Dave Stropky, VP Research Process Simulations Ltd East Mall, Vancouver, BC, Canada Industrial Process Modeling

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

Process Simulations Ltd 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

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

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

3D Process Modeling

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

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

PROCESS MODELING Process Modeling Stages INPROGRESSINDUSTRIALAPPLICATION 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 INITIALSTAGE

3D Process Modeling Information

3D Display 3D MODEL INFORMATION

Contour/Vector Planes 3D MODEL INFORMATION

Surface Plots 3D MODEL INFORMATION

Isosurface Plots 3D MODEL INFORMATION

Fuel/Air Distributions 3D MODEL INFORMATION

Integrated Information 3D MODEL INFORMATION

Industrial Applications

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

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

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

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

Wastewater Lagoons INDUSTRIAL APPLICATONS Flow patterns Residence Time Distributions Biological Models

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

Cyclones INDUSTRIAL APPLICATONS Flow Distribution Particle Distribution Efficiency Inlet ducting

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

Kilns INDUSTRIAL APPLICATONS lMulti-layer refractory heat transfer model lHeat transfer and lime calcination CaCO 3 = CaO + CO 2 Heat absorbed MJ/kg CaCO

Kilns: Input Data INDUSTRIAL APPLICATONS GEOMETRY

Kilns: Input Data INDUSTRIAL APPLICATONS BURNER GEOMETRY

Kilns: Input Data INDUSTRIAL APPLICATONS REFRACTORY

Kilns: Operational Data INDUSTRIAL APPLICATONS DCS Data Analysis

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

Kilns: Balance Sheets INDUSTRIAL APPLICATONS Energy/Mass Balance

Process Modeling Advantages 3D MODEL INFORMATION  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