2013 May JAPAN TAPPI JOURNAL
 
2013 May JAPAN TAPPI JOURNAL

Vol.67, No.5 Abstracts


Integrated Solution for Resource Management and Cost Reduction in Fiber Lines

Dinesh C. Mohta Ph.D.
Nalco Company, Asia Pacific Marketing
Shintaro Sato
Marketing , Katayama Nalco Incorporated

  In Japan, pulp production cost is one of the highest in the world mainly due to ever increasing cost of the imported wood chips. Given the variations in wood maturity and subsequent chips quality, it is always a challenging task to maintain smooth operations in the pulp mills. Hence to minimize this effect, it is necessary that more attention is given to cooking and washing operations for an optimal runnability of the fiber lines. The optimization of digester and brown stock washing operations will bring substantial improvements in bleaching and evaporator plants' operations together with higher pulp quality. As part of the digester optimization, the use of PenSurf Technology offers great benefits of improved production and in reducing and overall total cost of operations.
Further to minimize water borne issues, it is necessary to take the right steps to avoid scale formation in pipe lines and equipment particularly in the bleach plants. The drainage aid for the lime mud dewatering offers great advantages in not only increasing dry solids but also in minimizing the energy cost.
In addition to the process optimization, implementation of an integrated solution for specialty chemical management will not only achieve desired synergy for improved plant runnability and pulp quality but also set a new example of efficient resources (fiber, water and energy) management in pulp mills lower production cost and better environmental sustainability.


System Upgrade for Stock Preparation and Approach Flow

Masamori Tanaka
Paper Machine Eng. Dept., Voith IHI Paper Technology Co., Ltd.

  Fiber recovery system is one of the most important parts not only for approach flow but also for all of paper making system. To recover fibers can gain better yield, and to make clearer filtrate helps reducing specific water consumption. Moreover, if the consistency of white water is decreased by Fiber recovery system, it saves the consumption of power and chemicals, and also size and number of machines in water treatment system dramatically. DiscfilterTM helps this solution with state-of-the-art technology as BaglessTM sectors and Filtrate valve. C-bar F basket is another solution which has less installation cost. These technologies will supply much more benefit for the environmental-related future.


New Board Machine Concept

Yoshiki Kabutoya
Engineering Division , Metso Paper Japan Co., Ltd.

  The global containerboard production is moving toward lighter basis weights [1]. While the basis weights have decreased, the use of recycled fiber as containerboard furnish has increased. This is especially so in Europe where strong testliner is made primarily from old corrugated containers (OCC) and other recovered paper grades.
  The trend towards a more lightweight containerboard and a higher OCC content has opened the doors for high machine speeds through the use of a gap forming concept. Metso has utilized the long and extensive experience of efficient, fast-running paper machines when building fast containerboard machines.
  Following machines are introduced in this paper.
  Propapier PM 2 at Eisenhuttenstadt, Germany.
  Fujian PM6 at Zhangzhou, China
  Saica PM11 at Manchester, UK
  Jian PM3 at Jiaxing, China


EVERLOY Spray Nozzles for Paper Mills

Shunsuke Makino
Everloy Shoji Co., Ltd.

  Kyoritsu Gokin Co., Ltd. which is one of the leading manufactures of spray nozzles was founded in 1938 in Japan. The company brand : Everloy is well known especially in Japan. The more paper machines are large and speed is fast, the more demands for spray nozzle is increase. With such continuous demands, spray nozzles became indispensable high precision parts nowadays. EVERLOY will introduce Straight Jet and Flat Fan pattern nozzles for paper mills.


Formulations for High Speed Coated Inkjet Paper

B. Hallam, J. Preston, P. Biza, S. Booth and C. Nutbeem
IMERYS Pigments for Paper & Packaging Europe
Tatsuya Narahara and Etsuya Misawa
IMERYS Minerals Japan K.K.

