INNOVATIVE EQUIPMENT SOLUTIONS INNOVATIVE EQUIPMENT SOLUTIONS USING STATE OF THE ART USING STATE OF THE ART

PROCESS MODELLING TECNOLOGIES PROCESS MODELLING TECNOLOGIES

Process Simulations Limited

PSL CONTACTPSL CONTACTPSL CONTACTPSL CONTACT

Mail 1938 Western Parkway, Vancouver, BC V6T 1V5

Phone 604-222-0901

Email information@psl.bc.ca

Web www.psl.bc.ca

PSL VALUE STATEMENTPSL VALUE STATEMENTPSL VALUE STATEMENTPSL VALUE STATEMENT

Create real value to our clients by

Providing expert consulting for addressing complex operational problems using process simulation technology

Supplying user-friendly tools to help optimize processes and improve operator training

Delivering improved hardware components

PSL CONSULTING SERVICESPSL CONSULTING SERVICESPSL CONSULTING SERVICESPSL CONSULTING SERVICES

Determine the root cause of problems

Evaluate the success of proposed retrofits

Evaluate new equipment purchases

Improve equipment efficiency

Help with environmental emission limits compliance

Reduce operating costs

PSL COMPETENCIESPSL COMPETENCIESPSL COMPETENCIESPSL COMPETENCIES

Extensive experience in industrial process model development and application

Ability to predict equipment behaviour for any configuration

Proven ability to optimise equipment, solve complex operating problems, and improve operator training

Leaders in real time process visualisation

PSL FOCUSPSL FOCUSPSL FOCUSPSL FOCUS

Recovery, Bark & Utility Boilers

Lime Kilns

Headboxes

Wood Kilns

Digesters

Ducts, Heaters & Precipitators

Hydrocyclones

PSL MODELLING STATEGYPSL MODELLING STATEGYPSL MODELLING STATEGYPSL MODELLING STATEGY

Use modelling as measurements resolution is low and environment too severe

Can evaluate “what if” scenarios

Supplements operator equipment knowledge

Assists mills to make informed decisions regarding upgrades to reduce risk

Provide comprehensive information and 3-D view of equipment

PSL TOOLSPSL TOOLSPSL TOOLSPSL TOOLS Licensed UBC technology - State of

the art process models for boilers, lime kilns, headboxes and digesters

Advanced combustion sub-models

Interactive viewing tools to show equipment behaviour in real-time virtual reality

Software to provide effective training

PSL CLIENTSPSL CLIENTSPSL CLIENTSPSL CLIENTS Weyerhaeuser

Canadian Forest Products

Anthony-Ross

Ahlstrom

Sandwell

Kværner

Georgia Pacific

Tasman Pulp

Weldwood of Canada Limited

---- drying

---- pyrolysis

---- char

---- smelt

Base Modified

RECOVERY BOILERSRECOVERY BOILERSRECOVERY BOILERSRECOVERY BOILERS

Verified solution algorithm

Black liquor combustion

Gas phase combustion

Advanced radiation

Convective section

Char bed

Carry-over predictions

ISSUES ADDRESSEDISSUES ADDRESSEDISSUES ADDRESSEDISSUES ADDRESSED

Improve flow and heat distribution

High excess air

Emissions: CO, CO2, TRS, NOx,

Mechanical carryover & plugging

Superheater and waterwall tube thermal stress failures

Boiler stability & capacity increase

CE Boiler ModelCE Boiler Model

B&W Boiler ModelB&W Boiler ModelDifferent aspects of model results have been validated against data from operating boilers

Different aspects of model results have been validated against data from operating boilers

MODEL VALIDATIONMODEL VALIDATIONMODEL VALIDATIONMODEL VALIDATION

Water model measurements

Full scale measurements

Temperature measurements at bullnose

Carryover prediction trends

CO emission trends

Velocity measurements

Y

Z

X

2001601401201008060402050

Modified Air System

Total Carryoverat Superheater0.03%

Carryovermass flux[g/s/m

2]

Y

Z

X

2001601401201008060402050

Carryovermass flux[g/s/m

2]

