JAPAN TAPPI JOURNALVol.
June 2004 Abstracts
Heat Recovery from the Waste Water
Kushiro mill, Oji Paper Co., Ltd., Oji Engineering Kushiro Dept.
Kushiro Mill produces 700 thousand tons pｅr year of newsprint, coated paper,
mechanical "paper and linerboard by four paper machines with pulp plants
(KP, RGP, DIP and OCC). In compliance with social requirements on environmental
protection, Kushiro mill works for the increase in the wastepaper (DIP) utilization
rate, according to environmental of Oji paper. And the expansion of DIP plant
was completed in 2003.
As known, large quantities of warm water is necessary with DIP production process
for washing of the ink particles which deinked from the wastepaper. The location
of our mill is the cold districts, so it is necessary to use many amounts of
steam at the pulp and the paper machine process.
We had to make warm water by using a new source of heat, because the warm water
from the condencing turbine and machine waste heat was already consumed in the
mill. In this report, I describe the Heat Recovery from the new source which
is waste water, and the saving energy.
Improvement Example to Reduce Water Content of Paper Sludge
T. Hosaka, T. Kato and K. Kobayashi
Kushiro Mill, Nippon Paper Industries Co., Ltd.
We have worked the sludge boiler that utilizes the paper sludge (PS) as the
main fuel in 1992.And we are advancing the application of the renewable energy
that is substituted to fossil energy.
In recent years, with advancement of the waste paper utilization, the materials
for the paper making of our mill changed the de-inked pulp from the mechanical
pulp. Also the amount of PS increased with utilization of DIP, the ratio of PS
in the sludge boiler reached the point of approximately 70%.
On the one hand, the ash of mill draining rises due to the utilization of the
magazine waste paper, accordingly energy efficiency of the sludge boiler deteriorates.
This time, we assured equipment remodeling and PS-fluke stabilization in PS
dehydration process. As a result, PS percentage of water content decreased, as
for us, could improve PS combustion energy.
Energy Saving by Adopting the High Efficiency Steam Turbine
Kenji Okamoto and Toshiaki Hatakeyama
Saga Mill, Oji Paperboard Co., Ltd.
The Saga mill No.2 steam turbine of our company has operated for 34 years and
totally 12.0% efficiency decline at maximum output operation have been recognized
which consists of deterioration in the turbine, pressure loss at the reconstructed
extraction point and etc.
By replacing the turbine rotor, diaphragm and nozzle to the high efficiency
type which causes 14.85% efficiency improvement at maximum output operation and
by shifting the operation mode from the condensing power generation and purchasing
power to the extracting power generation, we have achieved both energy saving
and cost cut.
Energy Saving with Atmospheric Steam Reduction
Yatsushiro Mill, Nippon Paper Industries Co., Ltd.
At yatsushiro mill, coal fired power plant has been operated successfully since
1993and it contributes to the cost reduction of Yatsushiro mill.
In early 1998, installation of the world-class N2 newsprint machine was completed,
adding, substantially to our international competitiveness as a paper mill.
N 2 newsprint machine produces a haif of total production of Yatsushiro mill.
On that account, when N2 paper machine stopped, we would stabilize boiler load
with the releasing of atmospheric steam to decrease a large amount of the boiler
Power plant operators in a small group activity made a study of the stop timing
of a coal mill.
In this report, we describe the results of a small group activity successful
to archive the reducing of the atmospheric steam by a large marginies.
Activities of Energy Subcommittee at Niigata Mill, Hokuetsu Paper Mills, LTD.
Hokuetsu Paper Mills, LTD., Niigata Mill Technical Section
The annual consumption of Hokuetsu paper Mills, LTD. Niigata Mill is approximately
5,000kL per year, converted into heavy oil. The activity of main energy saving
has been started up since 1980 and now operating division, engineering division,
and administrating division cooperate in the energy saving by means of the Energy
Save Meeting. The target of the energy saving is 1% reduction of the annual energy
consumption for purchase. The energy saving result in last three years was 9,200kL,
and attained to the target. According to the classification of the energy saving
by pattern, 75% of the energy saving case are easily case that stop surplus instruments
by improvement the operating standard or changing flow. The recent main energy
saving case in Niigata Mill are changing impellers of medium consistency pumps
and examinations applying temporarily inverter unit for the preset motors.
