Vortrag auf der GreenTech, Amsterdam Apirl 2002

1
Knowledge Based Production and Quality Control
of Biobased Materials

• State of the Art
• Philosophy
• Example Fibreboard
• Example Fibres
• Technology Transfer

2
Quality Definitions

• Fundamental Properties
• Technical Properties
• Functional Properties
• Processing Properties
• Cost/Performance Ratio

3
State of the Art Process Technology
LT Low Tech HT High Tech LA Low
Added Value HA High Added Value
4
Philosophy Product Property Design

• Feed Back Feed Forward
• Product Process Design

100 Quality
5
Smart Processing Who Benefits?

• Costs and Profits are dominated by
  Throughput (Technology) and Added Value
  (Product).
• Mass Commodities Reduction of
  CV(Dinosaurs) Minimization of Ressources Guaran
  teed and Certified Quality
• Niche Markets Multipurpose Processes(SME)
  Property Design Specified Quality

6
Procedure

• Understanding
• Modeling
• Measurement
• Control

7
Example FUNDER Fibreboard Plant
8
Strategy

• Understanding
• Modeling
• Measurement
• Control

9
Understanding and Modeling the Process
FUNDER (Experimental Design)
10
Beech (Electron Micrograph)

• underprocessed optimum processing SFC 2 SFC
  3.5

11
Strategy

• Understanding
• Modeling
• Measurement
• Control

12
Process Modeling (Siemens)Prediction and
Property Design (reverse model)
Process
Chip Yard
Modeling
Data
Control Parameters
Diagnose
adaptive Fuzzy-Model
Soft Sensor
Dewatering
Optimization
Quality
13
Strategy

• Understanding
• Modeling
• Measurement
• Control

14
Optical Spectroscopy All in one Sensor
Fluorescence
UV / Vis - sNIR
NIR / MIR
Raman
l
l
l
Excitation / Absorption
200 - 400 nm (UV)
MIR

2500 - 25000 nm
633 nm
0

l

200 - 600 nm
l
n

l
400 - 700 nm (Vis)
4000 - 400 cm

Û
633 - 813 nm
-1

Fluorescence
l
l
Dn
7
00 - 1100 nm (NIR)
NIR
10
00 - 2500 nm
3500 - 0 cm
-1

l


200 - 900 nm
n
10000 - 4000 cm
-1
Excitation /Emission of Electrons
Excitation of Electrons
Excitation of Vibrations
Excitation of Vibrations,
(UV / Vis) and
Complementary to MIR
Rotations and Overtones
Overtones (NIR)
15
On-Line Control of Wood Chips
Diffuse Reflectance Probe at the Conveyer Belt
Measures and Controls Wood Chips On-Line.
16
In-Line Probe Blow Pipe
17
In-Line Probes
18
Infomation - Selection
Redundant Information
Useful Information

• Mathematical orthogonal (partitioned)
• Target transformation
• Pattern recognition
• Optical Partitioning

Non-Specific Information
No Information
19
Strategy

• Understanding
• Modeling
• Measurement
• Control

20
Measurements and Correlations
21
Predicted Wood Composition During Running
Production
22
On-Line Trials at Iggesund, June 2001

• Comparison of Spectroscopic Results with Digester
  Variables

.
23
On-Line Trials at Iggesund, June 2001

• Comparison of Spectroscopic Results with Digester
  Variables

PC 1 score of wood chip spectra versus PLS
result of 120 digester variables.
24
Man Made Fibres vs. Natural Fibres

• Man Made
• Tailor made design.
• Constant and guaranteed quality supply.
• Quality assessment standardized.
• .....
• etc.

• Natural Fibres
• Seasonal local variations.
• Decisive change during processing.
• No standards.
• .....
• .....
• etc.
• Biodegradation.

25
Example Global Flax all sNIR Spectra
(Happenstance Data)
Central Composite Design
26
Spectral Goniometry
27
Global Standard (IAF / Process Analysis)
E
D2
D1
C
B2
B1
A3
A2
A1
28
Transfer (see whole grain online qualification)
Cooperation with Industry (locally) and Global
Standardisation

• Local targets Define application
• Parameters, Data, Variables Global
  targets Define industrial standards
• Local targets Define application
• Performance(Quality) Global targets Define
  classes

29
Technology Transfer - Who Participates ?

• SME vs. Dinosaurs
• Innovations Know-How Transfer Visions
  Champions Communication
  Organisational Persistence
  Architecture No NIH

30
Marketing and Industrial Integration

• Global Player ?
• SME ?
• Problem Associative Data

31
On-Line Control and Process Modelling

• Integrated approach.
• Increase in productivity.
• Optimization of product yield.
• Maximization of material flow.
• Minimization of energy.
• Predictive maintenance and rapid diagnosis for
  faults.
• Constant and certified quality (100 ) adapted to
  market needs.

• Reduction of safety margins.
• Less complaints.
• Higher operational flexibility.

Guaranteed Quality
Customer Satisfaction
Added Value
ROI ca. 0.1 - 1 year
Produce Quality not only Test Quality !!
32
Thank You
33
Thank You