Paperi- ja selluteollisuus: Kestävän kehityksen rooli alalla ja alan tulevaisuus: Delfoi-tutkimus

Tutkimuksen tavoitteena oli hahmottaa paperi- ja selluteollisuuden nykytilaa ja tulevaisuutta kirjallisuuden sekä empiirisen tutkimuksen avulla. Tutkimuksen avulla hahmotettiin erityisesti kestävän kehityksen ja CSR:n merkitystä paperi- ja selluteollisuudessa, paperi- ja selluteollisuuden tämänhetkistä tilannetta sekä kilpailuedun lähteitä ja liiketoiminnan mahdollisuuksia alalla tulevaisuudessa. Tutkimuksen tutkimusmenetelmä oli kvalitatiivinen ja tutkimusmenetelmänä käytettiin Delfoi-menetelmää. Tutkimuksen perusteella voidaan todeta, että kestävä kehitys on tärkeä aihe paperi- ja selluteollisuudessa ja sen voidaan olettaa tulevaisuudessa olevan alalla vieläkin merkityksellisempi. Ympäristöllisistä tekijöistä ja näkökulmista on metsäteollisuudessa puhuttu jo vuosikymmenten ajan ja alan kansainvälistyminen sekä alalla viime aikoina tapahtuneet muutokset ovat nostaneet kiinnostusta kestävää kehitystä kohtaan entisestään. Tutkimuksen mukaan paperi- ja selluteollisuuden nykytilanne on tällä hetkellä haastava ja kilpailu alalla on kovaa. Syitä alan haastavaan tilanteeseen ovat alalla viime aikoina tapahtuneet muutokset ja kilpailun kiristyminen. Tulevaisuuden kilpailuedun lähteinä alalla voidaan nähdä muun muassa kestävään kehitykseen liittyvät tekijät, uudet tuotteet sekä materiaalit, markkinarakojen hyödyntäminen sekä kannattavuuden parantaminen. Uusia liiketoiminnan mahdollisuuksia alalla tulevaisuudessa ovat erikoistuotteet, bioenergia, innovaatiot, sivutuotteiden käyttö, kierrätettävät materiaalit, pakkausmateriaalit sekä biotalous.

Korkeasti kuormitetun soodakattilan likaantumisen ja päästöjen vähentäminen

Tässä työssä perehdytään korkeasti kuormitettujen soodakattiloiden tyypillisiin ongelmiin. Ongelmia ovat likaantuminen ja tukkeutuminen sekä liialliset päästöt. Työn teoriaosassa esitetään taustat likaantumiselle ja päästöjen muodostumiselle. Molemmat johtuvat suurelta osin tulipesän huonosta toiminnasta. Soodakattilan ilmajärjestelmä ja mustalipeän ruiskutus vaikuttavat tulipesän toimintaan. Usein tulipesän toimintaa voidaan parantaa ilmajärjestelmän ja lipeänruiskutuksen säätöjä muuttamalla. Suurempi muutos tulipesän toimintaan saadaan uusimalla perinteinen sekundääri-ilmajärjestelmä vertikaali-ilmajärjestelmäksi. Nykyaikainen vertikaali-ilmajärjestelmä sekoittaa savukaasut tehokkaasti ja saa aikaan tasaisemman virtauksen tulipesään. Myös mustalipeän korkea kloori- ja kaliumpitoisuus voivat aiheuttaa lämpöpintojen likaantumista. Oikea nuohointen sijainti on tärkeä tekijä kattilan puhtaana pysymisen kannalta. Työn kokeellisessa osassa selvitetään, kuinka erään eukalyptussellutehtaan korkeasti kuormitetun soodakattilan käytettävyyttä voidaan parantaa ja kapasiteettia nostaa soodakattilan toimintaa virittämällä. Kattilan nykyinen ajomalli ja ongelmat selvitettiin. Tulipesän toimintaa testattiin muuttamalla ilmajakoa primääri-, sekundääri- ja tertiääri-ilman välillä ja muuttamalla sekundääri-ilman syöttöä tulipesään. Testien ja kerätyn tiedon perusteella voitiin päätellä, miten soodakattilaa kannattaa modernisoida kapasiteetin nostamiseksi ja käytettävyyden parantamiseksi. Usein tulipesän toimintaa ja käytettävyyttä voidaan parantaa paljon jo pienilläkin muutostöillä. Kapasiteetin nostaminen vaatii tavallisesti suuremman investoinnin ja pidennetyn vuosihuoltoseisokin.

