Efficient tissue process for cost reduction and material savings: simulation-enhanced process development and performance optimization
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1 Efficient tissue process for cost reduction and material savings: simulation-enhanced process development and performance optimization Bettina Grashof 1*, Jonas Bergström 2, Caio Penteado 2, Magnus Bengtsson 3 1 Voith Paper GmbH & Co. KG, Heidenheim, Germany 2 Voith Paper Máquinas e Equipamentos Ltda, São Paulo, Brazil 3 Duni AB, Malmö, Sweden Keywords: Pre-dewatering system, technology development, energy savings, dry crepe, shoe press, system simulation Introduction The operation of a shoe press against the Yankee in dry crepe tissue paper production brings several advantages compared to a conventional press nip; product quality can be enhanced, raw material can be saved and energy consumption can be reduced. Decades after its introduction, the tissue shoe press has not changed significantly. The work presented here is the result of a Voith Paper and Duni/Rexcell joint development project aimed at greatly improving the efficiency of dry crepe tissue production. The objective of this collaboration was to reduce the environmental impact and to increase the performance of the production process. In dry crepe operation mode, and in combination with a shoe press, TissueLev, a pre-dewatering system positioned before the press, provides additional dryness after the press section. The pre-dewatering system enables a different operation point as the sheet enters the press in a modified state. This results in increased production capacity, a reduction of thermal drying energy and potential for fiber savings. A simulation-enhanced approach has been used to accelerate and focus process development and performance optimization. It combines, on the one hand, trials on the pilot plant and at the customers production site in Sweden. On the other hand, different simulation techniques are used: multiphysics system simulation, computational fluid dynamics (CFD) simulation, and image analysis and flow simulation of porous structures. The combined use of these mathematical simulation methods and trial and field data has led to much faster product and process development cycles and reduced risk. Furthermore, it enables insight process views and deepens process knowledge. Development approach The use of a simulation-enhanced development process offers benefits compared to a conventional approach solely based on engineering know-how and pilot trials for increasing the efficiency of the conventional dry crepe tissue process. The successful development of the new process and the optimization of the performance of the process have their origin in an indepth analysis of the customers needs. The use of Outcome-Driven Innovation (ODI) techniques ensures value creation for the customer during the innovation process. The combination of simulations and pilot trials accelerates the realization of new concepts. For the presented pre-dewatering system the first successful pilot trials were performed in the end of 2014 and the promising results confirmed In close cooperation with a lead customer the rebuild of their machines to the new technology took place in beginning of Speed and capacity targets on the customers machines were met in the end of * Corresponding author: bettina.grashof@voith.com, phone:
2 The technology of the newly developed pre-dewatering system is based on an additional permeable fabric, which runs with high tension over the suction turning roll, thereby creating a long and gentle press nip, which increases dryness before the shoe press (see Figure 1). Forming Drying Yankee cylinder Reeling Press Pre-dewatering system Figure 1: Schematic representation of a dry crepe tissue machine with pre-dewatering system Steam is evenly applied through a steam shower in the pre-dewatering system. The application of this technology leads to increased dryness after the press section, which in turn allows for increased production. During the development process, three different simulation techniques are employed to meet the multi-scale challenge of the tissue process. While typical pore sizes for fabrics or the tissue are in the range of several microns, the dimension of the whole tissue machine is several orders of magnitude higher (see Figure 2). Figure 2: Simulation tools adapted for multi-scale challenge System simulation is employed to model the process behavior in the entire tissue machine, predicting state variables like temperature or water saturation, but not resolving every detail. Therefore, effective material models are required. These material models in turn often rely on data from measurements or CFD simulations. In the development process presented in this work, the pre-dewatering system is rebuilt virtually as a system simulation model, which is used to investigate the condensation efficiency
