Puu-23.

5000 Planning and

Execution of Pulp and Paper
Investment Project (3 cr)
Process Engineering
15.10.2015
Jarno Peltonen
Contents

• Introduction
• Tools in process engineering
• Process engineering in different phases of a project
• Engineering case examples

Puu-23.5000
2
Introduction

• Process engineering is done in all phases of a project

• Process engineer’s role in a project
– Responsible for process concept and design
– Coordinating engineering in other disciplines (mechanical,
electrical, automation)
• Information to other disciplines
• Responsible for designed system process-wise (piping, control
valves, check valves, DCS etc.); system is possible to operate

Puu-23.5000

3
Tools in process engineering

• Office programs
– Word
– Excel
– Visio
– PowerPoint
– Outlook
• Simulation programs
– WinGems
– ProSim
• AutoCAD
• Pöyry databases
– ProElina
– Jalina
– JPDoc / Share@Pöyry

Puu-23.5000

4
 Investment project
Development

IMPLEMENTATION

PRODUCTION

Pre- Detailed Project- Engin- Procure- Construc- Warranty Close-

Concept Start-up Operation
Feasibility Feasibility initiation eering tion Phase down
ment
y

Investment Investment- Final Mechanical Hand- Project

idea decision ”go-ahead” Completion over Close-out

Min 2 years Min 1 year ~ 2-3 years ~ 0,5 years 1-2 years > 25 years

Puu-23.5000

5
Process engineering in different phases
of a project
• Pre-feasibility study
– Assessment of the technical viability of a proposed project
– Comparison of alternatives

• Feasibility study
– Preliminary design and of the chosen solution
– Investment cost estimate for investment decision

• Basic engineering
– Preparatory engineering for selection of equipment suppliers and
permit applications
– Investment cost estimate and budget for final ”go-ahead”

• Detail engineering
– Project implementation with selected processes

Puu-23.5000

6
PRE-FEASIBILITY STUDY & FEASIBILITY
STUDY

PROCESS ENGINEERING

Puu-23.5000

7
Pre-Feasibility

• Definition of design criteria

• Calculation of preliminary main dimensioning
• Preparation of preliminary process description
• Preparation of preliminary equipment lists for investment
cost estimates

Puu-23.5000

8
Feasibility

• Process concept
• Review of design criteria for process design
• Update of preliminary main dimensioning (balances)
• Calculation of preliminary energy balances
• Revision of process description
• Preparation of simplified line diagrams
• Update of equipment lists for revised investment cost
estimate
• Special studies
• Preliminary discussions with equipment suppliers
Puu-23.5000

9
Feasibility

• Design criteria for pulp mill

– Product (bleached/unbleached,
Softwood
ECF/TCF, etc.) Annual production ADt/a 350 000
– Raw-material base Operation days d/a 350
Average production,
– Cooking method bleached pulp ADt/d 1 000
– Production, ADt/a Capacity efficiency % 90
Woodhandling % 80
– Design factor Drying % 85
– Annual operating days Design capacity,
bleached pulp ADt/d 1 111
– Department capacities (from Raw material Pine + spruce
main dimensioning calculations)

Puu-23.5000

10
Feasibility

• Pulp mill main dimensioning – input data

Puu-23.5000

11
Feasibility

• Pulp mill main dimensioning – department capacities

Puu-23.5000

12
Feasibility
• Pulp mill energy balance

Puu-23.5000

13
Feasibility
• Pulp mill energy balance

Puu-23.5000

14
Feasibility
• Simplified line diagram

Puu-23.5000

15
BASIC ENGINEERING

PROCESS ENGINEERING

Puu-23.5000

16
Basic Engineering

• General process engineering

– Preparation of technical specification documents for enquiries
– Preparation of technical tender comparisons
– Participation in technical negotiations, minutes of meetings

• Process design
– Review of design criteria for process design
– Update of main dimensioning
– Update of energy balances
– Calculation of water and secondary heat balances
– Standards for the process design
– Definition of process flow substances
– Special studies

Puu-23.5000

17
Basic Engineering

• Departmental design criteria Selected

– Departmental dimensioning of
Wood handling

Debarking and Chipping m3sub/h 600

different mill departments
Chip screening m3loose/h 2 000

Fibreline

Cooking ADt/a 3 000

Deknotting/Screening ADt/a 2 900

Oxygen delignification ADt/a 2 800

Bleaching ADt/a 2 700

Drying ADt/a 2 800

Recovery plant

Evaporation t H2O/h 1 000

Recovery boiler tDS/d 4 000

Causticizing m3WL/d 10 000

Lime kiln t CaO/d 700

Puu-23.5000

18
Basic Engineering

• Water balance
– Mill water
– Cooling water
– Hot water
– Warm water
– Effluent
– Etc.

