasos de tiempo de pronóstico y en diferentes rangos del espectro (UV y/o Vis). Por lo tanto, es propuesto un sistema híbrido que es basado en siete metodologías de pronóstico. Así, los valores de los espectros de absorbancia pronosticados fueron transformados a los correspondientes indicadores de calidad de agua (WQI) para utilización en la práctica. Los resultados de pronóstico multivariado presentan valores bajos de APE comparados con los resultados de pronóstico univariado utilizando directamente los valores WQI observados. Estos resultados, probablemente, son obtenidos porque el pronóstico multivariado incluye la correlación presente en todo el rango de los espectros de absorbancia (se captura de forma completa o al menos gran parte de la variabilidad de las series de tiempo),una longitud de onda interfiere con otra u otras longitudes de onda. Finalmente, los resultados obtenidos para el humedal construido/tanque de almacenamiento presentan que es posible obtener apreciables resultados de pronóstico en términos de tiempos de detección para eventos de lluvia. Adicionalmente, la inclusión de variables como escorrentía (nivel de agua para este caso) mejora substancialmente los resultados de pronóstico de la calidad del agua.The monitoring of pollutants in urban sewer systems is generally conducted by sampling campaigns, and the resulting samples must be transported, stored and analyzed in laboratory. However, the developments in optics and electronics have enabled the merge of them into the UV-Vis Spectrometry. UV-Vis probes have the purpose of determining the dynamics of loads of organic materials (i.e. Chemical Oxygen Demand (COD) and Biochemical Oxygen Demand (BOD5)), nitrates, nitrites and Total Suspended Solids (TSS). In addition to the methods used for the calibration of the probes and the analysis of the time series of UV-Vis absorbance spectra, it is necessary to develop forecasting methods in order to use the online control monitoring in real time. The information from the collected data can also be used for decision making purposes and for real-time control applications. Forecasting is important for decision-making processes. Therefore, the objective of this research work was to develop either a forecasting method or forecasting methods applied to UV-Vis spectrometry time series data for online water quality monitoring in operating urban sewer systems. Five UV-Vis Absorbance time series collected at different on-line measurement sites were used, for a total of 5705 UV-Vis absorbance spectra data: four sites in Colombia (El-Salitre Wastewater Treatment Plant-WWTP, San Fernando WWTP, Pumping Station (PS) sewage called Gibraltar and constructed-wetland/reservoir-tank (CWRT)) and one site in Austria (Graz-West R05 Catchment outlet). The complete process proposed to be applied to UV-Vis absorbance time series has several stages and these are: (i) inputs, the UV-Vis absorbance time series,(ii) the time series pre-processing, outliers analysis, complete missing values and time series dimensionality reduction,and (iii) forecasting procedures and evaluation of results. The methodology proposed was applied to the time series with different characteristics (absorbance), this consists of Winsorising as a step in outlier removal and the application of the Discrete Fourier Transform (DFT) to complete the missing values. The new values replaced either outliers or missing values present the same, or almost the same, shape as the original time series, granted the macro vision of the time series coherence. Dimensionality reduction of multivariate absorbance time series allows to have less variables to be processed: PCA linear transformation captures more than 97% of variability for each time series (PC ranging from one to six, depending on absorbance time series behavior), and Clustering process (k-means) combined with Markov Chains. Forecasting procedures based on periodic signals as DFT, Chebyshev, Legendre and Polynomial Regression were applied and they can capture the dynamic behaviour of the time series. Several Machine Learning technics were tested and it was possible to capture the behaviour of the time series at calibration stage, the forecasting obtained valúes can follow the general behaviour compared with observed valúes (with exception of ANFIS, GA and Kalman Filter). Therefore, ANN and SVM have good forecasting performances for first part of forecasting horizon (2 hours). The evaluation of each forecasting methodology was done using four statistic indicators as Absolute Percentage Error (APE), Extended Uncertainty (EU), Set of observed values within Confidence Interval (CI) and sum of EU and Set of observed values within CI. The performance indicators provided valuable information about multivariate forecasting results to estimate and evaluate the forecasting time for a given forecasting methodology and determine which forecasting methodology is best suited for different wavelength ranges (absorbance spectra) at each study site s UV-Vis absorbance time series. Results from different comparison of several forecasting methodologies, highlight that there is not possibility to have a best forecasting methodology among the proposed ones, because all of them could provide a wide forecasting values that would complemented each other for different forecasting time steps and spectra range (UV and/or Vis). Therefore, it is proposed a hybrid system that is based on seven forecasting methodologies. Thus, the forecasted absorbance spectra were transformed to Water Quality Indicators (WQI) for practical uses. The multivariate forecasting results show lower APE values compared to the univariate forecasting results (APE values) using the observed WQI. These results, probably, were obtained because multivariate forecasting includes the correlation presented at whole absorbance spectra range (captures complete or at least great part of time series variability),one wavelength interferes with another and/or other wavelengths. Finally, the results obtained for a constructed-wetland/reservoir-tank system show that it is possible to obtain valuable forecasting results in terms of time detection for some rainfall events. In addition, the inclusion of runoff variables (water level in this case) improves the water quality forecasting results.Doctor en IngenieríaDoctorad