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2009 August JAPAN TAPPI JOURNAL


Vol.63 No.8 Abstracts


Outline and Operational Experiences of the Vertical Washer gZekooh

Saeko Akiyama, Takefumi Ide and Kiyoshi Yoda
TAIZEN Co., Ltd.

  To realize the target value, 62% of recycling old papers for 2010, the paper industry companies have made continuous efforts but situation of the paper industry is getting very tough, and will be tougher in future.
  Recycling method of old papers are mainly conducted in kneading, which is incidentally our specialty. With this method, quality of old paper pulp has been dramatically grown. However, quality differs depending on which washing equipment is used. And we needed to make a washing machine of higher washing effectiveness.
  And so we have developed the machine with higher washing function through centrifugal dehydration, and kneading function, and water displacement washing effectiveness. This new vertical separate type washing machine Zekoo (called, Vertical Z) has already been introduced at the convention in 2005. It has been 7 years since these machines have been used by customers. In the 7 years, we have improved the machine several times, and we are proud of the machine, which contributes to high quality of old papers.
  In this document, we introduce advantageous in using the machine practically, and instillation samples in addition to construction, performance and operational data of the Vertical Z.


COMPACT COOKINGTM G2 Technology

Yan Ju
Fiber Business Line, Process Technology, Metso Paper Japan Co., Ltd.

  Metso Paperfs fiber business line has developed COMPACT COOKINGTM G2 system that has become the most popular continuous kraft cooking process. COMPACT COOKINGTM G2 system can fully meet the requirements to, (i) build a new fiber line both for hard wood and for soft wood, (ii) increase the capacity for the existing cooking system, (iii) modify the existing cooking system for the purposes of increasing cooking yield, bleaching ability, and pulp quality as well as for the purposes of reducing energy consumption and environmental load.


The Practical Solution for Canvas Cleaning with AOKI-CLEANER

Toshio Kameyama
AOKI MACHINERY Co., Ltd.

   Environmental issue is concerned world widely. Japanese pulp and paper industry has concentrated to utilize the recycled paper at most since the 1960fs for the shortage of domestic wood resources, and currently not only cost performance but also for the preservation of wood resources and green earth. The more utilization of recycled paper is causing the worth quality of recycled paper, however the pulping process has developed in recycled paper dramatically, the paper machine area, especially dryer canvas area have not resolved in heavier contamination originated by sticky material such as hot melt, acrylic resin, pitch, etc.
  gAOKI-CLEANERh, blade type canvas cleaning device, compared with conventional gnet typeh and ghigh pressure water and/or air typeh, is the newest type canvas cleaner which is overcome those something wrongs. gAOKI-CLEANERh by introducing your paper machine, you will be satisfied with reducing sticky trouble amazingly, and further cost reduction, improving operation efficiency and product quality, together with result in the preservation of green earth.
   This report describes the superiority of its performance from practical solution of paper machine operation.


The Improvement of Formation and Paper Properties by Controlling the Structure of Polymer Additive

Yoshiya Yamaguchi
Shonan Research Center, HYMO Corporation

  Recently the retention aid system is required for applying papermaking process using high ratio of fine fiber@pulp or calcium carbonate filler at the high speed machines. For these papermaking processes, the poly-acrylamide (PAM) with higher molecular weight that is inappropriate for good formation is applied to achieve good retention. Furthermore, the improvement of not only retention performance but also paper properties is requested from a point of view of making paper of high quality. Under those circumstances, the use of straight-chain PAM has limitation in performance, and use of the structure -controlled-polymers would be effective for these problems.
   We have developed the several structure-controlled-polymers with different polymer production technology; Himoloc RX, ND, FR and FA.
    ERX: Structure-controlled reverse emulsion polymer having ultra high molecular weight
    END: Nano-cluster-type dispersion polymer
    EFR: High cationic charge density dispersion polymer with wide molecular weight distribution
    EFA: Anionic micro particle dispersion polymer for dual system
  In this report, we discussed how the structure-controlled-polymers were effective for the improvement of formation and paper properties.


Control of Scum Marks Appearing onto Paperboard with Stock Additives

Yuka Miyoshi
Paper Chemicals Department R & D Division, YUKA SANGYO CO., LTD.

   Nichiyu Solution Inc. has been selling nonionic polymer-based stock additives called gDETACh, which are especially optimum to solve stickies related problems deriving from recycled paper by modifying deposit surfaces to hydrophilic and non-tacky for its stable dispersion. This paper will propose that gDETACh functions modify wax surfaces to hydrophilic to improve dispersibility, and will introduce that middle layers' furnish treatment by gDETACh is optimum for controlling scum marks appearing onto paperboard.


Chemicals and Technologies to Reduce the Amount of Inorganic Coagulant for Wastewater Treatment

Satoshi Takebayashi and Minoru Watanabe
Chemical Division, Kurita Water Industries Ltd.

