2013 October JAPAN TAPPI JOURNAL
 
Vol.67, No.10 Abstracts


Maintenance Know-How Development in China and Southeast Asia

Junji Masunaga
Metso Paper Japan Co., Ltd.

  Maintenance practices at Asian mills vary a lot like in the Western world. Some mills have only corrective maintenance and they run until failure and some mills have very sophisticated maintenance management methods and they employ latest available management and technical know-how. There is always room for improvement. Metso has developed many tools, methods and concepts in order to assist its customers to become more competitive.
  This article introduces the way of the latest maintenance and the present situation and future in maintenance in China and Southeast Asia.


Introduction of Raumaster Finishing System

Masashi Shibaki
Itochu Machine-Tehnos Corporation

  Raumaster Paper was founded in 1984 in finland and one of the best company in paper and pulp finishing system. It has been over 20 and 30 years since current finishing system were started up in many paper and pulp mills in Japan and they are now facing the deterioration by long term use. Our company started the business with Raumaster Paper in 2012 in response to the market needs. The products lineup of Raumaster Paper is wide range. Raumaster Paper is capable of supplying tottaly automatic system from winder to truck loading system as well as stretch film wrapping system, core cutting system. We are honored to introduce Raumaster finishing system in this paper.


A Case Study on the Implementation of the Manufacturing Execution System (MES) for Paper Mills

Yukitoshi Iwata
Fujitsu Limited

  The current situation of the paper manufacturing industry, whose surrounding environment changes at a high pace, is that quick and innovative response in line with a business environment is an urgent necessity.
  The issues facing the paper manufacturing industry are 1) consolidation of revenue base, 2) concentration of priority areas of profitability, 3) the acceleration and expansion of global businesses, and so on.
  As the solution to deal with these issues, Fujitsu has developed the "SCM-Type Manufacturing Execution System for Paper Mills," which aims to turn effective, systematic production.
  The author shows the circumstances behind the implementation of this Manufacturing Execution System, the brief overview of the system and its concept, etc.


The Paperboard Trend of Malaysia and Southeast Asia and the Experience of Paper Mill Operation

Shinji Matsuyama
Paper Division, GS Paper & Packaging Sdn Bhd

  RecentlyCThe domestic paper industry is facing an unprecedented crisis, because paper demand has slumped due to a combination of factors such as advanced in ICT, the hollowing out of domestic industry accelerated by persistent yen appreciation, and an aging society with a low birth rate. In addition, imported paper has taken hold in an increasingly globalized market. Therefore, We have to expand our overseas business and corporate with oversea Oji group to adapt with those severe condition.
  Oji Holdings has been expanding overseas business from the 1970s, We started new slogan " Pursuing Efficiency in Domestic Business" "Expansion to Overseas" in 2001 , and then , We are proceeding streamline our domestic production structure and reducing cost to stabilize our earnings base .
  On the other hand, We are aggressively cultivate business in overseas in markets with growth potential such as Asian area. GSPP become Oji group in 2010.4 and We found Oji Paper Asia in 2010.10 in Malaysia. As a result, Malaysia is one of the most important area for us.
  This draft outlines the paperboard trend of Malaysia and Southeast Asia and the experience of paper mill operation.


The Proposals for Cost Reduction of Paperboard Production

Kenji Sakai, Naho Murata, Hidetoshi Sakamoto and Tomonori Nakamura
Shonan Reserch Center, HYMO Corporation

  In this paper, we propose cost reduction of paperboard by reducing pitch-troubles and improving the efficiency of wet-end additives.
  FR-801, FR-701H, and MT-910 are cationic organic polymers whose molecular weight, charge density and composition are designed appropriately, therefore, they are very effective in reducing pitch troubles such as web breaks and pitch deposition on machinery. These polymers also have high ability to fix size on pulp effectively and to decrease consumption of size. Furthermore, these polymers can be used as a substitute for Alum.
  In order to prevent the excess consumption of additives, selecting the most suitable drainage and retention aids (D-R aids) are important. The effects of D-R aids depend on the kinds of machine and paper, and are influenced by pH, electric conductivity, alum and paper strength agents. Therefore, we have been developing the different type of D-R aids with various charge density and flocculation ability. The polymers of these D-R aids have been designed as the contracted conformation in order to improve retention and drainage without the deterioration of dewatering, formation and paper strength. As the result, excess consumption of other additives is restrained.
  Using these additives having high abilities can decrease the consumption of paper additives and improve runnability. And consequently, it is effective in reducing production cost.
KeyWords: pitch, size, retention, drainage, alum, paper strength agent, paperboard, cost reduction,


The Measure for the Dissolved and Colloidal Substances in Linerboard Papermaking

Toshio Hokajo
Paper Chemical Business Division, Seiko PMC Co., Ltd.

