August 2003 Abstracts

Total Automation System for Paper Making Plant
Kenji 0hshima
Yaskawa Siemens Automation & Drives Corp. System design group

 "Open Networks", "Multimedia", "IT", all these are keywords to describe the recent trends in the automation of production facilities, which have provided for a more centralized management of complete plants. In the paper industry, Distributed Control Systems (DCS), Quality Control Systems (QCS), Drive Systems, and Maintenance Management Systems, are widely used, each of these being delivered by specialized vendors.
 This multitude of systems with different hardware, software and diverse engineering tools constrict the efficient use of resources in running a paper plant.
 Siemens demonstrated a way to solve these issues by providing a complete automation system based on a unified hardware base and only one kind of HMI. Yaskawa Siemens has developed technologies to support maintenance and diagnosis of equipment in the paper industry by remote monitoring systems via telephone or ADSL-connection.

Operating Results of New TWINDRUMTM Pulping Concept at SP Newsprint Co., Newberg, Oregon
Bernhard Muller
Engineering & Development Division, Voith IHI Paper technology Co., Ltd.

 In 2000, an order was placed by SP Newsprint to replace their wash deinking process with a state of the art deinking line. VOITH PAPER supplied the entire scope of equipment needed for the rebuild. The plant is designed to produce 550 BDMTPD of finished pulp. The raw material is made up of 80% old newsprint and 20% old magazine. The system was successfully started up in September 2001.
 A key role within the recycled fiber plant is attributed to the pulping stage. The pulping stage initiates the recycling process. Goals are to disintegrate the paper, without damaging the fiber and to release the printing ink and coating from the fiber surfaces. Another important requirement is that paper impurities remain as large as possible in size to facilitate an effective and early removal. The pulping module installed at SP Newsprint meets all those requirements by utilizing the new TwinDrum? drum pulper concept.

Application of OptiDwell Shoe Nip Calender
Matti Lares, Stefan Kuni and Martti Tuomist
Metso Paper Inc.
Hidehiko Yamazaki
Metso Paper KK

 Metso Paper has developed OptiDwell shoe nip calender which enables achievement of long dwell time, reduction of compression pressure and coutour calendering with extremely soft belt. This technology is based on Valmet shoe press and soft calender technologies. The first OptiDwell was started up to produce coated liquid packaging boards and coated white top liner boards at Korsnas PM5 in Sweden in 1994. Bulk saving and improvement of surface qualities of boards were easily achieved with OptiDwell. The second OptiDwell was started up at Korsnas PM4 in 2000. Two other OptiDwell were also delivered to other customers and started up.
 Metso paper has studied various kinds of applications of OptiDwell. OptiDwell is applicable not only for a final calender but also for a precalender. Pilot test results proved the effectiveness of new application of OptiDwell as a precalender for high-quality coated boards.

A New Pulping Method for Non-wood Resources for the Purpose of Lightening the Loading to Environment
Kyoji Suzuki and Kayoko Hoshino
Shizuoka University
Tetsuo Ide, Takefumi Ide, Kiyoshi Yoda and Tsutomu Hiyoshi
Taizen Co., Ltd
Kojiro Nakata
Fuji Technosupport

 The soft pressure type kneading machine(New Taizen) which has been used as useful deinking machine was attempted to use as a new instrument for the pulping of non-wood resources. This new pulping method is expected to lighten the loading to environment in comparison with traditional alkaline chemical pulping. We applied it to the straws.
 It was revealed that this new pulping method is hopeful for the straws, especially for a rice straw. Although some shives (fiber bundles) were found in the treated pulp, they may be separated into individual fibers by subsequent refining and bleaching or by higher alkali addition.

High Density & Continuous Pulping "KNEADINGPULPER"
Nobuo Isobe
Industrial Machinery Dept, Nippon Sharyo Co., Ltd.

 The quality deterioration of raw materials caused by a rise of used paper recycling rate brings about new problems that its processing plant becomes complicated and its energy consumption increases. "How should an environmentally friendly pulper be?" we approached the essence of pulping and have developed the high density and continuous pulping "KNEADINGPULPER" which assures an excellent recycling performance of used paper. The equipment consists of a long cylindrical tab and a multistage rotor provided in it. Raw materials supplied from its top are pulped with a high density while they are descending. They are kneaded to disperse printing ink at the lower part and continuously discharged through a screw feeder. The equipment could have following advantages, because of "Lower kneading speed" and "No vertical circulation of raw materials", which are not in the past.

Charge Management through Process Analyzers
Jukka Nokelainen and Takeshi Sato
Metoso Automation, Field Systems Division

 Modern automation solutions for papermaking wet end is a nice example how to utilize process analyzer as part of the machine controls. By wet end management we aim to have stable total and ash consistencies, drainage properties of the headbox suspension, and basic chemistry in paper machine short circulation. Stability is very important, because it´s directly connected to paper machine runnability as well as to quality of produced paper. The level and variation of charge have a considerable effect on process status and operation. On-line charge measurement provides valuable information about the wet end chemistry of the paper machine. It is possible to perform charge contgrol based on measurement by charge analyzer kajaaniCATi. The control provides many benefits for the papermaker. The benefits are process information, stability of process, runnability of papermachine and economical and effective use of chemicals.

