CASE STUDY OF COST SAVINGS WITH A NEW CHEMICAL MIXING SYSTEM AT MITSUBISHI PAPER HACHINOHE MILL PM7 potx

J.Matula J.Matula Wetend Technologies Ltd. Wetend Technologies Ltd. K.Sato K.Sato Mitsubishi Paper Mills Ltd. Mitsubishi Paper Mills Ltd. R.Watanabe R.Watanabe Mitsubishi Paper Mills Ltd Mitsubishi Paper Mills Ltd . . MITSUBISHI PAPER MILLS LIMITED WETEN D Te ch n o l o g i e s Case Study of Cost Savings Case Study of Cost Savings with a New Chemical Mixing System with a New Chemical Mixing System at Mitsubishi Paper Hachinohe Mill PM7 at Mitsubishi Paper Hachinohe Mill PM7 Contents Contents 1. Introduction of Mitsubishi Paper 1. Introduction of Mitsubishi Paper 2. 2. Background Background 3. Introduction of 3. Introduction of “ “ Jet Injection Jet Injection ” ” mixing technology mixing technology 4. Results 4. Results 5. 5. “ “ Step two Step two ” ” 6. 6. Conclusions Conclusions Contents Contents 1. Introduction of Mitsubishi Paper 1. Introduction of Mitsubishi Paper 2. 2. Background Background 3. Introduction of 3. Introduction of “ “ Jet Injection Jet Injection ” ” mixing technology mixing technology 4. Results 4. Results 5. 5. “ “ Step two Step two ” ” 6. 6. Conclusions Conclusions Outline of Mitsubishi Paper Group Outline of Mitsubishi Paper Group Ü Ü M M itsubishi itsubishi P P aper aper M M ills Limited (MPM) ills Limited (MPM) Mills Mills : : 5 mills in 5 mills in Japan Japan Product Product : : 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 Ü Ü Mitsubishi HiTec Paper GmbH Mitsubishi HiTec Paper GmbH Mills Mills : : 2 mills in 2 mills in Germany Germany ( ( Bielefeld and Flensburg) Bielefeld and Flensburg) Outline of Hachinohe Mill Outline of Hachinohe Mill Ü Ü Hachinohe Mill Hachinohe Mill Production Production : 0.9 million t/year : 0.9 million t/year Machines Machines : 7 paper machines and 3 off : 7 paper machines and 3 off - - coaters coaters T h e P a c i f i c O c e a n T h e P a c i f i c O c e a n MITSUBISHI PAPER MILLS LIMITED Outline of PM7 in Hachinohe mill Outline of PM7 in Hachinohe mill Ü Ü PM7 PM7 Build Build : : 1997 1997 Base weight Base weight : 48 : 48 - - 157gsm 157gsm Speed Speed : 1,300m/min : 1,300m/min Production Production : 13,000t/month : 13,000t/month Wire width Wire width : 5,800mm : 5,800mm HeadBox HeadBox : ModuleJet : ModuleJet Former Former : DuoFormer : DuoFormer - - D Press D Press : TNT+TF+ENP : TNT+TF+ENP - - C C Grade Grade : Base paper, Fine paper, Book paper, LWC : Base paper, Fine paper, Book paper, LWC MITSUBISHI PAPER MILLS LIMITED Contents Contents 1. Introduction of Mitsubishi Paper 1. Introduction of Mitsubishi Paper 2. 2. Background Background 3. Introduction of 3. Introduction of “ “ Jet Injection Jet Injection ” ” mixing technology mixing technology 4. Results 4. Results 5. 5. “ “ Step two Step two ” ” 6. 6. Conclusions Conclusions Decrease in FPR Decrease in FPR Ü Ü ‘ ‘ Optimization of wet Optimization of wet - - end end ’ ’ at PM7 since 2005 at PM7 since 2005 î î New retention system (Dual polymers) New retention system (Dual polymers) Ü Ü Decrease in FPR after ECF of pulp process Decrease in FPR after ECF of pulp process î î Because of increase in PCD of LBKP Because of increase in PCD of LBKP (*) LBKP = Laubholz Bleached Kraft Pulp (*) LBKP = Laubholz Bleached Kraft Pulp Ü Ü Increase in the consumption of retention aids Increase in the consumption of retention aids Change in dosing rate Change in dosing rate of retention aids of retention aids 100 110 60 80 100 120 Before ECF After ECF Dosing rate of retention aids (Set 'Before ECF' = 100) Necessity of Necessity of new chemical mixing system new chemical mixing system Ü Ü Request to new chemical mixing system Request to new chemical mixing system   Reduction in retention aids Reduction in retention aids   Improvement of FPR Improvement of FPR   No scale No scale and dirt and dirt   No sheet formation problem No sheet formation problem Ü Ü Examination of installation Examination of installation “ “ Jet Injection Jet Injection ” ” mixing mixing technology technology [...]