Competitive advantages of BTG Rotating Consistency

transmitter type MEK-2300

Ingemar Jansson
BTG Pulp & Paper Sensors
P2007en

BTG 2003

Competitive advantages of BTG Rotating Consistency transmitter type MEK-2300

This paper is based upon BTG Consistency seminar slide presentation available from BTG.
It covers the MEK-2300 Rotating Consistency transmitter section of this presentation.
Consistency transmitter

is then statistically evaluated and finally you obtain a figure

like: "better then +/- 0.005% consistency" for the MEK-2300
rotating transmitter or "+/-0.075%" for the active blade transmitter MBT-2300. Looking on these data you see that there is
no major difference, independent on what transmitter you
study. The data stated in the data sheets are basically fully
sufficient for all applications, for all transmitters!

MEK-2300
Rotating shear force measurement

The question is, how can you trust these data and use them in
a real specific application?
In the specific application/position you probably have a lot of
variations in the pulp suspension. The fiber type, the flow
velocity, the temperature, conductivity, air content, pressure
etc.; all may change from time to time.

Unrivalled transmitter for the most demanding

and difficult applications.
Provides the firm foundation for optimal process control.

Most probably you never have laboratory conditions in this

application and you will see distinct differences between the
different models, comparing them against each other.

Fig 1: MEK-2300 Rotating shear force measurement.

Introduction:
The MEK-2300 Rotating consistency transmitter uses the
shear force principle. It's a complete family with different
variants specified for most applications in the P&P industry.
It can measure between 1-16% consistency.

This paper will discuss these differences, based upon theoretical evaluations and practical experiences. It will show
that MEK-2300 is an
"Unrivalled transmitter for the most demanding and
difficult applications. And why it Provides the firm
foundation for optimal process control."
The paper will also describe why MEK-2300 still provides
the most accurate, safe and reliable consistency measurement on a general basis although new measuring principles
have emerged over the years.

Consistency transmitter
MEK-2300

Rotating shear force consistency measurement provides:

High accuracy
Safe operation
Universal use

Presently still the safest and most accurate

method to measure and control consistency

Consistency transmitter
MEK-2300

Fig 2: Rotating shear force consistency measurement.

Rotating shear force measurement

1-16 % Consistency

Before discussing all competitive advantages and details for

the transmitter it is very important to understand some basic
facts. When studying the data sheets for different kinds of
consistency transmitters, produced by BTG or some other
company, you must understand what a data sheet really says.
All data that are stated here are generally based upon practical and theoretical studies obtained in a laboratory environment. The data are probably fully correct and can be trusted,
but are normally only valid during the specific test conditions. At such a laboratory test you try to keep all variables
as controlled as possible to focus on the specific data you are
looking for. I.e. if you are trying to find the data for "Sensitivity" you use one specific kind of fiber at a specific consistency and freeness level, controlling the temperature and the
flow velocity etc. Then you extract a large number of lab
samples in a very controlled way and evaluate the result in
the lab also using very controlled conditions etc. The result

Background

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Product description
Applications

Fig 3: Background, Product description, Applications.

The Paper:
The paper is divided in
1. Background for the transmitter,
2. A description of it including its competitive advantages
compared to other transmitter types and
3. Applications; some typical applications where it shows
specific advantages over other instruments.

BTG 2003

Lets start with 1. Background for the transmitter:

See fig. 4 Rotating shear force.
BTG is one of the pioneers making consistency transmitters.
The first model was developed in the late 20s by the former
of the original Swedish company AB Klle-Regulatorer;
Dr.Torsten Klle. At that time the transmitter was used
together with the hydraulic controller, also developed by Dr.
Klle, connected to a control valve for the dilution water. A
complete consistency control loop was introduced.
The first model was quite simple and it was a kind of predecessor of the later static blade shear force transmitter.
Already at that time, Dr. Klle understood that you have to
avoid the impact of different flows and he implemented a
pump in the system to create a stable flow. This is the principle still used in the BTG rotating transmitters of today,
although the transmitter is completely different in its design.
Many models have seen the light over the years. In the mid
50s the K22 model came. It opened up the world market to
the company, introducing a simple and reliable way to control consistency. It was used together with the hydraulic controller tied to the dilution valve to form a simple easily
maintained control loop. The K22 model became a large
success and was produced in large numbers for 30 years, a
record hard to beat. By time the mills closed their process,
no open vessels anymore, and a new in-line measuring principle was required.
In the early 60s the K30/K31 model was developed. It was
an in-line transmitter using a rotating sensing element to
achieve high sensitivity and accuracy and a propeller to
avoid the impact of flow changes. Patents were granted.
Thousands of units were sold all over the world. It introduced the company, Eur-Control which was the name then,
to the large American market and became an immediate success there. At that time DeZurik, an American company, was
the dominant player there with their rotating transmitter.

The measuring principle developed for the K30 model is the

one still used for the BTG rotating transmitter, although the
details have been refined by time.
In the mid 70s the MEK and MPK-41 model came. The
measuring principle from K31 was the same but the design of
the transducer for the electrical model was considerably modified to give a more reliable signal. The mechanical design of
the drive part was simplified using a belt driven system
instead of an oil-filled gearbox.
The weight was reduced from 60 to 40 kg and the target was
to make the transmitter less costly to produce, resulting in a
lower sales price.
Many targets with the project were reached, the transmitter
was cheaper and the MEK-41, the electrical model gave a
more accurate measurement. The model however suffered
from maintenance problems mainly relating to the stuffing
box for the rotating shaft. The model was produced between
1974 and 1984 and also here several thousands of transmitters
were sold. A need to increase the reliability of the transmitter
and decrease the maintenance cost at the same time as the
measuring accuracy was maintained, or preferably improved,
was the base of the project to develop an improved model; the
MEK-2000 (electrical output signal) and the MPK-2000
(pneumatic output signal) models including their many variants for specific applications.

Rotating shear force Consistency transmitters. Models over

the years

and
e 20
I n th
30s

he
In t

s
50

In th

s
e 60

K31
K3

The K31 model was economic and easy to find a place for in
the piping system since it could be fitted close to the pump.
It was recognized by its reliability and many units have been
working in the field for 20-30 years. It was originally made
in a version to fit the Klle hydraulic controller but later on
modified to provide 3-15 psi pneumatic output signal and 420 mA electric signal. Pneumatic controllers were very popular at that time so the most common transmitter type was
the pneumatic one.

K22

In the 80s

In the 70s

MEK
- 2000

Fig 4: Rotating shear force Consistency transmitters. Models

over the years.

BTG 2003

P2007en

The pneumatic controllers had become more and more outdated and replaced by electrical controllers or even DCS, so
the MEK-2000 became the most popular model,
These models became a very large success for BTG. They are
known for their very high reliability and good measuring
properties. Close to 10 000 units have been produced between
1984 to 2001. The present model, MEK-2300, is mechanically very similar to the early produced units although numerous modifications have been implemented over the years.
MEK-2000 had an analogue electronics, but to increase the
measuring accuracy a digital electronics can bring considerable advantages. The output signal can be linearized, which
result in an accurate measurement over the entire measuring
span, and not only at the control point. With different measuring ranges you can calibrate the transmitter to read very accurate even if you change fiber grade or type etc. This resulted
in a new model, the "intelligent" MEK-2200. The difference
to the -2000 is a different electronics unit, the control box
mounted on the wall. This model was produced, in parallel to
the MEK-2000 model, from 1992-2002. Several thousand
units have been sold.

Lets now continue with the Product description.

The rotating shear force principle is a unique principle. You
should not equate this method with other shear force measurement principles used; it is very different from the measurement made by blade transmitters or even by other types of
rotating transmitters. They are all inferior in all respects,
which will be proven in this paper.

