Closed Water Systems On Paper and Board Machines Using The Dysco

Western Michigan University
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Master's Theses Graduate College
4-1982
Closed Water Systems on Paper and Board Machines Using the

Dysco Simulation Program
Stephen Robert Tremont
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Simulation Program" (1982). Master's Theses. 1751.
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CLOSED WATER SYSTEMS ON PAPER AND BOARD
MACHINES USING THE DYSCO SIMULATION PROGRAM
by
A Thesis
Submitted to the
Faculty of the Graduate College
in partial fulfillment of the
requirements for the
Degree of Master of Science
Department of Paper Science and Engineering
Western Michigan University

Kalamazoo, Michigan
April 1982
R ep ro d u ced with p erm ission o f th e copyright ow ner. Further reproduction prohibited w ithout perm ission.
CLOSED WATER SYSTEMS ON PAPER AND BOARD MACHINES
USING THE DYSCO SIMULATION PROGRAM
Stephen Robert Tremont, M.S.
Western Michigan University, 1982
This study was conducted to determine the accuracy of the DYSCO
simulation program in simulating the open and closed water system
on the pilot fourdrinier paper machine located in the Department
of Paper Science and Engineering at Western Michigan University.
The pilot machine was run at a maximum speed of 76 meters (250 feet)
per minute without the press and drier sections, as well as slower
speeds of 61 and 46 meters per minute. Retention data were obtained
for fiber, titanium dioxide, and water at the three speeds. Upon
entering these data along with stream inputs into the DYSCO simula
tor, it was found that good correlations were obtained for experimen
tal versus computer simulated flows and consistencies. Other simula
tions carried out for a proposed closed water system proved to be
feasible with little or no input of fresh water. Temperature data
for the closed system were also obtained.
ACKNOWLEDGEMENTS
I wish to thank Mr. John Fisher, Dr. Richard Valley, and Dr.
Raymond Janes for their assistance during the course of this study
and throughout my academic career at Western Michigan University.
I am indebted to Keith Manion, Lance Merrell and Bill Corriveau
for their assistance in gathering the experimental samples from
the pilot paper machine. I would also like to thank Sue Humecke
for her fine artwork in the figures and illustrations presented in
this paper, and Gayl Stuut for typing the manuscript.
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1310531
TREMONT, STEPHEN ROBERT

C L O S E D W A T E R S Y S T E M S ON P A P E R AND B O A R D
M A C H I N E S U S I N G THE D Y S C O S I M U L A T I O N P R O G R A M .
WESTERN M I C H I G A N UNIVERSITY, M.S., 1902
COPR. 1982 TREMONT, STEPHEN ROBERT

University
Microfilms
International 300 N. ZEEB RD., ANN ARBOR, Ml 48106
© 1982
STEPHEN ROBERT TREMONT
All Rights Reserved
TABLE OF CONTENTS
ACKNOWLEDGEMENTS ................................................ ii
LIST OF T A B L E S .................................................. v
LIST OF F I G U R E S .................................................. vi
INTRODUCTION .................................................... 1
_ THE CLOSED WATER SYSTEM ......................................... 2

T~~
Mill and Pilot Machine Studies ............................ 3
Savealls ...................................................... 6
M O D E L I N G ........................................................ 11
SIMULATION P R O G R A M S ....................... 15
F E M .......................................................... 15
GEMS ........................................................ 15
C H A M P S ........................................................ 17
M A X I M I L L ...................................................... 18
P O L A R O D O R .................................................... 19
O P C O M ........................................................ 19
P U B A L ........................................................ 20
D Y S C O ........................................................ 21
Integration Methods ................. 22
M o d u l e s .................................................... 24
THE CYLINDER BOARD MACHINE ..................................... 29
THE F O U R D R I N I E R ..................................................... 36
PRESENTATION OF PROBLEMS ....................................... 43
iii
EXPERIMENTAL PROCEDURE ........................................... 45
Pilot Machine T r i a l ......................................... 45
Simulation Experiments ....................................... 48
PRESENTATION AND DISCUSSION OF RESULTS ........................ 52
SUMMARY OF R E S U L T S ............................................. 78
C O N C L U S I O N S ...................................................... 79
RECOMMENDATIONS .................................................. 81
A P P E N D I C E S ...................................................... 82
BIBLIOGRAPHY ..................................................... 108
iv
L IS T OF TABLES
Table Page
1 Experimental Data - Pilot Machine -

46 M e t e rs/Minute .................................... 53

61 M e t e r s / M i n u t e .................................... 54

76 Meters / M i n u t e .................................... 55
4 Experimental Retention Fractions - Pilot Machine ... 56
5 Experimental Stream Parameters - Open System -

46 Meters / M i n u t e.................................... 57
6 Experimental Stream Parameters - Open System -

61 M e t ers/Minute.................................... 58
7 Experimental Stream Parameters - Open system -

76 Meters / M i n u t e.................................... 59
8 DYSCO Stream Parameters - Open System -

46 Meters / M i n u t e.................................... 61

61 M e t e r s / M i n u t e .................................... 67

76 Meter s / M i n u t e .................................... 63
11 DYSCO Stream Parameters - Closed System -

46 M e t e rs/Minute .................................... 64
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L IS T OF FIGURES
Figure Page
1 Model Of The Real World ........................ 13
2 Euler's Method ................................... 23
3 Runge-Kutta Method .............................. 25
4 Key For DYSCO Modules............................ 28
5 Primary Loop - Cylinder Machine................. 32
6 Primary Loop - Cylinder Machine - DYSCO . . . . 33
7 Closed Water System - Cylinder ................. 34
8 Wet End - Fourdrinier Pilot Machine ........... 37
9 Open Water System - Fourdrinier ............... 38
10 Closed Water System - Fourdrinier ............. 41
11 Open System Drainage Profile - 46 Meters/Minute • • 66
14 Fiber Consistency Profile - 46 Meters/Minute . . • • 70
15 Fiber Consistency Profile - 61 Meters/Minute . . • • 71
16 Fiber Consistency Profile - 76 Meters/Minute . . • t 72
17 Filler Consistency Profile - 46 Meters/Minute • • 74
18 Filler Consistency Profile - 61 Meters/Minute • • 75
19 Filler Consistency Profile - 76 Meters/Minute « • 76
vi
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INTRODUCTION
The concept of a closed white water system in the paper industry
has been a subject of discussion since 1929. Many of the problems
of white water systems: slime, foam, scale accumulation, paper qual
ity, fiber recovery, etc. are still a challenge to the papermaker.
By closing the white water circuits on paper and board machines,
environmental protection of waterways from mill discharges can be
achieved. The closure of systems internally represents one alterna
tive measure for pollution abatement in paper and board mills. Such
measures have several advantages over external treatment, provided
care is taken to avoid the impairment of operating conditions or
product quality. Experience gained in many mills with the closure or
partial closure of the white water circuit shows that a substantial
part of conventionally discharged pollutants can be excluded from
effluents and reused in paper products without negative effects.
Before the age of the computer, all mass and energy balances
were performed by hand where computation time was long and tedious.
However, with the aid of today's high speed electronic computers,
computation time is greatly reduced so that results are obtained
in minutes rather than days. Therefore, with the aid of the computer,
the effects of the closed water system can be predicted, understood,
and dealt with through simulation of the papermaking process.
THE CLOSED WATER SYSTEM
In closing a white water system, problems do accompany the clo
sure .
In the reuse of process water in a pulp and paper mill

situation, several types of problems can arise including
those associated with slime, foam, pitch, corrosion, in
creased temperature, scale formation, dissolved solids
buildup (alum, starch, rosin, drainage aid, retention aid),
sizing difficulties, total solids buildup (fines, clay,
titanium dioxide), felt plugging, reduced wire life, ^
reduced drainage rate, shower plugging and pH control.
It has also been observed that inorganic and organic

impurities in the water system of a paper or board mill
will become concentrated if the circuit is closed and will
impair the action of chemical papermaking aids. The most
effective methods of preventing this are treatments to
purify any fresh water adder}, modification of the process
and intensive pulp washing.
Simple calculations show that complete closure of the

water cycle will lead to salt accumulation of corrosive
hydrogen sulfide. These problems can be avoided by not com
pletely closing the system. Instead of fresh water, biolog
ically gurified outside effluents may be added to such a
system.
Due to the increase in biological and chemical contaminants
in a closed white water system, the corrosion resistance of existing
or proposed materials of construction are a matter of concern.
Gellman, I., "The Relationship Between Process Water Quality

Characteristics and its Reuse in Combination Boardmills," NCASI Tech
nical Bulletin, Part III no. 282, (Sept. 1975), p 1.
2
Auhorm, W. and Melaer, J., "Investigation of Disturbing Sub
stances in Closed Circuit Systems," Wochbl. Papierfabr. 107 no. 13,
(July 1979), p. 493.
3
Pothmann, D . , "Considerations Regarding Operation of Papermills
Without Effluents," Wochbl. Papierfabr. 103 no. 11/12, (June 1975),
p. 382.
3
Fluchner reported corrosion problems in a German mill in which gal
vanized pipelines transmitting clarified white water failed by corro
sion after one year in recycled conditions. Brecht"* reported corro
sion as the most difficult problem in German mills manufacturing
paperboard and packaging grades. An attempt to relate corrosion to
specific electrical conductivity did not correlate well with concen
trations of chlorides and sulfates. There was also some indication of
less corrosion under conditions of low conductivity and above neutral
pH.
Mill and Pilot Machine Studies
A study was done in Mississippi^ on the effect of water reuse
on the paper machine white water properties in a pulp and paper mill
with special emphasis on foaming properties. Recycling of paper ma
chine white water at recycle rates between 65 and 95% was simulated
in the laboratory using both bleached and unbleached kraft pulp. The
properties of the simulated white water were compared to actual
machine white water. Both the foaming tendencies and foam stability
increase rapidly as the white water recycle increases. The unbleached
pulp white water foaming tendency and foam stability were larger for
bleached kraft by a factor of 1.7 and 2.6, respectively, over the
4
Fluchner, W . , "Experience with Closed Water Circuits in Paper
Machines," Papier 29 no. 5, (May 1975), p. 206.
^Brecht, W . , "Closed Water Circulation Systems in Additional

Mills Processing Waste Paper," Wochbl. Papierfabr. 102 no. 7, (April
1974), p. 223.
^Lightsey, G. R. and Hall, W. R . , "Control of Foaming in Pulp

and Paper Mill White Water," Mississippi Water Resource Instititute
Project A-125, (Oct. 1979).
range of recycle rates. It was assumed to be due to the high acidity
of bleached pulp white water. Control of foaming in white water by
addition of defoamers was found to be less effective as the white
water recycle rate increased.
Lewis and Bowman^ conducted a study on an experimental paper
machine in which the system was 100% closed on a 24 hour basis for
a five day period. The paper quality, headbox concentrations, and
pigment retentions were tested at regular intervals. Paper strength
and sizing were found to be badly deteriorated after a period of two
days during which a typical offset furnish was used. For the last
three days of the test an experimental Pigment S was introduced into
the furnish, replacing part of the TiO^, and the system regained to a
condition stronger than the previous deteriorated one. Analyses of
sulfate ion, pH and total titratable acids indicated that acid, not
sulfate ion concentrations, correlated with strength and sizing de
terioration in the 100% closed system.

0
St. Regis Paper Company carried out extensive laboratory, pilot
plant, and mill trials to determine the changes in composition and
quality of water flowing to the headbox as the percentage of machine
white water recirculated in the mill was increased and how these
changes affected the quality of the paper and the wet-end chemistry
^Lewis, J. and Bowman, R. S., "Five Day Operation of a Paper

Machine Using 100% Recycle of White Water," TAPPI 53 no. 11, (Nov.
1970), p. 2112.
0
Dobbins, R. J., Roscoe, R. W., and Alexander, S. D . , "Influence
of Dissolved Electrolytes in a Closed Mill System," Proceedings of
TAPPI Spring Corrugated Container/Papermaking Conference,(Dallas,
Texas, 28 April, 1975), pp. 93-9.
on the paper machine. The pilot trials were carried out on the paper
machine at Western Michigan University and the mill trials were car
ried out with the same furnish as with the pilot trials on a commer
cial machine at the company's Sartell, Minnesota integrated pulp and
paper mill producing uncoated grades, mainly supercalendered catalog
paper. The pilot machine trials showed that increasing the white
water recirculation from 80% to 97%, increased the electrolyte level
from 800 ppm to 4000 ppm. Many of the normal wet end processes, es
pecially those depending upon ionic forces of attraction and repul
sion (formation, retention, drainage, etc.) were altered in the high
salt environment. There was a loss of tear and slight loss in tensile
strength at higher salt levels. However, it was concluded that in
creasing the white water recirculation at the Sartell mill should not
have any adverse effects on the quality of the catalog paper produced.
9
Lyman Aldrich and Raymond Janes conducted three continuous 3-5
day runs on a 30 inch wide fourdrinier paper machine at Western Michi
gan University to determine the technical and economic feasibility
of operating a fine paper machine with an essentially closed water
system. The closed run discharged only 1200 gallons of water per
ton of paper (over 97% reuse of water) as compared with the semi
closed run which discharged 13,000 gallons/ton (72% reuse). A 55
lb. offset paper was made using 50/50 hardwood/softwood bleached
kraft with 15% filler. Closing the water system from 72-97% resulted
9
Aldrich, L. C . , and Janes R. L . , "White Water Reuse on a Fine
Paper Machine," TAPPI 56 no. 3, (March 1973). pp. 92-96.
in the following benefits: (a) savings of 18% of filler while main
taining opacity and ash content, (b) savings of 50% alum and 20%
rosin while maintaining sizing, and (c) a 50% reduction in total BOD
in the effluent even though higher BOD concentrations were obtained.
Negligible differences were found in: (a) paper strength properties
(less than 10% decrease), (b) suspended solids (although dissolved
solids increased), (c) felt filling or pressing efficiency, (d) dirt
in paper, and (e) printability. Several minor operating equipment
changes were required to obtain these results. Microbiological tests
indicated increased biological growth as temperatures were raised
to 110°F, but the growth appeared to decrease when operating at 125°F.
A marked change in types of growth occured at the different tempera
tures .
Savealls
It is observed that most of the problems associated with a water
closure stem from the increase in organic and inorganic solids. There
fore, in order to control the system properly and economically, ex
cess solids must be removed and if possible recirculated back into
the product. Most mill systems in use today use some sort of saveall
to remove most or all of the particulate matter from the white water
before discharge or reuse. In a closed water system, the properly
designed saveall system can be utilized to efficiently control solids
buildup and remove excess contaminants which upset equilibrium in the
wet end chemistry of the papermaking process. In areas with limited
or poor quality water supplies, total closure offers advantages since
it will at the same time reduce the costs for process water purifica
tion. At present there are several mills in Europe operating with
zero-discharge.^ Whereas, in the past, this was thought to be
limited to coarser paper grades, even fine papers are now produced
under such conditions. These operating systems are a combination of
efficient savealls, the use of corrosion inhibiting piping, aeration,
biological treatment, and the use of chemicals to control the wet end
equilibriums needed for proper fiber formation on the wire. Since
corrosion is reported as the major problem in mills introducing a
closure or partial closure in the white water system, extensive use
of stainless steel/plastic piping is mandatory for long term water
transport. Also a properly designed saveall should recover" at least
95% of all suspended solids for most grades of paper.
There are five general types of savealls for fibers and filler.
11
These include:
1) Stationary
2) Revolving-screen or Cylinder
3) Vacuum-Filter
4) Settling, or Sedimentation Tanks
5) Flotation Units
The stationary inclined screen type of saveall is not as com
monly used presently as it was several years ago. These savealls
consist of an inlet headbox with feed slots, an inclined screen of
fine-mesh wire, and stock and whitewater discharge boxes. The white
"^Wenzyl, D. J., "Closure of Paper and Board Mill Production