Advantages of Commercial Rutile Titanium Dioxide Slurry for Paper Applications
Wayne Logan
DuPont Titanium Technologies
Shuichi Iyoda
DuPont Kabushiki Kaisha

 Paper mills have used titanium dioxide to generate opacity in high quality paper and paperboard for many years. Dry anatase pigments were used at first since this was the only technology available. Invention of the chloride rutile process created opportunities for new levels of performance in the paper industry. Commercial rutile slurry was introduced over 25 years ago to the North American market and has been continually improved. Over 95% of the titanium dioxide used in this market is commercial slurry. More recently the use of stable paper slurries has been growing in both Europe and Japan.
 Commercial rutile slurry offers performance advantages over slurry produced by the paper mill. High shear dispersion equipment allows optimization of the particle size and increased light scattering. Opacity gains of 10-12% have been demonstrated in the lab. Mill trials have confirmed even higher performance gains.
 Anatase pigments have a lower refractive index and generally larger particle size. Both attributes will contribute to lower scattering performance than a rutile pigment. Mill trials have demonstrated over 20% reduction in pigment use when switching from an anatase pigment to rutile.
 Handling and storage of slurry products is not difficult. Proper design of the equipment will insure trouble free operation and high product quality. Correct addition to the paper process will maintain the high performance of the pigment.

Function Enhancement of the Paper by Surface Sizing Agents and the Mechanism
Takanori Kurihara
Harima Chemicals, Inc.

 Surface treatment technology is one of the important roles to control the quality of paper in papermaking process. Particularly, surface sizing agents have performances not only to improve printability and water resistance but also to enhance surface strength of paper. In addition, it is possible to reduce cost of total paper chemical additives by using surface sizing agent. Since ink jet printability, for example, feathering, print through and others, on DIP-contained PPC has been increasingly required in the recent, it is expected to develop more effective surface sizing agents. On the other hand, stability and solubility of surface sizing agent in coating solution and low foaming in the papermaking process are required to use surface sizing agent with starch or others at high temperature.
 We have studied regarding printability on PPC and peel test on newsprint, and measured the dynamic properties by dynamic liquid penetration measurement and dynamic absorption tester on the sized papers with internal and surface sizing agents. Thus, this paper describes the consequences of the relationship among them.

A Study on Blistering Resistance with Acceleration of Air Permeability (II)
Nobuhiro Matsuda, Shigeo Yamanaka, Masaaki Yada and Yoshiaki Zama
Polymer Research Laboratories, JSR Corporation

 The blister of coated paper that is caused by rising water vapor pressure is a problem in web-offset printing. However accurate experimental determination of the blistering resistance is very difficult. Many commonly used laboratory methods do not correlate to real press experience, and it is very expensive to use commercial press trials for testing purposes. Therefore, predicting the blistering tendency of coated paper is very important.
 In the previous report, we reported that we developed our original air permeability tester with which we could measure the acceleration of the air permeability (AAP) of coated paper under high temperatures and high pressures during a short time. And we found that AAP was strongly related to the blistering tendency of coated paper.
 In this paper, we used various commercial A2 web-offset coated papers made in Japan, and studied on the blistering resistance. Then we found that the internal bond of base paper and AAP that had a direction from base paper layer to coating layer, were strongly related to the blistering tendency.

Keywords : Acceleration of air permeability, Air permeability, Internal bond, Blistering,Coated paper

Development Both Higher Opacity and Sheet Gloss GCC- Introduction of the FMT-OP Series -
Masayuki Oishi

 Recent trends have shown that the demands for Ground Calcium Carbonates (GCC) for paper coating are steadily increasing. Among the diverse property demands of GCC, increased Opacity and Sheet Gloss demands come to the forefront. FIMATEC, a GCC manufacturer, has previously developed SC-95(a particle size distribution controlled GCC). SC-95 has shown excellent properties in both gloss and picking resistance. However, SC-95 is designed for medium-fine to medium particle size and therefore cannot further improve sheet gloss properties.
 Using SC-95 technology as a base, FIMATEC now introduces the newest development in particle size distribution manipulation in the new OP-Series. The OP-Series is specifically designed for medium to fine particle sizes which improves sheet gloss. Other beneficial qualities include: improved Wet Void Volume %.
 Comparison properties of OP and SC series products are shown in the following report. All in all, OP-Series Test results show improved Sheet Gloss and Opacity characteristics .

Exact Sheet Counting and New Laser Ream Marking System
Mitsuaki Katsumata
Maruishi Co., Ltd., Engineering Dept.

 Newly developed sheet counting device and ream laser marking system are developed by Function Control Research B.V. These devices are very suitable to count the number of paper and board sheet which are piled on a pallet coming from sheeter. Conventional tape inserter for every ream in the skid can be eliminated.
 Exact sheet counting system can give many advantage for the industry. This sheet counting system with ream laser marking system has been working over 1.5 years in commercial operation, and it is a first experience in the world.

