PROCESS SIMULATIONS LTD. INNOVATIVE EQUIPMENT SOLUTIONS INNOVATIVE EQUIPMENT SOLUTIONS USING STATE OF THE ART USING STATE OF THE ART PROCESS MODELING TECHNOLOGIES PROCESS MODELING TECHNOLOGIES

PSL PROCESS MODELING TECHNOLOGIES PSL addresses and solves – equipment design problems, operational performance, operator training, environmental compliance, and safety issues by applying modeling technologies to provide – critical insight and internal views of the process – graphical representation of functional relationships between process variables and input to reduce cost and increase profits

BENEFITS OF ADVANCED PROCESS MODELING Reduce operating costs Increase quality and quantity Environmental compliance Increases reliability of equipment Determine the root cause of problems Evaluate success of proposed retrofits Can evaluate “what if” scenarios

DIRECT BENEFIT EXAMPLES Reduced unscheduled shutdowns – Recovery boiler: avoid water wash (0.5 million) Achieve environmental compliance – Power boiler: reduced emission and particulate Reduce operational costs – Lime kiln: avoid brick replacement (1 million) Improve operation – Digester: better temperature distribution (more uniform cook)

PSL PROCESS TOOLS Licensed UBC technology – State of the art 3-D process models Advanced specific sub-models for equipment Interactive viewing tools to show equipment behavior in real-time virtual reality All models developed in-house (source code)

PSL LEADER IN 3-D PROCESS MODELING Extensive experience in industrial process model development and application Proven ability to optimize equipment, solve complex operating problems, and improve operating training Leaders in real time process visualization Strong focus in industrial equipment in primary sector

USAGE OF PSL PROCESS MODELING TECHNOLOGIES Retrofits and New Equipment – reduce capital investment risks – testing of design before committing funds Process Engineering – determine and solve immediate problems – training of operators & reduce variations Corporate Headquarters – relate variation of equipment performance for different plants – converge faster to optimal usage of capital and human resources among various plants

PSL HISTORY 1986 to present – UBC modeling group (pulp and paper applications) 1993 – PSL Incorporated – Recovery Boilers 1995 – Bark boilers, Hydrocyclones 1998 – Headboxes, Lime kilns, Wood Kilns, Power Boilers 1999 – Digesters, PSL ProcessCam Technology 2000 – Gasifiers, Clarifiers, Training

3-D PROCESS MODELING

PSL CLIENTS PULP & PAPER Weyerhaeuser Canadian Forest Products Anthony-Ross IAE Kværner Georgia Pacific Tasman Pulp Sandwell Weldwood Ahlstrom

EQUIPMENT Recovery Boilers Bark Boilers Power Boilers Lime Kilns Wood Kilns Digesters Headboxes Clarifiers Hydrocyclones Simulators GasifiersValidation EquipmentScreens

LIME KILN 3-D steady-state lime kiln process model to predict the flow, heat transfer in the lime kiln, and product Use the model to solve problems in kiln operation and design Primary Air Secondary Air Gas/Oil Firehood Burner Motor Chains Limestone CaCO 3 Lime CaO DRYING ZONE CALCINING ZONE BURNING ZONE COOLING ZONE

? CONCERNING ISSUES Kiln efficiency Lower fuel costs Burner characteristics Refractory life Dams and rings Stable operation Flame shape and position Lower residual carbonate

WHY USE KILN 3-D MODELING Model provides comprehensive information throughout kiln at relatively low cost Can evaluate “what if” scenarios to improve operation Supplements operator knowledge of lime kiln operations Assists mill managers in making decisions regarding kiln refits/replacements Assists manufactures in optimizing burner and kiln designs

MODEL PREDICTIONS Gas flow velocity fields Temperature distributions and heat transfer to wall surfaces and mud Gas species (e.g. H 2, O 2, N 2, CO, CO 2, H 2 O, CH 4 ) distributions Pollutant emissions (e.g. NOx, TRS) Oil or solid fuel (tires, coke, coal) combustion and droplet trajectory Particulate emissions

MODEL PREDICTIONS Burner type/settings influence Flame shape (with thermal buoyancy effects) Aerodynamic and thermal influence of NCG Chemical species distribution Heat release profile to product Field calculations at >100,000 interior points Detailed gas flow mixing and aerodynamics Hood shape and secondary air ports influence Primary/Secondary/Fuel ratio influence

VALUE AND BENEFITS Validated and coupled combustion, convection, diffusion, and radiation models provide significantly more realistic solutions than non-thermal physical or mathematical models. Resulting predictions are used to: – Identify and eliminate poor combustion conditions. Reduce fuel consumption by optimizing kiln efficiency – Adjust Primary/Secondary/Fuel ratio and burner settings to maximize kiln efficiency

VALUE AND BENEFITS Identify and eliminate thermal hot spots that lead to reduced brick liner lifetime Use results to develop strategies for reducing ring formation Identify and fix problems with kiln performance due to hood shape and secondary air ports location/size Evaluate NCG injection alternatives - optimize injection

VALUE AND BENEFITS Evaluate alternative fuels Minimize Emissions Optimize heat transfer to mud Couple to PSL’s user-friendly simulator technology to provide excellent technology transfer and training for operators

EXCESS AIR, WALL HEAT, AND FUME HOOD Normal Excess Air Low Excess Air Wall Heat Transfer Particle Animation

TEMPERATURE PROFILES

VELOCITY PROFILES

FLAME PROFILE

BURNER ANGLE 0º -5º

NCG INJECTION No NCG With NCG Reduced Heat

INFLUENCE OF BURNER ANGLE AND EXCESS AIR

SIMULATION AND TRAINING

PROCESSCAM TECHNOLOGY j i j jji i S x u x                 3-D ModelSimulatorCoreSimulatorCore PhysicalModel Measurements OperatorexperienceProcessknowledge OperationalSimulators TrainingSimulators VirtualCameras

PROCESSCAM TECHNOLOGY

PROCESSCAM BENEFITS Simplified technology transfer Reduce equipment operating costs Provide more rapid solutions Improve operator training and safety Modeling available in “real time” “What If” mode of operator interaction Reduce variability in operations

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

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

INPUT CONTROLS & 3D VIEWER

CONCLUSIONS Process modelling can significantly improve industrial processes – reduce cost; increase profits More opportunities than those currently being pursued Increased reliance in process modelling technologies for equipment design and operation

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