Brief Review and Mathematical Modelling of Air Cushioned Pressurized Paper Machine Headbox

  • Authors

    • Parvesh Saini
    • Rajesh Kumar
    2018-06-25
    https://doi.org/10.14419/ijet.v7i3.4.16748
  • Paper machine, Headbox, Pressure/Stock Level, Headbox Consistency, Mathematical Modeling.

  • Today, the requirement of high grade papers is increasing day by day. To cater the need of high quality papers, new high-speed paper machines are being developed constantly. The whole economy of a pulp and paper industry depends on the quality of paper produced, quality of paper depends on the efficient operation of the major part of paper industry – paper machine. Paper machine is the heart of paper industry and has many subsystems. One of the important subsystem of paper machine is Headbox.   To have the desired quality papers, efficient working of headbox is highly required. To have desired operation from headbox, its precise control is necessary. The precise modelling of headbox, leads to design of efficient controllers for its proper control to get the desired response. This paper presents the mathematical modelling of headbox along with a brief review of various research performed on headbox.

     

     

  • References

    1. [1] M.B. Kothari, “Effect of Headbox Operational Variables on Paper Formulation,†Research Centre, West Coast Paper Mills Ltd., Dandeli, Mysore State IPPTA J., Vol. 10, No. 1, pp. 42, 1973.

      [2] Torsten Cegrell, Torbjörn Hedqvist, “Successful adaptive control of paper machines,†Automatica, Vol. 11, No. (1), pp. 53-59, 1975.

      [3] A.K. Sinha, D.A. Rutherford, “Computer-aided controller design for paper Machine,†PROC. IEE, Vol. 123, No. (10), pp. 1021-1025, 1976.

      [4] S. K. Sud, K. K. Biswas and A. K. Sinha, "Stochastic state-variable model for a paper-machine headbox," Proceedings of the Institution of Electrical Engineers, Vol. 124, No. (12), pp. 1249-1254, 1977.

      [5] B. Lebeau, R. Arrese, S. Bauduin, R. Grobet, C. Foulard, “Non-Interacting Multivariable Paper Machine Headbox Control: Some Comparisons with Classical Loops,†IFAC Proceedings Volumes, Vol. 13, No. (4), pp. 227-238, 1980.

      [6] F.M. D’Hulster, R.M. De Keyser, A.R. Van Cauwenberghe, “Application of Several Parameter-Adaptive Controllers to a Paper Machine Headbox,†IFAC Proceedings Volumes, Vol. 13, No. (4), pp. 251-259, 1980.

      [7] F.M. D'Hulster, R.M.C. De Keyser, A.R. Van Cauwenberghe, “Simulations of adaptive controllers for a paper machine headbox,†Automatica, Vol. 19, No. (4), pp. 407-414, 1983.

      [8] Kikiewich Z., and Panday, R.S.D., “Theory and design of paper machine,†vol.-I, Tara book agency Varanasi, 1983.

      [9] R. F. Sikora, W. L. Bialkowski, J. F. MacGregor and P. A. Taylor, "A Self-Tuning Strategy for Moisture Control in Papermaking," American Control Conference, San Diego, CA, USA, pp. 54-61, 1984.

      [10] Qijun Xia, Ming Rao, “Fault-tolerant control of paper machine headboxes,†Journal of Process Control, Vol. 2, No. (4), pp. 171-178, 1992.

      [11] Ying Y., Rao M. and Sun Y., “Bilinear control strategy for paper-making process,†Chemical Engineering Communications, vol. 111, No. (1), pp. 13–28, 1992.

      [12] Q. Xia, M. Rao, X. Shen, Y. Ying and J. Zurcher, "Systematic modeling and decoupling control of a pressurized headbox," Canadian Conference on Electrical and Computer Engineering, Vancouver, BC, vol. 2, pp. 962-965, 1993.

      [13] X. G. Wang, G. A. Dumont and M. S. Davies, "Estimation in paper machine control," IEEE Control Systems, vol. 13, No. (4), pp. 34-43, 1993.

      [14] Daniel L. Laughlin, M. Morari, Richard D. Braatz, "Robust performance of cross-directional basis-weight control in paper machines," Journal Automatica (Journal of IFAC), vol. 29, No. (6), pp. 1395 – 1410, 1993.