  Inorganic coagulants are effective to remove suspended solids from pulp and paper wastewater. However, cost reduction of chemicals and sludge disposal has been focused because both of them are highly increasing. We will introduce the application technologies to reduce inorganic coagulant consumption.
  1) Using organic coagulant to substitute the electrical neutralization function of inorganic coagulant.
  2) Monitoring and optimization system to control dosage of inorganic coagulant.


Energy- saving and High-efficient Progressive Cavity Pump
-The Best Pump for Coating Color Transfer-

Takeshi Kawamura
HEISHIN Ltd.

  Because of smooth dynamics, the progressive cavity (PC) pumps produce flow on a continuous basis. They are popularly used to transfer coating colors, pulps and chemical liquids etc. at paper plants. New energy saving and high efficiency PC pump called gD typeh are served to transfer mainly coating colors. Its rotor has oval cross section and its stator also has blunt triangle. Due to its shape, in D type six cavities are discharged per cycle, compared with two in N type. D type pumps little pulsate and can transfer delicate liquids without damaging and bubbling.


The Non-Cooling Cartridge Mechanical Seal for Pulp Pumps

Hidekazu Takahashi
Customer Service Dept., Eagle Industry Co., Ltd.

  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. Recently, a mechanical seal has been selected as a standard sealing device for such pumps. A cartridge seals are coming into wide use for work improvement, for being easy to handle and for installing correctly. And then the cartridge seals are used not only non-flushing use but non-cooling use in a plant. I will introduce the latest technology trend about the non-cooling cartridge mechanical seals for the pulp pumps.


New pH Electrode with Digital Communication

Yasuo Watanabe
Process Analytical Division, Mettler Toledo K.K.

  Last year, Mettler Toledo introduced the new digital pH electrode which is called gISM sensorh. But at that time, we had not so much experience and also available transmitter was limited due to the concept electrode. Now as Mettler Toledo developed the advanced ISM system, we introduce the benefit of this new system.


Cost Saving Concept for Coated Woodfree Papers
-Single Blade vs. Double Coated MSP-Blade-

Peter Dahlvik and Guillermo Bluvol
Research & Technology Services, Omya
Greg Welsch
The Dow Chemical Company
Alexander Hipp and Pekka Salminen
Dow Europe S.A.

  This paper presents a case study based on pilot coater trials comparing single to double coating. The single coating relates to the common procedure of surface sizing/pigmentation followed by blade coating. In the double coating approach, the surface sizing is replaced by MSP precoating on which a blade topcoat is applied. The double coating concept also evaluates the ratio of precoat to topcoat and the impact of running higher dry solids in the precoat.
   The obtained results demonstrate that higher solids content and therefore a faster immobilization of the coating allows reduction of the water soluble binder. Significant energy savings can be achieved through the reduced drying demand when running higher coating formulation solids. This could also translate into increased coater speed in cases where drying limitations may exist. Calculation of the related production cost (coating formulation and drying energy) indicates significant savings potential. In addition to the cost benefit, the proposed double coating concept also resulted in improved optical properties.


Insect Control of Paper Manufacturing Plant in the Pursuit of Efficiency and Effectiveness -Consideration of the Characteristics of the Plant, Build A Custom-made Measures-

Yoshimi Ichihara
Earth Environmental Service Co., Ltd.

  Our company is performing investigation/measure support business for protecting a product from an insect over many years in paper manufacturing plant all over the country. As a result of investigating many factories, the mechanism to which an insect is mixed with a product is not a general way. It is various. It has turned out that there is a characteristic tendency for every factory or its production equipment.
  The prevention plan with few results of an improvement is not analyzing the ginsect pollution scenarioh in a factory in many cases. gMeasure which is easy to implementh and gThe general measureh is implemented.@As a result, in the case of some factories, it had become an opposite effect. In order to reduce insect mixing efficiently effectively, it is important to clarify the ginsect pollution scenarioh in a factory, and to assemble a measure program rationally along with the scenario. The main point is three points.@It is analyzing the causal relationship between the product which the insect mixed, and a manufacturing process and manufacture environment. It is defining the turn of a measure based on a scientific basis. And it is making the organization where a related employee's can participate.


Model-based Predictive Adaptive Control of Pulp and Paper Mill Processes

Junji Mizuki
Project Engineering Group, Andritz K.K.

   This paper describes the application of a model based predictive adaptive process controller on a number of challenging pulp and paper mill control loops including paper machine reel brightness control, lime kiln temperature profile control, Recaust Area Control, Extraction Stage pH control, Digester Control and Pulp Dryer Control. These loops are difficult to control due to the time delay present in the response. Consequently, many of these processes are manually controlled resulting in inefficient operation and increased operator work load. Paper making includes many such processes that cannot be well controlled with conventional PID techniques. Model predictive control provides a practical alternative to achieve significant reduction in process variability to reduce operating costs.


