paper mills case study of cost savings limited with … paper mills limited wetend technologies ......
TRANSCRIPT
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J.MatulaJ.Matula Wetend Technologies Ltd.Wetend Technologies Ltd.
K.SatoK.Sato Mitsubishi Paper Mills Ltd.Mitsubishi Paper Mills Ltd.R.Watanabe R.Watanabe Mitsubishi Paper Mills LtdMitsubishi Paper Mills Ltd..
MITSUBISHIPAPER MILLSLIMITED
WETENDTechnologies
Case Study of Cost SavingsCase Study of Cost Savingswith a New Chemical Mixing Systemwith a New Chemical Mixing Systemat Mitsubishi Paper Hachinohe Mill PM7at Mitsubishi Paper Hachinohe Mill PM7
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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Outline of Mitsubishi Paper GroupOutline of Mitsubishi Paper Group
MMitsubishi itsubishi PPaper aper MMills Limited (MPM)ills Limited (MPM)
MillsMills :: 5 mills in 5 mills in JapanJapan
ProductProduct :: Printing paper, Office use paper, Printing paper, Office use paper,
Business communication paper, Business communication paper,
White lined board, Photographic paper White lined board, Photographic paper
Mitsubishi HiTec Paper GmbHMitsubishi HiTec Paper GmbH
MillsMills :: 2 mills in 2 mills in GermanyGermany
((Bielefeld and Flensburg)Bielefeld and Flensburg)
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Outline of Hachinohe MillOutline of Hachinohe Mill
Hachinohe MillHachinohe MillProductionProduction : 0.9 million t/year: 0.9 million t/year
MachinesMachines : 7 paper machines and 3 off: 7 paper machines and 3 off--coaterscoaters
The Pacific Ocean
The Pacific Ocean
MITSUBISHIPAPER MILLSLIMITED
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Outline of PM7 in Hachinohe millOutline of PM7 in Hachinohe mill
PM7PM7BuildBuild : : 19971997
Base weightBase weight : 48: 48--157gsm157gsm
SpeedSpeed : 1,300m/min: 1,300m/min
ProductionProduction : 13,000t/month: 13,000t/month
Wire widthWire width : 5,800mm: 5,800mm
HeadBoxHeadBox : ModuleJet: ModuleJet
FormerFormer : DuoFormer: DuoFormer--D PressD Press : TNT+TF+ENP: TNT+TF+ENP--CC
GradeGrade : Base paper, Fine paper, Book paper, LWC: Base paper, Fine paper, Book paper, LWC
MITSUBISHIPAPER MILLSLIMITED
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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Decrease in FPRDecrease in FPR
‘‘Optimization of wetOptimization of wet--endend’’ at PM7 since 2005at PM7 since 2005
New retention system (Dual polymers)New retention system (Dual polymers)
Decrease in FPR after ECF of pulp processDecrease in FPR after ECF of pulp process
Because of increase in PCD of LBKPBecause of increase in PCD of LBKP
(*) LBKP = Laubholz Bleached Kraft Pulp(*) LBKP = Laubholz Bleached Kraft Pulp
Increase in the consumption of retention aidsIncrease in the consumption of retention aids
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Change in dosing rateChange in dosing rateof retention aidsof retention aids
100
110
60
80
100
120
BeforeECF
AfterECF
Dos
ing
rate
of r
eten
tion
aids
(Set
'Bef
ore
EC
F' =
100
)
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Necessity ofNecessity ofnew chemical mixing systemnew chemical mixing system
Request to new chemical mixing systemRequest to new chemical mixing system
Reduction in retention aidsReduction in retention aids
Improvement of FPRImprovement of FPR
No scaleNo scale and dirtand dirt
No sheet formation problemNo sheet formation problem
Examination of installation Examination of installation ““Jet InjectionJet Injection”” mixing mixing technologytechnology
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Previous machine flowPrevious machine flow
HeadBoxHeadBox
PP
Stock BoxStock Box DCDC
CleanerCleaner
MSMS
MFPMFPCFPCFP
PP
CC--PAMPAM : Before CFP: Before CFP ((Quill nozzle)Quill nozzle)
AA--PAMPAM : Before MFP: Before MFP ((Quill nozzle)Quill nozzle)
AA--PAMPAMCC--PAMPAM
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With New Jet Injection Mixing, machine flowWith New Jet Injection Mixing, machine flow
HeadBoxHeadBox
PP
Stock BoxStock Box DCDC
CleanerCleaner
MSMS
MFPMFPCFPCFP
PP
CC--PAMPAM : Before MS: Before MS ((Quill nozzle)Quill nozzle)
AA--PAMPAM : After MS: After MS ((TrumpJet)TrumpJet)
AA--PAMPAM
CC--PAMPAM
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Concept of laboratory testConcept of laboratory test
