Paper Production Plant Research Articles

Fulfilling Eucalyptus raw materials for pulp and paper production plants

Eucalyptus is one of the major species used for pulp and paper industry. As industries develop, the need for Eucalyptus supply increases. However, there are challenges plantation companies must specifically determining eucalyptus market price potential risks in eucalyptus plantation and how eucalyptus plantation impacts the surrounding environment.. Stakeholders on eucalyptus supply chain have risks which have to be mitigated. The eucalyptus seedling and developer and the supplier hold crucial role in providing good quality eucalyptus raw material for pulp and paper production plants. This research is conducted to explore on ways to mitigate each stakeholders risk, challenges plantation companies face in fulfilling eucalyptus raw material for pulp and paper production plants. There are four stakeholders in eucalyptus supply chain: eucalyptus seedling developer and seller, supplier, distribution centre and pulp and paper production plants. Some of the major risk stakeholders are facing in eucalyptus supply chain are: early cut of eucalyptus trees, farmers’ lack of understanding on growing eucalyptus properly, small stem size, fluctuating eucalyptus wood price and low stock quantity. Some of the minor risk stakeholders are facing: earthquake, over fertilization, overwatering, cold climate, and plant setting. There are four methods used to determine eucalyptus pricing: cost-based pricing, customer-based pricing, competition-based pricing, and statutory pricing. Eucalyptus consume high amount of water which can cause dry areas around eucalyptus plantation area and low groundwater reservoir.

Eucalyptus plantation and its integrated supply chain in pulp and paper mill

Nowadays, demand of the pulp and paper production increases quickly. That increasing demand has led to demanding of eucalyptus plantation. That is why eucalyptus plantation has rapidly expanded and became the most planted tree species across the world over the last century. Not only because its unique characteristics, increasing of eucalyptus plantation also happened because its growing gives a socio-economic benefits, industrial benefits, and environmental impacts. However, increasing demand of eucalyptus certainly make availability of eucalyptus being determined, known as limited supply chain. Due to the increasing demand and limited supply chain, the eucalyptus wood supply should managed, by integrated the supply chain well. In this research study, the supply chain of eucalyptus wood for pulp and paper industry was diagnosed and divided into three degree, there are direct supply chain, extended supply chain, and ultimate supply chain. Four main stakeholders in this chain identified consisted of the eucalyptus seedling developers and sellers, the suppliers, the distribution centers, and the pulp and paper production plants.

Parametric and Nonparametric PID Controller Tuning Method for Integrating Processes Based on Magnitude Optimum

Integrating systems are frequently encountered in power plants, paper-production plants, storage tanks, distillation columns, chemical reactors, and the oil industry. Due to the open-loop instability that leads to an unbounded output from a bounded input, the efficient control of integrating systems remains a challenging task. Many researchers have addressed the control of integrating processes: Some solutions are based on a single closed-loop controller, while others employ more complex control structures. However, it is difficult to find one solution requiring only a simple tuning procedure for the process. This is the advantage of the magnitude optimum multiple integration (MOMI) tuning method. In this paper, we propose an extension of the MOMI tuning method for integrating processes, controlled with a two-degrees-of-freedom (2-DOF) proportional–integral–derivative (PID) controller. This extension allows for calculations of the controller parameters from either time domain measurements or from a process transfer function of an arbitrary order with a time-delay, when both approaches are exactly equivalent. The user has the option to emphasise disturbance-rejection or tracking with the reference weighting factor b or apply two different reference filters for the best overall response. The proposed extension was also compared to other tuning methods for the control of integrating processes and tested on a charge-amplifier drift-compensation system. All closed-loop responses were relatively fast and stable, all in accordance with the magnitude optimum criteria.

Combining Energy Management Indicators and Life Cycle Assessment Indicators to Promote Sustainability in a Paper Production Plant

This paper presents the application of an energy characterization method based on the ISO 50001 standard in a dry paper production plant. This plant operates using electricity, gas, and coal as energy sources. The last two energy sources are used to produce the steam and hot air used in the paper drying process. Through energy characterization, indicators such as energy baseline and consumption indicators were calculated for the plant, with which improvement opportunities were identified. These improvement opportunities were used as case studies for each energy source used and were based on the actual state of the plant. 2011 Midpoint+ ILCD method data was selected from the Ecoinvent database, using OpenLCA 1.7.0 for the energy assessment. The impact categories analyzed in this study were ecotoxicity, eutrophication of rivers and seas, climate change, and human toxicity. As a result of this work, it was found that energy-saving was possible by adjusting the production rate to a load factor of 77%, which implies a gas consumption of 1.6 kWh/kg and a value in the climate change category of 88.5 kg of CO2 equivalent. In addition, some technological improvement opportunities were economical and environmentally evaluated as a result of the sustainable improvement strategy implemented with energy management and life cycle assessment. The study of these technological opportunities showed that in order to achieve a sustainable industrial process, it is important to take into account energy, economic, and environmental criteria in the continuous improvement of the paper production process. In addition, it is of vital importance to analyze alternatives for technological change, which have a greater impact than operational alternatives according to energy, environmental and economic criteria.

