RAD-R146 379 COMPUTER MODEL FOR ECONOMIC STUDY OF UNBLEACHED KRAFT i/iPAPERBOARD PRODUCTION(U) FOREST PRODUCTS LAB MADISON WIP J INCE AUG 84 FSGTR-FPL-42

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MICROCOPY RESOLUTION TEST CHqARTM*TFOift 1IU OF STAa*OI 143 A

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United StatesCo p trM dlf rDepartment ofAgriculture C m ue o e oForest Economic

* Forest Servomie Study of.0 ProductsLaboratory

GenralUnbleached KraftTecnral .

FPL42Paperboard

ProductionC Peter J. Inc.

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* >AwkwIehd lireft peperboerd Is produced frmwood The computer modl dscibe In ths auweas

fibe In an Industrial pemein-- process. A highly developed entirey at goe FoMe Produfte Leoratuuy.secfc and detalled moe ftepoesIs on the Uniersit of Wcongli's VNIYAC 1110

presented. The model Is ale. preeented asworking optn ytm The progrem ie writn In standerdcomputer Program A Oee of the computer Program ANIP4RA agae. A rcmv veer shoud

* win provid data on physical Paramneters Of the proces at Nee have (I some basic experWnc or am"Iliart* anid on ploce of material Inputs and outputs. The with FORTRAN wopuerlagug and (2) a good

programw is then uW to calculate mateie and enry woorking knowledge of parametes In the modelwhrequirements of the prcsand to calculate 1elte at h ao aaeer na mlahdlmitrevenues and variable costs. The programn doen not paperboard production processderiv capital costs or fixed costs The program Ismost ueeful In estimating precisely the economicimpact of changes In physical parwaters Of theprocee., changes In technology, or changes in relatedprices As such, the model can be used to estimate theeconomic effect, on revenues and costs, oftechnological changes or changes In prkcs.m~

Keywordet Economics, technology, unbleached kralt* paperboard process, computer model.

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Computer Model forEconomic Study of (2>Unbleached Kraft SICPaperboard....

P ro d u c tio n ..... . Co-elAvail and/or

11st Spec ial

Peter J. Ince, Research ForesterForest Products Laboratory, Madison, Wis. .

Introduction ,.

Unbleached kraft paperboard Is produced from wood The computer model uses a set of data consisting offiber in fairly complex industrial papermaking about 180 physical variables of the process and alsoprocesses, typically in large paperboard mills. Such prices of various Inputs and outputs. (It does notmills usually include a wood preparation area, a kraft Include capital costs or fixed costs, such asdigester, a chemical recovery process, a paper administrative overhead or maintenance.) The datamachine, steam and power system, and related Include major process variables as well as many minorfacilities. Various publications and texts describe variables. As a result, the user is able to develop anthese processes.1 Overall, in modern conventional understanding of the sensitivity of results to specificmills there is a general similarity in process design and changes In the process. For example, the model canequipment configuration. be used to study the potential economic Impact of a

specific new technological development. First, given aBecause the production process is complex, any set of data that represent a "conventional" process,changes In supplies, equipment, or design may have the user can operate the model on those data to obtainfar-reaching effects on material and energy "base case" results, the conventional process materialrequirements, and costs and revenues. We have and energy requirements, revenues and variable costs.designed a computer model to calculate those material The user can then adjust all data variables that areand energy requirements of the unbleached kraft likely to change as a result of the new technologicalpaperboard process and to estimate the associated development. The user can then again operate therevenues and variable costs. This paper describes that model using the adjusted variables as data to obtainmodel. new results, new material and energy requirements,

and new revenue and variable cost estimates. Results'The Technical Association of the Pulp and Paper Industry (TAPPI) has can be compared to the base case results to provide anrecomnended texts on these processes, of which two re: understanding of the physical and economic Impact of

the new technology. Such results are useful InJoint Textbook Committee of the Paper Industry. Pulp and Paper planning research, setting research goals and priorities,Manufacture Series, Vol. I, II, and Ill. 2d ad. (MacDonald, Ronald G., and in evaluating the economic potential of results ofad.; Franklin, John J., technical ad.) McGraw.Hill, New York; 1969. technical research and developments In pulping and(Available from Tappl.) papermaking.

Casey, James P., ad. Pulp and Paper, Vol, I, II, and Ill. WileyIntereclence, New York; INS.

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Scope of Model Model Subroutines p

The computer model is a detailed representation of a Subroutine STPREP: Stock preparation, -modern unbleached kraft paperboard production paper machine, finishing, andprocess. A general diagram of the process is shown in shipping area 9" "figure 1. The model itself consists of nine separateelements or subroutines. The subroutines are as This subroutine calculates the quantities of variousfollows, in the order in which they are referenced by the inputs required in the stock preparation, papermain program: machine, finishing, and shipping area of the overallSTPREP, which models stock preparation, additives, process. It also reads prices of various inputs to that

paper machine, finishing, and shipping areas of the area. The data required for this subroutine includeprocess; total finished paper or paperboard product output (in .DIG, which models the digester, pulp washers, black dry tons per day), rates of use of chemicals and sizing

liquor evaporators, and concentrators area of the additives in stock preparation, moisture content ofprocess; sheet into and out of the paper machine dryer, and so

WDPREP, which models the wood preparation, on. Altogether, 26 items of data are required. Thedebarking, chipping, and chip-screening area of the specific parameters, each assigned a four-letter codeprocess; name, are listed in alphabetical order:

RECBLR, which models the recovery boiler, lime kiln, ACID -Quantity of concentrated sulfuric acid addedand recausticizing area of the process; to system in stock preparation (pounds/dry ton

ELEC, which models electric power requirements of the of paper or paperboard produced).overall process; ALUM -Quantity of alum added in stock preparation

STEAM, which models the steam system and electrical AU - ny alum add inq sock prparationcogeneration; as dry alum solids in liquid slurry (pounds/dry

PWRBLR, which models the power boiler, coal ton of paper or paperboard produced).-.handling, and desulfurizing area of the process; DBKT -Paper or paperboard recycled as dry "broke"

WATER, which models water supply and wastewater and trim to stock preparation (ratio of totaltreatment; and paper or paperboard production).

SALES, which models sales revenues, material, energy, DFOM -Quantity of defoamer additives in stockpreparation and machine areas (pounds/dry tonand labor costs associated with the process. of paper or paperboard produced).

The nine subroutines are described separately in detail. DSMC -Moisture content of sheet entering heatedEach subroutine requires a specific separate set of dryer section (ratio of total weight of sheet).

data input, which is provided along with sample values. PACD -Purchase price, f.o.b mill, of sulfuric acidA list of the mathematical calculations contained in (s/ton).each subroutine is also Included. A flow diagram, PALM -Purchase price, f.o.b. mill, of alum (/ton).showing the physical material and energy flows and PCOR -Price of recycled old corrugated, used as raw

showng he hyscal ateialandenery fowsandmaterial furnish in stock preparation (S/dryprocess areas associated with each subroutine, is toi).given whenever appropriate. Finally, a sample printout PDFM ton).from the computer model, based on the sample input -Purchase price, f.o.b. mill, of defoamer (S/ton).data, is provided as are user notes and guidelines for PMND -Minimum density of paper or paperboarddpatain oided are uder ncomteand guiine for product (dry pounds/I,000 feet).

pplication of the model. A complete listing of the PPAP -Price of other recycled paper used as rawprogram Is Included In the Appendix. material in stock preparation (S/dry ton).

PPDN -Average density of paper or paperboardproduct (dry pounds/I,000 feet).

PPMC -Average reel moisture content of paper orpaperboard product (total weight basis).

PPRD -Paper or paperboard production volume of themill (dry tons/day).

PRSN -Purchase price, f.o.b. mill, of rosin (S/ton).PSLM -Purchase price, f.o.b. mill, of slimicide (S/ton).PSTC -Purchase price, f.o.b. mill, of starch (S/ton).ROR -Recycled old corrugated raw material as a

ratio of total weight of paper (board) product(decimal ratio of dry product weight). Recycledfurnish enters in slockprep.

RCYD -Yield or recovery weight for recycled oldcorrugated (ratio of raw material dry weightrecovered in product).

RPAP -Recycled paper raw material as a ratio of totalweight of paper (board) product (decimal ratioof dry product weight).

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Pulpwood roundwood Power BoilerWood Preparation Fuelhandling Coal&

Debarking f Power boiler & woodPurcha sChipp ning furnace fuel

Purchased chips Chip screening Desulfurizing %

(Steam)Chips

Water Water Electricsupply to power, Electric

process to - Cogenerationprocess

Wastewater Water Steamtreatment from to

process process\ / (Steam)

Chemical Pulping White liquor

ConcentratedPulp ,black Chemical Recovery

used liquor Recovery furnace

Recausticizing

Washing, & Black Liquor ! .-

Prerefining Evaporators & imeConcentrators Lime

"m.rudj J

ulp stock Lime ReburningMud washers

, Lime kiln\V..

PapermakingStock preparation Finished productAdditives (paper or board)Paper machineFinishing & shipping

Figure 1.-Schematic of an unbleached kraft papermaking process.

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% RPYD -Yield or recovery rate for recycled paper raw Calculate each additive required (tons/day):! material (ratio of raw material dry weight

recoeredin rodut).TALM = PPRD x ALUM/2000.0

reovre Inprdut)

S ROSN -Quantity of rosin added in stock preparation TACD = PPRD x ACID2000.Oas rosin solids (poundsidry ton of paper or TSTC = PPRD x STRC12000.0

%paperboard produced). TDFM = PPRD x DFOM/2000.0!_ SLIM -Quantity of slimicide additives (poundsdry ton TRN= -Dx ON/0." of product). TSLM = PPRD x SLIM2000.0: STRC -Quantity of starch additives In stock A flow diagram (fig. 2) Illustrates the process areas and

preparation as dry solids (pounds/dry ton of parameters modeled In this subroutine. The datai' !paperboard product). parameters are underlined and parameters calculated

! SVAL -Average sales value, f.o.b. mill, of paper or (see list of calculations) in this subroutine are shown Inpaperboard product ($/dry ton). parentheses. Note that figure 2 Includes parameters_

TRWD -Trimmed reel width on sheet roll winder related to steam demands and electric power factors. (inches). used in later subroutines.

• .' Calculations in Subroutine STPREP are:

',- SuruieSG:Dgse,.upwses

.. Calculate total dry weight of chemical and sizing Sbrouineo DIG:porgetr, pulp wasersadditives, assuming all of alum, starch, and rosinblcliureaotrsan

" additives are In final product, plus one-half of acid, concentrators areai defoamer, and slimicide additives, by weightThssbotncaulesheqniisofIpsad

(pud/r tofprdc) outputs In the digesterI~s), pulp washers, black liquor-" ADTV = ALUM + STRC + ROSN + 0.5 x (ACID + DFOM + evaporators, and concentrators area. Results are based..- SLIM in part on the quantity of wood pulp required In stock

~preparation, as derived by the previous subroutine.: Calculate quantity of recycled old corrugated used (dry Fourteen additional items of data are required for this

tons/day): subroutine: .

