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Energy Conservation in Pulp and Paper Industry

Energy Conservation in Pulp and Paper Industry
Energy Conservation in Pulp and Paper Industry

PAPER & PULP INDUSTRY

Output of a Seminar on

Energy Conservation

in Paper and Pulp Industry

Sponsored by

United Nations Industrial Development Organization

(UNIDO)

and

Ministry of International Trade and Industry

(MITI), Japan

Hosted by

Ministry of Science,

Technology and Environment,

Thailand

The Department of Energy, Philippines

Organized by The Energy Conservation Center (ECC), Japan

1993

Thailand Philippines

PREFACE

The conservation of energy in an essential step we can all take towards overcoming the mounting problems of the worldwide energy crisis and environmental degradation.In particular, developing countries ate interested to increase their awareness on the inefficient power generation and energy usage in their countries. However, usually only limited information sources on the rational use of energy are available.

The know-how on modem energy saving and conservation technologies should, therefore, be

disseminated to governments and industrial managers, as well as to engineers and operators at the plant level in developing countries.It is particularly important that they acquire practical knowledge of the currently available energy conservation technologies and techniques.

In December 1983, UNIDO organized a Regional Meeting on Energy Consumption as well as an Expert Group Meeting on Energy Conservation in small- and medium-scale industries for Asian countries. During these meetings, it was brought out that, for some energy intensive industries, savings up to 10% could be achieved through basic housekeeping improvements, such as auditing and energy management.

All these experiences brought UNIDO to prepare a regional programme on the promotion and application of energy saving technologies in selected subsectors, since the rational use of energy calls for a broad application of energy conservation technologies in the various industrial sectors where energy is wasted.One of these energy intensive industrial sectors to be considered to improve efficiency through the introduction of modem energy conservation technologies is the pulp and paper industry.

The pulp and paper industry consumes much energy and water.The pulp and paper industry is also noted for great percentage of the energy cost in the total production cost.

In the pulp and paper industry, appreciable amounts of energy could be saved or conserved by regulating and insulating the temperature in the steam pipes, modifying the equipment to recover heat from the various units in the process of pulping and paper-making and effective use and reuse of paper machine white water.

Currently, UNIDO is implementing this Programme with the financial support of the Japanese Government, in selected Asian developing countries. This programme aims at adopting these innovative energy conservation technologies, developed in Japan, to the conditions of developing countries.

CONTENTS

Preface

1.production process of the pulp and paper industry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.Consumption in the pulp and paper production process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.Promotion of energy conservation technology (4)

3.1Waste-saving and effective use of energy (4)

3.2Energy conservation technology in the pulping process (5)

3.3Use of waste paper in the pulping process (8)

3.4Energy conservation technology in the papermaking process (11)

3.4.1 Paper breaking (12)

3.4.2 Impurities (15)

3.4.3 Press dewatering (18)

3.4.4Effective use of white water (25)

3.4.5 Drying (31)

3.5Energy conservation technology in refining process (33)

3.5.1Unit power consumption of refiner (35)

3.5.2Effective refining energy (36)

4.Energy conservation in the pulp and paper industry (37)

4.1Energy conservation in the papermaking process (38)

I

4.2Energy conservation in the pulping process (39)

Production process of the pulp and paper industry

The pulp and paper industry has been consuming much energy and water ever since Cailun (an inventor of paper in ancient China) invented paper in A.D. 105.He crushed the bark of the shrub with a stone mill to extract fibers, and separated the single fibers by washing them in water. When they were uniformly distributed underwater, they were dewatered and formed by a drain board Then the wet paper web was dried in the sun for a long time, and final paper products were obtained.

The basic principle in the manufacturing process of the pulp and paper industry today has undergone almost no change, but industry has developed into a process industry constituting the continuous production processes. Figure 1 shows an example of the production process.

The pulp and paper industry consumes much energy and water. The pulp and paper industry is also noted for a great percentage of the energy cost in the total production cost.

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2.Consumption in the pulp and paper production process

It is extremely difficult to grasp the energy consumption pattern in the entire pulp and paper industry.Since the pulp process differs considerably depending on production items and composi-tion of the material woods, it is difficult to define the representative pulping process.Table 1represents the unit consumption of the consumption pattern of steam and electric power summarized according to the recent data in Japan, using the model of the integrated fine paper mill for general printing paper and writing paper.

