Pioneering Innovations challenge conventional process chemistry and efficiently cut raw material costs with sustainable results docx

Pioneering Innovations challenge conventional process
chemistry and efficiently cut raw material costs
with sustainable results

Jouni Matula
Wetend Technologies Ltd; Savonlinna, Finland
www.wetend.com


WETEND
Technologies
TrumpJet with three nozzles – “injection mixing without delay”
WETEND
Technologies
TrumpJet

Flash Mixing process – no water nor filtrate
Clean headbox feed stock as TrumpJet
circulated injection liquid:
1. Eliminates completely use of fresh
water or any filtrate in this part of the
process
2. Saves the energy used to heat up the
fresh water
WETEND
Technologies
Fresh, clean water is a limited resource of nature
The water saving gives 2,5 million MWh potential to reduce
energy consumption
And approximately 2.000.000 tons of CO
2

emissions per
annum
Today TrumpJet installations in operation save
55 million m
3
fresh water and
reduce 2,5 million MWh water heating energy per
annum
WETEND
Technologies
The world biggest coated WF paper production line 4000 tn/d in
China
Energy and fresh water saving with three TrumpJet mixing stations:

• Fresh water saving: 2,3 million m
3


• Energy saving: 77 000 MWh

• CO
2
reduction: 44 000 tn
CO
2
emission reduction
approx 10% from the total
emission load of PM
WETEND
Technologies

TrumpJet Flash Mixing
Very fast mixing phenomenon
Mixing time 1 second or less

CVP= counter rotating vortex pair
with four major mixing engines
WETEND
Technologies
Flash Mixing close to the headbox
SC-magazine paper production line
TrumpJet Flash Mixing STATION
WETEND
Technologies


Copyright Wetend Technologies Ltd
20111230-001 JM
LWC paper, Finland
TrumpJet results with cationic retention aid
polymer

• Previous location: pre-screen
• TrumpJet location: on machine floor
2 seconds before headbox

• Chemical saving 50%

• Injection with headbox stock;
100% elimination of use of fresh water

• Payback time: very short
WETEND
Technologies
Copyright © Wetend Technologies Ltd
Flash mixing of papermaking additives
Conventional methods: Single pass % of additives to headbox vrs. dosage point

WETEND
Technologies
Copyright © Wetend Technologies Ltd
Flash mixing of papermaking additives

Focus of interest of
development and targeted
area in additive mixing
WETEND
Technologies
Copyright © Wetend Technologies Ltd
Flash Mixing concept and mixing in groups
State of the art: Chemicals and additives are dosed independently in separate dosing
points.

ABC mixing concept:
Selected chemicals and additives mixed in groups simultaneously
WETEND
Technologies
Copyright © Wetend Technologies Ltd
Nanoparticle
Micropolymer
Retention aid polymers

Sizing agent; ASA/AKD
New:
Starch & Filler
TrumpJet ABC of mixing
TrumpJet Flash Mixing of papermaking additives
close to headbox
WETEND
Technologies
Earnings and Sustainable results:
Case: A coated printing paper production line in USA
Power:
 Energy saving: 14650 MWh/a
 CO
2
emission reduction 2750 tons/a

Fresh Water:
 Water saving 300.000 m
3
/a

Raw materials and optimiced use of additives
 Saving of retention aid silica 43%
 Saving of retention aid polymer 17%


Process efficiency:
 Incresed filler content of sheet 4,7%
 Increase of reel speed 8%
 Reduced steam consumption!

