A Modular Process Modeling Tool for the Analysis of Energy Use and Cost in the Pulp and Paper Industry

A novel process modeling tool to facilitate the study of how various process changes in the paper dryer section affect the mill-wide energy system has been developed. A model library with steady-state block models describing paper dryers, heat recovery equipment, and auxiliary systems on component level have been developed using the software Extend. Process models are then created from these block models using graphical programming. In this article, the characteristics of the developed tool are described and a case study where the tool is shown to be useful for analyzing the energy performance of a hybrid dryer section is presented.     

Process Parameters Optimization for Energy Saving in Paper Machine Dryer Section

Due to high energy consumption in the Chinese paper industry, this study considers higher-energy efficiency for the multicylinder dryer section of paper machines. A common situation in the Chinese paper industry is that energy is consumed in extensive mode. In order to improve the energy efficiency of the paper machine dryer section, deeper analysis and optimization of process parameters are necessary.

A NLP optimization method is developed for integration of steam system and air system to reduce the steam consumption and decrease the loads of centrifugal blowers in the multicylinder dryer section of a paper machine. Equality constraints of the optimization model are extracted from different process modules based on material and energy balance. Inequality constraints are from the production capacity, operating condition, etc. Two illustrative examples are presented in this paper. The results show that the optimization model is adaptive and convenient for application. For a newsprint machine, less dry air and steam are used and the energy consumption can be reduced by about 8% in the dryer section. Applied on a linerboard machine which has surface sizing, the method can reduce the energy consumption by 5.6%.     

Energy system diagnosis of paper-drying process,Part 1: Energy performance assessment

Paper drying is a highly energy-intensive and complicated multivariate process. The dryer section plays an important role in the energy consumption of a paper machine, especially of thermal energy. A comprehensive method for assessing the energy performance of the dryer section was investigated in this study to improve energy efficiency. This method was divided into three component processes: energy and evaporation load audit, field test and observation, and energy flow analysis and energy efficiency estimation. In a case study, we found that the method could, in addition to analyzing the key factors that restrict drying efficiency, also depict the details of energy consumption clearly. At the same time, several significant energy-saving measures were suggested to improve the energy efficiency of the paper-drying process.     

Energy system diagnosis of paper-drying process,Part 2: A model-based estimation of energy-saving potentials

The pulp and paper sector is the fourth largest industrial sector in terms of energy use in the world. Of the numerous processes involved in paper-making by a paper machine, the dryer section is the process that consumes the largest amount of energy. A model-based method for estimating energy-saving potentials of the dryer section was put forward in the present study. It was done by four steps: establishing a mathematical model about energy consumption, determining the model parameters, benchmarking the drying performance to obtain the corresponding energy-saving measures, and estimating the energy-saving potentials by using the mathematical model. In a case study, a multi-cylinder dryer section was selected to illustrate the method. After a fundamental field test and observation, several operating problems that restricted the energy performance of paper drying were found. And then several reasonable energy-saving measures were suggested to the operators. Finally, applying the mathematic model, it was found that 0.32 ton of steam will be saved when producing 1 ton of paper in recommended operating conditions. With the designed capacity of 200,000 tons/year, the annual steam-savings will be 64,000 tons. Generally, the price of steam is 130–150 Chinese Yuan (about US$21–24) in China, and the annual economic benefits will be 8.32–9.60 million Chinese Yuan (about US$1.344–1.536 million).     

Implementation of a block-oriented model library for undergraduate process control courses in EMSO simulator

Process control courses usually have a section of the course focused on the building of block diagrams for modeling, simulation, and analysis of open and closed loop processes. For this purpose, students are often oriented to build models using SIMULINK or XCOS because of the versatility of these powerful tools in the easy construction of mathematical models using the concept of block-oriented programming. In this paper we propose a model library built in the software EMSO that allows the user to create block diagrams for process control studies. EMSO is a powerful tool for process modeling, dynamic simulation and optimization, freely available for academic purpose. With the developed library, analysis of systems responses, even for complex processes, can be carried out and PID controller tuning tasks are made easier and less time-consuming to the students, allowing them to advance in the study of more complex control strategies such as ratio, cascade, override, feedforward, among others. Students valued the developed tool as a very useful and practical one to favor a control course learning process and between equivalent and advantageous tool when compared with SIMULINK and XCOS.     

