|Results of the Fy 2005 follow-up
to JPA's Voluntary Action Plan and Report of Energy Situation in the
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 fossil
energy consumption per product unit for paper products by 13% from
of 1990 level.
Since FY1990, 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. The following are the results for FY2004
and reports of energy situation in the pulp and paper industry in
The survey also reported on energy consumption, CO2 emissions and
the position of the pulp and paper industry in Japan as related information.
Reducing Distribution Loss by Control of Reactive Power
Electric and Instrument Department, Yufutsu Mill,
Nippon Paper Industries Co., Ltd.
Useless energy has been consumed by the inefficiency operation
of the departure supply of power distribution equipment in the
Yufutsu Mill. The chance to aim the inefficiency operation was
to have discovered that receipt point was LEAD10%. Afterwards,
No.1 Generator was operating by the Power-Factor limitation control
since the departure supply of power distribution flow was investigated,
and it turned out that the outflow invalidity Reactive-Power in
the receipt point was a surplus. The operation of 100% or more
comes to cause the losses such as the generators and transformers
though operating it with Power-Factor 100% in the belt because
of the Power-Factor discount system in daytime is an ideal in Power-Factor
of the receipt point.
Therefore, the problem that the departure supply of power distribution
equipment holds from an electric viewpoint is dug up, and it introduces "Reducing
distribution loss by control of Reactive Power" executed in
November, 2005 in this announcement.
HITACHI High-Voltage Motor Drive Energy Conservation Service-New
Information & Control Systems Div. Hitachi, Ltd.
The industrial world in Japan including the pulp and paper has
worked on conservation of energy for a long term after the oil
crisis. As a result, it almost comes to the region in the limit
about energy conservation by past methods.
As for the user, the energy conservation was not enforceable because
there was an economical restriction though the necessity was recognized.
In such a circumstance. We inspired a new business model based
on the user's needs.
As the mechanism of concrete service, the user is do not need
an initial cost to introduce the inverter, and, as a result, pays
the service fee from a part ob the achieved advantage. It is a
scheme to which our company bears a part of risk of the amount
of conservation of energy that the user owes. We named this scheme "HDRIVE(R)"
After it had applied for the patent, the number of the total service
exceeded 50. This time, we would like to introduces the detail
Operational Experience of the Recycle Boiler
Hachinohe Mill, Mitsubishi Paper Mills Limited
The promotion of countermeasures for global environmental issues
is one of the most important management strategies of Mitsubishi
Paper Mills, Ltd. The Mitsubishi Paper Mills Environmental Charter
lists "Reducing overall CO2 emissions" as the first item
of it's action plan. Before the end of fiscal 2005, our target
is to reduce CO2 emissions by 20% of 1999 levels.
To meet this target we installed a waste boiler at the Hachinohe
mill in July 2004. Instead of burning fossil fuel, we used waste
tires, waste wood and paper sludge. The operation of this waste
boiler significantly reduced CO2 emissions and energy consumption.
Energy Saving on Cold-water Equipment of Chlorine Dioxide Generation
Ebetsu Mill, Oji Specialty Paper Co., Ltd.
As the environmental issues on dioxin have drawn bigger attention
recently in pulp & paper industry, we have been required to
adopt the new bleaching method (ECF, TCF etc) which don't use chlorine.
At Ebetsu mill of OJI SPECIALTY PAPER, we converted the bleaching
method into ECF in 2003. Simultaneously, chlorine dioxide generation
system was also renewed, altering main bleaching chemical from
chlorine to chlorine dioxide.
In the process of generating chlorine dioxide, gas is generated
first, then transformed into liquid by being absorbed in cold water.
As the conventional steam ejector cooling system requires much
energy to cool down the water, we have changed to "CHILLER and
Thermo-siphon system", the cold-medium and compressor system, making
energy consumption less than before.
Energy Saving at the Power Plant
Mishima Mill, Daio Paper Corporation
The power plant at Mishima Mill consists of 18 boilers and 14
turbines with a total rated output of 531 MW. It supplies all electricity
used at the mill and the surplus is sold to the market.