Base Case

Total Carryoverat Superheater4.06%

RETROFIT EXAMPLERETROFIT EXAMPLERETROFIT EXAMPLERETROFIT EXAMPLECarryover Mass Flux

RETROFIT EXAMPLERETROFIT EXAMPLERETROFIT EXAMPLERETROFIT EXAMPLE

Larger air ports provides better jet penetration

Increases gas mixing

Breaks up the vertical air core

Significantly reduces plugging rates

Reduces gas temperatures at superheater

BARK BOILER DELIVERBLESBARK BOILER DELIVERBLESBARK BOILER DELIVERBLESBARK BOILER DELIVERBLES Reduce operational costs

Improve overall thermal efficiency

Increase boiler capacity

Lower excess air

Improve gas mixing & combustion effectiveness

Minimize particulate carryover & unburned char

Minimize emission including CO and NOx

Optimize firing strategies for different loads/fuels

Analyze air and fuel system upgrade

Burners

Distributors

Overfire Ports

Undergrate Air

Upward gas velocity Upward gas velocity in a bark boilerin a bark boiler (1) base case (2) interlaced overfire air system

BARK BOILER EXAMPLEBARK BOILER EXAMPLEBARK BOILER EXAMPLEBARK BOILER EXAMPLE

Base Case Interlaced Case

HEADBOX MODEL CAPBILITYHEADBOX MODEL CAPBILITYHEADBOX MODEL CAPBILITYHEADBOX MODEL CAPBILITY Provide a powerful tool to

assist in design changes and optimisation

Provides detailed analysis to identify sheet-forming problems

Analyze flows inside a headbox by performing a complete simulation of the plenum, diffuser bank, and slice

Evaluate the effect of the approach and exit piping on the flow distribution

HEADBOX DELVERABLESHEADBOX DELVERABLESHEADBOX DELVERABLESHEADBOX DELVERABLES Decrease property variations

Improve paper quality

Analyze planned retrofits

Provide best available information to support management decisions

Optimise machine CD uniformity

Identify cause of flow non-uniformities

Suggest operational and design changes to meet production goals

HEADBOX DELVERABLESHEADBOX DELVERABLESHEADBOX DELVERABLESHEADBOX DELVERABLES

DIGESTER MODELSDIGESTER MODELSDIGESTER MODELSDIGESTER MODELS

First 3D liquid-solid two-phase digester model

Model coupled with the energy, conservation of species, and delignification

Curvilinear model with realistic set of boundary conditions

DIGESTER DELIVERABLESDIGESTER DELIVERABLESDIGESTER DELIVERABLESDIGESTER DELIVERABLES

Reduce risk in capital expenditures

Improve ROR

Reduce fibre property variations by controlling flows in the digester

Provide process information to solve corrosion

Improve process control and knowledge

Enhance equipment performance and reliability

ws0.00100.0002

-0.0006-0.0014-0.0021-0.0029-0.0037-0.0045-0.0053-0.0061-0.0069-0.0076-0.0084-0.0092-0.0100

Axial ChipVelocity

Cold BlowNozzles(15 l/s)

WashDischarge(25 l/s)

Upper CookDischarge(85 l/s)

QuenchDischarge(4 l/s) Extraction

Screens(42 l/s)

LowerCookScreens(120 l/s)

UpperCookScreens(85 l/s)

Lower CookDischarge(120 l/s)

Blowline

Chips (26.5 l/s)Liquor (40 l/s)

w0.00200.00150.00100.00050.0000

-0.0005-0.0010-0.0015-0.0020-0.0025-0.0030-0.0035-0.0040-0.0045-0.0050

AxialLiquorVelocity

Cold BlowNozzles(15 l/s)

WashDischarge(25 l/s)

Upper CookDischarge(85 l/s)

QuenchDischarge(4 l/s)

ExtractionScreens(42 l/s)

LowerCookScreens(120 l/s)

UpperCookScreens(85 l/s)

Lower CookDischarge(120 l/s)

Blowline

Chips (26.5 l/s)Liquor (40 l/s)

200187175162150137125112100877562503725

KappaNumber

Cold BlowNozzles(15 l/s)

WashDischarge(25 l/s)

Upper CookDischarge(85 l/s)

QuenchDischarge(4 l/s)

ExtractionScreens(42 l/s)

LowerCookScreens(120 l/s)

UpperCookScreens(85 l/s)

Lower CookDischarge(120 l/s)

Blowline

Chips (26.5 l/s)Liquor (40 l/s)

u-us0.0100.0090.0070.0060.0040.0030.0010.000

-0.001-0.003-0.004-0.006-0.007-0.009-0.010

SlipVelocity

Cold BlowNozzles(15 l/s)

