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Industrial Process Modeling

Industrial Process Modeling. Dave Stropky, VP Research Process Simulations Ltd. 206-2386 East Mall, Vancouver, BC, Canada www.psl.bc.ca. Contents. Introduction to PSL 3D Process Modeling Process Modeling Information Industrial Applications. Process Simulations Ltd.

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Industrial Process Modeling

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  1. Industrial Process Modeling Dave Stropky, VP Research Process Simulations Ltd. 206-2386 East Mall, Vancouver, BC, Canada www.psl.bc.ca

  2. Contents Introduction to PSL 3D Process Modeling Process Modeling Information Industrial Applications

  3. Process Simulations Ltd. 1986 UBC modeling group (pulp and paper) 1993 PSL Incorporated, Recovery Boiler Model 1995 Bark boilers, Hydrocyclones 1998 Headboxes, Lime kilns, Wood Kilns 1999 Digesters 2000 Gasifiers, Clarifiers 2001 Cement Kilns, Coal Fired Boilers 2002 Precipitators, BFB Boilers 2003 Lagoons 2004 Calciners 2006 Multiphase fluidized beds

  4. PSL INTRODUCTION Industrial Projects Since 1997 • 89 Recovery Boilers • 25 Bark/Biomass/Power Boilers • 13 Lime Kilns • 3 Headboxes • 4 Precipitators • 5 Cement Kilns • 4 Gasifiers • 1 Precalciner • 2 Wastewater Lagoons • 10 Others

  5. PSL INTRODUCTION PSL Advantages • Independent Analysis • Advanced & Validated Computer Models. UBC connection. • Equipment equipment-specific submodels to predict the behavior of complex processes • Combustion and Flow Analysis Expertise • Advanced, Intuitive, Interactive 3-D display and analysis technologies • Broad Industrial Application Experience

  6. 3D ProcessModeling

  7. PROCESS MODELING 3D CFD IN OUT OUT Principle of Conservation Mass Momentum Energy ……. IN = OUT

  8. PROCESS MODELING 3D CFD Modeling Examples Weather Buildings Jet engines Harrier jet Industrial Equipment

  9. PROCESS MODELING INITIAL STAGE IN PROGRESS INDUSTRIAL APPLICATION Literature review Plant\Mill interaction Process knowledge Commitment of industry Physical model Numerical model Model development Model validation Industrial testing Problem Solving Model proposed retrofits Alternate Fuels Equipment Optimization Cost Reduction Process Modeling Stages

  10. 3D Process Modeling Information

  11. 3D MODEL INFORMATION 3D Display

  12. 3D MODEL INFORMATION Contour/Vector Planes

  13. 3D MODEL INFORMATION Surface Plots

  14. 3D MODEL INFORMATION Isosurface Plots

  15. 3D MODEL INFORMATION Fuel/Air Distributions

  16. 3D MODEL INFORMATION Integrated Information

  17. IndustrialApplications

  18. INDUSTRIAL APPLICATONS Recovery Boilers • Air System Design • Liquor Injection • Carryover/Plugging • Wall Corrosion • Tube Cracking • Steam Production • Boiler load • Burner Design • NCG Injection • Emissions

  19. INDUSTRIAL APPLICATONS Bark Boilers • Air System Design • Fuel Injection • Carryover • Wall Corrosion • Steam Production • Boiler load • Grate Design • NCG Injection • Emissions

  20. INDUSTRIAL APPLICATONS PreCalciners • Meal Injection • NOx Reduction • Gas Flow Distributions • Fuel combustion • Emissions • Temperature Profiles • Operational Optimization

  21. INDUSTRIAL APPLICATONS Digesters Lignin Mass Fraction Carbohydrates Mass Fraction Kappa Number Chip Compaction • Chip injection • Flow uniformity • Chip uniformity • Wash/screen effects

  22. INDUSTRIAL APPLICATONS Wastewater Lagoons • Flow patterns • Residence Time Distributions • Biological Models

  23. INDUSTRIAL APPLICATONS Precipitators • Flow Distribution • Efficiency • Baffle Design • Inlet/outlet ducting • Screen Design • Egg Crates

  24. INDUSTRIAL APPLICATONS Cyclones • Flow Distribution • Particle Distribution • Efficiency • Inlet ducting

  25. INDUSTRIAL APPLICATONS Kilns • Flame Profile • Calcination • Brick Failure/Heat Load • Alternate Fuels • Air/Fuel Ratios • Burner Design • NCG Injection • Emissions

  26. INDUSTRIAL APPLICATONS Kilns • Multi-layer refractory heat transfer model • Heat transfer and lime calcination CaCO3 = CaO + CO2 Heat absorbed 1.679 MJ/kg CaCO3 @1089K

  27. INDUSTRIAL APPLICATONS Kilns: Input Data GEOMETRY

  28. INDUSTRIAL APPLICATONS Kilns: Input Data BURNER GEOMETRY

  29. INDUSTRIAL APPLICATONS Kilns: Input Data REFRACTORY

  30. INDUSTRIAL APPLICATONS Kilns: Operational Data DCS Data Analysis

  31. INDUSTRIAL APPLICATONS Kilns: Operational Data Fuel/Feed/Air Data Analysis

  32. INDUSTRIAL APPLICATONS Kilns: Balance Sheets Energy/Mass Balance

  33. 3D MODEL INFORMATION Process Modeling Advantages • Advanced, intuitive, interactive visual representation of industrial processes based on basic laws of physics • Software can be used to rapidly analyze and rectify process problems, or to create virtual equipment for operator training • Provides engineers and operators with significantly more information for analyzing equipment operations than is currently available • Reduced risk on retrofits and large capital expenditures • Allows for more informed recommendations for operational and design changes • Better equipment performance and reliability • Increased knowledge for operators, engineers, and managers leads to optimized equipment design and operation and ultimately to reduced operational and maintenance costs

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