Table 1Energy consumption pattern of pulp and paper processes

in an integrated fine paper mill

Process Evaporator Cooking

Bleaching Paper Causticizing Washing

machine Others Steam ton/paper ton Electric kWh/paper ton

Power 1.5

Cooking

Washing

140 1.00.45.9 (95%)Bleaching Refining 1502401,130 (84%)

3.0Paper machine 6000.3Others 220The paper machine, which is the greatest consumer of steam, followed by the black water concentration process, is also the greatest consumer of electric power.

-3-

Promotion of energy conservation technology

3.1Waste-saving and effective use of energy

The paper and pulp production equipment as a process plant is operated by electric power and thermal energy. Energy conservation is meant not to reduce the energy for operation, but to ensure “was@-saving” and “effective” use of energy, thereby resulting in reduced energy for operation.“Waste-saving” and “‘effective” use of energy is ensured by field technology.

“Waste-saving” use is provided by continuous operation from the start of operation to the day of shutdown determined by the production schedule, without the paper and pulp production being interrupted by the machine and steam system failure, electric failure due to accidents, or paper breaking on the paper machine.

This continuous operation requires:

1)Quality control system which permits the constant production of stable good-quality

products, without products rejected in the inspection, and

2)Preventive maintenance (PM) system which eliminates the possibility of machine and

equipment troubles or electric failure due to electric equipment failure.

The so-called total control system must be implemented every day as part of the routine work.

“‘Effective” use is to prevent dissipation and waste of heat of the energy supplied to the system or to recover it, and to provide uniform hydration in the cross direction on the wire part, press part and dryer part by ensuring the following equipment functions:

1)Improving the rate of circulated use of white water to reduce the wasteful discharge, which

leads to the reduction of new water used

The electric power for the pump, agitator and refiner is converted into thermal energy to raise the pulp slush temperature.Discharge of the white water means discharge of heat.

Maintenance of a high system temperature by effective circulation of the white water will

improve the dewatering rate and reduce the amount of steam used for drying. Effective

circulation of the white water will also improve the yield rate.

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2) 3) 4) 5) 6)Uniform nip pressure of the pressure to be ensured in the cross direction

Effective energy reduction cannot be gained by mere pressure increase. Uniform dewatering is ensured only by uniform pressure in the cross direction, which, in turn, will permit uniform drying and minimize the possibility of paper breaking.

Three functions of showering, squeezing and dewatering to be used to wash the press felt The felt cleaned and dewatered to have low-moisture content promotes suction of water in the pressing process. The use of hot water for shower provides effective washing and prevents the wet web temperature from lowering.

Dryer surface to be kept clean by effective use of the doctor thereby ensuring high heat conductivity

Drain within the dryer cylinder to be eliminated completely

Drain has a low heat conductivity, so it decreases heat efficiency.

Ventilation inside the dryer part to be uniform on the front and back, dryer pocket in particular to be eliminated completely

3.2Energy conservation technology in the pulping process

The following describes the concept of “wastesaving” and “effective” energy conservation, with particular reference to the chemical pulping kraft process.

Figure 2 shows the case of batch cooking.

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Cooking Control Gas Heat Recovery Blow Gas Heat Recovery

Figure 2 Batch cooking and heat recovery system

-6-

removed upon termination of the reaction; otherwise, it may affect the quality and yield. The following points should be noted for this series of reaction:

(1)

(2)

(3)

(4)Rise of reaction temperature

The cooking liquor is heated by the steam of the multi-tube heater, and the temperature inside the digester is raised. In the indirect heating method, scales which have low heat conductivity will be attached on the liquor side of the heater.Since the scales waste steam, attached scales should be removed on a periodic basis.

Control of reaction requirements

When the reaction temperature has risen, non-condensable gas will be produced, preventing the reaction. This gas must be removed. When it is removed, heat contained in the gas is recovered by the heat exchanger.

Pressure reduction

Immediately after the reaction, the pressure is reduced and the temperature is lowered. The pressure reducing speed is increased when a great amount of this high-temperature exhaust gas is cooled by the heat exchanger. At the same time, the heat contained in the gas can be recovered as hot water. Scales and pulps are attached to the gas discharging strainers provided on the gas side of the heat exchanger and on the top of the digester, and cause the gas discharge speed to be lowered. Periodic inspection and cleaning are essential to improve the efficiency of the strainer and heat exchanger.