RC RT = RCO R x ((PPRD - (PPRD x A DTVI2000.0))/RCYD) A N - c i e a k l co en r t n in w te iq rCalculate quantity of recycled paper used (dry (pounds/cubic foot white liquor).

dtonsPday): AALK -Active alkali (in white liquor entering digester),sodium hydroxide and sodium sulfide In white

RPPT = RPAP x ((PPRD -(PPRD x ADTV2000.0))DRPYD) liquor, In sodium oxide weight equivalentrecove rdo oi product)

Calculate wood pulp production quantity required (dry BSDS -Black liquor solids In weak black liquor fromtons of pulpsday): digester and washers to evaporators (tons ofPROD = PPRD -(PPRD x ADTV/2000.0)- (RCRT x RCYD) dry solids/dry ton of pulp).SyauP(RPPT x RPYD) CCBL -Solids content of concentrated black liquor,

exiting concentrators to salt cake mix tank InCalculate total dry paper throughput of paper machine, recovery boiler area (liquor solids weight ratioincluding product plus dry broke and dry trims volume of total liquor).recycled (dry tons/day): CEBL -Solids content of evaporated black liquor,Tlrexiting evaporators and entering concentrators

. TDPT = PPRD + (PPRD x DBKT) (liquor solids weight ratio of total liquor). lCNBL -Solids content of weak black liquor exiting

Calculate average operational paper machine speed washers to evaporators (black liquor solids(lineal feet of finished paper sheet/in): weight ratio of total black liquor weight).ASPD ((PPRD/1440.0) x (2000.0)(PPDNI1.0)(TRWD/12.0) PWMC -Pulpwood moisture content entering chip frsdinann(decimal ratio of wet weight).efCalculate maximum operational paper machine speed PYLD -Pulp yield, ovendry weight of pulp to dry(lineal feet of finished product/min): weight of pulp chip raw material entering

• digester (decimal ratio).MSPD = APPRD/ 0.0) x (20.0)(PMND/1000.0)/(TRWD12.0) SCLS -Total salt cake (sodium sulfate) losses, orSLI)n'prt"makeup chemicti l" requirements (salt cakeCalculate total water removal In heated dryer setion of added In recovery) (poundsdry ton of pulp).paper machine (tons/day): SoPL -Salt cake loss In pulp out of washers (ratio ofTWRD (TDPTI(.0 -DSMQ) -(TDPTIII.0 -PPMQ) total salt cake losses). (Remaining salt cake

AA se - are aali c on occur In evaporators,recovery furnace, and recausticdzing ahis.)

11dcia rai of dr woo weight).r r ee

N._ 4C al wes

W74zM," 7Z7-1. 7- I

Adiie tnia) PRD r osplia

ACDiie ( PAton) (PROD) dry tons rulp/day

old corrugated fiberboard/Stock Preparation, day, a $PCORldry ton

Refining & based on ROOR & RCYD

Alum < -(RPPT) dry tons other* (TL.,,recycled paper &

ALUM S PA~tonboardiday, 0 SPPAP/dryALUM0 SPALMtonton based on RPAP & RPYD

Refinedstock with

Defoamer additives &DF )Recycled recycleddry "broke" materials

D M $D ltn& trims Steam demands* OFM @PDFMtonfrom subroutine

STEAM:Machine

Rosin- turbines 14-pres. steamn for(TRsN)...i~ machine turbines

\V based on HPPU lbROSN @ SPRSN/ton steam/tlon product

Paper Machine (eunt e.pe.pOesHeadbox & (eunt o.pe.poes

Siiie(TSLM) ShetFrmn -Low-pres. steam for-U -PL~o auxil. & misc.,

SLIM $PSL/tonbased on SLPM(TOPT) dry tons total lb steam/dry ton

throghpuidayproductstarch thogptdy Wet sheet to

thermalstaSTRC e SPSYC/ton r--for thermocompressors,

\VDSMC based on HPTC lb

Paper Machine tmdrtoThermal Drying -- - -Mod.-Pres. steam

for thermal drying,4 based on SUPD lb %

steam/lb water

Electric power factors uremvdfo

A from subroutine ELEC:HP( HPM, HIP) Finishing & N

Shipping(MOR) tone water/day.4 removed from sheet

In thermal dryingPPRD@a ISYAL/ton,

f.o.b. mill

Figure 2 -Stock ppreration, paper mach/ne, fin/ahing and sh/pp/ng area: Subrout/ne

S F;WE5

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SOAP -Quantity of saponified fatty acids (soap) Calculate water in concentrated black liquor torecovered in soap skimmer in evaporator area recovery area (tons/day):(soap will go to external tall oil plant) (dry CBLW = (TBLSCCB - TBLSpounds/ton of wood chips into digester).(Ston). mill, of soap skimmings Calculate water removal in black liquor concentrators

TPSV -Turpentine sales value, f.o.b. mill (S/gallon). (tons/day):TURP -Turpentine recovery (gallons/ton of wood chips WRCN = EBLW - CBLW

into digester).Calculate white liquor volume to digester (thousandCalculations for Subroutine DIG are: gallons/day):

Calculate quantity of pulpwood chips required as input TWLV = ((TDAA x 2000.0Y)AACN)/133.6806"to digester (dry tons/day): A flow diagram (fig. 3) shows the process area andPPWD = PRODIPYLD parameters modeled in this subroutine. Parameters

calculated in this subroutine are in parentheses. NoteCalculate turpentine recovery from wood chips: also that figure 3 includes parameters related to steam

(A) Calculate recovery (gallons/day): demands and electric power factors used in latersubroutines.

TRPD = TURP x PPWD

(B) Turpentine specific gravity: Subroutine WDPREP: Wood preparationareaTSPG = 0.6 This subroutine calculates the quantities of various

(C) Turpentine recovery (tons/day): kinds of pulpwood required as input to the woodpreparation area. Six kinds of pulpwood are included in

TRTD :TRPD x (0.13368) x (62.4) x TSPG/2000.0 the model: hardwood species-roundwood, purchasedwhole-tree chips and purchased "clean" chips; and

Calculate black liquor solids to evaporators in weak softwood specles-roundwood, purchased whole-treeblack liquor (tons/day). chips and purchased "clean" chips. This subroutineTBLS = PROD x BSDS also calculates the quantities of wood "residues," bark

and fines, generated in the wood preparation area. ACalculate water to evaporators in weak black liquor total of 27 items of data is required by this subroutine:(tonsiday): HBPC -Weight ratio removed as bark In debarkingWBLW = (TBLS/CNBL). TBLS hardwood roundwood pulpwood (ratio of total

dry weight of purchased roundwood IncludingCalculate soap recovery and black liquor solids bark).remaining after soap recovery (tons/day): HCHM - Moisture content of hardwood purchasedSOPR = SOAP x PPWOi2000.0 "clean" chip pulpwood (decimal ratio of wetTOLS = TBLS- SOPR weight, average).

HTCF -Fines removed in screening hardwoodCalculate active alkali required in sodium oxide weight purchased "clean" chips (ratio of total dryequivalent (in white liquor to digester) (tons/day): weight of chips).

HWCD -Total weight per cord of hardwood roundwoodTDAA = AALK x PPWD pulpwood, wet weight basis (pounds/cord

wIncluding bark, as purchased).Calculate wet weight of pulpwood chips Into digester HWFR -Fines removed in screening hardwood(tons/day): roundwood chips (ratio of total dry weight ofPWIN = PPWD(I(.0 - PWMC) hardwood roundwood chips before screening).

HWMC -Average moisture content In hardwoodCalculate water in evaporated liquor to black liquor roundwood pulpwood (ratio of total wet weightconcentrators (tons/day): of pulpwood as purchased, Including bark).

HWPC -Hardwood purchased chip furnish (whole-treeEBLW= (TiBLSICEL) aTBLS nd "clean'" as a ratio of total hardwood into

Calculate water removal in evaporators (tons/day): digester (fraction of total dry weight ofhardwood purchased chip and roundwood

WRIEV WBLW - EBLW furnish).

funih)

6Ir

(PPWO) dry tons pulpwoodb4 reqJday

PYLD m

C~hips to digester Steam demands fromNt subroutine STEAM:

4 Chip Feed & Steaming* I ~(Digester) -- - - - - Low-pres. steam

for chip steaming* f vessel, based on

* I SLO lb. steam/dry

Turpentinetnw(TRPO) gal/day. b

White liquor from 1V orse ( Dons/day, Med.-pres. steamchemcalrecoery DigeterVesslsfor liquor& reaustcizng Iprenatin &heaters, based on

Cooking,&Biow------------------SUDH lb.steam/(TOA) tns ine efiers103 gal white

active alkaliday, liquor to digester. 4

white liquoriday,based on AACN' Pulp NII

and AAL Washer

(TBLS) + (SOPR) Soap recovery:dry tons black (SOPF) dry tonsiday,liquor solids a SISOPP/dry ton(BLS)/day to based on SOAP

Med.-pres. steamfor evaporator

\y steam Jets, basedDeshive Refining - - on SNJE lbiton BLS

HighDensty Lquorto evaporator

Strg Evaoraor Low-pres. steam forwater removal,based on SLEW lbstearnlb water

(WREV tonsremoved from*water removed/ liquor

day in evaporator Evaporated blackWashedliquor (TBLS)

pre-refined tn L/apulp

CEBL

BiackLiquor - -Low-pros. steam forConcentrators water removal in

concentrators,Elecric owe facorsbased on SLON lb[lcticpwe fctr steam/ilb water

from subroutine ELEC: (WACN) tons water CCBL removedHP(A~ HP(2M & HP(13) removed/day

in concentrators

(TILS) dry tons(PROD ton washd. HS/day to recovery

PROD)fnd pulpdy boiler in concentrated dq

to stock preparation lqo.' .J

Figure 3.-Digeater, pu/p waahing, pre-refining and evaporator area: Subroutine DIG.

7d

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HWTC -Hardwood whole-tree chips as a ratio of total Calculations for Subroutine WDPREP are:hardwood purchased chips (ratio of total dry Calculate quantity of softwood chips Into digester (dryweight of hardwood purchased chips).

HWTF -Bark and fines removed in screening hardwood tons/day):whole-tree chips (decimal ratio of total dry SPWD = PPWD x SFWDweight of hardwood whole-tree chips).

HWTM -Moisture content of hardwood purchased Calculate quantity of hardwood chips into digester (drywhole-tree chips (decimal ratio of wet weight, tons/day):average).

PHPC -Price or value of hardwood purchased "clean" HPWD = PPWD x (1.0- SFWD)chips (/ton as purchased, average).

