Printing industry actively promotes sharing of clean production experience
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The printing industry is one of the most important manufacturing industries in Hong Kong and is also at the forefront in the practice of cleaner production. Many printing peers have realized that in addition to the social responsibility of enterprises, the implementation of environmental protection measures can also obtain actual economic benefits. Recently, 51 Hong Kong-owned enterprises in the Pearl River Delta have been awarded the “Guangdong-Hong Kong Cleaner Production Partner” logo jointly issued by the Guangdong and Hong Kong governments. Among them, printing companies account for nearly one-fifth, including printing plants, paper mills and ink factories. They set a good example for manufacturers in the industry and other industries. Award-winning Dalang Zhongbian Co., Ltd. , China Business Joint Printing (Hong Kong) Co., Ltd. (China Business), Leo Jiekou Group (Hong Kong) Co., Ltd. (Leo), Jinbei Printing Co., Ltd. (Golden Cup), Zhongshan United Hongxing Paper Co., Ltd. (Hongxing), Huizhou Fuhe Paper Co., Ltd. (Fuhe) and Bauhinia Ink Co., Ltd. (Bauhinia Ink) are willing to share their experiences in promoting green production with readers of Hong Kong Printing. I hope to work with the industry to contribute to environmental protection.
Part 1: Environmental protection measures for printing plants
Make good use of energy
Use of thermal energy
Since 2006, Zhonghua Business has used the waste heat of waste flue gas from the recycling machine to convert thermal energy into hot water for the use of hot water in some dormitory houses; and later added a heat recovery unit to incorporate the original hot water. The system supplies hot water for waste heat recovery for the whole plant and all dormitories, saving a lot of electricity. At the same time, it uses waste heat to cool the office and the turbine wall.
Leo's heat pump air-conditioning system recovers waste heat, providing hot water for employees to bathe through insulated pipes, eliminating the need to burn diesel fuel, saving about 180,000 liters of diesel per year.
The Jinbei utilizes a solar heat absorption system with a high-efficiency heat pump to produce hot water for use in the dormitory.
Effective cooling
The Jinbei uses the central compression system and the gas supply network to replace the original decentralized air compressor, reducing the air-conditioning load of the workshop and improving production efficiency.
Leo's newly installed air-conditioning system can make ice at low-cost electricity during the night, use the ice to melt and provide cold air during the day, reduce the daily electricity load, reduce power generation, save money, and effectively improve the efficiency of electricity consumption in the area.
The middle edition reduces the height of the cold air of the plant, so that the air-conditioning can more directly cover the scope of heat generation, including employees and machines.
Utilizing a central vacuum pump system
Both Leo and Gold Cup use a central vacuum pump system to flexibly allocate resources to each machine through the pipeline. The vacuum is used to eliminate the noise and high temperature caused by the use of small vacuum pumps, and saves electricity by 76%.
Improve lighting
Replacing T8 tubes with T5 tubes is an effective way to reduce electricity. Jinbei, Zhongbian, Zhonghua Business and Leo have used this high-efficiency and low-consumption lighting device. According to data provided by Leo, the use of T5 light pipes saves about 22%.
China Business added lighting on the glue machine in the post-press center, using T5 light pipe with reflector. The power consumption of each light pipe was reduced by 6W compared with the original 36WT8 light pipe, and the illumination level was also improved accordingly. Energy saving is nearly 40%. They also installed the 250W metal halide lamp originally installed on the production machine and changed it to the 3.95W T5 energy-saving ball lamp.
Leo added a nano-reflector to the light pipe to enhance brightness and reduce the amount of light pipe; they also introduced solar lights to save power.
Setting up a special power system
Leo introduced two power systems in 2009. The power monitoring and power-saving system can instantly detect the abnormal situation of power consumption, make timely corrections, achieve safe use of electricity, and help to explore the space for saving electricity. In addition to reducing power consumption, the power-saving system can also improve power quality. As for the generator grid-connected system, during the power outage, the utility power can be seamlessly connected with the power supply of the generator in the factory to reduce the loss of power transmission due to the shutdown of the production equipment.
Reducing VOC
Waterless printing
The gold cup has been used for waterless printing many years ago. This technology can eliminate the use of water fountain liquid and at the same time improve the quality of printed products. If you need to use water fountain liquid, it will also use a low alcohol content and improve the formula. Reduce the alcohol content from 15% to 3%.
Use low VOC emission chemicals
Zhongbian, Jinbei, Leo and China Business use low VOC emissions chemicals, including environmentally friendly soy inks, environmentally friendly washing machine water and washing cloth water, no/low alcohol water bucket liquid, low odor UV oil, water-based coating rubber, etc. . These products are mainly formulated with a high flash point formula. According to domestic safety laws, liquids with a flash point above 61 degrees are not classified as flammable chemicals, so there is no need to store them in exclusive hazardous chemical warehouses, which indirectly reduces administrative costs. It also improves the fire safety of the workplace.