      [15] D. G. Sbarbaro and R. W. Jones, "Multivariable nonlinear control of a paper machine headbox," Proceedings of the Third IEEE Conference on Control Applications, Glasgow, vol. 2, pp. 769-774, 1994.

      [16] M. E. Elkadiri, S. Tarasiewicz, M. Berrada and P. Radziszewski, "Study of a digital controller by its application to a head-box in pulp and paper industry," 20th International Conference on Industrial Electronics, Control and Instrumentation, IECON '94, Bologna, vol. 3, pp. 1907-1913, 1994.

      [17] Ming Rao, Qijun Xia and Yiqun Ying, "Modeling and Advanced Control for Process Industries: Applications to Paper Making Processes," Ed. 1, Springer-Verlag London, 1994.

      [18] Allan Kjaer, Michael Waller, Peter Wellstead, “Headbox modelling for cross-direction basis weight control,†ISA Transactions, vol. 33, No. (3), pp. 245-254, 1994.

      [19] J.F. Whidborne, I. Postlethwaite, D.-W. Gu, “Robust control of a paper machine,†Control Engineering Practice, vol. 3, No. (10), pp. 1475-1478, 1995.

      [20] Makkonen, R. Rantanen, A. Kaukovirta, H. Koivisto, J. Lieslehto, T. Jussila, H.N. Koivo, T. Huhtelin, “Three control schemes for paper machine MD-control,†Control Engineering Practice, vol. 3, No. (10), pp. 1471-1474, 1995.

      [21] S. R. Duncan, "The design of robust cross-directional control systems for paper making," Proceedings of the 1995 American Control Conference, Seattle, WA, vol. 3, pp. 1800-1805, 1995.

      [22] Nissinen, H.N. Koivo, T. Huhtelin, “Multivariable PI Control of Industrial Paper Machine Headboxes,†IFAC Proceedings Volumes, vol. 29, No. (1), pp. 6686-6691, 1996.

      [23] M. Berrada, S. Tarasiewicz, M. E. Elkadiri and P. H. Radziszewski, "A state model for the drying paper in the paper product industry," in IEEE Transactions on Industrial Electronics, vol. 44, No. (4), pp. 579-586, 1997.

      [24] M. E. Elkadiri and M. Berrada, "The wet-end in pulp and paper industry: controllers and simulation results," Pulp and Paper Industry Technical Conference, 1997., Annual, Cincinnati, OH, USA, pp. 97-100, 1997.

      [25] K. Ezra Kwok, Michael Chong Ping, U. James Zurcher, P. Li, “Headbox Control using Model-Based Augmented PID Algorithm,†IFAC Proceedings Volumes, vol. 30, No. (9), pp. 419-424, 1997.

      [26] J. Bergstrom and G. Dumont, "An object-oriented framework for developing dynamic models of a paper machine," Dynamic Modeling Control Applications for Industry Workshop, IEEE Industry Applications, Vancouver, BC, pp. 63-69, 1998.

      [27] G.E. Stewart, D.M. Gorinevsky, G.A. Dumont, "Robust GMV cross directional control of paper machines," Proceedings of the American Control Conference (USA), pp. 3002 – 3007, 1998.

      [28] M. Zhang, D.M. Gorinevsky, and G.A. Dumont, "Tuning Feedback Controller of Paper Machine for Optimal Process Disturbance Rejection," Control Systems, Porvoo, Finland, 1998.

      [29] Gang Pan, Ping Li, Boliang Bao, Ezra K. Kwok, “A High-Performance Control System for Pressurized Headbox of Paper Machines,†IFAC Proceedings Volumes, vol. 31, No. (25), pp. 101-105, 1998.

      [30] J. J. Feeley, L. L. Edwards and R. W. Smith, "Optimal digital control of a laboratory-scale paper machine headbox," in IEEE Transactions on Education, vol. 42, No. (4), pp. 337-343, 1999.

      [31] J. Paattilammi and P. M. Makila, "Fragility and robustness: a case study on paper machine headbox control," in IEEE Control Systems, vol. 20, No. (1), pp. 13-22, 2000.

