J.MatulaJ.Matula Wetend Technologies Ltd.Wetend Technologies Ltd.

K.SatoK.Sato Mitsubishi Paper Mills Ltd.Mitsubishi Paper Mills Ltd.R.Watanabe R.Watanabe Mitsubishi Paper Mills LtdMitsubishi Paper Mills Ltd..

MITSUBISHIPAPER MILLSLIMITED

WETENDTechnologies

Case Study of Cost SavingsCase Study of Cost Savingswith a New Chemical Mixing Systemwith a New Chemical Mixing Systemat Mitsubishi Paper Hachinohe Mill PM7at Mitsubishi Paper Hachinohe Mill PM7

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

Outline of Mitsubishi Paper GroupOutline of Mitsubishi Paper Group

MMitsubishi itsubishi PPaper aper MMills Limited (MPM)ills Limited (MPM)

MillsMills :: 5 mills in 5 mills in JapanJapan

ProductProduct :: 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

Mitsubishi HiTec Paper GmbHMitsubishi HiTec Paper GmbH

MillsMills :: 2 mills in 2 mills in GermanyGermany

((Bielefeld and Flensburg)Bielefeld and Flensburg)

Outline of Hachinohe MillOutline of Hachinohe Mill

Hachinohe MillHachinohe MillProductionProduction : 0.9 million t/year: 0.9 million t/year

MachinesMachines : 7 paper machines and 3 off: 7 paper machines and 3 off--coaterscoaters

The Pacific Ocean

The Pacific Ocean

MITSUBISHIPAPER MILLSLIMITED

Outline of PM7 in Hachinohe millOutline of PM7 in Hachinohe mill

PM7PM7BuildBuild : : 19971997

Base weightBase weight : 48: 48--157gsm157gsm

SpeedSpeed : 1,300m/min: 1,300m/min

ProductionProduction : 13,000t/month: 13,000t/month

Wire widthWire width : 5,800mm: 5,800mm

HeadBoxHeadBox : ModuleJet: ModuleJet

FormerFormer : DuoFormer: DuoFormer--D PressD Press : TNT+TF+ENP: TNT+TF+ENP--CC

GradeGrade : Base paper, Fine paper, Book paper, LWC: Base paper, Fine paper, Book paper, LWC

MITSUBISHIPAPER MILLSLIMITED

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

Decrease in FPRDecrease in FPR

‘‘Optimization of wetOptimization of wet--endend’’ at PM7 since 2005at PM7 since 2005

New retention system (Dual polymers)New retention system (Dual polymers)

Decrease in FPR after ECF of pulp processDecrease in FPR after ECF of pulp process

Because of increase in PCD of LBKPBecause of increase in PCD of LBKP

(*) LBKP = Laubholz Bleached Kraft Pulp(*) LBKP = Laubholz Bleached Kraft Pulp

Increase in the consumption of retention aidsIncrease in the consumption of retention aids

Change in dosing rateChange in dosing rateof retention aidsof retention aids

100

110

60

80

100

120

BeforeECF

AfterECF

Dos

ing

rate

of r

eten

tion

aids

(Set

'Bef

ore

EC

F' =

100

)

Necessity ofNecessity ofnew chemical mixing systemnew chemical mixing system

Request to new chemical mixing systemRequest to new chemical mixing system

Reduction in retention aidsReduction in retention aids

Improvement of FPRImprovement of FPR

No scaleNo scale and dirtand dirt

No sheet formation problemNo sheet formation problem

Examination of installation Examination of installation ““Jet InjectionJet Injection”” mixing mixing technologytechnology

Previous machine flowPrevious machine flow

HeadBoxHeadBox

PP

Stock BoxStock Box DCDC

CleanerCleaner

MSMS

MFPMFPCFPCFP

PP

CC--PAMPAM : Before CFP: Before CFP ((Quill nozzle)Quill nozzle)

AA--PAMPAM : Before MFP: Before MFP ((Quill nozzle)Quill nozzle)

AA--PAMPAMCC--PAMPAM

With New Jet Injection Mixing, machine flowWith New Jet Injection Mixing, machine flow

HeadBoxHeadBox

PP

Stock BoxStock Box DCDC

CleanerCleaner

MSMS

MFPMFPCFPCFP

PP

CC--PAMPAM : Before MS: Before MS ((Quill nozzle)Quill nozzle)

