OPTIMIZING PAPER MAKING PROCESS OF A PAPER MACHINE

Abstract

The present disclosure relates to a system and a method for optimizing paper making process of a paper machine. The system described herein comprises a process device configured to receive a process parameters corresponding to characteristics of the material and chemical composition that is used in a paper making process. Further, the process device is configured to determine an optimal concentration level of a plurality of dosing additives based on the received process parameters. Finally, the process device is configured to control concentration level of the plurality of dosing additives for optimizing the paper making process based on the determined optimal concentration level.

Claims

1. A system for optimizing paper making process of a paper machine, the system comprising: a process device configured to: receive a process parameters corresponding to characteristics of the material and chemical composition that is used in a paper making process; determine an optimal concentration level of a plurality of dosing additives based on the received process parameters; and control concentration level of the plurality of dosing additives for optimizing the paper making process based on the determined optimal concentration level.

2. The system of claim 1, wherein, to determine the optimal concentration level, the process device is further configured to: compare the received process parameters with predefined reference values; determine deviations in the received process parameters based on the comparison; calculate an adjustment in the concentration level of the plurality of dosing additives based on the determined deviations; and determine an optimal concentration level of the plurality of dosing additives based on the calculated adjustment in the concentration level.

3. The system of claim 1, wherein the process device is further configured to: generate at least one control signal based on the received process parameters; and transmit the at least one control signal to at least one dosing pump, wherein the at least one control signal is transmitted to control the concentration level of the plurality of dosing additives.

4. The system of claim 1, wherein the process parameters corresponds to at least one of pH value, conductivity value, total suspended solids (TSS) concentration value, charge density value, or turbidity value.

5. The system of claim 3, further comprising: at least one dosing pump configured to determine amount of a plurality of dosing additives based on the at least one control signal received from the process device, and transmit the amount of the plurality of dosing additives in a controlled manner to a mixer.

6. The system of claim 5, further comprising: a mixer comprising: a nozzle mounted, via a tri-clamp arrangement, on a process pipeline, wherein the nozzle assembly includes an inner core for injecting the plurality of dosing additives received from the at least one dosing pump and an outer core for supplying dilution water; and a pressure-controlled booster pump configured to supply dilution water at a pressure higher than an internal pressure of a process fluid received from the process pipeline

7. The system of claim 6, wherein the mixer is configured to: receive the plurality of dosing additives from the inner core of the nozzle assembly and dilution water from the outer core of the nozzle assembly; generate a fine mist at a tip of nozzle assembly by combining the plurality of dosing additives with the dilution water; and perform mixing of the generated fine mist with the process fluid inside the pipeline.

8. The system of claim 1, further comprising: a charge analyzer unit configured to: continuously extract a filtrate from a headbox of the paper machine; measure a charge density value of the filtrate; and provide the measured charge density value as the process parameter to the process device.

9. The system of claim 1, further comprising: a turbidity tester unit that comprises: a filtrate unit configured to separate a filtrate from a pulp received from the paper machine; a vacuum pump coupled to the filtrate unit and configured to enhance the filtration of the filtrate from the pulp; a flow cell configured to receive the filtrate from the filtrate unit; and a turbidity sensor disposed within the flow cell and configured to measure turbidity value of the filtrate, and send the turbidity value to the process device.

10. The system of claim 9, wherein the turbidity tester unit further comprising: a water booster pump configured to supply pressurized cleaning water to the filtrate unit; and a filtrate drain valve configured to control the flow of pressurized cleaning water for flushing the filtrate unit.

11. The system of claim 1, wherein the process device is further configured to: receive at least one of a pH value, a conductivity value, and a total suspended solids (TSS) concentration value from a plurality of sensors, wherein the plurality of sensors is in communication with the paper machine.

12. A method of optimizing paper making process of a paper machine, comprising: receiving a process parameters corresponding to characteristics of the material and chemical composition that is used in a paper making process; determining an optimal concentration level of a plurality of dosing additives based on the received process parameters; and controlling concentration level of the plurality of dosing additives for optimizing the paper making process based on the determined optimal concentration level.

13. The method of claim 12, for determining the optimal concentration level, further comprises: comparing the received process parameters with predefined reference values; determining deviations in the received process parameters based on the comparison; calculating an adjustment in the concentration level of the plurality of dosing additives based on the determined deviations; and determining an optimal concentration level of the plurality of dosing additives based on the calculated adjustment in the concentration level.

14. The method of claim 12, further comprising: generating at least one control signal based on the received process parameters; and transmitting the at least one control signal to at least one dosing pump, wherein the at least one control signal is transmitted to control the concentration level of the plurality of dosing additives.