The product:
The MEK-2300 model is distinguished by
1. High measuring accuracy, i.e. its general design properties
and ability to handle disturbances of the measurement.
2. Safe operation; i.e. why it is able to work well over a very
long time of operation and still keeping its high accuracy. All
limitations are known and you know that you can trust the
measurenent. No worries, you can sleep well at night!
3. Universal use I.e. why you are able to use it almost everywhere in the process with a good result and in what specific
applications it brings an added value.

The need to decrease the sales price and to simplify for the
user resulted in the BTG Smart family where all consistency
transmitters and also other kind of transmitters were coordinated. All transmitters are then fed with 24 VDC from a junction box with a common design to fit all models and using a
handheld terminal for their setting. The user interface is very
similar for all the instruments resulting in an easy training
procedure and great user friendliness.
The MEK-2300 model came in 1995 and in the beginning it
used a simple junction box (type JCT-1000). The Junction
box is mainly a box where the connections for all cables and
handheld terminal are made and also a convenient place to fit
the power supply. In year 2000 this junction box was replaced
with type JCT-1100 where a display and pushbuttons for simple settings was introduced together with a new surface
mounted digital processor card in the transmitter.
Totally from 1984 to 2002 close to 15 000 units in the series
starting with MEK-2000 and ending with MEK-2300 has
been sold. If you include the older rotating types over 30 000
units have been sold over a period of more than 80 years. This
is one of the fundamental reasons what makes BTG the leading consistency company.

Consistency transmitter
MEK-2300

Almost

15 000 units installed MEK-2000 series

Over 25

BTG transmitter MEKMEK-2300

Consistency range: 1-16%

Very high measuring accuracy and

repeatability
Universal transmitter suitable for
most applications
Very high reliability
minimizes need of maintenance

Fig 6: Very high measuring accuracy and repeatability.

High measuring accuracy
Lets discuss the High measuring accuracy properties. Then
you first have to understand how the transmitter operates and
why it's designed the way it is. We will not describe the function of it in this context, it is already described in the data
sheet, in the service manual etc. We will just touch the benefits
of the design.
See fig. 7 Measuring principle

000 units installed all models

Installed in

Most Mills All over the World

Proven product Proven benefits Proven

process savings - Proven profit $$/

Fig 5: Number of installed units over the years.

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BTG 2003

Flow independent, high sensitivity to fiber consistency, high

signal-to-noise ratio and physical measurement:
The sensing element is rotating by its own force independent of
the flow velocity in the pipe. Its outer speed is typically around
5 m/s, i.e. double the normal pipe flow velocity. It is also fed
by its own flow, supported by the propeller, independent of the
pipe flow velocity.

Consistency transmitter
MEK-2300

Measuring principle

Difference in light opening

450 rpm

Provided that the transmitter is fitted into the pipe in a correct

way, it will be virtually unaffected by flow changes in the pipe.
No other transmitter type has this advantage and flow velocity
problems are very common, particularly for static blade type
transmitters, but also for rotating transmitters using different
measuring principles and sometimes even for certain types of
optical transmitters.

Force balance
transducer
with feed-back
function

4-20 mA /HART

Fig 7: Measuring principle.

Representative and stable measurement: Looking on the
part of the transmitter located into the pulp stream you find a
rotating sensing element and a rotating propeller. They both
rotate with the same speed. The pulp is mixed by the propeller
and pushed to the sensing element.
If you study fig. 8 you see a comparison of how large portion
of the pulp volume in the pipe you are measuring on. We
compare MEK to blade and optical transmitters. The figures
are relative to each other and no absolute values. You can see
that MEK measures on a five times larger volume than a
blade transmitter does, i.e. the sample volume you measure
on is five times larger. It is very important that you really
measure on a representative sample because it will have a
direct impact on the measuring result. The larger the sample
is, the larger is the possibility for measuring on a representative sample! With MEK it is less critical than with other transmitter types that the pump is a good mixer of the dilution
water (which it seldom is). It means that the measurement
will be more stable and accurate using MEK. It is commonly
known that blade transmitters often show unstable signal
resulting in a need to use a high damping (filter time), which
results in a slow and inaccurate consistency control. This is
partly a result of this fact.

Consistency transmitter
Measured relative volume

Rotating: 100

MEK-2300

Blade: 20

Fig 8: Measured relative volume

Optical: < 1

Due to the rotating motion of the sensing element, the transmitter will also be very sensitive to consistency changes, but only
to the fiber consistency! Compared to blade transmitters this
fact is very important when measuring at lower consistency
levels due to the higher shear force acting on the sensing element. Also type of fiber, fiber length, freeness, amount of fines
etc. will have an impact. More of this discussion later. Generally spoken you should not use a blade transmitter on a consistency lower than 2-2.5% depending on these factors, while the
MEK can be used down to 1-1.5%.
The signal-to-noise ratio shows the quality of the measurement
signal. The higher this level is the higher the quality. You can
say it reflects how much of the measurement signal consists of
non-desired background noise and how much the actual consistency signal is. Compared to static blade transmitters it has
been found in independent tests that the ratio for MEK is
approximately three times higher. So, also in this respect MEK
provides a more representative measurement.
Compared to measurement methods like microwave, nuclear
and certain optical types, the signal quality of MEK relies on
direct physical measurement properties. It's the forces created
when separating the fiber network because the sensing element
is cutting through it (together with drag forces acting on the
side of the sensing element). There are no complicated compensation algorithms needed for MEK. There are no additional
sensors (for compensation) needed, which may need their own
calibration, and no such components needed that may fail and
disturb the consistency measurement. MEK provides a straight
on, accurate and reliable measuring method.
Protected sensor: Since the sensing element of MEK is
located in the measuring chamber, inside the pipe wall, it will
be protected from foreign objects like stones or pieces of metal
or lumps of thickened pulp, flowing into the pipe at certain
occasions (start-up or shut-down etc.). Static blade transmitters
are often mechanically damaged while MEK very seldom is
damaged due to these reasons.
Accurate and long-time stable signal transducer: MEK uses
the force-balance principle with a built-in electro-magnetic
feedback function. As you can see from the description of the
measuring principle, we measure the angular difference
between the two shafts when a force created by the fibers in the
pulp suspension acts on the rotating sensing element. Then
you may ask yourself, why not just measure this angular
deflection using a force-movement type of system; why use a
complicated force-balance system? The reason is that we are
looking of achieving very high accuracy and sensitivity and
long-time stability of the transducer system.

BTG 2003

P2007en

Using a force-balance system you can work with very small

movements of the mechanical parts and thus obtain a very
high sensitivity, i.e. a small consistency change will give a
large signal difference. The signal resolution will improve as
well as the signal-to-noise ratio.
You will also simultaneously obtain a compensation for aging
of components (rubber parts etc.) and thus a very good long
time signal stability of the system.
Fig. 9 is a summary of all the specific features for MEK-2300
also including how sensitive it is for disturbing factors.
This will be further discussed and proven in the next section:
Universal transmitter for most applications.

The next figure shows how different types of fiber qualities

influences MEK. Here you have very different pulp qualities,
from a CTMP pulp giving a very strong fiber network and thus
very high shear force, to mechanical groundwood with short
fibers and a low network strength. MEK will have certain sensitivity for different fiber types and different pulp qualities.
Since MEK-2300 has four different measuring ranges it can
however be individually calibrated for each pulp type and thus
avoid this problem.