AA--PAMPAM : After MS: After MS ((TrumpJet)TrumpJet)

AA--PAMPAM

CC--PAMPAM

Concept of laboratory testConcept of laboratory test

Simulation ofconventional mixing points

(*) Tested at Mütec DFS retention analyzerHigh shearMedium shearLow shear

Agitator setting0sec 35sec 40sec 60sec

C-PAM beforecleaner fan pump

Drainage

A-PAM beforemachine fan pump

C-PAM beforemachine screen

A-PAM aftermachine screen

Simulation ofnew chemical mixing points

Result of laboratory testResult of laboratory test

46

48

50

52

54

56

58

60

62

64

0.000 0.010 0.020 0.030Dosing rate of retention aids [%]

(C-PAM+A-PAM)

TOTA

L FP

R [%

]

Simulation of newchemical mixing pointsSimulation of conventionalchemical mixing points

10

15

20

25

30

35

40

45

0.000 0.010 0.020 0.030Dosing rate of retention aids [%]

(C-PAM+A-PAM)

AS

H F

PR

[%]

Simulation of newchemical mixing pointsSimulation of conventionalchemical mixing points

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

TrumpJetTrumpJet®® Flash Mixing = Jet Injection Mixing for Flash Mixing = Jet Injection Mixing for papermaking additivespapermaking additives

Wetend Technologies Ltd is a Finland based corporation.

City of Savonlinna

FiberLaboratory

17

Injection stock

ChemicalMixing stock

TrumpJetTrumpJet®® Flash Mixing for papermaking Flash Mixing for papermaking additivesadditives

-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

18Jet Injection Mixing for papermaking additivesJet 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

19Jet Injection Mixing for papermaking additivesJet 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 CO2 emission

Jet Injection Mixing for papermaking additivesJet Injection Mixing for papermaking additivesTotal Annual Water and Energy Saving with 250 installations:35 million m3 (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 CO2 emissions per annum

PATENTED Jet Injection mixing technology

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

Content 4. ResultContent 4. Result

1)1) Reduction of retention aidsReduction of retention aids

and iand improvement of FPRmprovement of FPR

2)2) Saving energySaving energy

by reduction of dby reduction of dilution waterilution water

3)3) Extending shut down cycle forExtending shut down cycle for

prolonged prolonged lifetime of wires and feltslifetime of wires and felts

Content 4. ResultContent 4. Result

1)1) Reduction of retention aidsReduction of retention aids

and iand improvement of FPRmprovement of FPR

2)2) Saving energySaving energy

by reduction of dby reduction of dilution waterilution water

3)3) Extending shut down cycle forExtending shut down cycle for

prolonged prolonged lifetime of wires and feltslifetime of wires and felts

71

110

100

40

60

80

100

120

BeforeECF

AfterECF

WithTrumpjet

Dos

ing

rate

of r

eten

tion

aids

(Set

'Bef

ore

EC

F' =

100

)

With new ”Jet Injection mixing”

Reduction of retention aidsReduction of retention aids

--35%35%

Improvement of Total FPRImprovement of Total FPR

67

75

40

50

60

70

80

90

CoatBasePaper

FinePaper

BookPaper

SLWC LWC Average

TOTA

L FP

R [%

]

BeforeWith TrumpJetJet Injection mixing

Improvement of Ash FPRImprovement of Ash FPR

30

42

20

30

40

50

60

70

CoatBasePaper

FinePaper

BookPaper

SLWC LWC Average

AS

H F

PR [%

]

BeforeWith TrumpJet

Content 4. ResultContent 4. Result

1)1) Reduction of retention aidsReduction of retention aids

and iand improvement of FPRmprovement of FPR

2)2) Saving energySaving energy

by reduction of dby reduction of dilution waterilution water

3)3) Extending shut down cycle forExtending shut down cycle for

prolonged prolonged lifetime of wires and feltslifetime of wires and felts

Saving energySaving energyby reduction of dby reduction of dilution waterilution water

Reduction of dilution water of AReduction of dilution water of A--PAM linePAM line

90 L/min 90 L/min 30 30 L/minL/min

(24 GPM (24 GPM 8 GPM)8 GPM)