      [32] Jari P. H¨amalainen and Pasi Tarvainen, "Numerical Control of Paper Machine Headboxes," European Congress on Computational Methods in Applied Sciences and Engineering (ECCOMAS 2000), Barcelona, pp. 1 – 14, 2000.

      [33] Hämäläinen, J., Mäkinen, R. A. E. and Tarvainen, P., “Optimal design of paper machine headboxes,†International Journal of Numerical Methods in Fluids, vol. 34, pp. 685–700, 2000.

      [34] Paulo Nobile Diniz, Song Won Park, Jocelyn Freitas Bennaton, “An Anti-Windup Decoupling Nonlinear Control for a Paper Machine Headbox,†IFAC Proceedings Volumes, vol. 33, No. (10), pp. 893-898, 2000.

      [35] Dimitry Gorinevsky, Robert Vyse, and Michael Heaven, "Performance Analysis of Cross-Direction Process Control Using Multivariable and Spectral Models," IEEE Transaction on Control Systems Technology, vol. 8, No. (4), pp. 589-600, 1996.

      [36] Song, Z., Li, P. and Lou, Y., “Cross-directional Estimation and Predictive Control of Paper Machines Using DWT,†Developments in Chemical Engineering and Mineral Processing, vol. 9, pp. 5–13, 2001.

      [37] José Antonio Orccotoma, Jean Paris, Michel Perrier, “Paper machine controllability: effect of disturbances on basis weight and first-pass retention,†Journal of Process Control, vol. 11, No. (4), pp. 401-408, 2001.

      [38] Yap, E. F., Kwok, K. E. and Dumont, G. A., “Dynamic simulation and control of a paper machine wet end,†Canadian Journal of Chemical Engineering, vol. 79, pp. 296–303, 2001.

      [39] G.E. Stewart, DM Gorinevsky, Guy Albert Dumont, C Gheorghe, “The role of model uncertainty in cross-directional control systems - Robustness must be included in controller design,†Conference Paper in Pulp and Paper Canada -Ontario, 2001.

      [40] R. Whalley, M. Ebrahimi, “Optimum control of a paper making machine headbox,†Applied Mathematical Modelling, vol. 26, No. (6), pp. 665-679, 2002.

      [41] Kokko, T., Lautala, P., Huhtelin, T., "Adaptive Model Predictive Control of Consistency," 15th Triennial World Congress, Barcelona, Spain, 2002.

      [42] G. E. Stewart, D. M. Gorinevsky and G. A. Dumont, "Feedback controller design for a spatially distributed system: the paper machine problem," in IEEE Transactions on Control Systems Technology, vol. 11, No. (5), pp. 612-628, 2003.

      [43] Jari Toivanen, Jari P. Hamalainen, Kaisa Miettinen and Pasi Tarvainen, "Designing Paper Machine Headbox Using GA," Materials and Manufacturing Processes, vol. 18, No. (3), pp. 533–541, 2003.

      [44] J.P. Hämäläinen, K. Miettinen, P. Tarvainen, J. Toivanen, "Interactive Solution Approach to a Multiobjective Optimization Problem in a Paper Machine Headbox Design," Journal of Optimization Theory and Applications, vol. 116, No. (2), pp. 265–281, 2003.

      [45] Wang, Mengxiao, Sun, Yu & Tang, Wei., “Measurement and Control System and Engineering for the Pulp and Papermaking process,†Chemical Industry Press, Beijing, 2003.

      [46] A.F Gilbert, A Yousef, K Natarajan, S Deighton, “Tuning of PI controllers with one-way decoupling in 2×2 MIMO systems based on finite frequency response data,†Journal of Process Control, vol. 13, No. (6), pp. 553-567, 2003.

      [47] Junqiang Fan, "Model Predictive Control for Multiple Cross-Directional Processes: Analysis, Tuning, and Implementation," Ph. D thesis, department of electrical and computer engineering, the university of British Columbia, 2003.

      [48] Yeong-Koo Yeo, Sung Chul, YiJae Yong Ryu Hong Kang, "Modeling and Simulation of Wet-end White Water System in the Paper Mill," Korean Journal of Chemical Engineering, vol. 21, No. (2), pp. 358–364, 2004.