After the 1970s oil crisis, Daio Paper converted from heavy oil
to coal. Since 1985 we have also made the power plant more efficient
by installing more boilers and turbines that create higher steam
temperatures and operate at higher pressures. In addition, we have
increased utilization of recycled pulp, which has a low energy
consumption rate. As a result, we accomplished a 12% reduction
in fossil fuel energy consumption, as measured tonnage of paper
produced, in 2004 compared with that of 1990.
In a situation where we are striving to help prevent global warming,
we set a voluntary target of a 20% reduction in carbon dioxide
emission per tonnage by 2010 compared with that of 1990. We are
making further efforts in the area of energy saving and conversion
of fuel to achieve that target and reduce our energy costs.
Details of energy saving procedures at Mishima Mill are discussed
in the following section.
Technical Trend of Mechanical Seals for Pulp & Paper Plants
- The Cartridge Outside Mounted Mechanical Seal -
EAGLE INDUSTRY Co., Ltd., Customer Service 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. Accordingly, ease of maintenance
and foolproof design are getting of the essence. Anther interest
is interchangeability that cuts down spare needs. A new outside
mounted cartridge seal having such features is presented.
Efficient Mixing of Papermaking Chemicals with TrumpJet™ System
- Without Any Fresh Water -
Wetend Technologies Ltd.
A new innovation, developed TrumpJet™ Technology is used to inject
papermaking chemicals efficiently into headbox stock. The mixing
is greatly improved and consumption of chemical is reduced. The
injection liquid is circulated headbox stock or white water instead
of fresh water. Several installations operate with good results
and improved quality of production.
Energy Saving for Refiner
― The Latest Refining Technology for Saving Energy ―
Aikawa iron Works Co., Ltd.
The saving energy is a worldwide request and one of the most important
subjects in Pulp & Paper industry. This paper reports how to
improve energy saving for the existing refiner and the latest development
for refiner, which is called as "ADC" Aikawa Double ConiFiner.
Operational Results of Neutral Deinking for Old Newsprint and Potential
Application in Asia-Pacific Recycle Mills
Jim Merza, R. Daniel Haynes
Eka Chemicals Inc., USA
Johan Allen and Christine Chezick
Bowater Canadian Forest Products Inc.
Tembec Paper Group, Pine Falls Operations
Tembec - Spruce Falls Operations
Kozo Ibara and Yoshikazu Sonehara
Eka Chemicals K.K.
Earlier work has shown the success of a 10 day sulphite based
neutral deinking trial. The neutral deinking process has now been
introduced into several recycle mills. Evaluation of free ink content
and Lab scale studies showing the potential of this technology
for the Asia-Pacific Region.
The objective of this paper is to document similarity and changes
in plant operations by a survey of the recycle plant process and
comparison of mill data before and after conversion. The mill survey
includes information on pH, brightness, ink impairing brightness
measured by ERIC, ink removal efficiency, water brightness of grey
water, ash content, and solids loss at flotation. In addition,
a review of each mill's operational changes in ERIC and ISO Brightness
values is made after about 1 year of neutral deinking.
The results found all three mills able to match or to have a similar
ERIC value after flotation despite a higher ink fragmentation going
into flotation. Two of the three mills were able to reach or exceed
their target brightness based on average mill data. The third mill
averaged within one point of the target brightness and had a lower
final ERIC value. Based on these three mills it can be concluded
that sulphite based neutral pulper chemistry is able to operate
continuously under the varied mill operating conditions typically
experienced in the industry.
New Concept, High Efficiency Turbo Blower
Hiroyuki Hosoya and Naoki Tani
ITOCHU SANKI CORPORATION
Korean company, Kturbo Inc, has developed high efficiency Turbo
Blower (TB) series. TB series are the perfect turbo blowers with
semi-permanent foil air bearings, high speed motor. They can save
more than 30% of energy consumption compared with roots blowers.
TB series are oil-free and noise-free turbo blowers which are directly
driven by permanent magnet high speed motors supported by hydrodynamic
air foil bearings. Direct drive of the rotating shaft without mechanical
contact reduces the noise level up to 85dB@1m, and total product
weight and volume by 1/3 and eliminates the construction of basement
for vibration isolation.
