INNOVATIVE EQUIPMENT SOLUTIONS USING STATE OF THE ART PROCESS MODELLING TECNOLOGIES

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 604-222-0901 • Email information@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 B&W 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

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 Reversible Fan • Determine the air flow and moisture distribution in wood kilns • Optimize kiln operations and improve wood quality Fan Deck Automatic Vents Steam Spray Lumber Stack Booster Coil Load Baffle

27. FLOW IN TAPERED PLENUM PRESSURE

28. f ¶ æ ö ¶ j r f ç u ÷ S - G = ç ÷ i j j j x x ¶ ¶ è ø i i Process Model 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 EXAMPLE:Look at different states interactively

34. VIEWER EXAMPLE:Easy animation of flow and fuel combustion state

35. VIEWER EXAMPLE:Comparison of 8 states with synopsis