Paper Machine Chemical Dosing for Real-Time Optimization

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Solution Overview

Problem

The paper making process is constrained by limited testing frequency of chemical dosages, leading to compromised production efficiency and quality due to operator-dependent adjustments, which are often infrequent and labor-intensive.

Innovation Solution

A system and method that utilizes a process device equipped with AI/ML to autonomously learn inter-relationships among process parameters and desired results, continuously monitoring and adjusting chemical dosages in real-time to optimize the paper making process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If operator-dependent manual monitoring and adjustment of chemical dosages is used, then operational flexibility is maintained, but testing frequency is limited to 6-8 tests per day resulting in compromised production efficiency and quality

Engineering Contradiction:

Improvetesting frequencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system enables self-service automation where the paper making process autonomously monitors and adjusts chemical dosages without operator intervention. Sensors continuously measure process parameters and the control system automatically modifies dosing rates, eliminating the need for manual testing and adjustment while achieving frequent optimization cycles

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operations with automated sensing and control systems. Physical manual testing and adjustment actions are substituted by electronic sensors, processors, and automated dosing controls that continuously monitor and optimize chemical dosages without human intervention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If manual testing and adjustment by operators is performed, then system simplicity is maintained, but labor intensity increases and production efficiency is compromised

Engineering Contradiction:

Improveproduction efficiencyVSAvoidoperational simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system performs self-monitoring and self-adjustment of chemical dosages automatically. Sensors detect process conditions and the control system modifies dosing rates without requiring operator actions, thereby improving production efficiency while the system manages its own operation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements continuous feedback loops where sensors monitor process parameters such as retention and drainage characteristics, and the control system uses this feedback to automatically adjust chemical dosages in real-time, optimizing production efficiency through closed-loop control

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If frequent testing of chemical dosages is implemented, then paper quality optimization is improved, but manpower requirements and time consumption increase

Engineering Contradiction:

Improvepaper qualityVSAvoidtime for testing

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system implements continuous monitoring and adjustment of chemical dosages without interruption to the paper making process. Sensors continuously measure process parameters and the control system continuously optimizes dosing rates, eliminating the discrete testing intervals that consume time and manpower while maintaining constant quality optimization

Inventive Principle:

Principle #20Continuity of useful action

4Measurement precision

If manual monitoring of chemical dosages is used, then system complexity is kept low, but chemical dosing precision is compromised leading to wastage

Engineering Contradiction:

Improvechemical dosing precisionVSAvoiddosing system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Manual estimation and adjustment of chemical dosages are replaced by electronic sensors and automated control systems that precisely measure process parameters and calculate optimal dosing rates. This substitution enables high measurement precision while the automated system manages the complexity of precise control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The dosing system performs self-adjustment based on real-time sensor data, automatically optimizing chemical dosages without manual intervention. This autonomous operation achieves high dosing precision while the system independently manages the complexity of precise control and adjustment

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250320661A1Optimizing paper making process of a paper machine

Publication Date: 2025.10.16 ALADDIN SEPARATION TECHNOLOGIES INC

AI summary

The present disclosure relates to a system and a method for optimizing paper making process of a paper machine. The system described herein comprises a process device configured to receive a process parameters corresponding to characteristics of the material and chemical composition that is used in a paper making process. Further, the process device is configured to determine an optimal concentration level of a plurality of dosing additives based on the received process parameters. Finally, the process device is configured to control concentration level of the plurality of dosing additives for optimizing the paper making process based on the determined optimal concentration level.