Systems and its Effects on Production Conditions," Proceedings of
TAPPI National Conference. (Chicago, Illinois, March 1981), p. 120.
11
Ingraham, H. G. and Forslind, E. E., Papermaking and Paper-
boardmaking Vol. Ill, (McGraw-Hill, 1970), pp. 207-16.
water enters the headbox through a supply pipe and flows through feed
slots onto the inclined wire. The thickened stock rolls down into the
stock box, then through a discharge pipe, and is pumped back to the
system to be reused. Very few of these are in use today except for
special purpose use such as washing deinked stock or where long
fibered stock is employed.
The cylinder type of saveall operates with a continuously revolv
ing cylinder covered with fine wire. The white water flows inward
through the fine wire covering of the cylinder mold, leaving the
suspended fibers clinging to the outside surface, from which they
are removed by a couch roll and doctor. A variation of this type
of saveall, in which the cylinder starts and stops intermittently,
is known as the Bird saveall. This is a simple gravity saveall in
which the white water enters a vat, flows inward through the fine-
mesh wire covering the cylinder, and deposits a mat of fibers which
act as a filter. With the cylinder at rest, the mat thickens and
is picked up by a rubber couch roll. The units are built to provide
capacities from 750 to 2800 liters per minute (200 to 750 gpm).
The cylinder type of vacuum filter is widely used as a saveall
on all kinds of paper mill white water. The vacuum filter will retain
nearly all the white-water solids in the excess paper machine water
provided sufficient chemical-pulp fiber is added to enable the
machine to form a sheet rapidly. This sweetener stock should contain
at least 3 kg./lOOO liters (25 lb./lOOO gal.) chemical pulp to meet
this requirement. The white water solids are recovered by the mat of
stock that continuously forms on the surface of the disc or drum. The
9
best consistency for feed to a vacuum saveall is dependent upon the
nature and concentration of the actual solids present before addition
of the sweetener. With white water from paper machines using large
quantities of filler such as clay, calcium carbonate or titanium
dioxide, the ratio of fiber to filler in the saveall feed should be
three to one. With lower ratios of fiber to filler, the sheet formed
has insufficient porosity, and the finely divided fillers tend to
"bleed".
The disc vacuum saveall consists of a number of 2m., 3m. (7 ft.,
9 ft.), or larger diameter filter discs of eight, ten, or more sec
tors each, covered on both sides with wire or polypropylene cloth.
The discs are assembled around a hollow cast-iron or stainless-steel
shaft. The discs are supported in a stainless-steel vat. When the vat
is filled with sweetener stock and white water, the discs are sub
merged to a point above the center line. The discs rotate at a very
low speed, usually not over one rpm., and under a vacuum of about 250
mm. (10 inches) Hg. The sheet is formed on the wire depending on the
consistency of the incoming stock and is removed with high-pressure
showers before the disc is again submerged. The relatively high ef
ficiency of this type of saveall is attributed to three factors: 1)
the slow speed of rotation, 2) the relatively good vacuum maintained,
and 3) the separation of the clear and cloudy filtrates by automatic
valving. The clarity of the clear filtrate makes it suitable for
reuse in many shower applications. The cloudy filtrate may be
recycled to the filtrate vat for reprocessing.
The flotation saveall is adaptable to all types of furnishes
and white waters and produces a high-quality clarified water which
permits.its reuse in many places where fresh water would otherwise
be required. The operation is based on the flotation principle with
fine air bubbles being attached to the fiber and filler. Paper mill
white water containing fiber and filler is aerated by means of an
air-dissolving mechanism over a retention period. Flotation of solids
is accomplished by a controlled pressure drop along with flocculants.
The fiber and filler are directed to a flotation zone where they floe
and are skimmed off. The clarified water is passed out the bottom of
the unit. The effluent from this type of saveall will have a high
degree of clarity and will not contain more than .05 kg./lOOO liters
(.5 lb./lOOO gal.) filterable solids. The use of chemical flocculants
is required on filled grades only.
MODELING
In dealing with the wet end water system of a paper machine, a
model is needed to simulate the real processes occuring. Since model
ing is basically the process of planning and building a copy of a
real object, the model is only a representation of the actual phenome
non. Therefore, there are always certain details which are not in
cluded in the model. These deficiencies influence the applicability
of the model, especially when certain levels of detail are deliberate
ly omitted. Due to this, no one model is correct for all uses, but
only for those which it most closely resembles in the real world.
One area that is gaining vast interest is the simulation of
real world processes by the aid of computers with their large memory
capacity and quick computation times. Computer programs developed
to solve specific classes of problems are known as simulation models.
However, simulation models, like process models, are not applicable
to all problems. Forcing a simulation model to handle a problem for
which it was not designed is risky and will probably lead to failure
and discouragement.
Process simulation models are a combination of process models
and simulation models. These models are designed to solve a certain
class of problems associated with the real process to be simulated.
However, by attempting to extend these models beyond their initial
intent, there is a tendency to create invalid solutions and caution
is advised.
11
12
In order to classify both simulation and process models, a model
can be built of the real world. Figure 1 divides the real world into
eight classes, with three major groups. This figure shows that pro-,
cesses can be dynamic or steady state, continuous or discrete, deter
ministic or stochastic.
Dynamic processes are those that change with time. All real
processes are dynamic in nature. The modeling of dynamic processes
involves the solution of differential equations. If some of the pro
cess model must be represented by partial differential equations,
sophisticated techniques must be used to obtain the correct solutions.
Steady state processes are ones which do not change with time.
All the inptits, outputs, and processing conditions are constant.
Since no real processes are ever run this way, control systems are
used to keep the process at steady state. The basic function of steady
state processes is to transform inputs into outputs.
Continuous processes are those that utilize items which take
on a continuous range of values. An example of a continuous process
is temperature. Temperature can take any value yet the tendency is
to measure temperature with a discrete number, say 25°C. But the
actual value may be between 24.5 and 25.5°C. In modeling a process,
continuous models are generally the type considered.
Discrete processes are those that operate on individual or sepe-
rate items. An example of a discrete process is the assembly line
for car manufacture. Each car is individually made, painted, tested,
shipped, etc. Each car is distinguished from all the other cars yet
the same operation is applied to each separately. Process models
13
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MODEL OF THE REAL WORLD

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FIGURE 1
14
developed to study such systems must account for this individuality
in order to track an individual in the process.
Deterministic processes are those in which the process is de
scribed by a fixed set of numbers. A known input into the process
produces a known output. Deterministic models are the ones most often
used by engineers to describe processes.
Stochastic, or random processes, are closely associated with the
real world. Given a fixed set of inputs and process variables, the
output is still a random variable. A stochastic system also results
when the inputs or the process conditions vary randomly. A good exam
ple of a stochastic process in the retention of matter on a paper
machine wire. Even though a number is given to the percent retained
on the wire, this number has already changed since the measurement
was taken due to other random variables such as speed, temperature,
consistency, etc. By assuming that the number has not changed to
a significant degree, the deterministic model is applied to simplify
the actual process.
By these definitions, it is apparent that the production of
paper is a continuous, dynamic, stochastic process. However, an analy
sis of such a process is too difficult unless the process is somehow
simplified. One simplification that was already pointed out is to
assume that the process is deterministic and not random. Also steady
state results when the dynamic behavior of the system is ignored.
SIMULATION PROGRAMS
FEM
12
FEM (Facility Energy Management) is an energy balance and
accounting program for determining the energy system costs for opera
tion of a facility. When a process energy system is described appro
priately, the program calculates output data essentially from prin
ciples utilizing the complete steam tables which are part of its data
bank. A FEM output provides: 1) unit reports for boilers; 2) flows
in all lines, and into and out of each header; 3) condensate flows;
4) fresh water makeup; 5) desuperheating requirement; and 6) an an
nual energy summary. Input information involves: 1) defining consump-
tion and dispostion of condensate; 2) minimum rates of flow, produc
tion, and capacity; 3) assigning fuel priorities and energy data such
as heat value/unit, cost/unit, and availability; 4) the demand rates
and availability of purchased electric power. There are equations and
strategies in FEMS which simulate boilers, mechanically driven tur
bines, back pressure turbines, condensing turbines, pressure reducing
valves, desuperheaters, deaerators, flash tanks, heat exchangers,
thermo compressors and constant energy processes.
GEMS
In 1973, the rights to GEMS (General Energy and Material balance
System) were purchased in order to model a facility energy model
^Thomas, K. V., "Process Simulation Program," TAPPI 62 no. 2,

(Feb. 1979), pp. 51-57.
15
(FEM). This modular program was used to calculate the material and
13
energy balance for Potlach Corporation's bleached kraft mill at
Lewiston, Idaho. Their GEMS program included subroutines for modeling
the chip and sawdust mills, the bleach plant, and the machine room
chemical recovery system. By combining these subroutines with actual
log sheets, the simulation of the system was achieved. The process
steam flows were measured with portable sonic flowmeters and chemical
analyses were done by specific ion electrode techniques. These mea
surements were used to validate water, pulp, chemical and energy
balances.
14
Baldus used GEMS to calculate material and energy balances for
full kraft mill evaluation and design. Process units were analyzed,
simulated in detail and molded into the GEMS modular framework. The
areas simulated included pulping, bleaching, power generation and
recovery. The GEMS program was adapted to the General Electric MSRK
III Time Sharing System to aid in the practical application of the
program to real process problems by allowing easy access to GEMS.
Liquor recycle alternatives were examined, thus identifying changes
in energy consumption and environmental impact for various degrees
of mill system closure.
13
Rushton, J. D. and Gunseor, F. D., "Computer Simulation of
a Bleached Kraft Pulp and Paperboard Mill," Proceedings of TAPPI
Engineering Conference, (San Fransisco, California, 19 September,
1978), p. 145.
14
Baldus, R. F., "Development and Validation of General Compu
terized Unit Operations Related to the Pulp and Paper Industry and
Their Application on a Practical Base," (Ph.D. dissertation, Univer
sity of Idaho, 1978).
17
Van Scoffer and Edw a r d s ^ used the GEMS modular computer system
to evaluate various refiner and screen room configurations for a 100
ton per day newsprint mill undergoing modification. Results showed
that with optimizing refining and screening conditions the quantity
of mechanical pulp long fiber (+28 mesh Bauer NcNett) could be in
creased by 15 to 20% at constant shive or minishive levels. An inves
tigation of tear strength and drainage time for mechanical pulp/sul
fite pulp mixtures quantified the savings in sulfite pulp furnish
due to increased mechanical pulp strength. Economics for the new
system showed that additional fixed capital investments over the
base cost resulted in substantial savings due to reduction in chemi
cal furnish and applied refiner power.
CHAMPS
CHAMPS (Chemical, Heat and Materials Process Simulator) was
developed from GEMS. It differs from GEMS in specific block details
for the input and output processors and format. CHAMPS also includes
a process economics package. It is a process simulation model which
provides a fast means of defining all streams, evaluating the impact
of proposed action on significant streams, establishing the materials
(wood, water, bleaching and cooking chemicals) and energy (steams,
fuels, and power) required by a complex process system, identifying
process and economic sensitivities, and understanding alternative
*^Van Scoffer, K. and Edwards, L . , "Minimization of Chemical

Fiber Furnish in Newsprint," Proceedings of the TAPPI/CPPA Internal
Mechanical Pulping Conference, (Toronto, Canada, 11 June; 1979), p.
363.
18
procedures, recycling loops, and any changes in configurations on
the total system. The program uses blocks to indicate what is happen
ing to process streams as they mix, split, and react, along with
mathematical equations to define what happens to streams as they pass
through the blocks in a flow diagram. The streams are defined by
characteristics selected from the following: mass flow (liquor and
fiber); solids in liquor (total, organic, and inorganic); tempera
ture; ionic composition; and derived values and properties, such
as heat capacity, pH, color, BOD, consistency, and flow. When process
costs are of special interest, streams which impact the particular
interest are labeled and CHAMPS calculates a process cost statement
limited to these streams.
MAXIMILL
MAXIMILL^ is a computer modeling tool used to evaluate fiber
related processes. It is designed to optimize mill profitibility
while considering market, raw materials, machinery, energy, and pollu
tion constraints. MAXIMILL is easily used by plant personnel and
presents results in process pictures and graphs. It is used exten
sively by Weyerhaeuser Company for grade mixes/product mix decision,
standard costing, production scheduling and capital budgeting. It was
developed jointly by Computer Sciences Corporation and Weyerhaeuser.
^Thatcher, F., "Computer Assisted Pulp Mill Scheduling Using

MAXIMILL," Proceedings of TAPPI Annual Marketing Conference, (At
lanta, Georgia, 24 February, 1980), p. 77.
19
POLARODOR
The POLARODOR*7 system was designed to adapt to single or mul
tiple stage bleach plants and uses a dynamic predictive model with
self adjusting feedback trim based on actual sensor measurements.
The bleach plant control system of Rosemont at Eden Prarie, Minne
sota, combines dual chlorine sensors and proprietary digital control
stategies. Emperical models, developed during actual operations are
used to determine proper chemical dosages in caustic and hypochlorite/
chlorine dioxide stages based on a dynamic process model. An average
total chemical savings of 10% have been achieved and a 2% product
yield increase was attained due to reduced losses. The POLARODOR
system was developed by Potlatch Forest Industries and the Pulp and
Paper Research Institute of Canada.
OPCOM
12
OPCOM is an operating cost accounting program. It contains
standard information which is used to calculate operating costs.
This standard data includes unit costs (raw materials, chemicals,
labor rates, power and fuel), function requirements per unit of pro
duction (steam, kW. hr., operating and maintenance labor and materi
als, fuel, additives, etc.) and by-product quantities and values
(turpentine, soap, tall oil, etc.). Standard unit data in OPCOM in-
17Gutpa, R. M., "Bleach Plant Control Optimization Instrumenta

tion in Pulp and Paper Industries," Proceedings of ISAPUPID Confer
ence , (Albany, New York, 13 May, 1980). pp. 1-7.
^Thomas, K. V., "Process Simulation Program," TAPPI 62 no. 2,

(Feb. 1979), pp. 51-57.
20
elude digestors, washers, screens, recovery units, evaporators,
bleach plant units, stock preparation equipment, pulping processes,
steam and power plants, and environmental processes (primary, secon
dary, and tertiary). The user of OPCOM describes the mill by entering
information concerning raw materials, pulp processing lines, the
number of machines with grade rates, and the annual production of
each grade. The output contains direct variable and semi-variable
cost summaries by product, grade, cost center and the total unit of
production and annual costs.

18
Treiber developed a modular steady-state simulator of the
kraft pulping and recovery process. The modules were based on first
principles and empirical literature results. His test mill featured
a process cycle with at least four replicate process units at each
stage, operating in parallel. One simulation predicted $300,000 a
year savings as a result of a composition change in the pulping
reagent. Post-implementation measurements indicated savings up to
$500,000 a year. In support of the mill trial, a simple dynamic model
of the process was developed to allow calculation of a control stra
tegy to manipulate the reagent composition. The strategy was success
fully applied through a series of major process upsets.
PUBAL
19
PUBAL is a computer program designed to perform material and
18
Treiber, S. S., "Kraft Mill Simulation" (Ph.D. dissertation,
McGraw University, 1979).
19
Horgan, J., and Hughes, R. P., "Computerized Pulp Mill Process
Balance System," Proceedings of TAPPI Engineering Conference, (San
Fransisco, California, 19 September, 1978). pp. 115-125.
21
heat balances for process flows within pulp mills. The PUBAL program
is composed of a series of modules or subroutines corresponding to
basic process segments such as washing, screening and bleaching.
Data entered into the computer produces detailed data and graphical
diagramatical properties of the process.
DYSCO
20
DYSCO (DYnamic Simulation and COntrol) is a dynamic modular
simulator. It attempts to solve the process in a simultaneous manner
by appropriate storage of values calculated for the new point in
time. Two types of modules are available in DYSCO. Instantaneous
models are identical to steady state models in that inputs are alge
braically related to the outputs. Dynamic models are represented
by the standard mass balance equation;
d(V°c) = (Q°c). - (Q°c) + RV° Eq. 1

■;---- in out
dt
where: V is the volume of the vessel (V° refers to initial

volume)
c is the concentration of species
Q is the volumetric flow rate, initially
R is the rate of appearance (disappearance)
of species by some conversion process
t is the time
DYSCO is a rather large program which is designed to simulate
problems of various sizes. In the first phase the process is entered
as a flow sheet along with some other information. This information
is used to build two FORTRAN subroutines. One of them sets up the
calls to the process models while the other sets up dimensions for
20
Parker, P. E., "Dysco, A Modular Dynamic Simulator for the
Pulp and Paper Industry," Proceedings of the TAPPI National Confer
ence , (Chicago, Illinois, March 198l) p. 215.
22
all proper arrays. In phase two, the basic parameters describing
the process are entered. This second phase conducts the actual simula
tion. One of four integration methods may be selected. Euler's method
is the most common, although the variable step Adams-Moulton method
is convenient. A fourth order Runge-Kutta and a fourth order variable
step Runge-Kutta are also available.
Integration Methods
Any situation that concerns the rate of change of one variable
with respect to another leads to a differential equation. Two methods
mentioned to solve differential equations are Euler's method and
the fourth order Runge-Kutta method.
Euler's method is one of the oldest and best known numerical
methods for integrating differential equations. Euler's method uses
only the slope at a point, say xm >ym > computing the value of the
next point, ym + 1. The method is mathematically derived and illus-