The Examples of Energy-Saving in Oji Kure
Oji Engineering Co., Ltd., Kure Mill
Oji Paper has set itself the target of reducing its purchases of energy in unit
terms by 2010 by 10% compared with 1990, and promoting activity in the whole
company. Since 2000 when Oji Kure mill obtained environment control international
standard (ISO 14001)certification, we are performing energy-saving activities
in the program of the environmental management system (EMS).
I introduce some examples characteristic as a pulp-paper mill, and the situation
in the Kure mill from the latest energy-saving result.
The Improvement in an Energy Original Unit and the Energy-Saving Example in a
Futatuka Factory-Transition and Consideration of Energy and CO2 Original Unit-
Futatuka factory, Chuetsu Pulp & Paper Co., Ltd.
Chuetsu Pulp Futatuka Mill is in Takaoka-City of Toyama-Pref., which is located
in the middle of Kanto economic region and Kansai economic region, supplies the
products to the customers in both Tokyo and local area. The mill produces 180,000t/y
of newsprints mainly.
This time, the main theme of Energy-Savings Seminar is “Returning to the starting
point : an example of energy saving of the mill”, and our theme is “Transition
of energy consumption per unit and Example of energy-saving” concerning about
the change of fossil fuel consumption per unit from 1990 to 2002.
According to the data book 2003 investigated by Japan Technical Association
of Pulp and Paper Industry, both the purchase energy and CO2 consumption per
unit of Futatuka mill has been descending from the peak of 1993. Of course it
depends on the increase of production simply judging from the index of production
level, although, it is considered that the implementation of energy saving and
the improvement of efficiency has contributed mostly. I try to make the important
factor clear with adding consideration, and also the following is a successful
example of energy saving implemented.
The Recent Activity of Energy Conservation at the Kasugai Mill
Kasugai mill, Oji Paper Co., Ltd.
Ojipaper Co., Ltd.’s Kasugai mill started operating in 1952. Recently the mill
demands an ever increasing amount of electricity and steam. This is caused by
greater production of used paper products; use of ECF sequencing in bleaching
wood pulp; and increased electricity demands if new high-technology machinery.
In this paper the composition, usage and conservation of energy in the Kasugai
mill are reported.
We classified the energy conservation activity, which was carried out from1998
to 2002 (fiscal years), into 10 main themes and 6 sub-themes. Each amount of
energy conservation was converted to the crude-oil equivalent. It turns out that
conservation of about 7000 KLs and22,900 CO2 tons has been attained by the end
of 2002. The energy conservation effect is large and furthermore we’re going
to introduce seven examples whose technique could be applied to elsewhere.
Furthermore, in order to attain the independence action plan of the paper and
pulp industry titled; "Cutting down a purchase energy field unit ratio per
product for 10% compared to 1990, by 2010”, we set up the numerical target which
should be attained by the end of the 2008 fiscal year.
Energy Curtailment at Mishima Mill, Daio Paper
Mishima Mill, Daio Paper Co., Ltd.
The power generating facility at Mishima Mill has a 531 MW standard output and
consists of 18 power boilers and 14 turbines. It supplies all the electricity
used here and the surplus electricity is sold to the market.
After the oil crises Daio Paper shifted fuel dependence from heavy oil toward
coal. Since 1985 we have also attempted to be more efficient in the power plant
by raising the pressure and the temperature in the boilers and installing new
turbines, and increased production of recycled pulp which has a low energy consumption
In 2002, we accomplished a 15% reduction in fossil fuel energy consumption/paper
tonnage compared to 1990.