Kturbo blowers can be used for waste water treatment, conveying
system of cement factory, process air supply for paper and fiber
factories, etc. In particular, they are the best solution for food/beverage
and cement factories which need perfectly clean air.
Treatment of Waste Water from a Paper Manufactory by Magnetic Separation
-Production of Reused Water-
Koushi Fukunishi, Hiroshi Ida and Yoshiyuki Kakihara
MS Engineerings (Futaba Shouji Co., Ohsaka Chemical Izuo Labo.)
Purification of waste water from a paper factory was attempted
by super-conductive high gradient magnetic separation (HGMS)
in a pilot-plant scale of 2000 ton a day. The plant of 2000
ton/day drainage consists of three main tanks, ie., a reaction
tank, a separation tank (thickener), and a magnetic-separation
tank. In the reaction tank suspended and resolved substances
in waste water were magnetized with magnetite particles and
aluminum sulfate as coagulant (magnetic seeding). The resulting
heavy magnetic flock precipitated smoothly in the separation
tank and the remained magnetic flocks were captured by magnetic
filters in the magnetic-separation tank.
The original COD (Mn) values (chemical oxygen demand) of waste water from a
paper mill were in the range of 60〜200 mg/L. The COD values reduced to 30〜60mg/L
the sedimentation process and by the following magnetic-separation process. Their
transparency was also raised prominently (turbidity=5〜10 NTU).
In the magnetic-separation part, a super-conductive magnet of 3 Tesla was set,
and a filter container with 400mm-bore in diameter was filled with magnetic filters.
Floating magnetic flocks were trapped at the magnetic filters in high efficiency
of more than 98%. An exchange and a washing system of the mud filters were developed
by building up a continuous push out system. A production test of 2000 ton a
day gave reasonable results with a continuous automatic operation.
A Report on International Symposium on Wood Science and Technologies
Tokyo University of Agriculture and Technology
The University of Tokyo
International Symposium on Wood Science and Technologies (IAWPS2005)
was held in Yokohama on November 27-30, 2005 under co-organization
of The Japan Wood Research Society (JWRS) and The International
Association of Wood Products Societies (IAWPS). Total participants
were more than 500 including 149 from outside of Japan. 395
papers including 4 plenary lectures, 163 oral presentations
and 228 poster presentations were presented at 10 sessions.
33 papers including 12 oral presentations dealt with pulp and
paper science and technology.
Study on the Water Retention of Coating Color by Sandas Method
(Pressurized Filtration) Suggests that Using a Filter of 0.4m
Pore Size is More Reliable to Predict Performance of Color in Coating
Operation and Resultant Product Quality
Corporate Research Center, Mitsubishi Paper Mills Limited
AA-GWR water retention meter is a very popular and useful test method for
water reduction of pigment slurries. It is based on pressure filtration of
coating colors under an air pressure and suitable for estimating a penetration
phenomenon of a water phase from a coating color into a base paper under a
practical coating process. In this study various plastic filters with specific
pore sizes (5.0 to 0.05 m) were used for filtration of colors on AA-GWR.
The dewatering amount of the colors was compared to the runnability of the
color on a pilot blade coater. Some factors such as finer pigments and nonionic
materials made an amount of filtrated materials increase much. And the reasonable
correlativity between the runnability of coater and the dewatering amount
was spoiled. The unreasonable water retention values on 5.0 m pore size filter
were found on the evaluation of specific coating colors which contained nonionic
water soluble binders such as Polyvinylalcohol (PVA) and Hydroxyethyl starch
(HES) and finer pigments of TiO2 and CaCO3. These materials were not trapped
by the filter and reached the test paper. However it was found that the 0.4m
pore size filter was possible to be used to measure reasonable penetration
of water phase of such colors and to estimate the runnability on a coater.
Additionally water retention values measured by 5.0 and 0.4 m for common
coating colors were almost the same.
Keywords: AA-GWR, water retention, coating color, blade coater, filtration