T73 Motive Steam

Thermocompressor Design
and Operation for
High-Efficiency
By M. Soucy and G.L. Timm

Abstract: Thermocompressor sizing and operation are often misunderstood. Thermocompressors that do
not match the syphon design is a common industry problem. Oversized thermocompressors operating at
differential pressures higher than required are common. It is not unusual for thermocompressors to consume
twice as much motive steam as is required. This is common on machines that have converted to stationary
syphons without optimizing the thermocompressor size. This paper explores the latest developments with
high-efficiency thermocompressor design and its integration with syphons and dryer drainage components.

I
n todays paper machine operat-
ing environment, energy efficiency is
receiving intense focus. Historically
the application of thermocompressors
was much less evolved than it is today. Overzeal-
ous safety factors, inefficient designs, and old dryer
evacuation technology result in oversized thermo-
compressors that use excessive amounts of higher
cost motive steam. In the past, thermocompressor
sizing was as much an art as a science.
A thermocompressor is a steam control device
that uses high-pressure steam, referred to as
motive steam, to induce flow from a lower pres-
sure steam source and discharge the mixture at an
intermediate pressure. A typical thermocompres-
sor is shown in Fig. 1.
In a typical paper machine installation, the
thermocompressor is used to recompress the
blowthrough steam that is evacuated from the
dryers and separated from the condensate in the
condensate receiver station. Blowthrough steam is
steam that is not condensed in the dryers. Blow-
through flow is typically between 8% and 40% or
more of the condensing load in a given dryer. The
actual amount of blowthrough is dependent on
the syphon design, syphon size, dryer condensing
load, dryer pressure, differential pressure, machine
speed, and external line size. The blowthrough can
vary substantially within a given dryer section over
various operating conditions.
In paper machine operations, thermocompres-
sors are required to operate over a wide range of
operating conditions. In many machines, not only
do dryer pressure set points vary, but so do con-
densing loads and machine speeds. When sizing
a thermocompressor, the low-pressure operating
point determines the throat size, and the high
pressure operating point determines the nozzle
size. Since many mills operate over a wide range
of pressures the throat can be oversized for high-
pressure operation while the nozzle is oversized
for low-pressure operation. This compromise is
necessary to satisfy the operating steam pressure
range of the dryers. For the most efficient opera-
tion, careful design of the thermocompressor and
syphons must be followed.
Each thermocompressor is custom designed for
a specific application. The throat and nozzle size
are engineered to match the syphon characteristics
and operating pressure range. This means a 6"
unit on one machine will not necessarily perform
adequately in another 6" application.
A thermocompressor is controlled either by a
differential pressure set point, by a blowthrough
flow set point, or by algorithms determining dif-
ferential set points for a given set of operating
conditions. All three control methods have been
proven to be successful. A typical thermocompres-
sor steam section is shown in Fig.2.
Motive steam (i.e., high-pressure steam) is usu-
ally more costly to produce than lower-pressure,
make-up steam. Steam routed to the thermocom-
pressor bypasses the power generating turbine and
less electricity is produced. It is not uncommon for
there to be $2 to $4 per 1,000 kg of steam differ-
ence in cost between the two steam sources. The
M. Soucy
actual cost difference will vary depending on the
Kadant Canada Corp.,
boiler operating pressure, turbine extraction pres- Summerstown, ON
sures, and the purchased power cost. A typical mill
steam system is shown in Fig. 3.
RECENT ADVANCES
Recent advances in thermocompressor design
and a deeper understanding of the impact of
thermocompressor fluid dynamics on sizing cri-
teria have allowed for optimized internal geom-
etry and improved efficiency. Advanced computer G.L. Timm
modeling techniques have allowed for a much Kadant Johnson Inc.,
Three Rivers, MI