Energy savingsEnergy savings

25.225.2℃℃ ×× 6060L/min L/min ×× 4.24.2kJ/kgkJ/kg℃℃ ＝＝

2,5402,540kWh/daykWh/day

(*) (*) Fresh water temperature = 1Fresh water temperature = 11.8 1.8 CC

Warm water temperature = 37.0 CWarm water temperature = 37.0 C

Content 4. ResultContent 4. Result

1)1) Reduction of retention aidsReduction of retention aids

and iand improvement of FPRmprovement of FPR

2)2) Saving energySaving energy

by reduction of dby reduction of dilution waterilution water

3)3) Extending shut down cycle forExtending shut down cycle for

prolonged prolonged lifetime of wires and feltslifetime of wires and felts

0.16

0.09

0.00

0.10

0.20

0.30

0.40

0.50

CoatBasePaper

FinePaper

BookPaper

SLWC LWC Average

Ash

con

sist

ency

of

No.

1 w

hite

wat

er ta

nk [%

]

BeforeWith TrumpJetJet Injection mixing

Ash consistency of white waterAsh consistency of white water

3,480

1,949

0

500

1,000

1,500

2,000

2,500

3,000

3,500

CoatBasePaper

FinePaper

BookPaper

SLWC LWC TOTAL

Ash

flow

rate

pas

sing

thro

ugh

wire

[t/m

onth

] .

BeforeWith TrumpJetJet Injection mixing

Ash flow rate passing through wire Ash flow rate passing through wire

--44%44%

0.2040.198

0.171

0.160

0.100

0.120

0.140

0.160

0.180

0.200

0.220

TOP.W BOT.W

Wire

wea

ring

rate

[%/d

ay]

BeforeWith TrumpJetJet Injection mixing

Wire wearing rateWire wearing rate

TOP.WTOP.W--16%16% BOT.WBOT.W

--19%19%

After 60days Untouched Scratched

Before

With TrumpJet

Improvement of AKD dirt on Improvement of AKD dirt on top wiretop wire

With Jet Injection mixing

Prolonged Prolonged lifetime of wireslifetime of wires

Wire lifetime :Wire lifetime :

90 days 90 days 120 120 daysdays

Annual requirement of wire :Annual requirement of wire :

4 pieces/year 4 pieces/year 3 pieces3 pieces//yearyear

(*) (*) Both top wire and bottom wireBoth top wire and bottom wire

Total consistencyTotal consistency of pof press white waterress white water

0.08

0.05

0.00

0.05

0.10

0.15

0.20

CoatBasePaper

FinePaper

BookPaper

SLWC LWC Average

Tota

l con

sist

ency

of

Pres

s w

hite

wat

er [%

]

BeforeWith TrumpJetJet Injection mixing

Felt wearing rateFelt wearing rate

0.30

0.15

0.23

0.08

0.00

0.10

0.20

0.30

0.40

PuF 4PF

Felt

wea

ring

rate

[%/d

ay]

BeforeWith TrumpJet

PuFPuF--23%23%

4PF4PF--47%47%

(*) ‘FPR improvement’ + ‘optimization of felt conditioner’

Jet Injection mixing

Prolonged Prolonged lifetime of feltslifetime of felts

Felt lifetime :Felt lifetime :

60 days 60 days 80 80 daysdays

Annual requirement of felt :Annual requirement of felt :

6.0 pieces/year 6.0 pieces/year 4.5 pieces4.5 pieces//yearyear

(*) (*) All 5parts ( PuF / 1PBF / 3PF / 4PF / TF )All 5parts ( PuF / 1PBF / 3PF / 4PF / TF )

Extending shut down cycleExtending shut down cycle

Shut down cycle :Shut down cycle :

30 days 30 days 40 40 daysdays

Number of annual shut downs :Number of annual shut downs :

12 times/year 12 times/year 9 times9 times//yearyear

(*) (*) Each shut down time remains the same.Each shut down time remains the same.

