1. How to Apply Simulation in the Real World
Tier 3
How to Apply Simulation in the Real World

2. Statement of Intent Statement of intent
In this section an open – ended problem will be presented. Since this kind of problem can be solved from different points of view, some of them will be discussed in the following sections.

3. Structure of tier 3 Contents Approach to Open – ended problem
Case of Study.

4. Open – Ended Problems General concepts
An open – ended problem is one which does not have a single right answer.
Usefulness of open – ended problems:
Similar to most important real – world problems.
Develop creative divergent thinking skills.

5. How to approach open – ended problems
General concepts
How to approach open – ended problems
State the problem clearly, including goals, constraints, and data requirements.
Define the trade – offs intrinsic to the problem.
Define the criteria for a good solution.
Develop a set of cases to simulate which explore interesting options.
Perform the simulation and evaluate results against solution criteria.
Evaluate solutions against environmental and safety criteria.

6. Thermo – Mechanical Pulping Plant Study (TMP)

7. Thermo – Mechanical Pulping Plant
Case study
Case study
Construction of a
Thermo – Mechanical Pulping Plant
(TMP)
installed and operating cost.
Production and product quality.
Performance, energy, and efficiency.
Environmental impact.
Maintenance requirements.
Safety.

8. Justification Case study
The price of kraft and sulfite pulp has increased significantly in recent years.
Environmental impact of many older kraft and sulfite mill is now unacceptable.
Thermo – mechanical pulping (TMP) produces a good quality pulp at much less cost and environmental impact.

9. Case study
Objective
To study the economic feasibility of construction of a TMP unit in a mill already in existence.
Production (bleached pulp) 665 ton/d.
Freeness 60 ml.
brightness higher to 70 % ISO.
Return of investment (ROI) 5 years (20% each year).
Compliance with environmental and safety requirements.

10. Thermo – mechanical pulping process
Case study
Thermo – mechanical pulping process

11. Description of the TMP process
Case study
Description of the TMP process
Chips are heated with steam (before and during refining) to soften them and preserve long fibre.
Chips are refined to obtain pulp at 50% consistency.
The pulp is screened to obtain the desired fibre length distribution.
Rejects are refined again in the reject refining unit, with the accepts returned to the primary screen feed.
The screened pulp is then bleached.

12. Using Simulation in a Plant Design
Case study
Using Simulation in a Plant Design
A plant design requires of many combined equipments to obtain a desire product. Simulation is used to determine this target.
Select equipment.
Analyze “what if” scenarios.
Compositions, product production, and characteristics.
Improve performance.

13. Choosing parameter for working scenario
Case study
Choosing parameter for working scenario
Feasible operating ranges
Are the ranges in which the plant can operate (Temperature, Flow, Pressure, Size, etc.)
Impact and sensitivity variables
Defines a range of parameter variation for which the identified solution remains optimal.
Areas of maximum economic benefit
Cost sensitivity analysis provide a useful tool to determine the most economic operation range.

14. Multi-criteria optimization
Case study
Multi-criteria optimization
Designing a plant may have more than 1 alternative. It is hard to decide which option is best.
Taking a decision, may involve several aspect:
Operability.
Controllability.
Economic.
Some of the goals are usually conflicting each other, so that an optimal solution does not exist.
Safety.
Production.
Others.

15. Units proposed to be studied
Case study
Units proposed to be studied
Heat
Recovery
Bleaching
Effluent
Treatment

16. Reception and Storage Chips humidity 45%
Store, Refining and Reject
Reception and Storage
Chips humidity 45%
Chips between 10 and 30 mm will be accepted.

17. Store, Refining and Reject
Drum Washer
Washing Systems are an essential prerequisite for obtaining first-class final products.
Refiner

18. Thickener P-15 Bleaching Screens E-24 POM-006 P-16 Screens P-34 P-35
DIL-001
RES-002
EPA-001
POM-007
POM-010
P-32
Screens
reject
P-36
E-23
Bleaching
POM-008
E-22
E-21
Paper
machine
White
Water
REB-002
POM-009
White
Water
REB-001

19. Thickener Store, Refining and Reject
Drum Thickener is a simple and reliable filter for dewatering papermaking stock and broke as well as for virgin and recycled fibers in a consistency range from 0.5% to 5%.
Disc Filter is a vacuum filter. The vacuum is generated by drop legs. The stock is pumped to the inlet box through the feed section.

