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A numerical model of a vacuum dewatering process was established with a level-set method to simulate two-phase flow in a two-dimensional paper sheet model with constructed volume forces representing flow resistance in a three-dimensional environment. Nine cases of various volume force representations were investigated by comparing numerical and experimental data. Based on the dry content and dwell time relation, the best model is obtained when accounting for in-plane flow resistance at the paper–wire interface. Compared to the other numerical cases, considering the blockage of the pore space, the top layer of the wire plays an essential role in determining the flow resistance during the vacuum process. To validate the maximum dewatering rate obtained in the model, new experimental data with a higher frequency of sampling are needed. The computational time for the two-phase flow models in this study is extensively reduced due to the removal of the internal structure. This distinction enables time-efficient simulations of the vacuum dewatering process in which several dewatering parameters such as the level of the vacuum, the influence of a moving vacuum pulse, and higher basis weights could be investigated. [ABSTRACT FROM PUBLISHER]

A novel process modeling tool to facilitate the study of how various process changes in the paper dryer section affect the mill-wide energy system has been developed. A model library with steady-state block models describing paper dryers, heat recovery equipment, and auxiliary systems on component level have been developed using the software Extend. Process models are then created from these block models using graphical programming. In this article, the characteristics of the developed tool are described and a case study where the tool is shown to be useful for analyzing the energy performance of a hybrid dryer section is presented. [ABSTRACT FROM AUTHOR]

For printing and heavier grades, combining cylinder and impingement air drying into a multiple technique dryer section can enable higher productivity through higher machine speed. The large differences in local moisture content and temperature across the sheet which develop quickly under high intensity impingement drying provide the potential for reducing drying time by sheet reversal between impingement drying cylinders. This advantage was determined experimentally under low intensity impingement drying conditions. Use of the micro-scale based McGill dryer simulator for determining the advantage from sheet reversal between impingement drying cylinders was demonstrated for both laboratory and industrial impingement drying intensities. For completing the drying of 205g/m[SUP2] linerboard from 0.3 to 0.5kg/kg dry under 400°C air jets of Re 20000, drying time is about 30% less with sheet reversal between two impingement drying cylinders than for a single, larger diameter cylinder. This extensively validated dryer simulator enables determining advantageous design specifications and operating conditions for hybrid dryer sections involving combinations of cylinder and impingement air drying, a concept with potential to become common industrial practice. [ABSTRACT FROM AUTHOR]