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CFD and predictive modeling of temperature and calcination in a rotary lime kiln • Potential for steadier kiln operation, TAPPI Journal October 2024
ABSTRACT: Rotary lime kilns are used in the pulp and paper industry to calcine lime mud to lime. Lime kiln models provide a means to understand the complex phenomena occurring within the kiln to aid in problem-solving during operation. A two-dimensional (2D) computational fluid dynamics (CFD) and one-dimensional (1D) bed model was previously developed for steady-state and transient analysis. This study explores data extracted from the model over a longer time period. The simulated outlet gas and shell temperature are compared to measured data for validation. The capability of using the model to estimate the production rate, accounting for the residence time within the kiln, is discussed. The maximum refractory wall temperature is analyzed during operation. Fluctuations in the calcination location are compared to outer shell heat-map data to correlate the calcination location and ring formation and growth. The model results to date indicate that fluctuations in the calcination zone may contribute to problematic ring growth, though a direct correlation has yet to be established. Additionally, a method for steadier kiln control is introduced and discussed. A machine learning model is also developed to predict the calcination start location from industrial data and is compared to the CFD model for validation. This model can generate results quickly and without the need for knowledge in CFD software and theory. Good agreement is found between the CFD and machine learning model during operation, with a mean absolute error (MAE) of 0.46 m, a mean absolute percentage error (MAPE) of 0.92%, and a root mean square error (RMSE) of 1.17 m.
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Model development for real oxygen delignification processes, TAPPI Journal October 2024
ABSTRACT: Previous extensive work has been done on modeling the oxygen delignification process, based on how the basic parameters, i.e., temperature, kappa number, concentration of alkali, and concentration of oxygen, affect the delignification rate. However, these models are not used extensively to evaluate the performance of real processes, primarily because they have not been able to properly consider all the essential issues affecting delignification in practice. Such issues include the mass transfer and consumption of oxygen, which defines the concentration of dissolved oxygen in the process, and the effect of that concentration on the delignification rate. In this paper, a new way to model the oxygen delignification process is used in which these parameters, among other smaller matters, are taken into account. The basic model and its parameters were defined by the information obtained from the literature, delignification made in the laboratory tests, and mill processes and mill tests. An essential aspect of these studies was the information obtained from the oxygen concentration measured in the residual gas obtained from the top of the reactor. With the aid of this measurement, it was possible to define more accurately the consumption of oxygen and partial pressure of oxygen that define the concentration of dissolved oxygen in the reactor. Using mill experiments, a model was formed that predicts the operation of the oxygen delignification process. The model was used to show how much the process could be improved by optimizing the charge of the oxygen. The mill experiments also confirmed that mass transfer of oxygen is modeled correctly enough, except when the charge of oxygen is very low and/or the mixing is not efficient enough. In that case, there is variation in the concentration of oxygen in the process that should be taken into account in the modeling.
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Sulfur makeup in an unbleached kraft pulp mill, TAPPI Journal August 2024
ABSTRACT: Sodium sesquisulfate or “sesqui” (Na3H(SO4)2) is a by-product of chlorine dioxide production at kraft pulp mills. It is typically used for sodium and sulfur makeup in the liquor loop. Mondi Hinton Inc. (MHI) in Hinton, AB, Canada, was converting from bleached to unbleached kraft pulp production and was thus losing this source of makeup. The only option that was readily available as a substitute was sodium hydrosulfide (NaHS), which was cost prohibitive. Other options such as sodium sulfate (Na2SO4), emulsified sulfur, sulfuric acid (H2SO4), and sodium bisulfite (NaHSO3) were compared. The mill concluded that pelletized sulfur plus sodium hydroxide or “caustic soda” (NaOH) was the best option. Laboratory-scale experiments showed that pelletized sulfur dissolved in white liquor (WL). A mill-scale trial revealed that pelletized sulfur added to a causticizer had no adverse impacts on the downstream pressure filters or kiln operation. The sulfur reacted to produce polysulfide upstream of the WL storage tank, giving the liquor an orange hue. This polysulfide appeared to partially degrade into thiosulfate before being fed to the digester. The heavy black liquor (HBL) sulfur:sodium (S:Na) ratio did not change significantly, even though the sulfur/soda addition location was upstream of the original one. In addition, other properties such as liquor heating value and elemental analysis did not significantly change. Due to polysulfide/thiosulfate concentration in the white liquor, it was determined that the carbon steel equipment was at risk for corrosion. During the annual turnaround that occurred eight months after the addition of sulfur was started, the wash zone of the digester showed no signs of thinning/damage. The mill has been running exclusively with pelletized sulfur for 22 months (as of August 2024), realizing significant cost savings compared to the use of NaHS or other sulfur/soda addition options.