PHRW -Purchase price, f.o.b. mill, of hardwood Calculate quantity of softwood roundwood chips intoroundwood (/cord, average). digester (dry tons/day):

PHWC -Purchase price, f.o.b. mill, of hardwood whole- SRPW = SPWD x (1.0 - SWPC)tree chips (/ton as purchased, average).

PSPC -Price or value of softwood purchased "clean" Calculate quantity of hardwood roundwood chips intochips (S/ton as purchased, average), digester (dry tons/day):

PSF W -Purchase price, f.o.b. mill, of softwood HRPW = HPWD x (1.0- HWPQroundwood (/cord, average).

PSWC -Purchase price, f.o.b. mill, of softwood whole- Calculate quantity of softwood fInes removed Intree chips (/ton as purchased, average). scen softwood fines reod if

SBPC -Weight ratio removed as bark in debarking screening softwood roundwood pulpwood chips (finessoftwood roundwood pulpwood (ratio of total go to power boiler) (dry tons/day):dry weight of purchased roundwood, including SRFR = (SRPWI(1.0 - SWFR)) x SWFRbark).

SCHM -Moisture content of softwood purchased Calculate quantity of hardwood fines removed in"clean" chip pulpwood (decimal ratio of wet screening hardwood roundwood pulpwood chips (finesweight, average). go to power boiler) (dry tons/day):

SFWD -Softwood ratio of total pulpwood furnish Into HRFR = (HRPWI(1.0 - HWFR)) x HWFRdigester (decimal ratio of total dry weight offurnish). Calculate quantity of softwood bark removed from

STCF -Fines removed in screening softwood softwood roundwood (to power boiler) (dry tons/day):purchased "clean" chips (ratio of total dryweight of softwood purchased "clean" chips). SBRK = ((SRPW + SRFR)Y(1.0 - SBPC)) x SBPC

SWCD -Total weight per cord of softwood roundwoodpulpwood, wet weight basis (pounds/cord Calculate quantity of hardwood bark removed fromincluding bark, as purchased). hardwood roundwood (to power boiler) 1dry tons/day):

SWFR -Fines removed in screening softwood HBRK = ((HRPW + HRFR)I(1.O - HBPC) x HBPCroundwood chips (ratio of total dry weight ofsoftwood roundwood chips before screening).softwoodera oiudwe chiptbeforescreenin g).Calculate required quantity of softwood roundwood

SWMC -Average moisture content in softwoodpuwod(rs/a)roundwood pulpwood (ratio of total wet weight pulpwood (cords/day):of pulpwood as purchased,*including bark). CDSW = ((SRPW + SRFR + SBRK)(1.0-

SWPC -Softwood purchased chip furnish (whole-tree SWMQ)(SWCD/2000.0)and "clean") as a ratio of total softwood intodigester (fraction of total dry weight of Calculate required quantity of hardwood roundwoodsoftwood purchased chip and roundwood pulpwood (cords/day):furnish).

SWTC -Softwood whole-tree chips as a ratio of total CDHW = ((HRPW + HRFR + HBRK)/(1.0-softwood purchased chips (ratio of total dry HWMC))/(HWCD/2000.0)weight of softwood purchased chips). C

SWTF -Bark and fines removed in screening softwood Calculate quantity of screened softwood purchasedwhole-tree chips (decimal ratio of total dry chips into digester (dry tons/day):weight of softwood whole-tree chips). SPCH = SPWD x SWPC

SWTM -Moisture content of softwood purchasedwhole-tree chips (decimal ratio of wet weight, Calculate quantity of screened hardwood purchasedaverage). chips into digester (dry tons/day):

HPCH =HPWD x HWPC

-V. *1 4r .r *.-

a- - 0 . - - - -' .

- Calculate quantity of softwood fines, including fines Subroutine RECBLR: Recovery boiler,from whole-tree chips and "clean" chips screening lime kiln, and recausticizing area(fines to power boiler) (dry tonsiday): lm in n easiiigaeSWCF ((SPCH x SWTC)/(1.0- SWTF)) x SWTF This subroutine calculates the quantity of steam heatSPCF = ((SPCH x (1.0 - SWTC))(1.0 - STCF)) x STCF energy generated in the recovery boiler, with t

concentrated black liquor as fuel, and calculates theCalculate quantity of hardwood fines, including fines quantities of various other inputs required in thefrom whole-tree chip and "clean" chip screening (fines chemical recovery, recausticizing, and lime system

,l to power boiler) (dry tons/day): area. A total of 16 items of data is required for this

HWCF = ((HPCH x HWTC)/(1.0 - HWTF)) x HWTF subroutine:HPCF = ((HPCH x (1.0- HWTC))/(1.0 - HTCF)) x HTCF ACTV -Activity of white liquor (ratio of active alkali to

total alkali, in sodium oxide weightCalculate quantity of "clean" softwood chips including equivalents).fines (dry tons/day): AVLM -Lime availability (active calcium oxide weightSPC =ratio of total lime to slaker) (Remainder is

PC=(SPCH x 10 WT + Passumed to be inert material in causticizingreaction.)

Calculate quantity of softwood whole-tree chips CAUS -Causticizing efficiency of causticizing reactionincluding fines (dry tons/day): (measured as the weight ratio of sodium

SPWC = (SPCH x SWTC) + SWCF hydroxide to sodium hydroxide plus sodiumcarbonate in white liquor, expressed in sodium

Calculate quantity of "clean" hardwood chips including oxide weight equivalents, and in which thefines (dry tons/day): sodium hydroxide content of green liquor has

been subtracted from the white liquor contentHPCC = (HPCH x (1.0- HWTC)) + HPCF (standard TAPPI definition)).

SCalculate quantity of hardwood whole-tree chips CNMD -Consistency of the filtered lime mud enteringiclcudingafnes u y ons/ard d wthe lime kiln (dry weight of lime mud solidsincluding fines (dry tons/day): ratio of total weight of filtered lime mud).

" HPWC = (HPCH x HWTC) + HWCF EFKF -Average combustion heating efficiency of kilnfuel (ratio of higher heating value of fuel which

Calculate quantity of "clean" softwood chips as is not lost in combustion gases and excess airreceived (tons/day) (wet weight basis): exiting the kiln).SCCW = SPCC/(1.0 - SCHM) FLMR -Weight fraction of total lime mud recycled to

=the mud washer, representing uncalcinedCmaterial captured in the lime kiln flue gasCalculate quantity of softwood whole-tree chips as scrubber and emissions separator.

, received (tons/day) (wet weight basis): HHKF -Average higher heating value of kiln fuel

SWCW = SPWC/(1.0 - SWTM) (million Btu/fuel unit).CaloHRRB -Effective heat recovery ratio of recovery boilerCalculate quantity of "clean" hardwood chips as (decimal ratio of gross heat energy value ofreceived (tons/day) (wet weight basis): black liquor solids recovered as steam heatHCCW = HPCC/(.0 - HCHM) energy (adjusted for total heat inputs to

CC=P• CMfurnace and heat of reaction correction, aswell as for combustion heat losses). (Not to

Calculate quantity of hardwood whole-tree chips as be cs wt combustion heat ecoeryreceived (tons/day) (wet weight basis): efficiency of recovery boiler.)) ery

HWCW = HPWC/(1.0. HWTM) HVBL -Gross heat energy value (higher heating value) ,Sof black liquor solids (Btuldry pound).

* A flow diagram (fig. 4) illustrates the process area PLMU -Purchased lime make-up (average weight ratiomodeled In this subroutine. Parameters calculated in of total lime to slaker which is purchased orthis subroutine are shown in parentheses. Note also "make-up" lime).that the results obtained in this subroutine will be PPKF -Average purchase price of kiln fuel ($/fuel unit).based in part on the quantity of pulpwood required in PPLM -Purchase price, f.o.b. mill, of purchased limethe digester, as calculated in subroutine DIG. ($1ton).

SVSC -Sales value, f.o.b. mill, of surplus salt cakegenerated in chemical recovery anddesulfurization areas ($/dry ton of surplussaltcake).N" .. •

% •

• r j, O ,.* - ~.,. . *, *~~~S* ~ * '** S * ~ - 'S N' 's-~' ~ N ~ i /',, 4

j~'0 ----- L% N. . . . . . e,** ON"** S SeN

Clean* softwood chips.ISPCCI dry tons day. or

* . SCCWA tonsiday as--purchased. it SPSPC/ton. Ci

*H ceing WT

S/S. Purchased softwoodISPCF dryton ineWctip furnish to

day.F bdrydton Stie digester: (SPCH)day.base on TCFdry tons/day.

'ii..based on SWPC

Sotoo hoetie cis

-~ tSPWC) dry tons/day. or(WWtosdya-Total softwood

*purchased. q SPSWC/ton. friht ietrSoftood WTMIChip(SPWD) dry

raw Sreigtons/day.materials &eiigbased on

SFWO

*(COSW) cords/day,.hpfrih

on SWCD and SWMC Chipping. osia

(SIRK) dry tons bark/day. SF) r-. based on SBPC (SRFR) dry ton fines/

Rail &Truckday, based on SWFR

* & Wood Storage.Clean- hardwood chips:

(I4PCC) dry tons/day, or(I4CCVW) tons/day as-purchased. q SPHPC/ton,

* 'S Hwo whhipre chips:

'pr.F (PCdrtosdy to ieiadgse:(P

(H4WCW) dtons/day. s-

raw Sreig(PO rmaterials & Refining tnia

% CDNW) cords/dayines/

day. based VT

Nadw o teAd br £h og

orHW surpluday fuel furenish

% * & eii friht% *6 iH pK dr digester:

SSWL -Sodium sulfate ratio of total alkali in white Calculate actual dry weight of lime mud to lime kiln %liquor (one-half weight ratio in sodium oxide after correcting for particulate emissions and recycled %equivalents), fraction (to mud washer) (tons/day):

TKEG -Temperature of kiln exit gases (OF, average). WTLM = WTLM(1.0 - FLMR)TKPD -Average temperature of kiln product solids

exiting kiln (°F). Calculate weight of water entering lime kiln with

Calculations for Subroutine RECBLR are: filtered lime mud (tons/day):,' . WlMK = (WTLM/CNMD) x (1.0 - CNMD) '

Calculate heat energy to steam in recovery boiler C ((million Btulday): Calculate heat energy requirements for lime kiln C.-

HSRB = TBLS x (0.002) x HVBL x HRRB (million Btu/day) (assuming ambient temperature of70"F):

Calculate weight equivalent of total alkali (total sodium (A)Ep

compounds) in white liquor, in sodium oxide weight (A) Energy required to evaporate water in lime mud

equivalent (tons/day): entering kiln:

TALK = TDAA/ACTV WTEN = WIMK x (0.002) x (970.0 + (212.0 - 70.0) + (0.46 x(TKEG .212.0)))

Calculate weight equivalent of sodium sulfate in white (B) Energy into kiln product, assuming a specific heatliquor, in sodium oxide weight equivalent (tons/day): of 0.25 Btu/pound of kiln product/F above ambient