15. The method of claim 12, wherein the process parameters corresponds to at least one of pH value, conductivity value, total suspended solids (TSS) concentration value, charge density value, or turbidity value.

16. The method of claim 14, further comprising: determine, by at least one dosing pump, amount of a plurality of dosing additives based on the at least one control signal received from the process device, and transmit, by the at least one dosing pump, the amount of the plurality of dosing additives in a controlled manner to a mixer.

17. The method of claim 16, further comprising: receiving, by a mixer of the paper machine, the plurality of dosing additives from an inner core of a nozzle assembly of the mixer and dilution water from the outer core of the nozzle assembly; generating, by the mixer, a fine mist at a tip of the nozzle assembly by combining the plurality of dosing additives with the dilution water; and performing mixing of the generated fine mist with process fluid.

18. The method of claim 12, further comprising: continuously extracting, by a charge analyzer unit of the paper machine, filtrate from a headbox of the paper machine; and measuring a charge density value of the filtrate.

19. The method of claim 14, further comprising: separating, by a turbidity tester unit, a filtrate from the pulp received from the paper machine; and measuring, by the turbidity tester unit, turbidity value of the filtrate.

20. The method of claim 12, further comprising: receiving at least one of pH values, a conductivity value, and a total suspended solids (TSS) concentration value from a plurality of sensors, and wherein the plurality of sensors is in communication with the paper machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 illustrates an environment architecture 100 for implementing a system that optimizes paper machine process of a paper machine, in accordance with some embodiments of the present disclosure;

[0010] FIGS. 2a and 2b illustrate a turbidity tester unit, in accordance with some embodiments of the present disclosure;

[0011] FIGS. 3a-1 and 3a-2 illustrate a mixer, in accordance with some embodiments of the present disclosure;

[0012] FIG. 3b illustrates functionality of the mixer, in accordance with some embodiments of the present disclosure;

[0013] FIG. 3c illustrates an example of a mixer mounted on a process pipe, in accordance with some embodiments of the present disclosure;

[0014] FIG. 4 illustrates a flow diagram showing a method for optimizing paper making process of a paper machine, in accordance with some embodiments of the present disclosure; and

[0015] FIG. 5 illustrates a block diagram of an exemplary computer system, for executing embodiments consistent with the present disclosure, in accordance with some embodiments of the present disclosure

DETAILED DESCRIPTION

[0016] The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure.

[0017] Various embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The term or is used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms illustrative, example, and exemplary are used to be examples with no indication of quality level. Like numbers refer to like elements throughout.

[0018] The phrases in an embodiment, in one embodiment, according to one embodiment, and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0019] The word exemplary is used herein to mean serving as an example, instance, or illustration. Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations.

[0020] If the specification states a component or feature can, may, could, should, would, preferably, possibly, typically, optionally, for example, often, or might (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

[0021] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[0022] FIG. 1 illustrates an environment architecture 100 for implementing a system that optimizes paper machine process of a paper machine, in accordance with some embodiments of the present disclosure. The environment architecture 100 may be constituted by a paper machine 102 and a system 104. The environment architecture 100 may be implemented by one or more constituent elements other than the constituent elements illustrated in FIG. 1 and the same are not explained for the sake of brevity.

[0023] In an embodiment, the paper machine 102 may be an industrial equipment designed to convert a mixture containing cellulosic fibers, fillers (such as inorganic powders or granules), additives, and water into continuous reels of paper. The paper machine 102 may be constituted by a headbox, a forming section, a press section, and a drying section (not shown in FIG. 1).

[0024] In an exemplary embodiment, the headbox may a component from which the paper making process is initiated. Initially, a pulp slurry is introduced into the paper machine 102 by using the headbox. The headbox may distribute the pulp slurry evenly onto a moving wire mesh (also, referred as forming fabric).

[0025] In an exemplary embodiment, the forming section may be a section where the pulp slurry from the headbox may be spread across the forming fabric and water may be drained through the forming fabric by gravity and vacuum assistance. This process involved in the forming section may form a continuous wet paper web with the desired fiber orientation and uniformity.

[0026] In an exemplary embodiment, the wet paper web leaving the forming section may contain a significant amount of water. In the press section, the wet paper web may be passed through a series of press rolls that may remove more water by mechanical pressure. The wet paper web may be compressed between the rolls, reducing its moisture content.

[0027] In an exemplary embodiment, the drying section may be a section where partially dewatered paper may be introduced from the press section. The partially dewatered paper may pass over a series of steam-heated cylinders that evaporate the remaining water from the partially dewatered paper, further increasing its dryness. The drying section may consist of several cylinders arranged in groups to provide controlled drying conditions. After the drying section, some additional process may be performed in order to prepare continuous reels of paper.

