innovative equipment solutions using state of the art process modelling tecnologies process...
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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 [email protected]
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