Pulp mill applications

| July 30, 2020 |
© Yokogawa Electric Corporation
Pulp Mill Applications that
keep you up at night
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Pulp & Paper Webinar
September 24, 2020

| July 30, 2020 |
1
Presenters
Host
Cherlyn Marlow
Product Marketing Manager
Presenters
Host
Chris Costlow
Product Marketing Manager
Michael Zoghby Jr - Southeast Sales Manager – BBP
Michael has 15 years of experience selling in Industrial
Markets with a strong presence in Pulp & Paper.
Dennis Crosby – Southeast Analytical Sales Manager – Yokogawa
Dennis has 40 years of experience in Analytical instrumentation in
Liquid, Gas and Advanced Analytical (GC and TDLS) analyzers; selling
primarily to the Pulp and Paper and Power markets.
Paul Warburton- Southeast Field Instruments Sales Manager – Yokogawa
Paul has 28 years of industry experience with the last 24 years working at
Yokogawa. Previously held positions include flow meter product
management and technical support team leader for field instruments.
Wesley Chappell - Account Manager – BBP
Specializing in Pulp and Paper in South Alabama, South Georgia, and the
Panhandle

| July 30, 2020 |
Agenda
2
1. Plant Overview
2. Cooking (Digester) Process
 Why Liner Selection is important
 What is Total Insight and what does that mean for
me?
3. Washing & Bleaching
 Why are accurate pH readings critical
 Why is pH so maintenance intensive?
 So I am stuck with pH…..
What can I do to make it more manageable?
4. Summary

| July 30, 2020 |
3
Plant Overview

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Plant Overview
4
Wood Chips
Pulp
Paper

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5
Cooking (Digester)

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Cooking Process
Top
Digester
Blow
Tank
Screen
Screen
Thickener
Filtrate Tank
Cleaning Filter
To Washing/Bleaching
Insert Chips
Brown
Stock

| July 30, 2020 |
Cooking (Digester) Process
 The cooking process in one of the most
important steps in the cellulose processes,
as the better the chips are cooked, the less
lignin in the pulp. This results in more
efficiency in the final steps of the process,
which will save money and operation time.
 The Digester process could be continuous
or batch feed. Most companies are in
continuous mode (+/- 70%), due to the
larger production capacity and a better
result as a product uniformity.
7

| July 30, 2020 |
What is Black Liquor
 Black Liquor is an aggressive fluid used in the
Circulation and Extraction lines of the Digester and
Blow Line. It’s high concentration of Pulp and high
abrasive levels, result in extreme conditions that the
operator must be aware of.
 High temperature 150 °C (300 °F)
 High pressure 20 Bar (290 psi)
 High alkaline consistency
 Adhesive fluid
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| July 30, 2020 |
Cooking Process - Flowmeters
Circulation Line:
Preheated chips and liquor move
through the heating zone at 115 °C to
120 °C (239 ~ 248 °F) to allow optimum
saturation of the liquor into the chips.
Extraction Line:
The water comes out as residue, along
with the black liquor in the middle of the
digester. The hot liquor is drawn to a
low pressure tank where the steam is
generated for use in the steam vessel

| July 30, 2020 |
Cooking Process - Flowmeters
Washing transfer:
The cooked pulp is transferred to the
purification system, which by mechanical
process, separates the foreign materials
from the fibers (nodes, small sticks). The
pulp material is transferred to the washer
filters, whose purpose is to wash the
mass, separating all the soluble from the
cellulose fibers (delignation). The
cellulose is then routed to the bleaching
or else to manufacture Kraft paper. The
filtrate is called black liquor and is
transferred to the recovery process.

