Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010...

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Institut für Papier-, Zellstoff- und Fasertechnik 1 Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation the most effective way to save energy Drying Simulation the most effective way to save energy - deliberated discovering of potential energy reserves - effective check of changes in machine configuration - easy prove of extensive production conditions - convicting evaluation of energy savings

Transcript of Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010...

Page 1: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Drying Simulation – the most

effective way to save energy

- deliberated discovering of potential energy reserves

- effective check of changes in machine configuration

- easy prove of extensive production conditions

- convicting evaluation of energy savings

Page 2: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Process simulation – the art of thinking

Simulation of drying process as a tool

- to minimise (upgrade) project risks

- to learn process in difficult production conditions

- to look for energy savings

- to look for bottlenecks

- for troubleshooting

Page 3: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

History of Simulation of Paper Drying

Lot of theoretical publications and practical trials solving specific tasks of drying process but: -

- too theoretical to be generally used

- solving specific tasks, not applicable to the other

processes

- connected with expensive training

- not flexible enough for wide scope of applications

Page 4: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

New approach to Drying Simulation

The basic characteristic defined in 1997

- Capital imperative: “easy to use”

- Versatility for wide scope of applications

- Immediately understandable

- Open for new know-how

- Closed for user secrets (e.g. coating recipes)

- No licence charges

Page 5: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

DSfP- Drying Simulation for Papermaking

Each mathematical model of drying equipment is defined by:

- Equipment geometry, energy use and air conditions

- Laws of physics and thermodynamics

- Pre-tuned parameters using experience from real equipment

- Published R&D works from European and American universities and institutions over the last 20 yeas

- Published PhD works

- More than 10 years research and development of DSP mathematical structure.

Page 6: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on Icon“ of Equipment Library to configure own

machinery

Page 7: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on Icon“ from Drying Line to configure drying

equipment

Page 8: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on button“ to simulate drying process (over 40 MD

profiles)

Page 9: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on icon“ to display drying analysis with heat transfer

details

Page 10: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on icon“ to display quick, easy to understand Sankey

diagrams

Page 11: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

„Just click on grade“ to choose coating composition from library

Page 12: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Easy to understand paper drying properties in graphical form

Page 13: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Example of usual drying configuration representing above 90%

of drying machines

Page 14: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Using exhaust air of IR dryers in the Air Foil equipments and

simultaneously keeping drying Air Foil conditions

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Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Air Foil conditions before reconstruction

Page 16: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Air Foil conditions after reconstruction

Page 17: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Air Foils - gas savings 40,7%

Coater - gas savings 16,8%

Page 18: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

DSfP- Drying Simulation for Papermaking

Validation and verification approach

- DSfP checks the mass and heat balance of the

model at every stage of the calculations.

- Only real web temperature is used to validate DSfP performance. All other process variables are connected by thermodynamic laws.

- Simulated overall water balance result is validated by scanner measurements.

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Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

Advantages and properties of DSfP

DSfP is flexible, versatile, understandable and easy to use for: -

- Clear base to communicate with customers or suppliers

- Easy drying process analysis to optimise energy use

- Tool for technological troubleshooting

- Extremely quick functionality check of new equipment in drying

line

- Understandable and easy check of the energy efficiencies of all

drying equipment

Page 20: Drying Simulation the most effective way to save energy · Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation –the most effective way to save energy DSfP- Drying Simulation

Institut für Papier-, Zellstoff- und Fasertechnik

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Dr. Peter Fisera APV Tagung Graz 2010 Drying simulation – the most effective way to save energy

DSfP- Conclusion

Process simulation

is

the art of thinking

Thank you for your attention