September 2009
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Sharing the forest:
Quebec rewrites the rules
Two views of the B.C. tax revolt EXFOR & PAPTAC Annual Meeting preview JOURNAL OF RECORD, PULP AND PAPER TECHNICAL ASSOCIATION OF CANADA JOHNSON: Details of three 21st century pulp mills
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February 2009
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SEPTEMBER 2009 Vol. 110, No. 7 A Business Information Group Publication ISSN 0316-4004
FEATURES
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Forest Stewardship – Don’t be a Target Certification can be both a defense and a competitive advantage.
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STEWARDSHIP
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Sharing the Forest: Quebec Rewrites the Rules Quebec’s proposal takes responsibility for forest management and planning away from the industry and puts it in the hands of government and regional interests. Million-dollar Tax Battle Catalyst and Zellstoff-Celgar are withholding municipal taxes and challenging their tax rate in court, which leaves mill towns scrambling to cut their spending plans. EXFOR & Annual Meeting Preview The value of meeting face-to-face at EXFOR and the PAPTAC Annual Meeting is still strong. New features for 2010 include industry roundtables and more French-language content. Getting a Lot from a Little: Machine Clothing Upgrades to paper machine clothing offer a way to improve costs without large capital investments.
TECHNICAL PAPERS
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QUEBEC REWRITES THE RULES
21st Century Fibre Lines Configuration and key features of three of the world’s newest pulp mills are discussed. By T. Johnson (Beca Amec), B. Johnson (Beca Amec), P. Gleadow (Amec), H. Araneda (Celulosa Arauco Y Constitucion), F. Silva (Veracel Celulose), R. Aquilar (Veracel Celulose), C. Hsiang (Hainan Jinhai Pulp And Paper). The Sticky Potential of Adhesive Applications from Printed Products A test procedure to determine the recyclability of printed matter can also be used during the development of adhesives. By H.-J. Putz (Darmstadt University of Technology), S. Schabel (Darmstadt University of Technology), A. Faul (INGEDE). Mill Trial and Commercial Implementation of the New Bleaching Agent - THPS Adding tetrakis(hydroxymethyl)phosphonium sulfate (THPS) resulted in cost savings and a brightness gain of 2.0-2.3 ISO points. By T.Q. Hu (FPinnovations – Paprican), T. Williams (FPinnovations – Paprican), J.A. Schmidt (FPinnovations – Paprican), B.R. James (UBC), R. Cavasin (Cytec Canada), D. Lewing (Cytec Canada).
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IN EVERY ISSUE
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MISSION STATEMENT:
To promote the pulp and paper industry in Canada by publishing news of the people and their innovations in research, technology, management and financing, as well as forecasts of future trends. Authorized to publish papers of the Pulp and Paper Technical Association of Canada, which are identified by the symbol Serving the industry since 1903.
September 2009
PULP & PAPER CANADA
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CONTENTS
Everyone loses in tax debacle
I
n this issue, Brennan Clarke brings us the details of the tax revolt in British Columbia, where several forest products companies have refused to pay all or part of their municipal taxes, and a few mill towns find themselves with far less income than they had anticipated. I grew up in a mining town in Eastern Quebec, which is not very different from a mill town in B.C., or anywhere else in Canada, for that matter. Murdochville was isolated, sustained by a single, large employer, and subject to the vagaries of the global market for copper. So I can empathize with both sides in the municipal tax debate, but mostly with a third party, the townspeople, who will see and feel the effects. The town I grew up in had a population of about 5000 people when I lived there. (Now the population is about 1500, but that’s a whole other story.) Thanks to the largesse of the mining company (in its various incarnations – Noranda Mines, Gaspe Copper Mines), Murdochville had more amenities than any other town in the region – a curling rink, an arena, a public indoor swimming pool, a downhill ski facility, and an English school. As a kid, I didn’t concern myself with the politics of where the money for those facilities came from, but Murdochville was a true company town and directly or indirectly, many of life’s little luxuries could be traced back to the town’s main employer. A CBC documentary in 2002 called Murdochville “a town created for and by one employer.” It evolved from a camp for mine workers into a town in the 1950s, and later became known for a violent, months-long strike by mine workers. As the mine became less profitable and eventually closed, the town quickly showed physical manifestations of the company’s demise. Lawns and public spaces became unkempt. Gaps appeared in the neat rows of cookie-cutter houses as houses were sold off cheap and moved to neighbouring towns (if you can call 60 miles through the forest “neighbouring”). My parent’s house was sold and moved. Catalyst and Zellstoff-Celgar’s tax revolt has been interpreted as a Cindy Macdonald bullying tactic, but in a more chariEditor table light is could be considered a news releases: desparate defense. The companies media@ involved clearly have their backs pulpandpapercanada.com against the wall. In some cases, the letters to the editor: towns were given fair warning and cindy@ negotiations had commenced. pulpandpapercanada.com Arguments in Catalyst’s case against four municipalities began in September. It will be left for the B.C. Supreme Court to decide whose actions are deemed illegal – Catalyst’s or the towns’.
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PULP & PAPER CANADA
September 2009
EDITORIAL Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Contributing Editors HEATHER LYNCH
Sustaining member, Pulp and Paper Technical Association of Canada; Member, Canadian Business Press and Audit Bureau of Circulation.
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INDUSTRY NEWS
SHUTDOWN
Employee lockout shuts down Pine Falls newsprint mill
TEMISCAMING, QUE. — Tembec has locked out employees at its Pine Falls, Man., newsprint mill following a failure to reach a new collective agreement. The company says site management and mill employees worked together to ensure that the mill was shut down in a safe and environmentally sound manner. According to Tembec, it was seeking changes in the collective agreement that would have resulted in improvement in the site’s cost competitiveness necessary to allow it to meet challenges created by the profound structural change in the demand for newsprint. Tembec indicated that it had met with both local and regional representatives of the United Steelworkers and the Canadian Office and Professional Employees Union, in the presence of a Ministry of Labour conciliator. A Tembec news release states, “the USW team appeared to lack the sense of urgency to seriously engage in negotiating.” Chris Black, executive vicepresident and president of the paper group for Tembec, says the newsprint industry is in the most challenging period it has ever faced. “While current pricing levels and the higher valued Canadian dollar have aggravated this situation, the principal and critical issue is the dramatic oversupply of newsprint relative to current and foreseen demand,” he says. “Simply put, there will be additional mill closures and sites must be cost competitive in order to survive.” “Tembec has an overall strategy for improving the competitive position of Pine Falls, a critical element of which is to achieve an immediate and significant reduction in labour cost per tonne produced. However, it appears that serious negotiation on the critical cost issues will not be allowed to occur,” concludes Black. The company indicated that it is prepared to return to the bargaining table.
RESTART
Union signs, Fraser Papers will restart Edmundston pulp mill
EDMUNSTON, N.B. — Fraser Papers Inc. announced Aug. 11 that Communications, Energy and Paperworkers Union Local 29 in Edmundston, N.B., has ratified an agreement that will see the Edmundston pulp and energy complex return to full operation. The three-year agreement provides for a more competitive labour cost structure with future wage increases tied directly to the profitability of the company’s East Papers Operations. “We are pleased that we could reach an agreement that better positions the mill to be competitive in these difficult market circumstances and into the future,” says Peter Gordon, CEO of Fraser Papers. “I would like to thank all involved for their hard work during these sometimes difficult negotiations, including mill management, our hourly employees, local politicians, and particularly Premier Shawn Graham for providing the leadership, focus, and a path forward to the community and employees at a most critical time.” The fate of the mill hung in the balance for a few days, after the union voted on Aug. 6 to reject the company’s final contract offer. According to the local Telegraph-Journal newspaper, union members voted against a new four-year contract, which involved a 4% pay cut, with 54% rejecting the offer. Fraser Papers had said prior to the vote that it would have to permanently close the mill if the union rejected the offer. The union later reconsidered its vote and reached an agreement with the company. The mill was expected to restart during the week of August 30. Fraser Papers is an integrated specialty paper company which produces a broad range of specialty packaging and printing papers. The company has operations in New Brunswick, Maine, New Hampshire and Quebec. It is currently operating under creditor protection.
NO START
No deal for Mackenzie pulp mill restart
For a few days mid-September it looked like a Chinese corporation would buy the shuttered Mackenzie pulp mill in northern B.C., but an agent for the mill’s owners says the proposed deal is now dead. The Vancouver Sun reports that China’s United Petroleum Group was interested in the mill, but that “contingent liabilities” played a role in quashing the deal. One liability is the $6.5 million owed to the provincial government, which took over maintenance of the closed facility in January. Another is $3.7 million in back taxes owed to the town of Mackenzie. Time is running out for the mill. The provincial environment ministry shut down the boiler over the summer and has taken steps to prepare for a cold shutdown. “Volatile chemicals that posed a risk if left unattended have now mostly been disposed of, and the province does not plan on restarting the boiler this winter, essentially allowing the once-profitable pulp mill to freeze,” explains the Vancouver Sun’s Gordon Hamilton in a story on Sept. 14.
FOREST MANAGEMENT
AbitibiBowater sells Quebec timberland for $53 million
AbitibiBowater has completed the sale of approximately 121,000 hectares (300,000 acres) of private timberland in Quebec for $53 million in cash. The company plans to use the proceeds from this sale for general corporate purposes. Timberlands located in the Mauricie, Charlevoix, and Saguenay regions were sold to two newly formed limited partnerships held by Societe de gestion d’actifs forestiers Solifor, s.e.c. Timberlands located in the Cote-Nord region were sold to Amenagements forestiers Portneuf (3908666 Canada Inc.).
VISIT PULPANDPAPERCANADA.COM FOR DETAILS: ONTARIO BEGINS CONSULTATION ON FOREST TENURE REFORM…RESEARCHERS EXPLORING JACK s s s
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INDUSTRY NEWS EQUIPMENT
Metso to acquire coater and doctor blade business
Metso has announced that it will acquire the coater and doctor blade business of Pacific International, a division of Pacific/ Hoe Saw & Knife Company, located in Portland, Ore. The transaction is expected to be finalized and the business transferred during the third quarter of 2009. The acquisition will allow Metso to enter a new services market that is currently not in its portfolio, namely coater and creping blades for pulp and paper machinery. It will also complement Metso’s technology offering with ceramic coated blades. As a result, Metso will become a single source blade consumables provider. Pacific manufactures a complete line of machinery and equipment for the wood products and paper industries. Pacific has about 150 employees, of which 17 are expected to transfer to Metso. Metso is a global supplier of technology and services for mining, construction, power generation, automation, recycling and pulp and paper industries. FINANCE
AbitibiBowater launches creditor claims process
MONTREAL — AbitibiBowater has received approval for a process to call for creditor claims by the Quebec Superior Court in Canada and the U.S. Bankruptcy Court for the District of Delaware. The claims process outlines the procedures by which creditors can make claims against the company. These proposed procedures can be found on abitibibowater.com. “Launching the claims process at this juncture demonstrates continued progress in AbitibiBowater’s restructuring efforts,” states David J. Paterson, president and CEO. “This key step in our creditor protection filings will allow the company to better assess the scope and nature of creditor claims and assist AbitibiBowater in formulating a restructuring plan.” Under the claims process, creditor claims must be received by 4:00 p.m. (Eastern) on November 13, 2009. Creditor claims not received by this bar date will be extinguished, and the creditors
asserting such claims will not be entitled to participate in any forthcoming restructuring plan. Certain creditors are not required to file claims in the claims process including,
among other creditors, active employees or employees that were active at the date of AbitibiBowater’s creditor protection filing on April 16, 2009.
STOPS, STARTS, CHANGES AbitibiBowater idled indefinitely paper machines #4 and #5 at its Thunder Bay, Ont., mill, beginning Aug. 21. The decision puts 360 employees out of work, according to reports in a local newspaper, The Chronicle Journal. Jean-Phillipe Cote, the company’s director of public affairs and government relations, attributes the closure to erosion of the newsprint market and high operating costs. As a result of the paper machine shutdown, the Woodland mill will also decrease fibre production. According to The Chronicle Journal, Cote said AbitibiBowater is working with the unions on labour cost issues and with the Ontario government to address fibre and input costs in the hope that the company can restart PM5. Catalyst Paper will restart one line of pulp production at its Crofton NBSK kraft mill on Vancouver Island, citing improved market conditions. The kraft pulp mill was indefinitely curtailed in February of this year – removing approximately 400,000 tonnes of annual capacity. “Pulp markets have improved in recent weeks with stronger demand and pricing,” says Richard Garneau, president and CEO. “Better markets enable the restart on one of the two lines of our kraft mill. But chip supply is limited and fibre availability is expected to remain challenging through the balance of this year.” The restart is scheduled for early October and will result in 104 employees being recalled from layoff. Restart on the one line will add 210,000 tonnes of pulp capacity on an annualized basis. Kruger Inc. temporarily cut back production at its Quebec paper mills in August and September, by interrupting production for periods of one to three weeks. The company says the intent is to rebalance its order book in light of a significant drop in demand for various paper grades and unfavourable economic conditions, particularly the high value of the Canadian dollar against the US currency. The curtailment at its Brompton mill in Sherbrooke, Que. was extended by two weeks. Newsprint production was interrupted August 15 and was scheduled to resume on Sept. 22. At the Trois-Rivières mill, coated and supercalendered paper production was to be interrupted from August 26 to September 16, affecting some 450 employees. Newsprint production was interrupted from September 1 to 13, 2009. At the Wayagamack mill (also in Trois-Rivières) directory paper production was to be interrupted from August 31 to September 8, affecting some 80 employees. Coated paper production continued during this period. With these actions, Kruger cut its total production by 26,500 tonnes of newsprint, 7,500 tonnes of coated paper, 4,500 tonnes of supercalendered paper and 2,000 tonnes of directory paper. A second production line has been started at the Harmac pulp mill owned by Nanaimo Forest Products. The line will bring the mill’s output to almost 30,000 tonnes of northern bleached softwood kraft pulp per month.
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September 2009
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INDUSTRY NEWS PAPERMAKING
China becomes top paper producing nation
BEIJING — China has become the world’s top producer of paper, outpacing the United States, according to an article appearing on the ForestWeb industry information service which in turn cites data from ChinaPaperOnline. China produced 79.8 million tonnes of paper and paperboard in 2008, according to Zhao Wei, secretary general of the China Paper Association. That compares with U.S. production of 79.6 million tonnes of paper and paperboard in 2008, the article states. BANKRUPTCY
Receivers take control of B.C. forest industry financier
Recievers have assumed control of Forest & Marine Financial, a financier for small forestry businesses, after the company was unable to formulate an acceptable restructuring plan, according to the Nanaimo Daily News. The company sought creditor protec-
tion on March 26 after its chief creditor, Ontario-based liquidator Asset Engineering, called in a $13.3-million loan. The Daily News reports that president and CEO David Hitchcock learned on Aug. 12 that the court had not granted F&M creditor protection or granted its request for another 10 months to come up with the $13.3 million it owes. The firms that rely on F&M for financing will have to find a new source as the receivers examine the company’s books and evaluate its business model, said Hitchcock. “The financial markets are still very tight. I have no idea if some of our customers will be able to get the financing they need elsewhere.” INTERNATIONAL
Millar Western pulp shipments to comply with Lacey Act amendments
Millar Western is assuring its U.S. pulp customers that it will be fully prepared to meet the documentation requirements set out in recent amendments to the
Screening & Processing Size Reduction Material Handling
U.S. Lacey Act, which come into effect October 1, 2009. “Our U.S. lumber shipments have been subject to the Lacey Act amendments since May 2009,” explains Millar Western’s director of pulp sales and marketing, Steve Lord. “For some months now, we have been working with our customs broker and internal information systems group on developing a parallel system for pulp. It will be in place within the month, and, given our experience with lumber, we don’t expect any implementation issues.” Passed in May 2008, the Lacey Act amendments require importers to declare country of origin and species of all plants contained in their products. The reporting process will involve submitting monthly blanket declarations with shipment estimates to U.S. Animal and Plant Health Inspection Service (APHIS), which will then be reconciled to actual shipments. Millar Western produces approximately 300,000 air-dried-metric tonnes (admt) of hardwood, softwood and blended grades of BCTMP per year, for shipment to customers around the world.
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INDUSTRY NEWS FINANCE
Forest and paper sector losses slowed in Q2: PricewaterhouseCoopers Producers based in West see modest improvements; aggregate losses deepen in the East due to AbitibiBowater restructuring Vancouver — Canada’s forest, paper and packaging (FPP) sector continued to be negatively impacted by the global economic downturn during the second quarter of 2009. According to the PricewaterhouseCoopers (PwC) quarterly net earnings review, weak commodity prices and low demand throughout most of the period resulted in aggregate second quarter losses of $660 million for the 15 companies surveyed, compared to losses of $462 million during the same period in 2008. These losses are on top of net losses of $480 million in Q1 of 2009. One bright spot toward the end of Q2 was an improvement in pulp prices as exports to China increased. Costs of fibre, energy, and other inputs were lower during the quarter compared to last year. The Canadian – US dollar exchange rate was 13% weaker compared to the same period in 2008. During Q2 of 2009 Western Canadian FPP companies reported aggregate losses of $83 million, an improvement over the $128 million loss posted in the same period of 2008. Four of the nine Western Canada companies in PwC’s survey showed earnings improvements compared to Q2 of 2008; three of these posted positive earnings. Eastern Canadian producers posted an aggregate loss of $577 million compared to a loss of $334 million during Q2 of 2008. Four of the six Eastern companies surveyed reported improved results, however these modest improvements were overshadowed by $384 million of closure, impairment, and reorganization charges by AbitibiBowater. Two of the Canadian companies benefitted from US$191 million of US alternative fuel tax credits. “Some of Canada’s larger forest products companies will continue to have financial struggles until there is a sustained economic turnaround and demand picks up,” says Craig Campbell, leader, Performance Improvement, Global Forest, Paper & Packaging Industry practice for PwC. “The story in
the US was different during the quarter, with the ten largest forest products companies posting combined profits of US$839 million, primarily due to approximately US$1 billion in alternative fuel tax credits.” The ten largest European-based forest products companies incurred aggregate losses of €412 million in the second quarter of 2009, a drop of €871 million from the positive earnings of €459 million in the same period of 2008. Net earnings (loss): Western Canada Three months ended June 30, $ millions Company 2009 Q2 Ainsworth $25 Millar Western 12 Canfor 11 Catalyst (2) Interfor (15) Mercer (18) TimberWest (27) Western (30) West Fraser (39) Total ($83)
2008 Q2 ($34) 2 64 (124) (28) 1 2 (14) 3 ($128)
Net earnings (loss): Eastern Canada Three months ended June 30, $ millions Company 2009 Q2 Domtar $56 Cascades 30 Fraser Papers (9) Norbord (21) Tembec (38) AbitibiBowater (595) Total ($577)
2008 Q2 $24 (25) (16) (36) (27) (254) ($334)
letters editor TO THE
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September 2009
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INDUSTRY NEWS PEOPLE
Fortress Paper Ltd. has announced the following executive management promotions. Alfonso Ciotola, formerly the chief operating officer, has been appointed president of the corporation. Chad Wasilenkoff will continue as CEO and chairman of Fortress Paper. Erich Sulser has been appointed chief operating officer. Kurt Loewen has been promoted to chief financial officer, replacing Sulser. Fortress Paper is a producer of security and other specialty papers. Based in North Vancouver, Fortress Paper operates two paper mills in Switzerland and Germany.
energy and value-added bioforest economy products, as well as traditional supercalender paper for publishers and retailers. The cogeneration vision includes the generation of electricity and production of steam for heating and operational purposes. According to the Sault Star, the cogen facility would be fueled by 500 dry tonnes of biomass (wood waste) daily. That’s about twice the current amount of biomass that the mill uses in its boilers to produce steam but not electricity. Meanwhile, about 100 St. Marys employees were scheduled to begin returning to work Aug. 13. The recall coincides with a return to capacity production as two idled paper machines were also brought back on-line.