21
trated as follows
Suppose there is a solution y at the point x = x . Then the

m m
line can be drawn with the slope y' = f(xm >ym ) which passes through
the point x ,y . The situation is pictured in Figure 2. Here the

m m
curve is the exact but unknown solution and the line just described
is identified as L, . Now let y . be the point where L. intersects

1 m+1 r 1
the ordinate erected at x = x , = x +h. The equation ofthe line L,
m+1 m 1
is:
21
Dorn, W. S. and McCracken D. D . , Numerical Methods with For
tran IV Case Studies, (Wiley & Sons, 1972), pp. 360-78.
23
Ym+1
FIGURE 2
EULER'S METHOD
This equation is Euler's method. The error at x = x . i s shown as e.
m+1
The fourth order Runge-Kutta method is the most commonly used
method for integrating differential equations. It is similiar to
Euler's method except it uses half the iteration step so slopes are
calculated as the average of two points. The Runge-Kutta method is
illustrated in Figure 3. The classical Runge-Kutta method can be
defined by the following five equations:
• y 1 = y + h/6(k. + 2k„ + 2k„ + k. ) Eq. 3

m+1 m 1 2 3 4
where: k, = f(x ,y ) „ .
1 m 'm Eq. 4
k„ = f(x + h/2,y + hk.,/2) Eq. 5
i. m m l
k- = f(x + h/2,y + hk„/2) Eq. 6
J m m l.
k. = f(x + h, y + hk») Eq. 7
4 m m 3
An example FORTRAN program to solve the differential equation,

2
f(x,y) = y + 2y + 2, is given in Appendix A. A sample of the pro
gram's output is also given. By observing the Euler's and Runge-Kutta
solutions it is obvious the Runge-Kutta fourth order solutions are
closer to the actual solutions for the different iterations. For this
reason the fourth order Runge-Kutta method was used in the DYSCO
simulations for this study.
Modules
The DYSCO simulation uses flow diagrams as the first step in
25
FIGURE 3
RUNGE-KUTTA METHOD
26
the creation of the actual process to be simulated. The process is
first outlined in a flow diagram so individual steps in the simula
tion can be detailed. These steps are then correlated to the proper
DYSCO module so the process flow diagram becomes a DYSCO flow diagram
which the computer understands. The DYSCO modules include:
DYSSEP - This unit models a screen, filter or paper machine

wire.
DYSMIX - This unit models a T-pipe or mixing point.
DILUTR - This unit takes one input stream and dilutes it with
another stream to a desired consistency of any
set of components.
CONCNT - This unit models a screen, filter or paper machine

wire. It differs from DYSSEP in that the concen
tration of only one component can be controlled.
VALVE - - This routine models a parabolic control valve.
SAVALL - This unit models a disk type saveall. One input stream
is normally divided into three output streams,
clear filtrate, cloudy filtrate and a cake.
RGULTR - This unit regulates the flow of a particular component

or the total flow of a stream. Material is added by
the unit if needed.
MIXER - This unit serves a variety of purposes. It can:

(a) add multiple input streams together
(b) accumulate material
(c) add heat to the material in the mixer
(d) set up multiple output streams.
HEATER - This unit can mix several input streams together, then
add a specific amount of heat or change the tem
perature .
FGEN - This unit is used to generate a sinusoidal, exponen

tial, or pulse variation of any stream attribute or
unit parameter as a function of time.
CONTRL - This unit is a general purpose proportional, integral

and derivative controller. Any combination of the
three actions can be used.
DYSTRB - This unit models a distribution manifold.
Presently new modules are being added to the system to further
simulate real processes as well as heat and energy balances. DYSCO
was put on line with the DEC/10 computer at Western Michigan Univer
sity in December 1980. The original program was modified by the Inst
tute of Paper Chemistry in Appleton, Wisconsin for use in the pulp
and paper industry. The modules are illustrated in Figure 4.
o DYSMIX
DYSSEP (/\ )
SAYALL
FGEN
DYSTRB □ CONTRL
DILUTR VALVE
o MIXER
RGULTR
J]
T
%
CONVAL
INPUT
HEATER | SEWER
E 3
CONCNT
FIGURE 4
KEY FOR DYSCO MODULES
THE CYLINDER BOARD MACHINE
One area of interest for a simulation process is the affects
of water closure on machine variables and the dynamics of the wet-end
papermaking process. As previously mentioned, the papermaking process
is dynamic, stochastic and continuous. Therefore the simulation model
must have all necessary details incorporated into it. This will in
sure the model will resemble the real process of papermaking.
A papermaking process which is currently being "closed" with
respect to water usage is the formation of linerboard on conventional
cylinder machines. Since the linerboard is composed of several
layers, there are several separate cylinder molds needed to form the
plies. For example, if the linerboard consists of seven layers, then
seven cylinder vats are required.
Usually the linerboard contains one topliner, one underliner,
four filler layers, and a back liner. As each of the layers is formed
on the cylinder wire, white water passes through the screen and is
collected in a separate silo below each cylinder. White water is
drawn from the silo by a fan pump and mixed with thick stock from a
headbox located above the machine. The diluted stock is next pumped
through a pressure screen where accepts are sent directly to the
cylinder vats and pressure formers. This process is then repeated in
the next cycle, but on a continuous basis. Since this water loop
demands most of the water passing through the screen, it can be
termed the "Primary Loop".
29
The primary loops for the seven cylinder molds of a typical
machine all resemble one another except for the rejects from the
pressure screens and excess water from the silo overflows. The filler
primary loops are identical and the excess water from these four
filler silos empties into the filler pit where it is pumped to the
saveall or stored in a white water reserve tank, depending on the
solids content of the effluent. Rejects from the pressure screens
on the filler loops are sent to the saveall for fiber and filler re
clamation as well as for future water usage. The topliner primary
loop has a different treatment for screen rejects and excess water.
Here, since the stock used in the topliner is much cleaner than the
filler or backliner stocks, the rejects from the pressure screen
on this loop are sent to a battery of centrifugal cleaners where
accepts are returned directly to the headbox feed for the topliner.
White water which overflows the silo is held in a separate tank lo
cated under the machine. This water is used in the topliner makeup
in the topliner pulpers.
The backliner is somewhat cleaner than the filler, but still is
inferior to the topliner in most cases. The backliner primary loop
also involves the saveall system to reclaim fiber and filler in the
white water. Depending on the grades used in the backliner, overflows
and rejects may be mixed with the excess from the filler loop.
All excess white water entering the saveall loop enters into
some type of saveall which is usually a polydisk pressure type unit
discussed earlier.
Since these polydisk savealls have an efficiency of 95 to 97%,
31
the clean filtered water is stored in white water storage tanks for
future use as shower water or makeup water for the broke and raw
stock pulpers. By this method the water system may be closed with
minimal effluents leaving the mill.
By assuming a constant output for the cylinder machine, i.e.
150 tons/day, the solids needed for each cylinder may be calculated.
Then by knowing the consistency in the headbox, to the formers, and
the solids in the white water, a mass balance can be applied to the
fan pump and the flows needed from the silo and the headbox can be
calculated. These flows, however, are in a steady state situation and
are useful only in determining vessel sizes, i.e. storage tanks,
saveall sizes, etc.
The primary loop of the cylinder machine for a filler vat is
given in Figure 5. Here thick stock from the headbox is diluted with
white water from the silo, sent through a pressure screen, and ac
cepts pumped to the cylinder former. This primary loop is repeated by
the number of filler plies in the linerboard. A DYSCO flow diagram
is given in Figure 6 for one ply. Here the pressure screen and cy
linder mold are treated as a DYSSEP (dynamic separator) units, the
silo as a DYSMIX (dynamic mixer) while the fan pump is treated as a
DILUTR (dilutor). From this figure, the process can be simulated by
measuring the retention of solids on the cylinder wire, the amount of
accepts and rejects from the pressure screen, the consistency of the
headbox feed and the shower flow.
Figure 7 shows a DYSCO flow diagram for three filler plies in
a closed system. Here, the units and flows are numbered for identifi-
32
HEADBOX
SHOWERS
CYLINDER
MOLD
! 75 hp
PRESSURE
SCREEN
WHITE
WATER REJECTS
TO
SAVEALL
SILO
FILLER
PIT
FANPUMP
^ S A V E A L L LOOP 4
FIGURE 5
PRIMARY LOOP-CYLINDER MACHINE
33
CYLINDER PRESSURE
WET MOLD SCREEN
PLY
ACCEPTS
SHOWERS HEADBOX
FANPUMP
SILO
TO
SAVEALL
INPUT STREAM UNIT NO. TYPE FLOW

1 1 HEADBOX
8 SHOWERS
OUTPUT STREAM UNIT NO. TYPE FLOW

5 2 ' SCREEN REJECTS
6 3 WET PLY
9 1 EXCESS DILUTION
FIGURE 6
PRIMARY LOOP CYLINDER MACHINE-DYSCO
W et
29 P a p e r
show e sh o w e
I
pnow e
H ead
H ead
Box 20
S to c k v
C le a r
C lo u d y
FIGURE 7
CLOSED WATER SYSTEM-CYLINDER
CO
cation. Each ply is made and combined with the following ply in the
series. Inputs include thick stock from the headbox and shower water.
Outputs include wet plies to the next cylinder mold or press section
along with excess dilution white water to the saveall and screen
rejects. At the saveall, the white water is divided into a clear leg,
cloudy leg and stock cake. The clear leg could be used as shower
water, the cloudy leg as dilution water in the pulpers, while the
stock cake could be recirculated to the headbox feed.
The mass or volume units for all stream flows in a DYSCO simula
tion may be keypunched into the program as any desired unit per time
(liters/minute, gallons/hour, grams/second, tons/day, etc.) as long
as the units are consistent throughout the entire simulation. The
mass fractions of any components in the stream flow (fiber, filler,
water, etc.) must be input based on the mass or volume units chosen
previously. For example, if fiber and filler consistencies were calcu
lated using gram metric units, then the consistency percent of the
fiber or filler can be used directly as the mass fraction if the
stream units chosen are also metric. This simplifies unit conversions
since in the metric system, the density of water is one gram per
cubic centimeter which equals one gram per milliliter. Since we are
dealing with dilute aqueous flows in the wet end of a paper machine,
the use of metric units greatly simplifies calculations of mass frac
tions and stream flows.
THE FOURDRINIER
From its design, the cylinder machine is subject to centrifugal
forces depending on the operating speed. Therefore, the main dif
ference between the web-forming parts of the cylinder and fourdrinier
machines lies in the flat traveling wire of the fourdrinier, free
from centrifugal forces of the vat cylinder of the cylinder machine.
The fourdrinier wire is driven by the couch roll, or sometimes by the
wire drive roll, and is supported by the breast roll, hydrofoils,
table rolls, suction boxes, and the wire rolls. As the sheet travels
from the breast roll to the couch on the fourdrinier wire, the web is
relatively undisturbed at low to moderate speeds, whereas the web is
exposed to a washing action on the face of the cylinder mold in cy
linder machines.
The pilot plant fourdrinier machine at Western Michigan Univer
sity is capable of forming 35 to 91 kg./hr. (75 to 200 pounds/hour)
of paper (dry basis). The machine is approximately 76 centimeters
wide at the wire. Figure 8 gives the relative size, type, and number
of dewatering units on the pilot fourdrinier. After the pressurized
headbox, the web-forming table consists of a bank of small hydrofoils
(5 cm. wide), a bank of larger hydrofoils (7 cm. wide), followed by
two more banks of small hydrofoils (5 cm. wide). After the four sets
of hydrofoils are three table rolls of 10 cm. diameter each. The
table rolls are followed by two suction boxes, the dandy roll, two
more suction boxes, and finally the suction couch.
36
37
MACHINE
WET END-FOURDRINIER PILOT
• TJ FIGURE 8
. £
v> v>
8 £ £
X
o w O£ jo-
OQ = T3 ^
O >• >•
c e i l
o _
— o —— <u
o .q rop pC >
,5 ,B3 ? CO
CO CO
38
The white water from the first three hydrofoils empties into
the first tray below the wire. The white water from the first tray
is used as dilution water for thick stock (1.5 to 2% consistency)
from the machine chest to reduce the consistency to around 0.5% for
the headbox. The dilution of the thick stock occurs at the fan pump
just prior to the deposition of the diluted stock on the moving wire
at the slice. Also, any chemical additives or fillers can be added to
the thick stock in one of two mixing tanks prior to the fan pump.
White water from the fourth hydrofoil and table roll section
empties into the second tray located under the moving web. In the
present system, this white water is mixed with excess dilution water
from the first tray and sent to the sewer. The white water from the
suction boxes and suction couch is mixed with seal water from the
vacuum pumps and also sent to the sewer in the open system.
The DYSCO flow diagram for the wet end of the open system is
given in Figure 9. Here the hydrofoils, table rolls and suction units
are treated as DYSSEPs (dynamic separators). The fan pump is repre
sented as a DILUTR (dilutor), while the first and second trays as
well as the headbox are treated as DYSMIX (dynamic mixer) units. The
units and stream flows are numbered as shown so the flow diagram can
be translated into the first segment of the DYSCO program. Input
streams such as fillers, chemical additives, seal water, fiber, etc.
are labelled as well as the output streams. Stream flow descriptions
are given in Appendix D.
By reducing the effluents to the sewer on the pilot machine,
a system which is completely closed can be reached for the wet-end.
0 > ± ^ P |- H E ^ ►
24
7 15 17 19 21 23 25
U (u V
10 < j > ----- -#28
8 SEAL
WATER
121*
26 27
11
THICK
STOCK OUTPUT
STREAM UNIT NO. TYPE FLOW
12 7 E xcess Dilution W ater

24 13 W et P ap er
26 14 2nd Tray W h itew ater
27 15 S uction an d Seal W ater
FIGURE 9
OPEN WATER SYSTEM-FOURDRINIER
CO
vO
40
A DYSCO diagram for the closed system is given in Figure 10 for the
pilot machine. There is no fresh water input to the system except for
the seal water to the pumps. All excess dilution water and other
sewer losses are used to dilute pulp sheets in the beater to the
machine chest consistency. The thick stock is then refined in a Claf-
lin refiner to the desired freeness level. The thick stock is used to
fill the machine chest, which feeds the paper machine after dilution.
The beater is represented as another DILUTR in the system while the
Claflin refiner is treated as a MIXER. For a startup, fresh water
could be used to dilute the first batch of pulp sheets, however seal
and shower water can be used after sufficient time to accumulate the
water. Once the first batch of pulp is diluted and refined, the
machine can be started and paper produced. Now the excess water along
with the seal and shower water is used to prepare another beater load
of thick stock so the cycle is repeated. If any excess water from the
beater is present, it can be stored in a white water storage tank for
later use or sent through a saveall to reduce the solids level in the
water for use as shower water to further close the system.
Since the Claflin refiner tended to add some heat to the system
as stock passed through the unit, the increase in temperature of
the stock had to be accounted for. The MIXER module of the DYSCO
program has the capability to compute the increase in temperature
if the gram moles of substance and the external heat flux are known.
22
Farmer conducted a study for Mead Research Laboratories at Chilli-
22
Farmer, R. A., "Evaluation of Temperature Rise as a Means
of Refiner Control," Mead Research Laboratories Report no. 14904,
(July 1964), pp. 1-7.
41
CM
CN| V To
Q. <5
CO >
CL Q- CO
> % ”
h-
CLOSED WATER SYSTEM-FOURDRINIER