  Within a global market for printing and writing that is at best flat, consumption of paper for coated reel-fed (high speed) inkjet is growing. Growth is driven by the potential to print on demand, reducing the need for high inventory of printed material and making it possible to personalise the content. The rate of growth and ultimate target market size is widely debated by analysts and commentators, with the key difference being whether coated inkjet can also take market share in coated magazines from traditional offset printed grades.
  One of the most significant hurdles to delivering mass commercialisation of coated inkjet paper for magazines is the availability of a cost-effective paper substrate in a range of grades which has the look and feel of traditional magazine paper. This is because making good quality inkjet-compatible coated paper is challenging. In terms of mineral components, silica or surface modified mineral pigments are typically used to create a suitable pore structure that enables sufficient capillarity to give fast removal of the fluid components of the ink together with large pores to enable drainage of the ink volume. These types of mineral pigments are typically expensive compared to traditional coating pigments and inherently require low application solids which can prevent high speed coating. Other existing solutions are based on a cationically-charged formulation to help fix the ink close to the paper surface. This causes problems on paper machines that spend most of their time producing under anionic conditions. As a result, the papermaker must take great caution to avoid any contamination when switching between production runs.
  IMERYS has been working to overcome these issues in order to assist the papermaker in bringing to market a formulation that could genuinely make mass adoption of coated inkjet paper a reality. Our philosophy has been to concentrate on more traditional mineral pigment types from our extensive portfolio of materials and grades to enable high application solids and to maintain anionic formulation chemistry, reducing the pressure on the papermaker who wants to produce in campaigns. To make this possible, it has been necessary to develop a full-formulation understanding for this concept.
  In this paper we will expand on our view of the coated inkjet market, its size and technical needs. We will introduce the techniques that we have developed for characterising these papers and share application data of our proposed formulation concept, benchmarked against appropriate commercial grades.


The Non-Cooler Cartridge Mechanical Seal for the Hot Water Pumps

Hidekazu Takahashi
Engineering Div. , EAGLE BURGMANN JAPAN 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-cooler use for hot water pumps in a plant. I will introduce the latest technology trend about the non-cooler cartridge mechanical seals for the hot water pumps.


Optimization of Paper Machine Wetend by Optical Consistency Sensor which can Measure Ash Consistency
-Switchover of Quality Control from Dryend to Wetend-

Ryohei Watanabe, Takuya Maekawa, Yoshio Ishitsu and Keijiro Suzuki
Spectris Co., Ltd.

  BTG is a global market leader in measuring instruments for Pulp and Paper process and has been continuously developing the new innovative technologies.
  After the earthquake in 2011, the import paper from China and Europe is increasing, and this has gave serious influence to the management of Japanese paper companies.
  In this paper, BTG provides the way to improve the profitability of the paper machine by the optimization of the wetend and the stabilization of the basis weight with our optical consistency sensor.


Energy Saving by Reducing Water Content of Lime Mud Filter Cakes

Hideo Yamamoto, Yasuhiro Kagawa, Takashi Saigusa and Keiji Suruga
Kurita Water Industries Ltd.

  In KP caustic recycle process, a large amount of heavy oil is used as fuel of lime calcinations in the rotary kiln. Reducing the water content in the lime mud is an effective way to reduce heat loss in the lime kiln, and save heavy oil.
  This paper focused on a dewatering technology to increase the hydrophobic of the surface of CaCO3 particles by a new developed chemical. It is found that the lime slurry temperature is an important effect on dewatering aid. A new dewatering aid is developed by optimizing the hydrophobicity and its molecular weight. The new dewatering aid achieved 10% of heavy oil saving in a machine trial.


The Long Experience of Anaerobic Wastewater Treatment System for Pulp Mill Wastewater

Haruyuki Chiku, Takanori Takeshige, Atsushi Shimamoto, Nagako Watanabe
and Atsushi Nakano
Development and Analysis Center, Sumitomo Heavy Industries Environment Co., Ltd.

  The EGSB anaerobic wastewater treatment system is a very competitive method compared with aerobic treatment system because of space and energy saving system. We constructed the Biobed EGSB system in Pulp Mill for the treatment of drain wastewater from KP evaporator and operated over five years.
  The performance of EGSB system is good as for the removal rate of CODCr is about 80%, then we achieved the aimed energy-saving effect.


The Efficient Use of Paper Sludge Ash as a Soil Improvement Material

Hiroshi Mizuno
Yoshinaga Mill, Nippon Paper Industries Co., Ltd.