ACQUISITION
CHEMICALS
Cascades completes purchase of Atlantic Packaging’s tissue division
KINGSEY FALLS, QUE. — Cascades Inc. has completed the acquisition of the tissue division of Atlantic Packaging Products Ltd. The estimated value of the transaction is approximately $60 million. The acquisition will enable Cascades to increase its annual production capacity by 55,000 short tons of recycled paper and its converting capacity by approximately 70,000 short tons, adding close to $100 million in sales per year. According to Suzanne Blanchet, president and CEO of Cascades Tissue Group, the transaction will enable the company to further develop the Cascades Enviro100% recycled brand particularly in central and western Canada. Founded in 1964, Cascades produces, converts, and markets packaging and tissue products composed mainly of recycled fibres.
Buckman launches new brand identity
Buckman now has a new name and a new look. Dropping the word Laboratories from its corporate logo, the company is now known simply as Buckman. The change is a reflection of its growth from a small laboratory selling a few chemicals to a global supplier of chemistries, service, and expertise. Buckman has been in business for nearly 65 years, and has experienced tremendous organic growth. It now serves more than 90 countries, with customers in the pulp and paper, leather, and water treatment industries.
BIOMASS
St. Marys may still have hope of cogen contract
St. Marys Renewable Energy Corp., the energy subsidiary of St. Marys Paper Corp., has missed out on the first combined heat and power renewable cogeneration procurement contract announced by the Ontario Power Authority, but an OPA representative told the Sault Star the paper mill’s hopes for a combined heat and power facility “are very much alive.” The Sault Ste. Marie specialty papermaker filed application for a 35-MW multi-million-dollar cogeneration facility — about one-third of the 100 MW of purchase agreements available. “We want to explore with St. Marys an opportunity to partner on combined heat and power and cogeneration,” said Ben Chin, OPA’s vice-president of communications, the Star reports. “We’re very eager to explore this opportunity and I know they are,” said Chin. “We’re hoping that it can be expedited and that a good partnership opportunity can be explored.” The Sault Ste. Marie paper reports that Gord Acton, president of St. Marys Paper, has previously described the cogeneration application, which he had hoped could go operational by June 2013, as essential to the company’s business plan. It would allow the mill to transition from being a singleproduct paper mill into a multi-purpose site that would produce pulpandpapercanada.com
September 2009
PULP & PAPER CANADA
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ENVIRONMENT
Don’t be a
target
Certification of forest management practices can be both an assurance to customers and insurance against environmental protests.
J
By Cindy Macdonald, Editor
im Lopez, president and CEO of Tembec, nicely quantified the benefits of forest stewardship certification at the company’s annual meeting in January. Tembec began pursuing certification almost a decade ago, and all of the forest that it manages is certified to a Forest Stewardship Council standard. “We are the company with the largest certified forest base in the world,” Lopez said. That certification, for Tembec’s pulp business, “has opened up doors to preferred accounts and preferred markets. “In lumber, it has allowed supply contracts with big box stores. We have a great position with both Home Depot and Lowe’s, and a lot of that is attributable to our FSC position.” And there is a quantifiable bottom-line benefit as well, he stated. “It has also provided improved margins. We estimate that those improved margins amount to about $10 million per year, mainly in pricing because of the premiums we can obtain.” To put that $10 million in perspective, Tembec sales for fiscal 2008 were about $1.6 billion. Other benefits of certification, such as good PR, are not so measurable. Lopez continued: “And of course, the big intangible benefit that’s hard to quantify – but there is a very real value to it – is that we’ve avoided the highly publicized attacks by environmental organizations that we’ve seen against some of our competitors.”
Canada leads in certification
Photo courtesy of Greenpeace
“Flushing ancient forests down the toilet” was the theme of a Greenpeace campaign that targeted Kimberly-Clark. K-C has since revamped its procurement policy to specify fibre from Boreal forests should be FSC-certified, and has won the endorsement of Greenpeace.
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Forest certification in Canada has seen rapid growth in the last 10 years, and has brought the country to a leadership position in this sector. According to Paul Wooding of Canfor Pulp, 45% of the global total of certified forest is in Canada. Sstatistics from PEFC (Programme for the Endorsement of Forest Certification schemes), reveal that Canada has 74.8 million ha certified to the CSA sustainable forest management standard, and 47.9 million certified to the Sustainable Forestry Initiative (SFI) standard. Other nations leading the PEFC chart are the United States with 33.8 million ha and Finland at 20.8 million ha. FSC claims 39.4 million ha of certified area in North America. Another component of forest certification is Chain of Custody certification. In his presentation on the subject of forest certification standards at the PacWest meeting in June, Wooding described Chain of Custody as “a process of tracking products from their place of origin through various transfers to pulpandpapercanada.com
ENVIRONMENT
the final consumer.” Contrary to the situation Lopez describes for Tembec with its business clients, Wooding cited studies that show consumers are not willing to pay a price premium for stewardship-certified goods. In a study undertaken by Oregon State University, eco-labelled products outsold non-eco-labelled by a margin of two-to-one, as long as the price of both products was the same. A $0.50 price premium on the eco-labelled product almost reversed the ratio. Wooding’s conclusion is that certification will be the price of entry to key markets. Comparing the three most widely-used certification organizations, Wooding noted that the CSA standard is the most widely used in Canada. It was developed with the input of forest industry associations, and has a strong commitment to involve public opinion. The SFI standard, he said, has been more successful in Canada than in U.S. markets. FSC is a strong player in global markets, and is supported by major environmental groups.
Help consumers feel good about their purchase
Also speaking at PacWest, Lyn Brown, vice-president, corporate relations at Catalyst Paper, explained that her company has turned to logos to make consumers aware of the ecological benefits of its products. Catalyst uses a Paper Facts label, similar to a nutrition label, and notes the percentage of renewable energy used in the manufacturing process, because, she said, it is a quantifiable claim that can be proven scientifically. “Is that enough? No. It plays out against headlines of conflict and criticism,” she commented. “Consumers want a “feel good” purchase. Urban people have an emotional connection to trees.” Catalyst Paper recently obtained chain-of-custody certification from PEFC for its four Canadian paper mills. The certification replaces the PricewaterhouseCoopers chain of custody which the company implemented in 2004. Unlike the previous system, PEFC enables Catalyst to label select paper products as originating from forests managed to specific certification standards. In turn, customers are able to give their support for certification greater visibility with on-product use of a PEFC label or an SFI logo. “Catalyst has a well-established environmental management system at all our mills,” says Richard Garneau, president and CEO, “and this extends to our preference for certified fibre. Converting our B.C. mills to PEFC – a widely recognized chain of custody – lets customers know our fibre sourcing, tracking, and verification also measure up to high standards.” Catalyst will allocate and track available fibre supplies using the credit system so as to ensure that select paper products contain 100% certified fibre.
Pressure through the supply chain
While appealing to eco-conscious consumers and staying off the evening news are two primary motivators for pursuing forest stewardship certification, another driving force can be compliance with clients’ purchasing policies. pulpandpapercanada.com
Patrick Armstrong, president, Moresby Consulting, notes that customers may specify certification as a way to mitigate risk, respond to or avoid conflict and controversy, protect their brand, and boost employee morale. For example, when Home Depot was under attack by Greenpeace in the late 90s, Armstrong recalls, store employees were on the receiving end of protests, so the company moved quickly to develop a forest products procurement policy. Consumer confidence is sometimes a motivator, as are relations with regulators and corporate social responsibility. “I think it does give you a competitive advantage,” he concludes.
Canada’s forest certification standard updated
The Canadian Standards Association (CSA) recently released an updated version of its sustainable forest management standard. “This updated standard is a result of nearly three years of effort by a technical committee made up of forestry academics and researchers, forest companies, environmental groups, consumers, labour unions, Aboriginal people, and government regulators,” says John Dunford, chairman of the Forest User Group representing the CSA certified forest companies in Canada. “The additional requirements will further validate our commitment to sustainable forest management.” The CSA standard for sustainable forest management now has a suite of mandatory core indicators for measuring sustainable forest management across the country. It also requires ongoing public dialogue with local advisory groups, reflecting the Canadian context where more than 94% of forests are publicly owned. The CSA standard is internationally recognized for delivering on a full suite of sustainability criteria including: • Natural forests and wildlife habitat; • Water and soil protection; • Contributions to carbon uptake and storage; and • Recognition of and respect for Aboriginal rights and title.
Trouble on the horizon
With certification well established in Canada, Tembec’s Lopez counsels pulp and paper companies to be wary of public sentiment on the greenhouse gas (GHG) issue. “We believe this subject is going to be very, very topical, not just in Canada, but in North America. Indeed, it’s already very topical in Europe.” Lopez told participants at the Tembec annual meeting that his company has benefited from its efforts to reduce its greenhouse gas emissions. The company decreased its GHG emissions by 35% over the last three years, and can show a steady decline in the cost per tonne attributed to fossil fuels and electricity over that period, at a time when energy costs were rising quite sharply. Catalyst Paper’s Lyn Brown also identified some emerging issues that should be on the radar of forest products companies: water availability and management, social justice, transparency, waste management, and toxics. Keeping ahead of environmental issues could open doors for proactive companies, and keep protestors off the case. PPC September 2009
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COVER STORY
Quebec’s Bill 57 Forest Occupancy Act effectively takes responsibility for forest management and planning away from the forest products industry and puts it in the hands of government and regional interests.
Sharing th
Quebec rewri
By Carroll McCormick
S
o far, the chore of replacing Quebec’s 1987 Forestry Act with something that pleases everyone seems akin to felling a redwood into a Céline Dion concert without hitting any fans. The Fédération des producteurs de bois du Québec (FPBQ), a federation of Quebec wood producers that represents wood marketing boards which sell wood from private wood lots, fears Bill 57 will drive down wood prices. The Conseil de l’industrie forestière du Québec (CIFQ), which represents 95% of forestry industry players, says it will drive up fibre prices. AbitibiBowater, while sharing most of CIFQ’s views, politely explains that it wants proof that Bill 57 can meet its goals and that the industry sacrifices it occasions will not come to naught. The heavyweight environmental groups Nature Quebec and Greenpeace are in favour of the Bill’s ecosystem management goals, but wants them enshrined in tougher legal language. They think it’s madness for Bill 57 to green-light the conversion of vast swaths of forest into tree farms, and Greenpeace fears Forest Stewardship Council certification will become more difficult. Public hearings on the Forest Occupancy Act began in September.
Power to the people, not industry
The genesis of Bill 57 was a growing perception that Quebec’s forests have long been mismanaged, expressed in documents such as the Coulombe Commission on forest management and a “green book” on Quebec’s forests. “The forest industry in Quebec has lost credibility in good forest management. Bill 57 has the potential for better treatment of the forests than current 14
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COVER STORY
he forest:
rites the rules
law,” says Louis Bélanger, a professor and sustainable forest management specialist at Université Laval. He has also been responsible for Nature Quebec’s forest commission for the last 10 years. “This [bill] clearly stops 100 years of industry controlling the forests. We hope that this turning point will also be an environmental turning point. This is not complete power to the people, but it is a CIFQ director general Guy Chevrette step toward that.” complains that Bill Bill 57 has as its foun- 57 doesn’t guarantee dation several high-impact supply or competitive changes; e.g., taking forest fibre costs. management away from the forest industry and putting it in government hands. Regional round tables will participate in forest planning processes and the roles of local, regional, and First Nations interests will be strengthened. Timber supply and forest management agreements will be cancelled in 2013 when the Bill is due to take effect and guaranteed annual volumes will be reduced. A wood marketing board will auction off a percentage of the public timber. According to Bélanger, “The government is establishing, in theory, integrated and ecosystem-based forest management.” Other goals of Bill 57 include sustainable management, partnerships with private wood lot owners, and increasing the wood supply.
Industry worries about fibre supply
CIFQ director general Guy Chevrette complains that Bill 57 does not guarantee “supply, competitive costs, and an economic environment that lets us compete with other provinces and countries. “Who will want to do major repairs or invest in new equipment if there are not guaranteed supplies? In 2013, if we don’t have an amendment, we will not know what we will need to cut to have a competitive situation.” The supply of certain species up to 100,000 cubic metres will be 100% guaranteed, according to an explanatory document for Bill 57. For mills having an allocation over 100,000 cubic metres, 70% or more of that will be guaranteed. One reason for this is to ensure enough supply for a free market, another is to give the Minister of Natural Resources and Wildlife flexibility to manoeuvre should other needs for the wood supply arise. The marketing board will make wood available for businesses that have, to date, been shut out because they could not access supply. However, Chevrette warns, “To date, about 100 mills have closed. We are functioning at 50% capacity. If you already have the installed capacity it is not intelligent to have new players in the pulpandpapercanada.com
September 2009
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COVER STORY sawmill sector.” He continues: “We do not like much about Bill 57. We will accept a new approach because it will be important with the United States to have a marketing board. We accept integrated management, but we do not accept that the government will make the operations plans. It does not know how to make plans for a competitive situation. We want to be able to make plans.” FPBQ sells wood for 20,000 different wood lot owners each year. It fears that a lack of competition in some regions will depress prices. “We are not sure that the conditions will be there to ensure that the price of wood from public land will be kept up. Only part of the wood from public lands will sold competitively. Who will the buyers be, and will there be enough competition to keep the price at a real fair market value?” asks FPBQ director general Jean-Pierre Dansereau. “Buyers will have an incentive to keep the price low because the rest of the wood, about 70%, will still be guaranteed and will be set accordingly to the reference prices being established at auction.” The marketing board can set opening prices, reserve bids, and minimum bids, but, says Dansereau, “It might impossible for the government, in hard times, not to sell wood below costs to keep mills open.” He also laments that Bill 57 does not require that wood be purchased from private wood lot owners first and then from public lands only as a last resort. In fact, wood cut from private lots on contract is rotting on the ground while mills procure cheaper wood from public land, according to Dansereau. “We are in competition with the public lands, which the government has been using to [make and ensure] jobs. We will ask for more power in the [new] act to make sure that wood from private land has access to the market The explanatory document for the Forest Occupancy Act is available in French at http://www.mrnf.gouv.qc.ca/ publications/forets/evolution/explicatif-projet-loi.pdf. (The document was not yet available in English at press time.)
Ontario begins consultation on forest tenure reform
The Ontario provincial government recently released a discussion paper, entitled Ontario’s Forests, Ontario’s Future, that will guide both online public comment and a series of consultations that begin in September. “This review of our tenure and pricing system – which determines how companies get and pay for wood in this province – is an important step toward building a bright future for ourselves in forestry. I believe we can create a fertile environment for new and emerging opportunities for industry while, at the same time, preserving the best of our current system,” says Michael Gravelle, Minister of Northern Development, Mines and Forestry. A series of stakeholder and public consultations have been scheduled throughout the province in September and October. Additional information on the tenure review is available at ontario.ca/foresttenure. 16
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September 2009
and is not drowned out by wood from public land.” AbitibiBowater wants the government to show that putting wood on the free market will improve the industry’s competitiveness, and not drive up the cost of fibre, before it agrees to this proposal. “On what model does it base this proposition for this marketing board?” asks Pierre Choquette, manager for government relations and public affairs for AbitibiBowater in Quebec. AbitibiBowater also wants more detail on the government’s commitment, as the new forest managers, to third-party certification. “We have always told the government that certification adds to the reputation of the forest sector in Quebec and is a key requirement from most of our customers,” says Choquette. “Will the government oblige companies to certify or be more comfortable helping companies certify?” As for industry losing its right to manage the forests, Choquette comments, “We need clarity on this. This is an advantage for companies, to manage all the aspects of forest to sawmill … to lowering costs and provide synergy. If government demonstrates that taking forest management away from companies won’t raise costs and harm industry, we will work collaboratively with this.”
Good management, or tree farms?
Bill 57 ostensibly protects ecologically-sensitive zones, but Greenpeace Quebec finds it odd that it makes no mention of ecosystem-based management. “It is everywhere in the explanatory document, but it appears nowhere in Bill 57. This is a worrisome and not coherent approach,” says Greenpeace Quebec spokesman Nicolas Mainville. “We were very surprised that it does not include conservation in its vision. “It is as though all forests belong to the timber companies. We do not think that this is what the public has in mind. We are saying that the government and the Chief Forester should develop a plan for which areas should be protected before allocating volumes. The government is afraid that changing drastically how we manage forests will create an unstable climate for the industry. We do not agree. This is what the market is asking for.” Greenpeace and Nature Quebec are horrified with the Bill’s provision for “intensive silviculture” zones. The explanatory document writes that over time, 15 to 20% of the forests in Quebec could become such zones, which Nature Quebec calls “tree farms”. “The way government presents it, it is because of conservation needs that we need to produce more trees, and the way to do it is tree farms [this, according to the explanatory document, will take cutting pressure off the rest of the forests]. We say there are other ways to do it than destroy natural forests,” Bélanger says. In many ways Bill 57 has gone in the right direction, Bélanger concedes. He believes that the forest planning aspects of Bill 57 are well-written. “We are optimistic, but always realistic. We see positive elements. The lip service is there. Let’s transform it into law.” The Quebec government hopes to have the bill adopted by December. It would come into force in 2013. PPC pulpandpapercanada.com
FINANCE
L
ast fall, when Catalyst Paper Corp. CEO Richard Garneau revealed his company’s plans to withhold more than $17 million in property taxes from the four B.C. coastal towns that depend on its mills, he wasn’t anticipating a long and messy legal battle. “I had no clue then that this would end up going to court,” Garneau said in a recent interview. “It was probably dream-
ing on my part to think the arguments we were making would prevail.” After years of lobbying for reduced industrial tax rates in North Cowichan, Port Alberni, Campbell River and Powell River, with limited success, the company adopted a hard-line stance on the issue in the summer of 2008. Garneau began meeting with the four mayors in July 2008 See Catalyst, page 18
Milliondollar tax battle
Catalyst Pulp and Paper’s decision to pay only part of its tax bill to Powell River, B.C., leaves the town $2-million short of its expected tax revenue. Photo: Catalyst Paper
When British Columbia’s municipal tax deadline rolled around in July, several B.C. companies – including Catalyst Paper and Zellstoff-Celgar – took a simmering tax dispute to a new level by withholding all or part of their municipal taxes as they challenge their tax bill in court. The loss is a severe blow for the mill towns. They have been making small tax concessions for years, but it’s not enough for the beleaguered forest products companies, which just want to pay a fair price for the By Brennan Clarke services they use.
