1. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 1 How to Apply Simulation in the Real World 3 Tier

2. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 2 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. Statement of intent

3. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 3 Structure of tier 3  Approach to Open – ended problem  Case of Study. Contents

4. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 4 Open – Ended Problems 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. General concepts

5. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 5 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. General concepts

6. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 6 Thermo – Mechanical Pulping Plant Study (TMP)

7. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 7 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. Case study

8. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 8 Justification 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. Case study

9. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 9 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. Case study

10. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 10 Case study Thermo – mechanical pulping process

11. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 11 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. Case study

12. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 12 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. Case study

13. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 13 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. Case study

14. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 14 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. Case study

15. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 15 Units proposed to be studied Heat Recovery Bleaching Effluent Treatment Case study

16. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 16 Reception and Storage Chips humidity 45% Chips between 10 and 30 mm will be accepted. Store, Refining and Reject

17. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 17 Drum Washer Washing Systems are an essential prerequisite for obtaining first-class final products. Store, Refining and Reject Refiner

18. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 18 Thickener DIL-001 Screens reject Paper machine Bleaching P-15 RES-002 EPA-001 White Water REB-002 White Water REB-001 P-16 P-32 E-21 P-34P-35 E-23 E-22 POM-010 POM-006 POM-007 POM-008 POM-009 P-36 E-24

19. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 19 Thickener 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. Store, Refining and Reject

20. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 20 Mass Balance TMP plant

21. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 21 Mass balance

22. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 22 Mass balance

23. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 23 Mass balance

24. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 24 HEAT RECOVERY

25. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 25 Heat recovery system components Reboiler Vent condenser Feed water / condensate exchanger White water / condensate exchanger Feed water deaerator. Atmospheric scrubber. Heat recovery

26. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 26 Feed (demineralized) water inlet conditions Flow 1484 ton/day. Pressure 101.3 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. Heat recovery

27. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 27 Heat recovery system TMP Steam Silencer ATM Scrubber Pressurized Scrubber Reboiler Vent Condenser System Vent Feed Water Dirty Condensate Heater Clean Steam Scrubbed Steam The reboiler will treat the dirty steam coming from the refining lines to produce clean steam for the paper machines. Heat recovery

28. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 28 Vapor PTM Heat recovery

29. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 29 heat exchanger Heat recovery

30. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 30 BLEACHING

31. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 31 Bleaching It is necessary to add an bleaching process to satisfy the require brightness quality 70 %ISO. Bleaching

32. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 32 NaOH H2O2H2O2 SO 2 Bleaching Tower Sodium Silicate Pulp From Paper Machine Paper Machine Pulp 675 t/d Consistency 5% Mixer 13.3 t/d Concentration 50% 6 t/d Concentration 28.6% 26.5 t/d Concentration 50% 1 Dilution 2 Dilution 3 Dilution White water screw Pulp 643 t/d Consistency 31% Pulp 6 t/d Consistency 0.1% Storage Pulp 647 t/d Consistency 10% Pulp 663 t/d Consistency 3% SO 2 2.8 t/d 10% Water & Peroxide First press Second press

33. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 33 Effluent Treatment

34. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 34 Effluent treatment 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 26000 m 3 /d. Mud production.06 kg/kg DBO removed. Second Treatment RBS 22 t DBO/d Main Treatment MES clarifier volume: 1562 m 3 and height of 6.7m. The retention time is 8.3 hrs. for 4500 m 3 /d. Mud production 28 t/d Effluent treatment

35. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 35 Biological Reactor Clarifier Bleaching Rejects Treated water Screw Press SolidsPurge Press Effluent Treatment Effluent treatment

36. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 36 Process Analysis Cost Process analysis cost

37. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 37 Product Characteristics and cost Product

38. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 38 Operation cost Product

39. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 39 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. Process analysis cost

40. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 40 SAFETY

41. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 41 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. Safety

42. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 42 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. TIER 3 STEADY STATE SIMULATION PIECE PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 43 END OF TIER 3