MMEA (The Measurement, Monitoring and Environmental Efficiency Assessment) research program final seminar presentation by Product manager Heli Karaila, Valmet Ltd.)

1. MMEA Seminar 26.11.2015
Valmet
Wastewater Applications
Product Manager Heli Karaila Valmet

2. Valmet

3. 17.09.2015
North America
EMEA
South America
Asia-Pacific
China
Orders received
EUR 3,400 million
Net Sales
EUR 2,800 million
Employees 12,000
Market position
#1-2 Services
#1-2 Pulp
#1-3 Energy
#1-2 Paper, board, tissue
#1-3 Pulp and paper
automation
Valmet’s illustrative key figures with Automation
Based on combined figures from 2014
Sales by
business line
Services
Pulp and Energy
Paper
Automation
Sales by
geographic area

4. Unique offering covers process technology,
automation and services
 Valmet develops and supplies
advanced technologies, automation
solutions and services
 We combine pulp, paper and energy
technology, process know-how and
automation
– Enabling innovative product and service
development
– Increasing competitiveness
 Full scope offering differentiates
Valmet from its competitors
17.09.2015
Customer
Services Automation
Process technology

5. Valmet Automation
Proven performance from a trusted partner
17.09.2015
Valmet has delivered more than
4,500 automation systems
40,000 analyzers and measurements
Over 1,000 power plants worldwide utilize Valmet’s
process automation
Valmet is
#1 in QCS, analyzers and measurements
#1 in pulp performance optimization using advanced
controls.
#3 in pulp & paper control systems
Niche leader in Bio and Waste-to-Energy power plant
automation
Our presence today
1600+ Personnel
30+ Countries
55+ Automation Service
Hubs

6. Continued commitment to moving our
customers’ performance forward
1980s 1990s 2010 2014 2015 2016
Automation foundation
• Damatic ”Classic”
• Damatic XD
• Damatic Xdi
• PaperIQ
• Kajaani anazyzers
• Metso DNA (now
Valmet DNA)
• Integrated condition
monitoring
• Turbomachinery
controls
• Virtualization
• Compact controllers
• High-density I/O’s
• Metso IQ (now
Valmet IQ)
• IQ Fiber
• Image-based
sensors
• New MD & CD
Controls
• New IQ Profiler
actuators
• IQ Induction Profiler
• Next gen Web
Inspection systems
• Rotary
• OC, LC
• LS, Alkali R
• MR Moisture, FS5
• KappaQC
• Corrored
• Alkali C
Introducing the next level
in automation
• Valmet DNA growth story
continues
• Valmet IQ family further
strengthened
• Analyzer and measurement
portfolio will grow even
stronger
Industry leading offering
17.09.2015

7.  Valmet Wastewater applications
Cost efficient and
fit-for-purpose
solutions

8. 17.09.2015
 We have recognized
opportunities for our
competences in demanding
wastewater measurement
applications
 Developing Wastewater sector
creates attractive business
opportunity for us
 With advanced applications we
can provide the customers with:
– Cost savings
– Increased capacity
– Process efficiency
– Increased process performance
Wastewater opportunities
Our aim is to be the preferred supplier of waste-
water measurements and process
performance solutions

9. Wastewater Process / Sludge measurements
17.09.2015

10. Valmet Automation offering to the waste water
 Valmet Total Solids Transmitter; Valmet TS
 Valmet Low Solids Measurement; Valmet LS
 Valmet SDO , Sludge Dewatering Optimizer
 Valmet Conductivity Measurement products
 Valmet DNA automation system
17.09.2015

11. Valmet Automation offering to the waste water
 Valmet Total Solids Transmitter; Valmet TS
 Valmet Low Solids Measurement; Valmet LS
 Valmet SDO , Sludge Dewatering Optimizer
 Valmet Conductivity Measurement products
 Valmet DNA automation system
17.09.2015
,
Valmet LS and SDO
Research phase
done
in MMEA
Sludge / Solids research
continues

12. Valmet TS -Total Solids measurement
 A microwave measurement principle
 Sensor type and sizes:
 Standard model PN16 /232 psi
Sizes: DN50, DN80, DN100, DN150, DN200, DN250, DN300
 High pressure model PN 100/1450 psi
Sizes: DN100, DN150, DN 200
 Measurement range: 0 - 40 TS%
 organic and inorganic materials
 Sensitivity: 0.001 TS%
 Repeatability: 0.01 TS%
 Enclose class: IP65
 ATEX certification NEW !
– Certificate No. VTT 12 ATEX 058X
– II 3G Ex nR IIC T6 Gc
– Area classification : Zone 2
– For biogas / biofuel applications, where flammable
gases ( e.g methane ) could exists.
 Communication
 4-20mA + HART® Total Solids
 4-20 mA Process temp. /-Conductivity
 Profibus PA
17.09.2015

13. Valmet TS measurement principle
17.09.2015
 Valmet TS measures the time of flight of a microwave signal in the sludge
 Microwave’s delay time in water vs. total solids has a linear relationship
Microwave
delay time
(ps)
Total solids (%)

14. Valmet LS
17.09.2015
”The first measurement
system that really works in
centrate water.”
Customer statement
 Total suspended solids 0-5000 mg/l
 Specially developed to centrate
application
 Entrained air index, helps in
indentifying polymer overdosing
 Robust to impurities with optimum
optical properties
Total suspended solids measurement