Consistency transmitter
Fiber and grade dependence

MEK-2300

Output (%)

Consistency transmitter
MEK-2300

Specific features MEK-2300

Representative measurement: Measure on a large sample, mixed
and separated from main flow: Very good

Sensitivity for disturbance factors: Grade, Fiber type, Freeness,

Kappa No, Flow velocity : Very small - virtually negligible
pH, Temperature: Normally very small - in most cases negligible (can
be compensated if large changes)
Pressure, Air, Conductivity, Fillers: None (If total consistency is
required compensation can be made)

Signal quality: Signal damping and filtering: Very low - high quality
Response time and deadtime: Very short - good control ability
Signal-to-noise ratio: Very high - high quality

Cons. (%)

Calibration: Single sample or preset calibration for quick start.

Fig 11: Fiber and grade dependence MEK-2300

Multi-point calibration for maximum accuracy

Gives best measurement and control result - at almost all applications

Fig 9: Specific features MEK-2300

How disturbances will affect measurement.
As we concluded earlier, MEK is virtually unaffected by flow
changes. Fig 10 is one proof of that. The test shows the actual
consistency deviation, shown in % consistency, at a typical
consistency level: 3.3%. If you compare to a static blade transmitter (type A = common type), and imagine that you change
the flow velocity from 1 to 3 m/s, you find that instead of
showing 3.3%, like the lab sample does, the transmitter shows
3.75 %, an error of 0.45% consistency or approximately 14%.
The MEK does not show any error!

Comparing to a static blade transmitter you can see that the

deviation is much larger than for MEK, fig 12. The shear
force is here shown in force N (Newton) acting on the sensing
element, but please compare the relative difference between
different fiber types. If you compare the two figures you see
that for MEK the difference around 3% consistency is just
above 0.5% consistency while it for the blade transmitter is
2.5% consistency. The fiber types are not identical but it still
gives a clue.

Static blade transmitter

Fiber and grade dependence
G = TMP, freeness > 200 ml
F = TMP, freeness < 200 ml
E = Groundwood
J = Recycled fiber (OCC)
K = Recycled fiber (newsprint)

Reference:
Valmet Automation

Fig 12: Fiber and grade dependence Ref. Valmet Automation

Fig 10: Flow dependence

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Comparing a static blade and MEK, at the same conditions,

changing from a kraft pulp to a mechanical groundwood pulp
and imaging you try to control consistency to 3% you can see
the result in fig 13.
BTG 2003

MEK will show 0.1% difference, i.e. 2.9% instead of the correct 3% while the blade shows 2.62%, i.e. an actual consistency error of 0.38% that is almost four times larger than for
MEK. This is a fact that is not commonly known. Competition
claims that their static blades are just as good as an MEK but
this is one of the proofs that it is not!
Please note that this error does not only apply when changing
from one specific pulp type to another, also changing or having different blends or fiber type (raw material) or changing
the freeness level will have the same relative impact, a four
times larger error for a blade transmitter, static or active, it's
the same in this respect.

Consistency transmitter

The microwave transmitter (MIC-2300, Metso MCA or

Toshiba) does not measure the total consistency, only part of it.
Typically it measures around 60% on the filler, part but this
varies. Metso claims that their MCA measures the total consistency. This is not correct! Different filler types give different
result. Both MIC-2300 and MCA have a possibility to implement a compensation for different filler types and thus partly
avoid the problem, at least for many applications. If the filler
type varies you cannot compensate for it unless also different
measuring ranges are used. Generally you can however say
that, correctly adapted, microwave transmitters measure close
to total consistency. BTG TCT-2300, however, does not need
compensation and is the only transmitter that really measures
total consistency.

MEK-2300

Fiber and grade dependence

Consistency transmitter
Influence of fillers
Cons (%)

MEK-2300
Groundwood 3.0% Flow 2.0 m/s Temp 300 C. Coating clay added

KR = Sulfate Kraft
Optical reflection

GW = Mechanical groundwood

Lab.cons/ Optical Peak method

Blade
Rotating

3-2.62 0.38
2.62 = 2.62 = 16.4%
3-2.90 0.10
=
3 = 3.3%
3

Microwave

MEK-2300 vs. Common type Statical blade transmitter

Rotating sensor
Active blade
Static blade

MEK-2300 is much less influenced of changes in furnish

Fig.13 Fiber and grade dependence MEK

Another influence on the signal accuracy is the content of fillers of fines. First you have to understand what "Total consistency" really means. Fig. 14 explains this. Typical filler
components are china clay, calcium carbonate, titanium dioxide etc.

Filler (%)

Fig. 15 Influence of fillers, different measuring principles

A later made test, fig. 16 conclude that MEK does not sense
the fillers, only the fibers. MEK is a fiber consistency transmitter.

What does Total Consistency mean?

mean?

MEK-2300

Consistency transmitter
Feedback %

Signal %

Influence of fillers

Total Consistency [%] = Fiber Consistency [%] + Filler

Consistency [%]

Feedback %
B-sensor. 10% Hardwood Kraft + 50%
Groundwood + 40% Fiber
coatingconsistency
clay
%
Fiber Consistency %

Example: Total consistency is 3%. Ash content (= filler consistency)

is 30 %.
This means Filler consistency is 30% of 3% = 0.9% consistency.
Fiber consistency is 3 0.9 = 2.1% consistency.

Fig.14 "What does Total consistency mean"

The next figure, fig. 15, comes from a test made at BTG R&D.
The idea was to start with a 3% consistency pulp and then just
add fillers and observe the consistency reading. To be able to
compare the result between the different measuring principles
all results were recalculated to show the absolute consistency
deviation expressed in % consistency. Naturally if you just add
fillers, the total consistency will increase which is illustrated by
"lab. cons.". As can be seen, "optical reflection" (BTG OCT2300) is overcompensating, while all shear force transmitters
show a very little influence, they all mainly measure the fiber
consistency only.
7

B sensor. Fiber composition: 83% mechanical

groundwood, 17% Hardwood kraft. Increasing
level of fillers (coating clay)

Filler content %

MEK-2300 does not sense the fillers, just the fiber consistency. For total consistency
measurement a compenstion can be made.

Fig. 16 Influence of fillers MEK

The most common applications where the question if the
transmitter measures total consistency or not, applies for
broke chest, mixing chest and machine chest. This is where
perhaps 90% of all microwave transmitters have been
installed and thus replaced or beaten MEK at a project. So,
are these applications proper for and safe for microwave
transmitters to be installed at?

BTG 2003

P2007en

First you must be aware of the general features between the

different principles in this context, fig. 17. Microwave transmitters are very sensitive for air in the pulp; this is their main
disadvantage. We know that attempts have been made to
compensate for it, but so far without success. Pulp always
contain a certain amount of air, typically around 3%, but it
can be much more, 10%, or even 20% can occur in practice if
the process equipment is not arranged in a suitable way so
that air can enter. Close to the paper machine the air content is
typically low, and controlled. This may be the reason why
microwave transmitters often operate well here.

MEK however on the other hand, is not dependent of the air

content, pressure and conductivity. This is also true.
So which transmitter type should be used here? The answer is
naturally: you must investigate the actual measuring conditions; the choice is not obvious without doing that!

