The turbine generators（No. 2 & No. 3）in Gotsu Mill have had lots of issues due to their deterioration after 60 years since their construction, especially relating to their mechanical governers and hydraulic systems. However, it is impossible for us to replace these existing mechanical governers with electrical governers due to manufacturer limitations. Therefore, it was necessary to install a new turbine generator（No. 5）in order to continue steady operation.

Nippon Paper Industries regards Gotsu Mill as a main mill of the chemical product business, and a plan to increase the production of dissolving pulp was made. Taking into account a steam and power balance of the whole mill, an optimal evaporator and turbine generator（No. 5）were chosen and installed. The installation of the No. 5 turbine generator enabled us to utilize the steam previously lost in our mill, therefore achieving significant energy savings, cost reductions and a more stable operation.

At Nichinan mill, we set the targeted reduction of energy saving as “1.5％ of the total energy in the mill”and we are working as one to achieve this target.

However the amount of capital investment is on a downwards trend in recent years. And it is becoming to be diffi cult to fi nd and implement the new idea.

In these circumstances we continue to reduce energy consumption by deepening past energy saving case and referring to the idea from the other Oji paper mills.

In this paper, we introduce the examples of our energy saving eff ort which we had implemented.

In order to visualize gas-leak location as well as to detect gas-leak on gas pipes installed within a wide area of factories, we have developed a new portable and light-weight instrument, the “AIR LEAK VIEWER^® MK-750”. The “MK-750” brings the beam-forming technology using an ultrasonic microphone array to the conventional ultrasonic leak detection method. The ultrasonic microphones are positioned in array arrange ment which creates time delay（phase delay）between the microphones in the arrival of ultrasonic waves from its source, and the time delay（phase delay）of the microphone to that being the closest to the ultrason ic source becomes larger as the distant of the microphone becomes farther away from that microphone. This time delay（phase delay）between the ultrasonic microphones is determined from the distance of the micro phones and the ultrasonic wave orientation. The maximum amplitude obtained from overlapping the received waveforms at each ultrasonic microphone is given by correcting the time delay（phase delay）corresponding to the ultrasonic wave source orientation（that is, the gas-leak location）．

The gas-leak orientation is shown as a live image on the LCD of “MK-750V, and, one can promptly iden tify a gas-leak and its position on the “MK-750” LCD screen.

We carried out field tests on actual factories and gas-leaks on pipes containing compressed air, nitrogen gas, etc. were easily and efficiently detected up to 15 m apart from the gas-leak source by using the “MK 750”. In addition, the “MK-750” can identify a gas-leak even in a very noisy area, since it makes use of ultra sound while detecting.

The “MK-750” can detect ultrasound and determine its orientation based on the beam-forming technolo gy. Thus, the “MK-750” allows for ultrasound source detection in a wide area. For instance, corona discharges are known to emit ultrasound when they occur and by using a similar technology to “MK-750”，corona discharges can be not only detected but visualized. A portable instrument called “CORONA DISCHARGE VIEWER MK-760” has been released lately in order to perform electrical facilities diagnosis.

Due to the suppression of global warming and enforcement of the Minamata Convention, the switching of lighting equipment from existing light sources to LED light sources has become an urgent matter for the entire industry.

LED lighting is excellent from the perspective of energy savings/eco product, and it seems that erroneous information that it is a light source which does not get hot unlike conventional lighting and its merit are widely understood. Since heat–sensitive materials are often used as parts for LED lighting, heat dissipation design, which was not deemed important in existing lighting sources, has become a problem that affects the product life, and in particular, high temperature and dust impact. In applications where there there are special circumstances such as vibration, the product life can be severely impacted and disappoint users' expectations. Our products do not require ballasts. Independent type modules adopting AC drive chips and LED lighting for special environments of less than 70℃ are developed by a heat sink with a helix structure unparalleled anywhere. In addition, in this paper I would like to touch on the latest measures against heat, casing design, material improvement and development of new material LED chips to meet expectations for high temperature environment users above 70℃.

MIURA as a leading manufacturer of small once-through boilers has adopted “Plant infrastructure total solution” as a slogan and is promoting various eco-friendly proposal activities through water treatment devices for industrial water and compressors using in-plant process steam, and so on. This paper explains high-effi ciency and power-saving closed condensate recovery system in Paper industry.

In recent years, countries have been required to take measures against global environmental problems such as global warming, and Japan aimed to reduce CO₂ emissions in FY 2030 by 26％ from FY 2013 in the draft of the Paris Convention's promise ^1）．In order to contribute to the draft of the promise of the Paris Agreement, we have also started a project to save energy. In this paper, we report two cases, “Enhancement of primary screen efficiency of No.8 paper machine” and “Water conservation by adding secondary water filter of No. 9 paper machine” at the Niigata Mill.

