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JAPAN TAPPI JOURNAL June 2008


Vol.62 No.6 Abstracts


Results of the Fiscal Year 2007 Follow-up to JPA's Voluntary Action Plan and Report of Energy Situation in the Pulp and Paper Industry in Japan

Osamu Inada
Japan Paper Association

Abstract
  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 fiscal year 2010, reduce fossil energy consumption per product unit for paper products by 13% from that of fiscal year1990 level, CO2 emission per product unit for paper products by 10%. By 2010, the in-and-outside country afforestation area owned or managed expand to 600,000 ha.
  Since fiscal year 1990, 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 fiscal year 1990. This report shows the results for fiscal year 2006 and the change of the targets in Action Plan as well as energy consumption, CO2 emissions and the position of the pulp and paper industry in Japan, and information related Kyoto Protocol.


The Energy Conservation Measure for Small Steam System by Using Technology of Screw Compressor

Yasuo Fukushima
Shinsho Corporation

Abstract
  The method to generate electricity by using the decompression heat head of steam has been used in the industrial world from of old as an ideal energy form of use.
However, this is to be able to say to the large scale systems for a paper manufacture industry and a chemical industry, etc.Cand diffusion has decreased extremely additionally in a lot of small-scale steam systems. The reason is that a small steam turbine did not exist.
  The Kobe Steel, Ltd. group was made the best use of the technology of the screw compressor accumulated over many years and succeeded in the development of the small capacity steam generator. It is expected that it is possible to contribute to the conservation of energy of the steam system of all fields by being able to generate electricity by the decompression heat head even in the area of the small flowing boiler said to be impossible so far.


Saving Energy for RGP Process at Iwanuma Mill

Yoshifumi Chiba
Iwanuma Mill, Nippon Paper Industries Co., Ltd.

Abstract
  Based on Nippon paper Group's Charter on the Environment, Iwanuma Mill promotes saving energy and developing environmentally friendly technologies and products to cope with measures for global warming.
  Iwanuma Mill produces 55,000t of High-quality newsprint and coated paper per month. The mill is equipped with four paper machines and one coater. The pulps produced at this mill are DIP, KP (LBKP/NBKP switching) and RGP (Refining-Ground wood-Pulp) and supplies almost all production.
  Because RGP process needs an enormous power, the reduction of energy consumption is essential. However our RGP process has not been renovated since 1963. Therefore during 2002 to 2006 three major reconstructions had been carried out to renew obsolete equipment and to save energy.
  As a result of these improvements, specific energy has been greatly reduced and the calculated amount of CO2 gas discharge reduced about 26,000t per year.
  This report shows a series of examples in energy-saving achieved by the reconstruction of RGP process, including part of the work previously reported.


High Efficiency FAN

Hidemitsu Nagai and Yoshimasa Watanabe
Engineering Div., TERAL INC.

Abstract
  For the global warming prevention, it is necessary to reduce the CO2 exhaust in the world scale.
  Blowers are the main power consumption equipments such as the paper mill, ironworks, and the cement factories. The electric power and CO2 can be greatly reduced by making the highly effective blower.
  Our company succeeded in the development of the highly effective blower that is the highest level in the industry.
  This time, CTF3-OB/MOB turbofan (high-pressure type) and CMF3-OB mild fan (Middle-pressure type) blower series were turned on to the market. It introduces the domination of a highly effective blower with the episode of the development process.


Energy Saving by the High Efficiency Refiner Introduction

Kentaro Miyamoto
Osaka Mill, Oji Paperboard Co., Ltd.

Abstract
  The rise of the recent crude oil price causes the rise of the energy cost for paper manufacture industry with a lot of energy. On this account, the profit has begun to decrease greatly in each paper manufacturer. In addition, we must hurry energy saving to prevent global warming by the use of the fossil fuel. In our company, it is a very important problem to decrease energy consumption.
  In wastepaper pulp process of manufacture, it is the facilities that pulper, screen and refiner use a lot of energy. We carried out energy saving such as the introduction of energy saving facilities, the simplification of the flow, stop of the existing facilities and the intermittent driving in this factory. Besides, we introduced conical type refiner (Triconic Refiner/ Satomi Seisakusho Co., Ltd. - Pilao company) of the energy saving facilities. We introduce this energy saving effect.


A Thermal Insulation Reinforcement Example by the Vacuum Insulation Material Installation to the Coating Machine Dryer

Eishi Koizumi
Kanzaki Division, Oji Engineering Co., Ltd.