Pest Control Activities for Quality Assurance
Shinya Yokoo
Earth Environmental Service Co., Research & Development

 Contamination control-not only insect contaminant is one of the important activities for quality assurance (QA) of the product and it should be based on the preventive approach. In order to realize the effective prevention of insect contamination in the factories, we must establish the comprehensive system including hardware, software, and human-ware, which can solve the basic cause of contamination.
 We have been introduced the tailor-made comprehensive system against contamination to the wide variety of customer factories, which we call THC (Total Health Care) system. The framework of our THC system is as follows. After the annual program, we grasp an inadequacy by periodical on-site surveillance including visual inspection, sampling, monitoring, etc. Then we analyze the results of surveillance using statistical methods to decide the optimal action plan solving problems both existing and potential. The short-term action plan, which basically consists of hardware, software, and human-ware, is examined by the group discussion among factory member and us. Once the plan is accepted, we make it clear that whose responsibility, when/by when and where to execute, how to proceed, and why in order to make sure the plan into execution. After verification of execution, we validate the effectiveness of the plan by the close examination using statistical method. If the plan is ineffective, we refine the plan or adopt the alternative one. At least twice a year, we review and validate the annual program by the general statistical analysis because we must make the annual program more effective for the successive year. Continuous improvement of the comprehensive system can make the contamination control more and more effective year by year and our THC system enables it. In this paper we will explain the concept and procedure of our system in detail.

Web Inspection System "SmartView ICN"
Satoshi Suzuki
COGNEX K. K., Surface Inspection System Division

 COGNEX developed a new web inspection system, "SmatView ICN". This system has following 3 advanced technologies. (1) Superior Defect Detection using digital cameras and parallel processing, (2) Reliable Defect Identification by over 40 defect features, (3) Unequaled Visualization. It has also snapshot function for web formation analysis.

Acoustic Emission during the Tensile Straining of Paper from Hardwood Pulp-Effects of Beating and Addition of Dry Strength Resin-
Tatsuo Yamauchi and Takateru Hatanaka*
Graduate school of Agriculture, Kyoto University

 Acoustic emission (AE) that occurred during tensile straining of paper from hardwood pulp with and without dry strength resin was measured and analysed to investigate the process and mechanism of tensile deformation up to maximum load. Maximum amplitude distribution of the AEs that occurred during the straining manifested some changes of micro failures with increases in beating degree and addtion level of dry strength resin. The increase in bonding area by beating and increase in specific bonding strength by addition of the resin cause an increase in failure of strong fiber bonds. Although almost all of micro failures that occurred during the straining up to maximum load are attributed to those of weak fiber bonds, some strong fiber bonds and/or fibers themselves fail just before maximum load for the handsheets from beaten pulp. With addition of the resin, strong fiber bonds and fibers themselves begin to fail even in mid of the plastic deformation.

Keywords: Acoustic emission, Beating, Dry strength agents, Hardwood pulp, Tensile strength

Life Cycle Impact Assessment of Woodfree Papers Containing
Nonwood Pulp or Deinked Pulp
Katsuhito Nakazawa
Japan Science and Technology Corporation
Tomonori Honda
Graduate School of Engineering, University of Tokyo
Toru Katsura
Mitsubishi Paper Mills, Ltd.
Keiichi Katayama
Graduate School of Engineering, Tokai University
Ryoichi Yamamoto
Center for Collaborative Research, University of Tokyo
Itaru Yasui
Institute of Industrial Science, University of Tokyo

 Life cycle impact assessment for woodfree papers containing nonwood pulp (bagasse pulp and kenaf pulp) or deinked pulp (DIP) was investigated by eight kinds of environmental impact methods such as EPS1992, EPS2000, Eco-Point1993, Eco-Point1997, Eco-Indicator95, Eco-Indicator99, Panel method and Distance to Target method, based on the results of LCI (Life Cycle Inventory) analysis.
 Considering the environmental impact caused by CO2 emission from biomass, the environmental impact of woodfree paper containing DIP was smaller than that of other kinds of woodfree paper. Not considering the environmental impact caused by CO2 emission from biomass, the environmental impact of woodfree paper made from 100% wood pulp was smaller than that of woodfree paper containing DIP except Eco-Indicator99. It was evaluated by eight kinds of environmental impact methods that the environmental impact of woodfree paper containing kenaf pulp was the largest in four kinds of woodfree paper. In the comparison of the environmental impacts calculated by eight kinds of environmental impact methods for four kinds of woodfree paper, the ratio of total environmental impact of the kenaf pulp and DIP was less than 1.8 in seven kinds of environmental impact methods except Eco-Indicator99. It was confirmed that the environmental impact caused by CO2 emission was evaluated larger than that caused by other substances in eight kinds of environmental impact methods, especially accounting for about 70% in six environmental impact methods except Eco-Point1993 and Eco-Indicator99.

Keywords:Life cycle impact assessment, Woodfree paper, Bagasse pulp, Kenaf pulp, Deinked pulp