The printing industry is one of the most important manufacturing industries in Hong Kong, and it is also at the forefront in the practice of cleaner production. Many printing companies have already realized that the implementation of environmental protection measures can get practical economic benefits in addition to corporate social responsibility. Recently, 51 Hong Kong-funded enterprises with factories in the Pearl River Delta have been awarded the "Guangdong-Hong Kong Cleaner Production Partnership" logo jointly issued by the Guangdong and Hong Kong Governments, of which printing companies account for nearly one-fifth, including printing plants, paper mills and ink plants , They set a good example for manufacturers in the industry and other industries. Award-winning Dalang Zhongbian Co., Ltd. (Zhongbian), China Business United Printing (Hong Kong) Co., Ltd. (China Business), Leo Keikou Group (Hong Kong) Co., Ltd. (Leo), Jinbei Printing Co., Ltd. (Jinbei), Zhongshan United Hongxing Paper Co., Ltd. (Hongxing), Huizhou Fuhe Paper Co., Ltd. (Fuhe) and Bauhinia Ink Co., Ltd. (Bauhinia Ink), willing to share their experience of promoting green production with readers of "Hong Kong Printing", Hope to join hands with colleagues to contribute to environmental protection.
Part 1: Environmental protection measures of printing plants
Make good use of energy
Use of thermal energy
Since 2006, China Business has used the waste heat of waste flue gas from the recycling machine to convert heat energy into hot water for use in domestic hot water in some dormitories; and later added a heat recovery device to incorporate the original hot water The system supplies hot water heated by waste heat recovery for the whole plant and all dormitories, saving a lot of power; at the same time, it uses the waste heat for cooling and is used for the office and the turbine unit partition wall.
Leo ’s heat pump air-conditioning system recovers waste heat and provides employees with hot water for bathing through insulated pipes, eliminating the need to burn diesel and saving about 180,000 liters of diesel annually.
Jinbei uses a solar heat absorption system, coupled with a high-efficiency heat pump to make hot water, for use in dormitories.
Effective cooling
Jinbei uses a central compression system and a 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 during low-cost electricity hours in the evening, and use ice melting to provide cold air during the day, reduce the power load during the day, reduce power plant emissions, save expenses, and effectively improve the efficiency of electricity use in the area.
Zhongbian reduces the height of the plant's air-conditioning, so that the air-conditioning directly covers the range of heat energy generation, including employees and machines.
Using the central vacuum pump system
Both Leo and Jinbei use a central vacuum pump system to flexibly allocate resources to each machine through pipelines and pump through the factory. This eliminates the noise and high temperature caused by the use of small vacuum pumps in the past, and can save 76% of the electricity.
Improve lighting
Replacing T8 fluorescent tubes with T5 fluorescent tubes is an effective way to save electricity. Jinbei, Zhongbian, China Business and Leo have all used this high-efficiency and low-consumption lighting device. According to the information provided by Leo, the power saving after switching to T5 fluorescent tubes is about 22%.
China Business added a lighting lamp to the laminating machine in the post-press center, using T5 light tubes with reflectors. The electric power of each light tube was 6W lower than that of the 36WT8 light tube used originally, and the illuminance was also improved accordingly. Energy saving is nearly 40%. They replaced the 250W metal halogen lamp originally installed in the production machine with three 95W T5 energy-saving bulb lamps.
Leo added a nano-reflector to the light pipe, which can enhance the brightness and reduce the amount of light pipe; they also introduced solar lighting to save power.
Set up a special power system
Leo introduced two power systems in 2009. The power monitoring and power-saving system can immediately detect abnormal power consumption and make corrections in a timely manner to achieve safe power consumption and help explore the space for saving power. In addition to reducing power consumption, the power-saving system can also improve power quality. As for the generator grid connection system, during the power outage, the city power and the generator power supply in the factory are seamlessly connected to reduce the loss of power transfer due to the shutdown of production equipment.
Emission reduction VOC adopts waterless printing
Jinbei has used waterless printing many years ago, this technology can avoid the use of water bucket liquid, and at the same time can improve the quality of printed products; if you need to use water bucket liquid, it will also use a low alcohol content and improve the formula, Reduce the alcohol content from 15% to 3%.
Selection of low-VOC emission chemicals Zhongbian, Jinbei, Leo and Zhonghua Business all use low-VOC emission chemicals, including environmentally friendly soybean ink, environmentally friendly machine wash and tape water, no / low alcohol water bucket liquid, low odor UV oil , Water-based film adhesive, etc. These products are mainly formulated with high flash point formulas. 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. , Also improved the fire safety in the workplace.