Abstract
  The Kanzaki division on Oji Engineering Co., Ltd. is located in Amagasaki city, Hyogo Prefecture, and it is on the premises of Kanzaki mill, Oji Paper Co., Ltd. Amagasaki city is on the Osaka bay site, where Kanzaki river pours into and it is the tributary of Yodo river that the fountainhead is originated in Biwako.
  The main job in our mill is to do the series of commissions that are from developments of basic plan to material procurements, constructions and the test runs also. Not only we should own the responsibility as the member in Oji Paper Co., Ltd. but having with the accumulated technology and/or the know-how in the constructions or the operations experiences from paper, pulp plants, motivic, environmental equipments, we, Oji Engineering Co., Ltd. have been extending our business to the leading multi-engineering company.
  This time, Oji Engineering Co., Ltd. introduce an example, the improved insulation dryer that is "Vacuum insulation material" is applied instead of regular insulation materials.


Improvement on Operation of Paper Machine by Means of OnV FlocSpotter

Hideomi Uchikawa
Voith IHI Paper Technology Co., Ltd.
Voith Paper Automation Japan Co., Ltd.
Armin Bauer
Voith Paper Automation GmbH & Co. KG

Abstract
  For papermakers, formation is important: it is a measure of sheet uniformity and relates to other paper quality parameters, like printability. Reel sensors, however, provide only insufficient information about the formation of multi-layer products, such as board. With this in mind, Voith has built a formation sensor operating in the wire section. Now, the formation of every ply in a multi-layer machine can be measured on-line and thus no longer remains obscure. The sensor is a tool that makes machine optimisations and troubleshooting much easier. It also opens up the possibility to save raw materials, process chemicals or energy while keeping formation for a given grade at a desired quality level. The formation sensor is based on digital camera technology. Its housing is built for permanent operation in the harsh environment of the wire section and requires almost no maintenance. Formation is calculated according to established methods and, more than this, classified in a way similar to human perception.


Application of Eco-friendly Water Based Emulsion Polymer

Jiayi Chen, Tomonari Katou, Sakae Futaki, Yuko Okusa and Keiji Suruga
Kurita Water Industries Ltd.

Abstract
  An eco-friendly water based emulsion polymer (W/W) was newly developed for papermaking process application. It is oil free and elemental salt free. The W/W product contents two compounds, one is low molecular weight polymer with high charge density, another is higher molecular weight polymer with lower charge density. Each of them could be changed its charge density and molecular weight. Two product lines are developed, the Fixage 600s are fixative agents, and the Hi-form 100s are drainage retention aids. The Fixage 600s show excellent fixing effect comparing with the Epi-chlorohydrine polymer. The Hi-form is a good retention aid. A machine trial showed that the first pass ash retention was improved 8 point without any formation down, and machine speed is increased 5%.


Development of New Pulping Method under Near-Neutral pH Condition Using Hydrogen Peroxide and Metal Complex Catalyst

Ryugo Shimoyama, Yuji Kunisada and Takashi Oka
Development Dept. 1CNissin Kagaku Kenkyusho Co., Ltd.

Abstract
  Hydrogen peroxide is an oxidative bleaching agent which is quite ecological, relatively economic and easy to use. However, its oxidative reactivity is much inferior to chlorine-based bleaching agents. Therefore, many studies have been reported on the activation of hydrogen peroxide by bleaching activators or metal complex catalysts to enhance its reactivity.
  We tried to apply this catalytic oxidation method to the deinking process to develop a new pulping method. As using a manganese complex catalyst for repulping old papers, the residual ink area was reduced enough to apply this method to low alkaline deinking process.
  In this report, we described the development of the deinking catalyst for DIP process and the solution of the stickies problem and its ink elimination mechanism.


Use of High Aspect Ratio Kaolin as a Tool to Control the Strength and Stiffness Properties of Coated Papers

John C. Husband
Pigments for Paper Group, Imerys Minerals Ltd.

Abstract
  The mechanical properties of paper coating layers are very important in converting and printing operations.  These include stiffness,@resistance to fold cracking, dusting and pick resistance.  In this study we have prepared unsupported coating layers and measured the in-plane and z-direction tensile properties as a function of the kaolin particle aspect ratio.@We have then compared the results to pilot coated papers containing the same clays.
  A coating layer containing high aspect ratio fine clay has an elastic modulus 7-8 times higher than one containing only ground calcium carbonate. With appropriate binder systems, these layers can have a modulus which is of the same magnitude as that of basepaper. We show that this improvement can be used with advantage to increase stiffness or decrease basis weight whilst maintaining stiffness, in order to save costs. The in-plane tensile strength of the coating layers also increases with high aspect ratio particles.
  Kaolin - based coating layers differ from those based on ground calcium carbonate because of the platy nature of the clay particles. This gives different mechanical properties in the x-y and z-direction. This is shown by studies of the tensile strength of unsupported clay coatings. The coatings are stronger in the x-y direction than in the z-direction, with the magnitude of the strength difference depending on the aspect ratio of the kaolin plates. Ground calcium carbonate coating layers have the same strength in all directions.