| July 30, 2020 |
Black Liquor Challenges
 Taking flow measurements often become very complicated due to:
 Damage to the lining from the changes in pressure and temperature
conditions
 Damage due to the abrasive and adhesive fluids
 Leakage from electrodes, due to a deformation of the lining, resulting in a gap
between the lining and electrode

| July 30, 2020 |
Why liner selection is
important
12

| July 30, 2020 |
Example of Fiber Line, Bleaching Line and Digester Applications
 PFA Hardiness compared with PTFE competitors
Strengths – ADMAG – PFA Hardiness and Stability
AXF / AXG PFAPTFE
PTFE After 6 months PFA After 3 years

| July 30, 2020 |
14
Yokogawa ADMAG Model
Metal Hat Earth Rings
Welded Punch Plate
Inside of the sensor is
filled with Epoxy potting
Vent hole
Magnetic Flowmeter Construction – ADMAG TI AXG

| July 30, 2020 |
15
 Recommended specification
 PFA Lining
 To maintain sealing performance when the lining encounters abrasion from a slurry fluid.
 Metal Hat Earth Rings
 To minimize lining abrasion from a slurry fluid.
 Full welding of punch plate
 To prevent lining deforms at high temperature.
 Flow sensor filled with Epoxy potting
 To Increase heat dissipation for high temperature fluid measurement.
 To prevent the outflow of fluid when fluid leaks from the electrode.
 Vent Hole
 To release the permeable fluid that passed through the lining, to prevent blister of lining.
Black Liquor Specification – Blow line

| July 30, 2020 |
Dual Frequency Excitation
16
 Unique advanced excitation method: 6.25 & 75 Hz
simultaneously
 High frequency component (75 Hz) has a fast response and
stable measurement
 Slurry Noise Immunity
 Batching Application
 Low frequency Component (6.25 Hz) maintains zero stability
 Reduced OPEX

| July 30, 2020 |
Cooking Process – Pressure and Temp Transmitters
Various opportunities for Pressure and Temperature Transmitters
EJX Series
YTA Series
Remote Seals

| July 30, 2020 |
What is Total Insight and what
does that mean for me?
18

| July 30, 2020 |
Total Insight
Total Insight is a Yokogawa concept for optimizing operations and reducing
maintenance costs through every phase of the product lifecycle
19

| July 30, 2020 |
What does Total Insight do for me?
 Detection of Electrode Adhesion
 Detection of Flow Noise (Slurry)
 Data Logging (Offline Analysis)
 Verification (Device Health Diagnosis) Function
 Built-in, Standard (0.5%), and Enhanced (0.2%)
 Printable Report
20

| July 30, 2020 |
21
Washing & Bleaching

| July 30, 2020 |
Washing
 At this stage, the objective is to remove the
maximum amount of black liquor dissolved solids
from the pulp while using as little water possible.
The remaining solids and chemicals in the pulp will
interfere with later bleaching and other steps,
increasing the cost of the final process.
22

| July 30, 2020 |
Bleaching
 The objective of the bleaching process is to remove only the
chromophores (elements that provide color).
23

| July 30, 2020 |
24
 The Conductivity can be measured in many
stages of the pulping process and presents
many challenges for the sensor and mounting
options.
 The Yokogawa ISC40 Inductive sensor has a
wide measuring range of 1-2,000,000 micro
Siemens, 130 C and an 11/16” bore to
minimize plugging.
 Flat Surface sensors work well in thick stock
applications but orientation and insertion
depth needs to be taken into consideration.
 Yokogawa offers a cylindrical 4 pole
contacting conductivity sensor that has
performed well in stock washing applications
Conductivity Challenges
Conducell ConducellISC40

| July 30, 2020 |
Why are accurate pH readings
critical
25

| July 30, 2020 |
Environmental Concerns?
 Many measurements are used to monitor the process such as pressure,
temperature, and flow, but the process of bleaching highly depends on accurate
pH/ORP measurements.
26