Blowing

When the pulp in the digester is to be blown out by the internal pressure, the blow speed is increased and the blow time is decreased by increasing the differential pressure of the exhaust gas.Pulps are attached to the jet condenser which absorbs a great amount of gas and the thermal accumulator. Pulps also enter the heated dirty water, so they are attached to the heat exchanger for heat recovery. Since the pulps feature extremely small heat conductivity, they must be removed periodically.

-7-

For energy conservation in the pulp division, effective supply of energy for pulping must be ensured, and the extra energy required for pulping should be recovered as effectively as

possible, and should be put to reuse.

3.3Use of waste paper in the pulping process

The pulp and paper industry is highly evaluated for its effective reuse of the waste paper and for its attitude toward effective use of precious resources on earth. The waste paper once used only as paperboard has come to be used as newspaper, writing paper and toilet paper by the development of deinking technology (see Figure l), which has permitted manufacture of the products having almost the same quality as the new one.Such efforts have resulted in the utilization rate and recovery rate of as high as over 50% as shown in Figure 3.

Figure 3 Recovery and utilization rates of waste paper in Japan

-8-

Source: PPI Figure 4 Consumptlon rate of waste paper In the world

-l0-

3.4.1 Paper breaking

Paper breaking in the paper machine will lead to a waste of energy and reduced yield, causing costs to be increased. It also results in a considerable labor consumption. Paper breaking used to be considered as a matter of course:However, after a detailed analysis of the paper breaking is carried out, the problem will be greatly reduced as a result of improved operator skill, improved equipment ranging from material treatment to paper making process, and introduction of the instrumentation control.

(1)Analyzing causes for paper breaking

Figure 5 shows a chart for the characteristic factors which cause paper breaking.

Table 3 illustrates the outline list showing causes for paper breaking and their remedies.

Means to eliminate the possibility of paper breaking can be summarized as follows:

(a)Removal of shives, sand and other foreign substances

(b)Control of consistency of fibre in head box

(c)Improvement of formation

(d)Uniform pressure to ensure high dewatering efficiency

(e) Uniform evaporation and drying

The following points should be noted regarding technical problems involved in the equipment:

a)Selection of the equipment with insufficient functions (selection error)

b)Equipment not operating in conformity to the specifications

c)Neglected maintenance, inspection, repair, or performance checking of the equipment

therefore, required performances not fully used

d)Claim against electric failure not submitted to the section in charge inside or outside the

company; technical improvement delayed

It is their duty to check if each function is working, to review the operation method and to improve it if something is wrong.

-12-

Table 3 Causes for paper breaking and remedies

Places for paper breaking 1. Wet part (1) Couch

(2) Press

(3) Wet end 2. Dryer part

(1) Yankee

Dryer

(2) Multi

Dryer

3. Calender

part Classifications

Fall from couch

Breaking by

press

Uneven

dewatering

Fall in wet end

Breaking due to

faulty separa-

tion

Breaking due to

intrusion of

foreign sub-

stances

Breaking by

tension

Breaking by

tension

Edge breaking

crushing

Breaking by

foreign sub-

stances

Breaking in

machine

directions

Causes

Excess Moisture

W e t

Insufficient strength)

crushing

Roughened surface

on plain roll

Mixing of slime

Mixing of adhesive

substances

Faulty formation

Dirty blanket

Uneven line pressure

Faulty drawing

Excessive moisture

Mixing of shives

Triming water

cutting fault

Paper powder

attached

Damage on dryer

surface

Mixing of shives

and impurities

Faulty drawing

Faulty formation

Faulty drawing

between groups

Edge too dry

Mixing of shives

and impurities

Trimming water

cutting fault

Faulty formation

Incorrect roll crow-

ing

Mixing of shives

and impurities

Faulty formation

and wrinkling

Unevey drying and

wrinkling

- 14 -

Measures

Promotion of

dewatering on wire

promotion of

dewatering

Roll grinding

Removing the slime

Separation, removal

and dispersion

Formation correction

Promotion of blanket

washing

Crown correction

Drawing adjustment

Promotion of

dewatering (line

pressure increase)