SDSL = TALK x SSWL temperature:PLEN = TWLP x (0.002) x (TKPD - 70.0) x 0.25

Calculate weight equivalent of sodium carbonate inwhite liquor, in sodium oxide weight equivalent (C) Energy required for dissociation of calcium

(tons/day): carbonate in lime kiln, assuming a heat of dissociationof 1,390 Btu/pound of active calcium oxide in lime kiln

SDCA = TALK - (TDAA + SDSL) product:

Calculate weight equivalent of sodium hydroxide HDEN = (TWLP x AVLM) x (0.002) x (1390.0)produced in causticizing reaction, in sodium oxide (D) Energy into carbon dioxide produced In dissociationweight equivalent, corrected for sodium hydroxide reaction, assuming a specific heat of 0.25 Btu/pound ofpresent in green liquor, based on TAPPI definition of carbon dioxide gas/F above ambient temperature:causticizing efficiency (tons/day): CDEN = (TWLP x AVLM) x (44.0/56.0) x (0.002) x (3.25) x (TKEG -

SODH = (CAUS x SDCA)I(1.0 - CAUS) 70.0)

(E) Calculate energy Into recycled lime mud (e.g. fluecausticizingreaction f calcium oxide needed In gas dust) captured in scrubber and separators,

assuming a specific heat of 0.25 Btutpound ofCAOX = SODH x (56.0162.0) "dust"'/F above ambient:

Calculate quantity of purchased lime required EMEN = (WTLM x FLMR) x (0.002) x (TKEG - 70.0) x 0.25

(tons/day): (F) Calculate total heat energy requirements including a

PLRQ = (CAOX x PLMU)/(AVLM) 15.0% factor for thermal radiation heat losses:

Calculate total weight of lime produced in lime kiln to THEN = (WTEN + PLEN + HDEN + COEN + EMEN) x 1.15slaker (tons/day): Calculate gross energy input requirements in kiln fuel

TWLP = (CAOX/AVLM) - PLRQ (million Btu/day):GHEN = THENIEFKF,

Calculate weight of inert material in lime from lime kiln Cl e kl ue re q (

to slaker (tons/day): Calculate kiln fuel required (unitsday):

WINR = TWLP x (1.0- AVLM) TKFR = GHEN/HHKF

A flow diagram (fig. 5) shows the process area modeledCalculate theoretical dry weight of lime mud to lime In this subroutine. Parameters calculated in thiskiln (tons/day): subroutine are In parentheses. Note that figure 5WTLM = ((TWLP- WINR) x (100.0/56.0)) + WINR includes parameters related to steam demands and

electric power factors used In later subroutines. Notealso that the results of this subroutine depend on the

"4- quantity of black liquor solids, as calculated insubroutine DIG.

, * , . , .,,, d ' .- .,* . . .. -.• . '. ... ,. .. ,. -..'.'*

Salt cake from: Recovery furnace fluegas cleaners (emissions

Concntrted lac liqor:Power boiler furnace SO,(TUOLS) dry tonsiday control & salt cake

reclaim systemPurchased salt cake make-up

(if necessary), @ SPPSCINton

(Surplus salt cake sold a SSV$Cton)

R eovry oer \V\ Heat to superheated steam In recovery- ~Salt Cake --- boiler~ (HSNE) 10' Btulday, based on '

Mix Tanks, "VIAL Stuldry lb BLS and HRE heatRecovery recovery ratio

Slowdown Furnace Steam demands from subroutine STEAM:steam: & Boler SHPAH lbteamprouce

i FFC ratijo of j SAN lblton BLSItotal steam Smelt SMLIblton BLS1output SetSANDL lbfton BIS

Smet DsslvigSMEC lb/ton BLSSmel DisolvngSLAM lbfton BIS

Green Liquor M ltoBL-~~~~ r ~~~Clarification ---- Sf8'ltoBL

Green ------ SLRS lbfton BLSiquorPurchased make-up lime:

(d (PLO)" tonsiday, @ $PPLM/dregs) Sae&Liet lkrton, based on PLNU A, AVIM

Causticizers (CAOX) tons of Ca~lday Reburned lime from kiln:consumed in causticizing (TWLP) tonsiday, based onreaction (= available qatt ucaelime required), based on qAnttypuchsequantity of NaOH' generated AL& stoichiometric ratioof CaO to NaOH as NaO Kiln fuel requirement:

Lime KilnFR) fuel unite/day,(Reburning) * $PPlF* based en EFKF,

4,,& Storage HHKF, TKEQ, a TKPD

liquorLime mud to kiln: (WTLAM)Recycled material from dry tons mud/day

a'..'kiln, including "dust" including recycled A,and uncalcined mudInrmaeilbsdfrom scrubber & on stoichiomletric ratioseparator, based of CaCO, to Co

%J. n FLNAR(available lime in kiln5,. product); (WAIK tone

water/day In mud tokiln, based on CN

White Liquor Unfiltered lime md Lime Mud Washer,

S White liquor analysis (in Na,O equivalent):(TALK) tons total alkali/day (sodium comp.),

based on (TDAA) tons active alkalfday (from digester calculations) & ACTV,

(SDSL) tons Na,SO/day, based on SSWL,* (SOCA) tons NaCO,/day, based on total alkali Electric power factorsCaiidminus active alkali & H&,504, from subroutine ELEC:

wh iateur (WODH) tons NaOH/day generated in HP(1) A, 1411(14)to igete causticizing reaction, based

4 on CAUSFigure &.-Chemical recovery, lime kiln and recauatioizlng orea: Subroutine RECBLR.

12

'"NOV* * a., *.~. ~ ~ . .*%

%, 'b "

Subroutine ELEC: Electric Subroutine STEAM: Steam system,power requirements electric power, and cogeneration area

This subroutine calculates total electric power The purpose of this subroutine is to calculate the totalrequirements of the overall process. A total of 19 items process steam demands, to balance steam demandsof data is required: with steam output from the recovery and power boilers,

to determine the quantity of cogenerated electric(Total connected horsepower of machines and power, and to estimate the quantities of other relatedequipment by mill area): inputs and outputs for the steam system, electric

HP (1) - Wood preparation power, and cogeneration areas of the process. r.HP (2) -Digester and turpentine areaHP (3) - Washing and refining The model assumes three levels of process steam:HP (4) - Stock preparation high, medium, and low pressure. The model also

HP (5) - Paper machine area assumes all process steam is obtained via a

HP (6) - Additives area cogenerating turbine, which in turn obtains higher-HP (7) - Finishing and shipping pressure superheated steam from the power andHP (8) -Water supply and treatment recovery boilers. The assumptions built into this

HP (9) - Waste disposal subroutine reflect typical conventional process design. L

HP (10) - Power boiler, feedwater, and condensate areas AeqHP (11) - Coal handling A total of 46 items of data Is required for this

HP (12) - Recovery boiler area subroutine. They include steam loss ratios, heatHP (13) - Evaporators area exchange efficiency, enthalpies of steam, feedwater,HP (14) - Lime kiln and recausticizing and make-up water, ratios of steam recovered, turbineHP (15) - Air supply system generator efficiency, and various specific rates of

HP (16) - Odor collection system process steam demand throughout the entire process:AEFU -Average efficiency of electrical energy use in BFFC -Blowdown ratio for power and recovery boilers

mill equipment (decimal ratio of electric energy (pounds blown/total pounds of steam producedmem n t in boilers). (Blow to flash tanks assumed to

ALFC Average power load factor for mill equipment have low enthalpy and may be used to heat(decimal ratio of total connected horsepower) feedwater, but heat content is not accounted

ANML -Average nonmotor load for mill and related for here.)facilities, for lighting and miscellaneous CNSL -Losses from steam system In condensate(kilowatts). receiver and deaerator (pounds of steam or

condensate lost (e.g., In vents, etc.)/pound of

Calculations for Subroutine ELEC are: total feedwater to power and recovery boilers).FWHE -Feedwater heater heat exchange efficiency

Calculate total connected horsepower of mill machines (ratio of heat Input that exits in feedwater,and equipment: average).TCHP = 0.0 HCCN -Enthalpy of combined condensate from steam

system to deaerator (Btu/pound ofTCHP = TCHP + HP (I), for I = 1 to 16 condensate).

HCMW -Enthalpy of make-up water to deaeratorCalculate power load of mill machines and equipment (Btu/pound of make-up water).(total horsepower): HHPP -Enthalpy of high-pressure process steam

TPLD = TCHP x ALFC (Btu/pound of steam).HLPP -Enthalpy of low-pressure process steam

Calculate total electrical power demand of mill (Btu/pound of steam).machines and equipment (kilowatts): HMPP -Enthalpy of medium-pressure process steam

(Btu/pound of steam).TEED = (TPLD/AEFt) x 0.746 HSHP -Enthalpy of superheated steam from boilers

(Btu/pound of steam).Calculate total electrical power demand of mill, HTMS - Ratio of total high-pressure process steamincluding nonmotor load: recovered as medium-pressure process steam,

TEED = TEED + ANML excluding steam from turbines (ratio of totalhigh-pressure steam).

Note that the electric power factors are used in each ofthe process subroutines (see flow diagrams). %

13_ - Y .%% %,,'l

i. . . .

PKWH -Price of purchased electrical energy SMEC -Medium-pressure steam demand for emissions(S/kilowatt-hour). control (electrostatic precipitators) in recovery

SMLS -Ratio of total medium-pressure process steam boiler area (pounds/ton of black liquor solidsrecovered as low pressure process steam, to recovery furnace).excluding steam from turbines (ratio of total SMJE -Medium-pressure steam for steam jets inmedium-pressure steam). evaporators (pounds/ton of black liquor solids

SSSB -Superheated steam required for sootblowers In into evaporators).power and recovery boiler areas (pounds/total SMLH -Medium-pressure steam demand for secondarypounds of steam produced). black liquor heater In recovery boiler area

SVSE -Sales value of surplus electrical energy (pounds/ton of black liquor solids to recoverycogenerated in mill (S/kilowatt-hour). boiler).