3 and to optimize performance parameters. For calculating the flow in the porous fabrics and the tissue web, Darcy s law is used. Furthermore, equations describing heat transfer and condensation in the felt tissue belt system are implemented. As a result, temperature and dry content profiles can be calculated while passing through the pre-dewatering system. With the model virtual trials can be performed changing operation conditions, like vacuum settings and steam shower position, or fabric parameters, such as the belt permeability. In the CFD simulations, mass, momentum and energy balance equations are solved with numerical methods on a calculation grid. As a result, flow velocities, concentrations and pressure distribution can be visualized in detail. Within this project, the steam distribution in the pre-dewatering system is investigated for an analysis of the steam transport efficiency into the tissue web. The results can be either plotted graphically (see example next section) or given, like for the steam transport efficiency, as a quantitative number. The steam distribution is also an input parameter for the system simulation. Realistic material parameters for both fabrics and the tissue web are required as input parameters for the CFD simulations and for the system simulation model. Image processing and flow simulations of topographical images of porous structures enable a detailed view on the material structures and properties. They provide information on the pore size distribution, capillary pressure curves and relative permeabilities as a function of the water saturation. For the simulation of the pre-dewatering unit, especially the latter two are of great importance. They are implemented into the system simulation model using a Brooks-Corey model fit. Key results and future prospects The results of the CFD simulations are used to assess the performance of the well-designed and sized steam hood (see Figure 3). The hood design helps to prevent steam leakages to occur, and the stagnation flow of the steam ensures an evenly distributed flow without recirculation and eddies in the hood for optimized energy use. This behavior is shown in the streamline plot on the left-hand side of Figure 3. Additionally, a contour plot of the steam mass flow through the belt is shown on the right-hand side of Figure 3. It visualizes that in the plotted case with a reduced vacuum level the steam stays within the hood and does not leave it in machine directions and hence illustrates an optimized hood design for an efficient steam transport. Figure 3: Streamlines (left) and contour plot (right) of the steam flux distribution in the steam hood representing high process efficiency and optimized hood design The quantitative analysis of the steam mass flow distribution shown in Figure 3 demonstrates the high efficiency of the steam transport through the belt. For the simulation case with the vacuum level recommended in operation, an efficiency of more than 99% for the transport of steam into the belt and tissue has been realized. Based on this information, system simulations show a high degree of steam saturation and thus a high efficiency of its condensation in belt and tissue. This ensures that the applied heat of the steam is optimally used to increase the tissue temperature before entering the press. This finally results in higher after-press dryness and thus creating more production capacity.
4 Figure 4 shows a typical time-dependent temperature profile of the tissue, belt and felt in the pre-dewatering system. Figure 4: Characteristic temperature profile of belt, tissue and felt in the pre-dewatering system The steep temperature increase occurs when a narrow steam impulse is applied to the felt tissue belt system. The felt hardly changes its temperature due to steam application from the top and due to its comparably high heat capacity. Virtual parameter studies using the system simulation model support the trials performed at the customer s site and on the trial machine and create insight views into the underlying mechanisms. Within the simulation, fabric parameters can be easily varied, greatly reducing the number of trials needed, as only the most promising configurations need to be tested on the pilot machine. Figure 5 shows exemplarily the results for three belts with different permeability properties. Figure 5: Temperature increase over TissueLev unit for belt, tissue and felt using belts with different thicknesses The reduced caliper of Belt A leads to an additional temperature increase of 1.5 C for the tissue web compared to the configuration with Belt B. Belt C has changed structure properties influencing its permeability. The effect on the temperature difference when compared to that of Belt C is negligibly small, however. Nevertheless, trials on the pilot plant are essential for successful product and process development, because numerous operational effects and properties, such as runnability, cannot be assessed by simulation. Applying this simulation-enhanced development approach, and as a result of the joint performance optimization project, the positive effect of the pre-dewatering system on overall performance and efficiency, and hence the contribution towards an environmentally friendly
5 production process for tissue paper, can be shown. The machine speed at the field installation at the customer s site could be increased by around 15 to 20% using the pre-dewatering system in combination with a shoe press, and the dry content measured after the press could be increased by up to 5%. The use of simulations to support the process and product development of the predewatering system has led to deeper and improved process know-how, and it has also greatly helped to speed up the overall development process. During the course of this project, the strengths and advantages of a simulation-enhanced development and optimization approach were demonstrated.