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. 5. ““Step twoStep two””

6. 6. ConclusionsConclusions

Content 5. Content 5. ““Step twoStep two””

CC--PAM + AKD with Jet Injection PAM + AKD with Jet Injection mixing after the screenmixing after the screen

Present machine flow, PM7Present machine flow, PM7

HeadBoxHeadBox

PP

Stock BoxStock Box DCDC

CleanerCleaner

MSMS

MFPMFPCFPCFP

PP

CC--PAMPAM : Before MS: Before MS ((Quill nozzle)Quill nozzle)

AKDAKD : Stock Box: Stock Box

AA--PAMPAM

CC--PAMPAMAKDAKD

With new Jet Injection Mixing, machine flow, PM7With new Jet Injection Mixing, machine flow, PM7

HeadBoxHeadBox

PP

Stock BoxStock Box DCDC

CleanerCleaner

MSMS

MFPMFPCFPCFP

PP

CC--PAM + AKD : After MS (Jet PAM + AKD : After MS (Jet Injection Mixing)Injection Mixing)

AA--PAMPAM

CC--PAM PAM + + AKDAKD

Concept of laboratory test, PM7Concept of laboratory test, PM7

0sec 35sec 40sec 60secDrainage

Simulation ofpresent mixing points

(*) Tested at Mütec DFS retention analyzer

High shearMedium shearLow shear

Agitator setting

AKD at stock boxC-PAM beforemachine screen

C-PAM + AKDafter machine screen

A-PAM aftermachine screen

Simulation ofnew chemical mixing points

Result of laboratory simulation

10

15

20

25

30

35

40

45

50

0.12 0.14 0.16 0.18 0.2AKD dosing rate [%]

Stö

ckig

t siz

ing

degr

ee [s

ec]

AKD at stock box

AKD+C-PAM after machine screen

Result of laboratory test, PM7Result of laboratory test, PM7

Conclusion of installation in PM7Conclusion of installation in PM7

Possibility to reduce AKD by Jet Injection MixingPossibility to reduce AKD by Jet Injection Mixing

Possibility to reduce retention aids still morePossibility to reduce retention aids still more

because of success in the first Jet Injection Mixingbecause of success in the first Jet Injection Mixing

Decision to install TrumpJet Decision to install TrumpJet Chord Chord for CPAM and for CPAM and AKDAKD

Installation in October, 2008.Installation in October, 2008.

Conclusion of installation in PM7 for CPAM & AKDConclusion of installation in PM7 for CPAM & AKD

Results: Results: PM7, additive savings after flash injection installed also for CPAM and AKD

Filler content CPAM APAM AKD

Low - under 10% 10%* 10%* 20%

Middle 10%* 10%* 10%

High 20 – 30% 10%* 10%* 0%

***Filler retention before 30,2% after 41,9%, if old retention is kept, the saving of CPAM is 40%

***Mitsubishi Paper is now investigating the effect of dosing locations of filler and AKD to optimize sizing degree

ContentsContents

1. Introduction of Mitsubishi Paper1. Introduction of Mitsubishi Paper

2. 2. BackgroundBackground

3. Introduction of 3. Introduction of ““Jet InjectionJet Injection””mixing technologymixing technology

4. Results4. Results

5. Future plan5. Future plan

6. 6. ConclusionsConclusions

Optimization of wetOptimization of wet--end at PM7end at PM7

Optimization of wetOptimization of wet--end at PM7 since 2005end at PM7 since 2005

A) Optimization of retention systemA) Optimization of retention system

B) Stabilization of electric charge of white waterB) Stabilization of electric charge of white water

C) Optimization of biocideC) Optimization of biocide

D) Optimization of felt conditionerD) Optimization of felt conditioner

Encounter with sudden drop in FPREncounter with sudden drop in FPR

Investigation cause Investigation cause Installation Jet Injection Installation Jet Injection Mixing stationsMixing stations

ConclusionsConclusionsBy By ““Jet Injection MixingJet Injection Mixing”” (and optimization of wet(and optimization of wet--end),end),

Great reduction in production costGreat reduction in production cost

Increase in Increase in productivityproductivity by 3.5%by 3.5%

Planning to adapt Jet Injection technology to other Planning to adapt Jet Injection technology to other chemicalschemicals

One of THE solutions of One of THE solutions of ‘‘optimization of wetoptimization of wet--endend’’

‘‘Change chemicalsChange chemicals’’ + + ‘‘Improved equipmentImproved equipment’’

More effective resultMore effective result

MITSUBISHIPAPER MILLSLIMITED

WETENDTechnologies

Thank youThank you