TGEF -Turbine generator efficiency for conversion of SMMD -Medium-pressure process steamsteam energy to electrical energy (ratio of miscellaneous demand volume (pounds/ton ofsteam energy consumed to electric energy product).produced). SMPB -Medium-pressure steam demand for power

boiler area, air heaters, emissions control, andmiscellaneous (poundspound of steamAverage high-pressure process steam demands are: miscean poundsoudosta

"1 produced In power boiler).HPAH -High-pressure steam for air heater in recovery SMPD -Medium-pressure steam demand for paper

boiler area (pounds/ton of black liquor solids machine dryers (pounds/pound of waterto recovery boiler), removed In heated dryer section of paper

HPFW -High-pressure steam demand for power boiler machine).feedwater heaters (pounds/pound of feedwater SMSL -Losses from medium-pressure process steamto power boiler), system (ratio of total medium-pressure steam

HPMD -High-pressure steam miscellaneous demand not returned In condensate).volume (pounds/ton of product). SMST -Medium-pressure steam demand for smelt

HPPB -High-pressure steam demand for power boiler dissolving tank In recovery area (pounds/ton ofarea, air heaters, and miscellaneous black liquor solids to recovery boiler).(pounds/pound of steam produced in powerboiler). Average low-pressure process steam demands are:

HPPM -High-pressure steam demand of paper SLAH -Low-pressure steam demand for air heater inmachine and vacuum pump turbines recovery boiler area (poundstton of black iquor(pounds/dry ton of paper or paperboard solids to recovery).product). (This steam discharges to medium-.oist rcvr)pressure process steam header.) SLCN -Low-pressure steam demand for black liquorHPSL Loss-pressure process steam concentrators (pounds/pound of water removedsystHPSL -Losses from high-pressure process steam in black liquor concentrators).,,system (ratio of total high-pressure proc ess L A - o pr s u e t am d an f rd a rt r,s S steam not returned in condensate). LA-Low-pressure steam demand for deaeratorP ta nt Hh reured denfaer L (poundspound of total feedwater).

HPTC -High-pressure steam demand of paper SLOG -Low-pressure steam demand for digestermachine thermocompressors for dryer steaming vessel (pounds/dry ton of chips todrainage (poundsdry ton of paper or digester).paperboard product). SLEV -Low-pressure steam demand for black liquor

Average medium-pressure process steam demands are: evaporators (pounds/pound of water removedfrom blaek liquor In evaporators).

SMAH -Medium-pressure steam demand for air heater SLMD -Low-pressure miscellaneous steam demandin recovery boiler area (pounds/ton of black (pounds/dry ton of paper or paperboardliquor solids to recovery boiler), product).

SMAS -Medium-pressure steam demand for air supply SLPB -Low-pressure steam demand for power boiler. area (pounds/dry ton of pulp produced). area, air heaters, emissions control, etc.

SMBL -Medium-pressure steam demand for black (pounds/pound of steam produced in powerliquor guns In recovery boiler furnace boiler).(poundston of black liquor solids to recovery SLPM -Low-pressure steam demand for paperfurnace), machine auxiliary equipment and

SMDH -Medium-pressure steam demand for digester miscellaneous purposes (pounds/dry ton ofliquor heater (pounds/thousand gallons of product).white liquor to digester). SLRS -Low-pressure steam demand for heating green

SMFW -Medium-pressure steam demand for power liquor to slaker in recausticizing areaboiler feedwater heaters (pounds/pound of (pounds/ton of black liquor solids to recoveryfeedwater to power boiler), area).

14

4e

% % % % %

SLSE - Low-pressure steam demand for sulfur Calculate quantity of condensate to deaeratoremissions odor control, collection system (pounds/day) (PBFW Is feedwater to power boiler):

% (poundsidry ton of pulp produced).SLSL -Losses from low-pressure process steam PF SP 10+BF)

system (ratio of total low-pressure steam CNDA = ((SOPS + SORB) x (1.0 + 8FFQ) - TSLS -((SMFW +volume not returned in condensate to H.PFW) x PBFW) -(SLDA x (SOPS + SORB) x (1.0 +deaerator). BFFC)

Calculations for Subroutine STEAM are: Calculate enthalpy of feedwater to recovery boiler andpower boiler feedwater heaters (Btuipound of

Set initial feedwater enthalpy to zero: feedwater):

HFWR 0.0HFWT = ((TSLS x HCMW) + (CNDA x HCCN) + (SLDA xHLPP x (SOPS + SORB) x (1.0 + BFFC)) +

Calculate initial estimate of recovery boiler steam ((HPFW + SMFW) x HCCN x PBFW) - (CNSL xoutput (pounds of superheated steam/day): HCCN x ((SOPB + SORB) x (1.0 + BFFC))))/SORB =(HSRB x 1000000.0)/(HSHP - HFWR) ((SOPS + SORB) x (1.0 + BFFC)

Calculate Initial estimates of net boiler steam demands HW=(FR+HWy.(pounds of superheated steam/day): Recalculate steam output of recovery boiler

-(High-pressure process steam demands, approx.) (pounds/day):

*HPSD = ((HPPM x PPRD) + (HPTC x PPRD) + (HPAH x OS=(RBx100.oHHP-FW.3 TBLS) + (HPMD x PPRD)) Recalculate net high-pressure process steam demands

-,-(Medium-pressure process steam demands, approx.) (pounds/day):SMSD = ((SMPD x TWRD x 2000.0) + (SMJE x (TBLS + HPSD = ((HPPM x PPRD) + (HPTC x PPRD) + (HPAH x

SOPR)) + (SMDN + TWLV) + (TBLS x (SMEC + TBLS) + (HPMD x PPRD) + (HPPB x SOPB) +SMAH + SMST + SMLH + SMBL)) + (SMAS, % (HPFW % PBFW))PROD) + (SMMD x PPRD) - (HPPM x PPRD) - Recalculate net medium-pressure process steam((HPSD - (HPPM x PPRD)) x HTMS)) demands (poundsday):

-(Low-pressure process steam demands, approx.) SS (MDxTR 000 SD WVSLSD = ((PPRD x(SLPM + SLMD)) + (TBLS x(SLRS + (SMJE x (TULS + SOPFQ) + (SMAS x PROD) + 3

SLAH)) + (((SLEV x WREV) + (SLCN x WRCN)) x (TBLS x (SMEC + SMAH + SMLH + SMST +2000.0) + (SLOG xPPWD) + (SLSE xPROD) -(SMLS x SMBI4) + (SMP x SOPS) + (SMFW x PBFW +GMSD) - SMLP) (SMMD x PPRD) - (HPPtd x PPRD) - ((H PSD - (HPPM x

PPRD)) x HTMS))Calculate Initial estimate of power boiler steam output 6

(pounds of superheated steam/day): Recalculate net low-pressure process steam demandsSOPS = (HPSD + SMSD + SLSD - SORB + (S555 x SORB) (pounds/day):

+ (SLDA x SORB x (1.0 + BFFC))(1.0 - SSSB - SLSD = ((SLPM + SLMD) x PPRD) + ((SLRS +. SLAH) x* ((HPFW + SMFW + SLDA) x (1.0 + BFFC)) - TBLS) + (51EV x WREV x 2000.0) + (SLCN X*(HPPB + SMPS + SIPS)) WRCN x 2000.0) + (SLOG x PPWD) + (SISE x

a. ~Follow Iterative procedure to determine the steamPRD+(LPxSO)+(SDx(OB+-. ~energy balance (algorithm Iterates until equilibrium SR)x(. FC)-(MSxGS)-SL

.41enthalpy of feedwater to recovery boiler Is obtained): Recalculate steam output of power boiler (pounds/day):

* Calculate total steam and condensate losses from SOPS = (HPSD +4 SMSD + SISD - (SORB x (1.0 - SSS)))/(i.0 -steam system, equivalent to make-up water SSrequirements (pounds/day): PPFW = (SOPS x (1.0 + SFFC)TSLS =(SSS x (SOPS + SORB)) + (0.7 x FFC x(SOPS +

SORB)) + (HPSL x HPSD) + (SMSL x QMSD) +(SLSL x (8180 + (SMLS x GMSD))) + (CNSL x((SOPS + SORS) x(1.0 + BFFC)))

15

N %~-3,%& yy* IN.* * .v *'~~-~%*% 3 ~V.\~*

3* -l

,%

Check feedwater enthalpy. COLO -Oxygen content of coal (ratio of dry weight).COLN -Nitrogen content of coal (ratio of dry weight).

Reiterate to equilibrium. COLS -Sulfur content of coal (ratio of dry weight).CPRC -Price of coal, f.o.b. mill, for power boiler (S/ton

'. Calculate the enthalpy of feedwater to power boiler, out as-purchased) (supply unlimited at given price).of feedwater heaters (Btu/pound of feedwater): EXAR -Excess air admitted to power boiler furnace

(decimal ratio of the theoretical minimumHBFW = ((PBFW x HFWR) + (FWHE x (((HHPP- HCCN) x amount of air required for complete

HPFW x PBFW) + ((HMPP- HCCN) x SMFW x combustion, average).PBFW))))/PBFW HVWD -Combustion heat energy of wood and bark .

fuels, higher heating value (Btu/pound dryCalculate the steam heat energy demand on power weight, average).boiler (million Btu/day) (input to power boiler PCAS -Purchase price, f.o.b. mill, of caustic soda,subroutine): 50% sodium hydroxide (NaOH), (/ton).

SHDM = ((SOPB x HSHP) - (SOPB x HPFW))11000000.0 PPSC -Purchase price of sodium sulfate (NaISO4) saltcake for salt cake make-up (S/ton of salt cake).

!l Calculate the amount of electrical energy cogenerated UL-aitohetlssuconedfradRUHL. -Radiation heat losses, unaccounted for, andmiscellaneous heat losses, (decimal ratio of

(kilowatt-hours/day) (1 kilowatt-hour = 3413.0 Btu of total heat energy Input to power boiler).energy equivalent): SDOR -Sulfur dioxide (SO) removal from stack gases

COGN = TGEF x (((HSHP - HHPP) x HPSD) + ((HSHP. HMPP) In flue gas desulfurizing area (decimal ratio ofx SMSD) + ((HSHP - HLPP) x SLSD))/3413.0 total sulfur dioxide in stack gases).

SGTP -Stack gas temperature of flue gases beyondCalculate purchased electrical energy requirements effective heat recovery devices of power boiler(kilowatt-hours/day): (OF, average).-PEO =STRS -Sulfur dioxide generated from incineration ofPERQ =(TEED x 24.0)- COGN "TRS gases" In power boiler (pound/ton of pulpSREE = 0.0 production).

WDMC -Moisture content of wood and bark fuels used

Calculate surplus electrical energy, If any, produced in power boiler (decimal ratio of wet weight,

and sold (kilowatt-hours/day): average).q aWMAX -Maximum quantity of wood and bark fuel that

" If PERO < 0.0, SREE = -(PERO) can be used for fuel in power boiler (dryIf PERO < 0.0, PERO = 0.0 tons/day). (Coal is used for remainder of heat

energy.)A flow diagram (fig. 6) shows the process area mqdeled WODA -Ash content of wood and bark fuel (ratio of dryin this subroutine. Note that process steam demands wood weight).

RP% are shown on this diagram and also on the other WODC -Average ultimate analysis carbon content ofprocess flow diagrams. Parameters calculated in this wood and bark fuel used In power boilersubroutine are shown in parentheses. Note that the (decimal ratio of wood weight).results of this subroutine depend on previously WODH -Hydrogen content of wood and bark fuel (ratiocalculated values of a variety of process parameters of dry wood weight).from other subroutines, which determine the high-, WODN -Nitrogen content of wood and bark fuel (ratiomedium-, and low-pressure process steam demands. of dry wood weight).