CM
5 |2
CM
oo O
z;
i-
CO
CO
CM
FIGURE 10
Q-Uj
u.
&
OCO
oo CO
CO
cothe, Ohio where he calculated the temperature rise at various flow
rates of stock though a Claflin refiner. From the graphs presented in
the report, the temperature increase of stock from refining can be
determined for a given flow rate. For the proposed closed system, the
estimated flow rates through the Claflin refiner were approximately
100 liters/minute. This corresponded to a temperature increase of
l.l^C (34°F) per minute. The external heat flux was then calculated
in kilocalories and entered into the MIXER input data. Since tempera
ture increase is a problem in the closed system, a simulation using
the MIXER module will give an estimate of the temperature increase of
the system over a long period of time.
PRESENTATION OF PROBLEM
The objective of this study was to determine the applicability
of the DYSCO computer model to simulate the response of a real-world
papermachine wet-end system to varying degrees of closure. This inves
tigation also has the goal to assertain the strengths and weaknesses
of the simulation approach and to suggest means for improving the
simulation.
The DYSCO simulation program contains modules (subroutines)
which are applicable to modeling the wet end papermaking process.
These modules, however, require information about the actual process
to be simulated. In simulating the fourdrinier paper machine, this
information must include: (1) input stream flow rates and component
mass fractions, (2) the number of dewatering units on the machine,
(3) the fraction of each retained component in the web after a de
watering unit compared to the input mass quantity before the unit,
(4) the headbox flow, and (5) the component mass fractions in the
white water and output streams.
In order to simulate the closed water system of the fourdrinier
using DYSCO, the open system had to be understood first and simu
lated. By removing web samples from the moving wire along with white
water samples, component retention values were calculated for each
dewatering unit. This information along with input flow rates and
mass fraction of components in the input and output streams were used
in the actual computer simulation of t*he open system. By utilizing
43
the output flows of the open system in pulp sheet dilution, the
closure of the system was achieved.
EXPERIMENTAL PROCEDURE
The experiments for the fourdrinier paper machine simulation
were,divided into.two parts. The first half of the experiments dealt
with the sampling of the pilot machine to obtain data to be used
in the second half of the experiments; the actual computer simula
tion using DYSCO.
Pilot Machine Trial
On November 13, 1982, the pilot paper machine at Western Michi
gan University was used in an experiment to sample the moving web
at a maximum speed of 76 meters (250 ft.) per minute. Since the press
and drier sections tended to limit the speed of the machine, these
sections were eliminated by installing an auxilary pump in the couch
pit so the contents of the pit could be transferred over a sidehill
screen into a broke chest. From the broke chest, the pulp could be
used later in the experiment to simulate recycling conditions on
the fourdrinier.
The furnish used in the experiment was a 50:50 hardwood to soft
wood blend at a Canadian Standard Freeness of 341 and a consistency
of 1.73% (grams oven dry solids/100 grams furnish). Titanium dioxide
was the only filler mixed with the furnish. A 10% mixture of titanium
dioxide and water was metered into the first mixing tank, before
the fan pump, at a rate of one liter per minute throughout the experi
ment. This amount of filler gave approximately 20% filler on dry
fiber. The filler factor of titanium dioxide was 1.0 for ash test
calculations.
45
46
Blow samples of the wet web and white water samples were ob
tained at speeds of 46, 61, and 76 meters per minute. Samples on the
wire were lifted after each bank of hydrofoils, the table rolls,
suction boxes and suction couch (see Figure 8). Metal trays were
inserted under the first, third, and fourth foils to obtain estimates
of the quantity of white water passing through these units. Metal
weirs were inserted in the outflow troughs of the first and second
trays as well as the sewer trough to measure the effluent flows. The
weirs were cut at a 90° V-cut so tables given in Cameron Hydraulic

23
Data could be used for flow calculations.
24
A plastic wand similar to the one described by Goggin was
used to blow web samples off the wire. The wand was constructed of
2 centimeter diameter plastic pipe cut to 30 centimeters in length.
A 10 centimeter slit was cut into one end of the wand and a ball
valve was inserted on the other. The valve was attached to a high
pressure air line. When the wand was placed under the wire with the
slit facing the formed sheet and the valve opened, the velocity of
the air lifted the sheet from the wire where it could be caught in a
glass container. All web samples were collected using the wand except
those after the couch which were obtained by hand due to higher con
sistencies.
The metal trays which were inserted under the foils were made
23
Westaway, C. R . , Cameron Hydraulic Data, (Ingersoll-Rand,
1979), p. 2-11.
^Goggin, N. J., "Fourdrinier Sampling Techniques Provide Useful

Drainage-Rate Data," Pulp and Paper 55 no. 10, (Oct. 1981) p. 163.
47
to fit the width of the wire. A short pipe fitting was welded onto
one end of the tray and a hole cut in the tray wall. A plastic hose
was then attached to the fitting so that white water flow rates could
be measured with a bucket and stopwatch. To determine the flow from
the first foil, the time to fill a liter graduated cylinder was
clocked.
In the first part of the experiment, samples were collected and
the glass containers sealed to prevent evaporation and bacterial
contamination. The stock flow to the headbox was kept constant at 151
liters (40 gals.) per minute. At the higher speeds, some overflowing
of the couch pit was observed yet samples were successfully col
lected. This overflowing would not affect results because the couch
pit was merely a dumping chest for the formed web. Weir readings and
foil white water flow data were obtained.
In the second part of the experiment, the once-formed furnish
of the first part was used to simulate recycling of fibers. This
recycled stock contained titanium dioxide from the previous forma
tion. Again, a one liter per minute flow of the filler slurry was
introduced at the fan pump. The headbox flow remained at 151 liters
per minute but the contents of the couch pit were sewered. The web
samples, white water samples, and flow measurements were obtained at
speeds of 46, 61, and 76 meters per minute. Again, the couch pit
' overflowed at the higher speeds due to the buildup of stock in the
pit. White water flow data were obtained similarly to the procedure
of the first part. The Canadian Standard Freeness of the recycled
stock used was 355 at a consistency of .95%.
48
The white water and blow samples were analyzed for consistency
and ash content. The methods for determining consistency and ash are
given in Appendix B. Sample calculations are given after the proce
dure. Total consistency, fiber fraction and filler fraction were cal
culated on the basis of grams oven dry solids per 100 grams total
furnish.
Simulation Experiments
Before the simulation experiments could be started on the com
puter, the data from the pilot machine trial were needed. From these
data, a mass balance around the pilot machine were determined. The
headbox consistencies for part one of the pilot trial tended to
increase from .60% to .86% while the runs for part two stayed fairly
constant at .52% to .56% consistency. Since consistency of the head
box feed plays an important role in fiber and filler retention, the
data from the second part of the experiment with recycled furnish
were used in the computer simulations.
Once the retention values were known for the three components
(water, fiber, filler) and the input streams calculated from mass
balance equations, the DYSCO modules were utilized to simulate the
open system on the pilot fourdrinier. The DYSCO flow diagram of the
open water system is given in Figure 9 (Appendix D). The actual input
of the flow diagram to the DYSCO program will be described later.
Retention fractions were used in the DYSSEP units in the flow dia
gram. The DYSSEP units were used as a representation of a foil, table
roll, suction box, or the couch. Since white water in the first tray
was used to dilute thick stock at the fan pump, the units one through
seven were termed the "primary loop" in the open system. Appendix D
49
gives the flow stream numbers, unit numbers, and the location of the
stream in the flow diagram.
The flow diagram with unit and stream numbers, was entered into
the first segment of the DYSCO program. An array was set up by the
computer, and stored in memory, for the second part of the DYSCO
program. In the second part of the program, unit and stream para
meters were entered. These parameters include retention fractions,
mass fractions, temperature, pressure, and flow rates. The three
components used in the simulations were water, fiber and filler.
The fiber consistency of the furnish in the headbox was controlled
at the DILUTR (fan pump) module of the flow diagram.
Once the simulations for the open system were obtained at the
three wire speeds, the next step in the experiment was to hypothe
tically close the water system and attempt a simulation using no
fresh water. Figure 10 (Appendix D) shows the schematic of a pro
posed system to close the water system on the pilot machine. The
figure resembles the open system except the flows which previously
were sewered are now used as makeup water in the beater, represented
as unit 18. A Claflin refiner was added to the system to change the
freeness of the stock and represented as unit 19. The refiner added
heat to the system depending on the flow through the unit and number
of passes. Input streams included pump seal water, filler, and pulp
sheets. Outputs included wet paper and excess beater dilution water.
Any excess white water would be sent to a saveall or white water
storage tank for later use in case of a dilution water shortage, or
as shower water.
50
The flow chart given in Figure 10 (Appendix D), along with reten
tion fractions for 46 meters per minute, was entered into the DYSCO
simulation program. The actual input of the flow diagram, unit para
meters, stream parameters, and convergence criteria is given in Ap
pendix F. A documentation of the printout along with explanations is
also presented.
The slowest speed of 46 meters/minute was used in the closed
water system simulation because this is the speed at which the pilot
fourdrinier is commonly operated. Pulp sheets added were assumed to
contain 77» water and the headbox consistency was controlled for the
fiber fraction. The fiber component was controlled at the DILUTR (fan
pump) module. The module (subroutine) diluted thick stock from the
machine chest with first tray white water to the experimental headbox
fiber consistency. This could be accomplished with the DILUTR sub
routine because the thick stock was higher in fiber consistency than
the white water dilution stream. However, the filler consistency
could not simultaneously be controlled with the same module because
the dilution stream (white water) was higher in filler consistency
than the diluted stream (thick stock).
The simulation used the Runge-Kutta method of integration and
converged to steady state conditions. The stream parameters allowed

25
to be tested for steady state convergence are: temperature, pres
sure, flow rate, or component mass fraction. For example, if tem-
25
Lopez, L. A., "DYSCO: An Interactive Executive Program for
Dynamic Simulation and Control of Chemical Processes," (Ph.D. Disser
tation; University of Michigan, Chemical Engineering Dept., 1974).
51
perature is the stream parameter to be tested for convergence, all
the material streams in the simulation will be tested for changes in
temperature at successive simulation times during the simulation. In
the simulation for the closed system, the fiber mass fraction in all
streams was checked for steady state convergence. The stream flows,
temperatures (°K), and mass fractions of the components were calcu
lated by the DYSCO program.
PRESENTATION AND D ISC U SSIO N OF RESULTS
The mass balances around the wet end of the pilot machine were
calculated by hand using the experimental data from the pilot trial.
These balances were needed before any computer simulations were per
formed. The consistencies, filler data, and white water flows are
given in Table 1 for 46 meters/minute, Table 2 for 61 meters/minute,
and Table 3 for 76 meters/minute for the pilot runs using recycled
furnish. A sample mass balance around the first three hydrofoils of
the fourdrinier (primary loop) along with component retention frac
tions is given in Appendix C. In the calculations, the headbox flow
was converted from liters/minute to grams/minute. With this conver
sion, the total mass of components in the flow was calculated by mul
tiplying the flow (grams/minute) by the component consistency
(grams/100 grams). Retention fractions of the components were calcu
lated by dividing the component mass flow on the wire after a dewater
ing unit by the total mass flow in the web before the unit. Retention
fractions for water, fiber, and filler were calculated (Appendix C)
for the individual dewatering units under the fourdrinier wire. These
values are given in Table 4 along with an average retention value for
the three speeds, using recycled fiber furnish. Tables 5, 6 and 7
give the mass flows, mass fractions, and stream numbers of each compo
nent (fiber, filler, water) at 46, 61, and 76 meters/minute, respec
tively, using recycled furnish in the open water system. Appendix B
gives sample calculations for the mass balance around the primary
52
TABLE 1
EXPERIMENTAL DATA - PILO T MACHINE - 4 6 METERS/MINUTE
Blow Sample % Consistency % Fiber % Filler % Water
Headbox .527 .447 .080 99.473

First Foil 1.446 1.327 .119 98.554
Second Foil 2.165 1.995 .170 97.836
Third Foil 3.023 2.807 .216 96.977
Fourth Foil 3.318 3.086 .232 96.682
Table Rolls 3.364 3.121 .243 96.636
Suction Box 2.925 2.730 .196 97.075
Suction Box 5.422 5.113 .309 94.578
Suction Box 15.396 14.858 .538 84.604
Couch 16.835 15.321 .515 83.165
White Water % Consistency % Fiber % Filler % Water
First Foil .068 .033 .035 99.932

Third Foil .057 .015 .042 99.958
Fourth Foil .065 .010 .055 99.935
First Tray .052 .014 .038 99.947
Second Tray .101 .043 .059 99.899
Sewer .006 99.994
White Water Flow (Liters/Minute)
First Foil 7.9

Third Foil 3.5
Fourth Foil 3.7
First Tray 129.5
Second Tray 8.3
Sewer 12.4
Stock Flow_______ (Liters/Minute)
Headbox Flow 151
TABLE 2
Blow Sample 7- Consistency % Fiber % Filler % Water
Headbox .557 .482 .075 99.443

First Foil 1.778 1.648 .130 98.222
Second Foil 2.713 2.542 .171 97.287
Third Foil 3.197 3.016 .181 96.803
Fourth Foil 3.285 3.142 .173 96.715
Table Rolls 3.178 3.019 .159 96.822
Suction Box 3.281 3.113 .168 96.719
Suction Box 5.345 5.109 .236 94.655
Suction Box 13.427 12.989 .438 86.573
Couch 15.945 15.458 .487 84.055
White Water °/o Consistency % Fiber % Filler % Water
First Foil .089 .020 .069 99.911

Third Foil .083 .033 .050 99.917
Fourth Foil .089 .030 .059 99.911
First Tray .106 .036 .070 99.894
Second Tray
Sewer .010 99.990
First Foil 12.0

Third Foil 2.7
Fourth Foil 3.7
first Tray 129.5
Second Tray 8.3
Sewer 30.3
Stock Flow (Liters/Minute)
Headbox Flow 151
TABLE 3
Blow Sample 7« Consistency 7> Fiber % Filler 7» Water
Headbox .567 .496 .071 99.433

First Foil 1.429 1.313 .116 98.571
Second Foil 2.307 2.184 .123 97.693
Third Foil 2.939 2.803 .136 97.061
Fourth Foil 3.140 2.987 .153 96.860
Table Rolls 3.152 2.982 .170 96.848
Suction Box 3.087 2.967 .120 96.913
Suction Box 5.352 5.189 .173 94.638
Suction Box 11.162 10.887 .275 88.838
Couch 13.399 13.163 .236 86.601
White Water % Consistency 7» Fiber 7o Filler 7> Water
First Foil .102 .037 .065 99.898

Third Foil .111 .062 .049 99.889
Fourth Foil .131 .079 .052 99.869
First Tray .118 .055 .063 99.882
Second Tray .471 .191 .280 99.529
Sewer .077 ---- — 99.300
First Foil 13.3

Third Foil 1.4
Fourth Foil —
First Tray 129.5

Second Tray 8.3
Sewer 12.4
Stock Flow (Liters/Minute)
Headbox Flow 151
TABLE 4
EXPERIMENTAL RETENTION VALUES - PILO T MACHINE
46 61 76
Meters/Min. Meters/Min. Meters/Min. Average
First Foil
Water .303* .283 .349 .312
Fiber .908 .978 .930 .939
Filler .455 .499 .576 .510
Second Foil
Water .760 .626 .573 .653
Fiber .999 .975 .961 .978
Filler .950 .828 .612 .797
Third Foil
Water .702 .838 .767 .769
Fiber .997 .995 .991 .994
Filler .897 .893 .862 .884
Fourth Foil
Water .907 .964 .939 .936
Fiber 1.000 1.000 1.000 1.000
Filler .980 .915 .893 .929
Table Rolls
Water .989 1.033 .997 1.006
Fiber 1.000 .991 1.000 .997
Filler 1.036 .955 .908 .966
Suction Box
Water 1.148 .968 1.006 1.041
Fiber 1.000 .999 1.000 .996
Filler .919 1.019 .710 .882
Suction Box
Water .520 .598 .559 .559
Fiber 1.000 1.000 .993 .998
Filler .844 .858 .825 .842
Suction Box
Water .308 .359 .447 .371
Fiber 1.000 .998 .999 .999
Fi 1ler .599 .730 .758 .696
Couch
Water .895 .769 .807 .824
Fiber 1.000 .943 1.000 .981
Filler .870 .882 .710 .820
*Fractions represent total mass flowof component in the web after
dewatering unit divided by the totalof the component in the web
before the unit. (Appendix C).
TABLE 5
EXPERIMENTAL STREAM PARAMETERS

OPEN SYSTEM - 4 6 METERS/MINUTE
Flow Water Fiber Filler

Stream (Grams/Min. Fract ion Fraction Fract ion
1 151000 .994728 .004473 .000799

2 46200 .985538 .015624 .001264
3 104800 .999315 .000333 .000352
4 32630 .978355 .019953 .001702
5 13570 .999999 .000400 .000600
6 23110 .969775 .028069 .002156
7 9520 .999428 .001530 .000419
8 127890 .999470 .000140 .000380
9 128890 .999406 .000139 .000455
10 151000 .994728 .004473 .000799
11 83570 .990403 .008434 .001163
12 60460 .999406 .000139 .000455
13 1000 .900000 .000000 .100000
14 21020 .968190 .038580 .002323
15 2090 .999349 .000099 .000552
16 20800 .963630 .031205 .002432
17 215 .999990 .000000 .000010
18 23780 .970749 .027395 • .001956
1-9 -2970 1.000000 .000000 .000000
20 12695 .945783 .051128 .003089
21 11084 .999431 .000001 .000568
22 4370 .851418 .148582 .004378
23 8330 .997178 .000000 .002821
24 2985 .831647 .163206 .005147
25 385 .992235 .000000 .007764
26 2305 .999409 .000501 .000090
27 16829 .998051 .000001 .001948
28 12000 1.000000 .000000 .000000
TABLE 6