ANNUAL SAVINGS: MORE THAN 1 MILLION EUR
WETEND
Technologies
Copyright © Wetend Technologies Ltd
The process concept and use of stock or white water or solids containing filtrates for mixing is PROTECTED WITH PATENTS
ABC of mixing: Mixing of additives in pairs and in groups
close to papermachine headbox
 Three (3) mixing
stations: A,B,C
 Six (6) chemicals & additives
WETEND
Technologies
Copyright © Wetend Technologies Ltd
Nanoparticle
Micropolymer
Retention aid polymers
Sizing agent; ASA/AKD
New:
Starch & Filler
A Large Fine Paper machine with a world speed record, China
Starch and filler (GCC) mixing results with TrumpJet
®
Flash Mixing system
WETEND
Technologies

•Reduced starch consumption 20%
•Reduced CPAM consumption >30-40%
•Reduced APAM consumption >30-40%

•Total retention improved

•ASA dosage unchanged
•Consumption of OBA slightly reduced

•Critical production and sheet quality values remained the same or improved

•Reduced loss of good filler through rejects

 Total net efficiency of the production line improved

A Large Fine Paper machine, China

Mixing results of Starch and Filler with TrumpJet
®
Flash Mixing / ABC system:
Use of fresh water eliminated with all
three A,B,C mixing stations:
•Annual water saving total: 1 million m
3
•Annual energy saving: 33.000 MWh
•Annual CO2 reduction: 20.000 tons
WETEND
Technologies
Chemicals, Energy, Fresh water, CO
2

Mill scale cost savings at paper mills
with TrumpJet Flash Mixing technology

Typical earnings per papermaking line: 200.000 EUR … 1.000.000 EUR per year
Typical range of payback time: 2….8 months




From case examples: Three (3) machine paper mill:
Earnings: -2.000.000 EUR per year
-10.000.000 EUR in five (5) years

WETEND
Technologies
Chemicals, Energy, Fresh water, CO
2

Earnings at Board mills
with TrumpJet Flash Mixing technology


Three (3) board making lines (linerboard, packing board):

Fresh water saving: 1…2,5 m3/ton / per case

Energy saving: total 60.000…80.000 MWh

Chemical savings: 10…40% / per additive

Total earning approx. 2…3 million EUR/a and 10…15 million EUR in 5 years l

WETEND

Technologies
Potential World Wide
Flash Mixing Technology
WETEND
Technologies
Approx 2700 production lines for paper and board
with sheet trim > 3 meters

Potential to save clean, fresh water:
2 milj. m
3
/d
= 24 m
3
/s
= 0,5…2,5 m
3
/tn

Potential to save in the heating energy:
30 milj. MWh/a

Economical potential is approx 1 billion EUR

Source: Simulation of Wetend & Fisher International data base 2012
Flash Mixing Technology
Sustainability:
WETEND
Technologies
TrumpJet

water
TrumpJet
water
One half a liter of drinking water for
4 billion human beings, every day
TrumpJet Flash Mixing Technology – ABC of Mixing
Sustainability:
WETEND
Technologies
Estimated economical potential of earnings world wide with the
technology:
700…900 million EUR

Retention aid
PAM

Alkaline
sizing

Wet end
starch

Dry
strength

Wet
strength

TOTAL
150

000
105 000
1 500
000
120
000
60
000
Flash Mixing Technology
Savings in additives:
Example of annual addtive consumption: tons/a
Newsprint, printing and writing, packaging board, tissue
WETEND
Technologies
In-Line PCC
TM
:
New in-line production process of calcium
carbonate integrated into a papermaking
process
WETEND
Technologies
In-Line PCC
TM
• In a technology developed by Wetend Technologies Ltd PCC (Precipitated
Calcium Carbnate) is produced ”in–line” as an elementary part of
• PM Approach process before the headbox.
• Crystallization takes place around fibers, fibrills and fines generating a novel
Filler/Fiber composite structure into the stock furnish

• Important and fundamental element is efficient flash mixing process which
gives controlled mass transfer and thus fast crystallization process

WETEND
Technologies
In-Line PCC™
Key elements

- Filler/Fiber-composite
- Flash Mixing Reactor
- Carbonation process
- High quality Milk of Lime
- Milk of Lime production process
- Carbon dioxide source
- Process and engineering knowhow






WETEND
Technologies