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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
Industrial Process Modeling

Dave Stropky, VP Research

Process Simulations Ltd.

206-2386 East Mall, Vancouver, BC, Canada

www.psl.bc.ca

contents
Contents

Introduction to PSL

3D Process Modeling

Process Modeling Information

Industrial Applications

process simulations ltd
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

industrial projects since 1997

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 advantages

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
3 d cfd

PROCESS MODELING

3D CFD

IN

OUT

OUT

Principle of Conservation

Mass

Momentum

Energy

…….

IN = OUT

slide8

PROCESS MODELING

3D CFD Modeling Examples

Weather

Buildings

Jet engines

Harrier jet

Industrial Equipment

slide9

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

recovery boilers

INDUSTRIAL APPLICATONS

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

INDUSTRIAL APPLICATONS

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

INDUSTRIAL APPLICATONS

PreCalciners
  • Meal Injection
  • NOx Reduction
  • Gas Flow Distributions
  • Fuel combustion
  • Emissions
  • Temperature Profiles
  • Operational Optimization
digesters

INDUSTRIAL APPLICATONS

Digesters

Lignin

Mass Fraction

Carbohydrates

Mass Fraction

Kappa

Number

Chip

Compaction

  • Chip injection
  • Flow uniformity
  • Chip uniformity
  • Wash/screen effects
wastewater lagoons

INDUSTRIAL APPLICATONS

Wastewater Lagoons
  • Flow patterns
  • Residence Time Distributions
  • Biological Models
precipitators

INDUSTRIAL APPLICATONS

Precipitators
  • Flow Distribution
  • Efficiency
  • Baffle Design
  • Inlet/outlet ducting
  • Screen Design
  • Egg Crates
cyclones

INDUSTRIAL APPLICATONS

Cyclones
  • Flow Distribution
  • Particle Distribution
  • Efficiency
  • Inlet ducting
kilns

INDUSTRIAL APPLICATONS

Kilns
  • Flame Profile
  • Calcination
  • Brick Failure/Heat Load
  • Alternate Fuels
  • Air/Fuel Ratios
  • Burner Design
  • NCG Injection
  • Emissions
kilns26

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

process modeling advantages

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