集成物流能流和（？）流分析的造纸过程建模与在线仿真研究
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摘要
造纸过程复杂，能耗较高。建模和仿真是优化过程能效达到节能目标的重要技术手段。针对目前在造纸过程建模、仿真和用能分析中未能有效集成物流、能流和不能在线仿真和实时分析的不足，本文应用热力学第一定律和第二定律的基本原理，基于序贯模块法，用面向对象、面向模式、数据库和可视化编程技术，以造纸过程各种基本单元、过程和设备为对象，针对复杂的、多物料、多过程的造纸过程的传热传质特点和造纸过程的结构、功能特性，以纤维、空气、水分和水蒸汽间的传热传质为主线，以集成物流、能流和为主要研究内容，取得了如下主要研究成果。
1、在造纸过程建模中集成物流、能流和流衡算与分析，提出了集成物流、能流和流分析的造纸过程通用建模方法。开发了混合、分离、纸页、蒸汽混合、空气混合、湿热空气、热回收、空气加热、除渣器、浆池、浆泵、旋翼筛、流浆箱、浓缩机、白水池、烘缸组、汽水分离器、换热器、送(抽)风机、变送器、阀门、PID、延迟等23个功能模块。重点研究了纸页动态模拟的数学模型，它综合考虑了纸页接触干燥和对流干燥水分蒸发速率与蒸汽消耗、通风能耗、蒸汽与空气的状态变量和主要的设备变量等因素。所有模型具有能量和量分析功能并与传统的物流分析集成。在此基础上，基于序贯模块法，给出了应用功能模块构建干燥部模块流程图的方法。
2、开发并优化了基于IAPWS-IF97标准(2007.8Rev)的水和水蒸汽物性库，具有全面、精确、快速、提高了边界一致性和自动测试等优点。同时建立了干空气等造纸过程相关的物性数据库。
3、在Windows平台下，开发了一套全新的集成物流、能流和流分析的造纸过程在线仿真软件WinPAMS。它重新设计了软件体系结构，运用数据库技术，集成了物流、能流和降低了仿真流程的复杂性，提高了运算速度，用更友好的人机交互实现了造纸过程的静态、动态在线仿真和实时分析。将离线、封闭、零散的建模与仿真变成在线、开放和集成的建模与仿真。应用案例表明，开发的模型结构合理，仿真的结果与实际测量的结果基本一致。通过改变进不同烘缸段新鲜蒸汽的流量或压力等手段，可节省新鲜蒸汽用量，降低吨纸汽耗。
4、研究了基于模块模拟器、LP/NLP和能量系统“三环节”模型三种形式的造纸过程优化。分别给出了实际的优化案例，达到了各自的优化目标。以适应造纸工业对于优化操作的要求，尤其是实时、在线优化越来越高的要求。
本文的研究成果将为实现整个制浆造纸过程集成物流、能流和流分析的建模与仿真提供方法、技术和实现的基础，为更有效挖掘造纸过程的节能空间打下基础和提供优化方法。
本文的主要特色和创新之处是：1)建立并开发了集成物流、能流和流衡算、显示、存储、分析和优化的造纸过程若干单元模型和功能模块；2)开发并优化了水和水蒸汽物性库，建立了造纸过程相关的物性数据库；3)设计并开发了一套全新的、体系结构柔性的、能够在线仿真和实时分析的造纸过程仿真软件WinPAMS。
Papermaking process is complicated and of high energy consumption. To save energy byoptimizing process energy efficiency, modeling and simulation are the important technicalmethods. Considering that the present modeling, simulation and energy-using analysis ofpapermaking process are lacking in the integrated analyses of the material, energy and exergyflows, furthermore, cannot realize online simulation and real-time analysis. Thus in thisresearch, according the heat and mass transfer characteristics and the structure and functionfeatures of the complicated, multi-material, and multi-process papermaking process, first,based on the first and the second laws of thermodynamics and the sequential modularapproach, then by applied object-oriented, pattern-oriented, database and visualizedprogramming technologies, using the basic units, process and equipments of papermakingprocess as the study object, the heat and mass transfer among fibers, air, water and steam asthe principal line, the modeling and online simulation of papermaking process integratedanalysis of material, energy and exergy flows as main research contents, the following mainresearch achievements are gained.