[0028] In an embodiment, the system 104 may be constituted by a process device 106, a dosing pump 108, a mixer 110, a charge analyzer unit 112, a turbidity tester unit 114, and a server 116. At least one constituted elements of the system 104 may communicate with the paper machine 102.

[0029] In an embodiment, the process device 106 may be constituted by a control unit 118 and input/output (I/O) interface 120. The control unit 118 may comprise, but not limited to, a Programmable Logic Controller (PLC), a Human Machine Interface (HMI), relays, sensors, switches, and/or a communication device.

[0030] The I/O interface 120 may include communication protocols/methods such as, without limitation, audio, analog, digital, monaural, Radio Corporation of America (RCA) connector, stereo, IEEE 1394 high speed serial bus, serial bus, Universal Serial Bus (USB), infrared, Personal System/2 (PS/2) port, Bayonet Neill Concelman (BNC) connector, coaxial, component, composite, Digital Visual Interface (DVI), High Definition Multimedia Interface (HDMI), Radio Frequency (RF) antennas, S Video, Video Graphics Array (VGA), IEEE 802.11b/g/n/x, Bluetooth, cellular e.g., Code Division Multiple Access (CDMA), High Speed Packet Access (HSPA+), Global System for Mobile communications (GSM), Long Term Evolution (LTE), Worldwide interoperability for Microwave access (WiMax), Dedicated Short-Range Communications (DSRC), or the like.

[0031] In an embodiment of the present disclosure, the process device 106 may be in communication with a Distributed Control System (DCS) (not shown in FIG. 1) of the paper machine 102 using a wired or wireless communication protocol and may receive training process parameters for training the process device 106. The training process parameters from the DCS corresponds to parameters that influence the outcomes of retention (from the press section), drainage (from the drying section), and formation (from the forming section). The process device 106 may be equipped with Artificial Intelligence/Machine Learning (AI/ML) based programs that autonomously learn the intricate inter-relationships existing among training process parameters and desired results, specifically focusing on the retention, the drainage, and the formation qualities. Once the process device 106 may be trained, the process device 106 may evaluate the current state of process parameters and the desired retention, drainage, and formation results. Subsequently, the process device 106 adjust and control the dosages of chemicals used in the paper making process.

[0032] In an another embodiment of the present disclosure, the process device 106 may receive the process parameter information for evaluation from a plurality of sensors (not shown in FIG. 1). The plurality of sensors may be in communication with the paper machine 102. The plurality of sensors may comprise, not limited to, a Total Suspension Solid (TSS) sensor, a conductivity sensor, and a pH sensor. In an embodiment, the plurality of sensors may be a part of the process device 106. In an alternative embodiment, the plurality of sensors may be communicably connected with the process device 106.

[0033] The TSS sensor is a device that may be used to measure concentration of suspended solid particles in a backwater of the paper making process. The backwater may refer to water that may be drained or separated from the paper slurry as it undergoes dewatering and drainage in the forming section of the paper machine 102. As water drains through the fabric due to gravity and vacuum assistance, the water is collected and referred to as backwater. The backwater may contain various dissolved and suspended materials, including fibers, fillers, chemicals, and other contaminants. The backwater forms a significant recirculated component of headbox slurry and hence measurement of its TSS is vital significance and a macro-indicator of paper machine forming section's performance. Measurement of filtrate turbidity of headbox stock is a leading indicator of the TSS of backwater.

[0034] The conductivity sensor is a device that may measure concentration of suspended solids and dissolved solids present in backwater. The conductivity sensor may work on a principle that the ability of a solution to conduct electricity is directly related to the presence of ions. These ions originate from dissolved salts, minerals, and other substances present in the water. In the context of backwater analysis, the conductivity sensor may determine the concentration of suspended and dissolved solids, which can indicate the level of contamination, salinity, or overall water quality. The sensor typically consists of electrodes that come into contact with the water and measure the ease with which an electric current passes through it. The higher the conductivity, the greater the amount of dissolved ions.

[0035] The pH sensor is a device that may measure the acidity or alkalinity of the backwater at any given point in the paper making process. In particular, the pH sensor may consist of an electrode system, including a glass electrode sensitive to hydrogen ions and a reference electrode that provides a stable comparison voltage. When immersed in backwater, the Ph sensor may generate an electrical signal proportional to the hydrogen ion activity, which is then converted into a pH value.

