|2012 July JAPAN TAPPI JOURNAL|
Vol.66, No.7 Abstracts
Approach to Energy Saving in Niigata Mill |Energy Saving at Kraft Pulping Process|
Niigata Mill, Hokuetsu Kishu Paper Co., Ltd.
The influence of the big accident of an East Japan great earthquake and the first nuclear power plant of Fukushima of the Tokyo Electric Power which occurred on March 11, 2011 was anxious about the electric power shortage of summer, and the measure against electric power reduction was implemented also not only at a factory but at the home.
As a result of the industrial world, a home, and a community tackling together, rolling blackouts were avoided safely.
And also when promoting energy saving from now on, it became a big experience at the same time the importance of energy saving had been recognized anew.
At the Niigata Mill, the importance of energy saving has been recognized since 2009 and the project of energy-saving activities centering on a large-sized paper machine was started.
The energy-saving desired value was attained in December, 2010, the effect appeared gradually, and the activity has contributed to reduction of the amount of the energy used, and cost reduction greatly.
In this news, the contents of a measure and the example of the energy-saving activities at the Niigata Mill after large-sized paper machine energy-saving activities are introduced.
Energy Saving Introducing Vacuum Box instead of the Belt Drive Extractor
Kushiro Mill, Oji Paperboard Co., Ltd.
Oji Paperboard Kushiro Mill L-1 machine produces linerboard 1,370 ton per day. It is one of the largest linerboard machines in Japan. The paperboard produced in L-1 machine is composed of three layers. The type of former for back layer is Fourdrinier, for filler and top layers are Belbond-former. The belt drive extractor had been installed in the Fourdrinier since 1974.On average, 1.5 sets of rubber belts per year were used for this belt extractor.The belt is much expensive and it accounts for 10% of our budget for consumable equipment, additionally work load of replacement of the belt is too hard, so that the improvement of the cost and the work load was desired by renewing the equipment.
We installed the vacuum box with ceramic blade last May instead of the belt drive extractor at the same position.
As a result, the consumption of vacuum volume becomes less and we could save the energy by restructuring the vacuum system.
In this report, we introduce our investigation, the experience of the operation and the effect of the energy saving.
Increasing Refiner Efficiency by Spline Technology
Hokkaido Mill, Nippon Paper Industries Co., Ltd.
Recently most urgent task of humanity is to prevent global warming. And reducing carbon dioxide emissions is especially our main concern. So we are being required to increase efforts for energy saving in our mill. Though Refining stage in stock preparation which needs especially a great amount of energy had been modified to reduce power consumption constantly, still it is not exception.
At that time, we had known there is the spline technology to upgrade refiners by GL&V. The modification delivers a wide range of cost saving benefits (ex. reducing gross power consumption, improving fiber quality, extending plate life, and so on.). Results from hundreds of splined upgrade installations in foreign countries had proven the successful results. So we had decided to upgrade by GL&Vfs spline technology our refiner in 10PM stock preparation for the first time in Japan. The refiner had upgraded in Feb. 2011 and has been running for an annual. In this report, we introduce the energy saving modification in our mill, details of our achievements after modifying, and competitorfs (ex. AIKAWA, Andritz) spline technology from a customerfs standpoint.
Presentation of Underground Temperatures Renewal Type Geothermal Heat Pump System
- Increase of Geothermal Heat-Exchange Efficiency by Groundwater Forcible Flow of Shallow Layer Part-
Eco Power Co.,Ltd.
An underground temperatures renewal type geothermal heat pump system is a System which installs geothermal exchanger into the perpendicular hole excavated from surface of the earth to near 30 lower m, and extracts underground heat.
It sets up the interval of about 1-1.5m for the purpose of preventing between geothermal exchangers interfering in this System mutually with heat.@When continuing taking heat from the underground between long times, geothermal efficiency falls.@In that case, it operates the storage pump prepared near the geothermal exchanger, and make groundwater near the geothermal exchanger flow compulsorily.
If a coercive flow of groundwater takes place, the underground temperatures near geothermal exchanger will be improved and geothermal efficiency will go up.