I
n principle, Port Alberni Mayor Ken McRae has no quibble with Catalyst Paper’s claims that industrial property taxes in his municipality are far too high. But he also knows there’s no way the small Vancouver Island forestry town can afford to lose $3.3 million in taxes from its largest employer all at once. “We know it’s a serious issue and we’ve been looking seriously
at reducing industrial taxes for several years,” McRae says. “It’s all in how fast we go about it and how much we can afford.” After years of lobbying for lower property taxes, with limited success, Catalyst announced earlier this year it would be withholding more than $17 million from four B.C. towns that depend on its mills for tax revenue and employment – North Cowichan, Campbell River, Powell River and Port Alberni. See Port Alberni, page 18
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FINANCE municipal councils offered Catalyst more incremental tax breaks, but the company, reeling from the to communicate Catalyst’s growing discontent with economic downturn, was neither willing nor able to tax rates it claims are three or four times higher back down. than comparable jurisdictions in Canada and the And so, in June, Catalyst filed petition with the U.S. B.C. Supreme Court asking for a judicial review of By the time the recession hit in mid-October, property tax rates in the four communities. With a Garneau had made it “crystal clear” that Cataflurry of court hearings scheduled for September, lyst would pay each community no more than a Garneau said in August the municipalities’ refusal to $1.5-million flat fee based the company’s estimate address the issue left Catalyst with no other option. “The crux of our argument is the tax is unfair and of the municipal services it consumes. it’s driving investment out of B.C.,” Garneau says. In North Cowichan, where the tax assessment Catalyst CEO Richard Garneau says the “We’ve done all we can to impress on municipal on Catalyst’s Crofton mill topped $6 million this company had no year, the news translated into a potential shortfall of option but the take the governments that this is a shared problem and that the viability of the industrial economy in coastal $4.5 million, more than 20% of the town’s annual matter to court. B.C. is at stake.” tax revenue. Campbell River was left to grapple A wave of layoffs at Catalyst’s West Coast mills last winter with a similar deficit, while Port Alberni ($3.3M) and Powell underscored the company’s precarious financial position. River ($2.2M) also faced huge revenue losses. About two-thirds of the 750 workers at Catalyst’s Crofton mill in North Cowichan were laid off in late February. Within Left with no other option As they struggled to balance their budgets this spring, desperate days, the company shut down its Elk Falls mill outside CampCatalyst, from page 17
TAX TALLY
• Campbell River has reduced Catalyst’s taxes to about $5 million this year, a $900,000 drop since 2004. Catalyst announced the indefinite shut down of its Elk Falls mill near Campbell River in February, eliminating about 350 jobs.
Port Alberni, from page 17 Rather than pay $4 million to $6 million in property taxes to each community, Catalyst decreed it would pay a flat rate of $1.5 million, the company’s estimate of the value of municipal services it consumes. Catalyst has since filed petition in B.C. Supreme Court to have the tax rates overturned and incurred an automatic 10% penalty under B.C. law by refusing to pay up by the July 1 deadline. In court dates scheduled for September, the municipalities will argue that, by not paying its taxes, Catalyst is breaking the law. Campbell River Mayor Charlie Cornfield refused to be interviewed for this story, but is on the record saying he “expects Catalyst to pay their taxes just like any other taxpayer.”
Towns have made concessions
Powell River Mayor Stewart Alsgard says it’s unfortunate
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• North Cowichan council knocked more than $850,000 off Catalyst’s taxes this year, reducing the bill to just under $6 million. Catalyst laid off about two-thirds of the 750 workers at its Crofton mill this winter.
Catalyst has chosen to pursue the matter in court and says the municipality is more than willing to negotiate substantial reductions over time. “We’re aware of the problem and we’ve been making some adjustments,” Alsgard said. “We understand their position but we also want them to understand ours.” All four municipalities have made efforts to appease Catalyst in recent years. Powell River began reducing the company’s taxes by $200,000 a year in 2004 and has since pledged to shave an additional $250,000 in each of the next four years. Port Alberni is in the midst of a six-year plan to slash Catalyst’s taxes by $400,000 a year through 2012 and Campbell River and North Cowichan have knocked just under one million dollars each off the company’s levy in the last five years. North Cowichan Mayor Tom Walker said the town now takes in just 44% of its revenue from industry, down from 62% a few years ago. Catalyst spokesperson Lyn Brown called the reductions “too little, too late.” pulpandpapercanada.com
FINANCE bell River, eliminating about 350 jobs. About 327 people remain employed at Catalyst’s Powell River mill, despite a wave of layoffs in February that sidelined 125 workers, while the Port Alberni mill, which employs 275 workers, has been largely unaffected by the recession. Noting that the taxes on Catalyst’s Snowflake mill in Arizona are only $500,000 a year, Garneau said the rates in B.C. put the company at a “competitive disadvantage” with mills elsewhere in North America.
Rates unreasonable
The company is quick to point out that industry is taxed at 26 times the residential rate in North Cowichan and more than 10 times the residential rate in Campbell River, Port Alberni and Powell River. In Alberta, on the other hand, major industry rates are typically capped at four times the residential rate, Garneau says. Company studies claim that Catalyst’s tax rates range from 6.5 to 8.7 times the cost of municipal services provided in the four communities. “I would like to be able to sell our product at 8.7 times the
• Powell River began reducing Catalyst’s taxes by $200,000 a year in 2004 and has since pledged to shave an additional $250,000 in each of the next four years. About 327 people remain employed at Catalyst’s Powell River mill, despite layoffs in February that sidelined 125 workers
• Port Alberni has embarked on a sixyear plan to slash Catalyst’s taxes by $400,000 per year through to 2012, when the total will be about $3.8 million. The Port Alberni mill has been largely unaffected by the recession.
Alsgard is hoping for quick resolution in court this fall before the tax dollars Powell River did receive this year are all used up. But just in case, council has prepared a contingency plan that identifies reserve fund transfers, gas tax funds, and possibly borrowing to make up the shortfall. Cuts to road maintenance and other services are also possibilities. North Cowichan is also considering cutbacks and borrowing schemes to bridge the gap, while Port Alberni has reduced hours for city staff and may have to cut back municipal services. Castlegar unexpectedly joined the ranks of tax-starved B.C. mill towns when Zellstoff-Celgar Ltd. suddenly announced June 30 it would withhold $2.7 million in property taxes – representing about 47% of the town’s revenue. The resulting shortfall forced council to scrap $3 million worth of capital projects planned for this year, including all road paving, sidewalk maintenance, and a major sewer and water project. “We put almost our entire capital program on hold,” says Castlegar councillor Kevin Chernoff. “We cut everything we pulpandpapercanada.com
cost. That would be nice,” Garneau says. “I think $1.5 million for the services we consume is very generous.” Catalyst’s arguments are nearly identical to those being advanced by Zellstoff-Celgar Ltd. in a separate court action asking for a judicial review of “unreasonable” and “illegal” industrial tax rates in the East Kootenay town of Castlegar, where the company operates a pulp mill. Like Garneau, Celgar general manager Al Hitzroth says his pleas for a major tax reduction fell on deaf ears last fall, prompting the company to force the issue in court. “I clearly had asked them back in December for a 50% reduction. They came back with 1%,” he says. “That’s only $28,000 and we’re a major industry. It missed the mark completely.” Unlike Catalyst, Celgar withheld its entire property tax bill, including the portion earmarked for hospitals and schools, delivering the news to municipal politicians less than 24 hours before the July 1 tax deadline. “The decision was something we were contemplating to get some attention on this issue and we had run out of other alternatives,” Hitzroth said. “It was last-minute decision but it’s not a last-minute issue.”
• Taxes on Catalyst's Snowflake mill in Arizona are US$500,000 per year.
could without affecting…the city’s basic ability to function.” While Catalyst paid a lump sum for municipal services, Celgar withheld the entire amount, including school and hospital levies. Celgar manager Al Hitzroth claims the mill doesn’t use any municipal services and therefore should not have to pay, an argument that town officials reject. A recent finance department report noted that Castlegar’s industrial tax rate of 29.4 cents per $1,000 of assessed value is between 10 and 50 cents lower than most other mill towns in the province, Chernoff says. In late August, six months after Catalyst laid off two-thirds of the 750 workers at its Crofton plant, the company recalled 104 those workers and restarted one of its production lines in response to improving pulp prices. But the company’s CEO, Richard Garneau, says it will take more than an economic upturn to make the tax issue go away. “It’s not a question of the market, it’s a question of fairness,” PPC he says. September 2009
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www.paptac.ca
©
EXFOR & ANNUAL MEETING 2010 Renewal of the Pulp & Paper and Forest Industry: The Path to Sustainability Conference & Tradeshow
February 2-3, 2010 Montreal, Quebec (Canada)
I look forward to welcoming you to EXFOR© & Annual Meeting 2010 as we all take part in the renewal of our industry. Photo©Tourisme Montréal, Stéphan Poulin
André Bernier, General Manager, Catalyst Paper (Crofton Division) & Chairman -- PAPTAC
Buckman has exhibited and actively participated in EXFOR© for many years. What we benefit from in terms of visibility, contacts and business development is well worth the investment.
Montreal, Quebec (Canada)
Tom Johnstone, President, Buckman Canada
All these years of participating in EXFOR© have made me appreciate the business value of this event. I trust this new setting will rejuvenate the renowned luster of EXFOR©. Alain Lemaire, President & Chief Executive Officer, Cascades Inc.
EXFOR© & Annual Meeting is a great opportunity to learn about the new equipment that is available and we get to meet several of our suppliers. The industry is changing rapidly and this is key in helping us stay abreast of new technology. EXFOR© is very valuable for us. Blair Rydberg, Site Manager, Tolko Industries - Manitoba Operations
Our experience in 2009 was very positive and we will definitely be back in 2010. We met quite a few customers. The change in venue and traffic flow layout is much more conducive to interaction with customers. Sammy Di Re, Regional Sales Manager, Voith Paper Canada
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I have never missed one edition since I've been in this industry. It's a pivotal moment in the year where you can meet with your partners, customers and colleagues. There is plenty of discussion and ideas being generated through all the sessions and the different activities that are taking place in town in conjunction with EXFOR©.
2 3 9 10
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Jean Hamel, Vice President of FPInnovations’ Pulp and Paper Division
Who Will Attend? Production, Engineering, Purchasing and Maintenance Personnel & Supervisors Mill Managers Superintendents Operators Equipment & Chemical Suppliers Consultants Researchers Corporate Office Executives and Personnel Academics Students
Why EXFOR© & Annual Meeting? EXFOR© & Annual Meeting is the annual forum to advance your learning experience and enhance your professional development with the conference’s technical and business tracks which focus on challenges, opportunities and solutions for the industry get first-hand information on how the industry and business models are reshaping themselves find out about the latest research learn about current, emerging and innovating technologies visit the tradeshow and meet with your suppliers discuss business conditions and strengthen partnerships renew acquaintances and/or meet up with old friends expand your network play an active role in the renewal of our industry
Regular tracks: Keynote speech Papermaking New for Pulping 2010 Bleaching Research French track Energy & Biorefining Fighting back Engineering & Maintenance Mountain Pine Complete Business Track Beetle infestation I have attended several editions of EXFOR© Supplier Showcase Health & Safety and the Annual Meeting. It is an established Mill Managers’ Roundtable Roundtables event with an international audience and the technical program and tradeshow are very high quality. Each year, I have searched out and found new cost savings or operational improvement items that we have put into I rarely miss this annual gathering of our practice at our mill. The networking with so industry. In 2009, we took this opportunity many diverse professionals both on the to launch the book “Proceedings of the supplier and manufacturing side cannot be Fundamental & Applied Pulp & Paper matched at other venues. I highly Symposium 2008”, and to organize recommend attending and participating in all strategic meetings within Cascades and this forum has to offer. with some of our suppliers. Harold Norlund, Mill Manager, Nippon Paper Industries USA
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Dr. Roger Gaudreault, General Manager, Cascades R&D
September 2009
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EXFOR© & Annual Meeting is a unique opportunity to exchange with my industry colleagues. In February 2009, we were close to 30 participating in a Mill Managers’ roundtable. We are already planning the topics for the 2010 edition. Jean Descôteaux, General Manager, AbitibiBowater – Kénogami
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I am very happy to have participated in the event in 2009 and am planning to attend in 2010. I met several of my counterparts from other mills and got to hear presentations that generated interesting discussions on operations’ optimization.
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HOTEL FEATURES
PAPTAC and this event are key elements of our industry and provide an excellent venue for us to meet, network and learn. I look forward to seeing many of my counterparts and colleagues in February 2010. Scott Travers, President and COO, Minas Basin Pulp and Power Ltd.
This grand and gracious hotel treats guests to non-smoking floors, private floors with concierge services, a health centre and indoor pool. Each room is equipped with two telephones and high-speed Internet. The hotel is home to three restaurants, including the famous CAA/AAA four-diamond Beaver Club and connects directly to the boutiques of the city’s 30-km-long underground pedestrian network. Guests can also take advantage of its business centre, catering service and the Beaver Club’s gourmet boutique..
REGISTER NOW! Visit www.paptac.ca or call Carmie Lato at 514.392.6969 / clato@paptac.ca. Coming soon: check your inbox for the detailed preliminary program and other pertinent information.
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PULP & PAPER CANADA
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514.861.3511 or 1.800.441.1414 EXFOR© & Annual Meeting Rate: $165/night (Standard Fairmont room) Event code: PAP10
Reservation deadline: January 15, 2010
Being involved with PAPTAC's Atlantic Branch, this is a great venue to take the pulse on the industry in the rest of Canada and to connect with some of my counterparts from other committees and branches. The change in location at the Queen Elizabeth was also very positive and I look forward to 2010! Jon LeRoy, Process Engineer, Irving Pulp and Paper Ltd.
pulpandpapercanada.com
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PAPER MACHINE
Getting a lot
from a little
Upgrades to paper machine clothing technology offer pulp and paper facilities a critical opportunity to improve cost structures while steering clear of large capital ventures. By Heather Lynch
“P
aper machine clothing is a technology investment with a very rapid payback,” says Steve Cole, director of global product management for Xerium, which includes Weavexx, Huyck.Wangner, and Stowe Woodward. While the acquisition cost for paper machine clothing (PMC) accounts for less than 3% of the costper-average ton of paper produced, suppliers like Weavexx and Huyck.Wangner repeatedly document millions of dollars of value generated for customers as a result of applied fabric technology. Jim Moloney of Albany International agrees. “Although paper machine clothing is a small portion of overall paper machine operational cost, it is a critical part of paper machine operations. Therefore, paper machine clothing upgrades provide an opportunity to reduce costs and improve the economic position of our customers.” Moloney is director of marketing communications, Americas business corridor for PMC supplier Albany International.
Proper selection reduces energy needs
One of the biggest areas for cost savings through efficient use of PMC technology is energy. It is no secret the forestry industry remains highly susceptible to volatile energy prices, with the typical newsprint machine using the equivalent of 26 MW in steam in the dryer section per day. As Tom Coulter, vice-president of product management for Voith Paper Fabric and Rolls Systems, points out, educated PMC selection reduces this consumption. “Forming fabrics with thinner calipers, such as our PrintForm I 24
PULP & PAPER CANADA
September 2009
can improve sheet consistency off the couch by 1 to 1.5% and reduce former drive loads,” Coulter explains. For AstenJohnson, the key to a reduction in energy use lies in water removal. “In press, using the latest structures consistently delivers 1-2% of sheet solids, which means 4-8% less drying energy is required. While in the past gains in water removal were usually converted to speed increases, the current economic climate has shifted most of our customers’ focus to cost reduction and energy savings. Many customers will save the money rather than trying to produce extra tons,” notes John VanDerKolk, forming product manager – packaging for AstenJohnson. An emphasis on energy reduction through PMC technology has translated into targeted trials at research consortium FPInnovations, where mills seeking to keep a lid on energy costs improve paper properties such as formation, sheet surface quality, mechanical retention, and sheet strength through the use of PMC. “In these tough market conditions, paper mills need to find every way possible to lower their costs,” notes senior papermaking scientist Jimmy Jong. “At the same time, paper quality should not suffer as a consequence, and it’s important to maintain good machine runnability. Paper machine clothing produced using the latest technology can improve key paper properties, as well as drainage performance.” FPInnovations recently carried out a pilot machine trail with a PMC supplier to investigate the effects of forming fabric design on drainage, paper quality, and linting. “Our results show that different designs of fabrics had significant
influences on early drainage, formation, and linting performance,” Jong confirms. “Paper mills with linting issues could potentially improve their situation by selecting proper clothing designed for the right machine configuration and operating conditions.”