MEK-2300

Influence of air, pressure and conductivity

Air is present in the pulp in two forms, either tied to the fibers
or in the form of air bubbles. The size of the air bubbles
depends upon the line pressure; the higher the pressure, the
smaller they become. They also become solved in the water
with increasing pressure. Thus you need a certain min. pressure for a microwave transmitter to avoid influence from the
air content to the signal accuracy.
One problem, however, is that it is sometimes not possible,
with reasonable efforts, to increase the pressure and thus
avoiding the problem; the measuring principle cannot be
used, the pulp contains too much air.
According to information from all companies supplying
microwave transmitters the general rquest is min. 1.5 bar pipe
pressure.
This is valid if the air content is not too high, but what is an
acceptable level? Do you know how much it is for the application in question and are you sure it doesn't increase abowe
maximum at certain occasions? Is this a safe and reliable
measurement? Will it have an impact on the paper machine
runnability?
There are many uncertainties. The major user of microwave
transmitters, a Swedish mill, claim they need 1.8 bar pressure.
At the machine chest they have had problems and were forced
to install a larger pump, but then how much does this add to
the energy cost, see example fig. 20.
Other customers have said they even need 2.2 bar line pressure to be able to use microwave transmitters. Of course, this
all depends upon the air content they have.

MEK-2300:
Not influenced by air content
Not influenced by pipe pressure
Not influenced by conductivity changes

Microwave and Nuclear transmitters:

Inapplicable at high air content
Must have a min.pipe pressure 1.5 2.2 bar
Can not be used at high conductivity levels.
Difficult to compensate at lower levels.

Fig 17: Influence of air, pressure and conductivity

Fig. 18 shows an MEK installation in Finland at machine
chest where they use TMP pulp and add fillers. Naturally it
has been proven that MEK doesn't see the fillers, but in this
case the mill only wanted to measure the fiber consistency;
they are not interested in measuring the total consistency with
the consistency transmitter. They have a retention analyzer
and thus they find out the filler content and can calculate the
total consistency. Using a microwave transmitter here they
wouldn't know how large the fiber and how large the filler
content were, they would both have been included in one signal. Knowing the fiber content in the paper is of course also
an important issue.

Conductivity is not usually a problem close to the paper

machine, but sometimes acid is used for pH adjustment and
sometimes different dyes can make an impact. Generally,
microwave transmitters should not be used where there is a
conductivity > 3 mS/cm. You can make compensation at
higher levels but since the compensation also depends upon
the media temperature, the compensation is difficult. MIC2300 has here an advantage over competition since compensation possibilities are implemented. If the conductivity
exceeds 10 mS/cm, the signal becomes too much dampened
and it's impossible to measure anymore. Also here MIC-2300
has an advantage over traditional flow-through models; the
signal damping increases with distance between the antennas.
MIC has a relatively short distance and is thus less influenced. The larger the pipe size (using flow-through models),
the larger the difference is.
For blend, mixing and machine chest applications, microwave transmitters have an advantage over MEK in regard to
their ability to closer measure "total consistency" as well as
their ability to more closely measure consistency if fiber quality changes. This is true.

P2007en

MEK-2300 installed at
mixing chest at leading
paper mill in Finland
Accurate control
Measures fiber consistency
Not dependent upon air
content and pipe pressure
No by-pass, installed in-line

Fig 18: MEK-2300 installed at mixing chest at leading paper

mill in Finland

BTG 2003

Fig. 19 shows competitive microwave transmitters installed at

a German mill. As can be seen they were forced to install separate pump loops just to obtain correct pressure for the transmitters, an expensive and maintenance-demanding solution.
Still the transmitters don't operate fully satisfactorily. MEK
was also later on tried here, but because of low shear forces
due to bad fiber quality (recycled) and high filler level (30%),
MEK was not stable enough at the worst operation cases
(short fiber recycled combined with high, and changing, filler
level and large flow changes).
Also MEK has its limitations.
Later on it was proven that TCT-2300 gave the best result at
this particular application.
In many other applications of this kind it has been proven that
MEK works much better than microwave transmitters and
many of them have been replaced by MEK. Low pressure and
too high air content is the main reason. Recently we replaced
two competitive microwave transmitters at the machine chest
in Asia. Due to the stuff box design the pressure could not be
increased to reach proper level and the transmitters thus performed badly. MEK performed very well. At another machine
chest application in China we tried our microwave transmitter, but the result would have been equal to any other brand.
The data looked very good, high pressure far above min. rec.
level etc. The transmitter however failed badly, large consistency errors, 0.5% and more. The answer to the problem was
that the pulp contained a huge amount of air. Naturally the
MEK fixed the problem and worked perfectly.
This case also showed another observation; when the operating conditions are unsuitable for a microwave transmitter the
result is often very large consistency deviations, often 0.5%
or more. For MEK the deviation in unsuitable cases is mostly
much smaller, in the German case described above it was
around 0.2% consistency.

Consistency transmitter

Cost influence on pump

pressure increase

MEK-2300

Power cost increase/year

m
[USD] [SEK]
=

30000
200000

20000

Pipe size: 300 mm (12")

Flow: 1,8 m/s (0,55 fps)
Operation: 8000 h/year

150000

W
/K
nt
Ce W
08 K/K
,
13 SE
1
/KW
ent
4 C Kw
6,5 SEK/
0,5

100000

KW
Cent/
3,27 EK/Kw
0,25 S

10000
50000

Pressure increase

0
0

0,5

1,5

[bar]

MEK is not influenced by air / pulp pressure and conductivity like nuclear and
microwave consistency transmitters = Higher accuracy and Reduced costs

Fig 20: Cost influence on pump pressure increase

Conclusion: Summarizing MEK features regarding its ability
to measure accurately and reliably and its usage for most
applications you find that MEK provides very small or no sensitivity to most disturbance factors that can occur. It is more
expensive than a blade transmitter but superior to them in all
other respects.
Compared to microwave transmitters it cannot measure total
consistency and is more sensitive for fiber property changes
but it is not dependent of air, pressure and conductivity
changes. Microwave transmitters can only be successfully
used for a very limited amount of applications where the conditions are well controlled while MEK works mostly anywhere
in the mill. Generally MEK is the safest, most accurate and
reliable choice.
Consistency range: 1-16%

Very high measuring accuracy and

repeatability
Universal transmitter suitable for
most applications
Very high reliability
minimizes need of maintenance

Fig 21: Reliability and Maintenance

Transmitter design and maintenance questions

Microwave transmitter installations at mixing and machine chest.

Fig 19: Microwave transmitter installations

As mentioned earlier you must sometimes increase the pressure to be able to use a microwave transmitter. Fig. 20 shows
the economical impact on such a measure. It is for one typical
case. Imagine the power costs SEK0.5 / UScent 6.54 per
Kwh. If you then need to increase the pressure by 1 bar, you
see that the yearly increased power cost is approximately
USD 8,000. This cost should be added to the increased cost of
the microwave (or nuclear) transmitter compared to MEK.

The MEK-2300 transmitter is a mechanical transmitter with

many components. Competitors claim that the transmitter is
unreliable and will cause high maintenance costs. Is this true
or just an attempt to attack a competitor? Previously we concluded that the transmitters have been sold in nearly 15,000
units during a long period of time. Would you really be able to
sell a transmitter during so many years and in so many examples if it causes excessive maintenance? The answer is naturally not; it's a false statement! Since the transmitter is the 7th
generation since the 60s, all weaknesses have been found and
the transmitter has been continuously refined ever since - see
fig. 23. For those interested fig. 24 shows major product
improvements since the MEK-2000 model was introduced
1984. All of these improvements are aimed to increase the
accuracy, reliability and simplify for the user at the same time
as the reliability increases and the maintenance demand
decreases.

BTG 2003

P2007en

- All parts and material used in the design are optimized for
the very demanding applications in the P&P industry. It's
designed to withstand high temperature, corrosive media and
atmosphere, high moisture in the surroundings etc.