Flow Water F iber Filler

:ream (Grams/Min.) Fraction Fraction Fract ion
1 151000 .994434 .004820 .000746

2 43181 .982221 .016477 .001301
3 107810 .991090 .000199 .000692
4 27300 .972740 .025421 .001705
5 15880 .998293 .001101 .000606
6 22910 .968030 .030156 .001814
7 4390 .999171 .000331 .000498
8 128080 .998935 .000365 .000772
9 129080 .998866 .000362 .000772
10 151000 .994434 .004820 .000746
11 92140 .990403 .008434 .001163
12 70230 .998866 .000362 .000772
13 1000 .900000 .000000 .100000
14 22130 .967147 .031415 .001720
15 770 .999101 .000301 .000598
16 22820 .968213 .030194 .001593
17 -680 1.000000 .000000 .000000
18 22130 .967192 .031131 .001676
19 690 .999598 .000147 -.001068
20 13480 .946555 .051091 .002354
21 8640 .999355 .000025 .000620
22 5300 .865727 .129899 .004374
23 8180 .998924 .000031 .001045
24 4220 .840555 .154567 .004869
25 1080 .964056 .033509 .002435
26 770 .999101 .000301 .001720
27 18590 .999063 .000048 .000889
28 12000 1.000000 .000000 .000000
TABLE 7


:ream (Grams/Min.) Fraction Fraction Fract ion
1 151000 .994326 .004966 .000708

2 53110 .985711 .013130 .001159
3 97880 .998980 .000370 .000650
4 30690 .967929 .021845 .001226
5 22420 .997733 .000120 .001067
6 23690 .970601 .028029 .001369
7 7000 .998890 .000615 .000496
8 127300 .998818 .000632 .000550
9 128300 .998749 .000627 .000623
10 151000 .994326 .004966 .000708
11 88900 .990403 .008434 .001163
12 66200 .998749 .000627 .000623
13 1000 .900000 .000000 .100000
14 22320 .968599 .029867 .001534
15 370 .998686 .000789 .005250
16 22240 .960183 .029817 .001699
17 80 .999615 .000000 .000385
18 22350 .969126 .029663 .001200
19 -110 1.000000 .000000 .000000
20 12780 .994638 .051829 .001728
21 9570 .998969 .000536 .000495
22 6090 .891135 .108865 .002754
23 6690 .999206 .000000 .000793
24 5040 .868370 .131630 .002350
25 1050 .995345 .000000 .004655
26 450 .999445 .000422 .000133
27 17310 .998843 .000296 .000860
28 12000 1.000000 .000000 .000000
loop at 61 meters/minute. A negative number in the stream flow indi
cates a reverse flow direction from that indicated in Figure 9. For
example, from the pilot machine trial, it was found that some water
was actually being forced back into the moving web somewhere between
the table rolls and first suction box. This would then give a nega
tive stream flow since it was assumed in the mass balance that the
stream flow was out of the moving web. This negative stream flow may
lead to negative component mass fractions as well.
The mass flows and component mass fractions of the open system
were calculated by the DYSCO modules using the Runge-Kutta method
of integration and data from the pilot machine trial. The streams,
mass flows, and mass fractions are given in Tables 8, 9, and 10 for
46, 61, and 76 meters/minute, respectively. The stream numbers are
illustrated in Figure 9 and described in Appendix D. All three simula
tions converged to steady state at 6 minutes of simulation time. The
term "converged to steady state" was discussed in the Experimental
Procedure.
The mass flows and component mass fractions of the closed sys
tem, as computed with DYSCO, are given in Table 11. This system con
verged to steady state at 46 minutes of simulation time. The stream
numbers are illustrated in Figure 10 and described in Appendix D.
The temperature of the flow in each stream is also given in Table 11.
For the open system, the results of the DYSCO simulations were
compared with actual data obtained from the experimental pilot ma
chine trial. It was found that the DYSCO simulations computed a head
box flow of approximately 10 liters per minute greater than the ex-
TABLE 8
DYSCO STREAM PARAMETERS FOR STEADY STATE CONDITIONS

OPEN SYSTEM - 4 6 METERS/MINUTE - TIME = 6 . 0 0 MINUTES

Stream (Grams/Min.) Fraction Fraction Fraction
1 166506 .994503 .004470 .000978

2 51752 .985509 .013059 .001432
3 114754 .998560 .000597 .000774
4 39507 .981129 .017089 .001782
5 12244 .999642 .000055 .000303
6 27947 .973655 .024085 .002260.
7 11560 .999197 .000175 .000627
8 138559 .998709 .000515 .000720
9 139559 .998646 .000510 .0007860
10 166506 .994507 .004470 .000974
11 83470 .990400 .008400 .001160
12 56623 .998646 .000510 .00786
13 1000 .990000 .000000 .010000
14 25415 .971080 .026485 .002436
15 2531 .999501 .000000 .000499
16 25143 .970769 .026771 .002462
17 271 1.000000 .000000 .000000
18 25143 .970768 .026771 .002462
19 0 .000000 .000000 .000000
20 13417 .945941 .050165 .003894
21 11725 .999176 .000000 .000824
22 4613 .847323 .145894 .006783
23 8804 .997621 .000000 .002379
24 4199 .833220 .160297 .006484
25 414 .990187 .000000 .009814
26 2803 .999548 .000000 .000451
27 32944 .998948 .000000 .001052
28 12000 1.000000 .000000 .000000
TABLE 9


:ream (Grams/Min.) Fract ion Fraction Fraction
1 164944 .994166 .004820 .000969

2 47254 .981862 .016451 .001687
3 117680 .999107 .000149 .000680
4 29874 .972414 .025376 .002210
5 17389 .998084 .001118 .000789
6 25157 .967674 .029983 .002343
7 4714 .997699 .000804 .001497
8 139786 .998933 .000291 .000721
9 140786 .998934 .000289 .000723
10 164944 .994167 .004820 .000967
11 92140 .990400 .008400 .001160
12 67982 .998934 .000289 .000723
13 1000 .999000 .000000 .001000
14 24276 .996706 .031072 .002222
15 881 .004315 .000000 .005685
16 24276 .966706 .031072 .002222
17 0 .000000 .000000 .000000
18 23525 .965632 .032031 .002336
19 750 1.000360 .001005 -.001365
20 14385 .944339 .052383 .003278
21 9140 .999146 .000000 .000854
22 5663 .861131 .132791 .006079
23 8722 .998367 .000173 .001460
24 4489 .835287 .157950 .006763
25 1173 .960009 .036529 .003462
26 881 .994315 .000000 .005685
27 31786 .997839 .001420 .000742
28 12000 1.000000 .000000 .000000
63
TABLE 10


Stream (Grams/Min Fract ion Fraction Fract ioi
1 160148 .993973 .004986 .001021

2 56388 .985229 .013101 .001671
3 103760 .998725 .000536 .000668
4 32600 .967455 .021776 .001768
5 23787 .997252 .001211 .001536
6 25169 .970073 .027952 .001974
7 7431 .998070 .000860 .001071
8 134979 .998429 .000673 .000843
9 135979 .998433 .000668 .000845
10 160148 .993974 .004960 .001020
11 88900 .990400 .008400 .001160
12 64730 .998433 .000668 .000845
13 1000 .999000 .000000 .001000
14 23674 .968409 .029717 .001874
15 1494 .996443 .000000 .003557
16 23601 .968484 .029809 .001707
17 72 .943966 .000000 .056031
18 23601 .968484 .029809 .001707
19 0 .000000 .000000 .000000
20 13509 .945826 .051713 .002461
21 10092 .998813 .000488 .000699
22 6434 .887623 .108461 .003916
23 7074 .998764 .000099 .001137
24 5325 .865578 .131063 .003360
25 1109 .993415 .000000 .006585
26 1567 .994003 .000000 .005996
27 30276 .999074 .000186 .000740
28 12000 1.000000 .000000 .000000
TABLE 11
DYSCO STREAM PARAMETERS FOR CONVERGENCE TO STEADY STATE

CLOSED SYSTEM - 4 6 METERS/MINUTE - TIME = 4 6 MINUTES

:ream T(°K) (Grams/Min.) Fract ion Fract ion Fraction
1 294.9 172968 .995247 .004470 .000283

2 294.9 53745 .986523 .013062 .000415
3 294.9 119223 .999179 .000597 .000224
4 294.9 41018 .982385 .017098 .000517
5 294.9 12726 .999857 .000055 .000088
6 294.9 29006 .975238 .024106 .000655
7 294.9 12012 .999643 .000175 .000182
8 294.9 143962 .999278 .000514 .000208
9 294.9 144962 .999214 .000510 .000276
10 295.0 172996 .995247 .004476 .000283
11 295.0 86703 .991307 .008404 .000289
12 294.9 58679 .999214 .000510 .000276
13 298.9 1000 .990000 .000000 .010000
14 294.9 26374 .972783 .026511 .000706
15 294.9 2631 .999856 .000000 .000144
16 294.9 26092 .972488 .026798 .000714
17 294.9 282 1.000000 .000000 .000000
18 294.9 26091 .972544 .026800 .000656
20 294.9 13908 .948688 .050273 .001029
21 294.9 12182 .999781 .000000 .000219
22 294.9 4771 .851656 .146531 .001813
23 294.9 9136 .999366 .000000 .000634
24 294.9 4344 .837304 .160362 .001733
25 294.9 427 .997371 .000000 .002629
26 294.9 2913 .999870 .000000 .000130
27 294.9 21748 .999490 .000000 .000510
28 295.9 12000 1.000000 .000000 .000000
29 294.9 24662 .999535 .000000 .999465
30 294.9 95341 .999396 .000314 .000290
31 298.9 754 .070000 .930000 .000000
32 294.9 86690 .991312 .008400 .000288
33 294.9 9409 .999396 .000314 .000290
perimental headbox flow of 151 liters per minute. Since the headbox
flows were read from a chart, the DYSCO headbox flows were within the
experimental error of the chart graphs. Also the flows from the first'
and second trays agreed well with the experimental data obtained from
the weirs.
The open system drainage profile for 46 meters per minute is
given in Figure 11. This figure shows that a small quantity of water
was transferred back into the sheet at the first suction box after
the table rolls. During the time of the machine trial, the first
suction box was not under vacuum so it supported the wire but did not
aid in water removal. The last two suction boxes were under vacuum
and their contribution to drainage of the web was verified. The curve
computed from DYSCO correlated with the experimental curve. However,
the unit used to simulate the first suction box (DYSSEP), where some
water was put back into the sheet, was unable to use retention frac
tions greater than one, as would be the case in reverse flow.
Figure 12 shows the drainage profile across the fourdrinier
wire for 61 meters per minute. The DYSCO headbox flow was 165 liters
per minute versus 151 liters per minute experimental. Again there
was some water penetrating back into the sheet between the table
rolls and first suction box. This was not "understood" by the DYSSEP
module. Thus, it assumed a retention fraction of one for the white
water drainage. The experimental and simulated curves were in close
agreement for the trends in water drainage down the fourdrinier wire.
The drainage profile for 76 liters per minute is given in Figure
13. The DYSCO headbox flow was much closer to the experimental than
rH CM a a S
=#5 =tfc 0 0 O
to
COUCH
M M HI
Hi Hi Hi Hi EH . EH,, EH
M H M H pq O X O X O X
O O O O <u o D O D O D O
ft ft ft ft eh ft CO ft to PQ CO pq
100
a)
•p
125
§
•H
u
(U
ft
ro
U 150
P
cu EXP ----
•H * •
. DYSCO —
175
MACHINE SPEED - k6 meters/min WIDTH - o76 meters
EXPERIMENTAL HEADBOX FLOW - 151 liters/min
DYSCO HEADBOX FLOW - 166 liters/min
FIGURE 11
OPEN SYSTEM DRAINAGE PROFILE
O'
O'
H CM S s
zst O 0 0
=tfc =tfc
COUCH
HJ H HH
r-q FI Hi Hi 33 EH EH Eh
M H H H pq h O X O X O X
O O O O < o tD O t=> O t=» O
m pq
fa fa fa fa Eh P£ m pq m pq
d>
-P
§
U
d>
ft
* *------
ra
<i>
-p
•H EXP ----- ~ "■* -
Pi
DYSCO
175
MACHINE SPEED - 6l meters/min WIDTH -«76 meters
FIGURE 12
O PEN SYSTEM DRAINAGE PROFILE
O'
tH CM 0^ -ch s S s
=#5 0 O 0
H M M
COUCH
PI PI PI PI EH EH EH
M H M H pq h O X O X O X
0 O O O < o P> O DO P>o
ft ft ft ft eh k m pq m pq rn pq
100
<d
125
•p
§
8
ft
to 150
Sh EXP
1
<>
-p DYSCO
MACHINE SPEED - 76 meters/min WIDTH - .76 meters
FIGURE 13
OPEN SYSTEM DRAINAGE PROFILE
O'
00
69
for the other two speeds. Again, some water was pushed back into the
sheet at the first suction box in the experimental data, but the
retention fraction was assumed to be one by the DYSSEP module. Both
the experimental data and DYSCO simulations indicated a decrease
in drainage rate over the total wire as the speed was increased. This
indicated the drainage capacity of the wire was being exceeded.
A fiber consistency profile is given in Figure 14 for a wire
speed of 46 meters per minute. In the simulations, the fiber consis
tency was the one component controlled at the headbox. Therefore, the
DYSCO curve should match the experimental curve much closer if the
retention values were accurate. The fiber profiles for 61 and 76
meters per minute are given in Figures 15 and 16, respectively.
Again, these curves correlated well with the experimental data since
the fiber fraction was controlled.
The other component in the experiment was the filler, titanium
dioxide. Since the concentration of fiber in the thick stock was
greater than the fiber concentration in the white water used for
dilution, the DILUTR module (fan pump) was capable of diluting the
thick stock to the controlled headbox consistency. However, the
filler concentration of the white water was greater than the filler
concentration of the thick stock, so a simultaneous control of filler
and fiber concentration was not possible. Figure 17 shows the filler
consistency for 46 meters per minute. Even though the filler consis
tency was not controlled, the DYSCO curve shows the same trend as the
experimental line. A slight decrease in the filler consistency is
seen at the first suction box in the experimental curve due to the
COUCH
EXP
DYSCO
MACHINE SPEED - meters/min WIDTH - .76 meters

FIGURE 14
FIBER PROFILE
o
!h
§
W M
EH
m 8 H M H H
H
m
s
o
o
«
w
m
H 12 ■ EXP
Ph
- DYSCO
16
MACHINE SPEED - 6l meters/min WIDTH meters
FIGURE 15
FIBER PROFILE
=tfc H
H EH p
8 H M H H
«aj O
O X
D O
EH Oi m pq
12
EXP —
DYSCO —
MACHINE SPEED - 76 meters/min WIDTH - „76 meters
EXPERIMENTAL HEADBOX PLOW - 151 liters/min
FIGURE 16
FIBER PROFILE
-■J
N3
73
slight amount of water penetrating back into the sheet at this point.
Again, the DYSCO module assumed the retention fraction to be one.
In other respects, the lines correlate well even though the experi
mental headbox flow was slightly lower than the computed DYSCO flow.
Figures 18 and 19 show the filler consistency profiles for 61 and 76
meters per minute, respectively. These curves show a direct correla
tion between the experimental and simulated values. The filler pro
file curves show lower filler consistencies in the web at the higher
speeds. This is caused by the removal of more filler from the sheet
at higher speeds. At higher speeds, there are greater liquid veloci
ties during the initial deposition of solids on the wire.
By comparing the tables of DYSCO stream parameters versus experi
mental stream parameters for 46, 61, and 76 meters (Tables 5, 6,
7, 8, 9, and 10) for the open system, it is observed that the values
are in good agreement for the individual speeds. In the open system,
the streams 12, 26, and 27 (Figure 9) are sewered. These streams
contain valuable fiber and filler.
The simulation for the closed system at 46 meters per minute
is given for steady state convergence at 46 minutes in Table 11.
The stream flow numbers are described in Appendix D. This indicates
that the system is capable of running with no fresh water input
except for the 12 liters per minute of pump seal water which would
be sewered otherwise. Stream 33, in the simulation, is the flow to
the saveall or storage tank which has a value of 9 liters per minute.
This is quite small when compared to the open system.
During the simulation, the temperature of the pump seal water
H CM 0^ s s S
o 0 O
M H H
Q H
HH
Hi
Hi
Hi
Hi
rR
M
gs
pq i-q
EH
O X
EH
0 !xi EH
O X
w
a
t=>
O O O O <c o i=>o !=) O t=> 0 0
& pq Ph Ph eh (X to pq CO pq to pq 0
.05
>H .15
§
EH .25
to ^ -
M
to
s
o
0 .35
X
1
H
EXP
04
DYSCO
.55
.65
MACHINE SPEED - 46 meters/min WIDTH -.76 meters
FIGURE 17
FILLER PROFILE
"-4
-O
cvt s s p
=tfc =tt= 0 0 0
H H H p
P P P H P sa EH EH EH 0
< txj M M M H pq h O X O X O « p
O O O O <j 0 PO P O P O 0
K pq Ph Ph EH OS w pq w pq 03 pq 0
.05
is.
fH .15
w * -----
Eh
m .25
M
C/3
s
o
o .35
Oh
.45 EXP -
H
pH DYSCO -
.55
MACHINE SPEED - 6l meters/min WIDTH - o meters

