Imaging-Based Pulp Refining Control via Fiber Fibrillation Ratio
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Solution Overview
Problem
Current methods for monitoring and controlling pulp refining in paper, board, or tissue production lack effectiveness in determining fiber properties and optimizing chemical dosing, leading to suboptimal end product quality and energy consumption.
Innovation Solution
An imaging-based system that captures pulp samples, determines the ratio of fibrillated to non-fibrillated fibers, and uses this ratio to generate a control parameter for refining, adjusting parameters such as blade gap, chemical treatment, and energy input to optimize fiber properties and refining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional monitoring methods are used for pulp refining, then the process can be operated with simple equipment, but the determination of fiber properties and control precision are insufficient
Solution Approach 1:
The patent replaces conventional mechanical measurement methods with an imaging-based optical system. The apparatus captures images of pulp fibers and uses image processing to determine fiber properties, substituting complex mechanical measurement equipment with optical imaging and computational analysis, thereby achieving high precision while maintaining manageable system complexity
Solution Approach 2:
The patent creates a digital copy of the pulp fiber structure through imaging. By capturing images and processing them to extract fiber properties, the system works with a replicated visual representation rather than direct physical measurement, enabling precise determination of fiber characteristics without requiring complex contact-based measurement devices
2Strength
If extensive chemical dosing is applied to improve fiber properties, then end product quality can be enhanced, but energy consumption and process inefficiency increase
Solution Approach 1:
The patent implements a closed-loop feedback system where the imaging apparatus continuously monitors fiber properties during refining, and the control unit adjusts refining parameters in real-time based on the measured fibrillation ratio. This feedback mechanism enables precise control to achieve target fiber properties without excessive chemical dosing or energy input, optimizing the balance between product quality and resource consumption
Solution Approach 2:
The patent dynamically changes refining parameters (such as refiner speed, blade gap, or chemical dosage) based on the measured fibrillation ratio and fiber properties. By adjusting these parameters in response to real-time measurements, the system achieves optimal fiber modification with minimal energy and chemical input, avoiding the waste associated with fixed, overly aggressive refining parameters
3Strength
If intensive refining is applied to improve fiber bonding, then web strength increases, but energy consumption and fiber damage increase
Solution Approach 1:
The imaging-based monitoring system provides real-time feedback on fiber fibrillation and bonding characteristics, allowing the control unit to adjust refining intensity to achieve optimal web strength without excessive energy input. The system detects when sufficient fibrillation has been achieved and reduces refining intensity accordingly, preventing energy waste and fiber damage
Solution Approach 2:
The patent applies refining action selectively and proportionally based on measured fiber properties rather than applying uniform intensive refining throughout. By adjusting the degree of refining action according to the actual fibrillation ratio and fiber characteristics, the system achieves sufficient web strength with partial rather than excessive refining, reducing energy consumption and fiber damage
Data Source
AI summary
The refining of a fibrous pulp is monitored and controlled by capturing at least one image of a pulp sample, determining the amount of all fibers or non-fibrillated fibers in the at least one image, determining the amount of fibrillated fibers in the at least one image, determining the relation between fibrillated fibers and all fibers or non-fibrillated fibers in the pulp on the basis of the amount of fibrillated fibers and the amount of all fibers or non-fibrillated fibers in the at least one image, generating a control parameter on the basis of the determined relation between fibrillated fibers and all fibers or non-fibrillated fibers in the pulp, and controlling fiber refining by at least one pulp refining device on the basis of the control parameter.