[0036] In an embodiment of the present disclosure, the process device 106 may further receive information related to a charge density or zeta potential of suspended particles present in a filtrate at a time of paper making from the charger analyzer unit 112.

[0037] The filtrate may refer to liquid that is extracted from headbox water in the paper making process. The filtrate is the liquid portion that drains or is separated from the pulp slurry during the forming section of the paper machine 102, specifically, as the pulp slurry is spread over the forming fabric and the initial dewatering takes place. It is the water that is separated from the pulp slurry as it undergoes mechanical pressing and gravity-driven drainage on the paper machine 102.

[0038] In an embodiment, the charge analyzer unit 112 may be a device or an instrument to assess charge density and electrostatic interactions among suspended particles present in the filtrate extracted from the headbox water. The charge analyzer unit 112 may work on the principal of electrochemistry, utilizing electrodes and sensors to measure the electrical properties of the filtrate. By subjecting the filtrate to an electric field, the charge analyzer unit 112 may determine the overall charge on the suspended particles, indicating whether the charge may be predominantly cationic or anionic. In an embodiment, the charge analyzer unit 112 may measure zeta potential, providing data on the potential difference between the liquid medium and the particles surface layer.

[0039] In an embodiment, the charge analyzer unit 112 may be configured to continuously extract a filtrate from the headbox of a paper machine, analyze the electrical properties of the filtrate, and provide a measured charge density value as a process parameter to the process device 106. The charge analyzer unit 112 may be implemented as a device or an instrument designed to assess charge density and electrostatic interactions among suspended particles present in the filtrate extracted from the headbox water.

[0040] In an embodiment, the charge analyzer unit 112 may operate based on the principles of electrochemistry, utilizing electrodes and sensors to measure the electrical characteristics of the filtrate. In an implementation, the charge analyzer unit 112 may subject the filtrate to an electric field and determine the overall charge on the suspended particles. Based on the measurement, the charge analyzer unit 112 may identify whether the charge is predominantly cationic or anionic.

[0041] In an embodiment, the charge analyzer unit 112 may be configured to measure zeta potential, which represents the potential difference between the liquid medium and the surface layer of the suspended particles. The measured charge density value obtained from the charge analyzer unit 112 may be transmitted to the process device 106, where it may be utilized as a key process parameter.

[0042] In an embodiment of the present disclosure, the process device 106 may further receive the turbidity value of the headbox water from the turbidity tester unit 114. The detailed functioning of the turbidity tester unit 114 may be further explained with reference to FIGS. 2a and 2b in forthcoming paragraphs of the present disclosure.

[0043] In an embodiment, after receiving process parameters such as pH value, conductivity value, total suspended solids (TSS) concentration value, charge density value, and turbidity value, the process device 106 may be configured to compare the received process parameters with predefined reference values. In an embodiment, the predefined reference values may be stored in at least one database or memory of the process device 106. The predefined reference values correspond to optimal operating conditions determined based on at least one of prior experimentation, industry standards, or machine learning models trained on historical process data.

[0044] The process device 106, based on the comparison, may be configured to identify deviations in the received process parameters from the predefined reference values. In response to identifying such deviations, the process device 106 may be configured to determine corrective measures for adjusting the concentration levels of a plurality of dosing additives.

[0045] In particular, subsequent to identifying the deviations, the process device 106 may be further configured to analyze at least one of the magnitude of the identified deviations and determine corrective measures based on the analysis. The corrective measures may be determined using at least one of control algorithms, predictive models, or rule-based logic configured to compute an optimal quantity of each dosing additive required for correction.

[0046] Upon determining the required adjustments, the process device 106 may be configured to determine an optimal concentration level for each dosing additive based on the calculated adjustments.

[0047] After determining the optimal concentration level, the process device 106 may generate at least one control signal. After generation of the at least one control signal, the process device 106 may transmit the at least one control signal to at least one dosing pump 108. The at least one control signal may be configured to regulate the dosing of the plurality of additives in real-time to achieve the determined optimal concentration levels. The process device 106 may be further configured to continuously monitor the updated process parameters after executing the dosing adjustments and dynamically respond to further deviations, thereby implementing a closed-loop feedback mechanism for real-time process optimization.

[0048] In an embodiment, the at least one dosing pump 108 may be in communication with the process device 106. Based on this communication, the at least one dosing pump 108 may provide accurate and controlled delivery of dosing additive based on the at least one control signal received from the process device 106. In particular, the at least one dosing pump 108 may be configured to determine amount of a plurality of dosing additives based on the at least one control signal received from the process device. After determining the amount of the plurality of dosing additive, the at the least one dosing pump 108 may be configured to transmit the amount of the plurality of dosing additives in a controlled manner to the mixer 110. In an embodiment, the communication ability of the at least one dosing pump 108 may facilitate controlled delivery of the dosing additive for the paper making process based on real-time process conditions and requirements.