A Learning Process Simulator for Fluidized Bed Dryers Application to Bentonite Drying

A fluid bed dryer simulator was developed under Excel 5 wlth Visual Basic for Applications environment The simulator iS based on a mathematical model describing heat and mass transfer in the dryer. The total model incorporates empirical models for the Drying Constant and the Residence Time. These empirical models are crucial in the total model efficiency. Thus a procedure for updating the parameters of the empirical models is provided. This procedure constitutes the 'learnhg' property of the simulator. Two databases are Supplied. The first contains laboratory drying data and it is used for tuning the Drying Constant empirical model. The second contains industrial drying data from the real operation of the dryer, and it is used for tuning the Residence Time empirical model. The experience from the industrial application of the simulator proved that the simulator is a powerful tool for flexible operation of an industrial dryer. This paper is presents the total mathematical model of the dryer, the learning concept, and the databases, including useful information concerning the drying kinetics of bentonite. A simulator outline is presented and typical capabilities and uses are briefly described. A case study for flexible operation of an industrial dryer is discussed.     

A Learning Process Simulator for Fluidized Bed Dryers Application to Bentonite Drying

ABSTRACT

A fluid bed dryer simulator was developed under Excel 5 wlth Visual Basic for Applications environment The simulator iS based on a mathematical model describing heat and mass transfer in the dryer. The total model incorporates empirical models for the Drying Constant and the Residence Time. These empirical models are crucial in the total model efficiency. Thus a procedure for updating the parameters of the empirical models is provided. This procedure constitutes the ‘learnhg’ property of the simulator. Two databases are Supplied. The first contains laboratory drying data and it is used for tuning the Drying Constant empirical model. The second contains industrial drying data from the real operation of the dryer, and it is used for tuning the Residence Time empirical model. The experience from the industrial application of the simulator proved that the simulator is a powerful tool for flexible operation of an industrial dryer. This paper is presents the total mathematical model of the dryer, the learning concept, and the databases, including useful information concerning the drying kinetics of bentonite. A simulator outline is presented and typical capabilities and uses are briefly described. A case study for flexible operation of an industrial dryer is discussed.     

Study of Temperature and Moisture Distribution in Paddy in a Triangular Spouted Bed Dryer

A triangular spouted-bed dryer has been designed as part of a hexagonal continuous dryer for paddy. In the triangular-bed dryer, the spout of drying air is placed in one corner of the drying chamber. Combining six triangular units with the spout located in the center of the dryer allows a continuous process and reduces energy consumption due to the reduction of heat losses. The current study focuses on the distribution of moisture and temperature in an individual triangular bed. Models of distribution have been developed in order to provide a better understanding of the phenomena and to help in scaling-up of the design.     

MODELING AND SIMULATION OF CROSSFLOW MOVING BED GRAIN DRYERS

The drying of grain in dryers of a crossflow moving bed type was theoretically and experimentally studied. Two different dryer configurations were analyzed, a dryer with central air distribution and another with multiple air duels. Experimental information was obtained in pilot-size dryers. A mathematical model to simulate the process was developed. Hindered drying was accounted for by using the concept of relative drying rate. An adjustable factor, specific to the dryers, was used to account for the uncertainties of the contact area and the transfer coefficients encountered in the literature. Agreement between experimental results and simulations was fairly good. Simulations showed that distance between inlet air and outlet devices, air to solid flow ratio and dryer height to cross section ratio have great influence on the process. The mathematical model may be a useful tool for process exploration and optimization of this type of dryers.     

MODELING AND SIMULATION OF CROSSFLOW MOVING BED GRAIN DRYERS

ABSTRACT

The drying of grain in dryers of a crossflow moving bed type was theoretically and experimentally studied. Two different dryer configurations were analyzed, a dryer with central air distribution and another with multiple air duels. Experimental information was obtained in pilot-size dryers. A mathematical model to simulate the process was developed. Hindered drying was accounted for by using the concept of relative drying rate. An adjustable factor, specific to the dryers, was used to account for the uncertainties of the contact area and the transfer coefficients encountered in the literature. Agreement between experimental results and simulations was fairly good. Simulations showed that distance between inlet air and outlet devices, air to solid flow ratio and dryer height to cross section ratio have great influence on the process. The mathematical model may be a useful tool for process exploration and optimization of this type of dryers.     