Emerging market patterns in recycled paper trade

The international recovered paper trade serves two important functions: increasing raw material availability in the paper and board industry and providing economic incentives to recycle. The purpose of this paper is to shed further light on emerging patterns in this trade by empirically analysing the changes in the bilateral trade flows of recycled paper between 1992 and 2008. According to our estimations, two important changes have taken place in the 1990s and 2000s. First, the growing importance of developing economies in global recycled paper trade plays a significant role in import demand as a determinant of trade flows. Second, the changes in global trade patterns necessitate investigating the transportation cost measures used in applied research.

Feasibility of the use of recycled nutrients in fast growing pulpwood production

The application of pulp and paper mill (PPM) sludge in agriculture and forestry has been acknowledged as soil amendments and a plant nutrient source. The main objectives of this study were to evaluate the total cost of the use of recycled nutrients from PPM sludge in fast growing pulpwood production, and the financial profitability of fast growing pulpwood production with the use of these recycled nutrients. The investment and production costs of fast growing pulpwood plantation were directly acquired from a previous research, while the other data was compiled through different studies. The total cost of the use of PPM sludge was evaluated based on assumed factors. Discounted cash flow method was used to evaluate the financial profitability, using NPV and IRR as indicators. The results of estimated sludge nutrient contents were 16.2 g N, 2.9 g P, and 2.4 g K kg-1 of dry sludge. The sludge application rate was estimated at 1.36 Mg/ha in the first year. The total cost of the use of PPM sludge involved transport and spreading cost of US$49.15/dry ton. The fertilization cost applied in the financial model was designed in 3 different options and their results were as follows: option (1) was taken directly from the reference research (US$97/ha); option (2) was the use of sludge alone (US$66.75/ha); and option (3) was the use of sludge and TSP fertilizer (US$83.80/ha). The average NPV without discounting was US$248,180 while the IRRs ranged between approximately 3-4% with an average of 3.63%. Although option (2) and (3) contributed to higher IRRs compared to option (1), this increase was still not significant as the IRR was not sensitive to the total fertilization cost. The advantages are that this practice can be performed at a lower cost and the application rate can be still increased if necessary. It is better for forest plantations compared to agriculture and consequently supports reforestation program. In addition, it can be similarly applied in wood biomass production. A disadvantage is that the IRRs were not very favorable compared to the criterion of 11%. The sludge high in C:N ratio can cause nitrogen immobilization, and regulatory concerns may restrict and complicate the use of sludge landspreading and contribute to additional costs and processes.

Recovery boilers - history and future

Recovery boilers are built all over the world. The roots of recovery technology are longer than the roots of recovery boilers. But it wasn’t until the invention of recovery boilers before the Second World War that the pulping technology was revolutionalized. This led to long development of essentially the same type of equipment, culminating into units that are largest biofuel boilers in the world. Early recovery technology concentrated on chemical recovery as chemicals cost money and if one could recycle these chemicals then the profitability of pulp manufacture would improve. For pulp mills the significance of electricity generation from the recovery boiler was for long secondary. The most important design criterion for the recovery boiler was a high availability. The electricity generation in recovery boiler process can be increased by elevated main steam pressure and temperature or by higher black liquor dry solids as well as improving its steam cycle. This has been done in the modern Scandinavian units.