  Recently, in paper mills, white-water closed system by decreasing the usage of fresh water, increase of the usage rate of recycled pulp and reduction of basis weight of paper and paperboard are progressed. Under these circumstances, more contaminants tend to exist in papermaking systems. The contaminant is often called "anionic trash" and known that it is concerned to cause the lower productivity owing to the poor retention of pulp fiber and chemicals. However, there are few reports on qualitative and quantitative analyses on the contaminant.
  So, we define all of the substance except water and pulp fiber existing in papermaking systems as DCS (Dissolved and Colloidal Substances) and carried out detailed analysis on DCS obtained from paperboard mills.
  From the analytical results, we clarified that DCS in paperboard-making system mainly consists of calcium, sulfates, starches, small organic acids, etc. Because these components may cause the troubles such as poor retention, growth of pitch, scaling and a bad smell, measures for DCS are needed. It is considered that measures include retaining DSC on paper with coagulants and dosing chemicals hard to suffer from DCS. In this report, we introduce evaluation results of high performance coagulant for DCS "AC7314" and novel dry-strength agents hard to be affected by DCS.


Operating Experience of Lime Kiln with BrainWave-ACE System

Yasuyuki Sato
Ishinomaki Mill, Nippon Paper Industries Co., Ltd.

  KP plant at Nippon Paper Ishinomaki mill has two sets of rotary kilns, No.1 lime kiln (3.36m 90mL) and No.2 lime kiln (3.20mΦ 70mL). Although lime kiln utilizes heavy oil as an energy source, the increase in manufacturing cost is remarkable due to a sharp rise in the price of heavy oil in recent years. After the startup of the biomass boiler in 2006, Oil usage of the lime kilns have come to account for almost half of the heavy oil usage of whole mill.
  To reduce the amount of the kiln heavy oil used, we implemented the advanced control system "BrainWave-ACE" in 2010. In this paper, we report on operation experience of the kiln with BrainWave-Ace. Although this system has many installation records overseas, it is first installation in Japan.


ATMOS - The Sustainable Solution for Premium Tissue

Yukinori Takano
Paper Machine Eng. Dept., Voith IHI Paper Technology Co., Ltd.

  This article gives readers a overview of our completely new technology development for premium tissue production. Voith Paper launched this innovative technology under the name gATMOS (Advanced Tissue Molding System).
  For more than 30 years, premium tissue was produced only by the largest tissue paper producers, using Through Air Drying (TAD) technology. Only they could afford the high capital investment involved and the high production cost mainly attributable to energy consumption. But the innovative Voith ATMOS technology has changed this situation. ATMOS technology was developed at the Voith Tissue Process technology Center in Sao Paulo, Brazil in close teamwork with Voith Paper Fabric division. Thanks to this development, premium tissue can be produced at much lower investment and energy costs, also saving fiber and even using 100% recovered paper furnish.


Chemical Structures and Their Properties of Wood Components

Toshiyuki Takano
Graduate School of Agriculture, Kyoto University

  It is thought that wood components are produced by a tree for its survival, and have suitable chemical structures for the purpose. Then, the elucidation of relationship between chemical structures and their properties is one of the important approaches for new effective utilization of wood components. In this seminar, fundamental explanation for chemical structures of wood components and recent studies of wood components in our laboratory are mentioned.
  Wood consists of main component (cellulose, hemicellulose, lignin) and minor component (extractives). Cellulose has a suitable chemical structure for crystallization (linear polymer with strictly regular structures), and is a construction material of cell walls. Hemicellulose has a suitable chemical structure as an amorphous material, and contributes to the formation of 3D structures of cell walls. Lignin is an aromatic polymer, and plays important roles for the formation of vascular bundle in a tree. Extractives are the important components for controlling the characteristic properties of each tree. As our recent studies, the new analysis method for Lignin-Carbohydrate Complex (LCC) and novel cellulose derivatives for photo-current generation system are also described.


Cellulose Nanofiber for Energy and Materials Production

Takashi Endo
Biomass Refinery Research Center, Advanced Industrial Science and Technology

  In recent years, the development of utilization technology of woody biomass for energy and material has attracted much attention. The main component of wood is cellulose. The nature of cellulose in wood is an assembly of cellulose molecules called the cellulose microfibril. Cellulose nanofibers are bundles of cellulose microfibrils and have the feature of high strength and lightweight.
  In this study, we have used cellulose nanofibers obtained from wood as a core material, and have developed the nanofiber  reinforced composite and the pretreatment for enzymatic saccharification (bioethanol production).  Cellulose nanofibers can be directly prepared from wood by the combined process of wet-milling and hydrothermal treatment (hydrothermal-mechanochemical treatment). The nanofibers have a very large surface area. Therefore, the enzyme readily accesses the cellulose molecules and saccharify.
  In the production of nanofibers, water is essential. Thus, the drying process is required in the compounding of nanofiber with resin. However, the nanofibers tend to aggregate each other. We tried several methods to prevent aggregation of nanofibers in the composite. As a result, the masterbatch method was effective in dispersing of the nanofibers. The masterbatch was prepared by directly blending the nanofiber slurry into the low melting point polyolefin, evaporating water. The nanofiber-polypropylene composite containing just 1wt% nanofiber showed high strength and high elongation.


