Chemometric and signal processing methods for real time monitoring and modeling applications in the pulp and paper industry

Sammanfattning: In the production of paper, the quality of the pulp is an important factor both for the productivity and for the final quality. Reliable real-time measurements of pulp quality are therefore needed. One way is to use acoustic or vibration sensors that give information-rich signals and place the sensors at suitable locations in a pulp production line. However, these sensors are not selective for the pulp properties of interest. Therefore, advanced signal processing and multivariate calibration are essential tools. The current work has been focused on the development of calibration routes for extraction of information from acoustic sensors and on signal processing algorithms for enhancing the information-selectivity for a specific pulp property or class of properties. Multivariate analysis methods like Principal Components Analysis (PCA), Partial Least Squares (PLS) and Orthogonal Signal Correction (OSC) have been used for visualization and calibration. Signal processing methods like Fast Fourier Transform (FFT), Fast Wavelet Transform (FWT) and Continuous Wavelet Transform (CWT) have been used in the development of novel signal processing algorithms for extraction of information from vibrationacoustic sensors.It is shown that use of OSC combined with PLS for prediction of Canadian Standard Freeness (CSF) using FFT-spectra produced from vibration data on a Thermo Mechanical Pulping (TMP) process gives lower prediction errors and a more parsimonious model than PLS alone. The combination of FFT and PLS was also used for monitoring of beating of kraft pulp and for screen monitoring. When using regular FFT-spectra on process acoustic data the obtained information tend to overlap. To circumvent this two new signal processing methods were developed: Wavelet Transform Multi Resolution Spectra (WT-MRS) and Continuous Wavelet Transform Fibre Length Extraction (CWT-FLE). Applying WT-MRS gave PLS-models that were more parsimonious with lower prediction error for CSF than using regular FFT-Spectra. For a Medium Consistency (MC) pulp stream WT-MRS gave predictions errors comparable to the reference methods for CSF and Brightness. The CWT-FLE method was validated against a commercial fibre length analyzer and good agreement was obtained. The CWT-FLE-curves could therefore be used instead of other fibre distribution curves for process control. Further, the CWT-FLE curves were used for PLS modelling of tensile strength and optical parameters with good results.In addition to the mentioned results a comprehensive overview of technologies used with acoustic sensors and related applications has been performed.