PVDF Emblem/Micro Filter Water Recycling System

Makoto Matsushita
KGK Engineering Corp.
Yoshiharu Numata
Hitachi Plant KIDEN Engineering Co., Ltd.

Abstract
  Generally, there is huge volume of water used in Pulp & Paper Manufacturing Process. Besides, lack of water often happens in the summer season, which causes deterioration of water quality and shortening of Mill operation. Pulp & Paper Mills are required to counter-move to consider reduction of water consumption aiming "0-Emission"water recycling system.
  In this circumstance, we have developed and started to propose the new water filtering system with new PVDF emblem for the waste water, the white water and the process water treatment in Pulp & Paper Industry. The New PVDF emblem has very good features such as high SS filtering capability, strong against clogging and early restorable capability by washing compared with the traditional filtering emblem. Furthermore, the treated water by our PVDF emblem is proved to be quite adequate for cleaning and showering water which is to be sprayed through high pressure nozzles without clogging continuously. Taking this opportunity, we would like to report the details of very good merits & performance of the New PVDF emblem. We will be happy if you will change your opinion on the filtering emblem to how they are easy to handle with good results.


New Consistency Measurement Technique for Low Shear Force and/or Low Consistency Pulp
-Features and Benefits of BTG ACT-2500-

Emil Engvall
BTG Instruments AB, Sweden
Tetsuro Kakuda
Spectris Co., Ltd., BTG Division

Abstract
  Traditional blade consistency transmitters with moving or static blade have a limited sensitivity at consistencies down to 1 % fiber consistency. They also have limited sensitivity to pulp types with low shear force, like recycled fiber with low fiber quality.
  A new type of measuring technique has been developed. This technique uses a sensing element that oscillates at its resonance frequency. The transmitter shows great sensitivity even at low consistencies and low shear force.


A Report on Paperex2007
-December 7-10, 2007 at Delhi, India-

Kunitaka Toyofuku
JAPAN TAPPI

Abstract
  The Paperex2007 Conference & Exhibition was held in Delhi, Indian on December 7-10, 2007 hosted by Indian Paper Industry.
  There were 34 special presentations on 8 sessions. Total number of participant was approximately 500, and Indians occupied the major part of it. However, there were considerable participants from the foreign countries because India is attracting much interest as the huge market next to China. Accordingly presentations by the foreign countries occupied the majority. It should be pointed out the enormousness of the attached exhibition. In the area of more than 10,000 m2 totally, the exhibitions of more than 400 were performed in the 6 sites.
  In addition, I visited Indian Paper Manufacturers Association, Indian Pulp & Paper Technical Association, Central Pulp & Paper Research Institute and the paper mill respectively after the meeting. I report in conjunction with the meeting.


The Characteristics of Methane Fermentation of Paper Sludge (PS)
-The Relationship between the Chemical and Mineralogical Properties of PS and the Quantity of Methane Gas-

Takao Ando
Faculty of Risk and Crisis Management, Chiba Institute of Science
Kimio Hiyoshi
Fuji Industrial Research Institute of Shizuoka Prefecture
Shuji Shimada
Gakunan Daiich Cooperation of Paper Manufacturing Association
Naoto Matsue and Teruo Henmi
Department of Agriculture, Ehime Univ.

Abstract
  Paper sludge (PS) discharged from Fuji city, Shizuoka prefecture, reach about 1,198,806 tons/year at 2007, it is serious industrial waste.@ Therefore, the development of a technique for utilizing of PS is essential for recycling waste materials.
  In this study, we tried to methane fermentation treatment for creating new recycling process of PS. PS consists of cellulose through out paper remanufacturing processes and some kinds of minerals (e.c. talc, kaolinite, calcite) for adding materials as filler and pigment.  The cellulose in PS can be used for the material of methane fermentation. The methane fungus is taken from livestock sewage.   The relationship between mineral composition of PS and the generated methane gas volume is tried to clarify, it is obvious that following conclusions. The characteristics of suitable PS for methane fermentation were (1) ash contained about 8.2`30“, and the "ash rate" (ash/organic component)are about 0.2`2.0, (2) the amount of calcite content is about 37%`52%, (3) Ca + Mg in ash corresponding to 1g of organic component is about 0.1 `0.5g, (4) no chemically treated and refined cellulose in PS is desirable for methane fermentation, (5) PS can be used for the material of multiple stage (cascade type) recycling process which consist methane fermentation process (1st stage) and the zeolite synthesizing process (2nd stage) using residual material of 1st stage.

Keywords: Paper Sludge, methane fermentation, Kaolinite, Calcite, Zeolite