2014 July JAPAN TAPPI JOURNAL
 
Vol.68, No.7 Abstracts


2014 July JAPAN TAPPI JOURNAL

Shiori Uda
Mishima Plant, LINTEC Corporation

  Recently the sign of economic recovery began to appear by Abenomics which consists of three policies included bold financial policy. However, after the Great East Japan Earthquake in 2011, the energy cost in our plant is increasing more caused by rising of electricity power unit due to the shut down of nuclear power plants and increasing of LNG unit price due to influence of the depreciation of the yen. Accordingly, energy-saving activity is becoming increasingly important for our factory from the point of energy cost reduction. So, in this report , we'd like to introduce our energy-saving activities and actual results of energy cost reduction implemented in the past few years.


Factory Diagnostics and Optimization

Norio Fukushima
Ayabe Factory, OMRON Corporetion

  In October 2010, the Ayabe plant launched energy-saving efforts at its production site. The Ayabe plant aims to cut power usage in target areas for energy-saving to half the existing level by March 31, 2014. It was considered that it was difficult to press forward efforts due to concerns about a bad influence on quality and productivity.
  This plant developed and utilized gAndon environmental information systemh, by which we make gdiagnosesh for electric power and environment. It expanded energy-saving efforts to goptimizeh all things which plant place a high priority on, such as quality, productivity, environment, safety, and reassurance.
  As a result, the plant realized a 50% reduction in power consumed by clean rooms, which require a large amount of electricity. At the same time, the amount of air-borne dust was reduced by two-thirds. These are just some examples of the 36 documented energy-saving and environmental improvements that the plant had achieved in December 2013 by cutting electricity usage while improving productivity and product quality. The plant proved that with the participation of everyone in the plant, energy-saving efforts at its production became the goptimizationh Eco efforts which provide also to the improvement of quality and productivity.


Saving Energy of Water Pump with Fluiglide Coating

Tsuyoshi Mizuno
Foreign Product DepartmentC Tetsugen Jitsugyo Co.CLtd..

  FirstlyCthis paper describes the theory of the measurement at site on the water pump to understand the current performance of the pump such as headC horse power and pump efficiency.  The multiple calculations based on the thermodynamics and the special loop calculation makes it possible to quantify the performance relevant value without inputting the actual flow.  SecondlyC the polyester based gFluiglideh coating is introduced to optimize the performance of the existing pump in which the deterioration is obviously recognized.  The improvement of surface roughnessC lubrication property and water resistance with gFluiglideh has realized the less frictional loss and the identical flow area during the operation.  ThirdlyC the technology of gCorroGlassh is also noted to sustain the durability of coating for a longer period since the damage of used pump requires the proper surface to apply gFluiglideh.  The combination of the performance measurement and gFluiglideh coating has achieved the recovery of pump efficiency and clarified the return of investment before all the coating work is implemented.
  Statistical data which has been collected for a decade reveals the certain decrease of efficiency in used pump and indicates the possibility of recovery by applying the gFluiglideh coating.  It is true that most of the pumps with 100-400kW electric motor at site have spent excessive running cost per year due to the inefficient flow.
  Some of the case studies from UK and Japan have shown the decrease of the efficiency and the increase of the horse power in the used pumpC comparing them with the ones measured during the manufacturing.  After applying the gFluiglideh coatingC the user has recognized the noticeable decrease of horse power to achieve more efficient operation.
  Return of investment was guaranteed in early stage and the technology of Fluiglide was admitted by the user.


Energy Saving by Installing Cold-Water Type LNG Vaporizer

Seiji Sasaki
Facilities Department Takefu Plant, Rengo Co., Ltd.

  Rengo Takefu Plant manufactures cellophane, viscose processed paper, porous -cellulose beads, tinted film and other functional products.
  In the past, the plant had been using a hot-water type LNG vaporizer, which sourced heat from steam to fuel the boiler with natural gas.  On the other hand, the cold-water type LNG vaporizer we have recently installed utilizes heat from cool water used in the manufacturing process instead of steam.
  After introducing the current vaporizer system, we have achieved an energy saving by reducing the steam consumption used to vaporize LNG.  In addition, due to evaporative heat removal by LNG, the vaporizer generates cold water which can be utilized in the manufacturing process of cellophane, and thus we have reduced the load of a refrigerating machine creating the cold water.  The specific consumption of LNG and the power consumption of the refrigerating machine have reduced by 3.5% and 5.5% respectively.