Setting up special installations
The Gold Cup is equipped with a fully automatic cleaning tape on all printing presses, reducing the VOC emissions during cleaning and reducing the downtime required. Each press can reduce the use of wash-off water every year.
In addition, Leo specially designed the exhaust fan cover on the screen printing machine and added activated carbon filter to effectively reduce the VOC concentration of the exhaust vent.
Since 1997, China Business has invested about HK$30 million to install a secondary combustion unit for the rotary press drying furnace to reduce the emission of phenolic harmful gases from its burning of LPG and meet European emission standards.
On the glue machine, Zhonghua Commercial added the exhaust pipe and pulled the parts to the window position, increasing the number of air changes in the workshop to 15 times per hour to improve the workshop environment.
Forklift trucks used in the factory, Jinbei and Zhonghua Commercial have purchased more environmentally friendly battery forklifts, replacing diesel or gasoline shovel.
Reduce water use
Reuse water
In the Leo plant, the “Zhongshui”, which has been treated by the sewage treatment system, is now widely used in the daily needs of washing, drenching and flushing in the plant area. The annual net water consumption is 190,00 cubic meters.
Use insulating paint
Leo uses high-tech paints - insulating paints to isolate the radiant heat from the sun, and has a constant temperature function instead of using a sprinkler system to lower the room temperature, saving up to 29,160 cubic meters of cooling water per year.
Recycling waste and reducing consumption
Each manufacturer sets standards for the classification and recycling of wastes that suit their needs, and collects the production wastes and collects them for disposal by the government-approved recyclers for recycling.
Reuse washing machine water
Zhongbian introduced an automatic washing machine water treatment system. After the specially formulated washing machine water is precipitated and separated, the particles in the medium are physically filtered and reused. The system can also be used to treat wastewater, and the treated wastewater meets dischargeable standards, indirectly reducing huge wastewater treatment costs.
Control dust
Printing dusting in the production process is "love and hate", too little dusting will make printing over the bottom, especially in double-sided printing machines; excessive powdering will affect the printing quality, excessive dusting Flooding the workshop will affect the health and working environment of employees. Zhongbian has installed a powder pumping system to adjust the pumping capacity. The pumping capacity is larger than that of the general dust recycling machine in the market. It is also convenient to clean the machine and blow powder.
Use central ink supply system
China Business, Jinbei, Zhongbian, etc. all use the central ink supply system. The ink pump automatically supplies ink to the printing machine through the pipeline, which reduces manual work, improves production efficiency, and can clean the ink in large drums (200kg). Reduce waste of ink and metal ink cans. According to China Business's statistics, using the central ink supply system can reduce ink loss by 70% to 80% and save 500,000 metal ink cans.
Part II: Measures by paper manufacturers
In 2009, Hongxing completed two clean production projects related to flue gas desulfurization project and flue gas online monitoring system project, and a demonstration project for piloting a boiler technical transformation. The first two projects have been reviewed by the Cleaner Production Partnership Program and received a total of HK$30,000.
Since June 2009, the flue gas desulfurization facility has been officially put into operation. The concentration of sulfur dioxide in the flue gas before and after desulfurization has dropped from 800 to 1000 mg per cubic meter to 200 to 400 mg. The actual desulfurization rate is about 75%. The amount is low. The project also reduced sulfur dioxide emissions, and the two boilers collectively reduced emissions by about 500 to 580D per year.
In order to facilitate the monitoring of the pollutant concentration of the flue gas, Hongxing installed a flue gas online monitoring system to detect the concentration of pollutants every five seconds, so that the concentration of sulfur dioxide, carbon dioxide, nitrogen oxides and soot emitted by the current boiler is At a glance. These materials can be immediately sent to the data center of the Municipal Environmental Protection Bureau to improve the monitoring level of pollutants in Hongxing and the quality and efficiency of management of environmental protection agencies.
Fuhe's clean production program has improved the quality of manufacturing machinery, effectively utilizing and saving energy. Fuhe has carried out the following four large-scale technical renovation projects in both the production system and the auxiliary system.
1. Renovation of toilet paper machine
Fuhe introduced two DCT-60 crescent-type high-speed tissue machines from the Swedish mesto company to replace twelve rotary net tissue machines. The two new machines use the energy-saving design of the headbox SymFloll, TIS, and the grooved Yankee dryer and the closed high-efficiency hot air hood on the drying system, which has strong drying capacity and low heat loss. A lot of steam and cost. In addition, this paper machine is regulated by heat pump technology, which avoids waste caused by friction and eddy current when the valve is adjusted. The white water circulation recycling system is used together with the white water precipitation tower, so that the water system of the paper machine can roughly use circulating white water. Reduced water consumption and wastewater volume.
