OPPORTUNITY FOR REAL-TIME OPTIMIZATION IN A NEWSPRINT MILL: A SIMULATION CASE STUDY

Real-time optimization (RTO) is applied for the broke recirculation in the stock approach system of an integrated newsprint mill simulation. New optimal broke ratio profiles are set for the paper machine recipes each time the process is confronted with an important disturbance. The variability in the four paper machine headboxes is minimized while the inventory management is handled. The proposed approach is compared to the actual mill operation, making use of a detailed plant simulation. While maintaining broke tank level within an acceptable range, RTO brings the pulp variability down about an order of magnitude. It is expected that it could significantly reduce the sheet break occurrence in a real plant and therefore enhance its economical efficiency.