Journal articles
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Modeling the dynamics of evaporator wash cycles, TAPPI Journal July 2024
ABSTRACT: Kraft pulping is a process that utilizes white liquor, composed of sodium sulfide (Na2S) and sodium hydroxide (NaOH), for wood delignification and pulp production. This process involves washing the dissolved organics and spent chemicals from the pulp, resulting in the generation of black liquor. Prior to its use as fuel in the recovery boiler, the black liquor is concentrated in multiple-effect evaporators. During the evaporation process, the inorganic salts present in the liquor become supersaturated and undergo crystallization. Fluctuations in sodium, carbonate, sulfate, and oxalate can give rise to severe sodium salt scaling events, which significantly impact the thermal efficiency of the evaporators, and ultimately, pulp production. Dynamic modeling provides insights into fluctuations in liquor chemistry in the evaporators. The primary objective of this study was to employ dynamic modeling to evaluate the effects of wash liquor recovery from evaporator wash cycles. The dynamics associated with wash cycles encompass variations in the concentrations of salts and solids in the recovered wash liquor, changes in the flow rate of wash liquor recovery, and fluctuations in liquor volume within the liquor tanks. The dynamic model was developed using Matlab Simulink and applied to the evaporation plant of a pulp mill in South America. By utilizing one month of mill process data, the model enabled the evaluation of fluctuations in liquor chemistry due to evaporator wash cycles. The developed model has demonstrated the potential to estimate the concentration of key ions responsible for scaling and to contribute to enhancements in evaporator washing strategies.
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Online monitoring of the size distribution of lime nodules in a full-scale operated lime kiln using an in-situ laser triangulation camera, TAPPI Journal June 2024
ABSTRACT: To maximize efficiency of the recausticizing process in a pulp mill, producing a reburned lime with high and consistent reactivity is process critical. Prior investigations have demonstrated a correlation between the reactivity of lime and its nodule size, as well as the dusting behavior of the kiln. Therefore, monitoring the nodule size produced in the lime kiln could be a promising indirect method to measure the performance of the lime kiln. The objective of this investigation was to evaluate the utility of a laser triangulation camera for online monitoring of nodule size distribution for the lime kiln. A series of full-scale trials were performed in a lime kiln of a kraft pulp mill in which a camera was installed at the exit conveyor to analyze the lime discharging from the kiln. The nodule size distribution was analyzed for correlation with the lime temperature, flue gas temperature, and rotational speed of the kiln. The monitoring demonstrated temporal stability, and the results showed that the lime temperature had the most significant effect on the nodule size. The rotational speed of the lime kiln and the flue gas temperature showed limited effect on nodule size, but they had significant impact on the specific energy demand. The overall conclusion of the study is that the camera methodology effectively correlates lime temperature with nodule size distribution, and it advocates for the methods of implementation in automating lime temperature control, facilitating the production of consistently reactive lime at a lower specific energy consumption.
Journal articles
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Understanding the energy and emission implications of new technologies in a kraft mill: Insights from a CADSIM Plus simulation model, TAPPI Journal June 2024
ABSTRACT: Kraft mills play a vital role in energy transition because they have significant potential to reduce their own energy utilization and produce energy/products to decarbonize other sectors. Through biomass combustion and potential biogenic carbon emissions capture, these mills can contribute to offsetting emissions from other sectors. This research investigates the departmental and cross-departmental implications of technology upgrades on energy, steam, emissions, water, and chemicals using a CADSIM Plus simulation model. The model provides a comprehensive analysis of mass and energy balances, offering valuable insights into the benefits and limitations of each technology. The model facilitates scenario analysis and comparisons of process configurations, enabling data-driven decision-making for sustainable and competitive operations. Six high-impact technologies, including additional evaporator effects, weak black liquor membrane concentration, belt displacement washer for brownstock washing, oxygen delignification, and improvements to the pulp machine shoe press and vacuum pumps, are evaluated. Individual technologies resulted in energy savings of 1.2% to 5.4%, biomass consumption reductions of 8.6% to 31.6%, and total emissions reductions of 1.6% to 5.9%. Strategic decision-making must consider existing mill limitations, future technology implementation, and potential production increases. Future research will explore product diversification, biorefineries, and pathways to achieve carbon-negative operations, aiming to reduce emissions and secure a competitive future for kraft mills.