What lies ahead
As mills and suppliers alike prepare for a streamlined future industry, emphasis will be on optimal results achieved via minimal capital outlay. Albany International anticipates increased emphasis on machine speed, productivity and paper quality by its customers and invests 3% of sales into R&D. As a result, three new products – AeroPulse, Pressision and Inline – have been introduced to help mills achieve these results. “New technologies like these have translated into significant savings for papermakers through energy savings, quality improvements, and production efficiencies,” reports Moloney. “Raw materials and manufacturing equipment continue to evolve and are providing cost benefits to the papermaker. Further improvements in raw materials will enable the machine to reduce energy, improve life, and operate more efficiently.” Voith Paper envisions technological combinations that will propel the company’s way forward. “We are developing forming section packages consisting of forming fabrics, roll covers, and doctor blade technologies that will reduce energy pulpandpapercanada.com
PAPER MACHINE
consumption,” Coulter reports. “In the press section, press fabrics, roll covers and doctor blades will optimize sheet dewatering. Our dryer section packages, now under development, are targeting reduction of steam energy and drive energy in the dryer section.” AstenJohnson adopts a practical approach, noting the commercial issues facing its customers will dictate the direction in which PMC technology develops. While newsprint and Freesheet drove PMC development in the past, tissue and packaging lines are moving to the forefront of the industry and PMC technology will develop to accommodate this industry shift. “The market will also look for shorter supply chains, lower inventory levels, and faster lead times,” cautions VanDerKolk, noting this emphasis will force PMC manufacturers to look at innovative manufacturing processes and streamlined product offerings to meet these needs. “With the competitive nature of the market, we will also see more machine shutdowns, which means the machines that remain will be world class and will benchmark themselves with a global scope.” Weavexx and Huyck.Wangner will continue to advance technology to further enhance performance, while helping reduce operational costs for its customers. “Our focus will always revolve around reducing energy, attaining higher water removal rates, higher sheet quality, higher performance and efficiency levels, economic product life, and increased safety for installation and during operation,” reports Steve Cole. “We will also continue the system approach of using fabrics, felts, our Stowe Woodward roll covers and cover venting engineering as a complimentary process to producing a quality sheet at the lowest possible cost.” With a bird’s eye view on the industry, FPInnovations expects Albany International’s AeroPulse dryer fabric is said to improve heat transfer, leading to higher drying rates.
pulpandpapercanada.com
the next five to ten years for PMC to emphasize higher fabric support, longerlasting forming fabrics on the machine side thanks to the development of new polymers, and an increase in dimensional stability. “Member companies are well aware of the new developments in PMC technology,” Jong notes, recalling a recent pilot machine trial conducted by a member company and a supplier to evaluate the technical feasibility of a new clothing concept. “FPInnovations is heavily involved with several clothing suppliers in testing a series of new forming fabrics and press felts produced with the latest technologies in our pilot paper machine. A new design of forming fabrics with a warp-integrated sheet support concept was successfully used in producing paper with 50% filler in a pilot paper machine trial,” Jong reports. Overall, challenging market conditions continue to squeeze bottom lines and make capital expenditures on behalf of pulp and paper mills a difficult if not impossible option. As Jong summarizes,
searching for efficient PMC solutions with minimal capital outlay remains an attractive alternative to expensive investments for many organizations. “Our member companies have gone through a very challenging year due to the fastdeclining market conditions – especially in the printing and writing grades. To overcome this difficulty, many of our member companies have looked into developing new product opportunities on existing paper machines based on market size, technical feasibility, machine capability, competition, and long-term growth potential,” Jong says. This presents a unique opportunity for PMC suppliers to help mills improve their competitive position while reducing costs. As Jim Moloney of Albany International aptly notes, the name of today’s game is competition through cost reduction. “With the current economic situation, the focus of our efforts is helping our customers reduce their costs and improve their competitive position. Value creation is paramount.” PPC
Trends in machine clothing PPC asked the top four paper machine clothing suppliers to the Canadian industry what new applications they focused on in the last year, and what market drivers prompted them to direct resources to these particular areas. Here is a compilation of their responses. Albany International: Value creation with our forming, pressing, drying, and belting products is paramount. The main value drivers for our customers with many machines running at reduced operating rates or speeds are energy, sheet quality, drainage, and predictable life. In the forming section, triple-layer fabrics such as our InLine have reduced energy, improved sheet quality and productivity. We also introduced a new press fabric called Pressision and the trials have shown a significant improvement in sheet dewatering and overall energy. Weavexx and Huyck.Wangner: Our focus continues to be on developing and applying paper machine clothing technology that provides demonstrable and sustainable value to the papermaker. Some examples include our newest line of forming fabrics, Graphixx, which helps customers in the premium board
and packaging grades to improve their sheet finish. Voith Paper: The market continues to move forward and use of seamed fabrics in all applications is increasing. Therefore safe and easy installation is key. Voith has been working on the second generation of our Advanced Seam Technology. The newest design, AS G2, is yielding higher performance in a wide range of paper grades and press configurations. AstenJohnson: For North America, demand continues to grow for better seamed press fabrics that meet the needs of ever-demanding applications. A lot of our research and product development is focused on new ways to reduce the seam joint defect so it can run on tissue machines and high-speed shoe presses without adversely affecting the productivity or quality of product for those applications. September 2009
PULP & PAPER CANADA
25
T120 KRAFT PULP
21st Century Fibrelines By: T. Johnson, B. Johnson, P. Gleadow, H. Araneda, F. Silva, R. Aquilar, and C. Hsiang Abstract: The design and operation of three of the newest 21st century fibre lines are reviewed. The mills include Veracel Celulose, a Brazilian high-brightness eucalyptus pulp mill; Hainan Jinhai, a Chinese bleached hardwood kraft mill; and Celulosa Arauco Valdivia, a Chilean bleached eucalyptus and radiata pine batch mill. The configuration of each fibre line is outlined and the key features of the chosen technologies are discussed. Performance data for key mill operations and environmental control systems is given.
T
he design of a modern 21st century pulping complex is dramatically different from mills of the past. Pressures to maximize energy efficiency, improve product quality, reduce environmental impact, and optimize capital and operating costs have significantly shaped 21st century pulping and bleaching processes. New mills have responded to these demands by adopting efficient, low impact designs on economies of scale that far surpass most existing mills. New fibre lines have been built mainly in Asia and South America where access to fast growing raw material and other production advantages give favourable levels of cost and return. This paper benchmarks three mills started up in the early 21st century.
THE MILLS
Veracel The Veracel bleached eucalyptus pulp mill started production in May 2005 with a design capacity of 900,000 tpa. The mill is a joint venture between Aracruz Celulose and Stora Enso and is located in the north-eastern state of Bahia in Brazil. The Veracel fibre line consists of Lo-Solids pulping, two stages of oxygen delignification, and a fourstage, elemental chlorine free (ECF) bleaching sequence (Fig. 1). Logs are sourced from Veracel’s own plantations, currently totalling 87,000 hectares. Eucalyptus urograndis is the main species pulped. The mill has a design capacity of 900,000 adt per annum but actual production has consistently exceeded this target. Production in 2007 was in excess of 1,050,000 adt. The bleach plant, originally designed to operate as A/D0 (Eop) (D1n) D2 or A/D0 (Eop) D1 P has been modified to Dhot (Eop) D1 P. The pulp quality target of 97% prime quality, was achieved 59 days after start up. Hainan Jinhai The world’s largest single-line pulp mill, Hainan 26
PULP & PAPER CANADA
September 2009
Jinhai was designed to produce one million tpa of bleached hardwood kraft pulp. The mill is located on Hainan Island in southern China and covers 400 hectares. The management philosophy underlying the mill development was three-fold – economic benefit, social benefit, and ecological benefit. Hainan Jinhai produced its first pulp in November 2004. The mill’s fibre is Eucalyptus grandis and Acacia crassicarpa, in approximately equal volume, and is sourced internally from Asia Pulp and Paper’s (APP) 233,300 hectare plantation forests, and imported from Indonesia, Cambodia, and Vietnam to make up the balance. Additional plantings are planned with the goal to become self-sufficient in wood. Hainan Jinhai utilises Compact Cooking, two-stage Dualox oxygen delignification, and DualD hot chlorine dioxide bleaching (Figure 2). The mill’s produc-
T. JOHNSON Beca AMEC, Tauranga, New Zealand
B. JOHNSON Beca AMEC, Tauranga, New Zealand
P. GLEADOW AMEC, Vancouver, B.C.
H. ARANEDA Celulosa Arauco y Constitucion, Caldivia, Chile
F. SILVA Veracel Celulose, Bahia, Brazil
R. AQUILAR Veracel Celulose, Bahia, Brazil
C. HSIANG Hainan Jinhai Pulp and Paper, Hainan, China pulpandpapercanada.com
KRAFT PULP T121 area. Very low loadings to the recipient waters are a key requirement and are achieved by a combination of state-ofthe-art technology and internal measures. Effluent treatment consists of primary, secondary, and tertiary treatment stages followed by disk filtration to minimise suspended solids levels prior to discharge.
INNOVATIONS AND TRENDS IN FIBRE LINE TECHNOLOGY
Fig. 1. Veracel bleached eucalyptus fibre line. TABLE I. Digester key parameters Parameters
Veracel
Hainan Jinhai
Arauco Valdivia Arauco Valdivia
Digester Type
Continuous Steam/liquor 2 Lo-Solids 3,350 HW E. urograndis
Continuous
Batch
Batch
10 x 400m3 SuperBatch-K 1,527 SW P. radiata
43 3–8 25 17.5
2 Compact Cooking 3,020 HW Acacia (50%) E. grandis (50%) 40-50 <8 24 – 32 17 – 19
58 5–8 24 – 26 21
10 x 400m3 SuperBatch-K 1,680 HW E. nitens (70%) E. globulus (30%) 50 5–8 24 – 26 21
134
129 – 135
140
140
35 700/1900 Digester only 47 26 2.5 15.4
35 700/1350 Digester only 52 15 2.5 14.8
Number of Vessels Type of Cooking Capacity, ad tpd Wood Type Wood Species Chip Moisture % Chip Thickness, mm Chip Length, mm Active Alkali, % NaOH Active Alkali, g/L NaOH Sulphidity, % Steam Usage LP/MP, MJ/t Yield, % OD Kappa Number Dilution Factor Black Liquor Solids, %
32 < 30 1450 Digester < 6 t steam/t only Total mill 55.8 44 – 46 18 17 – 18 1.0 < 2.5 15.0 16 – 17
tion is used to supply pulp to the several APP paper machines in China. Arauco Valdivia Celuloso Arauco y Constitución’s pulp mill in Valdivia, Chile, started up in February 2004 and produces 550,000 tonnes of pulp annually. Valdivia is a ‘swing’ mill producing both radiata pine (60% of production) and ecualyptus pulp. The mill design was based on a maximum capacity rate of 1,700 pulpandpapercanada.com
ad tpd for pine and 1,900 ad tpd for eucalyptus. E. nitens (70%) and E. globulus are the eucalyptus species pulped. The pulping line consists of ten SuperBatch-K digesters of 400 m3 capacity followed by 4 stages of washing and screening (Fig. 3). Oxygen delignification is in two stages with 60% of delignification occurring in the first reactor. The ECF bleach sequence is D (Eop) D D. The mill is located in an environmentally sensitive
Pulping State-of-the-art cooking includes both continuous and batch processes utilising low cooking temperatures and optimised alkali profiles. Continuous cooking has predominated over the last decade, and typically consists of two vessels for softwood and one or two vessels for hardwood. With segregation of chips by species the norm, the chip feed is of uniform quality and thus results in reduced processing upsets. Lower cooking temperatures (145-153ºC) are typically used with kappa numbers in the range 26-35 for softwoods, 17-22 for birch, and 15-18 for eucalypts. The pulping equipment and process details for each of the fibre lines are summarised in Table I. Both Veracel and Hainan Jinhai operate continuous pulping systems. Veracel’s low level – Lo-Solids cooking system consists of an hydraulic impregnation vessel and a steam-phase digester. The main objective of the Lo-solids cooking is to increase the selectivity of the cook through low and uniform radial cooking temperatures and a uniform alkali profile. Cellulose dissolution is minimised in the principal and residual delignification phases, and relatively high yields of around 55% OD are achieved. The Compact Cooking process at Hainan Jinhai is producing in excess of 3,000 tonnes/day. Chips of uniform size and thickness are fed via a Compact feeder to the liquor impregnation vessel. The digester is of massive scale at 12.5 m diameter, with a retention time of about 6 hours. Cooking is at lower temperature with a low energy and alkali demand giving milder cooking conditions and pulp of good strength. Arauco Valdivia operates the modified batch cooking process SuperBatch-K. The ‘K’ refers to a modification of the liquor displacement system to mitigate the earlier problems with calcium complex formation September 2009
PULP & PAPER CANADA
27
T122 KRAFT PULP
Fig. 2. APP Hainan Jinhai bleached hardwood fibre line. TABLE II. Oxygen delignification key parameters Parameters
Veracel
Hainan Jinhai
Andritz
Kvaerner Dualox 2 3,020 Euc & Acacia < 0.7 < 0.5 10 – 11 1.8 2.0 0.2 1300 1050 250 2.5 17 – 18 10 – 12 (1.5 – 2.0) 3 presses 2 presses
Supplier
Arauco Valdivia Metso OxyTrac 2 1,527 Pine
Metso OsxyTrac 2 1,680 Eucalyptus
Knots, % 1.0 1.0 Screen Rejects, % 0.2 0.5 Consistency, In 11.0 11 Oxygen, % 1.6 2.1 NaOH, % 1.6 2.6 MgSO4, % – 0.2 Viscosity, In, dm3/kg 1250 1030 Viscosity, Out, dm3/kg 1150 844 Viscosity, Loss, dm3/kg 100 186 Dilution Factor 1.0 2.5 Incoming Kappa 16.5 26 Kappa Out 10 10 O2 Yield Loss, % (3.0) – Brown Stock Washing 2 DDs 3 presses Post O2 Washing 2 DDs 2 presses Note: 1. ( ) design 2. All chemicals as % actual chemical on bleached pulp basis.
1.0 0.5 11 1.1 1.6 0 1150 923 227 2.5 15 9.5 – 3 presses 2 presses
Number of Vessels Capacity, ad tpd Wood Type
2 3,200 Eucalyptus
in the front-end liquor systems and evaporation. Throughout the cooking cycle all liquors are pumped into the bottom of the digester and liquor is displaced through the screens located in the upper part of the digester. Displacement cooking claims to provide optimal cooking conditions for the duration of the cook resulting in retention of fibre strength and pulp of uniform qual28
PULP & PAPER CANADA
September 2009
ity. At Valdivia MP steam is used to reach the cooking temperature of 150-160ºC. Kappa targets for pine and eucalyptus are 26 and 15, respectively. Washing and screening Atmospheric diffusion washers and drum washers common in 20th century mills are replaced by presses and multi-stage DD washers that achieve high equiva-
lent displacement ratios (EDRs). Veracel has two parallel pressurized diffusers after the digester followed by 2-stage drum displacement (DD) washers prior to oxygen delignification. Arauco Valdivia uses a dewatering press, with 2.5-3.0% feed consistency and two displacement wash presses with 6-8% feed consistency. The dewatering press is fed directly with screen accepts, and the press filtrate is cooled before entering the filtrate tank to return it to optimum temperature for the digester displacement liquor and to enhance soap separation in the liquor tank. Hainan Jinhai uses Compact Press™ technology throughout the fibre line. Two wash presses in parallel follow the screening stage and pulp then passes to a third press prior to oxygen delignification. Deknotting and screening can be carried out either before oxygen delignification, as in the case of Arauco Valdivia and Hainan Jinhai, or after, as for Veracel. Veracel claims advantages in screening after oxygen delignification - less foaming making the pulp easier to screen, higher yields due to breakdown of shives, smaller and cleaner rejects, and advantages in the heat balance between the cooking and oxygen stages. For all three mills deknotting and primary screening occur in a single stage. Valdivia has 4 parallel DeltaCombi™ units for knot separation and a blower system for returning the knots to the digester chip bin. This knots return system has caused process instability, especially during eucalyptus campaigns, and is being modified to inject knots directly into the digesters. Veracel operates two parallel ModuScreen units for knots separation and primary screening, followed by washing and return of knots to the digester. Screening is either 3-stage (Veracel) or 4-stage (Valdivia) and the options with rejects are to recycle, as in the case of Veracel where they are cleaned, washed and returned to the oxygen delignification stage, or landfill them. Oxygen delignification Oxygen delignification is carried out at medium consistency and in two stages by all three mills. This is a significant difference to mills of the previous decade where oxygen delignification was typically one stage. The bulk of the delignification occurs pulpandpapercanada.com
KRAFT PULP T123
Fig. 3. Arauco Valdivia bleached fibre line. TABLE III. Bleaching key parameters Parameters
Veracel
Hainan Jinhai
Arauco Valdivia
Sequence Dhot (Eop) D P Dhot (Eop) D D Dh (Eop) DD Rate, ad tpd 3,100 3,000 1,527 Wood Eucalyptus Euc & Acacia Pine Washing 4 DDs 4 presses 5 presses Incoming Kappa 10 10 – 12 10 Stage 1 H2SO4 % 0.2 0.3 – 0.5 0 ClO2 % 0.59 0.5 – 1.0 0.92 Stage 2 NaOH % 0.85 1.5 1.5 O2 % 0.18 0.4 0.4 H2O2 % 0.20 0.2 – 0.3 0.3 Stage 3 ClO2 % 0.20 0.4 – 0.5 0.57 H2SO4 % 0.20 Stage 4 ClO2 % – 0.2 – 0.3 0.19 H2O2 % 0.1 NaOH % 0.24 Antichlor metabisulphite – NaHSO3 Shrinkage, % (2.5) (< 3.0) (2.8) Brightness, % ISO 90.4 88 – 90 > 90 Note: 1. All chemicals as % actual chemical on bleached pulp basis. 2. ( ) design
in the first reactor, which is typically run at lower temperature and higher pressure than the second reactor. Veracel runs its first reactor at a temperature of 92-96ºC, a pressure of 6-8 bar, with the addition of 60-70% of the alkali and oxygen charge. Valdivia adds all chemicals to the first reactor. Typically, the retention time in the first tower is about half that of the second tower. Veracel operates the second reactor at a temperature of 98-100ºC and a pressure of 3-5 bar. Oxygen delignification at the Hainan Jinhai mill is the two-stage Dualox™ process. pulpandpapercanada.com
Do (Eop) DD 1,680 Eucalyptus 5 presses 9.5 0 0.77 1.2 0.13 0.28 0.49 0.18
NaHSO3 (2.7) 90.1
The degree of delignification varies between 60% for softwood, and 40% for hardwoods. A significant portion of the hardwood kappa number is hexeneuronic acid which lowers the overall degree of delignification compared to softwoods. Valdivia’s kappa targets are 12 and 9.5 for softwood and hardwood, respectively, to preserve pulp strength and pulp yield. Bleaching The three mills have similar four-stage, ECF bleaching sequences (Table III), which are similar to that used in the
1990s. The original bleach sequence of Veracel was A/D0 (Eop) D P which was modified after start up to Dhot (Eop) D P. This resulted in a significant reduction in chemical consumption. Veracel’s bleach plant operates with upflow towers in all stages followed by a DD washer after each tower. The washing is counter current with filtrate from the pulp machine being used for washing on the final DD washer. Veracel, like the other two mills, has very low bleach chemical consumption. Arauco Valdivia’s bleaching sequence is a conventional ECF sequence, D (Eop) D D. The first bleaching tower is upflow, with a top scraper and a dropleg to the MC pump standpipe. The three other towers are upflow-downflow, with MC bottom. The upflow section of the Eop tower is a pressure vessel. Mixers are all dynamic type SMD-300 in all stages. Washing is with wash presses. The two first stages have displacement presses and the last two stages have simpler dewatering presses. Hot water is used for Eop washing, and pulp machine filtrate is used before the last D stage press. A minor amount of cold water may be added to the dilution before the first D stage for temperature control. The excess filtrates, both acid and alkaline, are filtered before they are sewered. To decrease emissions of COD, BOD and colour from the bleach plant, it is possible to recycle the alkaline filtrate from the Eop stage and use it for washing prior to the first bleaching stage. At Hainan Jinhai, the DualD bleaching process D (Eop) D D also has a hot chlorine dioxide first stage. As with the other two mills there are upflow/downflow towers in each D stage. Wash presses follow each bleaching stage. Brightness is in the range 88-90% ISO. To achieve consistent quality and cost efficiency the bleach plants have a high level of on-line instrumentation that allows tracking, analysis and optimal control of the bleaching process. Standard deviation of the final brightness is less than +0.5% ISO.
