APROS simulointiohjelmisto ja DYNAMO tutkimushanke

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APROS -simulointiohjelmisto ja DYNAMO
-tutkimushanke
Sami Tuuri, VTT Tuotteet ja tuotanto
Prosessi-integraatio 11.-12.9.2002, Dipoli,
Espoo.
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APROS - Advanced Process Simulation Software
Apros is a software tool for dynamic simulation
of processes, automation and electrical
systems. The benefits of Apros include a wide
validity range and scalability to large models
Apros is a product of Fortum Nuclear Services,
VTT Industrial Systems and VTT Processes
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Metso Automation, Tampere Mälarenergi AB,
Västerås NEK, Sofia, Bulgaria ESKOM, South
Africa Edison SpA, Milan Alstom Energy Systems
GmbH, Stuttgart Baden ABB Power Automation
GmbH, Baden Singapore Ministry of Environment,
Singapore VA Tech Elin GmbH, Vienna ABB Power
Plant Laboratories, Windsor, USA Tecnatom SA,
Madrid, Spain Endesa SA, Pontes Teruel,
Spain Ship Training Center, Espoo, Finland OECD
Halden Reactor Project, Norway KHIC Korea, South
Korea Azienda Energetica Metropolitana,
Torino TEPCO Chyoda, Tokio, Japan ABB Utility
Automation Ltd, Mannheim Foster Wheeler Energy
Ltd, Varkaus Karhula National Power Supply Co,
Thailand Stora Enso Ltd, Kaukopää Mills,
Finland Gianfranco Timoni Co, Busto Arsizio,
Italy Process Vision, Helsinki IPP Institut für
Plasmaphysik, Garching Sermet Oy,
Kiuruvesi SNPRI, Suzhou, China TPRI, Xian,
China
APROS customers world wide
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TEKES Technology Programme for Process
Integration 2000-2004DYNAMODesign and Analysis
of Process Dynamics in Pulp and Paper Process
Integration

• GOALS
• Develop tool (APROS Pulp and Paper) for dynamic
  modelling and simulation
• of pulp paper processes and automation
• extensive model libraries with accurate
• dynamic behaviour
• validation of models in industrial cases
• new features quality variability models
• easy-to-use process equipment libraries
• Transfer of dynamic simulation technology
• to pulp paper industry
• applications in close co-operation
• with partners
• M-real - Joutseno BCTMP plant
• Ahlstrom - Kauttua PM1
• Stora Enso - Kaukopää BM2 (extension)
• Andritz - Recovery boiler model library
• Metso - Model library of SymFlo, ValVac

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APROS and DYNAMO Key Features 2002

• Model libraries
• Solvers and generic model features
• consistency dynamics, delays
• simple tank dynamics solver combined to
  pressure/flow dynamics local model refinement
• tracking of pulp and paper processing history and
  fiber characteristics
• Open source models
• Gallery Training Manager
• Applications and technology transfer

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APROS Solvers

• Sequential solvers
• pipe delay tank dynamics
• paper web
• both ideal realistic controls
• consistency dynamics
• ideal mixing
• true plug-flow
• non-ideal mixing
• multi-delay components
• automation system
• analog automation
• binary automation

• Simultaneous solvers
• pressure-flow dynamics
• heat flow dynamics
• realistic controls
• electrical systems

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Laskentamallin valinta paikallisesti
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Mallien valmiusaste osaprosesseittain 1(2)
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Mallien valmiusaste osaprosesseittain 2(2)
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DYNAMO Joutsenon BCTMP-laitos

• hakkeen käsittelystä kuivatukseen
• ajotapojen kehittämiseen
• ns. tankkidynaaminen malli

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DYNAMO Kauttua PK1

• lajinvaihtojen kehittämiseen ja koulutukseen
• lyhyt kierto paine/virtaus-ratkaisijalla
• pitkä kierto tankkidynamiikalla

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Continuous Digester and Oxygen delignification

• Effects of
• Chip feed changes (chemical content, moisture)
• Changes in chemical charge (EA, HS)
• Temperature changes (circulation loops)
• Small flow rate changes (lt-constant compaction
  profile)
• Effects to
• average Kappa (and yield)
• temperatures
• residual alkali dissolved solids

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Example of hierarchical models

• Examples
• Pressure screen
• deaerator
• air pad headbox

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Pulp and Paper Processing History Data

• WHY?
• Need to model paper quality variables and
  tracking of fibre characteristics
• IDEA
• Model the quality only at the reel based on the
  processing history of the paper web
• IMPLEMENTATION
• Transport the processing history of the pulp
  along with the material property data related to
  flows

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Dynamic Paper Quality Modelling Utilising Fibre
Processing History Data
Quality Prediction for User Support

• freeness
• fibre length
• density
• light scattering coefficient
• tensile index
• tear index
• etc.

Operator Trainee
Realised Final Quality on Reel
Control Actions
Time
Experimental Quality Models
Fibre Processing Actions
Nip pressures Jet/wire-ratio etc.

• SW refiners
• SRE
• SEL

• HW refiners
• SRE
• SEL

SW PULP
HW PULP

• Tracking of fibre processing history in APMS
• time-variant fibre processing actions and
  controls
• time-variant quality parameters of original
  fibres

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Sellun jauhatus case
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OMINAISUUKSIEN MALLINNUS

• x-akseli SRE
• y-akseli SEL
• z-akseli vetolujuus
• Dataan sovitettu kolmiulotteinen pinta
• Vetolujuus lasketaan vasta kaikkien jauhinten
  jälkeen virtaukseen laitetuista parametreista SRE
  ja SEL.
• Periaate virtaukseen sijoitetaan laitteen
  parametreja. Paperin ominaisuudet lasketaan vasta
  tarvittaessa, esim. rullaimella.

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Open source models

• Users can develop own models writing Fortran or
  C programs
• Black box models
• Special DLLs e.g. solution of retention
  coefficients for former according to process
  conditions

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Parameterisation of an APROS Model by Using
Gallery Link
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Simulointi- mallien kehittäjät
Palaute ja muutostarpeet
Laitteiden parametrit
Kokonaisten prosessi- ja automaatio- ratkaisujen
kirjastointi
Laitteen hakukriteet ja valinta
Palomuuri
Laitemallien kirjastointi ja parametrointi
Päivitetyt mallikirjastot
Asiakkaan prosessin malli ja simulaattori
Muiden laitetoimittajien laitetiedot Internetissä
Prosessi- ja automaatioratkaisut
Laitemallit
Julkaisu ja ylläpito
Galleria Intranet
Galleria Extranet
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APROS Pulp and Paper - Hyötykäyttöön

• Tutkimus ja kehitys - prosessikokonaisuudet
• Integroitu prosessi ja automaatiosuunnittelu
• Koulutussimulaattorit
• Ajotapojen kehitys
• Poikkeustilanteiden harjoittelu ja häiriöiden
  selvitystyö
• Käyttäjät
• Laite- ja automaatiotoimittajat, tehtaat,
  suunnittelutoimistot, tutkimuslaitokset,
  korkeakoulut...

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APROS Pulp and Paper Extensions in Years 2001-2004
Participants of DYNAMO and GALLERY
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APROS and DYNAMO Key Features 2002

• Pulp and paper model libraries extended, not yet
  completed
• Solvers and models
• consistency dynamics, delays
• simple tank dynamics solver combined to
  pressure/flow dynamics local model refinement
• tracking of pulp and paper processing history and
  fiber characteristics
• Technology transfer
• industrial application cases
• hands-on simulation workshops