Pulp & Paper Canada January/February 2015 by Annex Business Media

PULP& PAPER CANADA

OVER 100 YEARS OF SERVING THE INDUSTRY

JANUARY/FEBRUARY 2015

NEW SENSOR AIDS BLEACHING

CASCADES SELLS, CATALYST BUYS IROQUOIS FALLS CLOSES

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Looking at the

BIG PICTURE: Global pulp and paper production and trade

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PULP& PAPER

January/February 2015 Vol. 116, No. 1 A Business Information Group Publication PRINT EDITION ISSN 0316-4004 ON-LINE EDITION ISSN 1923-3515

CANADA

OVER 100 YEARS OF SERVING THE INDUSTRY

COVER STORY 13 T he BIG Picture: Global Fibre, Pulp and Paper Data

Global production of wood products rose in 2013, but pulp and paper stagnated, according to the Food and Agriculture Organization of the United Nations.

FEATURES 12 C ascades Continues to Divest Assets At 50 years old, Cascades is paring back its operations to focus on particular sectors of strength: certain packaging markets, tissue paper and recovery.

17 N anotechnology Raises Doctoring Performance to New Level

Sponsored technical article by Kadant discusses how nanotechnology-enhanced doctor blades can have longer life.

18 I s Conductivity the Best Measurement of Bleach Plant Carryover?

A new sensor that can directly measure dissolved lignin content in the pulp slurry has applications for improving efficiency in washing stages, and optimizing bleach plant chemical charges.

IN EVERY ISSUE 4 Editorial 6 Industry News 11 Opinion: FPInnovations 11 Opinion: FPAC 23 Technology News 25 Classified Ads 26 Bio-Economy

MISSION STATEMENT: To promote the pulp and paper industry in Canada by publishing news of its people and their innovations in research, technology, management and financing, as well as forecasts of future trends. Serving the industry since 1903.

For breaking news, visit www.pulpandpapercanada.com Cover photo: Thinkstock

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Editorial

Seeing the Ripples of Transformation T

he year ended with a flurry of activity in the paper industry, suggesting the industry’s transformation is not over: cross-border acquisitions in both directions, plus partial and complete shutdowns Catalyst Paper is expanding into new geographic markets with the purchase of two mills formerly owned by NewPage. They give the company additional capacity for coated specialty, coated freesheet and coated groundwood paper, as well as lightweight and ultralightweight coated paper. CEO Joe Nemeth said the move gives Catalyst a more diversified and higher-value suite of products. Cascades, on the other hand, is trimming its operations. In 2014, it exited the fine papers market by selling the Rolland division, closed its kraft paper operations in East Angus and made an agreement to sell its boxboard manufacturing and converting operations to U.S.based Graphic Packaging Inc. CEO Mario Plourde said the divestments and closures are intended to reduce the company’s debt load and focus on core packaging sectors, tissue and the recovery business. If the Cascades/Graphic Packaging deal clears regulatory hurdles, it will bring the Canadian industry another owner, a large, multinational packaging company. Shutdowns in several Canadian mill towns were the price paid for weaker newsprint markets. In November, Kruger closed PM1 at the Bromptonville, Que., mill, ending 98 jobs. Resolute Forest Products shut down two paper machines in Baie-Comeau and Clermont, Que., and permanently closed the mill in Iroquois Falls, Ont., in December. Estimated job losses for the Resolute closures are 180 at Iroquois Falls and 120 for the two Quebec mills. Kruger cited unfavourable market conditions, in Cindy Macdonald Editor particular the continuing drop in demand for newsprint, as the reason for the decision. Resolute spread the blame more broadly, citing market weakness aggravated by cost and availability of fibre, transportation costs, power costs and the spruce budworm infestation in Quebec. The newsprint mill in Iroquois Falls had operated for more than 100 years. A local newspaper, the Timmins Daily Press, reported that residents and family members held a vigil outside the mill gates as the final shift headed home before dawn on Dec. 22. For some families, the mill has provided employment for several generations of workers. Danny McIntyre told the Daily Press: “It was the lifeblood of the town. It built the town. I live in a home that was built by Abitibi. … The whole area around the mill was built by the company. The company, when it was a good company to work for, took care of its employees, owned the hospital, paid the doctors before Medicare.” Optimists at PaperWeek Canada in February 2014 said the worst of the industry’s transition was over, but clearly some painful adjustments were still to be come.

Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Publisher JIM BUSSIERE 416-442-5600 ext. 3606 jim@pulpandpapercanada.com President, Business Information Group BRUCE CREIGHTON Vice President, Publishing ALEX PAPANOU Executive Publisher, Manufacturing TIM DIMOPOULOS

ADVISORY BOARD Richard Foucault Greg Hay Dr. Richard Kerekes Barbara van Lierop Dr. David McDonald Dennis McNinch Dr. Yonghao Ni Bryant Prosser Dr. Paul Stuart Ross Williams EDITORIAL/SALES OFFICES 80 Valleybrook Dr., Toronto, ON M3B 2S9 Phone: 416-442-5600. Toll Free: c da 800-268-7742; usa 800-387-0273

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Industry News Catalyst Paper expands with purchase of two U.S. paper mills B.C.-based Catalyst Paper Corp. has added significant paper capacity and extended its operations across North America with the purchase of two U.S. mills from NewPage: the Biron paper mill located in Wisconsin and the Rumford pulp and paper mill located in Maine. “This acquisition represents a new chapter in the history of Catalyst Paper,” says Joe Nemeth, president and CEO. “With the addition of the Rumford and Biron mills, Catalyst becomes a larger and stronger company with five facilities across North America and an estimated production capacity of 2.1 million tons of paper and 500,000 tons of pulp. Catalyst is now the only producer in North America with manufacturing facilities in the West, Midwest and East, and has an enhanced product suite to effectively meet global customer needs.” The cash payment made on closing was US$62.4 million. The addition of the paper mills increases Catalyst’s production capacity by approximately 65% or 995,000 tonnes per year. The Biron mill produces lightweight coated and ultra-lightweight coated paper. The Rumford mill maufactures coated specialty, coated freesheet and coated groundwood paper, and both hardwood and softwood kraft market pulp. Catalyst operates three pulp and paper mills in British Columbia, producing mechanical printing papers, newsprint and pulp. “With this transaction, Catalyst will be better able to serve new and existing customers through operational synergies and a more diversified and higher value suite of products,” said Nemeth, when announcing the transaction in October.

Tembec strike over, cogen project delayed one month A two-week strike by employees at Tembec’s Temiscaming site ended in early December. Unionized employees voted in favor of a four-year agreement. The strike began Nov. 26, and interrupted production the Temiscaming industrial complex, which has four main facilities manufacturing specialty pulp, high-yield pulp, multi-ply coated bleached board, phenolic resins and lignosulfonates. A union representative told French6

language broadcaster Radio-Canada that the union made many gains in this settlement, specifically on the subject of vacations and discipline. Roger Gauthier, regional president for the Unifor union, said labor relations had been an issue at the Tembec site for several years. Tembec estimates the financial impact of the work stoppage, including additional site security and access measures, to be approximately $5 million. In addition, the turbine for the Temiscaming cogen project is now scheduled to produce contract power by mid-January 2015, a delay of approximately one month from the previously scheduled date. The site in Temiscaming employs 850 people, of which 650 are unionized.

Industrial accident kills driver at Crofton mill A contract truck driver who delivered wood chips to Catalyst Paper’s Crofton mill was found dead in a chip silo on Dec. 11. The driver, Perry Vernon Thomas, was reported missing on the evening of Dec. 9, at which time the mill activated its Emergency Response Plan. The RCMP and WorkSafe BC were contacted and launched an investigation at the mill site. Thomas’ body was later recovered from a silo which is connected by a conveyor belt to the area where Thomas was delivering his load. Cpl. Jon Stuart of the North Cowichan/ Duncan RCMP, quoted in the Cowichan Valley Citizen, said officers at the scene “determined that there was enough to support the belief that the driver had been taken by a conveyor belt, and carried into one of the storage silos.” Stuart also said there is nothing to suggest a criminal act had taken place. WorkSafe BC is leading the investigation into the circumstances surrounding the accident to determine cause. The RCMP and the Coroner’s Office are also investigating.