1. A general modeling method of papermaking process integrated analysis of material,energy and exergy flows is proposed. By integrated balance accounting and analysis ofmaterial, energy and exergy flows in the modeling of papermaking process, twenty threefunction modules have been developed, which are Mix, Split, Paper, SMix, AMix, WAir,RHAir, HAir, Rejector, Tank, Pump, Screen, HBox, Condense, Pool, Dryer, SWSplit,GWSplit, Fan, Transm, Valve, PID, Delay. The dynamic mathematic models of paper moduleare studied in emphasis. The vaporization speed of paper surface contact drying andconvection drying, the steam consumption, the ventilation consumption, the state variable ofsteam and air, and the main equipment variable would be considered comprehensively. All ofthe models possess the analysis function of energy and exergy, and integrate with the traditional material flow analysis. On that basis and the sequential modular approach, thedryer section modular flow constructed by those23function models is presented.
2. The property libraries of water and steam, which is based on the IAPWS-IF97Standard (2007.8Rev), have been developed and optimized. The libraries are comprehensive,precise, and quick to be consulted with boundary consistency and automatic test function.Related to the papermaking process, the property database of dry air, flue gas, furnace coolingand lime-ash have been developed as well.
3. A new online simulation software of papermaking process integrated analysis ofmaterial, energy and exergy flows, called WinPAMS, has been developed under the platformof Microsoft Windows. The software architecture has been re-designed. The static and thedynamic online simulation and real-time analysis have been realized with more friendlyhuman-machine interface, by methods such as applying database technology, integratingbalance accounting, display, storage and analysis of material, energy and exergy flows,reducing the complexity of the simulation flow, improving the operating speed, etc. Thetraditional offline, close, separate modeling and simulation of papermaking process have beentransformed into online, open and integration. Case study shows that the developed modelsare reasonable and the simulation results are nearly consistent with the actual measuringresults. The amount of fresh steam can be saved by means of altering the inlet flow orpressure of fresh steam of different dryer sections, thus the steam consumption per ton papercan be reduced.
4. The papermaking process optimizations of the simulator built on modules, the LP/NLPand the energy system “three-link” model have been studied respectively. Actual cases withthe goals of optimization achieved have been presented. To meet the requirement of optimizedoperation in the papermaking industry, especially the higher and higher requirement of realtime, online optimization.
The research achievement of this paper can provide the methodology, the technology andthe realization foundation for the modeling and simulation of the whole pulp andpapermaking process integrated analysis of material, energy and exergy flows. It can provide basis and optimization methods for better energy conservation in papermaking process.
The main features and innovation points of this paper are:
1. Twenty three unit models and function modules of papermaking process have beenconstructed and developed, which integrate balance accounting, display, storage, analysis andoptimization of material, energy and exergy flows.
2. The property libraries of water and steam have been developed and optimized. Theproperty database of dry air, flue gas, furnace cooling and lime-ash have been developed aswell.
3. Brand-new simulation software of papermaking process, named WinPAMS, has beendesigned and developed, whose software architecture is flexible, with online simulation andreal-time analysis.
1、在造纸过程建模中集成物流、能流和流衡算与分析，提出了集成物流、能流和流分析的造纸过程通用建模方法。开发了混合、分离、纸页、蒸汽混合、空气混合、湿热空气、热回收、空气加热、除渣器、浆池、浆泵、旋翼筛、流浆箱、浓缩机、白水池、烘缸组、汽水分离器、换热器、送(抽)风机、变送器、阀门、PID、延迟等23个功能模块。重点研究了纸页动态模拟的数学模型，它综合考虑了纸页接触干燥和对流干燥水分蒸发速率与蒸汽消耗、通风能耗、蒸汽与空气的状态变量和主要的设备变量等因素。所有模型具有能量和量分析功能并与传统的物流分析集成。在此基础上，基于序贯模块法，给出了应用功能模块构建干燥部模块流程图的方法。
2、开发并优化了基于IAPWS-IF97标准(2007.8Rev)的水和水蒸汽物性库，具有全面、精确、快速、提高了边界一致性和自动测试等优点。同时建立了干空气等造纸过程相关的物性数据库。
3、在Windows平台下，开发了一套全新的集成物流、能流和流分析的造纸过程在线仿真软件WinPAMS。它重新设计了软件体系结构，运用数据库技术，集成了物流、能流和降低了仿真流程的复杂性，提高了运算速度，用更友好的人机交互实现了造纸过程的静态、动态在线仿真和实时分析。将离线、封闭、零散的建模与仿真变成在线、开放和集成的建模与仿真。应用案例表明，开发的模型结构合理，仿真的结果与实际测量的结果基本一致。通过改变进不同烘缸段新鲜蒸汽的流量或压力等手段，可节省新鲜蒸汽用量，降低吨纸汽耗。
4、研究了基于模块模拟器、LP/NLP和能量系统“三环节”模型三种形式的造纸过程优化。分别给出了实际的优化案例，达到了各自的优化目标。以适应造纸工业对于优化操作的要求，尤其是实时、在线优化越来越高的要求。
本文的研究成果将为实现整个制浆造纸过程集成物流、能流和流分析的建模与仿真提供方法、技术和实现的基础，为更有效挖掘造纸过程的节能空间打下基础和提供优化方法。
本文的主要特色和创新之处是：1)建立并开发了集成物流、能流和流衡算、显示、存储、分析和优化的造纸过程若干单元模型和功能模块；2)开发并优化了水和水蒸汽物性库，建立了造纸过程相关的物性数据库；3)设计并开发了一套全新的、体系结构柔性的、能够在线仿真和实时分析的造纸过程仿真软件WinPAMS。