15. Waste water treatment plan overview
©Valmet
Waste water treatment process
17.09.2015

16. Valmet LS – flow path
17.09.2015
After sample valve (1) the sample flows
to dearation vessel (2) where it is
deaerated and any debris is screened
out. The sample is then pumped (3) to
the optical unit and measured (4).
Finally the sample flows to the
laboratory sampling point (5).
The unit has an automatic weak acid
cleaning cycle, with programmable
interval timing, that backflushes the
unit to clean the optics (6).
All parameters can be set and the
results monitored with a local user
interface (7).
1.
6.
2.
4.
3.
8–14 l/min
8-14 l/min
7.
10m cable
©Valmet

17.  Strong measurement cell
 2 light sources, 6 signals
 Absorption, back-scattering and depolarization signals
Optical measurement
from the technology leader
17.09.2015
Led nir
Ledvis
Lednir/
Ledvis ref.
Polarizer
Spiege
l
Probe
BS
Linse
Spiege
l
Polarizer

18. Valmet LS
17.09.2015
 Constant and continuous sample
flow by using the centrifugal
pump
 Sample is deaerated and
contaminants screened before
entering the measurement cell
 Automatic cleaning
– Always includes: measurement cell,
sample lines and screens are cleaned
automatically, at configurable intervals
based on real cleaning need.
– Automatic cleaning chemical addition
(low concentration acid) at
configurable intervals, independent of
normal cleaning/flushing
 Advanced self diagnostic
– No measurement drift - light sources
inside the measurement cell are re-
calibrated using the clean flushing
water
– Diagnostics alert if dirt accumulating
in measurement cell begins to affect
TSS measurement
 Two LED light sources measure
absorption / scattering /
depolarization as light passes
through the centrate – critical for
accurate TSS!
Turnkey measurement system based on 20 years of experience

19. Valmet SDO
17.09.2015
Valmet SDO

20. Sludge dewatering control application
 Centrifuge: Removes solids from water by way of centrifugal force.
 The Dry Cake target value varies but usually cake solids are in the
12– 35% range. It is important that the Dry Cake TS % is as high as
possible in order the transport costs and incineration costs are
optimized
 Reject water / Centrate TSS needs to be minimized in order the
material is not circulating inside the plant and cause polymer and
dewatering costs .
 The centrifuge controllable
variables are
– Differential speed of centrifuge, torque
– Polymer dosing
 Centrifuge depended items are max
massflow, sludge consistency
and volumetric flow to the centrifuge
17.09.2015 ©Valmet

21. Centrate TSS Dry Cake TS interactions
- MPC technology needed
17.09.2015
Centrate TSS
Dry Cake TS
Controlledvariables
Manipulated variables
Difficult to control with separate loops
©Valmet
Polymer Torque

22. Valmet
Wastewater
applications
Application Review

23. Laboratory measurement is not enough
17.09.2015
0
1000
2000
3000
4000
5000
6000
30.11.10 0:00 5.12.10 0:00 10.12.10 0:00 15.12.10 0:00 20.12.10 0:00 25.12.10 0:00 30.12.10 0:00
Mittari Labra
0
500
1000
1500
2000
2500
3000
3500
19:12 0:00 4:48 9:36 14:24 19:12 0:00
Mittari Labra
Quality control of
centrate water
based on infrequently
taken lab samples
is not adequate
Lab sample represents
centrate quality at that
specific moment:
- After a half an hour
the situation can be
completely different!
mg/l
mg/l
Valmet LS Laboratory
Valmet LS Laboratory
©Valmet
Field
results

24. Valmet’s superior solid measurements
Valmet Total Solids
 Valmet TS (0-40% )
Valmet Low Solids
 Valmet LS (0-5000 mg/l)
17.09.2015
Field
results

25. 40% reduction in polymer
Viikinmäki WWTP, Finland
 Automatic control: Polymer
dosage is managed on the basis
of centrate quality within given
limits
 Two measurements: feed forward
and centrate
 Improved centrifuge performance
and reduced polymer
17.09.2015
0
500
1 000
1 500
2 000
2 500
3 000
21.1. 22.1. 23.1. 24.1. 25.1. 26.1. 27.1.
mg/l,kgTS/h
0,0
2,0
4,0
6,0
8,0
10,0
kgPE/tTS
TS-kuorma LINKO 4. REJEKTI SS Polymeeri
Manual control
Automatic control
--- sludge to drying --- polymer --- total suspented solids
Field
results

26. Reduction in centrate, improved dry cake
City of Oulu
17.09.2015
18.5
19
19.5
20
20.5
21
21.5
0
500
1000
1500
2000
2500
3000
3500
9:26:40
9:29:00
9:31:20
9:33:40
9:36:00
9:38:20
9:40:40
9:43:00
9:45:20
9:47:40
9:50:00
9:52:20
9:54:40
9:57:00
9:59:20
10:01:40
10:04:00
10:06:20
10:08:40
10:11:00
10:13:20
10:15:40
10:18:00
10:20:20
10:22:40
10:25:00
10:27:20
10:29:40
10:32:00
10:34:20
10:36:40
10:39:00
10:41:20
10:43:40
10:46:00
10:48:20
10:50:40
10:53:00
10:55:20
10:57:40
11:00:00
11:02:20
11:04:40
11:07:00
11:09:20
11:11:40
DryCake%
CentrateTSSmg/l
Centrate, Dry Cake
Centrate_TSS(mg/l)
Dry Cake_TS(%)
• Centrate TSS reduction from 2000 mg/l ->500 mg/l
• Dry Cake TS improvement from 20.25 % ->21.25%
Control to
auto mode
Field
results
Field
results

27. Reliable measurements -> Control, Optimization
–> performance increase and savings
17.09.2015