Table 1 shows that the net water consumption and steam consumption per ton of paper of the DCT-60 paper machine are significantly reduced, while in terms of energy consumption, although the power consumption per ton of paper is increased by 100 kWh, The steam volume has been reduced by about 2 tons, saving about 0.2 tons of standard coal per ton of paper.
2. Reforming boiler and its exhaust gas treatment device
When the old-type chain layer burning furnace adopts layer-fired combustion, it is easy to cause poor air supply, especially when the load is high, the combustion is less complete, and the residual heat value of the coal slag is also quite high, which causes great waste and insufficient thermal efficiency. Fuhe uses stratified combustion and composite combustion methods, using layered coal head and composite combustion technology to improve the boiler ventilation coefficient during the actual operation of the boiler, increase the heating area of the furnace, increase the furnace temperature, and make the flame before the flame. It burns more comprehensively, and can reduce the heat content of the slag and improve the combustion efficiency of the boiler. After the renovation, the new combustion method saves about 10% of coal.
The exhaust gas treatment device modified by the bag filter and the mastic foam desulfurization tower can be reduced to less than 50 mg per cubic meter by the WQMC long bag pulse bag filter. The original waste water membrane dust removal device was transformed into a foam desulfurization tower. After the transformation, the sulfur dioxide emission concentration can be reduced from 800 mg per cubic meter to less than 300 mg.
3. Reforming wastewater treatment system
Fuhe added the original wastewater treatment system (ie, a set of sedimentation tanks and six sets of air flotation tanks for primary treatment, and a biochemical treatment system capable of treating 3,500 cubic meters of wastewater per day for secondary deepening). A secondary biochemical treatment system that processes 15,000 cubic meters of wastewater per day and is equipped with an online monitoring system. The biochemical system adopts the medicinal air flotation + hydrolysis + aerobic wastewater treatment process, so that the wastewater water quality can meet the requirements of most processes and parts of paper production. Now, the physico-treated wastewater can be reused to the part where the pulping water quality requirements are low, and the rest is entered into the biochemical system for secondary deepening treatment. The wastewater after the second-stage deepening treatment is discharged to a pulping and papermaking workshop after being disinfected and sterilized. Since the new system was put into production, the wastewater reuse rate has increased from less than 50% to over 80%.
4, white water precipitation tower
The white water precipitation tower can reuse the white water of the paper machine in the production workshop. Since the untreated paper machine white water has a high concentration of suspended solids and cannot meet the water quality requirements of most toilet paper production processes, it cannot be directly recycled; white water contains more fine fibers and cannot be recycled. This will result in waste of waste materials, increased use of purified water, increased waste water production, and heavier loads at the wastewater treatment station, which will eventually increase wastewater treatment costs and other costs.
Fuhe adopts the new vertical flow type precipitation tower, which can directly precipitate the white water produced by the paper machine in the production workshop, recover the fiber, clarify the white water, and the treated water will be filtered by the ultra-clear screening program instead of the purified water. In the papermaking workshop, it is used for spraying, washing nets, etc., and the remaining processes for high water quality in the pulping workshop are effective, which effectively improves the reuse rate of wastewater, saves water resources, and effectively reduces the source of pollution.
Renovation of wastewater treatment systems and construction of white water precipitation towers can significantly reduce the net water consumption of production unit products. According to statistics from Fuhe in the past six months, the water consumption of toilet paper produced by the original rotary screen tissue machine has been reduced from 80 cubic meters per ton of paper to 30 cubic meters per ton of paper; and the newly introduced DCT-60 is high-speed. The tissue machine achieves a low usage of 15 to 20 cubic meters of purified water per ton of paper.
Part III: Environmental Measures for Ink Manufacturers
Bauhinia inks have undergone several improvement projects in production and ancillary facilities:
1. Renovated the original central exhaust system in the production area, added special exhaust facilities, accelerated the exhaustion of exhaust gases, and further improved the working environment.
2. Upgrade the solvent recovery system to improve recovery efficiency.
3. Increase the screw air compressor unit to replace the reciprocating compressed air system with higher energy consumption, and increase the inspection procedure of air leakage to reduce waste.
4. Add insulation material to the cooling conveying pipeline to reduce the heat loss of the cooling water, thereby reducing the energy consumption of the chiller and reducing waste.
In terms of office and living facilities, Bauhinia ink uses a lower 5 light pipe with better energy saving effect and brightness, and completes the maintenance procedure of the solar water heating system to ensure maximum performance.