Simulation ofconventional mixing points
(*) Tested at Mütec DFS retention analyzerHigh shearMedium shearLow shear
Agitator setting0sec 35sec 40sec 60sec
C-PAM beforecleaner fan pump
Drainage
A-PAM beforemachine fan pump
C-PAM beforemachine screen
A-PAM aftermachine screen
Simulation ofnew chemical mixing points
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Result of laboratory testResult of laboratory test
46
48
50
52
54
56
58
60
62
64
0.000 0.010 0.020 0.030Dosing rate of retention aids [%]
(C-PAM+A-PAM)
TOTA
L FP
R [%
]
Simulation of newchemical mixing pointsSimulation of conventionalchemical mixing points
10
15
20
25
30
35
40
45
0.000 0.010 0.020 0.030Dosing rate of retention aids [%]
(C-PAM+A-PAM)
AS
H F
PR
[%]
Simulation of newchemical mixing pointsSimulation of conventionalchemical mixing points
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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TrumpJetTrumpJet®® Flash Mixing = Jet Injection Mixing for Flash Mixing = Jet Injection Mixing for papermaking additivespapermaking additives
Wetend Technologies Ltd is a Finland based corporation.
City of Savonlinna
FiberLaboratory
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17
Injection stock
ChemicalMixing stock
TrumpJetTrumpJet®® Flash Mixing for papermaking Flash Mixing for papermaking additivesadditives
-Transverse injection exploits circulated headbox feed stock.-Use of fresh water or filtrate is completetly eliminated
-Flash mixing takes place in time of two seconds
PATENTED Flash-Injection mixing technology
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18Jet Injection Mixing for papermaking additivesJet Injection Mixing for papermaking additives
-Two or more additives can be mixed simultaneusly in groups
-Fast mixing makes it possible to bring the most important aditives close to the headbox to increase efficiency
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19Jet Injection Mixing for papermaking additivesJet Injection Mixing for papermaking additives
250 installation in 20 countries:
Typical results:- quality and process improvements- reduced additive consumption- total elimination of fresh water in dilution-reduced energy consumption -reduction of CO2 emission
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Jet Injection Mixing for papermaking additivesJet Injection Mixing for papermaking additivesTotal Annual Water and Energy Saving with 250 installations:35 million m3 (9 billion gal) of fresh water with 1,5 million MWh (5000 billion BTU) energy saving corresponding to more than 800.000 oil barrels
7+ hours
No energy needed to heat post-dilution water :
This gives 1,5 million MWh potential to reduce energy consumption and approx 1000.000 tons
of CO2 emissions per annum
PATENTED Jet Injection mixing technology
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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Content 4. ResultContent 4. Result
1)1) Reduction of retention aidsReduction of retention aids
and iand improvement of FPRmprovement of FPR
2)2) Saving energySaving energy
by reduction of dby reduction of dilution waterilution water
3)3) Extending shut down cycle forExtending shut down cycle for
prolonged prolonged lifetime of wires and feltslifetime of wires and felts
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Content 4. ResultContent 4. Result
1)1) Reduction of retention aidsReduction of retention aids
and iand improvement of FPRmprovement of FPR
2)2) Saving energySaving energy
by reduction of dby reduction of dilution waterilution water
3)3) Extending shut down cycle forExtending shut down cycle for
prolonged prolonged lifetime of wires and feltslifetime of wires and felts
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71
110
100
40
60
80
100
120
BeforeECF
AfterECF
WithTrumpjet
Dos
ing
rate
of r
eten
tion
aids
(Set
'Bef
ore
EC
F' =
100
)
With new ”Jet Injection mixing”
Reduction of retention aidsReduction of retention aids
--35%35%
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Improvement of Total FPRImprovement of Total FPR
67
75
40
50
60
70
80
90
CoatBasePaper
FinePaper
BookPaper
SLWC LWC Average
TOTA
L FP
R [%
]
BeforeWith TrumpJetJet Injection mixing
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Improvement of Ash FPRImprovement of Ash FPR