PERFORMANCE
The real measure of the success of these three mills is reflected in their overall performance – market, business and environmental performance. Control of the processes is excellent, product quality meets September 2009
PULP & PAPER CANADA
29
T124 KRAFT PULP TABLE IV. Fibre line performance Parameters
Veracel
Hainan Jinhai
Wood Species
E.urograndis
Acacia E. grandis
P. radiata
E. Nitens E. globulus
18 0.5
17 – 18
26 2.0
15
38 10.0 0.5
30 – 44 10 – 12
61.5 10 1.25
37 9.5 0.85
10.0
<3
6
6
90.4 1100 880 220
88 – 90
89.3 844 737 107
90.1 923 833 110
90.4 0.3
88 – 90 < 51
90.3 0.7
90.6 0.9
Digester Kappa Number Kappa Std. Deviation Oxygen Delignification Delignification, % Kappa Number Kappa Std. Deviation Washing Loss as kg COD/ADt Bleaching Brightness, % ISO Viscosity In, dm3/kg Viscosity Out, dm3/kg Viscosity Loss, dm3/kg Final Product Brightness, % ISO Dirt, ppm
Arauco Valdivia
700
Note: 1. Hainan dirt count units are mm2/m2.
TABLE V. Environmental parameters Parameters
Veracel
Hainan Jinhai
Arauco Valdivia
Flow, m3/day Primary Clarifier, # x m3 Bio-Treat Type
72,000 1 x 25,080 activated sludge
50,000 1 x 5,000 ASB
Secondary, m3 Sec Clarifier, # x m3 Tertiary, m3 Spill Containment Emergency Basin, m3 Nutrients Applied Cooling Towers Final Effluent Parameters BOD, kg/adt COD, kg/adt TSS, kg/adt AOX, kg/adt Colour, kg/adt Temperature, °C
2 x 14.26 –
60,400 Yes Anaerobic & aerobic Yes Yes
by area 60,000 N2 as urea 1 0.30 6.7 0.67 0.06 520 mg/L 35
2 x 44,750 2 x 8,700 2 x 590 by area 130,000 2
<3
0.07 1.5 0.23 0.03 0.55 28.5
Note: 1. Hainan Jinhai figures from reference (3) 2. Arauco Valdivia data corresponds to official data from 2007
market standards, and environmental performance is among the best in the world. All three mills are low cost producers. Table IV outlines key parameters that are commonly used to measure the performance of each unit operation. All mills have modern technology and good process control which results in minimal cellulose degradation and optimal fibre yields, low variability in process parameters and product quality, and minimum energy and chemical consumption. Mills typically produce one prime grade of pulp 30
PULP & PAPER CANADA
September 2009
only, which eliminates grade switching and maximizes productivity. Environmental performance The mill effluent treatment systems and final effluent parameters are shown in Table V. Veracel operates within the best environmental practices expected of a modern pulp mill. Effluent is treated in an activated sludge process and solid wastes are used to produce organic compost. The 2007 environmental performance figures show
the consistent operation of the mill within its permitted discharge levels, internal targets and best available technology (BAT*) guidelines (Table VI). The mill is believed to be amongst the best in the world in terms of effluent and air emissions, operating at approximately 50-75% of the legal limits. Water consumption is in the range of 22-24 m3/ tonne of pulp, with BOD and COD limits set at 0.3-0.4 kg/tonne and 5 kg/tonne, respectively. Veracel is probably the only mill that discharges its effluent upstream of its intake, which is a requirement of the mill’s operating licence. Atmospheric emissions are permanently monitored. There is one common stack for all air emissions. Emission control technology includes high efficiency electrostatic precipitators, an odorous gases (NCG) collection system, and stripping of foul condensates which are collected and burnt in the boilers. There is an odour perception network of 23 inhabitants in neighbouring communities. The Arauco Valdivia mill is located in an environmentally sensitive area, and based on some benchmarking of its permit, have some of the most stringent effluent limits for bleached kraft pulp mills anywhere. Valdivia has three permits that cover all parameters. The mill is in compliance with its permit targets. The Valdivia effluent treatment system treats three main mill streams: the low solid sewer which includes bleach plant effluents and excess evaporator condensates; the general mill sewer including effluent from landfill and the woodyard; the storm water system. Key features of the treatment system include: • a spill pond with spill pumps (130,000 m3); • Primary treatment for the main sewer including an automatic screen, primary clarifier, scraper, and fibre sludge pump; • Neutralisation stage, and cooling towers (two chambers); • Secondary treatment (two parallel lines) • aerated basins, nutrient addition, secondary clarifiers, scrapers, and fibre sludge pumps; • Tertiary treatment (parallel lines) – flocculation chambers, chemical addition (alum, polymer, peroxide), scrapers, and sludge pumps, • Disc filters (three) in parallel, to reduce pulpandpapercanada.com
KRAFT PULP T125 Table VI. Veracel effluent performance compared with permit, BAT and internal targets Parameters
Units
BAT*
Internal Target
Actual YTD Dec 07 Average
AOX Effluent COD Effluent BOD5 Effluent Suspended Solids Water Usage Effluent Discharge TRS Recovery Boiler as H2S TRS Lime Kiln as H2S Odour Complaints Colour
kg/adt kg/adt kg/adt kg/adt m3/adt m3/adt ppm ppm No. mg/l
<0.25 8 – 23 0.5-1.5 0.6-1.5 30-50 -
< 0.15 12.0 0.7 1.0 30 27 0.20 7.0 0 1000
0.06 6.7 0.31 0.67 27.7 24.7 0.05 5.7 11 520
suspended solids; • Cooling towers to control the final effluent temperature; and • Sludge handling system including two belt filter presses for sludge dewatering. Toxicological studies of acute toxicity (CL50) and chronic toxicity have demonstrated no impact in the recipient (river) environment. No lethal effects were detected for the species H. gracilicornis, D. obtusa, G.. affinis. y O. mykiis, nor any chronic toxicity in L. valdiviana, S. capricornotum, G. affinis y O. mykiis. Hainan Jinhai must also meet strict environmental standards. Effluent treatment is a combination of anaerobic and aerobic in three stages: primary, secondary,
and tertiary. Tertiary treatment is based on precipitation. Sludge from the treatment plant is dried and pressed to around 70% moisture and burned in the power boiler. All non-condensable gases from the fibre line are collected in a closed system and burnt in the recovery boiler. Hainan Jinhai reports an average water consumption of less than 30 m3/t pulp and a total COD discharge of less than 3 kg/t pulp. Hainan Jinhai and Arauco Valdivia both use a tertiary flocculation stage to remove additional organic material. This results in very low COD (and AOX) levels in discharged effluent compared to biological treatment alone, but incurs the expense of additional chemicals, and sludge han-
Résumé: Nous avons passé en revue la conception et le fonctionnement de trois des plus récentes usines de pâte à avoir été érigées au 21e siècle. Il s’agit des papetières Veracel Cellulose d’Eunapolis au Brésil, une usine brésilienne produisant de la pâte kraft blanchie à partir d’eucalyptus; Hainan Jinhai, de Hainan en Chine, une usine de pâte kraft blanchie de feuillus; et Celulosa Arauco y Constitucion, de Valdivia au Chili, une usine chilienne de fabrication en discontinu de pâte d’eucalyptus et de pin de Monterey. La configuration de chaque ligne de production et les principales caractéristiques des technologies employées font l’objet de discussion. Le communiqué présente des données sur les moyens employés pour maximiser le rendement et réduire l’impact des opérations sur l’environnement. Reference: T. JOHNSON, B. JOHNSON, P. GLEADOW, H. ARANEDA, F. SILVA, R. AQUILAR,
C. HSIANG. 21st Century Fibrelines. Pulp & Paper Canada 110(7):T120-T125(September 2009). Paper presented at the 2008 International Pulp Bleaching Conference in Quebec, Que., June 2-5, 2008. Not to be reproduced without permission of PAPTAC. Manuscript received Sept. 22, 2008. Revised manuscript approved for publication by the Review Panel Jan. 23, 2009.
Keywords: BLEACHED KRAFT PULP MILL, NEW FIBRE LINES, EUCALYPTUS, RADIATA
PINE, PERFORMANCE DATA, ENVIRONMENTAL PERFORMANCE, BEST AVAILABLE TECHNOLOGY.
pulpandpapercanada.com
Veracel
dling and disposal. Sludge disposal options include land application or incineration. The use of additional chemicals may also increase the discharge of inorganic salts in the final effluent. Tertiary treatment is considered in cases where receiving waters are of poor assimilative capacity, or otherwise restricted, and, as such, is identified as a supplemental or optional technology in recent BKP best technology reviews (Australia, 2004) [2].
ACKNOWLEDGEMENTS
The authors of this paper are grateful to the mill managers who have agreed to support this technical paper: Mr. Walter dos Santos Martins, Veracel Celulose; Mr Han Hong Liu, APP Hainan Jinhai; Mr Sergio Carreño and Mr José Vivanco, Celulosa Arauco y Constitución S.A., Valdivia.
LITERATURE
1. JOHNSON, A.P., JOHNSON, B.I., GLEADOW, P., SILVA, F.A., AQUILAR, R.M., HSIANG, C.J., ARANEDA, H. 21st Century Fibre lines, In Proceedings of International Pulp Bleaching Conference, Quebec City, p. 1 (2008). 2. Beca AMEC, “Independent Advice on the Development of Environmental Guidelines for any new Bleached Eucalypt Kraft Pulp Mill in Tasmania” for Resource Planning and Development Commission, Tasmania, http://www.rpdc.tas.gov.au/__data/ assets/pdf_file/0005/66335/Study_Report.pdf, Australia (2004). 3. RODDEN, G. The Birth of a Giant, Pulp and Paper International, 48:4 (2006).
September 2009
PULP & PAPER CANADA
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T126 RECYCLING
The Sticky Potential of Adhesive Applications from Printed Products By H.-J. Putz, S. Schabel, and A. Faul Abstract: A laboratory test method for the evaluation of the sticky potential of graphic paper products is described and values are presented which recycling-friendly paper products should fulfill. The test procedure helps to determine the recyclability of existing printed matter, but can also be used during the development of adhesives to improve the recyclability behavior during recovered paper processing. Examples of the sticky potential are given for different adhesive applications.
U
sually, paper as it is produced on paper machines is recyclable. During converting of paper into paper products materials can be applied on paper which can impair its recyclability, e. g. wax, printing ink, or adhesive applications. Usually, wax is related to packaging material only, ink is of relevance only for the reuse of printed matter in deinking mills, but adhesive is relevant for both graphic paper products as well as packaging material. Therefore, the behavior of adhesive applications during recycling is of particular interest for all paper mills using recovered paper.
POLITICAL ISSUES
In Germany, as well as in Europe, recycling targets exist for paper. In a way, Germany has become the front runner for the recycling politics of the European Union. The Packaging Ordinance regulates the recycling of packaging materials from paper, board, glass, plastic, and other materials. It was released in 1991 in Germany with targets to be fulfilled over time for each material. A similar law, the Packaging Directive, was issued for the EU in 1994. In Germany in 1994 an Ordinance on Avoidance, Recycling and Disposal of Waste was enacted, which became legislation in 1996 as the EU Council Resolution of “Strategy on Waste.” To avoid a special regulation on recycling of graphic paper products in Germany, in 1994 the graphic paper chain enacted a voluntary agreement about the recycling of graphic paper products. The recycling targets were fulfilled by the graphic paper chain and a prolongation was signed in 2001 to stabilize the recycling ratio for graphic paper products at a level of 80% ± 3% in the future. Another voluntary agreement was also presented by CEPI (Confederation of European Paper Industries) in 2000 with the first European Declaration on Recovered Paper. In contrast to 32
PULP & PAPER CANADA
September 2009
the German agreement, the European declaration covers all paper products and sets a recycling target of 56% in 2005 for all paper products. This first declaration was renewed in 2006 with a second declaration in which a higher recycling rate of 60% in was set for 2010 (www.paperrecovery.org). To make progress on improving the recyclability of graphic paper products the Task Force Deinking was established in 1997 within the German paper chain under guidance of INGEDE. This committee agreed one year later on a Guide to an Optimum Recyclability of Printed Graphic Paper. This guide was translated into English and signed by the following European associations: • CEPE (Conseil Européen de l’Industrie des Peintures, des Encres d’Imprimerie et des Couleurs d’Art) • CEPI (Confederation of European Paper Industries) • FAEP (Fédération Européenne d’Éditeurs de Périodiques) • FEICA (Fédération Européenne des Industries de Colles et Adhésifs) • INGEDE (International Research Association of the Deinking Industry) and • INTERGRAF (International Confederation for Printing and Allied Industries a.i.s.b.l.) The guide was released across Europe in 2002 and describes the actual status of the recycling of graphic paper products, their general requirements, and the demands for the future. Nevertheless, objective procedures and criteria are necessary to evaluate recyclability and to decide between poor or good recyclable graphic paper products. On a German level, a first draft of Orientation Values for the Recyclability of Printed Graphic Paper is being discussed in the Task Force Deinking as a supplement to the already signed “Guide.” The recyclability parameters and numerical values which are under discussion now
H.-J. PUTZ, Paper Technology and Mechanical Process Engineering (PMV) Darmstadt University of Technology Darmstadt, Germany
S. SCHABEL, Paper Technology and Mechanical Process Engineering (PMV) Darmstadt University of Technology Darmstadt, Germany
A. FAUL, INGEDE e.V. Bietigheim-Bissingen, Germany pulpandpapercanada.com
Deinking Chemicals
0.6 % Sodium Hydroxide 1.8 % Waterglass Hobart Pulper 0.7 % Peroxide m = 150 g b. d. Disintegration 0.8 % Surfactant t = 30 min T = 45 °C INGEDE c = 15 % Method 4 Somerville Classifier or Haindl Classifier m = 25 g b. d. m = 50 g b. d. Lab Screening t = 20 min t = 5 min // = 100 µm // = 100 µm n =6 n =3 • • VWater = 8.6 l/min VWater = 10 l/min
High Screenability of Stickies Low Sticky Conttent in Accept
Macro Sticky Size Distribution
Evaluation Parameters
Requirements
Share of Sticky Area ∅ < 2 000 µm, %
> 0 to ≤ 30 %
Sticky Area ∅ < 2 000 µm, mm2
≤ 4 000 mm²/kg b.d. paper product
Evaluation of the total reject of lab screening with 100 µm slot width
Reject Preparation
Macro Sticky Area
Figure 2: Orientation values for the sticky potential of adhesive applications.
FIG. 1. Simulation of lab scale adhesive fragmentation for printed matter according to INGEDE Method No. 12. Figure 1: Simulation of lab scale adhesive fragmentation for printed matter according to INGEDE Method No. 12.
100
Targets
Un de r
Adhesive Application Woodfree Copy Paper (Ash575°C = 20 % ± 3 %)
Di sc us si on
RECYCLING T127
FIG. 2. Orientation values for the sticky potential of adhesive applications.
Removal Efficiency, %
80
60
40
20
0 0
1,000
2,000
3,000
4,000
5,000
Sticky Size, µm
Limit of complete screenability of stickies with an equivalent circle diameter of 2 000 µm Figure 3: Removal efficiency of macro stickies by pilot screening depending on sticky size in pilot
FIG. 3.trials.Removal efficiency of macro stickies by pilot screening depending on sticky size in pilot trials.
are based on results obtained after the development of laboratory test methods for the evaluation of the recyclability which were initiated and financed by INGEDE.
DEFINITIONS
The Recycling Technology sub-committee of the German association of pulp and paper engineers and chemists, ZELLCHEMING, has defined the term stickies as the tacky components resulting from the raw material recovered paper [1, 2]. The term tacky component is a generic term which covers also pitch or white pitch. Stickies are classified according to their sources as primary and secondary stickies. The first group of stickies is introduced by the recovered paper and creates tacky particles under testing conditions. Secondary stickies are also tacky under testing conditions, but those particles originate from physico-chemical effects during recovered paper processing. A differentiation between macro and micro stickies is given by their size. Criterion of the determination is the dimension of the slot width during laboratory screening. For graphic papers a slot width of 100 µm is recommended. Detected stickies in the reject (overflow) are named as macro stickies, whereas the tacky particles in the accept (through flow) are named as micro stickies. Due to the three dimensional shape of the sticky particles, the slot width is the differentiation criterion in macro and micro stickies only, but does not correspond to the maximum dimension of the sticky particles in the accept. pulpandpapercanada.com
Numerous small stickies. In comparison unfavourable fragmentation.
Larger sticky particle size distribution. More advantageous fragmentation.
Exclusive large stickies. Optimum fragmentation.
Figure 4: Samples of the macro sticky evaluation of bookbinding adhesives. FIG. 4. Samples of the macro sticky evaluation of bookbinding adhesives.
TEST METHODS
The test method for the evaluation of macro stickies from adhesive applications on graphic paper products is described in detail in the INGEDE Method No. 12. Figure 1 includes the final modifications made in an INGEDE project and published at www.ingede.com [3]. Beside improved explanations in the method, the most important modifications are related to: – the material used for pulping (woodfree copy paper instead of short fibre pulp) – the screening device (the Somerville screen is allowed in addition to the Haindl classifier) – the image analysis system (the Simpatic system is allowed in addition to the Domas system). For the determination and visualization of the sticky particles in the screening reject, INGEDE Method No. 4 is used [4]. This method applies aluminum oxide powder with a certain grain size instead of the marking paper in the TAPPI “Pick-Up” Method T277 [5], better known in North America. From test comparisons with DIP we know that both methods give similar results and show the same trends, but the INGEDE method is more sensitive for pulps with low sticky content.
STICKY EVALUATION CRITERIA
The criteria evaluated for the differentiation of the sticky potential of adhesive applications are accepted by Task Force Deinking. Currently, the numerical values which have to be fulfilled by a recycling-friendly adhesive application are under discussion. September 2009
PULP & PAPER CANADA
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T128 RECYCLING
100
Cumulative Macro Sticky Area, %
75 E 115 Helico Pulper E 115 Hobart Pulper
50
USPS Helico Pulper USPS Hobart Pulper
25
0 0
FIG. 5. Assessment of the sticky potential test according to INGEDE Method No. 12.
1.000
5 724
Cumulative Macro Sticky Area ≤ 2 000 µm Ø, %
5.000
Macro Sticky Area ≤ 2 000 µm Ø, mm²/kg b.d. Orientation Value
40
4.000
30
3.000
20
2.000
10
1.000 0 1
2
3
4
5
6
Private
7
8
9
1
2
3
4
Catalogues / Business
1
2
3
4
5
6
Magazines
7
8
9 10 1
Figure 7: Cumulative macro sticky area below 2000 µm in percent for bookbinding back.
