JAPAN TAPPI JOURNALVol. 58, No.5
May 2004 Abstracts
Results of the FY 2003 Follow-up to JPA's Voluntary Action Plan and Report of Energy Situation in Pulp and Paper Industry in Japan
Japan Paper Association
The Japan Paper Association (JPA) has been actively working to save energy
since 1997 when it established its "Voluntary Action Plan
on Environmental Issues". JPA declared its policy of restraining
CO2 emissions as one of the actions: By 2010, reduce the unit of
fossil energy for paper products by 10% from that of 1990 level.
Since 1998, JPA has been following through on the actual results
of the unit of energy in the year, and has been publishing its
results compared with that in 1990 every year. The following
are the results for 2002 and the report of energy situation in
pulp and paper industry in Japan:
Unit of fossil energy in 2002 was smoothly reduced by 6.6% from
the level in 1990. However, the reduction in a unit of CO2 emissions
remained 2.3% because cost competitive coals have been largely
Paper and paperboard production increased by 9.8% in fiscal
2002 compared to that of 1990 level, whereas, increase in CO2
emissions remained at 7.3% from the 1990 level. A breakdown
of the 2.5% reduction from 9.8% to 7.3% shows that the pulp
and paper industry decreased by 2.2% and electric companies
contribute to reducing the remaining 0.3% (from effective generating
and transmission electricity).
According to 22 companies that replied to our questionnaires,
a total of 14.8 billion yen was invested in energy saving
measures for fiscal 2002 and the crude oil equivalent of energy
saved reached 290 thousand kiloliters per year. As far as
the estimation from 20 companies, 44.5 billion yen will be
invested and 254 thousand kiloliters per year will be saved
from 2002 onwards.
Energy-saving in Stock Preparation-Energy-saving by a Renewal to the Low No-load Horsepower Small Refiner-
Production Dept. Fuji Mill Nippon Paper Industries Co., Ltd.
Increasing the social demands to saving natural resources
and the environmental protection, the production of the recycled
paper has grown every year. The new plant of recycled pulp
operated at Fuji Mill in 2000, and it has corresponded to
the demand of recycled paper. While the production of products
with a high use ratio of recycled pulp are increasing, the
production of products with virgin pulp tend to decrease at
7,8M/C which manufacture colored paper, printing paper and
base paper of coated paper. Therefore the quantity of bleached
softwood, hardwood kraft pulp used for the paper machines
is decreasing. The capacity of the refiner and the pump for
bleached softwood kraft pulp in stock preparation becomes
excessive for the manufacturing condition with a little amount
of virgin pulp use. And it is in a situation that can't be
efficient power use. According to the situation of the pulp
flowing quantity and freeness target, we make a study of using
the small type of refiner for saving the energy.
Steam Saving in Paper Making Process-Steam Saving by Raising The Temperature of Pulp Slurry Using Hot Water and Recycling White Water from Paper Making Process-
Hachinohe Mill, Mitsubishi Paper Mills Ltd.
We have taken measures to reduce the energy consumption as
one of the environmental improvement plan based on ISO 14001
standard in the Hachinohe mill of the Mitsubishi Paper Mills,
Ltd. Company since 2001. And the target of the plan is to
reduce the ratio of steam and electricity consumption to the
paper production in the mill at the rate of 1 % every year.
Therefore we studied the actual conditions of processes
in the mill and made a plan to save fresh water from the
view point that cutting the heat loss by saving the warm
waste water sewage could lead to the saving of steam consumption
. Based on the plan, some measures have been carried out
In this paper we describe the way to make the best use
of hot water from a surface condenser in a black liquor
evaporation plant and the way to reduce the size of a sand
filter plant used for white water recovery from paper making
Energy Conservation of Screen
Kanto Mill (Ichikawa), Hokuetsu Paper Mills Ltd.
Kanto Mill(Ichikawa), Hokuetsu Paper Mills Ltd is the
factory which produces recycled paper, such as white board
paper, as a major product.
Taking advantage of conditions of location, and it is
working considering the used paper the cargo oh is collected
from a metropolitan area as main materials.
Although this used paper quality is becoming an aggravation
tendency in recent years,the quality level of the paper
called for is severe conversely.The equipment which
is greatly related to this quality level is screen equipment
before a materials tone part and a paper maker. I report
the example of two affairs about an improvement of a
quality side and change of power saving.