DYSCO HEADBOX FLOW - 165 liters min
FIGURE 18
FILLER PROFILE
Ln
H CM CM -3" S p s
=tfc O 0 0
H M M p
P p P P P EH EH EH 0
<JX H M M H pq p O X O X O X p
o O O O O <ijo P O P O PO 0
3 Ph Ph Eh k co pq co pq 0
.05
Vi.
JH
.15
o J K -----
s
w
EH .25
CO
H
CO
s
o 35
o
«
.45 EXP —
a
H
P4 DYSCO
.55
.65
MACHINE SPEED - 76 meters/min WIDTH - .76 meters
EXPERIMENTAL HEADBOX FLOW - 1 5 1 liters/min
FIGURE 19
FILLER PROFILE
O'
was slightly lower than the temperature of the recycled white water.
When these streams were mixed, the seal water cooled the white water.
This cooled white water stream was used as dilution water for pulp
sheets in the beater. After dilution the thick stock stream went to
the MIXER (Claflin refiner) where the thick stock temperature was
increased at about 0.1°K per minute from refining. However, after a
gain in temperature, the thick stock was diluted with the white water
stream from the first tray (primary loop) which was also slightly
cooler. Thus, the proposed closed system used seal water to slightly
cool the recycled white water and white water to slightly cool the
thick stock, after refining.
With no cooling, the system temperatures would increase to a
high level. The excess energy would be dissipated through radiation
losses to the environment of the system. From the literature, equi
librium temperatures would be reached in the range of 150-160°F,
which is tolerable, but sizing may be adversely affected. Therefore,
for long runs on the proposed closed systems, external cooling equip
ment would be required.
SUMMARY OF RESULTS
From this study, DYSCO was shown to be a useful simulating pro
gram for applications in the wet end papermaking process. DYSCO veri
fied mass balance data obtained from the open system pilot machine
trial at a maximum speed of 76 meters/minute as well as slower speeds
of 61 and 46 meters/minute.
Experimentally, it was found that increasing machine speed in
the open system caused a reduction in water drainage and filler reten
tion. The machine trial showed that some water was actually forced
back into the moving web between the table rolls and second suction
box. Although this decrease in web consistency was small, it intro
duced a limitation into the simulation model because the modules used
to represent the units on the wire could not "understand" retention
fractions greater than one.
The proposed closed water system simulated with DYSCO reached
a steady state convergence at 46 minutes with a minimal of fresh
water input. For the system closure, a stock temperature increase
of 0.1°K per minute was computed from the refining of the stock. How
ever, high stock temperatures were not encountered over the simula
tion time period due to the cooling action of input pump seal water
on the system. The closed system produced an effluent of 9 liters/
minute at a wire speed of 46 meters/minute. The pilot machine is
usually operated at speeds lower than 46 meters/minute. Therefore,
the proposed closed system was theoretically and experimentally
feasible at a wire speed of 46 meters/minute.
78
CONCLUSIONS
The application of the DYSCO computer model to simulate the
response of the real-world paper machine wet-end system at varying
degrees of closure was shown. The accuracy of the model to the open
system was verified from experimental measurements. Since, the pro
posed closed system was not installed, the accuracy of the simulation
results for this system were not verified.
To simulate the papermaking process, a model of the "real" paper
machine was created. However, to create the model, performance infor
mation about the "real" machine was obtained. Therefore, the model
was limited-by the accuracy of this information. Certain details were
left out of the model presented. These details included the addition
of components to the system which are found in the real papermaking
process. Components such as rosin, alum, retention aid, etc. were
ommited. Thus, limitations on the applicability of the model to the
"real" world were imposed. The presented model could be improved by
the introduction of more components to the system. This would make
the model more applicable to the "real" papermaking process.
The DYSCO (DYnamic Simulation and COntrol) program had certain
limitations to the simulating accuracy of the modules (subroutines).
These limitation deal with the type of "real" process to be modeled.
In the case of simulating the papermaking process, some of the DYSCO
modules contained "internal" limitations on their application.
As a representation of a dewatering unit, the DYSSEP (dynamic
79
separator) module was limited because accept (retention) fractions of
the components must be unity or lower. Also, the DYSSEP units did not
incorporate dynamic retention rates into stream flow calculations.
Thus, constant retention rates were used, unless the simulation was
stopped and new values keypunched in the program.
As a model of a fan pump or beater, the DILUTR (diluter) module
was limited because the components in the stream to be diluted had to
be higher in concentration than the dilution stream. Thus, simul
taneous control of multiple component concentrations in the diluted
stream was not possible if one controlled component in the dilution
stream was higher in concentration than the diluted stream.
The MIXER module was a good representation of a furnish refiner
because it caused agitation and added heat to the stock; as an actual
refiner would do. The headbox, and white water trays, were accurately
moduled by the DYSMIX (dynamic mixer) modules.
The simulation could be improved by reducing the "internal"
limitations of the modules. This could be accomplished by restructur
ing the FORTRAN subroutines in the program. This restructuring, how
ever, requires a good background in the FORTRAN computer language and
understanding of dynamic processes.
In spite of the above limitations of DYSCO, this program is
applicable to calculating mass balances around the wet-end of the
paper machine.
80
RECOMMENDATIONS
Since the DYSCO modules contain "internal" limitations to model
ing the real papermaking process, a restructuring of the software
would improve the simulation ability of the modules. By resturcturing
the FORTRAN subroutine in the modules, the capability for simulating
solids buildup, temperature increases, and dynamic drainage rates
would be possible.
The proposed closed system is theoretically feasible with minimal
fresh water input. However, since the system was not installed, a
check on the accuracy of the DYSCO stream flows was not possible.
Even though.the experimental and DYSCO stream flows for the open
system showed a good correlation, the experimental study of the closed
system is suggested to verify simulation results of this study.
The papermaking process modeled in this study used only three
components; fiber, filler and water. In actual mill conditions, other
furnish components are added to improve the quality or formation
of the paper. By using the paper machine models presented in this
study and the documentation described, the simulation of other com
ponents in the papermaking process would be possible.
81
82
APPENDIX A
EXAMPLE FORTRAN PROGRAM.TO SOLVE DIFFERENTIAL EQUATIONS USING

EULER'S METHOD AND A FOURTH ORDER RUNGE-KUTTA METHOD.
REAL YAC
C THIS IS THE ACTUAL SOLUTION TO THE EQUATION
REAL YE
C THIS IS THE EULER'S METHOD SOLUTION
REAL YR
C THIS IS THE RUNGE-KUTTA SOLUTION
REAL X,Y
C FUNCTION VARIABLES
REAL K 1 ,K 2 ,K 3 ,K4
C THESE FOUR VARIABLES USED IN THE RUNGE-KUTTA METHOD
REAL H, H2
C H IS THE INTERVAL SIZE WHILE H2 IS H/2
INTERGER N,I,J
C DO LOOP COUNTERS
C HERE IS THE SAMPLE FUNCTION TO BE SOLVED f(xy) = y2 + 2y + 2
F(X,Y) = (Y*(Y+2.)) + 2.
83
H=l./8.
C THIS SETS THE INTERVAL SIZE
2H=H/2
DO 50 J = 1 ,2
YE=2.55740773
YR=-2.55740773
X=0.0
YAC=(SIN(X-1))/COS(X-l)
N=INT(2.5/H)
WRITE (21,20) H
N=INT(2 .5/H)
WRITE(21,40) X,YR,YR,YAC
DO 100 1=1,N
YE=YE+(H*F(X,YE))
K1=F(X,YR)
K2=F(X+H2,YR+H2*K1)
K3=F(X+H2,YR+H2*K2)
K4+F(X+H2,YR+H*K3)
YR=YR+(H/6.*(Kl+(2.*K2)+(2.*K3)+K4))
X=X+H
84
100 CONTINUE
H=l./32.
H2=H/2.
50 CONTINUE
STOP
END
SAMPLE OUTPUT
THE VALUE OF H IS .125
X EULER'S METHOD RUNGE-KUTTA ACTUAL
.000000 -2.5574077 -2.5574077 0.00000000

.125000 -2.1292179 -2.1974122 -2.19744216
.250000 -2.8448263 -1.9315843 -1.93159655
2.25000, 1.6935308 2.0091809 2.0095696
2.37500 2.7245193 4.0354819 4.0419154
2.50000 4.5852629 12.6314130 13.1014220
APPENDIX B
PROCEDURE FOR CONSISTENCY AND ASH DETERMINATION
The method for determining consistency was as follows:
1) On analytical balance weight an empty 150 ml. beaker.
2) Mix the sample well and pour 50 ml. into the beaker and re-
weigh.
3) Pour the sample over a preweighed 11 cm. filter paper in

serted in a Buchner funnel. Forwhite watersample use
Millipore filter apparatus.
4) Place the filter pad in an oven at 125^0 for 24 hours.
5) Reweigh the dried filter pad and determine consistency.
6) In case of high consistency samples, dilute with distilled

water.
The procedure for ash tests was as follows:
1) Heatmuffle furnace to 900°C.
2) Place a porcelain crucible in furnace for 20 minutes.
3) Remove the crucible and place it in a desicator to cool fo

five minutes.
4) Weigh the crucible on analytical balance.
5) Place the cricible back into the oven for 10 more minutes,
remove, cool, and weigh.
6) Repeat step 5 until a constant weight is determined.
7) Fold the filter pad used in the consistency measurement so

it fits in the crucible.
8) Place the crucible and pad in the oven for 30 minutes.
9) Remove, cool, and weigh crucible and ash.
10) From consistency and ash data calculate ash content.
CALCULATION OF CONSISTENCY AND ASH CONTENT OF WEB SAMPLE
AFTER FIRST FOIL - 61 METERS/MINUTE (TABLE 6)
Experimental Data
Weight Beaker Stock 108.8428 grams

Weight Beaker -73.4080 grams
Weight Stock 35.4348 grams
Weight Dry Pad & Filter Paper 1.0701 grams

Weight Filter Paper -.4401 grams
Weight Dry Pad .6300 grams
Consistency
= Weight Dry Pad/Weight Stock

= .6300/35.4348 = .017778 = 1.778%
Experimental Data
Weight Crucible & Ash 19.1144 grams

Weight Crucible -19.0672 grams
Weight Ash in Sample .0472 grams
Weight Ash in Filter Paper -.0011 grams
Weight Ash in Pad .0461 grams
% Ash
= Weight Ash in Pad/Weight Dry Pad

= .0461/.6300 = .0732 = 7.32%
Filler Consistency
= (Total Consistency x % Ash)/Total Consistency

= (.017778 x .0732)/.017778
= .001301 = .1301%
Fiber Consistency
= Total Consistency - Filler Consistency

= .017778 - .001301 = .016477 = 1.6477%
Water Consistency
= 1. - Total Consistency = 1. - .017778

= .982221 = 98.2221%
APPENDIX C
MASS BALANCE AROUND MACHINE AT 61 METERS/MINUTE FOR

PRIMARY LOOP (FIGURE 9, UNITS 1-7)
Web Sample Headbox 1st Foil 2nd Foil 3rd Foil
7, Consistency .5566 1.7779 2.7126 3.1970

% Fiber .4820 1.6477 2.5421 3.0156
7o Filler .0746 .1301 .1705 .1814
White Water 1st Foil 3rd Foil 1st Tray Machine Chest
7, Consistency .0891 0829 1065 .9597

7, Fiber .0199 0331 0365 .8434
7, Filler .0692 0498 0700 .1163
Headbox Flow = 151 Liters/Minute = 151000 Grams/Minute
107, TiO£ Flow = 1 Liters/Minute = 1000 Grams/Minute
1) For Headbox to 3rd Foil
151(.5566) = XC3.1970) + Y(.1065)

151(.0746) = X ( .1814) + Y(.070Q)
X = 22.91 Liters/Minute to 4th Foil
Y = 128.09 Liters/Minute to 1st Tray Total Flow
2) For 1st Foil

151(.5566) = X(1.7779) + Y(.0891)
151(.0746) = X ( .1301) + Y ( .0692)
X = 43.18 Liters/Minute to 2nd Foil
Y = 107.82 Liters/Minute to 1st Tray From 1st Foil
3) For 3rd Foil

X(2.7126) = 22.91(3.1970) + Y(.0829)
X ( .1705) = 22.91 (.1814) + Y(.Q498)
X = 27.30 Liters/Minute to 3rd Foil
Y = 4.39 Liters/Minute to 1st Tray From 3rd Foil
4) Flow From Second Foil = Flow From 1st Foil - Flow to 3rd Foil
= 43.18 - 27.30 = 13.88 Liters/Minute to 1st Tray From
2nd Foil
88
5) 1st Tray Balance Check

1st Tray = 1st Foil + 2nd Foil + 3rd Foil
128.09 = 107.82 + 15.88 + 4.39
6) Dilution Water Required From 1st Tray for Machine Chest

Thick Stock
151(.5566) - 1(10) = X ( .9597) + Y(.1065)
151(.0746) - 1(10) = X ( .1163) + Y(.Q7)
X = 92.14 Liters/Minute From Machine Chest
Y = 58.85 Liters/Minute From 1st Tray
7) Excess Dilution Water = Water From 1st Tray - Water Required

= 128.09 - 58.85 = 70.23 Liters/Minute to Sewer
8) Fiber + Filler Inputs = .88 kg./min.