Selvitys erilaisten mäntyöljynkeittoprosessien toiminnasta

Työn tavoitteena oli tutustua eri mäntyöljyprosessien toimintaan. Sulfaattisellun valmistuksessa syntyy sivutuotteena mäntyöljyä. Se tuo lisätuottoa sellutehtaalle. Nykypäivänä mäntyöljyn valmistukseen on kiinnitetty yhä enemmän huomiota uusien jalostusmahdollisuuksien vuoksi. Mäntyöljyä syntyy, kun mustalipeän pinnalta kuorittu suopa palstoitetaan sopivalla hapolla. Suopa koostuu puun uuteaineista eli hartsi- ja rasvahapoista sekä saippuattomista aineista. Suopa pitää erottaa mustalipeästä mahdollisimman hyvin, jotta se ei aiheuttaisi ongelmia sellutehtaan eri prosessin vaiheissa. Suopaa voidaan erottaa mustalipeästä säiliöerotuksena, sentrifugeilla tai hydrosykloneilla. Suovan palstoitusprosessi voi olla erä- tai jatkuvatoiminen prosessi. Jatkuvatoimisia prosesseja ovat: sentrifugi-, säiliödekantointi- ja HDS-prosessi. Mäntyöljyä voidaan käyttää kemianteollisuuden raaka-aineena tai siitä voidaan jalostaa biodieseliä. Tämä biodiesel on niin sanottua toisen polven biopolttoainetta eli se ei sisällä ravinnoksi kelpaavaa raaka-ainetta. Nykypäivänä markkinoilla on sekä eräkeitto- sekä jatkuvatoimisia prosesseja. Suovan erotussäiliöiden rinnalle on tullut uusi sentrifugeilla tapahtuva suovan erotussysteemi.

The cytotoxicity of methacryloxylethyl cetyl ammonium chloride, a cationic antibacterial monomer, is related to oxidative stress and the intrinsic mitochondrial apoptotic pathway

Antibacterial monomers incorporated in dentin bonding systems may have toxic effects on the pulp. Thus, the cytotoxicity of antibacterial monomers and its underlying mechanisms must be elucidated to improve the safety of antibacterial monomer application. The influence of an antibacterial monomer, methacryloxylethyl cetyl ammonium chloride (DMAE-CB), on the vitality of L929 mouse fibroblasts was tested using MTT assay. Cell cycle progression was studied using flow cytometry. Production of intracellular reactive oxygen species (ROS) after DMAE-CB treatment was measured using 2,7-dichlorodihydrofluorescein diacetate staining and flow cytometry analysis. Loss of mitochondrial membrane potential, disturbance of Bcl-2 and Bax expression, as well as release of cytochrome C were also measured using flow cytometry analysis or Western blot to explore the possible involvement of the mitochondrial-related apoptotic pathway. DMAE-CB elicited cell death in a dose-dependent manner and more than 50% of cells were killed after treatment with 30 µM of the monomer. Both necrosis and apoptosis were observed. DMAE-CB also induced G1- and G2-phase arrest. Increased levels of intracellular ROS were observed after 1 h and this overproduction was further enhanced by 6-h treatment with the monomer. DMAE-CB may cause apoptosis by disturbing the expression of Bcl-2 and Bax, reducing the mitochondrial potential and inducing release of cytochrome C. Taken together, these findings suggest that the toxicity of the antibacterial monomer DMAE-CB is associated with ROS production, mitochondrial dysfunction, cell cycle disturbance, and cell apoptosis/necrosis.

VP22 herpes simplex virus protein can transduce proteins into stem cells

The type I herpes simplex virus VP22 tegument protein is abundant and well known for its ability to translocate proteins from one cell to the other. In spite of some reports questioning its ability to translocate proteins by attributing the results observed to fixation artifacts or simple attachment to the cell membrane, VP22 has been used to deliver several proteins into different cell types, triggering the expected cell response. However, the question of the ability of VP22 to enter stem cells has not been addressed. We investigated whether VP22 could be used as a tool to be applied in stem cell research and differentiation due to its capacity to internalize other proteins without altering the cell genome. We generated a VP22.eGFP construct to evaluate whether VP22 could be internalized and carry another protein with it into two different types of stem cells, namely adult human dental pulp stem cells and mouse embryonic stem cells. We generated a VP22.eGFP fusion protein and demonstrated that, in fact, it enters stem cells. Therefore, this system may be used as a tool to deliver various proteins into stem cells, allowing stem cell research, differentiation and the generation of induced pluripotent stem cells in the absence of genome alterations.