- The most critical parts to prevent failures are seals against

the media. Thus a metal bellows seal is used as the rotating

shaft seal. This seal type is an exclusive type designed to be
very flexible and sturdy. Its designed to withstand pressure
shocks, excessive shaft run-out, corrosive media, certain dry
running operations and high temperatures. The wearing faces
are made from silicone carbide, a material next to diamond in
hardness, to be highly wear resistant; at the same time it can
withstand large temperature shocks. A mechanical seal is a
wear item, but we have found that the average life time is over
five years. More in the paper mill and somewhat shorter in the
pulp mill, but it depends very much upon the application.
The flexible sealing between the two shafts is in fact a dual
seal; an O-ring made in specially developed highly resistant
fluor-rubber to suit virtually all applications in P&P. Only for
applications where the black-liquor content is very high
another quality, EPDM, is required. As a back up, if the Oring should leak after a long time in operation, a special rubber bushing prevents any further leakage. In all normal cases
it is only required to replace the low-cost O-ring on a regular
basis as a preventive measure. Typically this is only required
after 5-10 years of service.

Fig 22: Reliability

BTG transmitter MEKMEK-2300

Consistency range: 1-16%

- The motor is a special type. It has tropical insulation and is

wired to accept very large voltage variations; it's a wide-voltage motor. Standard option is a 3-ph motor that typically gives
the highest reliability but as an option a 1-ph motor is available to reduce the installation cost.

Reliable, well proven design

Fig 23: Cutaway view

Major product improvements MEK

(from analogue model MEKMEK-2000)

New electronics /MEK-2200: 1991

New transmission: 1991
New fastening of sensing element: 1992
New series of measuring vessel: 1994
New electronics /smart model MEK-2300: 1995
New Hand-Held terminal SPC-1000: 1995
New material Avesta 254 SMO: 1998
Single-phase motor: 1999
New Junction box JCT-1100/ Surface mounted card in tx.: 2000
Adapted for Fieldbus and OPC: 2000
Preset Calibration curves: 2000
Windowsbased program, complement to hand-held terminal: 2000

Fig.24: Major product improvements

P2007en

The shaft bearing arrangement is designed by SKF to obtain a

lifetime exceeding 10 years operation during highest possible
line pressure. The bearings are permanently greased, prestressed type angular contact bearings supported in a steel
sleeve to obtain a very stiff shaft arrangement that is beneficial for the mechanical seal lifetime. To protect from any possible leakage into the bearings they are protected with
labyrinth seals. To our knowledge, water has never penetrated
into the bearings; it's a very reliable arrangement.
The transmission is a modern timing type rubber belt. It is
oversized four times in relation to the motor power. Typical
lifetime exceeds 10 years before a replacement is needed
- The electronics is uncomplicated in its structure to obtain a
high reliability. The processor card located in the transmitter
is of "state-of-the-art" surface-mounted type. It withstands
vibrations very well. This also applies to the transmitter as a
whole; we know from all the installations as well as from tests
made at certification institutes, that this is true. We also know
that high media or ambient temperatures do not affect the
transmitter. When testing the transmitter we first inserted the
wet part of it into 95C water. Then we installed the complete
unit into an oven and raised the ambient temperature up to
70C; conditions that you hardly see even in the worst possible application. The transmitter still worked without problems. High temperatures and vibrations are commonly known
problems particularly for certain static blade transmitter
types.

BTG 2003

10

Based upon our vast experience we know that average time

before the first maintenance requirement is > 5 years in continuous operation. This typically means a replacement of the
mechanical seal, a simple and not too expensive action.
We also know that the transmitter typically requires a major
maintenance after 10-15 years in operation. Typical action
then is to replace all bearings, seals and the drive belt. Still
such a repair does not cost much more than to have a static
blade repaired (not valid for BTG transmitters, they can be
more easily repaired).
These times given are average, individual units can operate
for either longer or shorter periods, depending upon the application and other factors that may influence. Preventative
maintenance is the key factor to minimize actual maintenance. For the consistency transmitter this mainly means that
the water flushing system for the mechanical seal should be
regularly controlled and cleaned if necessary.

From a user and maintenance demand point of view the location is important since the transmitter in most cases is easy to
reach and handle.
The most important point is however its ability to bring a good
consistency control, a result partly depending upon its location
close to the pump. This will be discussed later on.
Fig. 26 show a typical installation of the transmitter, in this
case complete with a sampling valve, an item highly recommended. In this photo you can also find that the pump is
equipped with a variable speed motor. This is an installation
that can cause measurement problem particularly when the
pump operates at low speed since the pulp/dilution water mixing then can become less efficient. As we concluded earlier,
MEK-2300 however measures on a very large sample volume
and is thus less affected than other transmitter types. This particular installation also proves this theory; the unit works very
well also in practice!

The MEK-2300 transmitter has three years warranty, a proof

that it is a very reliable unit, which needs very little maintenance!
Due to its design and the way it operates, certain aspects upon
how the transmitter is installed must be explained. Competitors accuse the unit to be expensive and complicated to
install. This may me true, but in many cases the actual cost
for other types of consistency transmitters like blade or
microwave types can be just as expensive, and sometimes
even higher. This is particularly true if you need to make special piping arrangement to decrease the flow velocity by
installing a larger pipe to be within acceptable level (blade
transmitters) or increase the pressure by installing a separate
pump loop or replace the pump (microwave transmitters).
Sometimes also the static blade transmitter needs a separate
pump loop to have a stable velocity. All of these actions are
very expensive.
Selecting the 1-ph motor and using the mechanical seal without water flushing can decrease the installation cost for MEK.
Both of these possibilities can be used for most applications
and reduce the cost considerably.
Considering the way MEK-2300 is installed, you must consider that it can be mounted close to the pump that is advantageous in two ways - fig. 25.

Fig 26: MEK-2300 installation photo

Fig. 27 illustrates a typical MEK-2300 delivery content, complete with options.

MEKMEK-2300 typical installation

Typical delivery content

Consistency transmitter MEK-23XX
Junction box JCT-1100

Optimal Control

Hand-held terminal SPC-1000

User friedly

Measuring vessel or Weld-in stud

Easy to access located

close to floor level

Sampling valve type MPS-1000 or

MCS-1000 or FVS-1000

All settings made from

hand-held terminal or
Junction box

User manual and Service manual,

Test documentation
Options:
SPCWin PC program, Back-up card, Printer,
SLS-1000 lab sampler device, PC-documentation
software, various special service tools, etc.

Fig. 25 Typical installation

11

Fig. 27 Typical delivery content

BTG 2003

P2007en

The MEK-2300 transmitter is available in a large number of

variants, and materials. Fig. 28 is an overview of available
models.
- The basic model, named MEK-2300, is used in consistencies from 1-10% and at max. pressure class PN10.
The transmitter can be used in a large range of applications. It
can even be installed at the wall of a chest, an application
where few other transmitters can work.
- The medium consistency models for consistency 8-16% are
available in combinations for screened and "unscreened" pulp
and in pressure classes PN10 or PN25. Compared to the
standard transmitter, 1/3 higher torque levels can be balanced
to handle the high shear forces and these high consistency
levels. With "unscreened" pulp we mean pulp that contains
large knots or foreign material like stones or pieces of metal
that may mechanically damage the unit due to an impact. To
protect the transmitter, the rotating shafts and sensing element
are quipped with a special protection, a "banana"-shaped steel
bar. Transmitters in pressure class PN25 have a thicker flange
to handle the pressure requirements.
The MEK-2310 and -2312 models are often used in the
bleach plant and then the wetted material must often be
selected to handle the corrosive bleaching chemicals. Avesta
254SMO or Hastelloy C materials are then available.
- Designed for specific applications, MEK-2308 is equipped
to handle the tough conditions after a blow tank.
MEK-2320 is designed to handle extremely troublesome
applications after a recycled fiber pulper where large amounts
or spinning materials like strings and plastic strips are
present.
MEK-2340 is adapted for open vessels like for a "stuff box"
and has very long shafts, up to 1100 mm, and no shaft seal.