FILTOMAT
-Case Study for Optimization of White Water Filtration-

Kazuhito Gomi
Altech Co., Ltd.

   Paper production requires tons of water; and, among involved companies, reduction of the water has been main issue to tackle with for decades as it is the key to lead decrease in operation cost and negative effect on the environment. One of major answers for the issue is to apply filtration technology to white water, however, existing technology has critical disadvantages in some aspects such as initial cost, foot-print and maintenance works.
   In this paper, purpose and problems of recycling white water with existing technology are reaffirmed, and optimization of white water filtration technology with FILTOMAT is introduced with test result and on going operation status.


A Report on Anselme Payen Award Symposium in 237th ACS National Meeting

Toshiyuki Takano
Graduate School of Agriculture, Kyoto University

   The 237th American Chemical Society National Meeting was held on March 22-26 in Salt Lake City, UT, USA. Prof. Fumiaki Nakatsubo in Kyoto University was awarded an Anslem Payen award 2008 in division of Cellulose & Renewable Materials of the ACS National meeting, and Anselme Payen Award Symposium was held on March 22-24 in the division.


How Technological Innovations Changed Newsprint and Its Making Process
-Survey on Technological Developments in Newsprint Production in Japan (Part III)-

Kiyoaki Iida
Senior researcher in 2007, Center of the History of Japanese Industrial Technology, National Museum of Nature and Science, Executive Director emeritus, JAPAN TAPPI

   Part one of the series presented a short history of pulp and paper industry, background of selecting the theme and introductory briefing on basic technologies. Part two presented how newsprint and the way of producing it have evolved in the past 60 years, along with fiber source exploitation in 60 years. Part three describes how paper machine for new print production has developed in the past 60 years.
   Paper making process by hands, which was a kind of batch process, was invented about 2000 years ago. It was revolutionized to a continuous process called paper machine in the early 1800s. The paper machine greatly improved productivity in making paper and helped printing business to grow in the 1800s and the 1900s. How the paper machine has developed in the past 60 years is a subject of this part. As news printers have been improving printing technology, their qualitative requests to news print have becoming more and more severe. Due to international competition, its production cost has had to be reduced as much as possible. Japanese paper industry, by investing in new technologies one after another, has been improving its productivity with larger machines of faster running speed, satisfying qualitative requests, and supplying to most of the domestic market. Reliable and cooperative relationship with suppliers of technologies in Japan has played an important role in the evolution of paper machine.
   Part four of the series will discuss the characteristics of technology of Japanese paper industry against those of other countries.


Structural Micro-analysis of Residual Lignin in Pulp by Pyrolysis-GC Mass-spectrometry

Ai Hasumi, Akiko Nakagawa-izumi, Mitsuko Homma and Hiroshi Ohi
Graduate School of Life and Environmental Sciences, University of Tsukuba
Keiichi Nakamata
Technical and Development Division, Hokuetsu Paper Mills, Ltd.

  It is difficult to analyze residual lignin in pulp, especially in bleached pulp because of its low lignin contents. However, it would be possible to estimate it by using pyrolysis gas chromatography/mass spectrometry (Py-GC/MS) with an appropriate method.
  In this study, the ratios of syringyl units to guaiacyl units (S/G ratios) of wood meals, unbleached kraft pulps, oxygen bleached kraft pulps and total chlorine free (TCF) bleached kraft pulps were measured by Py-GC/MS. All samples were prepared from four kinds of eucalyptus woods, Eucalyptus nitens, E. grandis, E. macarthurii and E. smithii. The S/G ratios of wood samples were measured at intervals of 10 mm from pith to bark sides. E. nitens gave the highest S/G ratios in four woods. Results from all wood samples showed that the S/G ratios were slightly lower in bark side than pith side. It is important to know total ion peak areas of lignin degradation products from pulps for measurement of the S/G ratios. However, these peak areas were too small to measure directly. In order to estimate these peak areas, we calculated correction factors of lignin pyrolysis products obtained from wood samples, which were equal to the total ion peak areas divided by the main fragment ion peak areas. Then, the total ion peak areas of lignin pyrolysis products from pulps were estimated by multiplying the correction factor and the main fragment ion peak areas from pulps together, and the S/G ratios were measured using guaiacol, 4-methylguaiacol and 4-vinylguaiacol as guaiacyl type compounds, and syryngol, 4-methylsyringol and 4-vinylsyringol as syringyl type compounds. The result showed that the S/G ratios were decreased during pulping and bleaching. This result was correspondent to earlier studies on residual lignin with a different method. It was shown that this method was applicable for the calculation of the S/G ratios of bleached kraft pulps.

Keywords: pyrolysis, gas chromatography/mass spectrometry, bleached pulp, residual lignin, S/G ratio