Set up special devices
Jinbei installs automatic cleaning tape configuration on all printing presses to reduce the VOC emissions during cleaning and shorten the required downtime without manual intervention. Each printing press can therefore reduce the use of offset water.
In addition, Leo specially designed the exhaust fan cover on the screen printing machine and added activated carbon filtration to effectively reduce the VOC concentration of the exhaust vent.
Since 1997, China Business has invested about 30 million Hong Kong dollars to install a secondary combustion device for the rotary printing press drying furnace to reduce the emission of harmful phenolic gases generated by burning LPG and meet European emission standards.
On the laminating machine, China Business built an exhaust duct, and copied the machine parts, measured the volume, regained the vastness, guided the palm, asked the question, asked Huai, and improved the environment of the workshop 5 times.
For the forklifts used in the plant, Jinbei and China Business have purchased more environmentally friendly battery forklifts to replace diesel or gasoline shovel.
Reduce water reuse
In the Leo plant, the plant water after treatment by the sewage treatment system is now commonly used for daily needs such as floor washing, showering and toilet flushing in the plant area, reducing the amount of purified water by 19,000 cubic meters throughout the year.
Use thermal insulation paint
Leo uses a high-tech paint, thermal insulation paint, to isolate the radiant heat from sunlight, and has a constant temperature function, instead of using a sprinkler system to reduce room temperature, it can save 29,160 cubic meters of water for cooling every year.
Recycle waste and reduce consumption
Each manufacturer formulates standards for the classification and recycling of waste materials suitable for its own needs, and collects and collects the production waste materials, and submits them to a government-recognized recycler for disposal to facilitate 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 it are physically filtered and can be reused. This system can also be used to treat wastewater. The treated wastewater reaches dischargeable standards, which indirectly reduces huge wastewater treatment expenses.
Dust control
Printing powder spraying is love and hate in the production process. Too little powder spraying will make the printing bottom, especially in double-sided printing machines; too much powder spraying will affect the printing quality, and too much powder spraying will flood the workshop Will affect employee health and working environment. Zhongbian has installed a powder extraction system to adjust the air extraction. The air extraction is larger than the dust recovery machines on the market, and it is also very convenient to clean the machine and blow powder.
Use central ink supply system
Zhonghua Business, Jinbei, Zhongbian, etc. all use the central ink supply system. The ink pump automatically supplies the ink to the printing machine through the pipeline, which reduces manual work and improves production efficiency. Reduce the waste of ink and metal ink tanks. According to the statistics of China Business, the use of a central ink supply system can reduce ink loss by 70% to 80% and save 500,000 metal ink tanks. [next]
Part 2: Measures by paper manufacturers
In order to promote environmentally friendly production, Hongxing completed two clean production projects related to the flue gas desulfurization project and the flue gas online monitoring system project in 2009, and is also piloting a demonstration project for boiler technological transformation. The first two projects have passed the review of the Cleaner Production Partnership Program and received a total of HK $ 30,000 in funding.
Starting from June 2009, the flue gas desulfurization facility was officially put into operation. The concentration of sulfur dioxide in flue gas before and after desulfurization decreased from 800 to 1000 mg per cubic meter to 200 to 400 mg. The actual desulfurization rate is about 75%, which is in the raw coal The amount is lower. The project also reduced sulfur dioxide emissions. The total emissions of the two boilers were reduced by about 500 to 580 D tons of sulfur dioxide per year.
In order to facilitate the monitoring of flue gas pollutant concentration, Hongxing installed a flue gas online monitoring system to detect the pollutant concentration once every five seconds, so that the current concentration of sulfur dioxide, carbon dioxide, nitrogen oxides, and dust emitted by the boiler are all At a glance. These data can also be sent to the data center of the Municipal Environmental Protection Bureau in real time to improve Hongxing's monitoring level of pollutants and the management quality and efficiency of environmental protection regulatory agencies.
Fuhe's clean production plan improves the quality of manufacturing machinery, and effectively uses and saves energy. Fuhe has carried out the following four large-scale technological transformation projects in both production systems and auxiliary systems.
