BELO ORIENTE, Brazil,
Feb. 9, 2009
(Press Release) -
Sodium hydroxide is among the main inputs used in the pulp manufacturing process. From the technical standpoint, its importance is related to the widespread proven application and the fact that it's hard to find a substitute. Economically speaking, sodium hydroxide answers for a significant share of the overall production costs, ranking among the five inputs with the greatest impact on the manufacturing cost. These factors alone are more than enough to justify the need for developing sodium hydroxide consumption optimization projects at the Plant.
This was precisely the motivation behind the decision made by a group of employees from the Production Department to start a work aiming at reducing the consumption of this input by CENIBRA. A number of variables have been taken into account, such as the sodium hydroxide storage capacity, which for the current output represents approximately 15 days of consumption. Moreover, it was analyzed also the influence of sodium hydroxide on the consumption of other industrial inputs, like sulfuric acid and chlorine dioxide, and its effect on pulp quality, with particular emphasis on the proven relation between sodium hydroxide consumption and the final product (pulp) viscosity.
Two important actions have been implemented after review by the Quality Department and analysis of the main improvement opportunities. First, the pH was reduced in the alkaline production stages, without harming the pulp quality. Then, the sodium hydroxide dosing concept was changed in order to provide better mixing conditions and, as a consequence, to achieve improved yield.
Considerable gains for the company have already been derived from such changes. "The process modifications have been positive and they answer for a 15% reduction in sodium hydroxide consumption in the bleaching plant. In addition, the overall results of this project led to extra gains in terms of pulp quality, such as viscosity stability, and longer autonomy with the current storage capacity. Last but not least, we estimate cost savings to be around R$ 1.6 million per year", said the specialist Leonardo Pimenta.
Such a successful accomplishment arises essentially from the aggregation of resources and the use of problem analysis methodologies, while supported by a multidisciplinary teamwork and shared vision in idea discussions and decision making.