      [49] Shen, Guojiang, Hu, Dan & Sun, Youxian, “Modeling and Control of Basis Weight and Moisture in Papermaking Process Using Artificial Neural Networks,†Transactions of China Pulp and Paper, vol. 19, No. (1). pp. 151-156, 2004.

      [50] Tang, Wei, Wang, Mengxiao & Li, Minghui., “The Summarize about the Control of Headbox of Paper Machine,†Journal of Shaanxi University of Science and Technology (Natural Science Edition), vol. 23, No. (6). pp. 129-134, 2005.

      [51] E. Pajula, R. Ritala, “Measurement uncertainty in integrated control and process design—A case study,†Chemical Engineering and Processing: Process Intensification, vol. 45, No. (4), pp. 312-322, 2006.

      [52] Tang, Wei, Wang, Mengxiao, Li, Minghui & Xue, Huijian., “The Advanced Control Strategies and Decoupling Algorithms of Headbox,†Transactions of China Pulp and Paper, vol. 21, No. (1), pp. 107-114, 2006.

      [53] Ola Slätteke, "Modeling and Control of the Paper Machine Drying Section," Ph. D thesis, Department of Automatic Control, Lund University, Lund, Sweden, 2006.

      [54] Li, Minghui & Li, Yan., “Decoupling and Time-delay Control Strategy of Basis Weight and Moisture Content Measurement in Papermaking,†Transactions of China Pulp and Paper, vol. 22, No. (4), pp. 107-114, 2007.

      [55] Jack Tippett, "Consistency Control: Systematic and Scientific Design leads to Many Different Strategies," Emerson Process Management, 2007.

      [56] Zhongjun Xiao, "Study on the NN Decoupling Control System of Air-cushioned Headbox," Computer and Information Science, vol. 2, No. (3), pp. 87 – 93, 2009.

      [57] Foulger. Marc F, “Dilution control technology for new or existing headboxes,†GL & V USA Inc. 16731 County Route 155 Watertown, NY 13601 USA IPPTA J., vol. 21, No. (1), pp. 81, 2009.

      [58] Kumar Rajesh, A. K. Ray, "Artificial Neural Network Modeling and Control of Retention Process in The Wet End," International Journal of Information Technology and Knowledge Management, vol. 2, No. (2), pp. 259-264, 2010.

      [59] Yan Zhao and Qingyu Dai, "Design of adaptive fuzzy controller in air-cushioned headbox," 2nd International Asia Conference on Informatics in Control, Automation and Robotics (CAR), Wuhan, pp. 9-12, 2010.

      [60] Pradeep Kumar Juneja, A. K. Ray & R. Mitra, “Various Controller Design and Tuning Methods for a First Order Plus Dead Time Process," International Journal of Computer Science & Communication, vol. 1, No. (2), pp. 161-165, 2010.

      [61] Zhongjun Xiao, "Application of neural network decoupler in air-cushioned headbox control system," Chinese Control and Decision Conference, Xuzhou, pp. 2738-2742, 2010.

      [62] Pradeep Kumar Juneja, A.K. Ray & R. Mitra, "Model Predictive Control of Important Parameters in a Paper Machine Headbox", INDIAN CHEMICAL ENGINEER, vol. 53, No. (3), pp. 170-181, 2011.

      [63] Keliang Zhou, Pengzhen Chen, "Neural PID decoupling control of air cushion headbox based on genetic algorithms," 2nd International Conference on Artificial Intelligence, Management Science and Electronic Commerce (AIMSEC), pp. 4099 – 4102, 2011.

      [64] Juneja Pradeep Kumar, Ray A.K., Mitra R., "Advanced Prediction Based Control Strategy Application on A paper machine Headbox," IPPTA J., vol. 23, No. (2), pp. 149 – 153, 2011.

      [65] Juneja Pradeep Kumar, Ray A.K., Mitra R., “Various PID Controller Algorithms for Closed Loop Performance Of Consistency Parameter Of paper Machine Headbox In A Paper Mill,†IPPTA J., vol. 23, No. (2), pp. 127, 2011.

      [66] Tomi Roinila, Mikko Huovinen, Matti Vilkko, Tomi Helin, “Continuous Monitoring of Industrial Processes through Cross-Correlation Techniques,†IFAC Proceedings Volumes, vol. 44, No. (1), pp. 12171- 12176, 2011.