Activities for Energy Saving in Yonago Mill

Koji Ishitoya
Yonago Mill, Oji Paper Co., LtdD

  At our YONAGO mill, all members are working on the target "1.5% reduction of the total energy of our mill".
  However, it is becoming more and more difficult year by year to find new or drastic energy-saving matters.
  In spite of this difficult situation, by focusing on several projects, we have been successful in reducing the energy consumption of our mill continuously.
  This paper reports how we can achieve our target, and our energy-saving cases.


Heat Exchange Paint NeOCOAT

Yoshiyuki Fujioka
EcoloTec Corporation

  NeOCOAT is a next generation eco-paint which consumes heat by converting thermal energy to kinetic energy using eheat-exchange molecules' in paint. NeOCOAT can be applied to a wide range of surfaces including roofs, pathways, sports grounds, parking areas, indoor surfaces, and play equipment.
  In addition, it is effective in reducing air-conditioning costs and controlling condensation.


The Efficient Energy Reduction Method by Fixed Orifice Type Trap

Masaki Kimura
Z Engineering Co., Ltd.

  In paper pulp industry there are many processes of performing indirect heating by steam, and the steam which emitted heat is discharged from the steam trap as condensate. If a steam trap deteriorates, steam leaking will accrue, so the steam consumption of the whole factory tends to increase every year.
  Although the steam leak rate from a steam trap is different with an operating condition, preservation frequency, etc. an average loss rate exceeding 10% has also been reported, therefore can say that to reduce steam leakage from steam trap is an important factor for energy saving. In order to reduce steam loss, it is necessary to perform check and replace of steam traps frequently. however, if it is a large-sized factory, thousands or much more steam traps are also installed, so it is easy to imagine that is considerably hard to do it from the point of view of the labor and cost. Therefore, the repair of the steam trap is carried out after a steam leak trouble is actualized. And the steam loss before the repair is ignored.
  We propose the energy saving maintenance system using the "fixed orifice-type steam trap" which does not have a deterioration part unlike the steam trap as consumption part. This report introduces the introduction of the "fixed orifice-type steam trap" and the reduction of the steam leaking and maintenance cost by a new maintenance method.


Basic Lecture of Paper Board (4)
The Novel Needs and Future Trend

  In recent years, the change of industrial structure has been caused the change of the mainstream from paper to paperboard in paper and pulp industry.
  However, the demand of the paperboards in Japan hasnft shown upward trend, but has maintained a flat.
  Under these circumstances, the needs of customers for paperboard have shown several diversities in order to attain the cost reduction, and distinguish otherfs products. We have been conducted research and development in order to deal with customerfs needs.
  On the other hand, we strive to acquire the stable profit by raising the recovery rate and blending rate of the waste paper.
  We will outline the future needs and trend of the paperboard, and introduce the countermeasure to take advantage of waste paper for cost reduction and meeting demand, trend and need.


Corporate Profile & Product Information (6)
Katayama Nalco Inc.

  Katayama Nalco Inc. was established in 2004 as joint venture between Nalco Company and Katayama Chemical Co., Ltd. Katayama Nalco has over 80 years history as specialty chemical supplier. We provide process and water treatment chemical and services to various industries such as pulp and paper, primary metal, petro chemical, Automotive, food and beverage etc. Many pulp and paper makers declare openly reducing environmental impact while their manufacturing processes. We also focus on developing technology that provides not only economic but also environmental benefit to customer. Research and manufacturing network for pulp and paper is worldwide. We have wide range of product line that covers from digester to waste water treatment, all paper grades. Especially microbial treatment, retention and drainage, sizing, surfactant and cleaner are strengthen application. Nalco is a pioneer of emulsion polymer use. There is a best practice about polymer handling and feeding as mentioned below. In 2006 Nalco launched PARETOTM Mixing Technology to address polymer feeding issues. History was polymer and micro particle and development, in recently its application technology was considered. Todayfs requirements are suitable retention program for modern papermachine, addressing recycle fibre degradation, higher filler loading. Therefore we would release technology to solve those challenging.


Research Report
Performance Improvement of Activated Sludge

Masayuki Watanabe, Keiko Fujita, Miyuki Nakagawa, Hitomi Kimura and Hitoshi Okada
Japan Pulp and Paper Research Institute, lnc.

  Recently, regulation for effluent standards has become stricter, due to enhanced awareness of the environmental preservation in Japan. In this situation, improvement of wastewater treatment is important for the pulp and paper industry. The Activated sludge (AS) process is one of main wastewater treatments and many paper mills use this process. However, it has been unclear how bacteria affect the performance of AS, and the operation of the AS process often depends on operatorfs experiences.
  As a study of the development of higher performance AS, we have conducted investigations into the present situation of AS at several paper mills. As a result, we found out that the effluent from each mill was not always most effectively decomposed by the AS sample from the same mill. In the laboratory, we confirmed that high performance AS enabled us to improve degradability of wastewater which is resistant to decomposition. Based on the results of genetic analysis, bacteria of the order gRhodocyclalesh was likely to contribute to the performance of AS.