In the papermaking process, various integrated eff orts are demanded to reduce the energy consumption. To dry the wet paper to a targeted moisture value in the dryer section requires a large amount of energy. The energy effi ciency will be worse enough to aff ect the whole production process in the winter season, since at the lower temperature extra steam energy is required, which deteriorates the steam consumption rate. As a result, mitigating the steam consumption rate is crucial to reduce the energy consumption and to improve the productivity.

In this paper, an originally developed technology, Finesteam, is introduced to improve the heat transfer effi ciency. The core of this technology is to increase the water repellent ability in the inner surface of the dryer, so the liquid fi lm layer of steam condensed water can be avoided, which eff ectively reduces the heat conduction resistance. This technology is expected to optimize the heat transfer process. Results in this paper confi rmed that the reduction of the steam consumption rate is about 3 〜10％ on average.

Another advantage of this technology is that it can be applied cheaply and easily to the existing systems without changing the present operation conditions, making it a great option to reduce the energy consump tion. It will not aff ect the boiler water quality. In addition, an automatic control system has also been devel oped independently for the chemical feeding. Visualization is also possible with our most recent water proc essing monitor system, S.sensing ^®  WEB.

The effectiveness of technology has been successfully applied in single–cylinder Yankee dryers and multi–cylinder dryers, leading to more than fi fty cases of adoption in Japan and worldwide.

In this paper I would like to introduce the advantages and technologies of TurboMAX turbo blower. TurboMAX turbo blower consists of superior technologies like air-foil bearing, permanent magnet synchro nous motor, high efficiency impeller, high speed control technique and so on. As for the overall structure, blower, motor, inverter, touch panel controller and blow off valve are installed in one enclosure. This is a new style turbo blower called “air foil bearing-variable speed-single stage turbo blower”. Compare to the conven tional blowers, TurboMAX turbo blower has many advantages in “Saving energy” “Low noise and vibration”“Saving maintenance cost” “Space-saving and lightweight”. Especially, compare to the conventional root blow ers, TurboMAX turbo blower can reduce power consumption by 20％ on average.

As global warming is serious issue around the world now, reducing the power consumption is required to all industries regardless of its type and scale. Especially for paper industry which uses and disposes a large amount of water, reducing the cost for waste water treatment is a big challenge. In the process of waste wa ter treatment, aeration blower’s power consumption makes up the large proportion, and aeration blower usu ally runs for 24 hours every day. So, high efficiency aeration blower can contribute to the cost reduction of waste water treatment significantly.

In the latter half of this paper, I introduce an actual case of replacing 2 root blowers with 1 turbo blower （MAX 100）at municipal sewage-treatment plant for the field trial. As the result, we could confirm 25％ en ergy saving, 16 dB noise reduction, 25 μm vibration reduction, and 6℃ blower room’s temperature reduc tion.

ShinMaywa Industries, Ltd. launched TurboMAX turbo blower since 2012 in Japan, and some blowers have been delivered to paper factories. As for paper factory, we have delivered blowers to 8 paper factories so far and 12 blowers are in operation now. Especially, one of these blowers are used for flotator which is used in the deinking process during manufacturing recycled paper from used paper, and we confirmed TurboMAX turbo blower can reduce power consumption in non-aeration use too. I expect TurboMAX turbo blower can reduce the power consumption in many other uses too. I hope TurboMAX turbo blower contributes to the energy saving in many fi elds and it leads to the reduction of environmental burden of the globe.

Multivariable predictive control （MPC） application has been started for pulp mill in Japan. Honeywell’s multivariable predictive controller “Profit Controller” is widely accepted in process industry by its unique and advanced functions such as robustness and scalability for optimization. Lifecycle management is also important to utilize MPC and sustain its benefit for long time. Key points of lifecycle management and recommended support structures are described.

The washing process of KP （Kraft pulp） brown pulp stocks, following to KP cooking continuous digest­ er, is consist of a series of washing equipment. This multi stage washing process is not only to wash the brown pulp stocks eff ectively but also to recover KP cooking chemicals （expensive sodium compounds） and some wood lignin components that dissolved in the fi ltrated dilute black liquors. And the fi ltrated and ex­ tracted black liquors are send to the following KP causticizing process, and the chemicals are recovered fi nal­ ly.

In this KP washing process, “Countercurrent fl ow washing” strategy has been utilized in general, and ex­ pected to the washing process to achieve better washing states for the pulp stocks not to remain much chemicals in it. And, furthermore, they are required to be washed eff ectively with lesser amount of fresh wa­ ter usage, and, at once expected to decrease the energy loads of the following black liquor evaporation pro­ cess.

In this paper, a washing calculation model for this KP multi stage washing process that can simulate and estimate the chemical material balance was proposed. Next, utilizing the simulated results by this model and another “Cross fl ow washing strategy”, that used simple fresh washing water fl ow lines were compared. As the result, the eff ect of the “Countercurrent fl ow washing” was confi rmed from the superiorities of the simu­ lated results of the recovered chemical amounts in each washing fi ltrate line, lost chemical amounts to be car­ ried away attached to the brown pulp stocks and the variance of the recovered chemical consistencies etc.