Improved energy efficiency in paper making through reducing dryer steam consumption using advanced process control

Over the last two or three years, the increasing costs of energy and worsening market conditions have focussed even greater attention within paper mills than before, on considering ways to improve efficiency and reduce the energy used in paper making. Arising from a multivariable understanding of paper machine operation, Advanced Process Control (APC) technology enables paper machine behaviour to be controlled in a more coherent way, using all the variables available for control. Furthermore, with the machine under better regulation and with more variables used in control, there is the opportunity to optimise machine operation, usually providing very striking multi-objective performance improvement benefits of a number of kinds. Traditional three term control technology does not offer this capability. The paper presents results from several different paper machine projects we have undertaken around the world. These projects have been aimed at improving machine stability, optimising chemicals usage and reducing energy use. On a brown paperboard machine in Australasia, APC has reduced specific steam usage by 10%, averaged across the grades; the controller has also provided a significant capacity to increase production. On a North American newsprint machine, the APC system has reduced steam usage by more than 10%, and it provides better control of colour and much improved wet end stability. The paper also outlines early results from two other performance improvement projects, each incorporating a different approach to reducing the energy used in paper making. The first of these two projects is focussed on optimising sheet drainage, aiming to present the dryer with a sheet having higher solids content than before. The second project aims to reduce specific steam usage by optimising the operation of the dryer hood.

The structure of turbulent stratified and premixed methane/air flames I: Non-swirling flows

A series of flames in a turbulent methane/air stratified swirl burner is presented. The degree of stratification and swirl are systematically varied to generate a matrix of experimental conditions, allowing their separate and combined effects to be investigated. Non-swirling flows are considered in the present paper, and the effects of swirl are considered in a companion paper (Part II). A mean equivalence ratio of φ=0.75 is used, with φ for the highest level of stratification spanning 0.375-1.125. The burner features a central bluff-body to aid flame stabilization, and the influence of the induced recirculation zone is also considered. The current work focuses on non-swirling flows where two-component particle image velocimetry (PIV) measurements are sufficient to characterize the main features of the flow field. Scalar data obtained from Rayleigh/Raman/CO laser induced fluorescence (CO-LIF) line measurements at 103μm resolution allow the behavior of key combustion species-CH 4, CO 2, CO, H 2, H 2O and O 2-to be probed within the instantaneous flame front. Simultaneous cross-planar OH-PLIF is used to determine the orientation of the instantaneous flame normal in the scalar measurement window, allowing gradients in temperature and progress variable to be angle corrected to their three dimensional values. The relationship between curvature and flame thickness is investigated using the OH-PLIF images, as well as the effect of stratification on curvature.The main findings are that the behavior of the key combustion species in temperature space is well captured on the mean by laminar flame calculations regardless of the level of stratification. H 2 and CO are significant exceptions, both appearing at elevated levels in the stratified flames. Values for surface density function and by extension thermal scalar dissipation rate are found to be substantially lower than laminar values, as the thickening of the flame due to turbulence dominates the effect of increased strain. These findings hold for both premixed and stratified flames. The current series of flames is proposed as an interesting if challenging set of test cases for existing and emerging turbulent flame models, and data are available on request. © 2012 The Combustion Institute.

The structure of turbulent stratified and premixed methane/air flames II: Swirling flows

Experimental results are presented from a series of turbulent methane/air stratified flames stabilized on a swirl burner. Nine operating conditions are considered, systematically varying the level of stratification and swirl while maintaining a lean global mean equivalence ratio of φ̄=0.75. Scalar data are obtained from Rayleigh/Raman/CO laser induced fluorescence (CO-LIF) line measurements at 103μm resolution, allowing the behavior of the major combustion species-CH 4, CO 2, CO, H 2, H 2O and O 2-to be probed within the instantaneous flame front. The corresponding three-dimensional surface density function and thermal scalar dissipation rate are investigated, along with geometric characteristics of the flame such as curvature and flame thickness. Hydrogen and carbon monoxide levels within the flame brush are raised by stratification, indicating models with laminar premixed flame chemistry may not be suitable for stratified flames. However, flame surface density, scalar dissipation and curvature all appear insensitive to the degree of stratification in the flames surveyed. © 2012 The Combustion Institute.

A 5-step reduced mechanism for combustion of CO/H2/H2O/CH4/CO2 mixtures with low hydrogen/methane and high H2O content

In this study a 5-step reduced chemical kinetic mechanism involving nine species is developed for combustion of Blast Furnace Gas (BFG), a multi-component fuel containing CO/H2/CH4/CO2, typically with low hydrogen, methane and high water fractions, for conditions relevant for stationary gas-turbine combustion. This reduced mechanism is obtained from a 49-reaction skeletal mechanism which is a modified subset of GRI Mech 3.0. The skeletal and reduced mechanisms are validated for laminar flame speeds, ignition delay times and flame structure with available experimental data, and using computational results with a comprehensive set of elementary reactions. Overall, both the skeletal and reduced mechanisms show a very good agreement over a wide range of pressure, reactant temperature and fuel mixture composition. © 2012 The Combustion Institute..