  The paper sludge (PS) ash of Nippon Paper Industries Co., Ltd. Yoshinaga Mill had been re-used only for cement, but we started the development of soil improvement material as other application of PS ash with Fujita Co.,, Ltd. .   The results are followings.
1. The PS ash of Yoshinaga Mill is suitable for soil improvement material as it has
  excellent absorption capacity comparing with another product.
2. The PS ash of Yoshinaga Mill doesn't include harmful components except the elution of fluorine.
3. The manufacturing of soil improvement materials could be realized by establishing the appropriate treatment to control the elution of fluorine.
4. It is possible to control the elution of heavy metal and bad smell of mud.
  In this paper, we show the treatment method, fundamental properties of the improvement materials and report the results of application to some actual construction fields (dredging harbors and rivers and improving the illegal dumping spot). At present we examine the application for debris classification of the 2011 Off the Great East Japan Earthquake.


Carbon Credit Program in Alberta, Canada
- Carbon Offset Credit by Portable Chipping -

Kazuyoshi Noguchi and Takuya Yamamoto
Daishowa-Marubeni International Ltd.

  With increasing dependence of U.S. oil imports on Canada, Canadian oil sands production is growing significantly. Oil sands deposits are found in Western Canada, mostly in Alberta.
  Due to its unique nature, oil sands production requires significant amount of energy. In terms of greenhouse gas (GHG) emission, oil sands extraction, mining and upgrading are responsible for about 40% of Albertafs gas emission from industrial sector.
  On the other hand the government of Alberta is constantly under pressure of reducing carbon foot prints throughout the province. GHG reporting program in 2003 requires major industrial facilities to submit annual reports on their GHG emissions. In 2007, GHG reduction program was put in effect. Alberta is the only jurisdiction in North America with mandatory GHG emission reduction targets for large emitters across all sectors. This program promoted renewable energy developments.
  In this paper, outline of carbon credits in Alberta and offset credit awarded to portable chipping operation are described.


Structure-Control of Amphoteric Polyacrylamide and Its Performance as Dry Strength Resin

Hideo Baraki
Paper Chemical Business Division, Seiko PMC Co., Ltd.

  Dry strength resin is known as multifunctional chemicals to enhance paper/paperboard strength, drainage and retention. Especially, polyacrylamide (PAM) based dry strength resin is widely used in various paper/paperboard grades in Japan. Linear, Low-branched, and high-branched PAM containing both anionic and cationic groups were obtained with free radical polymerization. Molecular weight and structure of PAM were determined by gel permeation chromatography coupled on line to a multi-angle laser light scattering detector (GPC-MALS). The higher degree of branching, the more compact a polymer chain, which leads to decrease in the viscosity of aqueous solution.
  The effects of structure and molecular weight of amphoteric PAM on the performance of dry strength resin were investigated. The high-branched PAM with higher molecular weight showed greater performance in retention of PAM and paper strength. The zeta-potential of amphoteric PAM increased with the increasing of the degree of branching. The high-branched amphoteric PAM was able to form polyionic complexes in high salt concentration (electro conductivity, 650mS/m). The effective iconicity of amphoteric PAM could be controlled by changing the structure of polymer.


An Attempt to Produce Bio-Diesel from Pulping Byproducts
- In the Case of Tall Oil-

Hao Ren
Department of Light Industry & Science, NanJing Forestry University
Shigetoshi Omori
State University of New York, College of Environmental Science & Forestry

  Biodiesel is generally produced from food-related materials such as vegetable oil and animal fat (tallow). The most commonly used source is vegetable oil waste; however, its supply is limited. Should there be a shortage of vegetable oil waste, biodiesel production may turn to fresh vegetable oil as a source, with possible impacts on the food supply. Several non-food resources were investigated as prospective sources for biodiesel production, and pulping byproducts have shown potential. Tall oil was selected as a representative byproduct typical of the pulping process, and early trials showed that a reasonable amount of biodiesel yield was able to be produced. Initially, several issues were found which would limit the practicality of producing biodiesel from tall oil: reaction time, reaction temperature, reduction of chemical usages, the role of acetyl chloride, and the reduction of solvent consumption amount. Through experimentation, most of these potential issues were able to be mitigated, supporting the very real possibility of mass producing biodiesel from pulping byproducts.