Efficiency Improvement of GAS IR System on #51 Paper Machine
Yasunori Arakawa and Yoshihiro Kudo
Nippon Daishowa Paperboard Yoshinaga Co., Ltd.
Energy-saving is a priority matter in paper and board
manufacturing process, which consumes a lot of energy.
Nippon Daishowa Paperboard Yoshinaga Co. Ltd.
aiming "Full Recycling mill" is focusing on it anytime and anywhere in the mill.
By replacement the burners of GAS IR system to the
energy-saving type on #51 which produces on-machine
coated board, we successfully achieved the saving
of energy. After the burners replacement, the drying
capacity increased by improving thermal transmission
efficiency which can expect us the saving of gas
consumption. However, it was not so easy to determine
the optimum gas output under the actual machine operation.
This paper shows how we obtained the actual energy
Reduction of Turbine Bypass Blow off Steam by Lowering the Minimum Load of No. 4 Boiler
Sobue Mill Oji Paperboard Co., Ltd.
No. 4 boiler (CFB; Circulating Fluidized Bed type)
at our plant started operations in 1995 after our
mill's fuel conversion program by taking the place
of No. 3 boiler (heavy oil fired boiler).
The maximum steam generation of No. 4 boiler was
120t/h and it has been in operation with steam
generation between 95 t/h to 120 t/h when all four
paper machines were in operation. The operation
of one large paper machine was reduced from 2002
and the operation of the machine stopped in January
2003 completely. The required steam generation
now ranges between 75 t/h and 96 t/h.
Since the low-load operation of No.4 boiler causes
a blockage in the combustion-air blowing nozzle
at the bottom, the minimum operation load has
been kept at 75 t/h. However, after the suspension
of the large paper machine operation, power consumption
at our mill when other machines are stopped for
service and maintenance purposes has gone down.
At a boiler load level of 75 t/h, power generation
exceeds power consumption to result in a back
feed to the power supply utility company. As a
result, turbine bypass operation (blow off steam
through turbine bypass valve) has become necessary.
In order to lower blow off steam by the turbine
bypass operation, boiler operation needs to be
further lowered and grid nozzle modification
was seriously considered.
Grid nozzle type was changed from "pig
tail" to "arrow head" to prevent
bed material from entering the nozzle hole, so
that nozzle blockage would not happen in low-load
Thanks to the grid nozzle modification, the
present minimum load is as low as 62 t/h and
the rate of nozzle clogging by calculation
stands at 23%, which means there is no problem.
The boiler has been in operation without turbine
The reduction in blow off steam amount to
the air as a result of low-load operation
for the boiler currently amounts to about
Boilers Energy Conservations
Iwakuni Mill, Nippon Paper Co., Ltd.
Power plant at Nippon Paper Iwakuni mill
has six boilers: one bark boiler, two oil
boilers and three recovery boilers (two of
them are standbys), and nine turbine-generators
(three of them are standbys). All electricity
required for the mill operation can be generated
from the power plant. Iwakuni mill has been
modifying the operation, promoting reuse of
exhaust heats, replacing some old equipment
with higher efficiency ones and constructing
new high efficiency plants as well in order
to increase energy efficiency at the power
plant.Energy saving is one of the very important
issues these days for mill operations, however
at the same time effective solutions to achieve
valid energy saving cannot be easily recognized.
Therefore the mill now is challenging to reduce
energy consumption with new activity, such
as introducing responsibility share on each
sections for the target.
This describes the result of the construction
of Magna Drive, which started operation
in Oct. 2003 and the plan for heat recovery
of an oil boiler with S-CON, which is scheduled
in 2004, as considerable solutions of energy
The Energy Saving of the Power Plant
Nomachi Mill, Chuetsu Pulp and Paper Co., Ltd.
While no one predicts the future of the
Japanese economy, each company is striving
for cost reduction in order to survive.
On the other hand, pulp and paper companies
are tackling to energy-saving as the most
important theme from the viewpoint of cost
reduction and global environmental problem.
At Chuetsu-Nomachi Mill, we have been proceeding
to energy-saving in each process, then both
the amount of generating steam and using
power have increased due to the operation
of No.1 coater machine (April, 1998) and
DIP facilities (October, 1999). After we
tackled to energy-saving in order to lower
the load of the mill, as a result, we were
able to attain the heat recovery by passing
the circulation water (about 70℃) of the
Desox equipment of No.4 boiler through the
pre-heater of 1st FDF and 2nd FDF, and also
we were able to raise the temperature of
the deionized water by change of the extraction
of the raw water going into the deionized
water equipment. The example of application
is introduced, as follows.