| July 30, 2020 |
pH Challenges
 pH/ORP measurements can be a challenge in stock applications.
 Pulp Stock can be abrasive to the pH glass membrane. Different types on membrane glass and
bulb shapes can be selected to minimize abrasion (i.e. Heavy Duty Glass, Flat Surface,…)
 Chemical additives to the stock can cause pH glass coating issues. Periodic cleaning with a
dilute HCl acid solution (2%, 5% or 10%) will help remove coatings and restore the response and
accuracy of the pH electrode. The use of an enamel differential pH sensor (pH18) will help
prevent coating issues due to the slickness of the enamel surface .
 Since the Head Box pH measurement is the last measurement before the paper machine,
accurate pH measurements are critical. pH glass coating issues at the Head Box are a common
problem. The pH18 pH/Na differential sensors works well in this application.
27
Image Source: https://www.shutterstock.com/video/clip-
2971600-paper-pulp-rotates-machine---medium-shot

| July 30, 2020 |
pH Challenges – continued
 Excessive ClO2 that weakens the paper intensity will also shorten the life of a pH
electrode.
 Coating of the pH glass and plugging of the reference junction can cause sluggish
and inaccurate readings
 High pH values used to dissolved the reacted lignin, can shorten the life of the
reference electrode and can introduce process temperature compensation errors.
 Installation locations can be difficult to get a pH sensor directly into the process.
28
Before cleaning…..… …..….after cleaning

| July 30, 2020 |
29
Why does pH have to be so
maintenance intensive?

| July 30, 2020 |
30
Copyright © Yokogawa Corporation of America
pH – Acid or Base?
NEUTRAL
ACID
BASE
1.0
0.1
0.01
0.001
0.0001
0.00001
0.000001
0.0000001
0.00000001
0.000000001
0.0000000001
0.00000000001
0.000000000001
0.0000000000001
0.00000000000001
[H+ ]
.00000000000001
.0000000000001
.000000000001
.00000000001
.0000000001
.000000001
.00000001
.0000001
.000001
.00001
.0001
.001
.01
0.1
1.0
[OH- ]
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
pH
pH = -log [H+](Hydrogen Ion Concentration)
Moles/Liter

| July 30, 2020 |
pH Electrode- How does it work?
The following are the most significant potentials:
R
R
R
R
R
Et
E1
E4
E3
E2
E5
Electrolyte
Diaphragm
Membrane
Electrolyte
Liquid
E1E4
E3
E2
E5
Et
E1 = Potential between pH Glass and Process
E2 = Potential between pH Glass and Fill Solution (7 pH buffer)
E3 = Potential between Measuring Pin and Fill Solution
E4 = Potential between Reference Pin and Electrolyte (KCl)
E5 = Potential between Electrolyte and Process (Diffusion Potential)