2
3
Two parameters are observed at the moment. These are: the proportion of the sticky area (in percent) of all particles below an equivalent circle diameter of 2000 µm; and the total area of all particles below this equivalent circle diameter of 2000 µm should not exceed a certain level per kilogram of printed matter. Figure 2 shows the numerical values currently discussed in this context. The 2000 µm size limit for the macro stickies was determined by a pilot scale trial with identical adhesive applications at Voith Paper in Ravensburg, Germany and by lab scale trials. The adhesive applications used were hotmelt and dispersion adhesives for catalogue binding, a thin film dispersion adhesive, and a PSA with a total adhesive mass of 0.2 % related to paper. After high consistency pulping with deinking chemicals it was found in the accept of the pilot scale screening process (three stage forward) with 150 µm slot width, that no more macro stickies were observed by the lab test according to INGEDE Method No. PULP & PAPER CANADA
September 2009
4
Business Reports
FIG. 7. Cumulative macro sticky area below 2000 µm in percent for bookbinding back.
34
4.000 5.000 6.000 Equivalent Circle Diameter, µm
Figure 6: Cumulative macro sticky area after pilot and lab disintegration of two different PSAs.
Orientation Value
0
3.000
FIG. 6. Cumulative macro sticky area after pilot and lab disintegration of two different PSAs.
88
50
2.000
1
2
3
4
5
6
Private
7
8
9
1
2
3
4
Catalogues / Business
1
2
3
4
5
6
7
Magazines
8
9 10 1
2
3
4
Business Reports
Figure 8: Cumulative macro sticky area below 2000 µm in mm²/kg for bookbinding back.
FIG. 8. Cumulative macro sticky area below 2000 µm in mm²/kg for bookbinding back.
4. Figure 3 shows the removal efficiency of macro stickies in this pilot trial. Stickies above 2000 µm equivalent circle diameter are no longer detected in this pulp. Similar results with other adhesive applications were obtained in pilot trials at the CTP in Grenoble [6]. Additionally, we examined in modern DIP lines that after fine screening practically no macro sticky particles above a equivalent circle diameter of 2000 µm can be observed with the sticky determination method described. Based on the two parameters established by INGEDE, the goal becomes to have adhesive applications fragment into sticky particles that are as large as possible. The larger the particles after pulping the higher the possibility that they can be removed during an industrial screening process. Figure 4 shows three examples for bookbinding adhesives which result in a different fragmentation behavior. From the point of view of the most recyclingfriendly adhesive application, the example on the right hand side with the largest
sticky particles shows the most promising behavior during recycling. We examined the frequency distribution of the sticky particle size on the basis of the two parameters evaluated in the sticky potential test – the proportion of the sticky area below 2000 µm in percent compared to the total sticky area and the absolute sticky area below 2000 µm equivalent circle diameter. Figure 5 makes it evident that the theoretical distribution curve of the adhesive application A is better, compared with application B. Adhesive application A creates larger particles and the sum of all particles below 2000 µm is on a lower level in total. The pulping conditions in INGEDE Method No. 12 were developed in a way that the fragmentation behavior of the adhesive applications in lab and pilot scale are similar. Figure 6 shows the cumulative macro sticky area of two PSA applications pulped in lab scale (Hobart Pulper) in comparison to pilot pulping (Helico Pulper). It is obvious that for both PSAs pulpandpapercanada.com
RECYCLING T129
100
Cumulative Macro Sticky Area ≤ 2 000 µm Ø, %
Macro Sticky Area ≤ 2 000 µm Ø, mm²/kg b.d.
120.000
90
Orientation Value: 30 %
109367
Orientation Value: 4 000 mm²/kg
80
90.000
70
84279
60 50
62976
60.000
40
58521 46011
43566
30
28264
30.000
20
27718
10 0 1
2
3
4
5
6
7
8 Magazine
Figure 9: Cumulative macro stickymacro area below 2000 µm in percent PSA applications FIG. 9. Cumulative sticky area belowfor2000 µm in on magazines.
percent for PSA applications on magazines.
100
80
0 1
Orientation Value
3
4
5
6
1.000.000
8
Magazine
Macro Sticky Area ≤ 2 000 µm Ø, mm²/kg b.d. 9 = PSA products which fulfill both parameters
Orientation Value
| = PSA products which almost fulfill both parameters
100.000 10.000
60
7
10. Cumulative sticky area below 2000 µm inon FigureFIG. 10: Cumulative macro sticky macro area below 2000 µm in mm²/kg for PSA applications magazines. mm²/kg for PSA applications on magazines.
Cumulative Macro Sticky Area ≤ 2 000 µm Ø, % Model Suppositions: Attached PSA Area: 600 cm² Magazine Weight: 200 g
2
9
|
|
|
9
1.000
40
9
100
20
0
10
1
2
3
4
5
6
7
8
9
USPS Approved
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Supplier 1 (S1)
Supplier 2
SX
Figure 11: Cumulative macro sticky area below 2000 µm in percent PSAs in model FIG. 11. Cumulative macro sticky area forbelow 2000tests. µm
percent for PSAs in model tests.
the sticky size distribution and the result ing cumulative sticky areas are comparable between lab and pilot scale.
S1
in
1
1
2
3
4
5
6
7
10
11
12
13
14
15
16
17
18
19
Supplier 1 (S1)
20
21 22
23
24
25
26
27 28
Supplier 2
29
30
31 32
SX
33 34
35
36
S1
in
mm²/kg for PSAs in model tests.
The following results are related to lab scale trials with several adhesives, pulped with beech sulphite chemical pulp which was the former fibre raw material for this test according to INGEDE Method No. 12. All screenings were performed with the Haindl classifier equipped with a 100 µm screen plate. The adhesive applications tested were: • Public catalogues • Business catalogues • Magazines • Business reports • PSAs on magazines • PSA sheets used for model calculations. Bookbinding Backs Figure 7 shows the share of macro stickies below 2000 µm for adhesive applications on magazines, catalogues, and business
Pressure Sensitive Adhesives (PSA) The observed results look very different for PSA applications in magazines. In Europe, for special events such as Christmas, Eas
pulpandpapercanada.com
9
FigureFIG. 12: Cumulative macro sticky area below 2000 µm in mm²/kg PSAs in model 12. Cumulative macro sticky areaforbelow 2000tests. µm
reports. Most of these adhesive applica tions are based on hot melts. Except for three samples, all the other applications fulfill the requirement of a maximum pro portion of 30% for the total sticky area of all particles below an equivalent circle diameter of 2000 µm. A similar result is presented in Fig. 8 for the total sticky particle area below 2000 µm per kilogram of o. d. pulp. Two of the three samples mentioned before also exceed the orientation value of 4000 mm²/ kg for adhesive applications. In general, the adhesive applications for bookbinding backs seem to be not critical regarding the actual orientation values for stickies, at least for hot melt applications. In the future it is possible that lower orientation values will be stipulated for this type of adhesive applications.
RESULTS
8
USPS Approved
ter, or Valentine’s Day many magazines add a large PSA page with stickers around the magazine cover which can be used for several purposes. If such magazines enter the recycling mills to a certain degree – especially as returned magazines in which the area of PSA becomes very high com pared to paper mass – almost every paper mill could experience serious sticky prob lems. Figure 9 makes obvious that the 30% proportion for the cumulative particle area below 2000 µm equivalent circle diameter is exceeded by all products except one. Most of the products have a proportion above 75%. In Fig. 10 the total sticky area of all particles below 2000 µm equivalent circle diameter is shown. The orientation value of 4000 mm²/kg is exceeded manifold. The best of the eight PSA products con tributes with an area of 28 000 mm²/kg print product (No. 1) to the sticky load of the recovered paper. Eighty percent of the particles removed by lab screening are larger than 2000 µm equivalent circle diameter. A September 2009
PULP & PAPER CANADA
35
T130 RECYCLING second PSA product creates a similar sticky area of about 28 000 mm²/kg print product (No. 7). In contrast, this area is formed by 91% from particles below 2000 µm equivalent circle diameter which are in general more difficult to be removed completely by industrial screening. Additionally, it has to be expected that an adhesive application which fragments to 90% in particles below 2000 µm equivalent circle diameter creates a much higher proportion of particles which are below the scanner-based sticky detection limit of 100 µm compared to an adhesive application which contributes only to 20% of particles between 100 µm and 2000 µm. These particles – below 100 µm – are by definition micro stickies and it can be expected that they are only removed to a certain extent by industrial screening. The result obtained until now for PSA application on magazines does not indicate if a recycling-benign PSA application does exist. More than 35 different types of PSA were tested from various suppliers in a model test performed with 100 cm² PSA in 150 g o. d. chemical pulp. Several USPS-approved PSAs, European market products, and experimental adhesives were used in the test. Figure 11 shows the cumulative sticky area in percent for all particles below 2000 µm equivalent circle area. Twenty-five percent of all PSAs fulfill the first criteria of the orientation value of ≤ 30 %. Some of the best products are solvent-based adhesives. Products which obtain more than 80% of particles below 2000 µm might be classified as redispersible adhesives. For the model calculation of the PSAs used for a magazine cover, it was assumed a PSA application area of 600 cm² and a magazine weight of 200 g which corresponds at 60 g/m² to a magazine volume of about 55 pages. Figure 12 shows the result of the cumulative macro sticky area below 2000 µm equivalent circle diameter for the given model suppositions. It becomes obvious that only three PSAs fulfill both requirements completely (marked with a check ✓). The one column below 4000 mm²/kg without the check (No. 12) creates a low sticky area below 2000 µm equivalent circle area, but has a proportion of more than 80% in this size category and is definitely a redispersible PSA.
36
PULP & PAPER CANADA
September 2009
Three other PSA products almost achieve the second requirement of the orientation values (4000 mm²/kg) and are therefore marked with a circle ❍. At least four of these six PSA products are solventbased PSA and one at least is available on the European market. We are looking forward to performing with INGEDE an industrial trial in printing, converting, and manufacturing of a PSA cover for a magazine with such a recycling-benign adhesive application to confirm the lab findings with pilot trials.
CONCLUSIONS
For paper products, recyclability should become a quality criterion such as runnability, strength characteristics, or printability. In terms of graphic paper products, recyclability comprises deinkability and the sticky potential of adhesive applications. The developed laboratory test method serves for the evaluation of the sticky potential of adhesive applications on printed products. This laboratory INGEDE Method No. 12 was proven in pilot scale trials at two different locations regarding the sticky fragmentation behavior of adhesive applications. The comparison of lab and pilot scale trials shows good agreement of sticky fragmentation values, which is a prerequisite for a laboratory screenability test of stickies. From pilot scale it becomes evident which particle size spectrum of stickies is required to achieve maximum separation efficiency during industrial screening processes. Numerical values are under discussion for recycling-friendly adhesive applications. This criterion includes the proportion of the sticky area (in percent) as well as the
total area related to the mass of the print product below 2000 µm equivalent circle diameter. From the results of various adhesive applications (bookbinding backs of magazines, catalogues, business reports, PSAs) it becomes obvious that the development and use of a recycling-friendly PSA is much more difficult than for bookbinding back. In bookbinding several products exist which do not cause serious sticky problems, whereas only a few recycling-benign types of PSA exist which fulfill the actual requirements of INGEDE. In general, recycling-friendly adhesive applications should be improved in their screenability by high cohesive films. This can be realized by high softening points of the films, hard films, and chemical curing. Thick adhesive applications also improve the cohesion of the film and that means that bead or film applications are better than dot applications. INGEDE will continue to work with all parties in the paper chain on general improvements of the recyclability of printed matter.
LITERATURE
1. FAUL, A. Stickies terminology – the ZELLCHEMING approach. Progress in Paper Recycling 11(2): 66-69 (2002). 2. ANONYMOUS. Terminology of Stickies. ZELLCHEMING-Arbeitsblatt RECO 1/2006, Darmstadt, 2006. www.zellcheming.de 3. ANONYMOUS. Assessing the recyclability of printed products – Testing of fragmentation behaviour of adhesive applications. INGEDE Method No. 12, INGEDE, Munich, Draft 2003. 4. ANONYMOUS. Evaluation of Macro stickies in deinked pulp (DIP). INGEDE Method No. 4, INGEDE, Munich, 12/1999 5. ANONYMOUS. Macro stickies content in pulp: the “pick-up” method. TAPPI Method T 277 pm-99, TAPPI, Atlanta, 1999. 6. WITTSTADT, U., PUTZ, H.-J., SCHABEL, S. Recyclability of printed products 2002. INGEDE Final Report 8402 IfP, Darmstadt, 2004.
Résumé: Nous décrivons une méthode d’essai en laboratoire permettant d’évaluer le potentiel adhésif des produits de papiers graphiques et indiquons les valeurs requises des produits de papier aptes au recyclage. La méthode d’essai aide à déterminer la recyclabilité des matières imprimées, mais elle peut aussi être utilisée pour le développement d’adhésifs visant à améliorer la recyclabilité lors du traitement du papier recyclé. Nous donnons des exemples du potentiel adhésif de différentes applications. Reference: PUTZ, H.-J., SCHABEL, S., FAUL, A. The Sticky Potential of Adhesive Applications
from Printed Products. Pulp & Paper Canada 110(7): T126-T130 (Sept. 2009). Paper presented at the Recycling Conference 2004 in Quebec, Que., September 27 - 29, 2004. Not to be reproduced without permission of PAPTAC. Manuscript received June 23, 2004. Revised manuscript approved for publication by the Review Panel Dec. 2, 2008.
Keywords: RECYCLABILITY, GRAPHIC PAPER PRODUCTS, STICKY FRAGMENTATION, ADHESIVES, TEST METHOD.
pulpandpapercanada.com
BRIGHTNESS T131
Mill Trial of the New Bleaching Agent – THPS By: T.Q. Hu, T. Williams, J.A. Schmidt, B.R. James, R. Cavasin, and D. Lewing Abstract: An eight-day mill trial of adding tetrakis(hydroxymethyl)phosphonium sulfate (THPS) (at 1.0 kg THPS/t pulp) to hydrosulfite (Y) bleaching of spruce SGW pulp shows an average, additional brightness gain of 2.0-2.3 ISO points without any bleach plant or paper machine process upsets. This additional brightness gain, sustained during subsequent one-year commercial implementation of the “THPS + Y” bleaching technology, allows the mill to reach brightness target during the difficult summer period, and to reduce the consumption of expensive brightness-enhancing additives for LWC papers. Overall estimated cost saving to the mill is ~$250,000/year.
I
ndustrial bleaching of mechanical pulps is currently achieved by the use of alkaline hydrogen peroxide [1] and/ or sodium hydrosulfite (i.e. sodium dithionite) [2]. Alkaline hydrogen peroxide, in the presence of peroxide stabilizers such as sodium silicate and magnesium sulfate, is capable of providing a brightness gain of up to ~25 ISO points to most mechanical pulps. However, alkaline peroxide reduces the pulp yield by 2-5% and produces effluent with high chemical oxygen demand [3] due to oxidative degradation of lignin and hemicelluloses from the fibres. Sodium hydrosulfite is a cheap and selective bleaching agent currently used by 45 mills in Canada and in the US to bleach ~12 million tonnes of mechanical pulps/year. However, hydrosulfite can only provide a maximum brightness gain of ~10 ISO points to most mechanical pulps. In addition, hydrosulfite-bleached pulps are highly unstable; they undergo rapid brightness reversion when they are, for example, diluted with neutral paper machine white water and stored at elevated temperatures. The brightness ceiling and the brightness reversion of hydrosulfite-bleached pulps often make it difficult for mills to achieve the brightness targets for their products when the incoming wood is darker (e.g. during summer months) or when mills wish to produce higher brightness papers. Several other chemical agents capable of bleaching mechanical pulps have been reported over the past few decades [4-12]. Such bleaching has been achieved with, for example, sodium borohydride [4], thiols [5], formamidine sulfinic acid (FAS) [7], amino boranes [10], or a spirophosporane [11]. None of these agents has been used commercially for the bleaching of virgin mechanical pulps because of their high cost (e.g. sodium pulpandpapercanada.com
borohydride), high toxicity (e.g. thiol), or low bleaching ability (e.g. spirophosphorane). FAS has found applications in the bleaching and/or colour stripping of recycled fibres including mixed office waste [13,14]. Recently, Hu, James, and co-workers discovered that H2O-soluble, tertiary hydroxyalkyl phosphines and quaternary hydroxymethyl phosphonium salts are effective bleaching and brightness stabilizing agents for mechanical pulps [15-20]. These phosphorus (P) compounds have a bleaching power similar to or higher than that of sodium hydrosulfite, but are less sensitive to pH, consistency, and elevated temperature [15-19], and produce bleached pulps with higher thermal
T.Q. HU FPInnovations – Paprican Division, Vancouver, B.C. Thomas.Hu@fpinnovations.ca
T. WILLIAMS FPInnovations – Paprican Division, Vancouver, B.C.
R. CAVASIN Cytec Canada Inc., Niagara Falls, Ont. B.R. JAMES Dept. of Chemistry, UBC, Vancouver, B.C.
J.A. SCHMIDT FPInnovations – Paprican Division, Pointe Claire, QUE. September 2009
D. LEWING Cytec Canada Inc., Niagara Falls, Ont.
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T132 BRIGHTNESS stability [20]. Among the P-compounds discovered, tetrakis(hydroxymethyl) phosphonium sulfate (THPS), [P(CH2OH)4]2SO4, is the most promising candidate for commercialization because it is extremely water-soluble, air-stable, and is commercially available in large quantities (~10,000 tonnes/annum). Commercial, 75% solution of THPS, prepared from the reaction of phosphine, PH3, with 4.0 molar equivalents of formaldehyde, HCHO, and 0.5 molar equivalent of sulfuric acid, H2SO4 [21], is stable for months in the presence of air. THPS is used to make flame retardants for cotton and cellulose fabrics [22], as an iron-sequestering agent in oil fields [23], as a leather tanning agent, and as an environmentallyfriendly biocide for sulfate-reducing bacteria in industrial watertreatment including paper mill white water treatment [24]. Aqueous solutions of THPS are acidic (pH ~3.2) due to the small dissociation of THPS to tris(hydroxymethyl)phosphine (THP), P(CH2OH)3, formaldehyde, HCHO, and sulfuric acid (Eq. 1) (pKd = 12.20) [25,26]:
When THPS comes into contact with pulp slurries that have a pH of 5.0 to 7.0, the equilibrium will be shifted to the right and THP will become one of the dominant species in the solutions. THP, capable of undergoing nucleophilic addition to the C=C-C=O units in lignin chromophores such as coniferaldehyde and 2-methoxy-p-benzoquinone [27], is likely the active species in THPS bleaching. Although THP can be made from the reaction of PH3 with 3.0 molar equivalents of HCHO and is cheaper than THPS on the same molar phosphorus basis, it is not produced or used on a commercial scale because of its low stability. Previously, Hu, James, and co-workers have shown that THPS provides an ISO brightness gain of 7.7 and 10.5 points to a spruce TMP (from 58.2 to 65.9%) and a lodgepole pine TMP (from 54.6 to 65.1%), respectively [17,18]. In this report, we describe a laboratory evaluation and a successful eightday mill trial of THPS as a complementary bleaching agent to sodium hydrosulfite (Y) in the bleaching of spruce stone groundwood (SGW) pulp. During the mill trial and subsequent one-year commercial implementation, we combined a commercial THPS solution with the hydrosulfite solution near the bleach tower, and we designated such one-stage bleaching “THPS + Y” bleaching.