30
42
20
30
40
50
60
70
CoatBasePaper
FinePaper
BookPaper
SLWC LWC Average
AS
H F
PR [%
]
BeforeWith TrumpJet
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Content 4. ResultContent 4. Result
1)1) Reduction of retention aidsReduction of retention aids
and iand improvement of FPRmprovement of FPR
2)2) Saving energySaving energy
by reduction of dby reduction of dilution waterilution water
3)3) Extending shut down cycle forExtending shut down cycle for
prolonged prolonged lifetime of wires and feltslifetime of wires and felts
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Saving energySaving energyby reduction of dby reduction of dilution waterilution water
Reduction of dilution water of AReduction of dilution water of A--PAM linePAM line
90 L/min 90 L/min 30 30 L/minL/min
(24 GPM (24 GPM 8 GPM)8 GPM)
Energy savingsEnergy savings
25.225.2℃℃ ×× 6060L/min L/min ×× 4.24.2kJ/kgkJ/kg℃℃ ==
2,5402,540kWh/daykWh/day
(*) (*) Fresh water temperature = 1Fresh water temperature = 11.8 1.8 CC
Warm water temperature = 37.0 CWarm water temperature = 37.0 C
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Content 4. ResultContent 4. Result
1)1) Reduction of retention aidsReduction of retention aids
and iand improvement of FPRmprovement of FPR
2)2) Saving energySaving energy
by reduction of dby reduction of dilution waterilution water
3)3) Extending shut down cycle forExtending shut down cycle for
prolonged prolonged lifetime of wires and feltslifetime of wires and felts
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0.16
0.09
0.00
0.10
0.20
0.30
0.40
0.50
CoatBasePaper
FinePaper
BookPaper
SLWC LWC Average
Ash
con
sist
ency
of
No.
1 w
hite
wat
er ta
nk [%
]
BeforeWith TrumpJetJet Injection mixing
Ash consistency of white waterAsh consistency of white water
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3,480
1,949
0
500
1,000
1,500
2,000
2,500
3,000
3,500
CoatBasePaper
FinePaper
BookPaper
SLWC LWC TOTAL
Ash
flow
rate
pas
sing
thro
ugh
wire
[t/m
onth
] .
BeforeWith TrumpJetJet Injection mixing
Ash flow rate passing through wire Ash flow rate passing through wire
--44%44%
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0.2040.198
0.171
0.160
0.100
0.120
0.140
0.160
0.180
0.200
0.220
TOP.W BOT.W
Wire
wea
ring
rate
[%/d
ay]
BeforeWith TrumpJetJet Injection mixing
Wire wearing rateWire wearing rate
TOP.WTOP.W--16%16% BOT.WBOT.W
--19%19%
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After 60days Untouched Scratched
Before
With TrumpJet
Improvement of AKD dirt on Improvement of AKD dirt on top wiretop wire
With Jet Injection mixing
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Prolonged Prolonged lifetime of wireslifetime of wires
Wire lifetime :Wire lifetime :
90 days 90 days 120 120 daysdays
Annual requirement of wire :Annual requirement of wire :
4 pieces/year 4 pieces/year 3 pieces3 pieces//yearyear
(*) (*) Both top wire and bottom wireBoth top wire and bottom wire
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Total consistencyTotal consistency of pof press white waterress white water
0.08
0.05
0.00
0.05
0.10
0.15
0.20
CoatBasePaper
FinePaper
BookPaper
SLWC LWC Average
Tota
l con
sist
ency
of
Pres
s w
hite
wat
er [%
]
BeforeWith TrumpJetJet Injection mixing
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Felt wearing rateFelt wearing rate
0.30
0.15
0.23
0.08
0.00
0.10
0.20
0.30
0.40
PuF 4PF
Felt
wea
ring
rate
[%/d
ay]
BeforeWith TrumpJet
PuFPuF--23%23%
4PF4PF--47%47%
(*) ‘FPR improvement’ + ‘optimization of felt conditioner’
Jet Injection mixing
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Prolonged Prolonged lifetime of feltslifetime of felts
Felt lifetime :Felt lifetime :
60 days 60 days 80 80 daysdays
Annual requirement of felt :Annual requirement of felt :
6.0 pieces/year 6.0 pieces/year 4.5 pieces4.5 pieces//yearyear
(*) (*) All 5parts ( PuF / 1PBF / 3PF / 4PF / TF )All 5parts ( PuF / 1PBF / 3PF / 4PF / TF )
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Extending shut down cycleExtending shut down cycle
Shut down cycle :Shut down cycle :
30 days 30 days 40 40 daysdays
Number of annual shut downs :Number of annual shut downs :
12 times/year 12 times/year 9 times9 times//yearyear
(*) (*) Each shut down time remains the same.Each shut down time remains the same.