Works on the Increase in Electricity Demand in the Mill

Yoshitaka Aoyagi
Kanto Mill (Katsuta), Hokuetsu Kishu Paper Co., Ltd.

  All of steam and the electricity which are used in the mill are supplied from the No.2 biomass boiler (2B) and the No.2 steam turbine generator (2T/G) which started commercial operation in 2006. Since surplus electric power occurs even if it deducts the mill use about electricity, it supplies outside as electricity sales to utilities.
  Establishment of large-sized equipment is scheduled for 2013, it was expected that electricity demand carries out the increase in 900 kW by this operation, and we were anxious about reduction in electricity sales to utilities. Since the work on this increase in electric demand became important, promotion of power saving by energy-saving project and the increase in a production of electricity of 2 T/G were tackled.
  Moreover, photovoltaic generation equipment is due to work from March, 2014 as part of the renewable energy introduction which follows 2B in the mill.
  In this news, the contents of activity and the example of energy-saving project and the increase in 2T/G production of electricity are introduced. In addition, the photovoltaic generation equipment under construction is introduced.


Operating Experiences of SE Rotor

Yasuyuki Yamada
Gifu Mill, Oji Materia  Co.,Ltd.

  We have pulper, screen, a process of manufacture, it is the facilities that pulper, screen and refainer use a lot of energy.
  We simplified pulp process equipment, and have implemented various energy-saving measures, such as concentration of equipment.
  This time we focused on the rotor in the pulp process that consume the most power at Nakatsugawa mill and Ena mill, introduced 90 Type SE rotor is made of six blades by Rotor-Kogyo Co., Ltd..
  I will introduce the operating experience and energy saving about the Rotor in the case of Nakatsugawa mill, that was introduced in June 2011.


Advanced Operation in Activated Sludge Plant for the Stability Treatment and Reducing Energy by Using of KURISONIC, the Unique Monitoring Means for Sludge Settling Tank

Makoto Nomura
ENVIRONMENTAL RESOURCES MANAGEMENT SECTION2, INTEGRATED TECHNOLOGY GROUP
CHEMICALS DIVISION, KURITA WATER INDUSTRIES LTD.

  KURISONICTM is the unique sensor, which provides the condition monitoring means in sludge settling tank (SST). This measuring method is ultrasonic, like sonar, the sludge condition can be detected by its echo.
  The conventional operation in activated sludge plant is mainly based on DO and BOD load in aeration tank, however, the following two trials have been proceed by using of KURISONIC and obtained good results.
  1)  High Compaction Sludge Return Control in SST:
  - Higher return sludge concentration causes to improve at dehydrator to reduce  the cake water content, and to save cake waste cost.
  - Smaller volume of return sludge causes to gain HRT in aeration tank, and to improve stability treatment.
  2)  Excess aeration and Denitrification control from monitoring SST:
  - Lower SS effluent from SST causes to improve treated water quality, and to support the performance of plant.
  - Suitable aeration causes to save energy, to save electric cost and concerning CO2 gas discharge to the earth
  The operation with focusing to SST by using of KURISONIC is very effective in activated sludge plant.


High Efficient Fluoropolymer Heat Exchenger Enables Low Temperature Waste Heat Recovery of Boiler under 200℃
-Waste Heat Recovery at below Acid Dew Point is Available-

Masayumi Ishida
Kasama Operations Center, Clean technology component products
Products marketing, Junkosha Inc.