Multiply conditioned analyses of stratification in highly swirling methane/air flames

The effects of stratification on a series of highly swirling turbulent flames under globally lean conditions (φg=0.75) are investigated using a new high-spatial resolution multi-scalar dataset. This dataset features two key properties: high spatial resolution which approaches the 60 micron optical limit of the measurement system, and a wavelet oversampling methodology which significantly reduces the influence of noise. Furthermore, the very large number of realizations (30,000) acquired in the stratified cases permits statistically significant results to be obtained even after aggressive conditioning is applied. Data are doubly conditioned on equivalence ratio and the degree of stratification across the flame in each instantaneous realization. The influence of stoichiometry is limited by conditioning on the equivalence ratio at the location of peak CO mass fraction, which is shown to be a good surrogate for the location of peak heat release rate, while the stratification is quantified using a linear gradient in equivalence ratio across the instantaneous flame front. This advanced conditioning enables robust comparisons with the baseline lean premixed flame. Species mass fractions of both carbon monoxide and hydrogen are increased in temperature space under stratified conditions. Stratification is also shown to significantly increase thermal gradients, yet the derived three-dimensional flame surface density is shown to be relatively insensitive to stratification. Whilst the presence of instantaneous stratification broadens the curvature distribution relative to the premixed case, the degree of broadening is not significantly influenced by the range of global stratification ratios examined in this study. © 2012 The Combustion Institute.

The behaviour of laminar stratified methane/air flames in counterflow

Flames propagating through a mixture with a gradient of equivalence ratio have been previously demonstrated to travel faster or slower than their equivalent premixed flames. The present study aims to numerically investigate the response of strained laminar methane-air flames to such gradients. The flames are simulated in a counterflow configuration where a premixed reactant stream at equivalence ratio φR opposes a hot equilibrium stream at equivalence ratio φP. Premixed and stratified flames are compared with respect to the equivalence ratio φ* and the corresponding gradient ∇φ* at the point of peak heat release rate, for three strain rates, a=50, 300 and 500s-1 and a range of φ*. The effect of different stratification levels is also investigated by varying the ratio of φP to φR, Θ. Results indicate that, as long as flames stabilize within the diffusion layer and Θ>1, increased heat release rate Q is seen throughout the progress variable space in comparison to the premixed state. In contrast, an attenuation of heat release rate is seen for Θ<1. The enhancement (or attenuation) of heat release varies monotonically with Θ. The effect of stratification on flame behavior becomes more pronounced as the strain rate increases. The present study reveals the mechanisms for the propagation of quasi-steady stratified flames under lean and rich conditions: stratified flames are primarily dominated by the diffusion of heat under lean conditions, and diffusion of H2 under rich conditions. Thanks to species and thermal support, stratified flames continue to burn beyond the premixed lean and rich flammability limits. Further investigation on the unsteady response of flames to the fluctuating equivalence ratio implies that the steady results represent the unsteady response well, as long as φ* and ∇φ* are similar in both steady and unsteady cases. © 2013 The Combustion Institute.

Flow field measurements of a series of turbulent premixed and stratified methane/air flames

This paper presents flow field measurements for the turbulent stratified burner introduced in two previous publications in which high resolution scalar measurements were made by Sweeney et al. [1,2] for model validation. The flow fields of the series of premixed and stratified methane/air flames are investigated under turbulent, globally lean conditions (φg=0.75). Velocity data acquired with laser Doppler anemometry (LDA) and particle image velocimetry (PIV) are presented and discussed. Pairwise 2-component LDA measurements provide profiles of axial velocity, radial velocity, tangential velocity and corresponding fluctuating velocities. The LDA measurements of axial and tangential velocities enable the swirl number to be evaluated and the degree of swirl characterized. Power spectral density and autocorrelation functions derived from the LDA data acquired at 10kHz are optimized to calculate the integral time scales. Flow patterns are obtained using a 2-component PIV system operated at 7Hz. Velocity profiles and spatial correlations derived from the PIV and LDA measurements are shown to be in very good agreement, thus offering 3D mapping of the velocities. A strong correlation was observed between the shape of the recirculation zones above the central bluff body and the effects of heat release, stoichiometry and swirl. Detailed analyses of the LDA data further demonstrate that the flow behavior changes significantly with the levels of swirl and stratification, which combines the contributions of dilatation, recirculation and swirl. Key turbulence parameters are derived from the total velocity components, combining axial, radial and tangential velocities. © 2013 The Combustion Institute.

Study on small-strain behaviours of methane hydrate sandy sediments using discrete element method

Methane hydrate bearing soil has attracted increasing interest as a potential energy resource where methane gas can be extracted from dissociating hydrate-bearing sediments. Seismic testing techniques have been applied extensively and in various ways, to detect the presence of hydrates, due to the fact that hydrates increase the stiffness of hydrate-bearing sediments. With the recognition of the limitations of laboratory and field tests, wave propagation modelling using Discrete Element Method (DEM) was conducted in this study in order to provide some particle-scale insights on the hydrate-bearing sandy sediment models with pore-filling and cementation hydrate distributions. The relationship between shear wave velocity and hydrate saturation was established by both DEM simulations and analytical solutions. Obvious differences were observed in the dependence of wave velocity on hydrate saturation for these two cases. From the shear wave velocity measurement and particle-scale analysis, it was found that the small-strain mechanical properties of hydrate-bearing sandy sediments are governed by both the hydrate distribution patterns and hydrate saturation. © 2013 AIP Publishing LLC.