Promotion of screen-

ing

Effective use of the

doctor

Polishing the surface

Promotion of

screening

Drawing adjustment

Correcting the

formation

Drawing adjustment

Improvement of

dryer pocket

Promotion of screen-

ing

Water pressure

increas

Correcting the

formation

Correct the roll

crown

Promotion of

screening

Improvement of

dryer ventilation

Correcting the

formation

Removing the dryer

pressure

Equipment factors

Dewater rectify on

Wire Part

Setup of Pick up roll

Grinding

Heat kneeding

Flow rectify in Head

Box & Wire Part

Washing, squeeze,

dewater. grinding

Setup of high pressure

Press

Centr, Cleaner, Fine

Screen, High Pressure

Water Jet

Dryer cleaner

Bronze Doctor,

Dryer Grinding

Centricleaner

Flow rectify in Head

Box & Wire Part

Pocket Ventilation

Centricleaner, Fine

Screen

Flow rectify in Head

Box &Wire Part

Grinding

Centricleaner, Fine

Screen

3.4.2 Impurities

Shives, sands, pitches, slimes and deposits are defined as impurities.

Each of the pulping process, material pre-treatment process and papermaking process is provided with the device to remove the impurities.This is because too many troubles are caused by the impurities, and these are very difficult to remove.

(1)Troubles due to impurities

(a)Paper breaking may be caused by tension in the contraction process during the wet web

drying if impurities are located at the sheet edge.

(b)Even if pressure is applied to impurities by the press, they contain much moisture and will

produce black spots (fish eyes). To remove them, they must be overheated inevitably.

(c)This may cause the reduction of printing efficiency and even damage of the plate cylinder

when the user is printing. This may be the cause for claims against product quality.

Paper breaking will reduce efficiency, yield and production volume, leading to a great energy loss. Fish eyes are often accompanied by much energy consumption due to over-drying; they cause much curling, a poor paper quality and lower yield.

(2) Impurity removing measures

(a) Equipment

The coarse screen, centrifugal cleaner and material finishing screen for material pre-

processing have pressure and consistency suited to the equipment type.Without relying

on the manufacturer specifications, the dust removal rate shall be measured according to

the requirements of the process in the plan, and the appropriate work standards shall be set

up. Figure 6 illustrates the typical centrifugal cleaner.

The technological advance of the finishing screen is quite remarkable; the slit of 0.07 mm

has appeared, contributing to improved quality and reduced paper breaking.

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(b)Multi-stage removing of impurity

The multi-stage equipment is used when the impurity cannot be removed completely by the one-stage equipment. The impurity removal ratio is measured, and the equipment of the subsequent stage is installed for the existing equipment to provide a multi-stage configuration featuring sufficient capabilities. This will improve the pulp yield and quality and prevent paper from breaking, ensuring an improved overall yield.

(c)Removing the slime and deposits

The refining process and papermaking process provide the optimum conditions for the growth of microorganisms, and deposits are formed in many places. The deposits are especially formed at the positions which are invisible. Deposits must be removed periodically from the following positions by manual brushing or by a scraper:

a)From the fan-pump (large volume and low head pump) to the piping leading to the

head box

This position should be provided with the flange connection to facility at cleaning.

b)From the inside of the head box to the lip

Use the wooden scraper so that inner faces will not be damaged.(It must be prepared

for this purpose).

c)Side wall of the forming board under the wire, table roll journal, hydro foil, back of

the deflector and inner and outer surfaces of save-all devices

The amount of slime will increase if the amount of the circulated white water is increased, and the temperature within the system is raised. When the temperature has reached 45°C or more, there is no growth of deposits.

Note that the slime control agent is not an inhibitor; it does not remove the slime. It should be used for a long continuous operation.

-17-

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九年级物理能量的转化与守恒练习题

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可以把______能转化为______能;太阳能电池把______能转化为______能;植物的光合作用可以把______能转化为______能,燃料燃烧时发热,将______能转化为______能. 秋千荡起来,如果不继续用力会越荡越低,甚至停止;皮球落地后,每次弹起的高度都会比原来低.在这两个过程中,机械能______了,转化成了______能.机械能是否守恒______,能的总量是否守恒______.

认证方式pap chap协议解读

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初中九年级物理:能量的转化和守恒练习题含答案

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26 配置和检验 PAP 身份验证与 CHAP 身份验证

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初中九年级物理能量的转化和守恒

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