  Energy saving and power saving are critical issues to be addressed among all factory. Conventionally, there is the demand to recover the energy from low temperature waste heat gas.
  However, the waste heat gas recovering from the low temperature had been considered to be very difficult by acid dew point corrosion, scale adhesion of the heat transfer tube , and so on.  Junkosha's Heat Exchanger resolves above problem by improvements of Junflon® PFA heat transfer tube and the structure of heat exchanger.
  Four points are necessary to recover the waste heat from low temperature gas.
  ①  Corrosion resistance for the acid dew point
  ②  Reduction of the gas pressure loss
  ③  Reduction of the maintenance man-hour
  ④  Space saving and lightweighting
  Junkosha's products have been installed in a Sheet Glass Company and used in maintenance-free for 14 years. Thus it has been already proved that four points of characteristics are superior.
  In addition, we recently carried out a verification test with two papermaker's  boiler( multi-fuel fired boilerF180 t/h, black liquor recovery boiler:170 t/h)
  AS a results,  no corrosion,  scale adhesion,  abrasion and deterioration of the heat transfer tube,  were observed.
  Junkosha's fluoropolymer heat exchanger,uFLUORO-X® GRID SERIESv, provides  excellent corrosion resistance and the non-adhesiveness from low temperature gas. In addition, the overall heat transfer coefficient is very high(40`50 kcal/m2E℃Ehr) In conclusion, FLUORO-X® GRID SERIES has the most advantages than the product made of other materials.


The Latest Proposals for Improving Productivity of Paper Machine
- On Machine Equipment, Approach System -

Yoichiro Iwatani
Technical & Sales Dept., AIKAWA IRON WORKS CO., LTD.

  In the paper machine, productivity decline due to sticky contaminant or web break is a big problem. Therefore, to improve productivity of a paper machine, I will introduce the latest technology for the approach system and on machine equipment.


Technology for Reject Treatment and Recovery
-Fiber & Filler Recovery for Coated Paper and Board-

  The cleaner reject consists of valuable raw materials that can be reused in the process after treating them with our reject treatment technology, ATREX. Especially the paper and board mills producing coated grades have a lot of coating flakes in their current reject streams. The heavier the coating is the more difficult in deflaking with existing machinery. Double coated grades or coated board are good examples. When the reject stream is studied more carefully, one can detect fractions from fillers, coating flakes, residues from furnish like fiber knots or shives and contaminants like sand. When this stream is processed with ATREX reject recovery system, the target is to reach the original particles size distribution of coating pigments and fillers. At the same time fiber knots are disintegrated and shives grinded. It has been shown that all the fibers and more than 95% of the total reject stream can be recovered back to process. The pigment works as filler and the use of native filler can be subsequently reduced.

Report of 2013 TAPPI PEERS and 10th RFR Conference

Takehiro Kojima and Kazuhiro Kurosu
Nippon Paper Industries Co., Ltd.

  In 2013 TAPPI PEERS (Pulping, Engineering, Environmental, Recycling and Sustainability) and 10th RFR (Research Forum on Recycling) was held in Green Bay WI, USA on September 15-18. There were 82 oral presentations, 2 panel sessions and 5 workshops in these conferences. Total participants were 372 people, mainly from north America. This report introduced the summaries of these conference and several presentations.


Corporate Profile & Products Information (13)

YAMAUCHI CORP.

  YAMAUCHI CORP. was established as a manufacturer of rubber-belt for cars in 1918. Since then, YAMAUCHI has been contributing to several industries by developing the highest qualities thanks to its unique compounding technologies and excellent production technique.
  The representing products now are special rollers, belts and hysteresis torque limiters for multifunction equipment, precision molded resin and vibration isolation rubber for disc drives and single-cushion materials for PCB process.
  As for paper making industry, Yamauchi has developed PU roll covers, ceramic covers and grooved belts for closed shoe presses first in the world and has been the major player in the world.  
  Yamauchi is operating factories, all of them are certified both ISO9001 and ISO14001, two in Japan, two in ASEAN,  two in China and two in Europe so that Yamauchi is able to supply its high qualities to all over the world.
  We hereby introduce the features of our latest products for papermaking industry.


-Peer Reviewed-
Analysis of Moisture Wrinkles in Containerboard Rolls

Hironobu Hirano and Takao Kobayashi
Pulp and Paper Innovation Center, Oji Holdings Co., Ltd.

  Recently, containerboard basis weights have been decreasing in terms of resource or cost saving. Such a trend will cause some quality problems, one of which is moisture wrinkles observed in containerboard rolls.
  In this study, containerboard rolls manufactured by six different mills were stored in the same place for a period of time to observe moisture wrinkles and to monitor the moisture content of rolls. Multiple regression analysis of the result suggested that moisture wrinkles correlated significantly with stiffness, hygroexpansion and formation.
  Furthermore, numerical simulations using the finite element method were also performed to confirm the effect of these three factors on moisture wrinkles.