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Leveraging mill-wide big data sets for process and quality i
Authors: Jianzhong Fu and Peter W. Hart | ABSTRACT: The MWV mill in Covington, VA, USA, experienced a long term trend of increasing episodes of paper indents that resulted in significant quantities of internal rejects and production downtime. When traditional troubleshooting techniques failed to resolve the problem, big data analysis techniques were employed to help deter-mine root causes of this negative and increasingly frequent situation. Nearly 6000 operating variables were selected for a deep dive, multi-year analysis after reviewing mill-wide process logs and 60000+ PI tags (data points) collected from one of the major data historian systems at the MWV Covington mill. Nine billion data points were collected from November 2011 to August 2014. Strategies and methods were developed to format, clean, classify, and sort the various data sets to compensate for process lag time and to align timestamps, as well as to rank potential causes or indicators. GE Intelligent Platforms software was employed to develop decision trees for root cause analysis. Insights and possible correlations that were previously invisible or ignored were obtained across the mill, from pulp-ing, bleaching, and chemical recovery to the papermaking process. Several findings led the mill to revise selected process targets and to reconsider a step change in the drying process. These changes have exhibited significant impacts on the mill’s product quality, cost, and market performance. Mill-wide communications of the identified results helped transform the findings into executable actions. Several projects were initiated.
Journal articles
Magazine articles
Combustion behavior of kraft black liquor droplets from hot
Combustion behavior of kraft black liquor droplets from hot water pretreated hardwood and softwood chips, November 2016 TAPPI JOURNAL
Journal articles
Magazine articles
Novel CaCO3-polymer nanocomposite fillers for the improvemen
Novel CaCO3-polymer nanocomposite fillers for the improvement of bagasse-based papers, November 2016 TAPPI JOURNAL
Journal articles
Magazine articles
Cellulosic ethanol byproducts as a bulking agent, TAPPI JOURNAL January 2017
Cellulosic ethanol byproducts as a bulking agent, TAPPI JOURNAL January 2017
Journal articles
Magazine articles
Removal of silicon from green liquor with low-temperature precausticizing, TAPPI JOURNAL January 2017
Removal of silicon from green liquor with low-temperature precausticizing, TAPPI JOURNAL January 2017
Journal articles
Magazine articles
Editorial: The Laboratory of Soft Materials & Green Chemistr
Editorial: The Laboratory of Soft Materials & Green Chemistry at North Carolina State University, TAPPI JOURNAL July 2017
Journal articles
Magazine articles
Reduction of alkali loss in an ash leaching system, TAPPI J
Reduction of alkali loss in an ash leaching system, TAPPI JOURNAL July 2017
Journal articles
Magazine articles
Evaluation of the particle size of organosolv lignin in the
Evaluation of the particle size of organosolv lignin in the synthesis of resol resins for plywood and their performance on fire spreading, TAPPI JOURNAL July 2017
Journal articles
Magazine articles
Low consistency refining of mechanical pulp — system design
Low consistency refining of mechanical pulp — system design, TAPPI JOURNAL July 2017
Journal articles
Magazine articles
Editorial: Coating & Graphic Arts, Process Control papers ho
Editorial: Coating & Graphic Arts, Process Control papers honored at PaperCon, TAPPI JOURNAL June 2017