Fiber + Filler Outputs = .87 kg./min.
9) Water Inputs 92.3 Liters/Minute

Water Outputs 92.3 Liters/Minute
10) Retention Fractions for First Foil Retention Fraction

Water Flow Before Foil
151 liters x .994434 = 151.15 liters
Water Flow After Foil
43.2 liters x .982221 = 42.4 liters 283
Fiber Flow Before Foil
151 liters x .004820 = .728 liters
Fiber Flow After Foil
43.2 liters x 0.16477 = .712 liters .978
Filler Flow Before Foil
151 liters x .007146 = .113 liters
Filler Flow After Foil
43.2 liters x .001301 = .056 liters .499
11) Retention Fractions for Second Foil Retention Fraction

43.2 liters x .092221 = 42.43 liters
27.3 liters x .962874 = 25.56 liters 626
43.2 liters x .016477 = .712 liters
27.3 liters x .025421 = .694 liters 975
Filler Flow Before Foil Retention Fraction
43.2 liters x .001301 = .05620
Filler Flow After Foil
27.3 liters x .001705 = .04654 .828
12) Retention Fractions for 3rd Foil Retention Fraction

27.3 liters x .962874 = 26.56 liters
22.9 liters x .968030 = 22.17 liters .835
27.3 liters x .025421 ,6939 liters
22.9 liters x .030156 ,6906 liters .995
27.3 liters x .001705 ,04654 liters
22.9 liters x .001814 ,04154 liters .893
90
APPENDIX D
EXPLANATION OF STREAM NUMBERS FOR FOURDRINIER

OPEN AND CLOSED SYSTEMS
Stream No. Unit No. Type of Flow
1 1 Flow from headbox
2 2 Flow retained from first foil to second

foil
3 2 Flow retained from second foil to third

foil
4 3 Flow retained from second foil to third

foil
5 3 White water from second foil to first

tray
6 4 Flow retained from third foil to fourth

foil
7 4 White water from third foil to first

tray
8 5 Total white water from first tray
9 6 White water and filler to fan pump
10 7 Flow to headbox
11 Input or 19 Thick stock from machine chest
12 7 Excess dilution water from fan pump
13 Input Titanium dioxide slurry
14 8 Flow retained from fourth foil to table

rolls
15 8 White water from fourth foil to second

tray
16 9 Flow retained from table rolls to first

suction box
91
Stream No. Unit No. Type of Fiow
17 9 White water from table rolls to second

tray
18 10 Flow retained from first suction box

to second suction box
19 10 White water from first suction box
20 11 Flow retained from second suction box

to third suction box
21 11 White water from second suction box
22 12 Flow retained from third suction box

to couch
23 12 White water from third suction box
24 13 Wet paper from couch to press section
25 13 White water from suction couch
26 14 Total white water from second tray
27 15 White water and seal water from suction

unit
28 Input Pulp seal water
29 16 Second tray white water, suction and

seal water
30 17 Excess dilution white water from fan

pulp and stream 29
31 Input Pulp sheets fiber to beater
32 18 Diluted pulp sheets to Claflin refiner
33 18 Excess effluent to saveall
APPENDIX E
LIST OF EQUATIONS
Eq. 1 Standard Mass Balance Equation
^ . (Q°c).n - (Q-C) ♦ RV°
Eq. 2 Euler's Method
ymJ.
m + li = m + m m
Eq. 3 Runge-Kutta Method
ym+l = ym + h/6<kl * 2k2 * 2k3 + V
Eq. 4
k l " £<x'ym )
Eq. 5 k„ = f (x + h/2,y + hk./2)

z m m 1
Eq. 6. k„ = f(x + h/2 ,y + hk,/2)

j m m Z
Eq. 7 k. = f(x + h,y + hk~)

4 m "m 3
93
APPENDIX F
DOCUMENTATION AND DESCRIPTION OF THE

DYSCO PROGRAM TO SIMULATE THE CLOSED SYSTEM
COMMENTS ARE GIVEN IN BRACKETS.
.RUN DYSCOl
(THIS IS THE FIRST SEGMENT OF THE DYSCO PROGRAM. IN THIS SECTION,
THE UNIT NUMBERS, NAMES AND STREAMS ARE ENTERED. THE COMMAND "RUN
DYSCOl." ALLOWS ACCESS TO THIS SEGMENT.)
*** DYSCO: UNIVERSITY OF MICHIGAN DYNAMIC SIMULATION PROGRAM ***
*** MODIFIED FOR PULP AND PAPER MILL SIMULATION BY
*** THE INSTITUTE OF PAPER CHEMISTRY
** ENTER: A TITLE FOR THE PROCESS TO BE SIMULATED
CL0SE150R2 (THE TITLE OF THIS SIMULATION WAS CONDENSED FROM "CLOSED

SYSTEM, 150 FT./MIN. = 46 METERS/MIN., RUNGE-KUTTA INTEGRA
TION METHOD, DATA FROM EXPERIMENT ON RECYCLED FIBERS" TO
"CLOSE 150R2")
*** TOPOLOGY SECTION ***
** ENTER: THE TOTAL NUMBER OF UNITS IN THE SIMULATION
19 (REFER TO FIGURE 10 FOR THE FLOW DIAGRAM OF THE SYSTEM.)
** ENTER IN ONE LINE: UNIT NO. UNIT NAME = INPUT (MINUS)OUTPUT STREAMS
(THE FIRST NUMBER ENTERED AFTER THE "=" SIGN IS THE INPUT TOTHE UNIT.
OUTPUT STREAMS ARE PRECEEDED BY A SIGN. THE FIRST NUMBER FOR AN
OUTPUT STREAM OF A DYSSEP UNIT MUST BY THE ACCEPT STREAM. FOR THE
DILUTR UNIT, THE FIRST OUTPUT STREAM MUST BE THE STREAM TO BE
DILUTED.)
94
1 -DYSMIX = 10 -1 (HEADBOX)
2 DYSSEP = 1 -2 -3 (FIRST FOIL)
3 DYSSEP = 2 -4 -5 (SECOND FOIL)
4 DYSSEP = 4 -6 -7 (THIRD FOIL)
5 DYSMIX = 3 5 7 (FIRST WHITE WATER TRAY)
6 DYSMIX = 8 13 -9 (ADDITION OF FILLER)
7 DILUTR = 11 9 -10 (FAN PUMP)
8 DYSSEP = 6 -14 -15 (FOURTH FOIL)
9 DYSSEP = 14 -16 -17 (TABLE ROLLS)
10 DYSSEP = 16 -18 -19 (FIRST SUCTION BOX)
11 DYSSEP = 18 -20 -21 (SECOND SUCTION BOX)
12 DYSSEP = 20 -22 -23 (THIRD SUCTION BOX)
13 DYSSEP = 22 -24 -25 (SUCTION COUCH)
14 DYSMIX = 15 17 -26 (SECOND TRAY WHITE WATER)
15 DYSMIX = 19 21 23 (WHITE WATER FROM SUCTION UNITS)
16 DYSMIX = 26 27 -29 (COMBINATION OF SECOND TRAY AND

SUCTION UNIT WHITE WATER)
17 DYSMIX = 28 29 12 (ADDITION OF PUMP SEAL WATER)
18 DILUTR = 31 30 -32 (BEATER FOR PULP SHEET DILUTION)
19 MIXER _
32 -11 (CLAFLIN REFINER)
*** TOPOLOGY MATRIX *** (THE COMPUTER SETS UP AN ARRAY FROM THE
FLOW DIAGRAM PREVIOUSLY ENTERED.)
NUMBER - NAME STREAMS
1 DYSMIX 10 -1 0 0 0
2 DYSSEP 1 -2 -3 0 0
3 DYSSEP 2 -4 -5 0 0
4 DYSSEP 4 -6 -7 0 0
5 DYSMIX 3 5 7 -8 0
6 DYSMIX 8 13 -9 0 0
7 DILUTR 11 9 -10 -12 0
8 DYSSEP 6 -14 -15 0 . 0
9 DYSSEP 14 -16 -17 0 0
10 DYSSEP 16 -18 -19 0 0
11 DYSSEP 18 -20 -21 0 0
12 DYSSEP 20 -22 -23 0 0
13 DYSSEP 22 -24 -25 0 0
14 DYSMIX 15 17 -26 0 0
15 DYSMIX 19 21 23 25 -27
16 DYSMIX 26 27 -29 0 0
17 DYSMIX 28 29 12 -30 0
18 DILUTR 31 30 -32 -33 0
19 MIXER 32 -11 0 0 0
96
INPUT UNIT OUTPUT UNIT UNUSED

STREAMS NUMBER STREAMS NUMBER STREAMS
13 6 24 -13 0
28 17 33 -18 0
31 18 0 0 0
(THIS IS A CHECK ON THE ORIGINAL FLOW DIAGRAM FOR INPUT AND OUTPUT
STREAMS)
** DO YOU WANT TO MODIFY THE TOPOLOGY? ENTER: YES OR NO

(KEYPUNCH ERRORS ARE CORRECTED HERE.)
NO
** ENTER NUMBER OF COMPONENTS FOR SIMULATION.
3 (THE COMPONENTS IN THIS SIMULATION ARE WATER, FIBER, AND FILLER.)
END OF EXECUTION
CPU TIME: 0.61 ELAPSED TIME: 7:8.12
EXIT (THE ARRAY HAS BEEN STORED IN MEMORY FOR LATER USE IN DYSC02.)
.DO DYSCO.MIC
(THIS COMMAND CALLS DYSC02.)
.PATH SYS:=OLD:,STD:
.R OLD:FORTRA
*DMAIN.REL=DMAIN.FOR
DMAIN
* C
.R LINK
*DYSC02/0V/SA = DYSC02,DMAIN/SPACE:7000/LINK
*/N0DE:0 LINKA/LINK:A
*/N0DE:0 LINKB/LINK:B
*/NODE:B LINKB1/LINK:B1
*/G0
EXIT
(THE DATA BANK FOR DYSC02 HAS BEEN FOUND AND IS READY FOR DATA INPUT.)
•RUN DYSC02
(THIS COMMAND DOES NOT HAVE TO BE ENTERED, THE COMMAND "DO DYSCO.MIC"
WILL IMPLEMENT THIS COMMAND AFTER THE FILE IS FOUND.)
*** DYSCO: UNIVERSITY OF MICHIGAN DYNAMIC SIMULATION PROGRAM ***
MODIFIED FOR PULP AND PAPER SIMULATION BY THE INSTITUTE OF PAPER

CHEMISTRY
*** TOPOLOGY MATRIX ***

(THE ARRAY FROM DYSCOl IS REPEATED.)
** ENTER: THE MAXIMUM TIME FOR SIMULATION AND THE INITIAL TIME STEP
THE UNITS FOR TIME ARE ARBITRARY BUT MUST BE CONSISTENT THROUGHOUT
(FOR EXAMPLE, IF YOUR TIME UNIT IS 1 HOUR, THEN FLOW RATES MUST BE
IN MOLES/HR ETC.)
30 1
(IN THIS SIMULATION, THE FLOW RATE IS IN GRAMS/MIN. THE TIME STEP
IS 1 MINUTE.)
** ARE THERE ANY INFORMATION STREAMS? (SUCH AS STREAMS TO OR FROM

CONTROLLERS, CONTROL VALUES, RECORDERS, ETC.) ENTER: YES OR NO
NO
** ARE THERE ANY UTILITY STREAMS? (STEAM, COOLING WATER, ELECTRICAL

LINES)
ENTER: YES OR NO
NO
*** PHYSICAL PROPERTIES SECTION ***
** ENTER: THE PHYSICAL PROPERTY SYSTEM YOU ARE USING.

(INTERNAL, PENNSYLVANIA, OR PULPAPER)
PULPAPER
** ENTER: THE TOTAL NUMBER OF COMPONENTS
3 (WATER, FIBER, FILLER)
** NUMBER OF COMPONENTS IN THIS SIMULATION = 3
** ENTER: ONE COMPONENT NUMBER AND NAME ON EACH LINE
10 WATER
20 FIBER
30 FILLER
98
*** UNIT PARAMETERS SECTION ***

(IN THIS SECTION, THE UNIT PARAMETERS ARE ENTERED, THE PARAMETER CAN BE
TEMPERATURE, PRESSURE, FLOW RATES OR COMPONENTS.)
UNIT N O . 1
NAME --- DYSMIX (HEADBOX)
** ENTER: THE TOTAL NUMBER OF PARAMETERS REQUIRED FOR THIS UNIT
0 (DYSMIX DOES NOT REQUIRE ANY PARAMETERS.)
UNIT N O . 2
NAME DYSSEP (FIRST FOIL)
3 (WATER, FIBER, FILLER)
** THE TOTAL NUMBER OF PARAMETERS = 3
** ENTER: PARAMETER NAME = VALUE (ALL IN ONE LINE)

PARAMETERS MUST BE IN ASCENDING ORDER
WATER = .308
FIBER = .908
FILLER = .455
(THESE ARE THE RETENTION FRACTIONS OBTAINED FROM PILOT PLANT DATA.
FRACTIONS REPRESENT ACCEPTS AFTER THE UNIT. FOR EXAMPLE "WATER = .308"
MEANS THAT 30.8% OF THE WATER STAYED ON THE WIRE, 69.2% OF THEINPUT
STREAM PASSED THROUGH THE WIRE.)
UNIT N O . 3
NAME DYSSEP (SECOND FOIL)
** ENTER: THE TOTAL NUMBER OF PARAMETERS REQUIRED FOR THS UNIT

WATER = .760
FIBER = .999
FILLER = .950
99
UNIT N O . 4
NAME ------ DYSSEP (T H IR D F O IL )
** ENTER: PARAMETER NAME = VALUE (ALLIN ONE LINE)

WATER = .702
FIBER = .997
FILLER = .897
UNIT N O . 5
NAME DYSMIX (FIRST TRAY)
-
UNIT N O . 6
NAME DYSMIX (ADDITION OF FILLER)
-
UNIT N O . 7
NAME --- DILUTR (FAN PUMP)
2 (THIS UNIT CONTROLS COMPONENTS IN THE OUTPUT STREAM. FIBER IS

CONTROLLED BUT "2" MUST BE ENTERED BECAUSE THE COMPONENT NUMBER PLUS
SEVEN IS REQUIRED.)

FIBER = .00447 (HEADBOX FIBER CONSISTENCY IS .4470%)

PARAMETER = 9 (COMPONENT NUMBER PLUS SEVEN, SINCE FIBER IS COMPONENT
(TWO [WATER IS ONE, FIBER IS TWO, FILLER IS THREE] THE
NUMBER INPUT IS NINE.)
UNIT N O . 8
NAME ------ DYSSEP (FOURTH F O IL )

WATER = .907
FIBER = 1.000
FILLER = .980
UNIT N O . 9
NAME DYSSEP (TABLE ROLLS)
** ENTER: PARAMETER NAME = VALUE (ALLIN ONE LINE)

WATER = .989
FIBER = 1.000
FILLER = 1.000
UNIT NO. --- 10

NAME DYSSEP (FIRST SUCTION BOX)
** THE TOTAL NUMBER OF PARAMETERS IS 3

WATER = 1.000
FIBER = 1.000
FILLER = .919
R ep ro d u ced with p erm ission of th e copyright ow ner. Further reproduction prohibited w ithout p erm ission .
U N IT NO. ------ 11
NAME ------ DYSSEP (SECOND SUCTION BOX)
** ENTER: PARAMETER NAME = VALUE (ALL IN ONELINE)

WATER = .520
FIBER = 1.000
FILLER = .884
UNIT NO. --- 12

NAME DYSSEP (THIRD SUCTION BOX)

WATER = .308
FIBER = 1.000
FILLER = .599
UNIT NO. --- 13

NAME DYSSEP (SUCTION COUCH)

WATER = .895
FIBER = 1.000
FILLER = .870
102
UNIT NO. ------ 1 4

NAME ------ DYSMIX (SECOND TRAY WHITE WATER)
** ENTER: THE TOTAL NUMBER OF PARAMETERS REQUIRED FORTHIS UNIT
UNIT NO. --- 15

NAME DYSMIX (WHITE WATER FROM SUCTION UNITS)
** ENTER: THE TOTAL NUMBER OF PARAMETERS REQUIRED FORTHIS UNIT
UNIT NO. --- 16

NAME DYSMIX (COMBINATION OF SECOND TRAY AND SUCTION WHITE
WATER)
UNIT NO. --- 17

NAME DYSMIX (INTRODUCTION OF SEAL PUMP WATER AND EXCESS WHITE
WATER FROM FIRST TRAY)
UNIT NO. --- 18

NAME DILUTR (DILUTION OF PULP SHEETS IN DILUTR)
103

FIBER = .0084 (THICK STOCK TO MACHINE CHEST IS .84% FIBER)

PARAMETER = 9 (FIBER IS COMPONENT 2, 7 + 2 = 9)
UNIT NO. --- 19

NAME MIXER (THE CLAFLIN REFINER)
-
ENTER IN ORDER LISTED— DO NOT SKIP ANY
** ENTER 7 PARAMETERS: T(K), P (ATM), M(G.MOLES), EXTERNAL HEAT FLUX

AND MASS FRACTIONS IN THE SAME ORDER AS THE COMPONENTS

T(K) = 299.1 (TEMPERATURE IN REFINER)

P (A T M ) = 14.7 (PRESSURE IN REFINER)
M(G.MOLES) = 4642.8 (MASS OF FLOW THROUGH REFINER IN MOLES.
THIS VALUE REPRESENTS MOLES OF WATER FLOW
[83570 grams/ 18moles per gram = 4642.8
moles].)
EXTERNAL HEAT FLUX = 1927.8 (HEAT ADDED IN KILOCALORIES. THIS VALUE
WAS CALCULATED FROM THE STUDY BY FARMER .
HE FOUND A 34°F RISE IN TEMPERATURE FOR A
27 GALLON/MINUTE FLOW THROUGH A CLAFLIN
REFINER. THIS CONVERTS TO 7650 BTU'S =
1927.8 KILOCALORIES.)
WATER = .9904 (MASS FRACTION OF WATER)
FIBER = .0084 (MASS FRACTION OF FIBER)
FILLER = .00116 (MASS FRACTION OF FILLER)
*** STREAM PARAMETERS SECTION ***
** DO YOU WANT TO INITIALIZE ALL STREAMS SEPARATELY?
NO
** DO YOU WANT TO PUT DEFAULT VALUES IN MATERIAL STREAMS IN SM ARRAY?
NO
* THESE ARE THE INPUT STREAMS TO BE INITIALIZED.
13 28 31
104
** MATERIAL STREAMS **
** ENTER: T(K), P (ATM), FL0W(MASS/TIME), AND MASS FRACTIONS IN THE
SAME ORDER AS THE COMPONENTS (ALL IN ONE LINE SEPARATED BY BLANKS)
** ENTER: INFORMATION FOR STREAM 13 (FILLER ADDITION STREAM)
298.0 14.7 1000 .99 0 .01 (1000 GRAMS/MINUTE OF A 1% FILLER SLURRY.)
** ENTER: INFORMATION FOR STREAM 28 (PUMP SEAL WATER)
295.0 14.7 12000 1.0 0 0 (12000 GRAMS/MINUTE OF FRESH WATER.)
** ENTER: INFORMATION FOR STREAM 31 (PULP SHEETS)
298.0 14.7 754 .07 .93 0 (754 GRAMS/MINUTE OF FIBER.)
* ARE THERE ANY OTHER STREAMS YOU WANT TO INITIALIZE?
NO
** ARE ALL MATERIAL STREAMS LIQUID PHASE IN THIS SIMULATION?

