PaperMac and FlowMac in a largemill balanceØivind Opdal

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Content

▪ Mill project▪ PaperMac▪ FlowMac▪ Model validation▪ How we use the models in the project▪ Output from the models

▪ Show models

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Norske Skog

▪ Started as process engineer at Skogn 1991▪ Responsible for lab at Union from 1993-

1995▪ Process engineer at Union from 1996-2000▪ Joined NS R&D 2000▪ Process simulation has been my major tool

since 1996▪ Last years: 20% IT for TSD and 80%

simulation

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Ongoing Mill project

▪ Reduce production cost and improve paper quality.▪ Redesign of Mill layout.▪ Rebuilds/upgrades on Paper machines.▪ Increase DIP capacity.▪ Upgrades of TMP-lines.▪ Meet a new effluent permit.

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The FlowMac Model

▪ Have been developed over several years▪ Contains more than 11000 blocks.▪ First make a model of the mill as it is▪ Redesign and create a new layout

– Mass balances: water, fibre and energy

▪ Evaluate process design and operational possibilities and limitations with the new design– Flowmeetings

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Overview layout

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Evaluate process design

▪ Have weekly meetings with the Mill:– Visits or by using MS Netmeeting– We have a dynamic task list generated by the project

or superintendents– Results from this process are then given to the

engineering company for further study or implementation.

▪ For process evaluation we use the complete mill model, and also sub-models.

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FlowMac sub-models, so far

▪ TMP-line▪ Heat recovery and its connections▪ Boiler-house▪ DIP-plant

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Mass balances

▪ To define the new furnish mix we used PaperMac to model the future paper quality:– Made models of the different Paper machines– Validated the models towards present grade quality– Used the new furnish mix as input in the overall mill

model.

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Validation of Flowmac-models

▪ Hard work for the lab!▪ Data I use:

– Production data: tonne/hour– Consistency– Temperature– Ash– COD (or preferably COD-components)

▪ Time consuming….

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New furnishes for the PM

▪ How much filler could each paper machine take?▪ Mixture of fibre:

– TMP/DIP

▪ We used PaperMac to “answer” these questions…

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Simplified model

TMP

GWD

Market pulp

Bleaching

Energy

Energy

StarchOBADyes

Filler(s) Calander Paper

Broke

Anisotropy(measure MD and

CD properties)

KraftCTMPRMP

MachineSoft Super

- Hydrex- Alphatex- Pergopak HP - Martifill- Martipaque- Clay - Titanium dioxide - GCC, HC-HO - GCC, HO-65K - GCC, HC-HP - PCC, F-R120 - Intracarb 60 - Hydrocarb 60ME - Hydrocarb HOMEK

PeroxideHydrosulfite

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PaperMac models

▪ Have excluded most of the volumes (tanks, towers++)– Speeds up the simulation

▪ Include all major contributors to the paper quality

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Our basis for simulation of paper properties▪ Ideas from Professor Douglas Wahren and Lars

Nyborg▪ The Kubelka-Munk equations▪ SCAN G5:94 Basic equations for optical properties▪ Laboratory trials▪ Verify the models by utilisation of regular

measurements in the mills▪ Verify with full scale trials when and if full scale

trials is conducted▪ Only Statistically significant relationships are taken

into the model

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Validation, present grades PM1

5.004.815.084.975.075.07b*

-0.31-0.28-0.33-0.31-0.33-0.33a*

83.683.1783.6883.283.7283.32L*

0.190.390.310.310.340.26DeltaE

94.3594.193.192.992.1791.8Opacity, %

58.658.158.7585958.1ISO Bright, %

286288258268240258Tear CD, mN

32.9532.9833.03Tensile L/T

280127902574250024322370Tensile, N/m

7473.36868.16564.4Tykkelse, my

661661659657657657Density, kg/m3

9.49.49.49.49.49.4Moisture, %

48.848.445.044.742.542.2BW, g/m2

1515171718.819Broke, %

000000DIP, %

000000Filler, %

50/5010050/5010050/50100TM2A+B, %

000000TM1, %

00.400.702.9Kraft, %

SimulationMillSimulationMillSimulationMill

PM1 48.8PM1 48.8PM1 45 PM1 45 PM1 42.5 PM1 42.5

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Outputs from the work so far

▪ All models are available for the mill as Extend RunTime or Player versions.

▪ Dimensioning of new Disc Filters.▪ New water management

– We use the Flowmac model to illustrate and to test the new control strategy.

▪ Proposed a number of changes in TMP rebuild:– Avoid high temperature in chip wash and scrubber– Heat recovery system– Process changes to improve operational flexibility

(Location and size of tanks, capacity of pumps and pipings)

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Showtime…

▪ The big mill model▪ A PaperMac model▪ Boilerhouse sub-model

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Flowmac, well suited for:

▪ Decision support▪ Accumulation of knowledge