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

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 m3 • Energy sa

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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

WET ENDTechnologies

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TrumpJet with three nozzles – “injection mixing without delay”

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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

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Fresh, clean water is a limited resource of nature

The water saving gives 2,5 million MWh potential to reduce

energy consumption

annum

Today TrumpJet installations in operation save

55 million m3 fresh water and reduce 2,5 million MWh water heating energy per

annum

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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 m3

• Energy saving: 77 000 MWh

• CO2 reduction: 44 000 tn

CO2 emission reduction approx 10% from the total emission load of PM

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TrumpJet Flash Mixing

Very fast mixing phenomenon

Mixing time 1 second or less

CVP= counter rotating vortex pair

with four major mixing engines

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Flash Mixing close to the headbox

SC-magazine paper production line

TrumpJet Flash Mixing STATION

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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

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Flash mixing of papermaking additives

Conventional methods: Single pass % of additives to headbox vrs dosage point

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Flash mixing of papermaking additives

Focus of interest of development and targeted area in additive mixing

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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

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Nanoparticle Micropolymer

Retention aid polymers

Starch & Filler

TrumpJet ABC of mixing

TrumpJet Flash Mixing of papermaking additives

close to headbox

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Earnings and Sustainable results:

Case: A coated printing paper production line in USA

Power:

 Energy saving: 14650 MWh/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

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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

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Nanoparticle Micropolymer

Retention aid polymers Sizing agent; ASA/AKD New:

Starch & Filler

A Large Fine Paper machine with a world speed record, China

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•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

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

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Chemicals, Energy, Fresh water, CO2

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:

-10.000.000 EUR in five (5) years

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Chemicals, Energy, Fresh water, CO2

Earnings at Board mills

with TrumpJet Flash Mixing technology

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

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Potential World Wide

Flash Mixing Technology

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Approx 2700 production lines for paper and board with sheet trim > 3 meters

Potential to save clean, fresh water:

Source: Simulation of Wetend & Fisher International data base 2012

Sustainability:

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TrumpJet water

One half a liter of drinking water for

4 billion human beings, every day

TrumpJet Flash Mixing Technology – ABC of Mixing

Sustainability:

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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

Savings in additives:

Example of annual addtive consumption: tons/a Newsprint, printing and writing, packaging board, tissue

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In-Line PCCTM :

New in-line production process of calcium

carbonate integrated into a papermaking

process

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In-Line PCCTM

Calcium Carbnate) is produced ”in–line” as an elementary part of

Filler/Fiber composite structure into the stock furnish

gives controlled mass transfer and thus fast crystallization process

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- High quality Milk of Lime

- Milk of Lime production process

- Carbon dioxide source

- Process and engineering knowhow

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Copyright Wetend Technologies Ltd

In-Line PCC process – filler fiber fibril composite

…for PAPER & BOARD COMPOSITE PRODUCT FOR THE FUTURE

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In-Line PCC™ technology in action

UPM Jämsänkoski, Finland

• SC-magazine paper

• In-Line PCC –investment in

action

• Production at Q1/2013

Stora Enso Varkaus, Finland

• Fine paper 800 tons/day

• In-Line PCC –plant installed

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Copyright Wetend Technologies Ltd

In-Line PCC process

Advantages and benefits

•Powerful fiber loading effect – filler/fiber

composite

•Mechanical bonds - excellent retention

•Improves efficiency of additives

•Good optical characteristics

•Binds and eliminates interfering substances

resulting to a much cleaner process

•Reduced solids and COD of white water

•Modest investment cost

•A price competitive new raw material

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Summary: Wetend and TrumpJet Technology

Improve chemistry with mechanical means

• Innovations and agile operations have created remarkable new technology

and knowhow for the paper and board making industry

• Applications cover a large range of wet end additives with a novel manner

• Cost savings of TrumpJet system for a mill can be several millions of EUR

• Technology supports sustainable development and offers 1…2 billion EUR

potential to the global P&B industry to cut costs

• In-line PCC and Filler/Fiber composite contains new technology and a totally

new potential for all players

• Innovations have built a strong foundation for future development for our customers and business partners of Wetend

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Work done together rewards all parties

Thank You

Tiêu đề	Pioneering Innovations Challenge Conventional Process Chemistry and Efficiently Cut Raw Material Costs with Sustainable Results
Tác giả	Jouni Matula
Trường học	Wetend Technologies Ltd
Chuyên ngành	Process Chemistry and Sustainability
Thể loại	Report
Thành phố	Savonlinna

Định dạng
Số trang	30
Dung lượng	3,74 MB