WashDischarge(25 l/s)

Upper CookDischarge(85 l/s)

QuenchDischarge(4 l/s)

ExtractionScreens(42 l/s)

LowerCookScreens(120 l/s)

UpperCookScreens(85 l/s)

Lower CookDischarge(120 l/s)

Blowline

Chips (26.5 l/s)Liquor (40 l/s)

LIME KILNLIME KILNLIME KILNLIME KILN 3-D model to predict the flow, heat transfer, and

chemical species throughout kiln

Issues addressed improper secondary air flow distribution

flame shape

premature brick failure and overheat region

combustion efficiency and emissions

LIME KILNLIME KILNLIME KILNLIME KILN

[m]05101520

400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1900

Temperature distribution in the lime kiln

Temp[K]

WOOD KILNWOOD KILNWOOD KILNWOOD KILN

Determine the air flow and moisture distribution in wood kilns

Optimize kiln operations and improve wood quality

Automatic Vents Steam Spray

Load Baffle

Fan Deck Reversible Fan

Lumber Stack

Booster Coil

FLOW IN TAPERED PLENUMFLOW IN TAPERED PLENUMFLOW IN TAPERED PLENUMFLOW IN TAPERED PLENUM

p100.0

90.080.070.060.050.040.030.020.010.0

0.0

Base Case Tapered Plenum

PRESSURE

PSL SIMULATORSPSL SIMULATORSPSL SIMULATORSPSL SIMULATORS

ji

jjji

i

Sx

ux

Process Model

SimulatorSimulatorCoreCore

SimulatorSimulatorCoreCore

Physical Physical ModelModel

MeasurementsMeasurements

OperatorOperatorexperienceexperience

ProcessProcessknowledgeknowledge

OperationalOperationalSimulatorsSimulators

TrainingTrainingSimulatorsSimulators

Virtual Virtual CamerasCameras

C ha r B e d

B u llno s e

S u p e r-h e a terB a n k

G e ne ra to rB a n k

S p ra y

N eu ra l n etw o rk

Train in g D ata

V isu a l S im u la to r P ro d u c ts

P ro cessM od e lin g

D ifferent C onditions

N um erica l D ata Sets

D ata In te rp o la tio n

G U I In te r fa c e

P ro cessC am

C ha r B e d

B u lln os e

S u pe r-he a te rB a nk

G e n er a to rB a nk

S pr a y

N u m er ica l M o d e l

PROCESS SIMULATORSPROCESS SIMULATORSPROCESS SIMULATORSPROCESS SIMULATORS

SIMULATOR BENEFITSSIMULATOR BENEFITSSIMULATOR BENEFITSSIMULATOR BENEFITS Simplified technology transfer

Reduce equipment operating costs

Provide more rapid solutions

Improve operator training and safety

Modelling available in “real time”

“What If” mode of operator interaction

Reduce variability in operations

VIRTUAL CAMERAVIRTUAL CAMERAVIRTUAL CAMERAVIRTUAL CAMERA

3-D view of process occurring

Immediate and easy way to see effect of input variations on flow, temperatures, chemical species, combustion

Compliments, enhances, and challenges ways to view process

TRAINING TOOLTRAINING TOOLTRAINING TOOLTRAINING TOOL Operators can understand why some modes of

operation are better than others

Provide insight that would be impossible to obtain with traditional methods

Enable realistic training outside the envelope of parameters characterizing normal operation

New training scenarios can be programmed remotely

Shorten startups

VIEWER EXAMPLE:VIEWER EXAMPLE:Look at different states interactivelyLook at different states interactively

VIEWER EXAMPLE:VIEWER EXAMPLE:Look at different states interactivelyLook at different states interactively

VIEWER EXAMPLE:VIEWER EXAMPLE:Easy animation of flow and fuel combustion stateEasy animation of flow and fuel combustion state

VIEWER EXAMPLE:VIEWER EXAMPLE:Easy animation of flow and fuel combustion stateEasy animation of flow and fuel combustion state

VIEWER EXAMPLE:VIEWER EXAMPLE:Comparison of 8 states with synopsisComparison of 8 states with synopsis

VIEWER EXAMPLE:VIEWER EXAMPLE:Comparison of 8 states with synopsisComparison of 8 states with synopsis