6 Efficient tissue process for cost reduction and raw material savings: Simulation-enhanced process development and performance optimization B. Grashof 1, J. Bergström 2, C. Penteado 2, M. Bengtsson 3 1 Voith Paper GmbH & Co. KG, Heidenheim, Germany 2 Voith Paper Máquinas e Equipamentos Ltda, São Paulo, Brazil 3 Duni AB, Malmö, Sweden Tissue 2017 B. Grashof public
7 Content: 1. Motivation 2. Development approach 3. Simulation tools 4. Key results 5. Summary and outlook Tissue 2017 B. Grashof public
8 Pre-dewatering system: Joint development project with a lead costumer for next level napkin tissue Tissue 2017 B. Grashof public
9 Benefits of the pre-dewatering system TissueLev Creation of customer value: Forming Drying Yankee cylinder Reeling Increased efficiency at high machine speed, leading to increased capacity Press Potential to develop new tissue qualities Products with reduced environmental impact Pre-dewatering system Tissue 2017 B. Grashof public 4
10 Development approach: Simulation-enhanced process development and performance optimization Tissue 2017 B. Grashof public
11 Process development & performance optimization. Next Level Analyze customer needs by focusing on jobs to be done Use engineering know-how, pilot trials and simulation for rapid concept evaluation and realization Costumers needs Innovation process Product Development Start-up Use Outcome-Driven Innovation (ODI) techniques to ensure value creation for the customer Reduce risk during installation and support fast and smooth start-up Tissue 2017 B. Grashof public
12 Simulation tools: Adapted and efficient use of simulation tools for the highest performance Tissue 2017 B. Grashof public
13 Simulation tools adapted for multi-scale challenge Tissue 2017 B. Grashof public
14 Simulation approach for development of pre-dewatering system System simulation solving heat and mass balance equations Time-dependent prediction of state variables, e.g. temperature or dry content CFD simulation solving mass, momentum (and energy) balance equations Prediction of flow behavior including concentration and temperature distribution Image processing and flow simulation of µct-images of porous material and virtually generated structures Prediction of material size distribution or permeability Representation of multiple components and their interaction Fast simulation Detailed representation of flow behavior Detailed analysis of material parameters Tissue 2017 B. Grashof public 9
15 Key results: Efficient napkin tissue process for cost reduction and material savings Tissue 2017 B. Grashof public
16 Visualization of steam distribution with CFD Insight into steam application: High Evenly distributed flow No recirculation and eddies Up to 99% of steam transferred to belt/tissue system Low Tissue 2017 B. Grashof public 11
17 Visualization of steam distribution using CFD Steam hood Standard configuration Half vacuum Changed belt properties Tissue Virtual parameter study for a well-designed and sized steam hood Efficient use of steam for environmentally-friendly process Tissue 2017 B. Grashof public 12
18 Prediction of process behavior in pre-watering system using system simulation Forming Drying Yankee cylinder Reeling Press Pre-dewatering system Tissue 2017 B. Grashof
19 Virtual testing of different fabrics for fast process optimization High overall condensation efficiency of steam High tissue temperature resulting in increased after-press dryness Support of development to design optimized fabric for tissue application Tissue 2017 B. Grashof public 14
20 Positive effect of pre-dewatering system on overall performance and efficiency at costumer s site Thickness/bulk improvement > 10% at comparable basis weight Machine speed increase of around 15% - 20% Dry content increase after press up to 5% Tissue 2017 B. Grashof public 15
21 Summary and Outlook Next level of environmentally-friendly napkin tissue production using a predewatering system successfully implemented Simulation-enhanced development approach supports value creation for the costumer and provides deeper and improved process know-how Speed-up of development process using powerful new simulation techniques and strong partnerships with our costumers Tissue 2017 B. Grashof public 16
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