      [67] Y. J. Meng, B. Zhou, Y. Y. Liu, "The Design of Decoupling Control System for Air-Cushioned Head Box of Paper Machine Based on Siemens S7-PLC300," Advanced Materials Research, Vol. 457-458, pp. 1105-1110. Doi: 10.4028/www.scientific.net/AMR.457-458.1105, 2012.

      [68] M. Hamdy, I. Hamdan and M. Ibrahim, "Non-fragile bilinear state feedback controller for a class of MIMO bilinear systems," 8th International Conference on Computer Engineering & Systems (ICCES), Cairo, pp. 146-151, 2013.

      [69] Kumar Rajesh and Mandeep Guleria, "Robust control of Non-Linear Parameters of Paper machine Headbox," International Journal of Application or Innovation in Engineering & Management (IJAIEM), vol. 2, No. (6), pp. 259 – 264, 2013.

      [70] Pradeep Kumar and Juneja, A. K. Ray, “Robustness Analysis of Various Controllers Designed for Consistency of a Headbox,†Journal of Forest Products & Industries, pp. 14-17, 2013.

      [71] Puneet Dhaka, Rajesh Kumar, "Design & Development of Robust Control for Paper Making Headbox System," International Journal of Enhanced Research in Science Technology & Engineering, vol. 3, No. (5), pp. 432-438, 2014.

      [72] Deepak Parashar, Aseem Chandel, Girijapati sharma, Divya Parashar, “Modeling and Control of MIMO Headbox System Using Fuzzy Logic,†International Journal of Engineering Research and Applications, vol. 4, No. (12) (Part 3), pp.118-123, 2014.

      [73] Ogunwusi, A.A. and H.D. Ibrahim, "Advances in Pulp and Paper Technology and the Implication for the Paper Industry in Nigeria," Industrial Engineering Letters, vol. 4, No. (10), pp. 3 – 11, 2014..

      [74] Minisha Moudgil, Rajesh Kumar, "Design of Robust Controller for Multivariable Paper Making Approach Flow System," International Journal of Electrical and Electronics Engineers, IJEEE, vol. 7, No. (1), pp. 78 – 84, 2015.

      [75] D. Sharma, R. Kumar and V. Verma, "Fuzzy tuned proportional integral derivative control of paper machine headbox," 2015 Annual IEEE India Conference (INDICON), New Delhi, pp. 1-4, 2015.

      [76] Rajesh Kumar, Minisha Moudgil, "Multiple-Input Multiple-Output Paper Machine System Control Using Fuzzy-PID Tuned Controller," Proceedings of Fifth International Conference on Soft Computing for Problem Solving Volume 437 of the series Advances in Intelligent Systems and Computing, pp. 145-155, 2016.

      [77] M. Hamdy and I. Hamdan, "Non-fragile controller design for a class of multivariable bilinear systems," IMA Journal of Mathematical Control and Information, vol. 33, no. 2, pp. 441-455, June 2016..

      [78] Y. Cao, P. Yan, S. Lin, Z. Zhou and W. Zhang, "KF-based MPC For the cascaded headbox system in papermaking process," 36th Chinese Control Conference (CCC), Dalian, pp. 4369-4374, 2017 (doi: 10.23919/ChiCC.2017.8028045).

      [79] Z. Zhou, S. Guo, S. Lin and W. Zhang, "Internal model control on hybrid headbox system," 36th Chinese Control Conference (CCC), Dalian, pp. 4397-4401, 2017 (doi: 10.23919/ChiCC.2017.8028050).

      [80] Pradeep K Juneja, Mayank Chaturvedi, Saurav Suman, Kajal Antil, “Modeling of stock consistency in approach flow system of headbox,†3rd IEEE International Conference on Internet of Things: Smart Innovation and Usages, Bhimtal UK (India), 2018.

  • Downloads

  • How to Cite

    Saini, P., & Kumar, R. (2018). Brief Review and Mathematical Modelling of Air Cushioned Pressurized Paper Machine Headbox. International Journal of Engineering & Technology, 7(3.4), 57-65. https://doi.org/10.14419/ijet.v7i3.4.16748