Journal articles
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Effects of tissue additives on copy paper forming and properties, TAPPI Journal February 2024
ABSTRACT: Laboratory tests were conducted in an effort to determine the effects on paper machine process attributes and the properties of paper made from recycled copy paper furnish upon the addition of chemical agents that are commonly used in the production of hygiene tissue products. Due to continuing growth in tissue and towel grades of paper, such agents are experiencing greater usage. Charge titration test results revealed that certain dry strength agents associated with tissue manufacturing have the potential to shift the balance of charge in papermaking furnish to less negative or even positive values. Creping adhesive was found to contribute to fine particle retention, especially when present at relatively high levels. Release aid and a polyacrylate dispersant had the opposite effect. Low addition levels of both a creping adhesive and a debonding agent surprisingly increased a wide range of strength attributes of paper handsheets in comparison to sheets prepared from unaltered recycled copy paper furnish. The debonding agent decreased paper strength at higher levels of addition. Such effects appear to depend not only on the expected effects of agents themselves, but also on how they affect the charge balance of the wet-end system.
Journal articles
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The role of hornification in the deterioration mechanism of physical properties of unrefined eucalyptus fibers during paper recycling, TAPPI Journal February 2024
ABSTRACT: Physical properties of cellulosic paper deteriorate significantly during paper recycling, which hinders the sustainable development of the paper industry. This work investigates the property deterioration mechanism and the role of hornification in the recycling process of unrefined eucalyptus fibers. The results showed that during the recycling process, the hornification gradually deepened, the fiber width gradually decreased, and the physical properties of the paper also gradually decreased. After five cycles of reuse, the relative bonding area decreased by 17.6%, while the relative bonding force decreased by 1.8%. Further results indicated that the physical property deterioration of the paper was closely related to the decrease of fiber bonding area. The fiber bonding area decreased linearly with the reduction of re-swollen fiber width during paper recycling. Re-swollen fiber width was closely related to the hornification. Hornification mainly reduces the bonding area of unrefined eucalyptus fiber rather than the bonding force. The work elucidates the role of hornification in the recycling process of unrefined eucalyptus fibers and the deterioration mechanism of paper physical properties, which will be helpful to control the property deterioration of paper and achieve a longer life cycle.
Journal articles
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Dynamic out-of-plane compression of paperboard — Influence of impact velocity on the surface, TAPPI Journal February 2024
ABSTRACT: Processes that convert paperboard into finished products include, for example, printing, where the paperboard is subjected to rapid Z-directional (ZD) compression in the print nip. However, measuring and evaluating the relevant properties in the thickness direction of paperboard are not necessarily straightforward or easy. Measuring at relevant, millisecond deformation rates further complicates the problem. The aim of the present work is to elucidate some of the influences on the compressive stiffness. Both the initial material response and the overall compressibility of the paperboard is studied. In this project, the effect on the material response from the surface structure and the millisecond timescale recovery is explored.The method utilized is a machine called the Rapid ZD-tester. The device drops a probe in freefall on the substrate and records the probe position, thus acquiring the deformation of the substrate. The probe is also allowed to bounce several times on the surface for consecutive impacts before being lifted for the next drop. To investigate the time dependent stiffness behavior, the probe is dropped several times at the same XY position on the paperboard from different heights, thus achieving different impact velocities. The material response from drops and bounces combined allows study of the short-term recovery of the material. The material in the study is commercial paperboard. The paperboard samples are compared to material where the surface has been smoothed by grinding it. Our study shows that there is a non-permanent reduction in thickness and a stiffening per bounce of the probe, indicating a compaction that has not recovered in the millisecond timescale. Additionally, a higher impact velocity has an initial stiffening effect on the paperboard, and this is reduced by smoothing the surface.
Journal articles
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Non-process elements in the recovery cycle of six Finnish kraft pulp mills, TAPPI Journal March 2023
ABSTRACT: In this work, the aim was to study the distribution and accumulation of the non-process elements (NPEs) in the recovery cycle of Finnish pulp mills and look at whether the geographical location (North vs. South) correlates with the current Finnish NPE levels. In addition, a comparison to older similar Finnish measurements was made with an attempt to analyze the reasons behind differences in the most typical non-process elements, aluminum (Al), silicon (Si), calcium (Ca), phosphorus (P), magnesium (Mg), manganese (Mn), chlorine (Cl), and potassium (K), taking into account the main elements in the white liquor, sodium (Na) and sulfur (S). The extensive laboratory results gained in this study are from seven sampling points at six pulp mills and present analytical data of metal concentrations. The data obtained presents an update to previous NPE studies. The levels found did not statistically differ between North and South Finland. The NPE levels, apart from phosphorus, found in Finnish pulp mills today have not changed considerably compared to the levels in earlier investigations in the 1990s. In the newest data, the phosphorus concentration was consistently higher in the as fired black liquor, electrostatic precipitator (ESP) ash, lime mud, and green liquor than in the previous results. In addition, the levels of Al, Si, Ca, P, and Mg in recovery boiler ESP ash were consistently higher compared to the older results. As the mills start to close their systems more, a stronger accumulation of NPEs can be expected, increasing the likelihood of more operational problems in the process. Further understanding of where the NPEs accumulate and how they can be most effectively removed will be valuable knowledge in the future.