WODO -Oxygen content of wood and bark fuel (ratio of s.

Subroutine PWRBLR: Power boiler area dry wood weight).WPRC -Purchase price, f.o.b. mill, of wood fuel (S/dry

This subroutine calculates the quantities of fuels ton) (or 2x selling price of surplus fuel).

required for the power boiler furnace, the amount of Calculations for Subroutine PWRBLR are:. sulfur dioxide in flue gases, the quantity of reclaimed

salt cake, and the quantities of other process Inputs In Calculate quantity of wood and bark residues producedthe power boiler, odor collection, and emission control and available for fuel (dry tons/day):area. A total of 24 data items is required for this ORES = SRFR + HRFR + SBRK + HBRK %subroutine:C - se t oo ro tl g Calculate higher heating value of coal via Dulong. CLMVC -Moisture content of coal ('ratio of total wei,,ht, foml (Bulr .p• u.nd):

including moisture, average).COLA -Ash content of coal (ratio of dry weight). HVCO = (145.44 x COLC + 620.0 x (COLH + COLOIB.0) +COLC -Carbon content of coal (ratio of dry weight, 41.0 x COLS) x 100.0

ultimate analysis).COLH -Hydrogen content of coal (ratio of dry weight).

16,Vm% % % % % % %

; - - , . -, ,, ,, . ,, .. , , - .. ,. -. -, - i , , , , , , , , , , , .x . . .d . .%,~

Steam from recovery boiler: Steam from power boiler: 'Note: The enthalpy__ of feedwater to

(SOPB) lb steam/day, based I I (SOPS) lb steam/day, recovery boileron (HSRI ) Btu/day heat to i based on total steam & power boiler '

steam, enthalpy of requirements minus feedwater heatersSfeedwater (HFWT), & steam provided by (HFWT) is

enthalpy of steam HSHP I recovery boiler calculated viaan iterativeprocess that F

Total steam requirements balances all steam

, Superheated High-Pregsure Steam (lb/day) = Steam for energy inputs &

Hi, Mad., & Low pres. outputs for theplus steam for soot milli blowers

Steam for soot blowers ( WIin power & recovery I (SREE) kWh/day "surplus"boiler furnaces, Cogenerating system: electric power,based on sss.,,v

CIA (o) W I."-Power (r

Generator (PERO) kWh/day purchasedelectric power.

Total Hi-pres. -dSteam demands: (ON ~ia

I-PSD) lb/day, High-Pressure-Process Steam I ceneratedincl. all Header S team HHPP based on steamprocess I I a endemands plus Steam losses, based & enout fpes into&OE ,u o1 turbine.HPMD on HPSL TOEF, & conversion

Return from Hi pres., I

including steamfrom paper machine Electric

turbines & HTMs Power.

V.- I .

Total Med.-pres. Medium Pressure-Process Steam Total electric powersteam demands: Header Steam HUPP requirements of mill:

(5SD) l/ay, including I(TEED) kW, based onall process demands Steam losses based tetal connected hp ofplus SMMD I on SMSL equipment In sub-

Return from Med. pres. ALFC, & ANL kAWincluding SMLS ratio I Iof Med-pres. steam I& all excess steamfrom Med.-pres. header

Total Low-pres. Low-Pressure-Process Steam- steam demands: Header Steam HLPP Mr(SS)I/aicuigMake-up water requirements: .

(SLSD) lb/day, including (SL)l/absdoall process demands Steam losses, based I(TSLS) b/day, based on, , J total process steam &plus SLUD on 1ILSL condensate losses plus

Combined condensate from blowdown & soot blowersteam system: (CNDA) steam, make-up water

- lb/day, based on total HCMWprocess steam demandsminus process steamlosses Fewtrt oe)Irecovery boiler i

Condenste Condensate Receiver (HFWT) tbWHCCN and Deaerator

Steam demand: SLDA - - -

I Condensate losses, based on CNSL&g.

a,' Figure .- Steam system, electric power and cogeneration area: Subroutine STEAM.

17'C 1.

• . ... ,.... .... .... _ ' P ."r.. .'. ...... •.......... ...... .. .... i. ._ .. .. "f• .

Calculate heat energy recovery from coal (Btu/dry ton): Calculate surplus salt cake produced, If any (tons/day):

,o Call SUBi (HVCO, COLC, COLH, COLO, COLN, CLMC, SGTP, If PSCR<0.0, SSCK = -(PSCR)EXAR, RUHL, RCCO) If PSCR<0.0, PSCR = 0.0 o

* Calculate heat energy recovery from wood and bark Calculate weight of surplus wood fuel (wet tons/day)fuel (Btu/dry ton): (including moisture In fuel):Call SUBI (HVWD, WOOC, WODH, WOO, WODN, WDMC, SURB = SURB/(1.0 -WDMC)SGTP, EXAR, RUHL, RCWD)

Calculate weight of purchased wood fuel (wet tonsday)Determine total quantity of wood and bark residues and (including moisture In fuel):purchased wood fuel used In power boiler (dry tons): OWOD = QWOO/(1.0 - WDMC)

WM = SHDMIRCWDIf WMIWMAX, WMAX = WM Calculate weight of purchased coal fuel (wet tons/day)If QRES>WMAX, SURB = ORES - WMAX (including moisture In fuel):If QRES>WMAX, QWOD = 0.0If QRES>WMAX, ORES = WMAX

WOD = WMAX. QRES A further subroutine, SUB1 (HV, C, H, X, XN, PM, T2,if QWOD(0.0, OWOD = 0.0 EX, HL, RC), calculates heat energy recovery from

Calculate heat energy recovered from wood and bark combustion of wood, bark, or coal (million Btu/ton of

residues, and purchased wood fuels (million Btu/day). dry fuel):HTRB = ORES x RCWD HV = higher heating value of fuel (Btulpound)HOC = carbon content of fuel (ratio of dry weight)

H = hydrogen content of fuel (ratio of dry weight)of coal required (dry tons/day): X = oxygen content of fuel (ratio of dry weight)

Calculate quantity oXN = nitrogen content of fuel (ratio of dry weight)

OCOL = (SHDM - (HTRB + HTRW)YRCCO PM = moisture content of fuel (ratio of wet weight of fuel)If OCOL<O.O, QCOL = 0.0 T2 = stack gas temperature of combustion system beyond

effective heat recovery devicesCalculate heat recovered from coal (million Btu/day): EX = excess air as a ratio of theoretical air required for

combustion in furnaceHL = miscellaneous radiation and unaccounted-for heat

losses, ratio of heat energy InputCalculate quantity of sulfur dioxide In stack gases RC = heat recovery (million Btuldry ton of fuel)(tons/day): TI = ambient temperature of air and fuel (-e 60.0)

SDSG = (COLS x OCOL x 2.0) + (STRS x PROD/2000.0)Calculate heat loss caused by fuel moisture and

Calculate quantity of salt cake reclaimed as sodium hydrogen In fuel (Btuldry pound of fuel):sulfate (tons chemical/day; the factor of 2.21875 is the HLMH = (970.0 + (212.0 - TI) + (0.46 x (T2- 212.0))) x (H xstoichiometric weight ratio of sodium sulfate to sulfur 9.0 + PM(1.0 - PM)dioxide):

SSDS = SDSG x SDOR x 2.21875 Calculate heat loss caused by dry gas and excess airbased on specific heats of dry gases:

Calculate quantity of caustic soda (50% sodium HLDG = M -Ti x (024 x (H x 80) + (Cx 2667) -XQ/0232)hydroxide) required for desulfurization process (tons L + ((((H x 8.0) + (C 22) x0.68 +chemical/day; the factor of 2.5 Is the stoichiometric X+( x 0. +(C x .667 x)0.2) %weight ratio of 2x sodium hydroxide to sulfur dioxide): XN) x 0.25 + (C x 366667 x 022))

CSDS = SDSG x SDOR x 2.5 Calculate "conventional" heat losses due to radiation,miscellaneous and unaccounted-for losses:

Calculate purchased salt cake requirements (tons/dayof salt cake, as sodium sulfate): HLMS = HV x HL

PSCR = (SCLS x PROD/2000.0) - SSDS Calculate heat recovery (Btuipound of dry fuel):SSCK - 0.0 RCLB = HV- (HLMH + HLDG + HLMS)

Calculate heat recovery (million Btu/dry ton of fuel):

RC = RCLB x 0.002

18

%- -. ,,

N1 t& . . . . . .

IIA flow diagram (fig. 7) shows the process area modeled Subroutine SALES: Sales revenues,in this subroutine. Parameters calculated in this material, energy, and labor costssubroutine are in parentheses. Note that bark and. fines removed from pulpwood In wood prepartion aref e f p n r iThis subroutine calculates total process revenues, andused as fuel in the power boiler furnace, subject to the material, energy, and labor costs (revenues and costsmaximum quantity of wood fuel that can be used. Note are calculated per year, per day, and per ton of product)also that results of this subroutine depend on the based primarily on all of the process input and output

steam energy balance calculated in the previous calculations of the previous subroutines. A total o} 13subroutine, which determines the quantity of steam Items of data is required:output required from the power boiler. AMLB -Average maintenance labor requirements

Subroutine WATER: Water supply and (number of hourly wage maintenance workersneeded/day (8-hr shifts each)).

wastewater treatment AMWG -Average maintenance labor wage rate,including all fringe benefits and related

This subroutine models the water supply system and expenses (/hr).wastewater treatment, including calculating the CCTC -Cost of cooling tower chemicals (coolingquantity of mill water required, the quantity of water system for process water) (S/ton of paper

treatment chemicals, the quantity of wastewater (board) product).

effluent, and the quantity of effluent treatment CFWC -Cost of feedwater chemicals for treatment of" chemicals required. Seven items of data are required: boiler feedwater (S/ton of paper (board)

EFLF -Effluent flow to wastewater treatment facilities products).of mill (gallons/dry ton of paper or paperboard DFCS -Cost of dryer felts for paper machine dryers

o. product). (S/dry ton of product).ETCH -Effluent treatment chemicals (nutrients such DPYR -Effective number of days per year that the mill

i as nitrogen and phosphoric compounds) (units is in operation (days/year).(gallons, pounds, etc.)/thousand gallons of EXLB -Average nonprocess labor requirementsuntreated effluent). (number of hourly wage non-process workers

PETC -Average price of effluent treatment chemicals needed/day (8-hr shifts each)).(S/unit (gallons, pounds, etc.)). EXWG -Average nonprocess labor wage rate, Including

PWCH -Average price of feedwater treatment all fringe benefits and related expenses (S/hr).chemicals (/unit of chemical (pounds, gallons, PLWG -Average process labor wage rate, Including alletc.)). fringe benefits and related expenses (S/hr).