1. Transform toilet paper machine
Fuhe introduced two DCT-60 crescent-type high-speed toilet paper machines produced by Swedish mesto company to replace twelve rotary screen toilet paper machines. These two new machines use the energy-saving design headbox SymFloll, TIS, and the groove design of the Yankee dryer and closed high-efficiency hot air hood in the drying system. The drying capacity is strong, the heat loss is low, saving A lot of steam and cost. In addition, this paper machine uses heat pump technology to adjust, avoiding the waste caused by friction and eddy current during valve adjustment; its white water recycling system is used in conjunction with the white water precipitation tower, so that the paper machine water system can generally use recycled white water, greatly Reduced the amount of purified water and waste water.
2. Transform the boiler and its exhaust gas treatment device
When the layered combustion is used in the old chain layer furnace, it is easy to cause poor air supply, especially when the load is high, the combustion is more incomplete, the residual heat value of the coal slag is also very high, causing a lot of waste, and insufficient thermal efficiency. Fuhe switched to stratified combustion and compound combustion methods, using stratified coal head and compound combustion technology, which increased the boiler ventilation coefficient during the actual operation of the boiler, increased the heating area of ​​the furnace, and increased the temperature of the furnace, so that the flame was not burned. Avoid boil enzymes? Do you know? Zhishan stall vomiting? Jun Jun? Ji acridine? Avoid tricks? Save 8 brains mantle? Lu Na bogey pepper? 0%.
Exhaust gas treatment device modified by bag filter and hemp foam desulfurization tower, after being treated by WQMC type long bag pulse bag filter, the exhaust dust concentration of smoke and dust in exhaust gas can be reduced to less than 50 mg per cubic meter. The original granite water film dust removal device was transformed into a foam desulfurization tower. After the transformation, the sulfur dioxide emission concentration can be reduced from about 800 mg / m3 to less than 300 mg.
3. Reconstruct the wastewater treatment system
In addition to the original wastewater treatment system (that is, a settling tank and six sets of floatation tanks for primary treatment, and a biochemical treatment system that can process 3,500 cubic meters of wastewater per day for secondary deepening treatment), Fuhe added A set of secondary biochemical treatment system that can treat 15,000 cubic meters of wastewater per day, and is equipped with an online monitoring system. The biochemical system adopts the wastewater treatment process with medicinal air floatation + hydrolysis + aerobic, so that the quality of wastewater can meet the requirements of most processes and parts of paper production. At present, part of the wastewater after physical and chemical treatment can be reused to parts with lower pulping water quality requirements in the pulping workshop, and the rest enters the biochemical system for secondary deepening treatment. Except for a small amount of waste water after the secondary deepening treatment, the rest is disinfected and sterilized and then reused in the pulp and papermaking workshop. Since the new system was put into production, the wastewater reuse rate has increased from less than 50% to more than 80%.
4. White water precipitation tower
The white water precipitation tower can reuse paper machine white water in the production workshop. Untreated paper machine white water has a high concentration of suspended matter, which cannot meet the water quality requirements of most toilet paper production processes, so 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 production of wastewater, and a heavier load on wastewater treatment stations, which will ultimately increase wastewater treatment costs and other costs.
Fuhe adopts the new vertical flow sedimentation 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 clean water will be filtered through the ultra-clean screening program, which can replace the clean water It is used for spraying and washing nets in the papermaking workshop, and the rest is used for processes with high water quality requirements in the pulping workshop. This effectively improves the reuse rate of wastewater, saves water resources, and effectively reduces the source of pollution.
The transformation of wastewater treatment systems and the construction of white water precipitation towers can significantly reduce the net water consumption of production units. According to the statistics of Fuhe in the past six months, the water consumption of the original rotary screen toilet paper machine for producing toilet paper has been reduced from 80 cubic meters of water per ton of paper to about 30 cubic meters of water; and the newly introduced DCT-60 high speed The toilet paper machine also achieves a low consumption of 15 to 20 cubic meters of purified water per ton of paper. [next]
Part 3: Environmental protection measures of ink manufacturers
In the production and auxiliary facilities, Bauhinia Ink has carried out several improvement projects:
1. Renovated the original central exhaust system in the production area, added special exhaust facilities, accelerated exhaust gas extraction, and further improved the working environment.
2. Upgrade the solvent recovery system to improve recovery efficiency.
3. Increase the screw-type air compressor unit, replace the reciprocating compressed air system with higher energy consumption, and increase the inspection procedure of the gas path leakage to reduce waste.
4. Increase the installation of insulation materials in the cooling transmission 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 energy-saving and brighter lower 5 light tubes, and improves the maintenance procedures of the solar hot water system to ensure maximum effectiveness.
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