Methods and Materials
General Tetrakis(hydroxymethyl)phosphonium sulfate (THPS), [P(CH2OH)4]2SO4, was provided as a 75% solution (pH = ~3.2, specific gravity = 1.41 at 20°C) by Cytec Canada (Niagara Falls, Ont.) for both the laboratory bleaching and the mill trial. For the laboratory bleaching, the active THPS concentration was determined based on the procedure for the quantitative determination of tris(2-carboxyethyl)phosphine [28]. Sodium hydrosulfite (Y), Na2S2O4, was purchased from Fisher Scientif38
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ic and its active concentration determined according to TAPPI Test Method T622 cm-01 [29]. Spruce stone groundwood (SGW) pulp slurry (~4.0% Cs) was taken at the exit of the SGW storage in a Paprican member mill. The pulp slurry was dewatered in the lab to ~20% Cs to allow for accurate Cs determination. The filtrate (pH 5.0) was saved aside in a refrigerator and used for the laboratory bleaching experiments (see below) while the pulp was frozen to maintain stable brightness. All chemicals doses used for the lab bleaching are reported in percentage with respect to oven-dried (o.d.) weight pulp. Laboratory sodium hydrosulfite (Y), THPS, or “THPS + Y” bleaching For Y or THPS bleaching, the dewatered spruce SGW pulp (4.0-20 g o.d.) was combined with a known amount of the saved filtrate and Y (0.2-1.0%) or THPS (0.1-1.0%) in a polyester bag to give a 4.0% Cs pulp slurry. For “THPS + Y” bleaching, Y (0.2-1.0%) was combined with 0.1% THPS in a small amount of the saved filtrate, and added along with a known amount of the saved filtrate to the dewatered spruce SGW pulp (4.0-20 g o.d.) in a polyester bag to give a 4.0% Cs pulp slurry. The bag was sealed with minimal headspace above the pulp slurry, and immersed in a water-bath heated at 65°C for 1.0 h with hand-mixing of the bag after 10 minutes. The polyester bag was cooled in a water-bath to ~20°C. The pulp was diluted with deionized (DI) water to 0.5-1.0% Cs, and the pulp slurry was filtered with the filtrate being recycled once to recover the fines. The same dilution and filtration were then repeated once. Handsheets (200 g/m2) of the Y-, THPS- or “THPS + Y”-bleached pulps were prepared according to PAPTAC Test Methods (Standard C.5) [30], and their ISO brightness determined in a Technibrite Micro TB-1C instrument (Technidyne Co., New Albany, IN) according to PAPTAC Test Methods, Standard E.1 [31]. Mill trial of “THPS + Y” bleaching THPS (Cytec Canada,) was added via an L-shaped, stainlesssteel tubing (see Fig. 3) to the sodium hydrosulfite addition line ~0.3 m away from the pulp line connecting the unbleached SGW storage tank and the up-flow bleach tower in the groundwood plant at the mill. The L-shaped stainless-steel tubing was connected with a nylon tubing (3/8 inches) to a ProMinent SIGMA/1 pump (ProMinent Fluid Controls Ltd. Guelph, Ont.) and then to a THPS tote (see Fig. 3). The flow rate of THPS was manually adjusted on the pump to give a dosage of 1.0 kg/t pulp (i.e. 0.1% THPS) based on the SGW pulp production rate. The addition rate of sodium hydrosulfite (Y) was controlled at 8.0 kg/t pulp (i.e. 0.8% Y) prior to, during, and after the mill trial. Unbleached and bleached pulp slurries were taken manually once every four hours or longer at the exit of the SGW pulp storage tank and at the exit of the down-flow bleach tower, respectively (see Sampling Points A and B in Fig. 4). The temperature and the pH of the pulp slurries were measured immediately after sampling. Handsheets (200 g/m2) of the pulps were prepared according to PAPTAC Test Methods (Standard C.5) [30], and their ISO brightness determined in a Technibrite Micro TB-1C instrument according to PAPTAC Test Methods, Standard E.1 [31]. pulpandpapercanada.com
BRIGHTNESS T133 Results and Discussion
Trial background The mill bleached its spruce SGW pulp (typical ISO brightness = 64-66%, full production rate = ~350 metric tons/day) with 0.8-1.0% sodium hydrosulfite (Y) at 4.0% Cs, pH 5.0 and ~65°C. The bleaching occurred in an up-flow tower followed by a down-flow tower with a combined retention time of 1.0 h. Some of the Y-bleached pulp exiting the down-flow bleach tower was sent to paper machines (PMs) 2 and 3 that were run under acidic papermaking conditions. The rest of the Y-bleached pulp exiting the down-flow bleach tower was dewatered through a twin-wire press to ~35% Cs (to remove the acidic filtrate), diluted with neutral PM 4 white water to 4.0% Cs, and stored in a bleached pulp storage tank at pH ~6.8 and 50°C for up to 6.0 h before being sent to PM 4 to make LWC papers (see Fig. 4). Trim bleaching of the stored, Y-bleached pulp going to PM 4 with up to 1.0% sodium hydrosulfite was often needed to meet the ISO brightness target (~70%) of the LWC papers. When producing hi-brite (≥75% ISO brightness) LWC papers or when the ISO brightness of the unbleached SGW pulp was < 63%, the mill usually needed to add expensive brightness-enhancing additives in the coating formulation. The mill was interested in the possible use of THPS to: 1) achieve the same brightness target with less bleach chemical; 2) overcome the brightness ceiling of Y bleaching so that ~70% ISO brightness target could be achieved when the brightness of the chips/unbleached SGW pulp was low (e.g. in the summer months); and/or 3) reduce the dosage of expensive brightnessenhancing additives when producing hi-brite LWC sheets. Laboratory evaluation of THPS and “THPS + Y” bleaching We first evaluated the bleach response of the spruce SGW pulp (ISO brightness = 66.2%) to Y and to THPS bleaching, respectively, at 4.0% Cs, pH 5.0 and 65°C in the laboratory. We found that at lower bleach chemical charges, THPS gave slightly higher brightness gain than Y, but at higher charges, THPS gave lower brightness gain than Y (Fig. 1). The lower bleach response of the pulp to THPS than to Y at higher bleach chemical charges was likely due to the incomplete reaction of ≥0.5% THPS with the pulp within 1.0 h at 65°C. Bleaching of the spruce and lodgepole pine TMP pulps to give an ISO brightness gain of 7.7 and 10.5
Fig. 1. Bleaching of the SGW pulp (ISO brightness = 66.2%) with sodium hydrosulfite (Y) or THPS at 4.0% Cs, pH 5.0 and 65°C for 1.0 h. pulpandpapercanada.com
points, respectively, with THPS was done at 90-130°C for 3.0 h [17,18]. We next studied the bleaching of the spruce SGW pulp with 0.1% THPS and 0.2-1.0% Y combined in one-stage as an attempt to use THPS more effectively. These experiments were done based on the following considerations: 1) because the bleaching reaction of THPS with pulp was slow at 65°C, complete reaction of THPS with pulp over one hour would likely occur only at ≤0.2% THPS; 2) because THPS is more expensive than hydrosulfite, use of 0.1% THPS and perhaps ≥0.5% Y would be more economical; 3) because the bleaching chemistry of THP, the likely active species involved in the bleaching of the pulp with THPS, is different from that of hydrosulfite [27], a combination of THPS and Y might achieve a higher brightness than using either chemical alone; and 4) one-stage, simultaneous use of THPS and Y would be easy to implement in the mill. The results of our laboratory study are shown in Fig. 2 and Table I. Y bleaching was able to provide a maximum ISO brightness gain of 3.0 points to the SGW pulp (from 66.2 to 69.2%). When 0.1% THPS was used by itself to bleach the pulp, an ISO brightness gain of 0.9 point was obtained. Surprisingly, combining 0.1% THPS and Y produced a synergistic bleaching effect on the pulp at ≥0.35% Y and particularly at TABLE I. Results from laboratory bleaching of the SGW pulpa with hydrosulfite (Y) and/or THPS THPS (%)
Y (%)
0.1 – 0.1 – 0.1 – 0.1 – 0.1 – –
– 0.35 0.35 0.5 0.5 0.75 0.75 1.0 1.0 1.5 2.0
ISO Brightness ∆Brightness (%) (ISO point) 67.1 67.6 68.7 68.6 70.1 69.1 70.6 69.2 71.2 68.8 69.1
0.9 1.4 2.5 2.4 3.9 2.9 4.4 3.0 5.0 2.6 2.9
Synergyb (ISO point) – – 0.2 – 0.6 – 0.6 – 1.1 – –
ISO brightness of the unbleached SGW pulp = 66.2%; bSynergy = ∆Brightness(THPS + Y) - ∆Brightness(THPS) - ∆Brightness(Y). a
Fig. 2. Bleaching of the SGW pulp (ISO brightness 66.2%) with sodium hydrosulfite (Y) or “0.1% THPS + Y” at 4.0% Cs, pH 5.0 and 65°C for 1.0 h. September 2009
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T134 BRIGHTNESS ≥0.50% Y (Table I). For example, bleaching of the pulp with 0.1% THPS and 1.0% Y produced a synergy of 1.1 ISO points; the synergy equals brightness gain from “0.1% THPS + 1.0% Y” bleaching minus brightness gain from 0.1% THPS bleaching minus brightness gain from 1.0% Y bleaching = 5.0 – 0.9 – 3.0 = 1.1. Because of such a synergy, adding 0.1% THPS to 1.0% Y bleaching provided an additional ISO brightness gain of 2.0 points to the pulp (i.e. the brightness ceiling of Y-bleached pulp was raised by 2.0 ISO points). Without the use of THPS, an increase of Y dosage from 1.0 to 1.5 or 2.0% failed to overcome the brightness ceiling of Y bleaching at a maximum ISO brightness gain of 3.0 points (Table I). In separate studies, we have found that whether and how much synergy can be achieved with “THPS + Y” bleaching depends on the sodium hydrosulfite formulation, the pulp type, the temperature profile (preheating vs. no preheating) of the pulp immediately before the addition of the bleach chemical, the efficiency of air removal, and the bleaching pH. We have also found that onestage, “THPS + Y” bleaching with a weight ratio of Y/THPS ≥6.0 removes the formaldehyde formed from the dissociation of THPS to THP through the reaction of formaldehyde with Y or bisulfite (a by-product of Y bleaching). The removal of formaldehyde from the bleaching system is important because formaldehyde is an irritant for the respiratory tract. Mill trial of “THPS + Y” bleaching Encouraged by the laboratory “THPS + Y” bleaching results, a mill trial of adding 1.0 kg THPS/t pulp (i.e. 0.1% THPS) to the Y bleaching of the SGW pulp was conducted in June 2005. The objectives of the mill trial were: 1) to quantify the additional
brightness gain provided with 1.0 kg THPS/t pulp; and 2) to determine whether the addition of THPS to the Y bleaching would cause any process upsets in the bleach plant or on the paper machine. For the mill trial, an L-shaped, stainless-steel tubing was connected to the sodium hydrosulfite (Y) addition line ~0.3 m away from the pulp line connecting the SGW storage tank and the up-flow bleach tower (Fig. 3). This L-shaped, stainless-steel tubing was connected with nylon tubing to a ProMinent SIGMA/1 pump and then to the THPS tote (~1.4 tons of THPS on 100% basis). The addition rate (0.0 or 1.0 kg/t pulp) of THPS was controlled manually on the SIGMA pump based on the pulp production rate. The addition rate for Y was automatically controlled by the mill’s control system at 8.0 kg/t pulp (i.e. 0.8% Y) prior to, during and after the “THPS + Y” bleaching trial. Samples of the pulp slurries were manually taken once every four hours or longer at various locations with the key sampling points being at the exit of the spruce SGW storage tank (Sample Point A) and at the exit of the down-flow bleach tower (Sample Point B) (Fig. 4). The temperature and pH of the pulp slurries were measured immediately after sampling, and the ISO brightness values of the pulps were measured on the handsheets made from the pulps. TABLE II. Dataa for mill trial of “THPS + Y” bleaching, sodium hydrosulfite charge was 8.0 kg/t THPS ISO Brightness ISO Brightness ∆Brightness Unbleached (kg/t) (%) at sample (%) at sample (ISO) point pulp temp. point Ab point Bb (C°) (unbleached) (unbleached) – 1.0 1.0 1.0 1.0 1.0 1.0 1.0
64.2 65.0 63.9 64.9 61.9 63.4 62.9 62.5
68.7 71.7 69.9 70.1 70.1 71.1 70.5 68.9
4.5 6.7 6.0 5.2 8.2 7.7 7.6 6.4
68 67 62 63 77 72 71 70
From samples collected over 3 days; b(See Fig. 4 for location of sample point).
a
Fig. 3. Set-up for the “THPS + Y” bleaching mill trial.
Fig. 4. Simplified bleaching process diagram in the bleach plant and the two key sampling points A and B during mill trial of “THPS + Y” bleaching.
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Fig. 5. ISO Brightness gain of 0.8% Y and “0.1% THPS + 0.8% Y” bleaching vs. bleached and unbleached pulp slurry temperatures, respectively, from the analysis of samples collected over 50 days. pulpandpapercanada.com
BRIGHTNESS T135 Data collected over the first three days of the mill trial are listed in Table II. Before THPS was added to the system, control Y bleaching samples were taken and analyzed. The ISO brightness gain from the Y bleaching was 4.5 points (from 64.2 to 68.7%). Such a brightness gain was typical of what the mill had been able to achieve with 8.0 kg Y/t pulp. A few hours after the “THPS + Y” bleaching had been started and the system reached a steady state, samples were taken again and analyzed. The ISO brightness gain from the “1.0 kg THPS/t pulp + 8.0 kg Y/t pulp” bleaching was 6.7 points (from 65.0 to 71.7%), 2.2 points more than the control Y bleaching. The next six sets of samples taken from the “THPS + Y” bleaching all gave superior results with the ISO brightness gains ranging from 5.2 to 8.2 points (Table II). It was noticed that the highest brightness gain of 8.2 points was achieved on the unbleached pulp with the highest temperature (77°C) while the lowest brightness gains (5.2 and 6.0 points) were obtained on the unbleached pulps with the lowest temperatures (≤63°C) (Table II). Encouraged by these results, the “THPS + Y” bleaching was allowed to run for 5 more days and twelve additional sets of pulp samples were taken and analyzed. Eight additional sets of pulp samples for the control Y bleaching were also taken and analyzed several hours after THPS addition stopped and the system reached a steady state. These control Y bleaching samples were taken over a period of 42 days. Figure 5 shows the brightness gains of the Y bleaching and of the “THPS + Y” bleaching vs. the bleached and the unbleached pulp slurry temperatures, respectively, from the analyses of these additional samples and those shown in Table II. The brightness gain from the Y bleaching correlated linearly (with R2 = 0.8706) to the bleached pulp temperature. The brightness gain from the “THPS + Y” bleaching correlated linearly with the unbleached pulp temperature, but the data were more scattered (R2 = 0.4861) than those from the Y bleaching. Nonetheless, an average, additional brightness gain of 2.0 – 2.3 ISO points was clearly demonstrated for the “THPS + Y” bleaching over the Y bleaching. When the brightness gain of Y bleaching was plotted vs. the unbleached pulp slurry temperature, or the brightness gain of THPS bleaching was plotted vs. the bleached pulp slurry temperature, a lower R2 was obtained (R2 = 0.5226 and 0.2296, respectively), but an average, additional brightness gain of ~2.0 ISO points could again be clearly seen for the “THPS + Y” bleaching over the Y bleaching. During the 8-day mill trial of the “THPS + Y” bleaching, there were no process upsets in the bleach plant or on the paper machine. Compared with bleaching with hydrosulfite only, on average, the amount of Y used for the trim bleaching of the pulp going to PM 4 was reduced by 2.6 kg/t, while the ISO brightness of the pulp after trim bleaching was 1.2 points higher. Mill implementation of “THPS + Y” bleaching and estimated cost saving Following the successful mill trial discussed above, the mill has implemented “THPS + Y” bleaching on a semi-permanent basis over one-year period. The mill has consistently obtained an additional ISO brightness gain of ~2.0 points on the SGW pulp with 1.0 kg THPS/t pulp added to the Y bleaching. Such an additional brightness gain has allowed the mill to reach the pulpandpapercanada.com
brightness target when the ISO brightness of the unbleached SGW pulp is lower than 62.0% in the summer months, and to reduce the dosage of brightness-enhancing additives in the coating colour when producing hi-brite, ≥75% ISO LWC papers. The cost saving from “THPS + Y” bleaching has been estimated at $250,000/year by the mill personnel.
CONCLUSIONS
An eight-day mill trial of using the phosphonium compound, THPS, as a complementary bleaching agent to sodium hydrosulfite (Y) in the bleaching of spruce stone groundwood (SGW) pulp, has been successfully conducted. Addition of 1.0 kg THPS/t pulp to the hydrosulfite bleaching provided an average, additional brightness gain of 2.0-2.3 ISO points to the pulp without any process upsets in the bleach plant or on the paper machine. The brightness gain from such a “THPS + Y” bleaching correlated linearly with the unbleached pulp slurry temperature. The additional brightness gain from “THPS + Y” bleaching over the Y bleaching has been sustained during the subsequent one-year commercial implementation. It has allowed the mill to reach the brightness target when the ISO brightness of the unbleached SGW pulp is lower than 62.0% in the summer months, and to reduce the dosage of brightness-enhancing additives in the coating colour when producing hi-brite, ≥75% ISO LWC papers. The cost saving to the mill has been estimated at $250,000/year. Use of “THPS + Y” bleaching with a weight ratio of Y/THPS ≥6.0 removes the formaldehyde formed from the dissociation of THPS to THP through the reaction of formaldehyde with Y and/ or bisulfite.
ACKNOWLEDGEMENTS
We would like to thank: people at the Paprican member mill who participated in the mill trial for their participation and support; Drs. Tom Browne and Paul Watson of Paprican for supporting our work; Dr. Gilles Dorris of Paprican for an internal review of the manuscript; and NSERC for financial support via an I2I grant.