PWTR - Price of mli water (S/thousand gallons of PSIB -Average process labor requirements (numberwater Input requirements). of hourly wage process personnel needed/day

WATR -Mill water requirements (gallons/dry ton of (8-hr shifts each)).paper or paperboard product output). RCST -Cost of roll covers for finished rolls of paper or

WTCH -Water treatment chemicals required (average paperboard product(S/dry ton of product). runits (pounds, gallons, etc.)/thousand gallons WCST -Cost of wires for paper machine (S/dry ton ofof water into mill), product).

WFCS -Cost of wet felts for paper machine (S/dry tonCalculations for Subroutine WATER: of product).

Calculate total mill water Input requirements (million Calculations for Subroutine SALES are:gallons/day):

TMWR = WATR x PPRD/1000000.0 Calculate mill revenues for paper (board), turpentine,"soap," surplus electrical energy, excess reclaimed salt

Calculate mill water treatment chemical requirements cake, surplus bark (S/day):(units of chemicals (gallons, pounds, etc.)/day): 1,1) = SVAL x PPRD

* TWTC = WTCH x TMWR x 1000.0

-.-> "-" . Calculate total effluent flow to wastewater treatment R(2,) = TPV x TRPD. (millions of gallons/day): R(3,1) = SOPP x SOPR

,-. TEFL = EFLF x PPRD11000000.0*:. R(4,1) = SVSE x SREE

Calculate effluent treatment chemical requirements(units of chemicals (gallons, pounds, etc.yday): R(5,1) = SVSC x SSCK

TETC = TEFL x ETCH x 1000.0 6,1) = (WPRC x 0.5) x SURB V

A flow diagram (fig. 8) shows the process area modeledin this subroutine.

19.V

*.r * * * % % ,4 * -" .% -% 4 --= : ' , - -

'p..

Power boiler fuels:

Wood Fuel (ORES) dry tons bark & fines/dayStorage & removed from pulpwood in woodHandling preparation

'p System < (aWOD) dry tons purchased wood fueUday, 0 $WPRC/ton as-purchased

(OCOL) dry tons purchased coal iday,Wood 0 SCPRC/ton as-purchased

Caustic soda (50% NaOH) fuelfor salt cake reclaim: Nt:Fe unii ae(CSDS) tons/day,Noe qtt, (PCASD ton, based on on: (1) All bark & fines areSDOR & stoichiometric used, subject to energy needs

CoalFuel(SH11) & to maximum wood fuelratio of 50% NaOH to Storage & allowed In furnace WMAX;. SO, Handling (2) Any surplus bark & fines

System ae sold at % SWPRC#ton;(3) Purchased wood fuel makesup remaining energy needs,subject to the limit of WMAX(4) Purchased coal makes upremaining energy needs;

Emission Control (5) Heat energy to steam inReclaimed salt cake Desulfurization 101 Btuidry ton for

to recovery furnace: & Salt Cake Coal wood fuel (RCWD9) & coalReclaim (ROM Is basled on: IEXAUI, llUL,(SDS) tonsday, based ,SOW. HVWD. (HVCO WODC, CLEC,on SDOR & stoichiometric WOOC. COLC, WOmi, COIH. WOOO,ratio of NaSO, to SO, COLO. WOON, COIL, WODA COLA,

a OL

Mill-wide Odor gases, IncludingTotal SO, in flue gases: reduced sulfur

(SDSO) tons/day, based Sulfur compoud Ieo nd, areon S from odor S ystem Incinerated incollection & from power boiler furnacecoal fuel

FlegssSteam demands from Fsubroutine STEAM: "

L KUe1.51 Ibldry ton pulpHeat to steam in power boiler:

- (8DM)e 10'Btwday, bae Furnaceon steam output oerHPP lb rsqb producedi----l-r SLmB lb reoJlb prouce

Slowdown steam: \ -l p

*FFC ratio of Power boiler fedwatersteam output (= iuperfeated steam

output of power- I boiler plus blowdown

I steam, lb/day), at(HBFW) Btullb of

I feedwater, based onFWHE

Power boiler feedwater Feedwater HPFW lb steam/lb feedwater(from deaerator) Heater S11ft lb steam/Ilb feedwater

for Power IBoiler i Electric power factors from

subroutine ELEC:HP(Ift HP(Ilh & HP(116

Figure .- Power boiler are: Subroutine PWRBLR.

20 .

%'

Water tratmn chemicals:

TotWate trealen wahemreqaems:s(TWTC) unis/ay gallons/ayunitse

oTMWR)1'galn/ayAae Water Supply Mill water supply:oystTm (TMWR) 100 gal/day,

<@ SPWTR/10 3 gal

4 Effluent treatment chemicals:(TETC) units/day, @ SPETC/unit (lb),based on ETCH

Total wastewater effluent: I-1* (TEFL) 10' gal/day, WastewaterTead

based on EFLF Treatmeteun

Electric power factors

HP8,HP(9). & HP(15)

Figure 8L- Water supply, weateWater treatment and air supl frs uromrutine ELEC:.

area:Subrotine ATER

% %% ,o

'a%

Calculate fuel and energy costs for coal, wood fuel, Calculate costs of other miscellaneous chemicals fornatural gas, electrical energy (S/day): cooling tower, boiler feedwater, mill water treatment,

• .3. effluent treatment (/day):VC(1,1) =CPRC xQCOL

VC(18,1) = CCTC x PPRD

VC(2,1) = WPRC x OWOD VC19,1) = CFWC x PPRDVCQ(3,1) = PPKF x TKFR

.. V3,) = PPKFxTKFR VC(20,1) = PWCH x TWTC

S V4,1) = PKWH x PERO VC(21,1) = PETC x TETC

Calculate pulpwood and recycled fiber raw material Calculate other variable costs, for roll covers, wires,costs for softwood roundwood, hardwood roundwood, wet felts, dryer felts, mill water supply (s/day):softwood "clean" chips, hardwood "clean" chips,softwood whole-tree chips, hardwood whole-tree chips,recycled old corrugated, and recycled paper (/day): VQ22,1) = RCST x PPRD

VC(5,1) = PSRW x CDSW VC(23,I) = WCST x PPRD

VC(6,1) = PHRW x CDHW VC(24,1) = WFCS x PPRD

VC(7,1) = PSPC x SCCW VC(25,1) = DFCS x PPRD

VC(8,1) = PHPC x HCCW VC(26,1) = PWTR x (TMWR/1000.0)

VC(30,1) = PSWC x SWCW Calculate labor costs, for process labor, nonprocesslabor, and maintenance (S/day):

VC(31,1) = PHWC x HWCWV ,= xHVC(27,1) = PSLB x PLWG x 8.0

VC(32,1) = PCOR x RCRTVC(28,1) = EXLB x EXWG x 8.0

VC33,1) = PPAP x RPPTVC(29,1) = AMLB x AMWG x 8.0

Calculate costs of additives in stock preparation foralum, sulfuric acid, starch, defoamer, rosin, slimicide(S/day):

VQ9,1) = PALM x TALM

VQ10,1) = PACD x TACD

VQ1,1) = PSTC x TSTC

VC(12,1) = PDFM x TDFM

VQ13,1) = PRSN x TRSN

% VC(14,1) = PSLM x TSLM

Calculate costs of make-up and reclaim chemicals for*Q kraft process for salt cake, lime, caustic soda for salt

cake reclaim (S/day):VC(15,1) = PPSC x PSCR

VC(16,1) = PPLM x PLRO

VQ17,1) = PCAS x CSDS

22

V V... Vp# ;,'V,,.,', .;, ; . ... , " 'V . .' ,.. v ,\ ... ".'.. ... . .". ",'..., .. "," , ." , .- ,.,', .. ",, Zo., r

Sample Program Output User Notes, Guidelines, and Summary

Figure 9 shows a sample of the program output. The A complete listing of the sample data and the programoutput includes material balances, steam and energy are provided in the appendix. Data are readbalance, electric power, fuel and chemicals summary, sequentially by each subroutine. The program uses theand a revenue and cost summary for the overall input format corresponding to the data list in theprocess. appendix, and includes complete output format

corresponding to the output shown in figure 9.The output is largely self-explanatory. The materialbalances show the inputs and outputs in various parts The mathematical procedures used In the model wereof the overall process. The steam and energy balance designed to be simple and straightforward, althoughshows the quantities of steam and energy produced in the overall process is complex. The model and samplethe recovery and power boilers, and the various steam data were verified by comparison with physicaland energy demands. Note that the steam demands parameters and estimated cost data provided by aand losses balance with steam output of the boilers. consulting engineering firm that has been InvolvedThe revenue and cost summary provides an economic recently in design and Installation of unbleached kraftinterpretation of the overall process. "Contribution paperboard mills. The model and sample data

,' margin" is total revenues minus total variable costs. correspond to modern mill and process design criteriaContribution margin is the net amount of revenues that as verified in informal contacts with numerous industry

, can be regarded as available to cover fixed costs and personnel and reviews of numerous trade journalcapital costs, with the remaining amount available for articles describing features of specific modern mills.earnings or profit. Taxes are not considered here. The model has also been tested at a variety of extremeNote also that the variable costs include some items, parameter values and appears to provide reasonableparticularly labor, that are probably "semivariable" in a and satisfactory results.strict sense. That is, as level of production increasesor decreases, labor cost and other "semivariable" costs The computer model permits a user to make quick,will not change in direct proportion. precise estimates of the effects of major economic,

'-9 technological, or physical changes in an overallThe sample data values presented in the appendix were conventional unbleached kraft paperboard productionused to obtain the output in figure 9. process. With the model, users can develop their own

basic set of data that reflects their concept ofconventional process design and conventional processparameters. Then the user may adjust the basic set ofdata to reflect a specific process or economic change,and can obtain precise estimates of the effect of thatchange in a matter of minutes, using the computermodel. The model is also Inexpensive to run. Thus it isuseful In evaluating research opportunities, process

,.. alternatives, and the results of applied technicalresearch on the unbleached kraft paperboard process.

One final word of caution is necessary. The user mustkeep in mind that changes in one or several of the dataparameters might necessitate changes in other data

* parameters. For example, If pulp yield is changed, It isprobably true that the amount of black liquor recovered

- .' per ton of pulp will need to be changed also. Otherdata parameters can also be affected. Therefore, theuser needs to have some familiarity with the overallprocess and with the way in which various dataparameters are likely to be related to each other. Ageneral rule to follow in using the model is thefollowing: Whenever changes are made in any of thedata, review all of the data to see If correspondingchanges must be made In other values too. After auser develops familiarity with the model, that procedurewill likely become second nature.