MEK-2300

STD: 1-10% MC: 8-16%

MEK-2300
10 bar

Consistency transmitter
MEK-2300

Sensing elements
Normal consistency
Basic type

A
B

Fiber type Lower limit

Long
Short
Sludge

(2220-2320)

18

m
5m
in
7.3

Medium consistency

Upper limit

0.8
0.8

%
%

2.5
2.5

%
%

1.5-2

10-15

Long

1.0

5.0

Short

1.5

6.5

Long

1.5

Short

2.0

%
%

8.5
10.0

Basic type

G
H
I

%
%

120mm
4.7in

150mm
6in

125mm
5in

Fiber type Lower limit

Upper limit

Long

10

Short

11

Long
Short

7
8

%
%

12

13

Long
100mm
4in

Short

9
10

%
%

14
15

%
%

80mm
3.1in

Long
Short

11
12

%
%

18
18

%
%

Specially adapted sensing elements for all applications

Fig 29: Sensing elements

When connecting the transmitter to the pipe, a special mounting arrangement is required - fig. 30. Basically an expansion
of the pipe to 300 mm is needed when the pipe is between
100-250 mm. This pipe expansion is called "measuring vessel". Depending upon pressure, PN10 or PN25, the design is
different, a streamlined model for PN 10 and a globe form for
PN25. The low-pressure vessel is specially designed to avoid
any air being trapped at horizontal installations and also to
avoid the risk of plugging at higher consistencies. It is available in a range of variants; welded or flanged to the pipe, different materials, left- or right-hand versions etc.

Special: 1-10%

MEK-2310

MEK-2308

MEK-2311

MEK-2314

MEK-2312

MEK-2320

MEK-2315

MEK-2340

10 bar

The sensing elements for MC are shaped like an S and developed to obtain good sensitivity and to minimize the flow sensitivity.

For larger pipe dimensions, 300 mm and larger, a weld-in stud

can be welded directly to the main pipe.

Consistency transmitter
MEK family. Variants
available in MEK-2300 series

The size is selected to maintain a suitable working range for

the feedback balancing system and to secure a stable signal
combined with high sensitivity for consistency changes.

21
8.3 0m
in m

Transmitter variants and its installation

MEK-2300

Consistency transmitter

10 bar/Unscreened

Mounting parts. Low pressure PN10 (150 psi)

10 bar/Unscreened 25 bar

25 bar

Consistency: 1-16%

10 bar/Anti-spinning

25 bar/Unscreened Open flow box

Materials: 316SS (std), 254SMO, Hastelloy C

Pressure class: 10 bar (std -150 psi) or 25 bar (360 psi)

Measuring vessel

Fig 28: Variants in the MEK-2300 series

Pipe size 100-250 mm (4-10)

weld fitted (std) flange fitted (option)

The sensing elements are specifically adapted for different

applications. Basically the sensing elements are streamlined
and shaped like a star for consistency levels up to 10%. The
idea is to create a representative measurement and avoid any
problems from hang-up. The higher the consistency, the
smaller the size is of the sensing element.

P2007en

Sampling valve included (option)

Weld-in stud
Pipe size 300 mm (12)
Inspection cover (option)
B

Fig 30: Mounting parts Low pressure

BTG 2003

12

Why is accurate Control important ?

Consistency transmitter
Mounting parts

MEK-2300

High pressure version. Max. 25 bar at 226 C (363 psi/439 F)

Available in 316SS (std), 254SMO and Hastelloy C

Tightened Distribution

Measuring vessel

Weld-in stud

Pipe size 150-250 mm (6-10)

weld fitted (std)
Flange fitted, PN25/ANSI 300
(option)

Pipe size 250 mm (10),

200 mm (8) at suitable conditions

Fig 31: Mounting parts High pressure

Consistency control
The next topic to discuss is "Optimal Control"; why does
the selection of transmitter type compared to another one
make an impact on the control result?
This discussion may seem theoretical to persons used to the
day-to-day problems but still it is of greatest importance to the
result; the well working consistency control loop. Still the
matter is explained in a very simple way compared to what
you find in general textbooks available.
The consistency control loop itself is not discussed here. It is
discussed in the general part of "BTG Consistency Control
Seminar" and a specific paper is available. This paper has
been presented at Tappi 99 and is called: "Consistency Control; designing the Control loop". It is also discussed in the
book "Accurate Consistency", mentioned above.

Setpoint Response and Regulation

Fig 33: Why is accurate control important?

A good process control can provide many advantages. Fig. 34
shows what a good process control can mean at a bleaching
stage in a pulp mill. By a tighter distribution (better and more
accurate control) you can often be able to shift the set target.
You can perhaps use less amount of expensive fibers and
replace with less costly or reducing the amount of expensive
chemicals. Also reduction of the energy consumption, widening a production bottleneck to increase production rate etc.,
can be the result. There are numerous examples why a better
control is important.
The most important control in a pulp or paper mill is
consistency! If you know consistency (and flow) you
know how much fibers are present in the different
process stages. Thus consistency control is the basic
parameter to control and a tighter distribution here
is of greatest importance for the result!

Consistency transmitter
Typical installation

Process Control Provides...

Provides...

MEK-2300

Variability Reduction

Optimal Control

Example: Bleachplant Control

9Increased Production

Reliable

9Chemical Cost Reduction

9reduction in variability

User friedly

9AOX Reduction
9Environmental Compliance

Shift Target = $$$

9Improved Pulp Quality

Fig 32: Typical installation

First you may ask yourself: Why is it important to have an
accurate control and what are then the implications?
Un uncontrolled process shows large variations, in this case
the consistency varies. By introducing a control (control loop)
you may reduce the magnitude of the variations, i.e. you
tighten the distribution. When making a step change, i.e.
changing the controller set point to achieve a lower consistency, you should reach the new level as soon as possible
avoiding oscillations. Reaching the new level faster also
means a tighter distribution! A tighter distribution means
"money"; reduced costs or better product quality!
13

9Easier Bleach Plant Operation

9- Recovery from Upsets

9Operating Flexibility

Fig 34: Variability reduction

Comparing Control ability for different consistency transmitter types: Even if you are only somewhat familiar with
control issues you are probably aware of the "dead time
issue" which is of central importance if you are aiming at
designing a control loop.In an automation dictionary dead
time is explained as follows:

BTG 2003

P2007en

"Time interval between the instant when a variation of an

input variable is produced and the instant when the consequent variation of the output variable starts". Popularly
explained, dead time is the time it takes from making an input
change until the change starts to influence the process (or
equipment). In a consistency control loop there are several
dead times involved. You have built-in dead times in the
equipment involved (in the consistency transmitter, in the
dilution water valve positioner/actuator etc.). You may have a
signal filtering damping the signal etc. All these factors mean
certain dead times, in practice all added together to make an
influence to the process to be controlled.

culated for a vertical installation by a factor 1.5 if the transmitter is installed on a horizontal pipe after a bend.
- Also multiple bends, pipe bends directly following each
other, are common and in such a case the recommended calming length is increased even further.

Sensor Location is Important!