[0049] In an embodiment, the dosing additives may be, not limited to, one or more coagulants, one or more flocculants, and formation aid chemicals. Each dosing additive may be associated with different dosing pump 108.

[0050] In an embodiment of the present disclosure, the dosing additives may be injected into the mixer 110. The mixer 110 may be placed before the headbox of the paper machine 102. The mixer 110 may perform efficient mixing of the dosing additive in order to provide efficient paper making process. The detailed functioning of the mixer 110 may be further explained with reference to FIG. 3 in forthcoming paragraphs of the present disclosure.

[0051] In an embodiment, the process device 106 may be in communication with the server 116. The process device 106 may utilize functionality of server 116 such as scalability, flexibility, and centralized data storage and may enable a seamless aggregation of data from multiple devices outside the environment architecture 100, even when located in diverse geographical locations. This unified approach empowers comprehensive analysis of trends and Key Performance Indicators (KPIs), thereby empowering the process device 106 to make more informed and strategic decisions for end users. Further, with the adoption of functionality of the server 116, the process device 106 may ensure minimal to zero data redundancy, high accessibility, and real-time insights, accessible from virtually anywhere with an internet connection. The integration of the process device 106 and the server 116 may create a harmonious synergy between edge computing real-time processing and cloud data analysis.

[0052] Moving to FIGS. 2a and 2b, which illustrate a turbidity tester unit 200 (same as the turbidity tester unit 114 of FIG. 1), in accordance with some embodiments of the present disclosure. The FIG. 2a illustrates a first view of the turbidity tester unit 200 and the FIG. 2b illustrates a second view (opposite to the first view) of the turbidity tester unit 200. The turbidity tester unit 200 may perform operation of measurement of the filtrate turbidity of the headbox water and communicate the measured filtrate turbidity to the process device 106.

[0053] In an embodiment, a representation of the components of the turbidity tester unit 200 along with their abbreviations may be shown below in Table 1.

TABLE-US-00001 TAG ITEM SM1 Pulp Inlet Valve SM2 Pulp Feed Valve SM3 Pulp Flushing Valve SV1 Filtrate Valve SV2 Filtrate Drain Valve SV3 Fresh Water Inlet BP Water Booster Pump VP Vacuum Pump TM Turbidity Meter L3 Drainage Jar Top Level L2 Drainage Jar Ground L1 Drainage Jar Low Level L4 Flow Cell Full Level

[0054] In an embodiment, the turbidity tester unit 200 may perform an operation in order to provide indications for advance prediction of the trend of falling or raising retention values and provides early opportunity to correct the dosages pro-actively without actually waiting for the consistency results of the headbox and backwater. The operation of the turbidity tester unit 200 may be as described below:

[0055] In an embodiment, prior to initiating an operation on a filtrate unit 202, a hose pipe connection may be established from flow pipe to the filtrate unit 202 and from the filtrate unit 202 to a drain 204.

[0056] Upon initiating the operation, a first operation may be performed. In the first operation, a pulp inlet valve and a pulp flushing valve may be opened. The opening of these valves may allow the introduction of a flushing fluid to wet the pulp and remove any residual stagnation from a previous test. The flushing process ensures that any leftover pulp or contaminants from a previous cycle may be expelled.

[0057] Upon completion of the first operation, a second operation may be performed. In the second operation, the pulp flushing valve may be closed and a pulp feed valve may be opened. The opening of the pulp feed valve may allow the introduction of pulp into the filtrate unit (202). A level control arrangement may be provided to regulate the pulp feed and prevent overfilling. In particular, the level control arrangement may monitor the pulp level within the filtrate unit (202) and automatically cease further feeding upon detection of a predefined pulp level threshold.

[0058] Following the completion of the second operation, a third operation may be performed. In the third operation, filtration of the pulp may be initiated. As the third operation may start, the pulp may move towards a conical chamber 206 and start filling the conical chamber 206. The filtration operation may be enhanced by application of negative pressure to the filtrate unit 202. The negative pressure may be created by a vacuum pump.

[0059] Sequentially, the fourth operation may be executed. In the fourth operation, the filtration valve between the conical chamber 206 and a flow cell 208 may be opened. The opening of the filtration valve may allow to fill the flow cell 208 by the filtrate associated with the pulp.