Tangential microfiltration of orange juice in bench pilot

The aim of this study was to introduce the tangential microfiltration (TMF) technique on the production of orange juice (TMFJ), and compare it with pasteurised juice (control) as regards chemical composition and sensorial characteristics. We used a TMF pilot equipped with four monotubular ceramic membranes (0.1, 0.2, 0.8 and 1.4mm) arranged in series with a filtering area of 0.005 m² each. Commercial flash-pasteurised orange juice was used as the initial product. Experiments were divided into three parts: a) the characterisation of the TMF pilot; b) optimisation of operational conditions; c) production of the TMFJ. In the second part, membrane with 0.8-mm pores presented best flux followed by those with 1.4-, 0.1-, and 0.2-mm pores. However, to guarantee permeate sterility, we chose the membrane with 0.1-mm pores for TMFJ production. Initially, the orange juice was sieved in order to separate part of the pulp, being subsequently submitted to TMF. A mixture of retentate and pulp was made, and was subsequently pasteurised. We obtained the TMFJ by adding the permeate to the mixture. TMFJ presented soluble solids content (°Brix), pulp, pH, and titrable acidity similar to the initial pasteurised juice (control). Nevertheless, 28% of vitamin C was lost during the TMFJ production. According to the juice taster panel, the control juice presented best sensorial characteristics (greater aroma intensity and fruity flavour) when compared with the TMJF.

Storage stability of cashew apple juice preserved by hot fill and aseptic processes

Cashew (Anacardium occidentale L.) apples from Pacajus, Ceará State, Brazil, were processed into high pulp content juice. The juice was packed either by hot fill or an aseptic process and evaluated for physical, physical-chemical, and sensorial changes during a 12-month storage period at room temperature. The results indicated that pH, soluble solids, total acidity, total sugar content and color did not change significantly during storage nor were affected by the type of filling. The sensorial analysis showed that juice acceptance remained high throughout the storage period regardless of the filling system. Differences in juice viscosity persisted between both processes.

Enthalpy-entropy compensation based on isotherms of mango

Moisture equilibrium data of mango pulp were determined using the static gravimetric method. Adsorption and desorption isotherms were obtained in the range of 30-70 ºC, to water activities (a w) from 0.02 to 0.97. The application of the GAB model to the experimental results, using direct nonlinear regression analysis, provided agreement between experimental and calculated values. The net isosteric heat of sorption was estimated from equilibrium sorption data, using the Clausius-Clapeyron equation. Isosteric heats of sorption were found to increase with increasing temperature and could be well adjusted by an exponential relationship. The enthalpy-entropy compensation theory was applied to sorption isotherms and plots of deltaH versus deltaS provided the isokinetic temperatures, indicating an enthalpy controlled sorption process.

Carbon sources for Power-to-Gas applications in the Finnish energy system

This thesis is done as a part of the NEOCARBON project. The aim of NEOCARBON project is to study a fully renewable energy system utilizing Power-to-Gas or Power-to-Liquid technology for energy storage. Power-to-Gas consists of two main operations: Hydrogen production via electrolysis and methane production via methanation. Methanation requires carbon dioxide and hydrogen as a raw material. This thesis studies the potential carbon dioxide sources within Finland. The different sources are ranked using the cost and energy penalty of the carbon capture, carbon biogenity and compatibility with Power-to-Gas. It can be concluded that in Finland there exists enough CO2 point sources to provide national PtG system with sufficient amounts of carbon. Pulp and paper industry is single largest producer of biogenic CO2 in Finland. It is possible to obtain single unit capable of grid balancing operations and energy transformations via Power-to-Gas and Gas-to-Power by coupling biogas plants with biomethanation and CHP units.