Parametric and Nonparametric PI Controller Tuning Method for Integrating Processes Based on Magnitude Optimum

Integrating systems are frequently encountered in the oil industry (oil–water–gas separators, distillation columns), power plants, paper-production plants, polymerisation processes, and in storage tanks. Due to the non-self-regulating character of the processes, any disturbance can cause a drift of the process output signal. Therefore, efficient closed-loop control of such processes is required. There are many PI and PID controller tuning methods for integrating processes. However, it is hard to find one requiring only a simple tuning procedure on the process, while the tuning method is based either on time-domain measurements or on a process transfer function of arbitrary order, which are the advantages of the magnitude optimum multiple integration (MOMI) tuning method. In this paper, we propose the extension of the MOMI tuning method to integrating processes. Besides the mentioned advantages, the extension provides efficient closed-loop control, while PI controller parameters calculation is still based on simple algebraic expressions, making it suitable for less-demanding hardware, like simpler programmable logic controllers (PLC). Additionally, the proposed method incorporates reference weighting factor b that allows users to emphasize either the disturbance-rejection or reference-following response. The proposed extension of the MOMI method (time-domain approach) was also tested on a charge-amplifier drift-compensation system, a laboratory hydraulic plant, on an industrial autoclave, and on a solid-oxide fuel-cell temperature control. All closed-loop responses were relatively stable and fast, all in accordance with the magnitude optimum criteria.

Synthesis and Application of a Cationic Polyamine as Yankee Dryer Coating Agent for the Tissue Paper-Making Process.

Tissue paper is of high importance worldwide and, continuously, research is focused on improvements of the softening and durability properties of the paper which depend specifically on the production process. Polyamide-amine-epichlorohydrin (PAE) resins along with release agents are widely used to adhere the paper to the yankee dryer (creping cylinder) in paper manufacture. Nevertheless, these resins are highly cationic and they normally adhere in excess to the paper which negatively affects the creping process and the quality of the paper. For this reason, a low cationic polyamine-epichlorohydrin coating (Polycoat 38®) was synthesized from a diamine supplied by Disproquin S.A.S. and epichlorohydrin. The analysis of the synthesized polymer was carried out by Fourier transform infrared spectroscopy (FTIR) and nuclear magnetic resonance (1H-NMR). The molecular weight of the polymer was obtained by gel permeation chromatography (GPC), physical-chemical properties such as kinematic viscosity, percentage of solids, density, charge density were measured and compared with a commercial PAE resin (Dispro620®) Thermal stability of the Polycoat 38® and glass transition temperature in presence of a release agent (Disprosol 17®) were also evaluated by thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC), respectively. Finally, a peel adhesion test and an absorption durability assessment were carried out together with the evaluation of the creeping efficiency of the paper by caliber and tensile measurements in a tissue (towel paper) production plant, demonstrating a superior performance in the paper creping process as compared to some commercially available products.

Enhancing the Production Efficiency in Paper Recycling Plant through Thickness Measurement

The whole world is moving towards recycling or green campus; such an initiative is focused here. In order to make use of the recycled raw materials completely without any wastage, certain measurements are necessary. Such measurement is the paper or board thickness has been proposed in this paper. The paper thickness measurement plays a vital role in order to minimize the pulp wastage and increase the production rate. The measurement technique utilized for paper thickness measurement is the ultrasonic method. The ultrasonic sensor-based paper thickness measurement helps in getting optimized results of maximum utility and minimal wastage. The thickness measurement indicator is designed to monitor the paper or card board thickness in an effective way. The improves the productivity of the paper production plant.