34 Pulp & Paper Canada September/October 2010 pulpandpapercanada.com


better understanding of the intricacies of flow dynamics within
the thermocompressors and have resulted in improved internal
geometries. Motive nozzle position, nozzle shape, throat entrance
geometry, and throat length all influence the efficiency of the
thermocompressor. These variables can be modeled and opti-
Fig. 1. Typical thermocompressor.
Fig. 2. Typical thermocompressor steam section.
Fig. 3. Typical mill steam system.
pulpandpapercanada.com September/October 2010 Pulp & Paper Canada
peer reviewed T74
mized using computational fluid dynamic modeling software.
Figure 4 shows how the computer modeling software reveals
flows within the thermocompressor body. Figure 5 illustrates the
thermocompressor performance of a machine with misapplied
thermocompressors. Replacing the oversized thermocompressors
with a high-efficiency design resulted in a 50% savings in motive
steam. Properly sizing the thermocompressors resulted in another
50% savings in motive steam. In this example, the 1,900 tpd
southern linerboard mill used 60 bar steam that was sent through
a 17 bar pressure reducing valve rather than through the power
generating turbine. The cost difference between motive and
make-up steam was $3.75 per 1,000 kg of steam.
The dryers on this machine consumed 125,000 kg/hr of steam,
with 44,000 kg/hr being motive steam to the thermocompres-
sors. The mill had previously changed from rotary to stationary
syphons, but did not evaluate the sizing and performance of the
thermocompressors. Since the thermocompressors were oversized,
it was difficult to operate at the low differential pressures and
blowthrough steam flows the new stationary syphons allowed.
With the correct thermocompressor design, the machine was
able to operate at lower differential pressures. The mill would be
able to reduce the motive steam by 35,000 kg/hr for the eight
thermocompressors used on this machine. This was worth more
than $1,000,000 per year in savings to this mill, as steam energy
was used to generate electricity instead of create differential for
the dryers.
One measure of thermocompressor efficiency is the entrain-
ment ratio. This is the ratio of suction steam to motive steam.
Since it is economically beneficial to minimize motive steam
usage, we would like to maximize the entrainment ratio. Proper
sizing and optimizing the geometry of the thermocompressor has
resulted in improving the entrainment ratio by 25% to 50%. This
corresponds to as much as 75% reduction in motive use when
compared to current operations.
With advanced modeling techniques the new internal geom-
etries can often be fit into existing thermocompressor envelopes,
minimizing the piping changes necessary to install a better design.
HIGH-EFFICIENCY THERMOCOMPRESSOR DESIGN
AND OPERATION
In order to achieve high-efficiency operation of a thermocompres-
sor section, the thermocompressor design must be driven by the
actual syphon characteristics and drying constraints of the steam
section. Required differential pressures, blowthrough steam flows,
dryer pressures, condensing loads, and machine speeds must be
taken into account over the range of grades produced.
Minimize the load on the thermocompressor
Once the drying parameters are understood, the amount of
blowthrough steam to be recompressed should be minimized.
Differential pressures should be minimized, accurately moni-
tored, and controlled. In many cases differential pressures are not
minimized due to poor transmitter installation and uncalibrated
equipment. Differential pressure set points are run at the worst
case scenario often with additional safety factors added. Accurate
differential pressure indication is the first requirement for proper
syphon operation and optimization of thermocompressor motive
steam use.
35
T75 Motive Steam
There is often justification for changing from rotary to station-
ary syphons based on the reduction in thermocompressor motive
steam. Since stationary syphons are not subjected to the centrifu-
gal forces found with rotary syphons, the differential requirement
when using stationary syphons is much lower. Many machines
run differentials as low as 0.20 bar with blowthrough rates in the
Fig. 4. Advanced computerized flow modeling.
Fig. 5. Motive and suction flows.
Fig. 6. Comparison of two different thermocompressor
geometries.
36 Pulp & Paper Canada September/October 2010 pulpandpapercanada.com
8% to 12% of condensing load range with stationary syphons.
This is compared to 0.7 bar and 20% to 40% blowthrough rates
with rotary syphons. Stationary syphons inherently require less
motive steam provided the thermocompressors are properly sized.
Modern stationary syphons have proven to be highly reliable,
and when matched with dryer bars, drying capacity increases and
surface temperature uniformity is maximized.
In some cases condensate and blowthrough steam piping is
undersized. This creates additional pressure drop requiring exces-
sive differential pressures. Lowering blowthrough flows with
proper syphon sizing and design lowers velocity in these lines.
The sizing is less critical and erosion is reduced. In one mill,
more than $100,000 in annual piping replacement cost was due
to excessive line velocity caused by poor thermocompressor sizing
and operation.
In some cases the condensate separator tanks are too small to
provide efficient condensate/blowthrough separation. Conden-
sate carryover with the blowthrough steam can result. Erosion
of the thermocompressors and inaccurate measurement of the
blowthrough steam flow is the result. Often the tank internals are
worn and may even be missing, further allowing for condensate
carryover.
Properly size thermocompressors
Thermocompressors should be sized based on actual operat-
ing conditions with appropriate safety factors for suction flows.
Actual motive flow pressures at the thermocompressor rather
than header pressure values should be used when sizing the
thermocompressor. In some cases motive steam pressure varia-
tions are not well understood and poor thermocompressor sizing
and operation result.
The motive steam pressure should be at least 1.2 times the
suction pressure (absolute pressure) to achieve good performance.
Since care should be taken to minimize the load on the thermo-
compressor, accurate pressures for suction pressure (i.e., discharge
pressure less differential pressure and line losses) should be uti-
lized.
Optimize thermocompressor geometry
Specific geometry variations within the thermocompressor greatly
affect performance and efficiency. Using computational model-
ing shows that two different designs of thermocompressors use
differing amounts of motive steam. In this case the motive steam
pressure (Pm) was 27 bar, the dryer section pressure (Pd) was 8.3
bar, and the suction pressure (Ps) 7.5 bar. Blowthrough flow was
5,800 kg/hr. Figure 6 shows how for the given set of operating
conditions a high-efficiency thermocompressor can be installed
which will use less motive steam. In this case the motive steam
was reduced from 4,045 kg/hr to 3,136 kg/hr, a 22% savings. This
was realized by optimizing geometry of the thermocompressor
assembly. This is typical of the savings in motive steam that can
be gained by using a high-efficiency thermocompressor geometry
versus the conventional designs found in the industry.
Properly manage differential pressure and blowthrough set
points
Differential pressure control is one of the more common meth-
ods to control a thermocompressor loop. Differential pressure

