INNOVATIVE EQUIPMENT SOLUTIONS

1
Process Simulations Limited
INNOVATIVE EQUIPMENT SOLUTIONS USING STATE OF
THE ART PROCESS MODELLING TECNOLOGIES
2
PSL CONTACT

• Mail 1938 Western Parkway, Vancouver, BC V6T
  1V5
• Phone [phone]
• Email information_at_psl.bc.ca
• Web www.psl.bc.ca

3
PSL 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

4
PSL 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

5
PSL 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

6
PSL FOCUS

• Recovery, Bark Utility Boilers
• Lime Kilns
• Headboxes
• Wood Kilns
• Digesters
• Ducts, Heaters Precipitators
• Hydrocyclones

7
PSL 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

8
PSL 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

9
PSL CLIENTS

• Weyerhaeuser
• Canadian Forest Products
• Anthony-Ross
• Ahlstrom
• Sandwell
• Kværner
• Georgia Pacific
• Tasman Pulp
• Weldwood of Canada Limited

10
RECOVERY BOILERS

• Verified solution algorithm
• Black liquor combustion
• Gas phase combustion
• Advanced radiation
• Convective section
• Char bed
• Carry-over predictions

11
ISSUES 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

12
MODEL VALIDATION

• Water model measurements
• Full scale measurements
• Temperature measurements at bullnose
• Carryover prediction trends
• CO emission trends
• Velocity measurements

CE Boiler Model
BW Boiler Model
Different aspects of model results have been
validated against data from operating boilers
13
RETROFIT EXAMPLE
Carryover Mass Flux
14
RETROFIT 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

15
BARK 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

16
BARK BOILER EXAMPLE
Upward gas velocity in a bark boiler (1)
base case (2) interlaced overfire air system
Base Case
Interlaced Case
17
HEADBOX 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

18
HEADBOX 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

19
HEADBOX DELVERABLES
20
DIGESTER 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

21
DIGESTER 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

22
(No Transcript)
23
(No Transcript)
24
LIME 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

25
LIME KILN
26
WOOD KILN

• Determine the air flow and moisture distribution
  in wood kilns
• Optimize kiln
  operations and
  improve
  wood quality

Reversible Fan
Fan Deck
Automatic Vents
Steam Spray
Lumber
Stack
Load Baffle
Booster Coil
27
FLOW IN TAPERED PLENUM
PRESSURE
28
PSL SIMULATORS
Operator experience
Process knowledge
Operational Simulators
Simulator Core
Training Simulators
Measurements
Virtual Cameras
Physical Model
29
PROCESS SIMULATORS
30
SIMULATOR 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

31
VIRTUAL 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

32
TRAINING 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

33
VIEWER EXAMPLELook at different states
interactively
34
VIEWER EXAMPLEEasy animation of flow and fuel
combustion state
35
VIEWER EXAMPLEComparison of 8 states with
synopsis