The cost analysis of material handling in Chinese traditional praying paper production plant

Chinese traditional praying paper industry is an industry which produced Chinese traditional religion praying paper. This kind of industry is rarely examined since it was only in Small and Medium Enterprise (SME’s- form). This industry produced various kinds of Chinese traditional paper products. The purpose of this research is to increase the amount of production, reduce waiting time and moving time, and reduce material handling cost. The research was conducted at prime production activities, consists of: calculate the capacity of the material handler, the frequency of movement, cost of material handling, and total cost of material handling. This displacement condition leads to an ineffective and inefficient production process. The alternative was developed using production judgment and aisle standard. Based on the observation results, it is possible to reduce displacement in the production. Using alternative which by-passed displacement from a rolled paper in the temporary warehouse to cutting and printing workstation, it can reduce material handling cost from 2.26 million rupiahs to 2.00 million rupiahs only for each batch of production. This result leads to increasing of production quantity, reducing waiting and moving time about 10% from the current condition.

Dynamic modeling of paper drying processes

A dynamic model describing the behavior of a multi-cylinder drying section in paper production plants was developed based on the mass and heat balances around drying cylinders. The balance equations consist of sets of differential equations describing heat and mass transfer around the canvas, the web and the drying cylinders. Values of cylinder temperatures and moisture contents were estimated and compared with operation data. To obtain further information for energy consumption, the generation of entropy at each drying cylinder was investigated based on the model developed.

Geochemical Characterization of Organic Pollutants in Effluents Discharged from Various Industrial Sources to Riverine Systems

The detailed characterization of the organic composition of industrial effluents discharged from various industrial branches and the distribution of the emitted pollutants in the surface waters in North Rhine-Westphalia have been done with the use of non-target screening analyses. Based on the characterization of molecular structures of wastewater constituents, their quantification as well as the available information on their origin and industrial applications, the identification of typical organic representatives for petrochemical and food effluents has been performed. Among a wide range of hydrocarbons detected in the petrochemical effluents, several novel organic wastewater constituents have been found for the first time. In the effluents from paper production plant, potential industrial indicators were distinguished, such as resin acids (abietic and dehydroabietic acids) and photoinitiators (Irgacure 184). The monitoring of the behaviour of certain environmentally relevant and newly described pollutants in the contaminated river systems allowed the identification of several industrial site-specific markers. Particularly, 2-(chloromethyl)-1,3-dioxolane, an unknown contaminant, exclusively found in the effluents from a chemical production complex, was present in the river under discharge at high concentrations downstream the contamination source. The comprehensive and detailed evaluation of the anthropogenic markers in the industrial effluents is a promising tool for the environmental assessment of industrial emissions, especially if accompanied with toxicological and ecotoxicological investigations of novel environmental contaminants.

Dynamic modeling of the steam supply system for a paper drying cylinder

A dynamic model describing the principles of a steam supply system for a paper drying cylinder used in paper production plants was developed based on the mass and heat balances around the cylinder. The balance equations consist of sets of differential equations describing heat and mass transfer around the canvas, the web and the drying cylinder. The effects of the steam valve adjustment on steam pressure, temperature and moisture content were investigated based on the model developed. It was found that application of simple model predictive control to the operation of steam supply system is enough to achieve satisfactory drying performance in a single paper drying cylinder.

Hazardous waste management in Chilean main industry: An overview

The new “Hazardous Waste Management Regulation” was published in the Official Newspaper of the Chilean Republic on 12 June 2003, being in force 365 days after its publication (i.e., 12 June 2004). During the next 180 days after its publication (i.e., until 12 December 2004), each industrial facility was obligated to present a “Hazardous Waste Management Plan” if the facility generates more than 12 ton/year hazardous wastes or more than 12 kg/year acute toxic wastes. Based on the Chilean industrial figures and this new regulation, hazardous waste management plans were carried out in three facilities of the most important sectors of Chilean industrial activity: a paper production plant, a Zn and Pb mine and a sawmill and wood remanufacturing facility. Hazardous wastes were identified, classified and quantified in all facilities. Used oil and oil-contaminated materials were determined to be the most important hazardous wastes generated. Minimization measures were implemented and re-use and recycling options were analyzed. The use of used oil as alternative fuel in high energy demanding facilities (i.e., cement facilities) and the re-refining of the used oil were found to be the most suitable options. In the Zn and Pb mine facility, the most important measure was the beginning of the study for using spent oils as raw material for the production of the explosives used for metals recovery from the rock. In Chile, there are three facilities producing alternative fuels from used oil, while two plants are nowadays re-refining oil to recycle it as hydraulic fluid in industry. In this sense, a proper and sustainable management of the used oil appears to be promissory.