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. 5. ““Step twoStep two””
6. 6. ConclusionsConclusions
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Content 5. Content 5. ““Step twoStep two””
CC--PAM + AKD with Jet Injection PAM + AKD with Jet Injection mixing after the screenmixing after the screen
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Present machine flow, PM7Present machine flow, PM7
HeadBoxHeadBox
PP
Stock BoxStock Box DCDC
CleanerCleaner
MSMS
MFPMFPCFPCFP
PP
CC--PAMPAM : Before MS: Before MS ((Quill nozzle)Quill nozzle)
AKDAKD : Stock Box: Stock Box
AA--PAMPAM
CC--PAMPAMAKDAKD
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With new Jet Injection Mixing, machine flow, PM7With new Jet Injection Mixing, machine flow, PM7
HeadBoxHeadBox
PP
Stock BoxStock Box DCDC
CleanerCleaner
MSMS
MFPMFPCFPCFP
PP
CC--PAM + AKD : After MS (Jet PAM + AKD : After MS (Jet Injection Mixing)Injection Mixing)
AA--PAMPAM
CC--PAM PAM + + AKDAKD
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Concept of laboratory test, PM7Concept of laboratory test, PM7
0sec 35sec 40sec 60secDrainage
Simulation ofpresent mixing points
(*) Tested at Mütec DFS retention analyzer
High shearMedium shearLow shear
Agitator setting
AKD at stock boxC-PAM beforemachine screen
C-PAM + AKDafter machine screen
A-PAM aftermachine screen
Simulation ofnew chemical mixing points
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Result of laboratory simulation
10
15
20
25
30
35
40
45
50
0.12 0.14 0.16 0.18 0.2AKD dosing rate [%]
Stö
ckig
t siz
ing
degr
ee [s
ec]
AKD at stock box
AKD+C-PAM after machine screen
Result of laboratory test, PM7Result of laboratory test, PM7
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Conclusion of installation in PM7Conclusion of installation in PM7
Possibility to reduce AKD by Jet Injection MixingPossibility to reduce AKD by Jet Injection Mixing
Possibility to reduce retention aids still morePossibility to reduce retention aids still more
because of success in the first Jet Injection Mixingbecause of success in the first Jet Injection Mixing
Decision to install TrumpJet Decision to install TrumpJet Chord Chord for CPAM and for CPAM and AKDAKD
Installation in October, 2008.Installation in October, 2008.
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Conclusion of installation in PM7 for CPAM & AKDConclusion of installation in PM7 for CPAM & AKD
Results: Results: PM7, additive savings after flash injection installed also for CPAM and AKD
Filler content CPAM APAM AKD
Low - under 10% 10%* 10%* 20%
Middle 10%* 10%* 10%
High 20 – 30% 10%* 10%* 0%
***Filler retention before 30,2% after 41,9%, if old retention is kept, the saving of CPAM is 40%
***Mitsubishi Paper is now investigating the effect of dosing locations of filler and AKD to optimize sizing degree
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ContentsContents
1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper
2. 2. BackgroundBackground
3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology
4. Results4. Results
5. Future plan5. Future plan
6. 6. ConclusionsConclusions
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Optimization of wetOptimization of wet--end at PM7end at PM7
Optimization of wetOptimization of wet--end at PM7 since 2005end at PM7 since 2005
A) Optimization of retention systemA) Optimization of retention system
B) Stabilization of electric charge of white waterB) Stabilization of electric charge of white water
C) Optimization of biocideC) Optimization of biocide
D) Optimization of felt conditionerD) Optimization of felt conditioner
Encounter with sudden drop in FPREncounter with sudden drop in FPR
Investigation cause Investigation cause Installation Jet Injection Installation Jet Injection Mixing stationsMixing stations
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ConclusionsConclusionsBy By ““Jet Injection MixingJet Injection Mixing”” (and optimization of wet(and optimization of wet--end),end),
Great reduction in production costGreat reduction in production cost
Increase in Increase in productivityproductivity by 3.5%by 3.5%
Planning to adapt Jet Injection technology to other Planning to adapt Jet Injection technology to other chemicalschemicals
One of THE solutions of One of THE solutions of ‘‘optimization of wetoptimization of wet--endend’’
‘‘Change chemicalsChange chemicals’’ + + ‘‘Improved equipmentImproved equipment’’
More effective resultMore effective result
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MITSUBISHIPAPER MILLSLIMITED
WETENDTechnologies
Thank youThank you