ENTER: YES OR NO
YES
*** CONVERGENCE CRITERIA SECTION ***
** DO YOU WANT TO TEST FOR CONVERGENCE TO STEAY STATE CONDITIONS?

ENTER: YES OR NO (CONVERGENCE TO STEADY STATE DESCRIBED IN EXPERIMENTAL
PROCEDURE)
** ENTER: TOTAL NUMBER OF STREAM PARAMETERS TO BE CHECKED FOR

CONVERGENCE
** ENTER: PARAMETER NAME = TOLERANCE FRACTION

POSSIBLE PARAMETERS : TEMP, PRESS, FLOW, OR COMPONENT NAME
FIBER = .005 (FRACTION = E. A = FRACTION FOR RELATIVE CHANGE BETWEEN

T(1+1) AND T(I). B = FRACTION FOR RELATIVE CHANGE BETWEEN
T(I) AND T(I-l). IF A IS LESS THAN E OR B IS LESS THAN E,
THE SYSTEM CONVERGES.)
*** CONVERGENCE CRITERIA ***
FIBER .500000E-02
105
* * ENTER IN ONE L IN E : THE UNIT CALCULATION ORDER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
** CALCULATION ORDER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
DATA BEING WRITTEN TO DEVISE 3
** DO YOU WANT TO USE RECIPE? ENTER: YES OR NO (DYSCO ALLOWS THE USER
TO APPLY STEP OR RAMP FUNCTION CHANGES TO ANY STREAM OR UNIT PARA
METERS AT ANY TIME DURING THE SIMULATION.)
NO
** DO YOU WANT TO ENTER ARBITRARY TABULAR FUNCTIONS? ENER: YES OR NO

(THE ROUTINE TABLE ALLOWS THE USER TO GENERATE THE VALUE OF ANY STREAM
OR UNIT PARAMETER AS AN ARBITRARY FUNCTION OF SIMULATION TIME BY DE
SCRIBING IT AS A SERIES OF COORDINATE POINTS
(t.,x.) WHERE x. IS THE
J J J
VALUE OF THE PARAMETER AT TIME t .. THREE TABULAR FUNCTIONS CAN BE
J
ENTERED FOR ONE PROCESS SIMULATION.)
NO
*** STREAM PARAMETERS MATRIX ***
** STREAM PARAMETER VALUES FOR TIME = 0.000
STR T p FLOW XI X2 X3
(NO.) (°K) (ATM.) (GRAMS/ (WATER) (FIBER) (FILLER)
MINUTE)
1 0.0 0.0 0 0.000000 0.0000000 0.000000
2 0.0 0.0 0 0.000000 0.000000 0.000000
3 0.0 0.0 0 0.000000 0.000000 0.000000
3 0.0 0.0 0 0.000000 0.000000 0.000000
4 0.0 0.0 0 0.000000 0.000000 0.000000
5 0.0 0.0 0 0.000000 0.000000 0.000000
6 0.0 0.0 0 0.000000 0.000000 0.000000
7 0.0 0.0 0 0.000000 0.000000 0.000000
8 0.0 0.0 0 0.000000 0.000000 0.000000
9 0.0 0.0 0 0.000000 0.000000 0.000000
-1.0 0.0 0.0 0 0.000000 0.000000 0.000000
11 0.0 0.0 0 0.000000 0.000000 0.000000
12 0.0 0.0 0 0.000000 0.000000 0.000000
13 298.0 14.7 1000 0.990000 0.000000 0.010000
14 0.0 0.0 0 0.000000 0.000000 0.000000
15 0.0 0.0 0 0.000000 0.000000 0.000000
16 0.0 0.0 0 0.000000 0.000000 0.000000
17 0.0 0.0 0 0.000000 0.000000 0.000000
18 0.0 0.0 0 0.000000 0.000000 0.000000
19 0.0 0.0 0 0.000000 0.000000 0.000000
20 0.0 0.0 0 0.000000 0.000000 0.000000
21 0.0 0.0 0 0.000000 0.000000 0.000000
22 0.0 0.0 0 0.000000 0.000000 0.000000
23 0.0 0.0 0 0.000000 0.000000 0.000000
24 0.0 0.0 0 0.000000 0.000000 0.000000
25 0.0 0.0 0 0.000000 0.000000 0.000000
26 0.0 0.0 0 0.000000 0.000000 0.000000
26 0.0 0.0 0 0.000000 0.000000 0.000000
27 0.0 0.0 0 0.000000 0.000000 0.000000
28 295.0 14.7 12000 1.000000 0.000000 0.000000
29 0.0 0.0 0 0.000000 0.000000 0.000000
30 0.0 0.0 0 0.000000 0.000000 0.000000
31 298.0 14.7 754 0.070000 0.930000 0.000000
32 0.0 0.0 0 0.000000 0.000000 0.000000
33 0.0 0.0 0 0.000000 0.000000 0.000000
** DO YOU WANT TO PRINT STREAM PARAMETERS AT INTEGRAL MULTIPLES OF

THE INITIAL TIME STEP 1.00000 (YES) OR OF THE CURRENT TIME STEP (NO)?
YES
**ENTER: PRINTING FREQUENCY
1 (THE COMPUTER WILL PRINT STREAM PARAMETERS FOR EVERY MINUTE OF SIMU
LATION TIME.)
107
** ENTER INTEGRATION METHOD: 1=EULER, 2=RUNGE, 3=RUNGV, 4=ADAMSN,

5=TREAN OR
** DO YOU WANT AN EXPLANATION OF THE COMMANDS: P,V,S,U,D,T,N,Z,X AND

G? ENTER: YES OR NO
YES
** YOU ARE ALLOWED DURING THE SIMULATION TO:

(P) ENTER A NEW PRINTING FREQUENCY AS A MULTIPLE OF INITIAL TIME
STEP 1.00000
(V) ENTER A NEW PRINTING FREQUENCY AS A MULTIPLE OF CURRENT TIME
STEP
(S) CHANGE STREAM PARAMETERS
(U) CHANGE UNIT PARAMETERS
(D) DISPLAY UNIT PARAMETERS
(T) CHANGE INTEGRATION OF TIME STEP FOR EULER OR RUNGE
(N) SPECIFY NO ADDITIONAL CHANGES IN THE SIMULATION AND POSSIBLE
REASSIGNMENT OF THE OUTPUT DEVICE FOR THE PRINTING OF THE
STREAM PARAMETERS
(Z) SPECIFY NO ADDITIONAL CHANGES
(X) STOP THE PROGRAM
(G) CHANGE GRAPHICAL OUTPUT (GRAPHICS TERMINAL ONLY)
** ENTER COMMAND: P,V,S,U,D,T,N,Z,X, OR G
** ARE YOU GOING TO MAKE MORE CHANGES DURING THIS SIMULATION?

ENTER: YES OR NO
NO
** ENTER: TERMINAL ... TO CONTINUE PRINTING AT THE TERMINAL

FILE ... TO TRANSFER THE PRINTING FROM NOW ON TO OUTPUT
FILE
TERMINAL
(THE SIMULATION IS STARTED. STREAM PARAMETERS ARE PRINTED AT THE

CHOSEN TIME STEP. A SAMPLE OUTPUT OF THIS SIMULATION IS GIVEN FOR
CONVERGENCE TO STEADY STATE IN TABLE 11. THE CONVERGENCE WAS REACHED
AFTER 46 MINUTES OF SIMULATION TIME.)
BIBLIOGRAPHY
Aldrich, L. C., and Janes R. L . , "White Water Reuse on a Fine Paper

Machine," TAPPI 56 no. 3, (March 1973): pp. 92-96.
Auhorm, W. and Melaer, J. "Investigation of Disturbing Substances in

Closed Circuit Systems," Wochbl. Papierfabr. 107 no. 13, (July
1979): pp. 493-502.
Baldus, R. F. "Development and Validation of General Computerized

Unit Operations Related to the Pulp and Paper Industry and Their
Application on a Practical Base." Ph.D. dissertation, Univer
sity of Idaho, 1978.
Brecht, W . , "Closed Water Circulation Systems in Additional Mills

Processing Waste Paper," Wochbl. Papierfabr. 102 no. 7, (April
1974): pp. 223-227.
Dobbins, R. J., Roscoe, R. W . , and Alexander, S. D . , "Influence of

Dissolved Electrolytes in a Closed Mill System." In Proceedings
of TAPPI Spring Corrugated Container/Papermaking Conference,
Dallas, TX: 28 April, 1975.
Dorn, W. S. and McCracken D. D. Numerical Methods with Fortran IV

Case Studies. New York: Wiley & Sons, 1972.
Farmer, R. A. "Evaluation of Temperature Rise as a Means of Refiner

Control," Mead Research Laboratories Report no. 14904, (July
1964): pp. 1-7.
Fluchner, W. "Experience with Closed Water Circuits in Paper

Machines," Papier 29 no. 5, (May 1975): pp. 206-211.
Gellman, I. "The Relationship Between Process Water Quality Charac

teristics and its Reuse in Combination Boardmills," NCASI Tech
nical Bulletin, Part III, no. 282, (Sept. 1975): pp. 1-31.
Goggin, N. J., "Fourdrinier Sampling Techniques Provide Useful

Drainage-Rate Data," Pulp and Paper 55 no. 10, (Oct. 1981): pp.
163-169.
Gutpa, R. M . , "Bleach Plant Control Optimization Instrumentation in

Pulp and Paper Industries." In Proceedings of ISAPUPID Confer
ence , pp. 1-7, Albany, NY: 13 May, 1980.
108
109
Horgan, J., and Hughes, R. P. "Computerized Pulp Mill Process Bal

ance System." In Proceedings of TAPPI Engineering Conference,
pp. 1-7, San Fransisco, CA: 19 September, 1978.
Ingraham, H. G. and Forslind, E. E. Papermaking and Paperboardmaking.

Vol III. New York: McGraw-Hill, 1970.
Lewis, J. and Bowman, R. S. "Five Day Operation of a Paper Machine

Using 100% Recycle of White Water," TAPPI 53 no. 11, (Nov.
1970): pp. 2112-2118.
Lightsey, G. R. and Hall, W. R. "Control of Foaming in Pulp and Paper

Mill White Water," Mississippi Water Resource Instititute Pro
ject A-125, (Oct. 1979): pp. 1-87.
Lopez, L. A. "DYSCO: An Interactive Executive Program for Dynamic

Simulation and Control of Chemical Processes." Ph.D. disser
tation, University of Michigan, 1974.
Parker, P. E. "Dysco, A Modular Dynamic Simulator for the Pulp and

Paper Industry." In Proceedings of the TAPPI National Confer
ence , pp. 215-221, Chicago, IL: March 1981.
Pothmann, D. "Considerations Regarding Operation of Papermills With

out Effluents," Wochbl. Papierfabr. 103 no. 11/12, (June 1975):
pp. 382-387.
Rushton, J. D. and Gunseor, F. D. "Computer Simulation of a Bleached

Kraft Pulp and Paperboard Mill." In Proceedings of TAPPI
Engineering Conference, pp. 145-150, San Fransisco, CA: 19 Sep
tember, 1978.
Thatcher, F. "Computer Assisted Pulp Mill Scheduling Using MAXIMILL."

In Proceedings of TAPPI Annual Marketing Conference, pp. 77-90,
Atlanta, GA: 24 February, 1980.
Thomas, K. V. "Process Simulation Program," TAPPI 62 no. 2, (Feb.

1979): pp. 51-57.
Treiber, S. S. "Kraft Mill Simulation." Ph.D. dissertation, McGraw

University, 1979.
Van Scoffer, K. and Edwards, L. "Minimization of Chemical Fiber Fur

nish in Newsprint." In Proceedings of the TAPPI/CPPA Internal
Mechanical Pulping Conference, pp. 363-370, Toronto, Canada: 11
June, 1979.
110
Wenzyl, D. J. "Closure of Paper and Board Mill Production Systems and

its Effects on Production Conditions." In Proceedings of TAPPI
National Conference, pp. 120-135, Chicago, IL: 6 March, 1981.
Westaway, C. R. Cameron Hydraulic Data. Woodcliff Lake, NJ: Ingersoll-

Rand, 1979.

Closed Water Systems On Paper and Board Machines Using The Dysco

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Western Michigan University

Master's Theses Graduate College

Closed Water Systems on Paper and Board Machines Using the

Follow this and additional works at: https://scholarworks.wmich.edu/masters_theses

Part of the Materials Science and Engineering Commons

This Masters Thesis-Open Access is brought to you for

Stephen Robert Tremont

Western Michigan University

Stephen Robert Tremont, M.S.

Western Michigan University, 1982

This study was conducted to determine the accuracy of the DYSCO

simulation program in simulating the open and closed water system

on the pilot fourdrinier paper machine located in the Department

of Paper Science and Engineering at Western Michigan University.

speeds of 61 and 46 meters per minute. Retention data were obtained

tal versus computer simulated flows and consistencies. Other simula­

tions carried out for a proposed closed water system proved to be

feasible with little or no input of fresh water. Temperature data

for the closed system were also obtained.

and throughout my academic career at Western Michigan University.

I am indebted to Keith Manion, Lance Merrell and Bill Corriveau

for their assistance in gathering the experimental samples from

for her fine artwork in the figures and illustrations presented in

this paper, and Gayl Stuut for typing the manuscript.

Stephen Robert Tremont

The following explanation o f techniques is provided to help you understand

2. When an image on the film is obliterated with a round black m ark it is an

3. When a map, drawing or chart, etc., is p a rt o f th e m aterial being p h o to ­

4. For any illustrations th a t c a n n o t be reproduced satisfactorily by xerography,

TREMONT, STEPHEN ROBERT

WESTERN M I C H I G A N UNIVERSITY, M.S., 1902

COPR. 1982 TREMONT, STEPHEN ROBERT

STEPHEN ROBERT TREMONT

All Rights Reserved

_ THE CLOSED WATER SYSTEM ......................................... 2

Integration Methods ................. 22

THE CYLINDER BOARD MACHINE ..................................... 29

PRESENTATION OF PROBLEMS ....................................... 43

Pilot Machine T r i a l ......................................... 45

Simulation Experiments ....................................... 48

PRESENTATION AND DISCUSSION OF RESULTS ........................ 52

BIBLIOGRAPHY ..................................................... 108

1 Experimental Data - Pilot Machine -

2 Experimental Data - Pilot Machine -

3 Experimental Data - Pilot Machine -

4 Experimental Retention Fractions - Pilot Machine ... 56

5 Experimental Stream Parameters - Open System -

6 Experimental Stream Parameters - Open System -

7 Experimental Stream Parameters - Open system -

8 DYSCO Stream Parameters - Open System -

9 DYSCO Stream Parameters - Open System -

10 DYSCO Stream Parameters - Open System -

11 DYSCO Stream Parameters - Closed System -

1 Model Of The Real World ........................ 13

2 Euler's Method ................................... 23

3 Runge-Kutta Method .............................. 25

4 Key For DYSCO Modules............................ 28

5 Primary Loop - Cylinder Machine................. 32

6 Primary Loop - Cylinder Machine - DYSCO . . . . 33

7 Closed Water System - Cylinder ................. 34

8 Wet End - Fourdrinier Pilot Machine ........... 37

9 Open Water System - Fourdrinier ............... 38

10 Closed Water System - Fourdrinier ............. 41

tal versus computer simulated flows and consistencies. Other simula

3. When a map, drawing or chart, etc., is p a rt o f th e m aterial being p h o to

of white water systems: slime, foam, scale accumulation, paper qual

achieved. The closure of systems internally represents one alterna

In closing a white water system, problems do accompany the clo

Fluchner reported corrosion problems in a German mill in which gal

vanized pipelines transmitting clarified white water failed by corro

sion after one year in recycled conditions. Brecht"* reported corro

specific electrical conductivity did not correlate well with concen

with special emphasis on foaming properties. Recycling of paper ma

sulfate ion concentrations, correlated with strength and sizing de

pecially those depending upon ionic forces of attraction and repul

strength at higher salt levels. However, it was concluded that in