Homogeneous and Heterogeneous Catalytic Ozonation of Pulp Bleaching Effluent

AbstractCatalytic ozonation is a promising treatment method for both water and wastewater. In this study, in order to increase the biodegradability of bleaching wastewater from an integrated pulp- and -paper production plant, granulated activated carbon-(GAC), iron-(Fe

Bilinear model predictive control of grade change operations in paper production plants

In this work the bilinear model predictive control method is applied to control the grade change operations in paper production plants. Because of the high nonlinearity of the grade change processes, control of the grade change operations has been performed manually by experienced engineers in the plants. In some cases the bilinear model can be very effective to represent nonlinear processes. In this study a bilinear model for paper plants is identified first. It is found that the bilinear model tracks the plant without significant discrepancy. Based on the multivariable bilinear plant model the optimal input variables are computed using the one-step ahead prediction method. Even for frequent changes in paper grades the bilinear model predictive control scheme exhibits good control performance.

Modeling of the Drying Process in Paper Plants

In this study a model for the drying process in paper production plants was developed based on the mass and heat balances around drying cycles. Relationships for the heat transfer coefficients between the web and the air as well as between the drying cylinder and the web were extracted from the closed-loop plant operation data. It was found that the heat transfer coefficients could be represented effectively in terms of moisture content, basis weight and reel velocity. The effectiveness of the proposed model was illustrated through numerical simulations. From the comparison with the operation data, the proposed model represents the paper plant being considered with sufficient accuracy.

Modeling of the drying process in paper plants

In this study a model for the drying process in paper production plants was developed based on the mass and heat balances around drying cycles. Relationships for the heat transfer coefficients between the web and the air as well as between the drying cylinder and the web were extracted from the closed-loop plant operation data. It was found that the heat transfer coefficients could be represented effectively in terms of moisture content, basis weight and reel velocity. The effectiveness of the proposed model was illustrated through numerical simulations. From the com- parison with the operation data, the proposed model represents the paper plant being considered with sufficient ac- curacy.

Failure of stainless digester shafts in a paper production plant

The stainless steel connecting shafts of digester discharge screws of a paper production plant failed within a relatively short period after the production start of the plant. To investigate the reasons for these failures, stress analysis and material characterization of the broken shafts were performed. The test program included tensile, impact and hardness tests and metallographical and fractographical investigations. Fractographical examination verified that crack growth due to fatigue would have not been a contributing damage mechanism. Existence of chromium carbides together with a martensitic structure in the welded regions between the shaft body and its blades had provided potential zones for crack initiation. Stress corrosion cracking (SCC) was judged as the main damage mechanism in the failure of the shafts. The high temperature steam containing aggressive chemical species caused SCC. Thus, the material selected for the DDS shaft is not proper with respect to resistance to the corrosive atmosphere in the digester housing.

Failure study of connecting shafts of a plug screw feeder in a paper production plant

The connecting shafts of two plug screw feeder units of a paper production plant failed within a relatively short period after the production start of the plant. To investigate the reasons for these failures, material characterizations of the broken shafts were performed. The program included tensile, impact and hardness tests and metallographical and fractographical investigations. Fracture surfaces of the failed shafts were studied using light and electron microscopy. Obvious striations and beach marks could be observed by fractographic examination. The fracture features observed on the fracture surfaces reveal that (a) the shafts had experienced fatigue crack growth before the final failure; (b) the crack growth initiated from a sharp undercut at the threaded part of the shaft; (c) the fatigue driving forces have combined torsional and bending loading, having torsional as the governing load.

THERMOCOMPRESSOR DESIGN FOR EFFICIENT ENERGY RECOVERY OF PAPER PRODUCTION PLANT DRYERS

The operational performance of a paper production plant can be significantly improved by appropriate process interventions. This paper deals with energy aspects of the most important section of such a plant, the paper drying section. A significant intervention that would lower the operational cost of the drying process is proposed. It refers to the recompression of low pressure steam leaving the dryers by means of a thermocompressor that would utilize high pressure steam coming from the plant burners. The mathematical model of the thermocompressor is evaluated and its design procedure is formulated as a mathematical programming problem involving appropriate objective function and constraints.

Optimal chemical control of populations developing drug resistance.

A system of differential equations for the control of the growth of certain populations by the use of chemical treatment is presented. Rather general growth rates and kill rates of drugs, as well as drug resistance, are considered. A class of optimal control problems with a performance criterion depending on a parameter is formulated and shown to admit the same basic optimal strategy. Applications to cycle nonspecific chemotherapy and control of the growth of bacterial populations in cellulose media in paper production plants are described.