requirements to evacuate a given dryer can vary greatly. Machine
speed, dryer pressure and condensing load dictate the differential
requirement. Operators will typically set differential pressures to
the level that will prevent dryer flooding for all operating condi-
tions. The worst case differential pressure is excessive for most
operating conditions, resulting in higher motive steam flows and
wasted energy.
Another method that is used to control a thermocompres-
sor loop is to measure the blowthrough flow coming off of the
separator tank and vary the thermocompressor opening to control
the amount of blowthrough steam flow. Differential pressure var-
ies as the operating pressure and condensing load changes. The
blowthrough flow is controlled to a constant percentage of the
condensing load in the dryers. Controlling blowthrough steam
flow simulates the syphon requirement but it does not take into
account the minimal differential requirements of syphons. Blow-
through flow control requires very good condensate separation in
the separator tanks or the measurement will be inaccurate. New
high-efficiency separator tanks are often required to implement
blowthrough flow control.
The best practice for controlling dryer evacuation and mini-
mizing blowthrough is through managed differential control.
Algorithms are used to continuously calculate the required dif-
ferential pressure based on the syphon curves, operating pressure,
machine speed, and sheet-on status. Operators are not required to
establish the set points. The correct differential pressure is always
present and the amount of motive steam used is held to the mini-
mum necessary. Differential pressure is automatically reduced on
sheet breaks to prevent venting and steam waste.
Prevent over the top operation
The thermocompressor design must accommodate the operating
pressure range of the drying system. The throat diameter is based
on the low-pressure operating point and the nozzle diameter is
based on the high-pressure operating condition. This can lead to
the condition where there can be too much motive steam flow
when operating at low discharge pressures. Excessive motive
steam flow can lead to over the top operation. This condition is
also commonly referred to as choked flow, although this term
is misleading. Over the top occurs when the thermocompres-
sor no longer increases suction flow with increasing motive flow.
With traditional methods of control, operation in the over the
top region will result in the thermocompressor going wide open,
consuming maximum of motive steam. The control action will
open the vent valve once the thermocompressor has reached maxi-
mum. This will result in steam waste and is the most inefficient
pulpandpapercanada.com September/October 2010 Pulp & Paper Canada
peer reviewed T76
operating point for the system. Over the top operation must be
prevented.
Over the top operation can be eliminated with proper ther-
mocompressor sizing, utilizing the correct differential pressure
set point, and through DCS logic. Managed differential pressure
control ensures that the operators do not use excessive differential
set points that will force over the top operation. Knowing the
thermocompressor sizing and operating characteristics, the over
the top point can be calculated using algorithms programmed
into the DCS. The logic prevents the thermocompressor from
going into the over the top position based on the operating
conditions for the thermocompressor. This logic must be installed
with full understanding of individual thermocompressor curves.
SUMMARY
Many mills will be able reduce motive steam requirements by
optimizing thermocompressor operation. Reductions in motive
steam have the potential to substantially improve the energy
efficiency of the mill and the operation of the dryer drainage
system. It is important to match the thermocompressors to the
syphons. Properly designed syphons will minimize the load on the
thermocompressor. By taking advantage of new understanding of
flow dynamics within the thermocompressor, the geometry can
be optimized to minimize the amount of motive steam required.
Proper operation of the dryer drainage system is needed to achieve
continuous benefit. This can be accomplished by using an under-
standing of thermocompressor operation to improve the control
logic within the DCS.
Rsum: Le choix de thermocompresseurs de dimensions et caractristiques
adquates est souvent mal compris. Un thermocompresseur qui ne correspond
pas la conception du siphon est un problme courant dans lindustrie. Souvent,
des thermocompresseurs trop grands fonctionnent des pressions diffrenti-
elles plus leves que ce qui est requis. Cela explique que de nombreux thermo-
compresseurs consomment deux fois la quantit de vapeur motrice requise. On
observe ce phnomne sur les machines converties aux siphons stationnaires
sans optimisation du gabarit du thermocompresseur. Cet expos explore les
derniers dveloppements concernant la conception de thermocompresseurs
haute efficacit et leur intgration aux siphons et composantes dvacuation
de scheurs.
Keywords: THERMOCOMPRESSOR, HIGH-EFFICIENCY, OPTI-
MIZED GEOMETRY, SYPHONS, DRYER DRAINAGE SYSTEMS,
ENERGY EFFICIENCY, MOTIVE STEAM AND CFD ANALYSIS
Reference: SOUCY, M., TIMM, G.L. Thermocompressor Design and
Operation for High Efficiency, Pulp & Paper Canada, 111(5): T73-T76
(Sept/Oct 2010). Paper presented at the PAPTAC 94th Annual Meeting
in Montreal, February 5-7, 2008. Not to be reproduced without permission
of PAPTAC. Manuscript received November 29, 2007. Revised manuscript
approved for publication by the Review Panel June10, 2010.
37