Energy Saving Techniques for Paper Factory
-Managing both Economic and Environmental Efficiency for Effective Utilization of Energy-
Hitachi Plant Technologies, Ltd.
This year will be finished commitment period of Kyoto protocol. But it will be forecasted increase CO2, cause of Tohoku earthquake on March 11, 2011. We must save energy quickly. Especially we must reduce power quantity consumed at summer season. At first, we tried to energy saving at Semiconductor plant and LCD panel plant, so we improved our ability of energy saving techniques. They have big clean room. Recent year, we try to energy save at Food factory, Chemical plant and Automotive factory. Today, we explain at gBasic approach for Energy saving techniquesh, gReport case of energy saving at a semiconductor planth, gReport case of energy saving at the other planth and gReport unique Energy saving techniquesh.
Air Compressor Pursuing Energy Saving, Power Saving and CO2 Reduction
Tomohiro Kaneko and Yasukuni Tanaka
Miura Co., Ltd.
MIURA as a leading manufacturer of small once-through boilers has adopted gPlant infrastructure total solutionh as a slogan and is promoting various eco-friendly proposal activities through water treatment devices for industrial water and compressors using in-plant process steam, and so on. This paper explains following technologies;
EFeatures and energy-saving effects of the steam-driven air compressor with compression heat recovery unit
The Latest Technology of Metso Air System
Project & Engineering, Paper Business Line, Metso Paper Japan Co., Ltd.
Air systems have a significant influence on the energy consumption of paper and board production via the drying process.
The role of air systems becomes even more important when once used energy is bound into the evaporated water and further into the exhaust air. Process air, water and, if needed, also machine hall heating can be done without primary energy just using heat recovery. There is energy saving potential in all the paper and board machines. The nearer to the optimum performance the machine is, the more challenging becomes the realization of an individual saving project. The solutions often have connections to several paper making sub-processes and energy production. The basis of the energy saving is to run the existing machinery properly. In most of the cases, this can be done without any or with minor investments.
Pulping Technologies for High Quality Pulp from Low Quality Waste Paper
- The Technologies of Andritz FibreFlow® Drum Pulper -
Andritzfs waste paper treatment technologies cover the whole system of DIP and OCC treatment process. Andritz has provided with many turn-key base systems, too. FibreFlow® Drum Pulper (FFD) has been a key technology in these systems. Pulping process is a first one in the waste paper treatment system. Employing FFD for the pulping process enables contaminant load to reduce greatly and as a result can make an excellent system with a good quality and high cost-efficiency. In other words, FFD can create high quality pulp from low quality waste pulp.
In this paper, a pulping principle and references of FFD, a situation of raw materials in Japan, advantages of FFD when FFD treats various kinds of raw materials and experiences of FFD are described.
Honeywell Process Solutions, Pulp & Paper and Printing Sales Dept., Honeywell Japan Inc.
The papermaking business has undergone dramatic change over the past few years.
Honeywell has conducted many interviews with customer to understand how these changes are affecting papermakers and what they are looking for in paper machine automation to help address these new challenges. We found three themes dominating the wish lists of papermakers today.
EThey are want better visibility into the papermaking process in order to improve quality.
EThey are looking for equipment that it easy to operate service and maintain.
EThey are looking to reduce total cost of ownership.
Honeywell has addressed these needs with Experion MX, its next generation of paper machine automation. Experion MX provides an integrated user interface that makes it easier for operators to view and control the process. New and enhanced measurements and advanced multivariable controls improve product quality and operational efficiency. The resulting reduction in service and maintenance costs, and unscheduled downtime, along with increased production and less waste provides the lowest total cost ownership.
Rapid Simultaneous Substance Identification in Pulp and Paper Mill Effluent by GCMS
Keiko Fujita, Hiro Iwata and Hitoshi Okada
Japan Pulp and Paper Research Institute, Inc.
The effluent from the pulp and paper mills contains various chemicals, most of which, including accidentally generated ones, are neither identified nor quantified. We have so far targeted mainly organic chloride substances that are easily identified and quantified; but we need an efficient method to identify more substances in the effluent.