20. Mass Balance TMP plant

21. Mass balance
Mass balance

22. Mass balance
Mass balance

23. Mass balance
Mass balance

24. HEAT RECOVERY

25. Heat recovery system components
Reboiler
Vent condenser
Feed water / condensate exchanger
White water / condensate exchanger
Feed water deaerator.
Atmospheric scrubber.

26. Feed (demineralized) water inlet conditions
Heat recovery
Feed (demineralized) water inlet conditions
Flow 1484 ton/day.
Pressure KPa.
Temperature 90°C.
Clean steam outlet conditions
Flow 1484 ton/day.
Pressure 250 KPa.
Temperature 127.4°C.
Condensate outlet conditions
Flow 1744 ton/day.
Pressure 300 KPa.
Temperature 133.5°C.

27. Heat recovery
The reboiler will treat the dirty steam coming from the refining lines to produce clean steam for the paper machines.
TMP Steam
Silencer
ATM
Scrubber
Pressurized
Reboiler
Vent
Condenser
System
Feed Water
Dirty Condensate
Heater
Clean Steam
Scrubbed
Steam
Heat recovery system

28. Heat recovery
Vapor PTM

29. Heat recovery
heat exchanger

30. BLEACHING

31. Bleaching
Bleaching
It is necessary to add an bleaching process to satisfy the require brightness quality 70 %ISO.

32. Second press
First press
Pulp
Water
&
Peroxide
Pulp 675 t/d
Consistency 5%
Mixer 2
Dilution
screw
NaOH
13.3 t/d
Concentration 50%
Bleaching
Tower
SO2 2.8 t/d
SO2
Pulp 647 t/d
Consistency 10%
Sodium
Silicate
Storage
10%
6 t/d
Concentration 28.6%
H2O2
26.5 t/d
Concentration 50%
Pulp 643 t/d
Consistency 31% 1
Dilution
Pulp 6 t/d
Consistency 0.1%
White
water 3
Dilution
Pulp 663 t/d
Consistency 3%
Paper
Machine
From Paper
Machine

33. Effluent Treatment

34. Effluent treatment Main Treatment MES
clarifier volume: 1562 m3 and height of 6.7m. The retention time is 8.3 hrs. for 4500 m3/d.
Mud production 28 t/d
Second Treatment RBS 22 t DBO/d
Biologic Sequential Reactor. It consist of 4 basins operating in automatic sequence. Replenishment, Reaction, Sedimentation and racking.
DBO 20 t/d
MES 11 t/d
Total flow m3/d.
Mud production .06 kg/kg DBO removed.

35. Effluent Treatment Effluent treatment Bleaching Rejects Press
Clarifier
Biological
Reactor
Treated water
Screw Press
Purge
Solids

36. Process analysis cost
Process Analysis Cost

37. Product Characteristics and cost

38. Product
Operation cost

39. New equipment and Installation Cost
Process analysis cost
New equipment and Installation Cost
The company 1 offers a cheaper project cost, therefore, it is chosen as the company which provide the equipment.
The detail description in each stage is describe below.

40. SAFETY

41. Safety
Safety
The new plant must follow the rules of health and safety. The equipment acquired uses new technology so the risk of accident is low.
The possible danger sources must be identified and a manual written to describe the procedure to follow if an accident occurs.

42. This Tier is not finished, things to point out in the project:
Conclusion
This Tier is not finished, things to point out in the project:
What were the best solutions found.
Why were they preferable to others.
How would simulation help to find these solutions.
What are the advantages of using simulation in a project like this, versus other approaches such as using a standard design, adapting a plant design from elsewhere, or building a pilot scale process.

43. END OF TIER 3