In a chemical plant for the production of high-quality paper products, various additives had to be fed into the pulp process with high accuracy. Dosing took place under demanding process conditions and required reliable, reproducible control. The objective was a modular automation solution that can be used both in mobile pilot plants and in stationary plants.
At a glance
- Industry: Chemical industry / process industry
- Application: Dosing of additives in a pulp mill
- Medium / process: Chemical additives, continuous flow process
- Challenge: High dosing accuracy and flexible system configuration
- STASTO solution: Modular automation package with control valves, pneumatic ball valves and safety technology
- Result: Reproducible process control and scalable system architecture
The challenge
In the described chemical plant, various additives are precisely introduced into the pulp flow to ensure consistently high paper quality. Even minor deviations in dosing can affect the product properties and impair downstream process steps.
The system was originally designed as a mobile test rig. Accordingly, all components had to be compact, flexible, and at the same time robust. In addition to precise flow control, safety aspects such as pressure monitoring and protection against fault conditions also had to be taken into account.
Standard solutions proved to be insufficient, as they either did not provide the required control accuracy or could only be adapted to different test setups with considerable effort. Therefore, an integrated, modularly expandable automation concept was required.
The STASTO solution
Together with the plant operator, a STASTO automation package was developed that is specifically tailored to the requirements of the dosing task.
Used were:
- Control valves for precise flow regulation
- Pneumatically actuated ball valves for safe shut-off
- Limit switch boxes for position feedback
- Safety valves and pressure retaining valves
- Flow monitor for process monitoring
The combination of adjustable control valves and robust shut-off valves enabled precise control of the additive supply. Pneumatic actuators were selected to ensure reliable, low-maintenance operation even with frequent switching cycles.
Particular attention was paid to the modular design of the package. The components were integrated in such a way that extensions or modifications are possible at any time. This made it possible to transfer the solution from the mobile test system to stationary, permanently installed systems and adapt it accordingly.
Close coordination with the machine and plant manufacturer ensured that the automation package could be seamlessly integrated into the existing control and process environment.
The result
The automation package used has achieved stable and reproducible dosing of the additives. The precise control contributes significantly to consistent product quality.
The integrated safety and monitoring technology has increased operational safety and reduced the risk of malfunction conditions. The clear structuring of the components facilitates maintenance and servicing.
In addition, the standardized package solution simplifies the procurement and planning of further systems. The modular expandability supports future adaptations to changing process requirements.
Added value for machine builders
- Integrated solution combining control and shut-off technology
- High adaptability to changing process requirements
- Simple integration into existing control systems
- Reduced engineering effort through preconfigured packages
- Scalability from test systems to production systems
This solution is particularly suitable for
- Chemical plants with dosing processes
- Pulp and paper industry
- Pilot and test systems
- Process systems with variable media supply
- Systems with high requirements for control accuracy
Contact
Are you planning a process or dosing application with precise flow control and integrated safety technology?
Talk to our experts – we will be happy to advise you.