However, facing the reality where reduction in carbon dioxide emission is required
to meet the demands of global warming prevention, we are making independent efforts
in the area of energy curtailment and fuel, with the aim of more than a 10% reduction
by 2010 compared with 1990 level.
Energy curtailment cases in Mishima Mill are discussed in the following section.
BTF Dilution Headbox System- Comparison Data between before and after BTF Retrofit
Design Section, Kawanoe Zoki CO., Ltd.
We will give a presentation on how much product quality can be expected to improve
by retrofitting the BTF system to an existing headbox, based on machine startup
data in the USA and Canada.
Since many roll type headboxs are still in operation in Japan, we will also
introduce data of two kinds of roll type headboxes this time.
The first system in Japan started up in July this year. We are sure we will
be able to talk about an interesting result of installation in the near future.
Developments for High-Speed, High-Efficiency &Stable Paper Coating
Mitsubishi Heavy Industries, LTD., Hiroshima R&D Center
Mitsubishi Heavy Industries, LTD., Paper & Printing Machinery Division
Mitsubishi Pilot Coater has been rebuilt to improve high-speed coating performance
and to realize the simultaneous both side film coating． This rebuild enables
our new developments for high- speed, high-efficiency and stable coating technology
and customer's coating trials for verifying the performance of coater or coating
The efficiency of the state of the art "MJ-Sizer" for misting reduction
and web stabilization, and the novel "Ejector & Steam substitution System" for
high-speed free jet type applicator for prevention of air entrainment at the
interface between coating color jet and base paper surface, have been verified
by using this high-speed pilot coater． Several fundamental studies on film coating,
blade coating and curtain coating are also being carried out to realize the high-speed,
high-efficiency and stable coating operation．
In this report, we present our new high-speed pilot coater and some new technologies
for high-speed coating．
Technical Trend of Mechanical Seals for Pulp & Paper Plants−Mechanical Seal
Technology meeting Environmental Preservation−
Eagle Industry Co. Ltd., Seal Engineering Dept.
A mechanical seal prevents or reduces outboard leakage of toxic chemicals and
saves energy and resources. Therefore, it can be deemed as one of the important
environmental instruments that is directly and indirectly contributing environmental
preservation. In a pulp & paper plant, many numbers of varieties of pumps
are utilized such as water pumps, pulp pumps and chemical pumps all through the
production processes from digesting to painting. In recent years, a mechanical
seal has been selected as a standard sealing device for such pumps to pursue
economical advantages by save energy, save resource and save maintenance points
of view and is greatly contributing environmental preservation. I will make brief
explanation of the mechanical seals first and then show you examples of environmental
issues and contributions achieved by the mechanical seals.
Improvement of Hardwood Pulp Yield in Continuous Kraft Cooking and Estimation
of Pulp Yields (Part I)−Optimal Conditions for Yield Increase and Estimation
Using Carbohydrate Analysis−
Tomoya Yokoyama and Hiroshi Ohi
Institute of Agricultural and Forest Engineering, University of Tsukuba
Technical and Development Division, Hokuetsu Paper Mills, Ltd.
The optimal conditions of isothermal cooking (ITC) for yield improvement of
hardwood kraft pulp were established using Acacia mearnsii wood in a laboratory.
The addition of both 1% sulfur and 0.04% soluble anthraquinone on wood gave an
about 4.5-5% higher pulp yield at a kappa number of about 17. The highest yield
was obtained when 70% of total active alkali and 100% of both PS and AQ were
added at the beginning, and successively, black liquor was exchanged with fresh
white liquor containing the remaining 30% of total active alkali just after the
cooking temperature reached 135°C. A linear correlation was observed between
pulp yields and ratios of xylose to glucose (X/G ratios), liberated from the
pulps by an acid hydrolysis. This result means that a pulp yield can be estimated
by knowing an X/G ratio of the pulp. However, it was indicated that the linear
correlation for Acacia mearnsii can not be applied to cooking of different wood
Keywords: kraft cooking, isothermal cooking, polysulfide, anthraquinone, carbohydrate,