Comparison of Several Multi-Cylinder Paper Drying Simulation Models

Many models for simulation of paper drying in multi-cylinder dryer sections exist. In this work. three independently developed models are directly compared using the same reference data The models consired are the Texas A&M model, the Kuiosa model, and the VTT model. Predicted moisture contents plus cylinder and avenge web temperatures along the dryer section are presentcd for the different models. Predicted average evaporation rates during drying are also shown. Three major differences in the model details are highlighted. The effects of these differences on model accuracy evaluated by considering two different paper grades dried with two different machine geometries. This work is the first published direct comparison of different simulation models. The reference machine data provided can be used for comparison of these three models to other models.     

Effect of operating parameters on the drying performance of multicylinder paper machine dryer section

The drying performance of multicylinder dryer section in a paper machine was investigated under various operating parameters: Inlet paper solid content (48–50%), inlet paper temperature (45–50°C), supply air temperature (100–90°C), and exhaust air humidity (75–85?g H₂O/kg dry air). The variation in environmental conditions was also considered. In this study, an improved static model was utilized to study the influence of these operating parameters on paper drying. The model was constructed using sequential modeling approach based on the drying techniques of multicylinder dryer section of a paper machine. The calculated paper solid content leaving each paper drying module and energy use is in agreement with the measured results. The simulation results showed that higher paper solid content and temperature entering the dryer section, lower supply air temperature, and higher exhaust air humidity were favorable for drying performance within the studied range of these parameters.     

Comparison of Several Multi-Cylinder Paper Drying Simulation Models

ABSTRACT

Many models for simulation of paper drying in multi-cylinder dryer sections exist. In this work. three independently developed models are directly compared using the same reference data The models consired are the Texas A&M model, the Kuiosa model, and the VTT model. Predicted moisture contents plus cylinder and avenge web temperatures along the dryer section are presentcd for the different models. Predicted average evaporation rates during drying are also shown. Three major differences in the model details are highlighted. The effects of these differences on model accuracy evaluated by considering two different paper grades dried with two different machine geometries. This work is the first published direct comparison of different simulation models. The reference machine data provided can be used for comparison of these three models to other models.     

Investigation on Drying Performance and Energy Savings of the Batch-Type Heat Pump Dryer

Simulation of the heat pump cycle and the drying process has been carried out to obtain the design parameters of the dryer. The analysis indicates that a specific moisture extraction rate (SMER) greater than 3.4 kg/kWh can be obtained. A box-type heat pump dryer has been developed and investigated for the performance of drying of shredded radish. Heat pump drying took 1.0–1.5 times longer than hot air drying. However, the heat pump dryer showed considerable improvement in energy savings. The SMER of the heat pump dryer was about three times higher than that of the hot air dryer.     

Experimental Studies on a Newly Developed Mixed-Flow Dryer

Mixed-flow dryers are of great importance in worldwide agriculture for the drying of grain, corn, and rice. Unfavorable dryer designs can result in uneven particle and air flow distributions and, thereby, cause inhomogeneous gas–solids contact and drying conditions. As a consequence, the grain drying can locally be very uneven with high fluctuations of the moisture distribution over the dryer cross section. The main reasons are design and construction of the dryer apparatus and the discharge device. A new mixed-flow dryer design has been developed that promises more homogeneous drying, higher energy efficiency, and increased product quality. Firstly, the new dryer design was proved with respect to particle flow. For this purpose, a new test dryer was constructed. A series of particle flow experiments was performed using colored tracer particles. The flow of the tracer particles was observed through a transparent acrylic front wall by image analysis. Based on a comparison with the traditional design, the advantages and disadvantages of the new design were evaluated. The experimental investigations were accompanied by numerical simulations of the particle flow pattern using the discrete element method. The effects of design properties and different air duct arrangements were studied. The present results show that we are at the beginning of a new development concerning the optimization of mixed-flow drying apparatuses.     