| July 30, 2020 |
Temperature - pH vs. mV
pH/mV Ratio (measured with regard to the saturated calomel electrode)
pH Temp.° C 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100°
0.0 379.4 393.3 407.1 421.0 434.9 448.8 462.7 476.6 490.5 504.4 518.3
0.5 352.3 365.2 378.1 391.0 403.9 416.8 429.7 442.5 455.5 468.3 481.2
1.0 325.2 337.1 349.0 360.9 372.8 384.7 396.6 408.5 420.4 432.3 444.2
1.5 298.1 309.0 319.9 330.8 341.7 352.6 363.6 374.5 385.4 396.3 407.2
2.0 271.0 280.9 290.8 300.7 310.7 320.6 330.5 340.4 350.3 360.3 370.2
2.5 243.9 252.8 261.7 270.7 279.6 288.5 297.5 306.4 315.3 324.2 333.2
3.0 216.8 224.7 232.7 240.6 248.5 256.5 264.4 272.3 280.3 288.2 296.1
3.5 189.7 196.6 203.6 210.5 217.5 224.4 231.4 238.3 245.2 252.2 259.1
4.0 162.6 168.5 174.5 180.4 186.4 192.3 198.3 204.3 210.2 216.2 222.1
4.5 135.5 140.5 145.4 150.4 155.3 160.3 165.3 170.2 175.2 180.1 185.1
5.0 108.4 112.4 116.3 120.3 124.3 128.2 132.2 136.2 140.1 144.1 148.1
5.5 81.3 84.3 87.2 90.2 93.2 96.2 99.2 102.1 105.1 108.1 111.1
6.0 + mV 54.2 56.2 58.2 60.1 62.1 64.1 66.1 68.1 70.1 72.1 74.0
6.5 ⇑ 27.1 28.1 29.1 30.1 31.1 32.1 33.1 34.0 35.0 36.0 37.0
7.0 ╟ 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
7.5 ⇓ 27.1 28.1 29.1 31.1 31.1 32.1 33.1 34.0 35.0 36.0 37.0
8.0 - mV 54.2 56.2 58.2 60.1 62.1 64.1 66.1 68.1 70.1 72.1 74.0
8.5 81.3 84.3 87.2 90.2 93.2 96.2 99.2 102.1 105.1 108.1 111.1
9.0 108.4 112.4 116.3 120.3 124.3 128.2 132.2 136.2 140.1 144.1 148.1
9.5 135.5 140.5 145.4 150.4 155.3 160.3 165.3 170.2 175.2 180.1 185.1
10.0 162.6 168.5 174.5 180.4 186.4 192.3 198.3 204.3 210.2 216.2 222.1
10.5 189.7 196.6 203.6 210.5 217.5 224.4 231.4 238.3 245.2 252.2 259.1
11.0 216.8 224.7 232.7 240.6 248.5 256.5 264.4 272.3 280.3 288.2 296.1
11.5 243.9 252.8 261.7 270.7 279.6 288.5 297.5 306.4 315.3 324.2 333.2
12.0 271.0 280.8 290.8 300.7 310.7 320.6 330.5 340.4 250.3 360.3 370.2
12.5 298.1 309.0 319.9 330.8 341.7 352.6 363.6 374.5 385.4 393.3 407.2
13.0 325.2 337.1 349.0 360.9 372.8 384.7 396.6 408.5 420.4 432.3 444.2
13.5 352.3 365.2 378.1 391.0 403.9 416.8 429.7 442.5 455.4 468.3 481.2
14.0 379.4 393.3 407.1 421.0 434.9 448.8 462.7 276.6 490.5 504.4 518.2

| July 30, 2020 |
Process Temperature Compensation
5
6
7
8
9
10
11
12
13
14
15
5 6 7 8 9 10 11 12 13 14
PH AT PROCESS
TEMP.
PH AT REFERENCE TEMPERATURE
pH as a Function of Temperature
10°C
25°C
40°C
80°C
pH 11 at 25°C
becomes 9.8 pH at 80°C

| July 30, 2020 |
Typical pH Electrode Problems
34
 Poisoning of Internal Element
 Rapid Depletion of Electrolyte
 Plugging of the Junction
 Ground Loop Effects
MEASURE
(GLASS) Electrodes
 Coating of the pH Membrane
 Slow Response (High Impedance)
 Abrasion and/or Breakage
 Temperature Shock
REFERENCE
Electrode

| July 30, 2020 |
35
pH glass- What does that sensor look like when it is new?
H+
H+
H+
H+
H+
H+
H+
H+
 pH glass is “porous”
 Special recipe  defines “hole size”
 pH glass only selective for H+
pH glass
H+
H+

| July 30, 2020 |
36
pH glass- What Happens to the glass with age/usage?
 The glass layer get thinner
 Not equal over the whole glass
 Gives less response to pH changes
 Thinner glass faster  not in this case
pH glass

| July 30, 2020 |
So I am stuck with pH…..
What can I do to make it more
manageable?