Papermaking process is complicated and of high energy consumption. To save energy byoptimizing process energy efficiency, modeling and simulation are the important technicalmethods. Considering that the present modeling, simulation and energy-using analysis ofpapermaking process are lacking in the integrated analyses of the material, energy and exergyflows, furthermore, cannot realize online simulation and real-time analysis. Thus in thisresearch, according the heat and mass transfer characteristics and the structure and functionfeatures of the complicated, multi-material, and multi-process papermaking process, first,based on the first and the second laws of thermodynamics and the sequential modularapproach, then by applied object-oriented, pattern-oriented, database and visualizedprogramming technologies, using the basic units, process and equipments of papermakingprocess as the study object, the heat and mass transfer among fibers, air, water and steam asthe principal line, the modeling and online simulation of papermaking process integratedanalysis of material, energy and exergy flows as main research contents, the following mainresearch achievements are gained.
1. A general modeling method of papermaking process integrated analysis of material,energy and exergy flows is proposed. By integrated balance accounting and analysis ofmaterial, energy and exergy flows in the modeling of papermaking process, twenty threefunction modules have been developed, which are Mix, Split, Paper, SMix, AMix, WAir,RHAir, HAir, Rejector, Tank, Pump, Screen, HBox, Condense, Pool, Dryer, SWSplit,GWSplit, Fan, Transm, Valve, PID, Delay. The dynamic mathematic models of paper moduleare studied in emphasis. The vaporization speed of paper surface contact drying andconvection drying, the steam consumption, the ventilation consumption, the state variable ofsteam and air, and the main equipment variable would be considered comprehensively. All ofthe models possess the analysis function of energy and exergy, and integrate with the traditional material flow analysis. On that basis and the sequential modular approach, thedryer section modular flow constructed by those23function models is presented.
2. The property libraries of water and steam, which is based on the IAPWS-IF97Standard (2007.8Rev), have been developed and optimized. The libraries are comprehensive,precise, and quick to be consulted with boundary consistency and automatic test function.Related to the papermaking process, the property database of dry air, flue gas, furnace coolingand lime-ash have been developed as well.
3. A new online simulation software of papermaking process integrated analysis ofmaterial, energy and exergy flows, called WinPAMS, has been developed under the platformof Microsoft Windows. The software architecture has been re-designed. The static and thedynamic online simulation and real-time analysis have been realized with more friendlyhuman-machine interface, by methods such as applying database technology, integratingbalance accounting, display, storage and analysis of material, energy and exergy flows,reducing the complexity of the simulation flow, improving the operating speed, etc. Thetraditional offline, close, separate modeling and simulation of papermaking process have beentransformed into online, open and integration. Case study shows that the developed modelsare reasonable and the simulation results are nearly consistent with the actual measuringresults. The amount of fresh steam can be saved by means of altering the inlet flow orpressure of fresh steam of different dryer sections, thus the steam consumption per ton papercan be reduced.
4. The papermaking process optimizations of the simulator built on modules, the LP/NLPand the energy system “three-link” model have been studied respectively. Actual cases withthe goals of optimization achieved have been presented. To meet the requirement of optimizedoperation in the papermaking industry, especially the higher and higher requirement of realtime, online optimization.
The research achievement of this paper can provide the methodology, the technology andthe realization foundation for the modeling and simulation of the whole pulp andpapermaking process integrated analysis of material, energy and exergy flows. It can provide basis and optimization methods for better energy conservation in papermaking process.
The main features and innovation points of this paper are:
1. Twenty three unit models and function modules of papermaking process have beenconstructed and developed, which integrate balance accounting, display, storage, analysis andoptimization of material, energy and exergy flows.
2. The property libraries of water and steam have been developed and optimized. Theproperty database of dry air, flue gas, furnace cooling and lime-ash have been developed aswell.
3. Brand-new simulation software of papermaking process, named WinPAMS, has beendesigned and developed, whose software architecture is flexible, with online simulation andreal-time analysis.
引文
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