PROCESS SIMULATIONS LTD.

slipperhangingAI and Robotics

Nov 14, 2013 (3 years and 11 months ago)

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PROCESS SIMULATIONS LTD.


INNOVATIVE EQUIPMENT SOLUTIONS


USING STATE OF THE ART


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

PROCESS
R&D
VALIDATION
INDUSTRIAL
APPLICATION
PROCESSCAM
WOOD KILNS



GASIFIERS

DIGESTERS


LIME KILNS




SETTLING TANKS

HEADBOXES



SCREENS


HYDROCYCLONES



PRECIPITATORS/HEATERS

POWER BOILERS




RECOVERY BOILERS



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

Gasifiers

Validation

Equipment

Screens

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



-


NCG INJECTION

No NCG

With NCG

Reduced
Heat

INFLUENCE OF BURNER ANGLE

AND EXCESS AIR

SIMULATION AND TRAINING

PROCESSCAM TECHNOLOGY

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3
-
D Model

Simulator

Core

Physical

Model

Measurements

Operator

experience

Process

knowledge

Operational

Simulators

Training

Simulators

Virtual

Cameras

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Visual Simulator
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Process
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Numerical Data Sets
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GUI
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ProcessCam
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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

FOR INFORMATION, SERVICE
REQUESTS, OR PRODUCTS


www.psl.bc.ca


Brochures, Movies, Presentations


Services and ProcessCam Products


Email to
info@psl.bc.ca


Tel: (604) 822
-
1940