[0060] Following the fourth operation, a fifth operation may be performed to monitor and sense the filling status of the flow cell 208. A turbidity sensor positioned at an upper region of the flow cell 208 may be configured to detect the presence of filtrate. The turbidity sensor may generate a digital signal indicative of the fluid level within the flow cell 208. This sensed data may then be transmitted to the process device 106 for real-time monitoring and control.

[0061] The final operation may be to open a filtrate drain valve and a water booster pump to enhance the pressure of water which flows in a reverse manner to the top of the filtrate unit 202, thereby removing the pulp settled on a mesh. In particular, the fifth operation may be cleaning operation. During a cleaning operation, the filtrate drain valve may be opened, and the water booster pump may be activated to enhance the pressure of the cleaning water. The pressurized water may flow in a reverse direction, entering from the bottom and moving toward the top of the filtrate unit 202. This reverse flow dislodges and removes any pulp or solid particles accumulated on a mesh or filtration surface within the filtrate unit 202. By flushing out the settled pulp, the cleaning process ensures that the filtrate unit 202 remains free from blockages.

[0062] Moving to FIGS. 3a-1 and 3a-2 which illustrate a mixer 300-a (same as the mixer 110 of FIG. 1), in accordance with some embodiments of the present disclosure The FIG. 3a-1 illustrates a first view of the mixer 300-a and the FIG. 3a-2 illustrates a second view (opposite to the first view) of the mixer 300-a. The mixer 300-a may be constituted by a Tri-clamp arrangement 302, a bottom mantle 304 having an outer core, a top mantle 306 having an inner core, an inner core adjusting scale 308, and threaded ports 310.

[0063] In an embodiment, mixer 300-a may be made of corrosion proof Stainless Steel. The tri-clamp arrangement 302 may be configured for fixing on a process pipeline. The bottom mantle 304 having an outer core may be arranged on the tri-clamp arrangement 302. The bottom mantle 304 may have threaded ports 310. The threaded ports 310 may be configured for insertion of water and chemical into the process pipeline and/or extraction of water and chemical from the process pipeline. The top mantle 306 having the inner core may be arranged on the outer core of the bottom mantle 304. The inner core adjusting scale 308 may allow the top mantle 306 to be adjusted above the bottom mantle 304 along the core.

[0064] Moving to FIG. 3b which illustrates a functionality of the mixer 300-b (same as the mixer 110 of FIG. 1), in accordance with some embodiments of the present disclosure. In the process of the mixer 300-b, the dilution water (indicated by grey arrows in FIG. 3b) may flow around the inner core (associated with the top mantle 306) and may exit at the tip of the inner core as a spray jet outward. As the dilution water flows outward, the mixer 300-b may create a small vacuum enabling the chemical (indicated by black arrows in FIG. 3b) flow through the inner core and both combine at the tip of the nozzle and form a fine mist. This increases the contact area of the chemicals with the process fluid inside the pipeline where chemical needs to be dosed and mixed. Multiple nozzles can be fixed on the pipe for the same application, placed equally spaced along the circumference. The angle of spray jet and multiple jets cover the entire cross-sectional area of the process fluid flowing inside the pipe. This approach achieves more than 90% mixing and reducing the length of straight pipe significantly to achieve proper mixing of chemical with process fluid.

[0065] Moving to FIG. 3c which illustrates an example of the mixer 300-a (same as the mixer 110 of FIG. 1) mounted on a process pipe, in accordance with some embodiments of the present disclosure.

[0066] The nozzle is mounted on the process pipe and tightened through the tri-clamp arrangement 302. A delivery pipeline for dilution water from the water booster pump and chemical lines are connected to the threaded ports 310. The dilution water such as fresh water, clarified water, or any process water having TSS below a certain level), pressurized through the pressure-controlled water booster pump, is fed to the threaded port in the bottom mantle 304. Similarly, the chemicals from the dosing pump 108 is fed to the threaded port in the top mantle 306.

[0067] Moving to FIG. 4, which illustrates a method 400 of optimizing paper making process of a paper machine (such as the paper machine 102 of FIG. 1), in accordance with some embodiments of the present disclosure. The method 400 shown in FIG. 4 may be used in conjunction with any of the computer circuitry, systems, devices, elements, or components disclosed herein, among others. In various embodiments, some of the method elements shown may be performed concurrently, in a different order than shown, or may be omitted. Additional method elements may also be performed as desired.

[0068] The method 400 starts at step 402, at a step 402 the method 400 may include receiving a process parameters corresponding to characteristics of the material and chemical composition that is used in a paper making process. In an exemplary aspect, a system 104 of FIG. 1 may be configured to carry out the process steps disclosed in step 402.

