INNOVATIVE EQUIPMENT SOLUTIONS USING STATE OF THE ART PROCESS MODELLING TECNOLOGIES Process Simulations Limited

PSL CONTACT l Mail 1938 Western Parkway, Vancouver, BC V6T 1V5 l Phone l l Webwww.psl.bc.ca

PSL VALUE STATEMENT Create real value to our clients by l Providing expert consulting for addressing complex operational problems using process simulation technology l Supplying user-friendly tools to help optimize processes and improve operator training l Delivering improved hardware components

PSL CONSULTING SERVICES l Determine the root cause of problems l Evaluate the success of proposed retrofits l Evaluate new equipment purchases l Improve equipment efficiency l Help with environmental emission limits compliance l Reduce operating costs

PSL COMPETENCIES l Extensive experience in industrial process model development and application l Ability to predict equipment behaviour for any configuration l Proven ability to optimise equipment, solve complex operating problems, and improve operator training l Leaders in real time process visualisation

PSL FOCUS l Recovery, Bark & Utility Boilers l Lime Kilns l Headboxes l Wood Kilns l Digesters l Ducts, Heaters & Precipitators l Hydrocyclones

PSL MODELLING STATEGY l Use modelling as measurements resolution is low and environment too severe l Can evaluate “what if” scenarios l Supplements operator equipment knowledge l Assists mills to make informed decisions regarding upgrades to reduce risk l Provide comprehensive information and 3-D view of equipment

PSL TOOLS l Licensed UBC technology - State of the art process models for boilers, lime kilns, headboxes and digesters l Advanced combustion sub-models l Interactive viewing tools to show equipment behaviour in real-time virtual reality l Software to provide effective training

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

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

ISSUES ADDRESSED l Improve flow and heat distribution l High excess air l Emissions: CO, CO2, TRS, NOx, l Mechanical carryover & plugging l Superheater and waterwall tube thermal stress failures l Boiler stability & capacity increase

CE Boiler Model B&W Boiler Model Different aspects of model results have been validated against data from operating boilers MODEL VALIDATION l Water model measurements l Full scale measurements l Temperature measurements at bullnose l Carryover prediction trends l CO emission trends l Velocity measurements

RETROFIT EXAMPLE Carryover Mass Flux

RETROFIT EXAMPLE l Larger air ports provides better jet penetration l Increases gas mixing l Breaks up the vertical air core l Significantly reduces plugging rates l Reduces gas temperatures at superheater

BARK BOILER DELIVERBLES l Reduce operational costs l Improve overall thermal efficiency l Increase boiler capacity l Lower excess air l Improve gas mixing & combustion effectiveness l Minimize particulate carryover & unburned char l Minimize emission including CO and NOx l Optimize firing strategies for different loads/fuels l Analyze air and fuel system upgrade

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

HEADBOX MODEL CAPBILITY l Provide a powerful tool to assist in design changes and optimisation l Provides detailed analysis to identify sheet- forming problems l Analyze flows inside a headbox by performing a complete simulation of the plenum, diffuser bank, and slice l Evaluate the effect of the approach and exit piping on the flow distribution

HEADBOX DELVERABLES l Decrease property variations l Improve paper quality l Analyze planned retrofits l Provide best available information to support management decisions l Optimise machine CD uniformity l Identify cause of flow non-uniformities l Suggest operational and design changes to meet production goals

HEADBOX DELVERABLES

DIGESTER MODELS l First 3D liquid-solid two-phase digester model l Model coupled with the energy, conservation of species, and delignification l Curvilinear model with realistic set of boundary conditions

DIGESTER DELIVERABLES l Reduce risk in capital expenditures l Improve ROR l Reduce fibre property variations by controlling flows in the digester l Provide process information to solve corrosion l Improve process control and knowledge l Enhance equipment performance and reliability

LIME KILN l 3-D model to predict the flow, heat transfer, and chemical species throughout kiln l Issues addressed l improper secondary air flow distribution l flame shape l premature brick failure and overheat region l combustion efficiency and emissions

LIME KILN

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

FLOW IN TAPERED PLENUM PRESSURE

PSL SIMULATORS j i j jji i S x u x                 Process ModelSimulatorCoreSimulatorCore PhysicalModel Measurements OperatorexperienceProcessknowledge OperationalSimulators TrainingSimulators VirtualCameras

PROCESS SIMULATORS

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

VIRTUAL CAMERA l 3-D view of process occurring l Immediate and easy way to see effect of input variations on flow, temperatures, chemical species, combustion l Compliments, enhances, and challenges ways to view process

TRAINING TOOL l Operators can understand why some modes of operation are better than others l Provide insight that would be impossible to obtain with traditional methods l Enable realistic training outside the envelope of parameters characterizing normal operation l New training scenarios can be programmed remotely l Shorten startups

VIEWER EXAMPLE: Look at different states interactively

VIEWER EXAMPLE: Easy animation of flow and fuel combustion state

VIEWER EXAMPLE: Comparison of 8 states with synopsis