Puu-23.5000

19
Basic Engineering

• Bleach plant water balance

Puu-23.5000

21
Basic Engineering

• Process simulation (WinGems)

Pre-oxygen wash

1st W asher 2nd W asher

E-value = 4 E-value = 5

178.8 / 0 / 84.6
DF = 2.1 DF = 2.1
Oxygen stage(s) Post Oxygen wash 178.7 / 0 / 80

1st W asher 2nd washer:

66
E-value = 5 E-value = 5
M IX NaOH
5 62
MP-steam DF = 2 DF = 2
O2 MP-steam
197.5 / 10 / 96.9
188.1 / 10.5 / 94.7

53
13
658.3 / 3 / 95

680.1 / 0 / 95.1

383.1 / 5 / 98.6

364 / 5 / 85.2
159.6 / 12 / 86.2
209.9 / 0 / 95.1

87.6 / 0 / 96.9

131.7 / 0 / 96.9

M IX COM20
BM IX 6 COM21
BM IX
61 25 26
M IX
34
M IX
stream 132, post-wash 55

402.3 / 0 / 96.9

402.3 / 0 / 84.6
67 kg COD/ODt bleached
110 kg Na2SO4/ODt bleached

219.3 / 0 / 96.9
DI LUT E DI LUT E
DI LUT E DI LUT E 35 54
64 65

Puu-23.5000

22
Basic Engineering

• Process design continues…

– Preparation of line diagrams
– Preparation of connections between departments diagram
– Update of equipment lists for investment cost estimate
– Technical documents for contracts
– Preparation of process description and control philosophy for
detailed engineering

Puu-23.5000

23
Basic Engineering
• Line diagram

Puu-23.5000

24
DETAIL ENGINEERING

PROCESS ENGINEERING

Puu-23.5000

25
Detail Engineering

• General process engineering

– Preparation of technical enquiry specifications
• for tanks, vessels and agitators
• for pumps and vacuum pumps
• for auxiliary equipment
– Equipment and machinery specifications for purchase
• Checking of contract documentation

Puu-23.5000

26
Detail Engineering

• Process design
– Preparation of dimensioned flow sheets
– Establishment of process and equipment data base
– Compilation of final process and equipment data
– Compilation of lists
• Equipment and motor
• Pump
• Tank, vessel and agitator
– Preparation of flow diagrams for process utilities
– Process engineering of interconnections between mill
departments
– Checking pump calculations
– Preparation of PI-diagrams

Puu-23.5000

27
Detail Engineering
• Flowsheet

Puu-23.5000

28
Detail Engineering
• PI-diagram

Puu-23.5000

29
Detail Engineering

• ProElina database – input, e.g. equipment data

Puu-23.5000

30
Detail Engineering
• ProElina database – output, e.g. a pump list

Puu-23.5000

31
Detail Engineering
• Interconnecting piping diagram

Puu-23.5000

32
Detail Engineering

• Process Descriptions etc.

– Detailed process description
– Loop functional description (or diagram)
– Interlocking, group start and sequence description (or diagram)

– Operating display design

– FAT-testing on functional level (Factory acceptance test)
– Space classification (for safety)
– Participation in HAZOP analysis
– Documents required by local legislation

Puu-23.5000

33
Detail Engineering

• Loop functional description

851-HC-4002 BLEND CHEST DISCHARGE CONTROL

Function
Closing valve on the suction side of the pump 851-045 FEED PUMP PRIMARY STAGE .

In AUTO mode the valve opens according to start signal of the pump 851-045 FEED PUMP PRIMARY STAGE and when the valve
has opened 75 %, the pump starts.

In AUTO mode the valve closes, when screening flushing is started or pump 851-045 FEED PUMP PRIMARY STAGE is stopped.

Interlocks
Valve can be opened, when:
- 851-LC-4001 BLEND CHEST LEVEL > LL limit = 5 %

Alarms

Puu-23.5000

34
Detail Engineering

• Interlocking diagrams

Puu-23.5000

35
Detail Engineering
• Operating display design

Puu-23.5000

36
Detail Engineering

• Operating Instructions
– Process start-up
– Operation procedures
– Shut-down procedures

• Training
– Preparation of training material
– Training

Puu-23.5000

37
Detail Engineering

• Engineering for commissioning and start-up

– Definition of water run test loops
– Compilation of check-out lists
– Technical definitions for the execution of commissioning, test runs
and start-up
– Participation in commissioning, test runs and start-up
– Compilation of commissioning and test run results
– Assessment of performance against guarantees

• As-built documentation
– Equipment, pump, tank etc. lists
– PI-diagrams
– Operating manuals

Puu-23.5000

38
Detail Engineering

• Commissioning check-out after start-up is expensive

Start-up curves
125
Production 2000 ADt/d

% of design capacity
100
Difference 15 000 ADt/month C
J
75
BHKP price 485 EUR/ADt G

50
Profit 7,275 MEUR/month
25

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

m o nths a fte r the sta rt-up

Puu-23.5000

39
ENGINEERING CASE EXAMPLES

PROCESS ENGINEERING

Puu-23.5000

40
Engineering Case Examples

• Analysis of an operating system

– Operations improvement, operating performance criteria
• Time efficiency (availability)
• Production stability
• Ratio of actual production to practical maximum capacity
• Energy balance
• Wood consumption
• Water consumption
• Personnel productivity
• General overheads
• End product performance

Puu-23.5000

41
Engineering Case Examples
• Analysis of an operating system
– Operations improvement, duration curves

7000

6000

5000

4000
ADt/d

3000

2000

1000

0
0
20
40
60
80
100

140
160

200
220

260
280

320
340
120

180

240

300

360
Days
2001 (ce = 73.8 %) aver. 2001 = 2572 MSR 2001 = 3475
2002 (ce = 76.6 %) aver. 2002 = 3685 MSR 2002 = 4810
2003 (ce = 88.3 %) aver. 2003 = 5077 MSR 2003 = 5748

Puu-23.5000

42
Engineering Case Examples

• Analysis of an operating system

– Operations improvement, effluent volume reduction

Puu-23.5000

44
Engineering Case Examples

• Analysis of an operating system

– Operations improvement, effluent volume reduction

Puu-23.5000

45
THANK YOU!

CONTACT:
NAME: Jarno Peltonen
TITLE: Director, Pulp Technology
MAIL: jarno.peltonen@poyry.com

Puu-23.5000
47