Feasibility of industrial implementation of laser cutting into paper making machine

Laser cutting implementation possibilities into paper making machine was studied as the main objective of the work. Laser cutting technology application was considered as a replacement tool for conventional cutting methods used in paper making machines for longitudinal cutting such as edge trimming at different paper making process and tambour roll slitting. Laser cutting of paper was tested in 70’s for the first time. Since then, laser cutting and processing has been applied for paper materials with different level of success in industry. Laser cutting can be employed for longitudinal cutting of paper web in machine direction. The most common conventional cutting methods include water jet cutting and rotating slitting blades applied in paper making machines. Cutting with CO2 laser fulfils basic requirements for cutting quality, applicability to material and cutting speeds in all locations where longitudinal cutting is needed. Literature review provided description of advantages, disadvantages and challenges of laser technology when it was applied for cutting of paper material with particular attention to cutting of moving paper web. Based on studied laser cutting capabilities and problem definition of conventional cutting technologies, preliminary selection of the most promising application area was carried out. Laser cutting (trimming) of paper web edges in wet end was estimated to be the most promising area where it can be implemented. This assumption was made on the basis of rate of web breaks occurrence. It was found that up to 64 % of total number of web breaks occurred in wet end, particularly in location of so called open draws where paper web was transferred unsupported by wire or felt. Distribution of web breaks in machine cross direction revealed that defects of paper web edge was the main reason of tearing initiation and consequent web break. The assumption was made that laser cutting was capable of improvement of laser cut edge tensile strength due to high cutting quality and sealing effect of the edge after laser cutting. Studies of laser ablation of cellulose supported this claim. Linear energy needed for cutting was calculated with regard to paper web properties in intended laser cutting location. Calculated linear cutting energy was verified with series of laser cutting. Practically obtained laser energy needed for cutting deviated from calculated values. This could be explained by difference in heat transfer via radiation in laser cutting and different absorption characteristics of dry and moist paper material. Laser cut samples (both dry and moist (dry matter content about 25-40%)) were tested for strength properties. It was shown that tensile strength and strain break of laser cut samples are similar to corresponding values of non-laser cut samples. Chosen method, however, did not address tensile strength of laser cut edge in particular. Thus, the assumption of improving strength properties with laser cutting was not fully proved. Laser cutting effect on possible pollution of mill broke (recycling of trimmed edge) was carried out. Laser cut samples (both dry and moist) were tested on the content of dirt particles. The tests revealed that accumulation of dust particles on the surface of moist samples can take place. This has to be taken into account to prevent contamination of pulp suspension when trim waste is recycled. Material loss due to evaporation during laser cutting and amount of solid residues after cutting were evaluated. Edge trimming with laser would result in 0.25 kg/h of solid residues and 2.5 kg/h of lost material due to evaporation. Schemes of laser cutting implementation and needed laser equipment were discussed. Generally, laser cutting system would require two laser sources (one laser source for each cutting zone), set of beam transfer and focusing optics and cutting heads. In order to increase reliability of system, it was suggested that each laser source would have double capacity. That would allow to perform cutting employing one laser source working at full capacity for both cutting zones. Laser technology is in required level at the moment and do not require additional development. Moreover, capacity of speed increase is high due to availability high power laser sources what can support the tendency of speed increase of paper making machines. Laser cutting system would require special roll to maintain cutting. The scheme of such roll was proposed as well as roll integration into paper making machine. Laser cutting can be done in location of central roll in press section, before so-called open draw where many web breaks occur, where it has potential to improve runability of a paper making machine. Economic performance of laser cutting was done as comparison of laser cutting system and water jet cutting working in the same conditions. It was revealed that laser cutting would still be about two times more expensive compared to water jet cutting. This is mainly due to high investment cost of laser equipment and poor energy efficiency of CO2 lasers. Another factor is that laser cutting causes material loss due to evaporation whereas water jet cutting almost does not cause material loss. Despite difficulties of laser cutting implementation in paper making machine, its implementation can be beneficial. The crucial role in that is possibility to improve cut edge strength properties and consequently reduce number of web breaks. Capacity of laser cutting to maintain cutting speeds which exceed current speeds of paper making machines what is another argument to consider laser cutting technology in design of new high speed paper making machines.

