Process Clarity Projects

Silcar

Dynamic Load Matching Simulation of Hospital CHP System

Silcar

Process Clarity staff designed and built a dynamic process simulation of a Combined Heat & Power (CHP) system implemented in multiple hospitals across Victoria, Australia. Each consisted of a natural gas turbine and turbogenerator with exhaust duct firing and heat recovery steam generator. The sites which were being examined had the requirement to supply a load where both heat and power varied over the course of the day, and over the seasons, from the gas fired cogeneration plant. The simulation was used to predict fuel consumption based on a variety of control strategies and was the centerpiece of a successful bid to take over operations and maintenance of the CHP plants.

 

Silcar was a JV between Siemens and Thiess that was wholly acquired by Thiess in 2013.


Link: http://www.thiess.com.au/our-business/services/energy

Silcar

Coal Power Station Operator Training Simulation

Silcar

Process Clarity constructed a high-fidelity dynamic process simulation of the Fluidized Bed Coal Power Island for use in training operations staff at a greenfields nickel processing facility. The simulation started with the combustion side; including the circulating coal, ash & sand, air & combustion products and heat exchange modeled through air preheaters, boiler tubes, economizer, superheater tubes and fluid bed heat exchangers. The water & steam side was modeled to include all of the heat exchange surfaces with the combustion side along with the deaerators, steam preheaters, HP turbine & IP/LP turbine with passouts, condenser & hotwell. Fluid dynamics were modeled to the highest level of realism with true pipes, pumps and valves implemented with their design characteristics. Once the simulation included all process elements of the power station validated against the design data a front end was applied to the simulation which mimicked the appearance and process control of the plant Distributed Control System (DCS). The simulation is an integral part of the operator training systems at the site as they move on from commissioning to production.

 

Silcar was a JV between Siemens and Thiess that was wholly acquired by Thiess in 2013.

Link: http://www.koniambonickel.nc/index.php?lang=en

Heywood Pulp Mill

Greenfield Pulp Mill (TMP) Site Simulation

Heywood Pulp Mill

Process Clarity was invited to join a group of companies that were designing a new greenfields Thermo-Mechanical Pulp (TMP) Mill for Victoria, Australia. The project was made particularly challenging by the fact that no effluent discharge license was allowed by the State for this area, so the mill was going to have to be a Zero Liquid Effluent (ZLE) design. We created a high level simulation of the entire site so that all members of the team could have a clear picture of the challenges which need to be addressed. Thanks to our work with the simulation and previous experience with ZLE sites we quickly became the key player in facilitating communications between the three main companies in the group; one responsible for pulping operations, another for water treatment and the third for power production. We were able to illustrate several ways in which the teams could improve the overall site performance by using Integrated Process Design techniques and our thorough understanding of the ZLE limitations allowed us to point out where original process designs would not meet the project objectives.


Link: http://www.penolapulpmill.com.au/