The largest dead time however mostly is the dead time

between where the dilution water is introduced to the pump
suction and the consistency transmitter. This dead time is the
time it takes for the pulp to flow between the dilution point
and the measurement point.
To achieve the best consistency control it's very important
that this dead time becomes as short as possible since it will
directly influence the control loops ability to reduce disturbances. Factors that will influence dead time are:

Consistency sensors are susceptible to

DEADTIME
________
Place them as close as possible to the dilution

Fig 35: Sensor location is important

- The ability for the transmitter itself to be installed on a turbulent flow. A turbulence is created in a pump, bend or at a
half-open valve. The fibers in the pipe will have different
velocities and the conditions in the pipe are generally unstable. At a certain distance after these disturbance sources the
turbulence evens out and the flow seen across the pipe diameter is uniform, all the fibers will flow with the same velocity
in the same direction. This stage is called plug flow.

Effective Consistency Control

The location where plug flow is formed is not only depending

on the distance in itself, but also depending on consistency
level, fiber type and flow velocity. Generally lower consistency, shorter fibers and higher flow velocity all increase the
distance to where the plug flow is formed - see "Accurate
Consistency", chapter 2.
Some types of consistency transmitters can be installed at
more or less turbulent flow conditions. Some optical and
microwave transmitter types can be installed on very turbulent flow conditions directly after the pump outlet, while
MEK requires a relatively straight flow, even if it is turbulent.
Thus a short calming length is needed after the pump, bend or
valve. Blade consistency transmitters and other types of rotating transmitters (not MEK) need fully developed plugflow
conditions.
- Practical possibilities to install a transmitter at a recommended point. Normally there is space enough directly after a
pump, on the vertical section, to install an MEK since it can
be installed on a turbulent flow (but also works on a plug
flow). Thus the dead time in most cases can become short and
it's also easy to reach the transmitter from the floor.
A blade transmitter always need plug flow conditions and
often there is not enough space on the vertical section after
the pump to obtain this condition and follow the calming
length recommendations. You often have to install it after a
bend (one or several) on the horizontal section. The piping is
in most cases already existing being designed and built without considering the demands for a consistency transmitter.
Thus the distance between the dilution water inlet and the
consistency transmitter very often becomes very long resulting in a very long dead time.
- The recommendation is to multiply the calming length cal-

P2007en

Fig 36: Effective Consistency control

Impact of dead time and controller tuning: The most common method to tune a controller for consistency is the
Lambda method (Lambda tuning). The main advantage of this
method compared to traditional methods (Ziegler-Nichols,
Chien, Hrones and Reswick etc.) is that you may decide how
rapid the control should be, before optimizing it. In this
method the variable is called (Lambda).
To decide you have to make a step-response test of the process. The control loop must be open (i.e. it's not on control and
the controller is set on "Manual"). Then you can find out the
deadtime (Td) and open loop time constant (). The dead time
(Td) is the time it takes from the change of the set point is
made until the consistency transmitter start to pick up the
actual consistency change.The open loop time constant () is
the time it takes for the signal to reach 63% of full value.
According to Lambda tuning practice should be selected to
3 x or 3 x Td, whichever is the largest. For consistency control tuning it is recommended to use Td as the denominating
factor (reference: EnTech / Emerson Process Management
2002 - Consistency Control loop Dynamic Specification).

BTG 2003

14

In the example fig. 37 and fig. 38 a typical response for a

blade type consistency transmitter is shown when a set point
change on the controller is made to increase the consistency,
i.e. the control valve is closing. In this example Td is approximately 20 s for the blade transmitter. (At a typical flow
velocity 1 m/s it means that the distance between the dilution
water injection point and the transmitter is 20 m, a very common location in practice for a blade transmitter due to the
practical implications mentioned above). Then becomes 3 x
Td = 3 x 20 = 60 seconds.

Excessive Deadtime and Filtering

Blade consistency transmitter

Dilution valve opening

B

Td
Deadtime ~ 20 sec

If you compare to a rotating transmitter type MEK (or microwave /optical), which can be located much closer to the
pump, Td is 2 seconds and becomes 3 x 2 = 6 seconds.
Based upon these values you can then calculate the parameters for the PID controller, the Controller gain Kc and the
Integrating time Ti (Reset). The Derivate time (Rate) is set to
0.
But what will this mean for the control result using the different types of transmitters? Then you have to study a factor
called Cut-off frequency. The Cut-off frequency Tc is given
by the formula Tc = 2 ( + Td). Since we already know
and Td we can easily calculate Tc.
For the blade transmitter Tc = 2 (60 + 20) = 503 s ~ 8.5 min
and for MEK Tc = 2 (6 + 2) = 50 s < 1 min.
Since the Cut-off frequency Tc is the frequency where the
consistency controller can begin to attenuate disturbances of a
larger period, the value is critical. Frequencies faster than Tc
will not be attenuated!
Looking on the process, at different parts, what frequency
variations can you expect?
- Large tanks, storage chests etc. have long retention time, the
cut-off frequency is low. Thus the dead time Td is not a very
important issue. On the other hand, if the chest is equipped
with a special compartment using an intense mixing and you
have a double dilution, where the course dilution is fed into
this mixing compartment and the fine dilution before the
pump, the retention time can become short!
Generally spoken, traditional large volume chests do not
require transmitters giving very short cut-off frequency, a
blade transmitter can work satisfactory in this respect. For
modern type of chests using mixing compartment, they can be
better controlled using transmitters like MEK
(or optical/microwave).
- Small volume tanks or chests, type mixing chests or couch
pits or process equipment like washers, screens etc., means
higher cut-off frequency. Here consistency transmitters giving a short cut-off frequency can make a significant improvement for the control result, they are really able to treat the
incoming variations so that the control loop can make the job:
a smooth stable outgoing consistency without variations.

15

4
Open loop Time Constant () ~ 30 sec
Output signal blade type
transmitter (not in control)

Fig. 37 Excessive dead time and filtering

Control ability:
ability: Comparison between BTG Rotating
(and Microwave/
Microwave/ inin-line optical)
optical) VS.

Blade type consistency transmitters

Typical Dead time (Td ): Rotating 5 s. Blade 20 s (require plug flow

conditions)
Open loop time constant (): Rotating 10 s. Blade 30 s
Lambda () method most common for consistency control tuning
Short period disturbances: =Closed loop time constant. = x 3 for
stability > Rotating 30 s, blade 90 s > Slower tuning for blade transmitter >
Less response for incoming disturbances > Less accurate control!
Larger period disturbances: Cut-off frequency Tc = 2( +Td) is the
frequency where the consistency controller can begin to attenuate
disturbances of larger period. The cut-off frequency is ~ 4 min for rotating vs.
12 min for blade transmitter > A blade transmitter does not touch disturbances
with periods less than 12 min > Less accurate control!

Fig 38: Control ability:

Comparison between BTG rotating and blade transmitters

Applications and Proofs for MEK

As we discussed earlier, MEK can be successfully installed on
a large variety of applications; in both pulp and paper mills, in
all kinds of processes and in a very large consistency span,
from 1 to 16%. The transmitter is universal in its wide field of
applications.
Some applications are particularly interesting, and often considered as "difficult".
The background for these applications and considerations for
control and selection of type of consistency transmitter is not
discussed in this paper, please see "Accurate Consistency"
chapter 7 for details.
Paper mill applications: Two typical examples of applications in the paper mill are shown in figs. 39 to 43. Fig. 43 is
particularly important since it includes two actual proofs that
MEK provides an advantage over blade transmitters.