[0069] At a step 404, the method 400 may include determining an optimal concentration level of a plurality of dosing additives based on the received process parameters. To determine the optimal concentration level, the method 400 may include comparing the received process parameters with predefined reference values, determining deviations in the received process parameters based on the comparison, calculating an adjustment in the concentration level of the plurality of dosing additives based on the determined deviations, and determining an optimal concentration level of the plurality of dosing additives based on the calculated adjustment in the concentration level. In an exemplary aspect, the system 104 may be configured to carry out the process steps disclosed in step 404.

[0070] At a step 406, the method 400 may include controlling concentration level of the plurality of dosing additives for optimizing the paper making process based on the determined optimal concentration level. To control concentration level of the plurality of dosing additives, the method 400 may include generating at least one control signal based on the received process parameters and transmitting the at least one control signal to at least one dosing pump, wherein the at least one control signal is transmitted to control the concentration level of the plurality of dosing additives. In an exemplary aspect, the system 104 may be configured to carry out the process steps disclosed in step 406.

[0071] FIG. 5 illustrates a block diagram of an exemplary computer system 500 for implementing system 104 of the present disclosure. The computer system 500 may include a central processing unit (CPU or processor) 501. The processor 501 may include at least one data processor for executing processes. The processor 501 may include specialized processing units such as, integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc.

[0072] The processor 501 may be disposed in communication with one or more input/output (I/O) devices 508 and 509 via I/O interface 507. The I/O interface 507 may employ communication protocols/methods such as, without limitation, audio, analog, digital, monaural, RCA, stereo, IEEE-1394, serial bus, universal serial bus (USB), infrared, PS/2, BNC, coaxial, component, composite, digital visual interface (DVI), high-definition multimedia interface (HDMI), RF antennas, S-Video, VGA, IEEE 802.n/b/g/n/x, Bluetooth, cellular (e.g., code-division multiple access (CDMA), high-speed packet access (HSPA+), global system for mobile communications (GSM), long-term evolution (LTE), WiMax, or the like), etc.

[0073] Using the I/O interface 507, the computer system 500 may communicate with one or more I/O devices 508 and 509. For example, the input devices 508 may be an camera device, antenna, keyboard, mouse, joystick, (infrared) remote control, card reader, fax machine, dongle, biometric reader, microphone, touch screen, touchpad, trackball, stylus, scanner, storage device, transceiver, video device/source, etc. The output devices 509 may be a printer, fax machine, video display (e.g., cathode ray tube (CRT), liquid crystal display (LCD), light-emitting diode (LED), plasma, Plasma display panel (PDP), Organic light-emitting diode display (OLED) or the like), audio speaker, etc.

[0074] In some embodiments, the processor 501 may be disposed in communication with external elements such as external computer systems, servers, network elements. The network interface 510 may employ connection protocols including, without limitation, direct connect, Ethernet (e.g., twisted pair 10/100/1000 Base T), transmission control protocol/internet protocol (TCP/IP), token ring, IEEE 802.11a/b/g/n/x, etc.

[0075] In some embodiments, the processor 501 may be disposed in communication with a memory 503 (e.g., RAM, ROM, etc.) via a storage interface 502. The storage interface 502 may connect to memory 503 including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as, serial advanced technology attachment (SATA), Integrated Drive Electronics (IDE), IEEE-1394, Universal Serial Bus (USB), fibre channel, Small Computer Systems Interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, Redundant Array of Independent Discs (RAID), solid-state memory devices, solid-state drives, etc.

[0076] The memory 503 may store a collection of program or database components, including, without limitation, user interface 504, an operating system 505, a web browser 506 etc. In some embodiments, the computer system 500 may store user/application data, such as, the data, variables, records, etc., as described in this disclosure. Such databases may be implemented as fault-tolerant, relational, scalable, secure databases such as Oracle or Sybase.

[0077] The operating system 505 may facilitate resource management and operation of the computer system 500. Examples of operating systems include, without limitation, APPLE MACINTOSH OS X, UNIX, UNIX-like system distributions (E.G., BERKELEY SOFTWARE DISTRIBUTION (BSD), FREEBSD, NETBSD, OPENBSD, etc.), LINUX DISTRIBUTIONS (E.G., RED HAT, UBUNTU, KUBUNTU, etc.), IBM OS/2, MICROSOFT WINDOWS (XP, VISTA/7/8, 10 etc.), APPLE IOS, GOOGLE ANDROID, BLACKBERRY OS, or the like.

