Model-based optimization of a CompactCooking G2 digesting process stage

A CompactCooking™ G2 (Valmet) digesting system represents a challenging process stage to be optimized in the context of a kraft pulp mill. Its highly non-linear behavior due to liquor recycling and heat integration poses a barrier to traditional trial-and-error optimization conducted by physical lab-scale simulation. Hence, this thesis aims to design a solution based on numerical simulation and mathematical optimization, whose results can be directly applied on industrial-scale as computed optimal set-points for the supervisory control. Based on published, first-principles, pulp digester models, a customized dynamic model was developed in Matlab/Simulink to simulate a complete CompactCooking™ G2 stage. The process model is founded on Purdue wood reaction kinetics and Härkönen chips bed compaction models, and it seamlessly takes into account process characteristics mentioned above. The non-linear model was validated by comparison against historical data of an industrial unit (200 h), and then employed in the design of a steady-state optimizer for this process stage by means of linear programming. Simulation results showed very good agreement in terms of liquors residual alkali, weak black liquor solids, and blowline kappa, despite high uncertainty on disturbances data and model simplifications. However, simulated kappa showed higher sensitivity to temperature fluctuations than the plant signal, likely indicating the need for more detail when modelling heat transfer phenomena. As to the optimization goal, a base case scenario (plant steady-state) was identified from industrial data to attempt process economics optimization. The results showed a potential for increasing profit or reducing variable costs in at least 2 USD/ADt, which for a modern pulp mill represents annual benefits between 1 – 2 million USD depending on production rate and mill availability. Further, the simulation model showed remarkable results when used in a novel process analysis technique, called here simulated contribution, letting to explain the variability of blowline kappa in terms of multiple-time-scale process dynamics. In conclusion, a model-based optimization method has been successfully designed for the CompactCooking™ G2 system, and potential economic benefits should encourage industrial testing and further work to develop a real-time optimizer software technology

Real-time observer model for Kraft wood digester.

Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, 2005.At SAPPI-Tugela a continuous Kraft wood chip digester operates in EMCC mode (extended modified continuous cooking). Chips are initially exposed to a NaOH / Na2S liquor at high temperature in the top section. The chips move downward in plug flow passing circumferential screens used to draw liquor for various circulations. About midway down the spent black liquor is removed and the chips enter the cooler bottom section where some further reaction and washing occurs. Liquor level and chip level are maintained close to each other near the top. Chips require 8-12 hours to pass through the digester, depending on the chip feed rate. The key parameter of interest at the digester exit is the Kappa number, which is a measure of the extent of delignification which has occurred. Different board and paper products require different Kappa number pulp feed. (Final properties such as tensile, tear and bursting strengths will also depend on the way fibres have been modified in the digestion). The objective of this investigation is to predict the Kappa number of the product pulp in real-time, thus facilitating quicker reaction than the present dependence on laboratory analysis permits, possibly even allowing closed-loop control. The extent of delignification depends on liquor strength, temperature and exposure time, with final Kappa number also depending on the properties of the chip feed (wood type and moisture content). Compensation to maintain a steady Kappa number is made difficult by the long and varying residence time, and the fact that any changes apply to the whole profile held up in the digester. A number of static models for Kappa number prediction have been developed by previous workers, but these do not compare well with plant measurements. The collection of data from the Sappi-Tugela reactor, and the pulp quality reports, have been used to determine an efficient model. This step required a considerable data collection exercise, and similar results to the quality reports have been obtained using a simple linear model based on this data. The problem of model error is being reduced by arrangement as a Smith Predictor, in which the model is intermittently corrected by available laboratory analyses. At the same time, an interface was created, in order to synchronise measurement data for the chips presently leaving the reactor. In order to deal with the dead time, each parcel of chips entering the reactor is effectively tracked, and the changes in Kappa number integrated for reaction time under the varying conditions in transit. Knowing the present inventory of the reactor, this model can also be run forward in time as a predictive controller, to determine optimal control actions for maintenance of the target Kappa number

Adapting an existing batch pulp digester model for use in continuous digesters

Dissertation (MEng (Control Engineering))--University of Pretoria, 2020.A mathematical model of a continuous Kraft wood digester was developed and tested. The model relies heavily on the work done previously by Christensen, Albright & Williams (1982). The batch Kraft digester model developed by Christensen et al (1982) was adapted to model a continuous Kraft wood digester at Ngodwana, South Africa. This adaptation centres around utilizing the method of lines to account for changes in both time and height of the digester simultaneously. The model was able to simulate the Kappa number of the digester accurately to an average absolute error of 7.88 that was reduced to 2.87 after certain process parameters were optimized for. A moving horizon state estimator was introduced into the model in an effort to keep internal state prediction accurate. This addition brought the average absolute error down further to 2.75. Adaptive control was also implemented into the model. The plant data the model was compared against to determine its accuracy was filtered with the use of a rolling median filter to reduce the influence introduced by noisy and infrequent measurements.SappiChemical EngineeringMEng (Control Engineering)Unrestricte

Malfunction of process instruments and its detection using a process control computer

From an initial concern with investigation of ways in which the process control computer could learn the project was narrowed down to instrument malfunction detection. Preliminary surveys in industry were made and from there general ideas of modes of failure of some instruments were obtained. A wider survey of instruments in different environmental conditions followed. Failure information and reliability data on about 9,500 instruments representing a total of about 4,500 instrument years’ operating time were obtained. [Continues.

Production of vanillin from lignin present in the kraft black liquor of the pulp and paper industry

Tese de doutoramento. Engenharia Química. Faculdade de Engenharia. Universidade do Porto. 200

Energy: A continuing bibliography with indexes, issue 17

This bibliography lists 1292 reports, articles, and other documents introduced into the NASA scientific and technical information system from January 1, 1978 through March 31, 1978

ECASTAR: Energy Conservation; an Assessment of Systems, Technologies and Requirements

A methodology for a systems approach display and assessment of the potential for energy conservation actions and the impacts of those actions was presented. The U.S. economy is divided into four sectors: energy industry, industry, residential/commercial and transportation. Each sector is assessed with respect to energy conservation actions and impacts. The four sectors are combined and three strategies for energy conservation actions for the combined sectors are assessed. The three strategies (national energy conservation, electrification and diversification) represent energy conservation actions for the near term (now to 1985), the mid term (1985 to 2000) and the far term (2000 and beyond). The assessment procedure includes input/output analysis to bridge the flows between the sectors, and net economics and net energetics as performance criteria for the conservation actions. Targets of opportunity for large net energy net energy savings and the application of technology to achieve these savings are discussed