Automation 1n the WET End ProcessTM
Voith Paper Automation Japan Ltd.
The literal German translation for approach
flow system is Constant Part. It suggest
that all process variations in this area
directly upstream from the headbox have
to be reduced a minimum in order to produce
high quality paper.
Pressure, flow and consistency variations
can be reduced or eliminated by applying
state-of-art process technology. Much
of this is well known, proven technology.
However, recent developments with new
measuring instruments now permit the control
of chemical behavior of the stock suspension
of in the approach flow system.
By combining retention with these new
online measured parameters, and ensure
both high quality and consistency of
the finished paper.
Total retention, filler retention, charge
or gas content should be controlled
depending upon the furnish composition
of the grades that are produced.
It will be shown in this paper how
this can be integrated into the overall
control architecture of Quality Control
Management of the paper machine.
Various practical experiences outline
the high potential of these new control
Deoxygenate Equipment for Boiler Water by Nitrogen Gas
Toyobo Engineering Co., Ltd., Environment Solution Division
Our Deoxygenate equipment for boiler
water spends less Nitrogen Gas than
other equipment. It may be about 1/3
quantity of old equipment. Our Deoxygenate
equipment use special technology to
make fine bubble. It is very effective
for Deoxygenate from boiler water
by Nitrogen Gas.
If you use chemicals for deoxygenate
boiler water. Our Deoxygenate equipment
for boiler water saves large money.
Although this equipment is a condensation
filter, with the existing technology
which adds a condensation agent
in the water for processing, it
is equipment condensed only by
there being nothing, making into
the shape of complications or a
pellet substances, such as water
magnesium oxide processed specially,
and passing processing water to
This equipment is equipment which
converts an established waste
incinerator so that the dioxin
regulating method may be suited.
Pulp Bale Breaker-Pre-shredding
for Stabilized Operations and
Industrial Machinery Department.NIPPON SHARYO, LTD.
Bale Breaker : SSI's slow-speed,
high-torque shredders offer important
solutions to meet your product
reclamation and pre-processing
needs. Shredding bales prior to
pulping enables the hydropulper
to be meter-feed a steady stream
of consistently sized material.
This improves and accelerates
the blending process, resulting
in increased capacity and efficiency
(through lowered hydropulper energy
and maintenance cost).Users have
also reported reduced chemical
usage and costs (because of accelerated
material breakdown) as well as
an improved end product.
Automatic Pallet fork transport system-Automatic Pallet-Robot-
Maruishi iron works Co., Ltd.
Maruishi manufactures and sells
Pallet Shrink- Packing Machine
and Pallet Dust Remover and so
on, which have been developed
under a technical tie-up between
ourselves and REKER in Germany
We would like you to introduce
the following Pallet-Robot.
Pallet Robot is the full automatic
fork style of skid transport
system. The characteristic is
. Fully automatic working operation.
. No deforming sheets during pick-up and transport.
. Pick-up of a single skid out of a complete set.
. Transport of skids in any direction, also free turning of robot.(available for any kind of sheeter)
. One pallet robot can handle several sheeters, capacities up to 80 skids/hour.
(depending on layout)
We would produce results
such as we delivered more
than 5 Pallet-Robots to
Europe and one Pallet Robot
to Japan in 2001.
Study on the Effect of
Testing Conditions on
Compressive Strength and
Bursting Strength of Board
Masataka Ito, Hideki Izumi＊＊ and Yoshio Yoshida
Material Analysis Center, R & D Div., Oji Paper Co., Ltd.
JIS P 3902 "Linerboards" specifies
the compressive strength
by ring crush tester and
the bursting strength by
Mullen high pressure bursting
tester. The both strength
tests have comparatively
large variance on the test
results among the testers.
In this report, we studied
the effect of testing conditions
on the both strengths of
On the compressive strength
test, the parallelism
of the upper and lower
platens, the position
of test piece holder on
the ring crush tester,
the position of test piece
seam in the test piece
holder, the kinds of die
cutters and the kinds
of ring crush testers
had effect on the results.
On the bursting strength
test, the pressure at
10mm bulge height of
diaphragm and the kinds
of bursting testers had
effect on the results.
Keywords: testing conditions, compressive strength, bursting strength, board, ring crush tester,high pressure bursting tester