[0078] In some embodiments, the computer system 500 may implement the web browser 506 stored program components. The web browser 506 may be a hypertext viewing application, such as MICROSOFT INTERNET EXPLORER, GOOGLE CHROME, MOZILLA FIREFOX, APPLE SAFARI, etc. Secure web browsing may be provided using Secure Hypertext Transport Protocol (HTTPS), Secure Sockets Layer (SSL), Transport Layer Security (TLS), etc. Web browsers 506 may utilize facilities such as AJAX, DHTML, ADOBE FLASH, JAVASCRIPT, JAVA, Application Programming Interfaces (APIs), etc. In some embodiments, the computer system 500 may implement a mail server stored program component. The mail server may be an Internet mail server such as Microsoft Exchange, or the like. The mail server may utilize facilities such as Active Server Pages (ASP), ACTIVEX, ANSI C++/C#, MICROSOFT, .NET, CGI SCRIPTS, JAVA, JAVASCRIPT, PERL, PHP, PYTHON, WEBOBJECTS, etc. The mail server may utilize communication protocols such as Internet Message Access Protocol (IMAP), Messaging Application Programming Interface (MAPI), MICROSOFT exchange, Post Office Protocol (POP), Simple Mail Transfer Protocol (SMTP), or the like. In some embodiments, the computer system 500 may implement a mail client stored program component. The mail client may be a mail viewing application, such as APPLE MAIL, MICROSOFT ENTOURAGE, MICROSOFT OUTLOOK, MOZILLA THUNDERBIRD, etc.

[0079] Some of the advantages of the present disclosure are listed below.

[0080] The present disclosure provides real-time optimization of paper making process by performing continuous monitoring and eliminating the limitations of manual testing.

[0081] Using mixing device (i.e., mixer 110) enhances dosing precision, chemical efficiency, and water conservation i.e., saves fresh water consumption, as this approach provides an ability to use process water of low concentration (TSS) instead of fresh water. Additionally, the mixing device minimizes chemical wastage while improving overall paper making process efficiency.

[0082] The present disclosure involves real-time data analysis, predictive modelling, and continual learning which improve efficiency of paper making process and quality of production of paper by the paper making process.

[0083] The foregoing method descriptions and the process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the order of steps in the foregoing embodiments may be performed in any order. Words such as thereafter, then, next, etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Further, any reference to claim elements in the singular, for example, using the articles a, an or the is not to be construed as limiting the element to the singular.

[0084] As used herein, the term unit may be implemented in hardware and/or in software. If the unit is implemented in hardware, the unit may be configured as a device, e.g., as a computer or as a processor or as a part of a system, e.g., a computer system. If the unit is implemented in software, the unit may be configured as a computer program product, as a function, as a routine, or as a program code.

[0085] The hardware used to implement the various illustrative logics, logical blocks, modules, and circuits described in connection with the aspects disclosed herein may include a general purpose processor, a Digital Signal Processor (DSP), a special-purpose processor such as an Application Specific Integrated Circuit (ASIC) or a Field Programmable Gate Array (FPGA), a programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but, in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Alternatively, or additionally, some steps or methods may be performed by circuitry that is specific to a given function.

[0086] In one or more example embodiments, the functions described herein may be implemented by special-purpose hardware or a combination of hardware programmed by firmware or other software. In implementations relying on firmware or other software, the functions may be performed as a result of execution of one or more instructions stored on one or more non-transitory computer-readable media and/or one or more non-transitory processor-readable media. These instructions may be embodied by one or more processor-executable software modules that reside on the one or more non-transitory computer-readable or processor-readable storage media. Non-transitory computer-readable or processor-readable storage media may in this regard comprise any storage media that may be accessed by a computer or a processor. By way of example but not limitation, such non-transitory computer-readable or processor-readable media may include Random Access Memory (RAM), Read-Only Memory (ROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), FLASH memory, disk storage, magnetic storage devices, or the like. Disk storage, as used herein, includes Compact Disc (CD), laser disc, optical disc, Digital Versatile Disc (DVD), floppy disk, and Blu-ray Disc, or other storage devices that store data magnetically or optically with lasers. Combinations of the above types of media are also included within the scope of the terms non-transitory computer-readable and processor-readable media. Additionally, any combination of instructions stored on the one or more non-transitory processor-readable or computer-readable media may be referred to herein as a computer program product.

[0087] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of teachings presented in the foregoing descriptions and the associated drawings. Although the figures only show certain components of the apparatus and systems described herein, it is understood that various other components may be used in conjunction with the supply management system. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, the steps in the method described above may not necessarily occur in the order depicted in the accompanying diagrams, and in some cases one or more of the steps depicted may occur substantially simultaneously, or additional steps may be involved. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0088] The various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.