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
Previous machine flow
Previous machine flow
HeadBox
HeadBox
P
P
Stock Box
Stock Box
DC
DC
Cleaner
Cleaner
MS
MS
MFP
MFP
CFP
CFP

P
P
󲆛
󲆛
󲆅
󲆅
󲆀
󲆀
󲆙
󲆙
󲆅
󲆅
󲆀
󲆀
󲆙
󲆙
󲆅
󲆅
C
C
-
-
PAM
PAM
With New Jet Injection Mixing, machine flow
With New Jet Injection Mixing, machine flow
HeadBox
HeadBox
P
P

Stock Box
Stock Box
DC
DC
Cleaner
Cleaner
MS
MS
MFP
MFP
CFP
CFP
P
P
󲆛
󲆛
󲆅
󲆅
󲆀
󲆀
󲆙
󲆙
󲆅
󲆅
󲆀
󲆀
󲆙
󲆙
󲆅
󲆅

C
C
-
-
PAM
PAM
Concept of laboratory test
Concept of laboratory test
Simulation of
conventional mixing points
(*) Tested at Mütec DFS retention analyzer
High shear
Medium shea
r
Low shear
Agitator setting
0sec 35sec 40sec 60sec
C-PAM before
cleaner fan pump
Drainage
A
-PAM before
machine fan pump
C-PAM before
machine screen
A
-PAM after
machine screen
Simulation of
new chemical mixing points

Result of laboratory test
Result of laboratory test
46
48
50
52
54
56
58
60
62
64
0.000 0.010 0.020 0.030
Dosing rate of retention aids [%]
(C-PAM+A-PAM)
TOTAL FPR [%]
Simulation of new
chemical mixing points
Simulation of conventional
chemical mixing points
10
15
20
25
30
35
40
45
0.000 0.010 0.020 0.030
Dosing rate of retention aids [%]

(C-PAM+A-PAM)
ASH FPR [%]
Simulation of new
chemical mixing points
Simulation of conventional
chemical mixing points
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
TrumpJet
TrumpJet
®
®
Flash Mixing = Jet Injection Mixing for
Flash Mixing = Jet Injection Mixing for
papermaking additives
papermaking additives
Wetend Technologies Ltd is a Finland based corporation.
City of Savonlinna
FiberLaboratory
17
Injection stock
Chemical
Mixing stock
TrumpJet
TrumpJet
®
®
Flash Mixing for papermaking
Flash Mixing for papermaking
additives

additives
-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
18
Jet Injection Mixing for papermaking additives
Jet 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
19
Jet Injection Mixing for papermaking additives
Jet 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 CO
2
emission
Jet Injection Mixing for papermaking additives

Jet Injection Mixing for papermaking additives
Total Annual Water and Energy Saving with 250 installations:
35 million m
3
(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 CO
2
emissions per annum
PATENTED Jet Injection mixing technology
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
Content 4. Result
Content 4. Result
1)
1)
Reduction of retention aids
Reduction of retention aids
and i
and i
mprovement of FPR
mprovement of FPR
2)
2)
Saving energy

Saving energy
by reduction of d
by reduction of d
ilution water
ilution water
3)
3)
Extending shut down cycle for
Extending shut down cycle for
prolonged
prolonged
lifetime of wires and felts
lifetime of wires and felts
Content 4. Result
Content 4. Result
1)
1)
Reduction of retention aids
Reduction of retention aids
and i
and i
mprovement of FPR
mprovement of FPR
2)
2)
Saving energy
Saving energy
by reduction of d
by reduction of d
ilution water

ilution water
3)
3)
Extending shut down cycle for
Extending shut down cycle for
prolonged
prolonged
lifetime of wires and felts
lifetime of wires and felts
71
110
100
40
60
80
100
120
Before
ECF
After
ECF
With
Trumpjet
Dosing rate of retention aids
(Set 'Before ECF' = 100)
With new
”Jet Injection mixing”
Reduction of retention aids
Reduction of retention aids
-

-
35%
35%
Improvement of Total FPR
Improvement of Total FPR
67
75
40
50
60
70
80
90
Coat
Base
Paper
Fine
Paper
Book
Paper
SLWC LWC Average
TOTAL FPR [%]
Before
With TrumpJet
Jet Injection mixing