Quality evaluation of fresh-cut ‘Pérola’ pineapple stored in controlled atmosphere

The purpose of this research was to determine the best gas mixture in controlled atmosphere conditions to store fresh-cut ‘Pérola’ pineapple, particularly in relation to the maintenance of visual quality and reduction of microbial growth. After sanitation, fruit was manually peeled, sliced and dipped in 20 mg.L-1 NaOCl solution for 30 seconds. Then, the excess liquid was drained and the slices were placed in sealed glass jars connected to a flowboard installed in a cold room (5 ± 1 °C). Desired gas mixtures were supplied continuously for 12 days from cylinders connected to the flowboard. Controlled atmospheres of 2:5, 2:10, 2:15, 5:5, 5:10, 5:15, 8:5, 8:10 and 8:15 (O2:CO2, %) and air were used. The product was evaluated for pulp color, total and fecal coliforms, mesophilic and psychrotrophic aerobic, mold and yeast counts. Total and fecal coliforms were not detected. The fresh-cut ‘Pérola’ pineapple was not very sensitive to storage in controlled atmosphere, considering that the slices had little browning and were free of contamination, that would affect the food safety at the end of the storage period

Meesauunin vaipan konepajavalmistus ja laaduntarkastus

Meesauuni on osa sulfaattisellutehdasta ja sen kemikaalikiertoa. Se on pyörivä kaltevaan tasoon asetettu rumpu-uuni, joka voi olla jopa 160 metriä pitkä ja halkaisijaltaan 5,5 metriä. Kalkki on kiertävä apukemikaali, jota käytetään soodakattilalta tulevan viherlipeän muuttamiseen valkolipeäksi. Meesauunin tehtävänä on kierrättää kalkki (CaO) uudelleen käytettäväksi kaustisoinnissa syntyneestä meesasta (CaCO3). Meesauunin vaipan konepajavalmistus on prosessina hyvin yksinkertainen, mutta toleranssivaatimukset ovat hyvin tiukat suhteutettuna meesauunin kokoon. Vaippalohkojen valmistus on siirtynyt halpatyövoiman maihin lähelle loppukäyttäjiä, joten vaatimukset piirustusten laadulle, valmistukselle, ohjeille ja tarkastamiselle ovat lisääntyneet. Uunin vaippa toimitetaan asennuspaikalle useassa lohkossa ja jokainen vaippalohko on tarkastettava ennen toimitusta. Virheellisten vaippalohkojen siirtyminen asennuspaikalle on estettävä. Työn tavoitteena oli parantaa meesauunin vaippalohkojen konepajavalmistuksen laaduntarkastusta. Tässä työssä tutkitaan mittausmenetelmiä vaippalohkojen geometrian mittaamiseen. Tärkeimmät uunin toiminnallisiin ominaisuuksiin vaikuttavat muototoleranssit vaippalohkoille ovat ympyrämäisyys ja keskiviivan suoruus. Virheet näissä toleransseissa aiheuttavat vaurioita uunin muurauksille ja liian suuria kuormituksia tuennoille. Vaippalohkot on mitattava pyöritysrullaston päällä ja konepajan olosuhteissa, mikä aiheuttaa omat haasteensa. Vaippalohkojen suuret massat ja dimensiot aiheuttavat vaippalohkoihin muodonmuutoksia. Muodonmuutokset täytyy olla hallinnassa, mikäli halutaan käyttää CMS-laitteistoja (Coordinate Measuring System). Meesauunin vaippalohkot ovat mitattavissa radiaalimittauksina tai käyttäen CMS-laitteistoja.