LITERATURE
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T136 BRIGHTNESS Mechanical Pulp with Sodium Percarbonate and Amineborane – Bleaching Response and Brightness Stability, J. Pulp Paper Sci. 28(5): 171-175 (2002). 13. KRONIS J.D. Optimum Conditions Play Major Role in Recycled Fiber Bleaching with FAS, Pulp & Paper 9: 113-117 (1996). 14. FILLION, M., AGER, P., GAUDREAULT. Comparison of Bleaching Sequence (PF, PH and PY) for Deinked Mixed Office Waste (MOW) Containing Various Percentages of Mechanical Pulp, Proc. 92nd PAPTAC Annual Meeting, B179-186 (2006). 15. HU, T.Q., JAMES, B.R. New Bleaching Agents for Mechanical Pulps – A Discovery Made Possible by the Pursuit of Green Chemistry, Can. Chem. News 56(4): 27-28 (2004). 16. HU, T.Q., JAMES, B.R., YAWALATA, D., EZHOVA, M.B. Bleaching and Brightness Stabilization of Lignocellulosic Materials with Water-soluble Phosphines and Phosphonium Compounds, US Patent 7,285,181 B2, October 23, 2007. 17. HU, T.Q., JAMES, B.R., YAWALATA, D., EZHOVA, M.B. A New Class of Bleaching and Brightness Stabilizing Agents. Part I: Bleaching of Mechanical Pulps, J. Pulp Paper Sci. 30(8): 233-240 (2004). 18. HU, T.Q., JAMES, B.R., YAWALATA, D., EZHOVA, M.B., CHANDRA, R. A New Class of Bleaching and Brightness Stabilizing Agents. Part II. Bleaching Power of a Bisphosphine, J. Pulp Paper Sci. 31(2): 69-75 (2005). 19. HU, T.Q., JAMES, B.R. A New Class of Bleaching Agents for Mechanical Pulps, Proc. 91st PAPTAC Annual Meeting C97-101 (2005). 20. HU, T.Q., JAMES, B.R., YAWALATA, D., EZHOVA, M.B. A New Class of Bleaching and Brightness Stabilizing Agents. Part III: Brightness Stabilization of Mechanical Pulps, J. Pulp Paper Sci. 32(3): 131-136 (2006). 21. RICKELTON, W.A. Phosphine and Its Derivatives, in Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed. Vol. 18, 656-668 (2000). 22. CALAMARI, T.A., HARPER, R.J. Flame Retardants for Textiles, in Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed. Vol. 10, 998-1022 (2000). 23. JEFFERY, J.C., ODELL, B., STEVENS, N., TALBOT, B. Self Assembly of a Novel Water Soluble Iron(II) Macrocyclic Phosphine Complex from Tetrakis(hydroxymethyl)phosphonium Sulfate and Iron(II) Ammonium Sulfate: Single Crystal X-ray Structure of the Complex [Fe(H2O)2{RP(CH2N(CH2PR2) CH2)2PR}]SO4•4H2O (R = CH2OH), Chem. Commun. 101-102 (2000). 24. HAACK, T.K., DOWNWARD, B., TALBOT, B. Tetrakishydroxymethyl Phosphonium Sulfate (THPS): A New Biocide with Environmental Benefits for Paper Mills, 1997 Tappi Engineering & Papermakers Conference Proceedings, Tappi Press: Atlanta, 1115-1119 (1997). 25. ELLZEY, S.E., JR. Preparation of Pure THP Sulfate, Textile Chem. Color. 10(5): 12 (1978). 26. FRANK, A.W., DAIGLE, D.J., VAIL, S.L. Chemistry of Hydroxymethyl Phosphorus Compounds, Part II. Phosphonium Salts, Textile Res. J. 52(11): 678-693 (1982). 27. CHANDRA, R., HU, T.Q., JAMES, B.R., EZHOVA, M.B., MOISEEV, D.V. A New Class of Bleaching and Brightness Stabilizing Agents. Part IV: Probing the Bleach-
ing Chemistry of THP and BBHPE, J. Pulp Paper Sci. 33(1): 15-22 (2007). 28. HAN, J.C., HAN, G.Y. A Procedure for Quantitative Determination of Tris(2carboxyethyl)phosphine, an Odorless Reducing Agent More Stable and Effective than Dithiothreitol, Anal. Chem. 220: 5-10 (1994). 29. Analysis of Sodium Hydrosulfite, TAPPI Standard Testing Method T 622 cm-01 (2001). 30. Forming Handsheets for Optical Tests of Pulp (British Sheet Machine Method), PAPTAC Standard Testing Method C.5 (1993). 31. Brightness of Pulp, Paper and Paperboard, PAPTAC Standard Testing Method E.1 (1990).
Résumé: Des essais sur huit jours en usine portant sur l’ajout de sulfate de tétrakis(hydroxyméthyl)phosphonium (THPS) (à 1,0 kg de THPS/t de pâte) lors du blanchiment à l’hydrosulfite (Y) de PMD d’épinette ont permis d’accroître de 2,0 à 2,3 points le degré de blancheur ISO sans perturber le fonctionnement de l’atelier de blanchiment ou de la machine à papier. Ce gain de blancheur supplémentaire, soutenu durant la mise en oeuvre commerciale subséquente de la technologie de blanchiment « THPS + Y », permet à l’usine de réaliser son objectif de blanchiment pendant la difficile période de l’été, et de réduire la quantité d’additifs dispendieux consommés pour accroître la blancheur des papiers LWC. Les économies estimatives réalisées par l’usine sont de l’ordre de ~250 000 $ CA par année. Reference: HU, T.Q., WILLIAMS, T., SCHMIDT, J.A., JAMES, B.R., CAVASIN, R., LEWING, D. Mill Trial of the New Bleaching Agent – THPS. Pulp & Paper Canada 110(7): T131-T136 (September 2009). Paper presented at the 2007 International Mechanical Pulping Conference, June 1, 2007. Not to be reproduced without permission of PAPTAC. Manuscript received September 20, 2007. Revised manuscript approved for publication by the Review Panel Nov. 13, 2008.
Keywords: BLEACH, BLEACHING, BRIGHTNESS, COSTS, MECHANICAL PULPS, PHOSPHONIUM COMPOUNDS, SODIUM HYDROSULFITE, TETRAKIS(HYDROXYMETHYL)PHOSPHONIUM SULFATE, TERTIARY PHOSPHINES.
PAPTAC Seminar on Improving Paper Machine Efficiency & Productivity October 21-22, 2009 FPInnovations - Paprican, Pointe-Claire, Que Carmie Lato, clato@paptac.ca, 514-392-6969
Johan Gullichsen Colloquium Forest Biomass - Quo Vadis? Nov. 19, 2009 Espoo, Finland irmeli.hannula@papereng.fi, www.papereng.fi
ABTCP-PI Pulp and Paper International Congress & Exhibition 26-29 Oct. Sao Paulo, Brazil www.abtcp-pi2009congressoexpo.org. br/ingles/
2009 Specialty Papers Conference November 4-5, 2009 Chicago, Ill. Barbara Rojas, 207-781-9608, www.specialtypaperconference.com
International Chemical Recovery Conference March 29 – April 1, 2010 Williamsburg Lodge, Williamsburg, VA Shauna Rice, 770-209-7237 or srice@tappi.org
PAPTAC EXFOR and Annual Meeting Feb. 2-3, 2010 Montreal, Que. Carmie Lato, clato@paptac.ca, 514-392-6969 www.paptac.ca
Progress in Paper Physics Seminar June 7-10, 2010 Montreal, Que. Norayr Gurnagul, 514-630-4101, ex 2241, Norayr.gurnagul@fpinnovations.ca, www.paprican.ca
Events
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September 2009
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TECHNOLOGY NEWS
Roll cover boosts machine speed, dewatering capacity Pindo Deli in Karawang, Indonesia, converted a standard rubbercovered suction press roll on PM 5 to Voith’s SolarSoft polyurethane cover. The SolarSoft cover has a suction, blind-drilled, and grooved surface design, with 45.6% open area compared with 29.57% on the previous roll. “The improvement of open area significantly improved the dewatering capacity and has immediately led to a 5 to 20% increase in machine speed dependent on the tissue grade,” explains Usep Saepul, production manager PM 5. “This change is a major move forward leading to a production increase of between 5 and 12.7 tons per day.” SolarSoft is the latest generation in polyurethane covers of the Voith Paper Rolls Solar series. It is specially developed for suction rolls and pressure rolls of tissue machines. The first results clearly show that the machine speed, output, and felt life can be increased, along with significant improvements in tissue quality. In addition, the high tear resistance and elasticity of SolarSoft provide high operating safety and machine availability. Voith Paper Rolls Division 613-632-4163, www.voithpaper.com
Pressure-sensing press roll now available
Xerium Technologies, Inc. has announced full commercial availability of SmartRoll, the industry’s first continuous pressure-sensing paper machine press roll. Xerium has been conducting on-site customer testing since introducing the SmartRoll in late 2008. The SmartRoll significantly increases production efficiency and reduces downtime by providing a constant stream of true operating condition information to paper machine operators or mill managers while the paper machine is in operation. Xerium’s SMART Technology employs a proprietary embedded sensor system to extract data from the roll cover during machine operation. By enabling on-the-run adjustments, the SmartRoll helps optimize production, reduce energy consumption and control costs. “Our SMART Technology represents a technological leap forward for paper processing,” says Stephen R. Light, president, CEO and chairman or Xerium Technologies. Mounted across the width of the roll cover, the SmartRoll sensors are monitored by head-mounted electronics that rotate with the roll and transmit data wirelessly to a dedicated computer. A custom operator interface provides dynamic monitoring of the pressure profile, pressure profile standard deviation, and roll speed, and also provides a historical data log for benchmarking and comparison purposes. Armed for the first time with accurate real-time knowledge of nip performance, the operator can adjust machine parameters without guesswork to make corrections to the sheet’s moisture profile as it exits the press section. The benefits can include: increased output, reduced downtime, extended press felt life, extended roll cover life, reduced consumption of materials, reduced energy costs, and early warnings of potential roll cover failures. Stowe Woodward Co. 819-565-9000, www.xerium.com/stowewoodward/
pulpandpapercanada.com
Kadant introduces modular shower system
Kadant AES has extended its line of cleaning and conditioning products with the Genesis modular shower system. The new shower system offers costeffective modular components that can be added to the single-tube shower system as needs change. The base module includes a single tube shower pipe and spray nozzles, and can be upgraded with internal stainless steel brushes, oscillation, and a second (outer) tube for optimal performance. The Genesis modular shower system also features a slide bearing design with alignment keys, split polyethylene bushing, and shower pipe rotation to optimize nozzle spray angle. The stationary shower systems are upgradeable to oscillating shower systems using the EMO III or Genesis oscillators available from Kadant AES. Kadant Canada 613-931-2305, www.kadant.com
Clariant launches Web presence for defoamers business
Clariant has launched a comprehensive web presence for its newly acquired defoamers business. The web pages are found at www.defoamers.us. Visitors to the Defoamers web pages can download product bulletins, request product samples, ask a question or make a general inquiry, and send email directly to technical, sales, and customer service contacts for the business. In May, Clariant acquired the XL Performance Chemicals from FibroChem LLC and its affiliates. Clariant 800-942-7239, www.defoamers.us
September 2009
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TECHNOLOGY NEWS
Magnetic filter reduces downtime
At the Adi Prima Suraprinta newsprint mill in Indonesia, high produc tion downtime due to bearing and seal failure was a problem. The bearing and seal failures were attributed to contaminated hydraulic fluid. A local equipment distributor re co mm e n d e d ins t allin g a m a g n e t i c f i l t e r r o d (O E I â&#x20AC;&#x2122;s 3RNC5812) into an oil reservoir. After four days of operation, the magnetic filter was removed and inspected. High concentrations of ferrous metal, down to submicron size, were captured by the magnetic filter. Since the installation of the OEI magnetic filter the fluid cleanliness has improved tremendously, reducing component wear and increasing uptime. The OEI magnetic f ilter is easily
Andritz to supply greenfield kraft pulp mill in China
Andritz Pulp & Paper will supply all process technologies for a 700,000 t/y bleached hardwood kraft greenfield pulp mill to Zhanjiang Chenming Pulp & Paper Co., Ltd., a subsidiary of Shandong Chenming Paper. The scope of supply comprises the wood process systems, the fibre line (cooking, washing, screening and bleaching systems), the pulp drying and bale finishing plant, as well as the chemical recovery island (evaporation plant, recovery boiler, and recausticizing plant with lime kiln). In addition, Andritz will supply the complete stock preparation and approach flow system for a fine paper machine to be installed at the same mill. The total value of the orders is approximately 160 MEUR. The pulp mill is targeted for start-up in mid2011. Andritz Ltd. 514-631-7700, www.andritz.com
Good things come in small packages. To inquire about advertising in Pulp & Paper Canada Contact cleaned and the trapped contamination can be analyzed for component wear identif ic ation allowing pre dic tive maintenance planning. One Eye Industries 403-242-4221, www.OneEyeIndustries.com
Jim Bussiere 800-363-1327, ext 222 Fax: 514-630-5980
Moventas to deliver mechanical drives for paper machine line
Moventas will deliver mechanical power transmission equipment for a paper machine line supplied by Metso to China. Moventas is responsible for drives covering the entire paper production line and related machinery. Also included are the layout engineering and a spare parts package. The paper machine dryer section is equipped with the DRG drive concept developed by Moventas for high-speed paper machines. Roll handling and off-line machine unwind and wind-up drives are included in the delivery. In addition, Moventas will supply integrated drives for deflection compensated rolls and suction press rolls. Moventas Santasalo Oy 358 20 184 7100, www.moventas.com
Equipment
Advertiser Index
Albany International . . . . . . . . . . . . . . . . . . . . . . . . www.albint.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Andrew Merrilees . . . . . . . . . . . . . . . . . . . . . . . . . . . www.merrilees.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Buckman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.buckman.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cook Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . www.cookeng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Dick Engineering. . . . . . . . . . . . . . . . . . . . . . . . . . . . www.dickeng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Fairmont Queen Elizabeth . . . . . . . . . . . . . . . . . . . www.fairmont.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Freeman Staffing Inc. . . . . . . . . . . . . . . . . . . . . . . . . www.freemanstaffing.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Gamajet Cleaning Systems Inc. . . . . . . . . . . . . . . www.gamajet.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Indeck Power Equipment Co. . . . . . . . . . . . . . . . . www.indeck.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Jeffrey Rader Corporation . . . . . . . . . . . . . . . . . . . www.jeffreyrader.com/ppc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Kadant Canada Corporation . . . . . . . . . . . . . . . . . www.kadant.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Kemira Chemicals Inc. . . . . . . . . . . . . . . . . . . . . . . . www.kemira.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PAPTAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.paptac.ca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Phoenix Process Equipment Co. . . . . . . . . . . . . . www.dewater.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Poyry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.poyry.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Sandwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.sandwell.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Spraying Systems Co.. . . . . . . . . . . . . . . . . . . . . . . . www.spray.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wabash Power Equipment . . . . . . . . . . . . . . . . . . www.wabashpower.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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pulpandpapercanada.com
Professional Connections Careers
Equipment
PulP & PaPer Jobs Freeman Staffing, Inc. specializes in the placement of engineers (all disciplines), production type supervisors, managers, mill and/or plant managers and corporate executives in the pulp & paper industry, North America-wide. For specific current job searches call us or contact our web site. All resumes are treated with complete confidentiality.
Freeman Staffing, Inc.
(800) 221-9629 or FAX (360) 653-8271 email: markp@freemanstaffing.com
web site: www.freemanstaffing.com
Consultants
Engineering services for the pulp and paper industry
Telephone 416. 391. 2322 E-mail mail@dickeng.com Web site www.dickeng.com
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• Any Chest, Digester, Pulper, Vessel or Tote • Fastest & Most Efficient Technology • Rotary Impingement GAMAJET® Cleaning Systems, Inc., 604 Jeffers Circle - Exton, PA 19341 Gamajet.com • sales@gamajet.com • 1-877-GAMAJET
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September 2009
PULP & PAPER CANADA
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TECHNOLOGY NEWS
Pumps suitable for material with larger solid particles Wilden’s PX20 Original Metal air-operated double-diaphragm (AODD) pumps feature operating capabilities that make them ideal for pumping materials that contain larger solid particles. This ability makes them suitable for use in the paint, wastewater treatment, pulp and paper, and mining industries. Wilden PX20s are 102 mm (4 in.) pumps that feature the clamped configuration that Jim Wilden invented in 1955. They have lube-free operation and can pass solids as large as 35 mm (1-3/8 in.). An Ultra-Flex elastomer option helps ensure long life, maximum solid’s passage and maximum mean time between replacement. Wilden 909-422-1730, www.wildenpumps.com
Metso’s optimal refining solution implemented at Stora Enso Imatra Stora Enso has implemented at its Imatra mill in Finland Metso’s Advance Quality Control system for bleached chemi-thermomechanical pulp (BCTMP) production to reduce energy costs and pulp quality variability. The project started as a trial project for the main line refiners and then was expanded to include impregnation, screening, and reject refining. The Advance Quality Control system was integrated with kajaaniMAP and kajaaniTQA analyzers to provide on-line
quality measurements for the management of the pulp quality. The purchase of the main line refining advance control was based upon a reduction in specific energy of 4% and quality variability of 40%. The trial evaluation of the screening and reject system continues and is expected to be completed during the third quarter of 2009. Metso Pulp & Paper 514-380-2418, www.metso.com
How to lower operating costs in drying and blow-off operations
A new white paper published by Spraying Systems Co. takes an in-depth look at how to reduce or eliminate compressed air use in drying and blow-off applications and achieve dramatic savings. Replacing open pipe with manifolds equipped with air nozzles or air knife packages powered by blower air often results in savings of tens of thousands of dollars per year. The paper reviews various air nozzle options that use compressed air, provides application guidelines and estimates the savings each option offers over open pipe. Products discussed include air nozzles that produce a high-impact air stream and are ideal for moving materials and cleaning, drying and cooling parts; variable air amplifiers that produce a constant, high-velocity air stream for very targeted drying and blow-off; and low-flow air knives that produce a uniform, high-velocity air flow across the entire length of the knife. Spraying Systems Co. 630-665-5000, www.spray.com/savewaterandair
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September 2009
pulpandpapercanada.com
If you use steam to dry paper, you need to read this.
The dryer section consumes more than 75% of the steam energy on a typical paper machine. In 2008, Kadant Johnson identified more than $10 million of energy savings opportunities around the globe. In addition to the energy saving benefits, the dryer performance evaluations identified opportunities for improving operating efficiency, runnability, and machine productivity. With more than 1,000 dryer studies completed to date, Kadant leads the industry with its drying process and application expertise. Put Kadantâ&#x20AC;&#x2122;s years of experience and process knowledge to work for you. Visit us online at www.kadant.com/dryer or contact your local Kadant Regional Sales Manager to schedule a dryer performance evaluation today. www.kadant.com
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