Recently in the food industry, strict rules have been introduced to regulate the amount of pesticides remaining in the food. To measure them rapidly, new methods have been developed. One of them is Rapid Simultaneous Substance Identification by GCMS, using a database that covers hundreds of environment-related substances and pesticides. We utilized this method to analyze the effluent from the pulp and paper mills. In addition to the substance database already installed, we added some substances directly related to our own industry, such as Chloro-phenols and wood extracts.
As a result, we found that substances were present in the effluent only in trace amounts, and that in each case the concentration was far below the regulation limits for both inside and outside the country.
Prospect of Bio-Refinery Researches
Forestry and Forest Products Research Institute
For the mitigation of global warming, the promotion of woody biomass utilization as energy and materials for the replacement of petroleum as well as the increase in the self-sufficiency rate of industrial wood is adopted as a policy of Japanese government. In this seminar, recent studies on the bio-refinery using steam explosion, alkaline cooking and ionic liquids are mentioned.
It is known that steam explosion is a good method for separation and conversion of a certain kinds of hard woods. Recently, it has also been made clear that this technique is applicable to the production of functional materials from un-utilized bamboo and multifunctional food fibers from bagasse. Alkali cooking method is an excellent bio-refinery technology not only for the bio-ethanol production but also for the lignin utilization. Ionic liquids as green solvent for chemical conversion have been focused recently, although bio-refinery using them is now at the basic stage. Several woody biomasses contain essential oils which have a biological activity for promoting manfs health. Therefore, establishment of bio-refinery containing the vacuumed microwave steam distillation process for extracting them is promising.
Relationship between Hexenuronic Acid Content of Pulp and Brightness Stability in Accelerated Aging
Eiko Kuwabara, Xin Zhou, Mitsuko Homma, Shiho Takahashi, Mikio Kajiyama and Hiroshi Ohi
Graduate School of Life and Environmental Science, University of Tsukuba
Six types of pulps that were prepared under acidic or neutral papermaking conditions were investigated about behavior of yellowing or the others after accelerated aging tests. The relationship between the hexenuronic acid (HexA) content of pulps and yellowing was clarified for non-chlorine-bleached pulps (elemental chlorine-free (ECF) and totally chlorine-free (TCF) bleached pulps) prepared from hardwood oxygen-bleached kraft pulp (LOKP). A trial test of enzymatic removal of HexA from LOKP was attempted by treatment with a crude enzyme solution containing a new hexenuronidase.
The results indicated that the brightness reversion of LOKP that was prepared by acidic papermaking and underwent a humid accelerated aging test was greater than that of LOKP that underwent a dry accelerated aging test. On the other hand, the brightness of LOKP increased after sunlight exposure aging test. Under sunlight exposure, the structure of the lignin in bleached thermomechanical pulp (TMP) and bleached chemical thermomechanical pulp (BCTMP), which is similar to the lignin in wood, changed to coloring structures. However, the effect of this change on brightness reversion was minimal in acidic papermaking. Plain paper copier (PPC) paper and news printing (NP) paper, which are prepared by mixing used paper with secondary fibers, were assumed to consist of both chemical and mechanical pulps and therefore showed a relatively stable brightness in spite of accelerated aging conditions and pH in papermaking.
Under conditions of neutral papermaking, LOKP showed the least brightness reversion and the brightness of TCF and ECF pulps were similar to each other. On the other hand, the yellowing of TCF and ECF pulps prepared in acidic papermaking tended to increase with the increase in HexA content of the pulps. In addition, the pulps had the following order of good brightness stability: full-bleached TCF, full-bleached ECF, semi-bleached TCF, and LOKP.
HexA removal from LOKP with crude enzymes solution containing hexenuronidase (activity for ¢-X3: 2-O-( α-hexenuronic acid)-D-xylotriose) was optimum under the following treatment conditions: 0.24 U/g, pH 5.5, 40, and 6 h. It was shown that 40 mmol/kg of xylose was dissolved into the filtrate when 20 mmol/kg of HexA was removed from the pulp; however, the decrease in the pulp yield was minimal.