papermac and flowmac in a large mill balance and flowmac in a... · dip, % 0 0 0 0 0 0 filler, % 0...
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PaperMac and FlowMac in a largemill balanceØivind Opdal
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Content
▪ Mill project▪ PaperMac▪ FlowMac▪ Model validation▪ How we use the models in the project▪ Output from the models
▪ Show models
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Norske Skog
▪ Started as process engineer at Skogn 1991▪ Responsible for lab at Union from 1993-
1995▪ Process engineer at Union from 1996-2000▪ Joined NS R&D 2000▪ Process simulation has been my major tool
since 1996▪ Last years: 20% IT for TSD and 80%
simulation
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Ongoing Mill project
▪ Reduce production cost and improve paper quality.▪ Redesign of Mill layout.▪ Rebuilds/upgrades on Paper machines.▪ Increase DIP capacity.▪ Upgrades of TMP-lines.▪ Meet a new effluent permit.
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The FlowMac Model
▪ Have been developed over several years▪ Contains more than 11000 blocks.▪ First make a model of the mill as it is▪ Redesign and create a new layout
– Mass balances: water, fibre and energy
▪ Evaluate process design and operational possibilities and limitations with the new design– Flowmeetings
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Overview layout
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Evaluate process design
▪ Have weekly meetings with the Mill:– Visits or by using MS Netmeeting– We have a dynamic task list generated by the project
or superintendents– Results from this process are then given to the
engineering company for further study or implementation.
▪ For process evaluation we use the complete mill model, and also sub-models.
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FlowMac sub-models, so far
▪ TMP-line▪ Heat recovery and its connections▪ Boiler-house▪ DIP-plant
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Mass balances
▪ To define the new furnish mix we used PaperMac to model the future paper quality:– Made models of the different Paper machines– Validated the models towards present grade quality– Used the new furnish mix as input in the overall mill
model.
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Validation of Flowmac-models
▪ Hard work for the lab!▪ Data I use:
– Production data: tonne/hour– Consistency– Temperature– Ash– COD (or preferably COD-components)
▪ Time consuming….
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New furnishes for the PM
▪ How much filler could each paper machine take?▪ Mixture of fibre:
– TMP/DIP
▪ We used PaperMac to “answer” these questions…
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Simplified model
TMP
GWD
Market pulp
Bleaching
Energy
Energy
StarchOBADyes
Filler(s) Calander Paper
Broke
Anisotropy(measure MD and
CD properties)
KraftCTMPRMP
MachineSoft Super
- Hydrex- Alphatex- Pergopak HP - Martifill- Martipaque- Clay - Titanium dioxide - GCC, HC-HO - GCC, HO-65K - GCC, HC-HP - PCC, F-R120 - Intracarb 60 - Hydrocarb 60ME - Hydrocarb HOMEK
PeroxideHydrosulfite
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PaperMac models
▪ Have excluded most of the volumes (tanks, towers++)– Speeds up the simulation
▪ Include all major contributors to the paper quality
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Our basis for simulation of paper properties▪ Ideas from Professor Douglas Wahren and Lars
Nyborg▪ The Kubelka-Munk equations▪ SCAN G5:94 Basic equations for optical properties▪ Laboratory trials▪ Verify the models by utilisation of regular
measurements in the mills▪ Verify with full scale trials when and if full scale
trials is conducted▪ Only Statistically significant relationships are taken
into the model
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Validation, present grades PM1
5.004.815.084.975.075.07b*
-0.31-0.28-0.33-0.31-0.33-0.33a*
83.683.1783.6883.283.7283.32L*
0.190.390.310.310.340.26DeltaE
94.3594.193.192.992.1791.8Opacity, %
58.658.158.7585958.1ISO Bright, %
286288258268240258Tear CD, mN
32.9532.9833.03Tensile L/T
280127902574250024322370Tensile, N/m
7473.36868.16564.4Tykkelse, my
661661659657657657Density, kg/m3
9.49.49.49.49.49.4Moisture, %
48.848.445.044.742.542.2BW, g/m2
1515171718.819Broke, %
000000DIP, %
000000Filler, %
50/5010050/5010050/50100TM2A+B, %
000000TM1, %
00.400.702.9Kraft, %
SimulationMillSimulationMillSimulationMill
PM1 48.8PM1 48.8PM1 45 PM1 45 PM1 42.5 PM1 42.5
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Outputs from the work so far
▪ All models are available for the mill as Extend RunTime or Player versions.
▪ Dimensioning of new Disc Filters.▪ New water management
– We use the Flowmac model to illustrate and to test the new control strategy.
▪ Proposed a number of changes in TMP rebuild:– Avoid high temperature in chip wash and scrubber– Heat recovery system– Process changes to improve operational flexibility
(Location and size of tanks, capacity of pumps and pipings)
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Showtime…
▪ The big mill model▪ A PaperMac model▪ Boilerhouse sub-model
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Flowmac, well suited for:
▪ Decision support▪ Accumulation of knowledge