P1_f06 - WPS 417 Fall 2006 PROBLEM 1: Paper Machine Part 1...

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WPS 417 Fall 2006 PROBLEM 1: Paper Machine – Part 1 Due: Attached is a flow diagram of a simplified paper machine system. Table 1 contains the technical data for this machine. Develop the GEMS block diagram and simulation for this flowsheet. Run the base case. Write both blocks and streams to Excel to check the balance and validate your simulation against the data in Table 2. TABLE 1 TECHNICAL DATA FOR PAPER MACHINE WET END *Furnish: Pulp Cons. Temp. Dis. Solids ODMt/day % ºC g/l Hardwood 295.0 12.0 45 3 Fine Pine 36.3 8.0 35 2 Kamyr Pine 68.0 12.0 45 2 Other Input Streams Flow, Mt/hr Temp,ºC Headbox showers 35 45 Trim shower 105 25 Wire shower to wire pit 195 25 Couch Roll & wire shrs to couch pit 90 25 Press felt showers 65 45 Saveall shower 10 25 Wire Pit: Steaming Temp., ºC Pressure Direct 60 2828 mm Hg Refiners: Power input Yield loss 100 kWhr/tpulp 1 % Screens: Feed consistency 0.51 % Accept consistency 0.47 % Reject consistency 1.4 % Estimated reject rate 10 % Filler added: 13.5% on fresh fiber 15% cons. 45ºC Pulp retained,% Consistency,% Filler,% Wire & suction boxes 82.5 17 53.7 Couch Roll 99.0 20 94.0 Presses 99.5 35 99.0 Saveall, recovered solids 96.0 8 80.0 Additional information: Consistency to stock chest 3.5% Consistency to machine chest 2.5% Trim split 3.0% Overflow from wire pit to sewer 50 Mt/hr (over)
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Saveall Operation: Sweetener added 1% of total furnish Cloudy filtrate 40% of flow 60% of filler 97% of fiber Clear filtrate for level control in Rich WW tank 20 Mt/hr Estimates for start-up: Leaving wire pit 5200Mt/hr 0.001 SS conc 60ºC 0.6/0.4 Fib/ Fill Table 2 Simulation Verification Against Mill Data Mill Data Simulation Production off presses, ODt/day Fiber 334 Filler 46 Furnish, ODt/hr 16.6 Filler, ODt/hr 2.2 Screens Rejects, ODt/day 62.3 Consistencies, % Headbox 0.52 Rich White Water 0.11 Out of Couch Pit 0.36 Flows, gpm Cloudy to sewer 556 Excess Clear 746 White water to sewer 220 Water usage, gpm Headbox showers 154 Wire showers 859 Stock density (lb/gal) from Cameron = 8.34 + (3.33 * %K/100)
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Case Study: Your mill is slated for review by state environmental regulators to determine if the mill will be able to meet new standards for effluent quantity and quality. The task force assigned to direct the inspection has collected data from the paper machine which will allow determination of the current usage points and quantities. As the leader of the group, you feel reasonably sure that the usage in gallons/ton pulp are in excess of the new regulation and have requested a simulation to
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P1_f06 - WPS 417 Fall 2006 PROBLEM 1: Paper Machine Part 1...

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