23

N A TEaaI AIL.S BALAN0CEI Is. 06121T01. PULP"SPIS &1N10EAPOATORS

A. NEIS4ST OF PULP 05OU orSES ('&tI.F351.STOCK PREPARATION. &OOLTItyc. oaflS sesCIINI.

-FINISHING AND SNIPPING A,1IAN167 a o"/AA. FINISHED PO001W? OUTPUTS

'4 S440Dllssa . PUL.PWOOD CHIPS INTO 0ISESTESS(N"OISTUat CONTENT 6.4 Is TOTAL -T. 9601611733DlTNIV1 455. TONS/S0AT. SamG PGGOoMCT OUTPUTYAl &14Ta sTl.1 913STTN/AI 89. TONI/NAT. EATEN IN POOCTI

S. NECYCLEDON 0 $ MORE (TO STOCN P~IMP.Is C. TURPENTINE RECOVERY 1 1110 CNIP$$

315.01 0OT TONS/NAT 3.S TONS/NaT

C. TOTAL PAPER NACHINE AND OSltes TNSOUENPUT (A *Its

14311.0 0PT TONB/OST 0. 555CM LIDGOR SOLINS IN6 NE:9 BLACK9 ITMNNEN uI. I"S34 NAS LIK210O1 POON KAsNESs TO IVAPORATOS

A I

0. ANDITIVES AND NECYCLES NATINIALS 11N STOCKPREP&NATIN 114 . SOAP RECOVERY FROM SLACK LIOUOGS

14.0 ONS/AT ALN IS.3 site TONSATY.I TONS/AT &TCI

'N ~:a l. OSOTlN F. MATES REMOVAL$ INO EVAPORATORS a CONeNTRATORS

.6 DON? TONS/OAT MECTCLEN COMUTE 5508 TNI/ A~T at"Ni. IN EVAPONATORS%.6 TONStOA T LINCSE1 (904.10KSOL CONTENT TO CONCCENTRATORDI S6.N 2)

763.4 TONS/OAT SATCN Sgo. iS CoaCENTRAT0083 ;9. TOTAL M11GST &so ITIVES ANO RECYCLED P&TENIALS E (OLDS CONTENT To RECOVERT 8011L101 611.0 SI

PRODUICT (INCLUDES ALL RECYCLED AT RECOTERT ATi.ALL ALAN :STANC". NostN- PLUS HALF OP ACID.

GOP MC: ALCIICIE)K. BLACK LISUDS CONCENTRATE TO OECOTENT BOILES2:.OrpnyTONSCAT1691.4 TONS ST SKLIOS/OAT

P. e~l"N O PULP INTO STOCK PREPARATION Too"DIGETER a . 3 8N. WHITE LISUOS TO 01698TERI

1316.7 0If TONS/OAT TOSND6LONIA

K. MTESSINOAL N OTIS ECTONS373:. TONS/OAT ACTIVE ALKALI9. WTERREMVALIN DVER81I~t~tl(SONIAN OXIDE EOUIGALENTI

C.ATE. MST. CANT, 1NTO SITES 65.0 0 TOTAL AT.)(AVG. MlOT. CSNT. OUT SF DOVER 5.0 2 TOTAL Mf.)

III.~~~~~~ MOSPEPSTO AISN T. JANTITY 00 "CLEAN' HARDOOD

-A. VOLUME ON PUDLPWOOD INTO D2K"2S 110 .04 IVK 1STTONG/OAT NS"I. TONS/OAT. As ReceiveN

a-T .S?)a) 101161 TOGNT(GKoo sE CONTENTS 144N31)9

S. VLUME ON SANK ANN Pings SIMONES 35.6 Only TONS/OAT To DIGESTERANN MOUTON TO PONES0 "ILE, I.. DRY ToNSNA FYINES

336.5 may TENS/OAT

. AGE. GOANTIT? OP GOITWM efAOLE.TNEE CHIPSC. TOTAL TOLUNE ON PUL.P OOfuet RIOWINEN MEU E P5OATS1

INCLUDING SWlK ANN FINES 'ME SELON .)N3. R Il.0

0904.0 B1STTOS/AT ISTI.4 TONS/OAT. As SECEITEN

. AVI. UANTTT F SOTEM(MOISTURE CONTENT so.@%)

PUL.P a-O afON a SO Islas bawl OATS t 1 1ST AA TO TM S I'llTE93.60 IonsT T IS/A INoSVisa. BaT TONS/FOAT. ON0 571I COROS/SAw

lNoIsetNE CONTEST 1.4s3 A &aS. OUANTITT OP ANmoSOm "'NGLE-1tSE CHIPS-~ SEGOISEN PEA gaTS

55. 1S ON/A TO O11119111lef31 t A.ONs/ on ISM 55.3 10 ON/NAT. on

A~.11ON? TONG/OAT PINES I? TONS/OAT. as RECEITEN

.0. ~ SSE. OANTSITOP iASo EG" SoSJmSOGOB 9OPULP"O EM toWSE PER WAs sa.9 1T TONS/A TO 091818T91.0:5. 1ST TONS/NA1T IFINES

537.6 1ST TONS/OAT, ON830.S CoSGIsTo

MONISTURE CONTENTS so.#%)

S.9 sT, TONS/AT fiNES

AV$ TSUANITT OF 'CLEAR' SOFNUOA.CHIPS 014SUIKO PoA OaTS

378.1 s, TONS/OAT.aON750.5 TNOSAT. As SECEITED

(MOISTURE COVINTT 10.121

110 low TOSPAT P0 IESTR4

Figure 9.-Sample program output 1,400 T.PAD Conventional proceas; 1962 Price data.

24

067: 16 V. % %N

....- ZLL ION...

.49 .1 2. 1. .7

6 1 A 0 6 a 08 a I 6 01.1 1 £LO 8118461a 1 PU C S I GUOR9. 1. .4L 36.3. s 9 to$191 1466 't0 16U16 ?IS0 t1 7343. 305.3 1.636 ~ i& OILLION C0OON0 0ONRO ,(E. 1661 61 60 178.53 .3 3. 79 .0

000 10620, 6711716 1.1 WISC6 Low. PRSSR6O".? .4

TOTAL $T1AM OUTPUT 23.86S .979 334.9 3398.1 23.671 Ps011863 .46093 .03833 SIT.:)( as .431 .3603

RIA 9A~lTOTAL 87166 DEMAR01 Ma.ss .9 3346.9 1341.11 21.6161146 ACOSTA 61*0 1 11. ... L

6060.06 WATER pe0*1610 4.63? .164 -6-S600761.06 .731 .033 lose.? 43: .?P1as1 66167 8908..~16

64166(0 MC 1:318! 4 43: .3:1 633.1, 811: 0.386PEC0 (. 0601 0618 3.IR"CT0S0l .64 3P46 1. .0P0WER so"LE 1861 01. 333 .03 13. 72. 1 .3

M18C. 616" 66138481 a TEAM .600 .640 .0 0 .0

66608U PRE8SU61 P301188 I 11. .1.U.1L6.3

0316710 IIUO 014116 .I10 .1 ?S. 368.4 6.7: .35017*6084106 376 41 .06 .43 9. .0 .,a043I0"61 46"14 .069 .03 4 .9: :3 .667436 E1ATE08 8..6 1.600 .43 13331.3 11.6 .S1

811.LAC 1. IS 1.6.07..3 .00s 17. 6.6 .3

PON[*1 60311610 646 676NTN Y. :143 .03 691.0, J6. .6 A"got6 011*1 611. .0 .060 .4 0.0

PRCED 96(68 .764111 .6131 7404.0t 306S.830 S.2691

M 9 S a a 9 a 49 y 6 A A C EMVALP OFVARIUS LOW

617 ~~H I1N4 161N6 M AN66C 16141.70 006614? 91(6 676 14 681 614.7

P0C1 6010 ' (04( 644716 8636 I4 3'4S 16461..09 6411 4t 00.0Rt" RCCl

p6a16 11.16 3174. 883. 71 (3070 06416706138E10V167 8031.16 36066. 603. 301 6066:11471 6.

101A41 1 01 I9060is. 3339. 26.94 PO0 611. 6011.144610 6.6. 61166718! 61471643

PKIO0AA941 70 POW16 8031.66 *S3.6

N60T 67166, 8787109PRVIM VOE. 3661 P;:4;.O. :64eo"66:71083S

6666691.9018 14631 1416. 4.CR OL ,T 41101

8746s 6.08668 O 0ls. 63. .00 64"is0" PRE 6361E PRCSS$ta 8.

67(66 1.0S8ES 90. 03. .70

M074n 617K 1666837. 383. 89

LOU~~~~ 01%SUIPRCS9, 715 7373. CN 16*7 9907 s8811 76141.,

III&" OSSES1?3%. CIA..

Figure 9. -Sample program output 1,400 T. P.D. Conventional process; 1962 Price data (continued).

25

%6MOI *V VV

% %~...~~.J.~ . .ao a. % %l N - r.

a a, IF a 9 a . C 0 aT . V aoaptI C00va10VI10x STOCKstzo 6cPump. Ae PAPER MACNI63ABOSISM g3uys

ALUH- , oSa 1213.64"111 San0. 0.56 6"B.

SULFURIC AM3 to5 8 7.00110111 l005. .IF SH.

S/SAYGM S/SS 10 61UAL stP0Am3 (a S 661.60/10) togs. :.15 33.00090 to S 160.04/TS"I 6". .63 N44101.

* 5396636 LINICISO t (S 114.n0/oW) 1am. .39 Son33.

P6"WAS PRO0DUCT (6 9890.91"6 y0u) 6040. 690.00 144130000.

161.1. OIE SO o (S S6.65/155L) 130. .1.0 solo"4.TALL ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ Ig I*OP t s#lo3lt. 58 ain TE ISCEL.LANEOUS C63SICA1.S CUTlS

TOTAL. REVEUS 405111. 395.761063993963. COOL IS Un5 C6NICALs SI. .04 1900:"ILES noEticeT CHEMIZCALS 11..1 0561NavPl OOTU56115 CMICAS so9. 11, M0ass9.

-~PO96 TREATMENT0 CHEMICALS 0391. 1.93 am1". 10501

CLA.56100 HP ( 0.913266C 5.06 1011M.CL66' 1ASC CO:P IS "360.0/O)1'3. 11 1905346. OTHER5 VAIABLE COUT$. 1 630

S0PT:SOFUSTWO CHIPS to a 29.0611 Boos1. 4.6.01063514. PPS CHg66(sl. .1 571.063500 M60N6OSE CHIP toS 001.00TONI 1609. 1.0? 1318. FINSHE WEL L Como 0.36 .106.

s6vm ta'T.136194.619SGB PEVIAl0 RISK. .66 09110.

PITO") 8.00 ( 30/1093. 10.61 9130. MT , s 46

LACOAL COB' TO A VARIABLE0 Co16t. 6.31. 0103116.1t

COAL to1 66 (6 .se/6CI 115. 1.30 310361.uses006 FULCYC (0 6 &&.$*/TONS 13066. 16.11 5360916.

465.0 ANDS SALTCAMI RECLAIM CHE6MI61. 50U1S

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