HOW TO INCREASE THE DRYER EFFICIENCY - LOSS PREVENTION ON A PAPER MACHINE

In order to reduce superfluous energy consumption, the dryer section of an open paper machine was investigated experimentally. The recorded data covered the energy - and mass balances of both the individual drums and the whole dryer section, the state characteristics of the dryer air and some characteristics of the product. In the constant rate period of evaporation the specific heat consumption shows the minimum between 100 1050C dryer surface temperature while the specific evaporation performance is in direct proportion to it. The extent of the increase in energy consumption and of the decrease in evaporation performance below the critical value of moisture content is also demonstrated. Additional possibilities of energy saving exist mainly in aeration and in the more efficient operation of the presses. Some of the results are the characteristics of the investigated machine. It is believed, however, that the results referring to the effect of dryer surface temperature and moisture content are of a general validity and can be applied to other systems as well.     

HOW TO INCREASE THE DRYER EFFICIENCY - LOSS PREVENTION ON A PAPER MACHINE

In order to reduce superfluous energy consumption, the dryer section of an open paper machine was investigated experimentally. The recorded data covered the energy - and mass balances of both the individual drums and the whole dryer section, the state characteristics of the dryer air and some characteristics of the product. In the constant rate period of evaporation the specific heat consumption shows the minimum between 100 1050C dryer surface temperature while the specific evaporation performance is in direct proportion to it. The extent of the increase in energy consumption and of the decrease in evaporation performance below the critical value of moisture content is also demonstrated. Additional possibilities of energy saving exist mainly in aeration and in the more efficient operation of the presses. Some of the results are the characteristics of the investigated machine. It is believed, however, that the results referring to the effect of dryer surface temperature and moisture content are of a general validity and can be applied to other systems as well.     

INTERMITTENT THIN LAYER CORN DRYING

ABSTRACT

In this study a block oriented modelling technique was introduced in order to simulate the intermittent drying technology process. First, the relevant blocks of the parameters concerning to drying air and the properties of material to be dried were developed. These blocks were then used to set up the full modell of a fix bed dryer including the temperature and moisture distribution of drying air and The material along the depth of the dryer. The simulation results were compared to Bakker-Arkema model with a good agreement. Finally, several measurements were performed for the case of thin layer of com to prove the advantage of the intermittent drying technology. It has been founded that in both energy saving and quality of dried product the intermittent technology has a significant contribution.     

A Funtadamental Study on Particle Transport Through Rotary Dryers for Flight Design and System Optimisation

ABSTRACT

A model for particle transport in a flighted horizontal rotary dryer is developed in this paper. Mathematical principles applied to the current study are in the areas of differential calculus and analytical geomentry. In contrast to the conventional approaches which are either based on mpirical/semi-empirical correlations or obtained from the investieation of single particle trajectories, this paper develops rigorous mathematical analysis of the transport of bulk solids. A variety of important issues in rotary drying, such as axial flowrate of solids, retention time distribution and solid holdup are addressed and treated by using non-traditional methods. Since the model takes dimension, number and geometry of flights into account, it possesses the following two haracteristics : (1) it is not only useful in the study of rotary drying dynamics, but lso applicable to other processes employing flighted rotating cylinders (such as granulation drumsand crushers) and (2) based on the model, an optimal drum configuration can be designed by using optimisation techniques. The model can be incorporated within a distributed arameter dryer model developed previously to form a more rigorous integrated dynamic model. A heoretical foundation for optimal flight design by using the current model is explained.

A pilot scale perspex rotary dryer equipped with a video camera has been constructed and used for model validation. Raw sugar was handled in the experiments. Particle transport was observed and measured by using a flow visualisation technique supplemented with traditional sampling methods. A significant model quality improvement has been observed through a comparative study between the newly developed model and conventional ones.     

Steady-State Modeling of Multi-Cylinder Dryers in a Corrugating Paper Machine

In this study, a steady-state model was developed to describe the paper drying process and to analyze pocket dryer conditions for a multi-cylinder fluting paper machine in Iran's Mazandaran Wood and Paper Industries. The machine has 35 cylinders grouped in three drying groups and the cylinders are heated from the inside by steam. The model is based on the mass and energy balance relationships written for fiber, air, and water in the drying section. In this research, the heat of sorption and its variations with paper temperature and humidity changes have been taken into account. Temperature and moisture variation of the paper web and cylinder surface temperature in the machine direction were predicted by the proposed model. Also, temperature and humidity of air in the drying pockets and hood exhaust were estimated by the proposed model. Moreover, the model can predict the evaporation rate and specific drying rate with sufficient accuracy in comparison with the TAPPI standard. Finally, the main modeling parameters were compared with the available operating data and the effectiveness of the developed model was verified through validations.