... Drainage 60sec Agitator setting High shear Medium shear Low shear (*) Tested at Mütec DFS retention analyzer Result of laboratory test 64 45 62 40 ASH FPR [%] TOTAL FPR [%] 60 58 56 54 52 50 48 46 0.000 Simulation of new chemical mixing points Simulation of conventional chemical mixing points 0.010 0.020 Dosing rate of retention aids [%] (C-PAM +A- PAM) 0.030 35 30 25 20 15 10 0.000 Simulation of new chemical. .. FiberLaboratory City of Savonlinna TrumpJet® Flash Mixing for papermaking additives 17 -Flash mixing takes place in time of two seconds -Transverse injection exploits circulated headbox feed stock -Use of fresh water or filtrate is completetly eliminated PATENTED Flash-Injection mixing technology Injection stock Mixing stock Chemical Jet Injection Mixing for papermaking additives 18 -Fast mixing makes... machine flow Stock Box DC HeadBox Cleaner C-PAM MS P P CFP MFP With New Jet Injection Mixing, machine flow Stock Box DC HeadBox Cleaner C-PAM MS P P CFP MFP Concept of laboratory test Simulation of conventional mixing points C-PAM before cleaner fan pump Simulation of new chemical mixing points C-PAM before A- PAM after machine screen machine screen A- PAM before machine fan pump 0sec 35sec 40sec Drainage... mixing With TrumpJet 75 67 70 60 50 40 Coat Base Paper Fine Paper Book Paper SLWC LWC Average Improvement of Ash FPR 70 ASH FPR [%] 60 Before With TrumpJet 50 42 40 30 30 20 Coat Base Paper Fine Paper Book Paper SLWC LWC Average Content 4 Result 1) Reduction of retention aids and improvement of FPR 2) Saving energy by reduction of dilution water 3) Extending shut down cycle for prolonged lifetime of. .. lifetime : 90 days î 120 days Ü Annual requirement of wire : 4 pieces/year î 3 pieces/year (*) Both top wire and bottom wire Total consistency of press white water Total consistency of Press white water [%] 0.20 Before With TrumpJet Jet Injection mixing 0.15 0.10 0.08 0.05 0.05 0.00 Coat Base Paper Fine Paper Book Paper SLWC LWC Average Felt wearing rate PuF -23% Felt wearing rate [%/day] 0.40 0.30... chemical mixing points Simulation of conventional chemical mixing points 0.010 0.020 Dosing rate of retention aids [%] (C-PAM +A- PAM) 0.030 Contents 1 Introduction of Mitsubishi Paper 2 Background 3 Introduction of “Jet Injection” mixing technology 4 Results 5 “Step two” 6 Conclusions TrumpJet® Flash Mixing = Jet Injection Mixing for papermaking additives Wetend Technologies Ltd is a Finland based corporation... for papermaking additives Total 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 postdilution water : This gives 1,5 million MWh potential to reduce energy consumption and approx 1000.000 tons of CO2 emissions per annum... for prolonged lifetime of wires and felts Ash consistency of white water Ash consistency of No.1 white water tank [%] 0.50 Before Jet Injection mixing With TrumpJet 0.40 0.30 0.20 0.16 0.09 0.10 0.00 Coat Base Paper Fine Paper Book Paper SLWC LWC Average Ash flow rate passing through wire 3,480 Ash flow rate passing through wire [t/month] 3,500 Before With TrumpJet Jet Injection mixing 3,000 2,500 1,949... lifetime of wires and felts Saving energy by reduction of dilution water Ü Reduction of dilution water of A- PAM line 90 L/min î 30 L/min (24 GPM î 8 GPM) Energy savings 25.2 2,540kWh/day 60L/min 4.2kJ/kg (*) Fresh water temperature = 11.8 C Warm water temperature = 37.0 C Content 4 Result 1) Reduction of retention aids and improvement of FPR 2) Saving energy by reduction of dilution water 3) Extending... 1,000 500 0 Coat Base Paper Fine Paper Book Paper SLWC LWC TOTAL -44% Wire wearing rate 0.220 Wire wearing rate [%/day] 0.204 TOP.W -16% 0.198 0.200 0.180 BOT.W -19% 0.171 0.160 0.160 0.140 Before With TrumpJet Jet Injection mixing 0.120 0.100 TOP.W BOT.W Improvement of AKD dirt on top wire After 60days Before With With TrumpJet Jet Injection mixing Untouched Scratched Prolonged lifetime of wires Ü Wire . Savings Case Study of Cost Savings with a New Chemical Mixing System with a New Chemical Mixing System at Mitsubishi Paper Hachinohe Mill PM7 at Mitsubishi Paper. J.Matula J.Matula Wetend Technologies Ltd. Wetend Technologies Ltd. K.Sato K.Sato Mitsubishi Paper Mills Ltd. Mitsubishi Paper Mills Ltd. R.Watanabe R.Watanabe