BTG 2003

P2007en

Local
setpoint

C ONS IS T EN C Y TR AN SMI TT ER

MEK-2300

CS

Remote
control

Specific Refining
Energy Control

Drainage
Rate Control

MEK for Paper machine Control

Low consistency 1-10%

F
FT

Output
Power

Accurate Consistency Control - The foundation for

successful Paper Machine operation
Stock Proportioning Control- Accurate Control of each
fiber flow is essential for optimal product quality and
minimized consumption of high cost fiber

CRC

DRT-5200
I

MEK-2300

Mixing Chest Control - Final Consistency Control, is

essential for optimal Machine runnability and profitability

MPS-1000

Standard model
MEK-2300

Cs=3.5%

Fig 42: MEK for paper machine control

Fig 39: Refiner Control

MEK for Refiner Control

Low consistency 1-10%
Accurate Consistency Control - the foundation for
successful Refiner Control
Specific energy refining control the most advanced
control system
Improved and safer runnability of the
paper machine - less web brakes, higher product quality
Tighter tensile strength settings - reduces power
consumption and product variations. Increased amount
of low cost fibers can be used and risk for
downgraded paper is reduced
MEK provides safe accurate measurement, not
depending on flow variations, furnish variations,
line pressure etc.

Foundation for successful Refiner Control to optimize Paper Machine

runnability and profitability

Fig 40: MEK for refiner control

M EK -2300

Valve pos

Cs

C O N S I S T E N C Y T R A N S MI T T E R

BWCS

Valve
input

SP
Actual BW

C O N S IS T E N C Y T R A N S MIT T E R

M EK-2300

VBW-10
MEK-2300

RET-5300

Machine chest

In the second example the situation was very similar, the mixing chest before the paper machine. The mill is located in
Maine, USA. They mix mechanical groundwood and kraft
stock. The produced paper quality specification states that to
keep the required properties, the paper must contain min. 50%
groundwood pulp. If it becomes lower the properties do not
meet the standard, the paper must be degraded and sold to a
lower price or repulped, which is not cost efficient.

An MEK was installed directly in-line after the pump.

The controlled consistency now was improved to 3 +/- 0.05%.

CRC

Mixing
chest

Actual proof and savings fig. 43:

The background for the first example, the illustration, is that
the mill, located in Louisiana USA, is controlling the consistency after a mixing chest in the paper mill. The mill produces
a paper grade where they use pine or a mixture of pine and/or
blend kraft stock.
The consistency control is very important since it decides the
amount of kraft stock and also how much it needs to be
refined. After replacing the static blade transmitter with an
MEK they could see the standard deviation be reduced from
0.4343 to 0.0477, i.e. a reduction of almost 0.4% consistency.
The good result was distributed in the mills internal newsletter.

When using the static blade transmitter the control accuracy

was found to be 3 +/- 0.15% consistency. This meant they had
to increase the amount of kraft stock to 53% to meet the specification. Also worth to mention was that the blade transmitter
was installed using a separate pump loop to maintain a stable
flow velocity. This pump loop did cost a lot of additional
money for power and maintenance which they wanted to
avoid.

FT

MEK-2300

MEK provides Accurate, Reliable control independent of

flow velocity, conductivity, line pressure, fiber variations etc

Safe, accurate, reliable Control for the most critical applications in the
Paper mill

Refiner Control

Standard model
MEK-2300

After Machine chest - Essential part of the Basis weight

Control system (QCS)

Wire Pit

The result they got was a reduction of expensive kraft stock

and they could replace it with the cheaper groundwood stock
and thus save 2 MUSD / year! The payback time for the transmitter installation was less than a month!

Paper machine Consistency Control

Fig 41: Paper machine consistency control

P2007en

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Why did the result in the two cases become so

much better using MEK?
- Much lower sensitivity for different fiber types. Changing from mechanical groundwood to kraft pulp or from pine
to blend kraft stock only meant a very small shift in transmitter signal. The shift was so small that it was difficult to detect
using ordinary lab methods, including the statistical uncertainty.
- Virtually no flow sensitivity. Installation directly in-line
without expensive pump by-pass arrangements.
- Better control ability. Short dead time between dilution
and measurement results in considerably better ability to
attenuate incoming disturbances and provide a smooth stable
consistency control.
Continuous digester Consistency Control

Fig 44: Continuous digester consistency control

Continuos digester Consistency Control

Medium consistency 8-16%
Enables early consistency control in process
Improves digester stability (level control, retention
time)
Enables accurate yield and production rate
calculations

Special model
MEK-2315
30% higher torque
Special MC-sensing
element and mech. seal

Fig 43: Consistency proof and savings

25 bar (300 psi) flange with

deflector

Pulp mill applications:

Stabilizes blow line Kappa no. and optimizes

the internal washing
Prevents hang-up in digester and plugging in the
blow line, washer or refiner
Transmitter really operates reliable in the very
tough measuring conditions (MC, high pressure,
high temp, high pH, varying flow, impurities)

Enables better over-all control of the digester. Improves pulp mill economics

Three examples from the chemical pulp mill; consistency control after the continuous digester, after the blow tank and inlet
to the bleach plant are described - fig. 44, fig. 46 and fig. 48.
In the recycled fiber pulp mill the application after the pulper
is shown - fig. 50. All of these applications are very difficult,
but for various reasons, and other types of consistency transmitters can hardly be successfully used here.

Fig 45: Comments to fig. 44

Why does MEK provide a superior result in the

pulp mill?
- Robust design. Withstands badly cooked woodchips, knots,
stones and metal pieces, highly concentrated pulp jams, backflows, heavy vibrations, high temperatures - in the pulp or
ambient etc.
- Really measures pulp consistency, small influence of disturbance factors. Virtually insensitive (or to a very small
degree only) for flow variations, conductivity, air content,
pressure, fiber type, freeness, etc.
- Excellent controllability. Can control disturbances and
changing conditions very well.

Blow tank consistency control

(Or HD storage chest)

Fig 46: Blow tank consistency control

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P2007en

Blow tank consistency control

For special applications. Consistency 2-8%

Optimizes production capacity and

eliminates risk for plugging in screens and
cleaners
Can withstand the very tough process
conditions. Proven in hundreds of
installations
Insensitive for variations of air/pressure
or conductivity in pulp.

Special model
MEK-2308

Is virtually insensitive for changes in flow

velocity

Deflector to protect from

debris
Extra sturdy mech. Seal
No propeller

The only reliable transmitter available for the application.

Optimize screen and cleaner operation

Batch pulper consistency control recycled fiber

Fig 47: Comments to fig. 46

Fig 50: Batch pulper consistency control

Batch pulper consistency control

For special applications Consistency 1-10%
For the most demanding pulper applications.
Proven in many installations
Enables early consistency control which
stabilizes the subsequent steps in process
Enables a high optimal consistency without
risk for plugging in the screen and pump.

Special model
MEK-2320

Specially designed to prevent hang-up and

spinning
Standard MEK-2200/MEK-2300 for less
demanding pulper applications

Cone protects from

spinning
Special anti-spinning
sensing element

Optimizes pulper and cleaner production for

maximum capacity and runnability

Clean-flushing with
water

Bleach plant consistency control

Fig 48: Bleach plant consistency control

Fig 51: Comments to fig. 50

Bleach plant consistency control

For medium Consistency 8-16% (MC)
For accurate consistency control and dry tonnage
calculation
Is insensitive for variations of air/pressure or
conductivity in pulp.
Is virtually insensitive for changes in flow velocity

Special model
MEK-2310/-2312
30% higher torque

Brings the reliable foundation for correct chemical

dosing. Minimizes chemical costs and improves pulp
quality

Flange for 10 or 25
bar pressure
Special MC sensing element
Wetted parts in 316 SS,
254 SMO or Hastelloy C

Fig 49: Comments to fig. 48

P2007en

Additional information:
- Data sheets, manuals, papers, articles etc. available from BTG.
- Accurate Consistency; A handbook on consistency measurement in pulp and paper processing. Available from BTG, TAPPI
and Paptac.

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