| July 30, 2020 |
Solution Options
 Unfortunately in pH measurements one size fits
all usually doesn’t work very well.
 Completing an Application Data Sheet helps to
ensure all the process information is known.
 Then we have to ask the other 20 questions to make
sure we understand what you are trying to
accomplish. Some of which could be accuracy, low
or no maintenance, long sensor life, retractable or
fixed entry, sensor or housing materials, ……
38

| July 30, 2020 |
Solution Options - continued
39
pH18 Differential pH sensor is a 316SS
shaft coated with H+ and Na+ sensitive
enamel allowing for pH measurements.
There is no electrolyte to be depleted or
replaced and no reference junctions to be
clogged.
We measure the voltage difference
between the two glass electrodes to
calculate the pH of the solution.
The enamel prevents coating issues in
Head Box applications and the strength of
the SS shaft makes the sensor ideal in
stock applications.

| July 30, 2020 |
Sensor Selection – Differential pH Electrodes
40
Poisoning: No Ag/AgCl element to poison
Coating/Plugging: No junction to coat or plug
Electrolyte Depletion: No electrolyte to be depleted
TRADE OFFS
NOT a true pH measurement
Affected by Cation Changes in the process
Reduced measurement range

| July 30, 2020 |
pH Sensors…. Which is BEST for YOUR installation
41
 Wide-Body selection with
prongs or flat surface option
 Combined 12mm for use in
pneumatic retractables
 Hamilton Polilyte Plus
REMEMBER:
pH measurements one size fits all
usually doesn’t work very well.

| July 30, 2020 |
Retractable Assemblies
 PH87/97/DP
with a Solid State
Reference
42
 PR10 for use with
FU20 style sensors
 Extract retractable for
online automated
cleaning

| July 30, 2020 |
Cleaning, Cleaning, Cleaning
 Clean the electrode before any maintenance or calibrations are
performed.
43
 Alkaline or Scale
 Acidic Coatings
 Oil, Grease, Organics
Cleaning SolutionContaminant
 2, 5 or 10% hydrochloric acid (no
more then 10%)
 Weak caustic (less than 4% NaOH)
 Typically a hot, soapy detergent
(like Dawn) or if coating is difficult
an organic solvent compatible with
sensor materials.

| July 30, 2020 |
Real – Time Sensor Diagnostics
44
Process Guard
Real-time Online
impedance checking to
detect pH glass breakage,
when the sensor is out of
solution or when the
reference junction is
starting to become coated.
Maintenance Manager
Sensor wellness function
shows the condition of the pH
glass and reference electrode,
predicts when the next
calibration is due and when
the sensor should be
replaced. The calibration
logbook stores past and
present calibration values to
help determine the present
condition and the remaining
life of the electrode.

| May 21, 2020 |
45
Conclusion and Wrap-up

| May 21, 2020 |
Yokogawa’s OpreX™ Pulp & Paper Solutions
Field instruments and systems that enable highly precise
measurement, data acquisition, and analysis
46
Transmitters
Flow Meters
Liquid
Analyzers
Controllers
Recorders
Gas
Analyzers

| June 18, 2020 |
Fully Stocked | Fully Staffed | Fully Safe
Yokogawa factories and warehouses are ready to ship!
Need it now?
Call us at (800) 888-6400
 Actively Shipping with
Standard 10 day Lead Times
 Get 2 day shipping with North
America Quick Ship Program
 Transmitters
 Flow Meters
 Gas Analyzers
 Liquid Analyzers
 Data Acquisition Recorders
 Controllers
 Most process instruments are
assembled in the United
States.

| June 18, 2020 |
Future Webinar Topics
48
LIVE WEBINAR
Pulp Mill Applications
That Keep You Up at Night
Part 2: The Clean Up
NOVEMBER 5th 2020 – 11AM EST

| July 30, 2020 |
49
Q&A
Select and send all questions to “Panelist” now so that
we can address these
Questions
If you have any questions for this Webinar topic, please
send them to webinars@us.yokogawa.com

| July 30, 2020 |
The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank You For Your Attendance
50

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