Two forest industry executives among Canada’s most powerful women On the list of Canada’s Most Powerful Women: Top 100 for 2014 determined by Women’s Executive Network are Anne Giardini, former president of Weyerhaeuser Co., and Nancy Marcus, corporate vice-

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president, consumer marketing with Kruger Products. Women’s Executive Network (WXN) describes Nancy Marcus as “one of Canada’s most recognized marketing professionals in the conNancy Marcus sumer packaged goods industry,” and notes her keen strategic insights and bold marketing innovations. Anne Giardini, in addition to her role as president of Weyerhaeuser (which ended with her retirement in October 2014), recently became the Chancellor of Simon Fraser University. A long-time leader within Canada’s resource industry, Giardini serves on the boards of several industry associations. She is a lawyer by training, and was named one of Canada’s 25 most influential lawyers. To read more on about Giardini and Marcus, please see the extended story at www.pulpandpapercanada.com.

Iroquois Falls newsprint mill permanently closed Resolute Forest Products has announced the permanent closure of its newsprint mill in Iroquois Falls, Ont., and the permanent closure of two paper machines at mills in Quebec. The move will remove 465,000 tonnes of newsprint capacity from the market, and result in job losses for about 300 employees. The decision to reduce newsprint capacity is a result of the ongoing weakness in the global newsprint business, exacerbated by fiber-related issues, including both availability and costs, as well as transportation challenges, the company says. In Quebec, power costs played a role in these decisions, as well as the spruce budworm infestation. “Market conditions have had a major impact on our newsprint operations in both Ontario and Quebec, and the cost position of these operations has made them vulnerable to the structural decline in newsprint,” said Richard Garneau, president and CEO. The Iroquois Falls mill employs approximately 180 people and has an annual production capacity of 210,000 tonnes of www.pulpandpapercanada.com

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Industry News newsprint. It was scheduled to close on December 22, 2014, with closure-related activities running into January 2015. The currently idled paper machine #1 at BaieComeau was permanently closed as of Dec. 5, and paper machine #4 in Clermont will be permanently closed on or about January 30, 2015. The closures at Baie-Comeau and Clermont will result in the loss of approximately 120 positions and the permanent removal of approximately 255,000 tonnes of newsprint capacity. Garneau also used the closure announcement to go on the offensive with regard to the company’s ongoing public relations battles with environmental groups. “There is another issue that cannot be ignored in these decisions: the ill-founded attacks of environmental activist groups. Their inaccurate and deceptive campaigning, which misrepresents the company’s forest management practices, was also a factor.” Resolute Forest Products produces newsprint, specialty papers, market pulp and wood products. The company owns or operates nearly 40 pulp and paper mills and wood products facilities in the United States, Canada and South Korea, and power generation assets in Canada.

Domtar converting paper machine to fluff pulp at Arkansas mill Domtar has announced a $160-million capital project to convert a paper machine at the Ashdown, Arkansas, mill to a fluff pulp line. Fluff pulp is used in absorbent applications such as baby diapers, feminine hygiene and adult incontinence products. The project will result in the permanent reduction of 364,000 short tons of annual uncoated freesheet production capacity in the second quarter of 2016. Domtar manufactures, markets and distributes a wide variety of fiber-based products including communication papers, specialty and packaging papers and absorbent hygiene products.

Resolute will heat closed Fort Frances pulp mill The closed Fort Frances pulp mill has been given a reprieve. After discussion between Resolute Forest Products, the Ontario government and Unifor, a union representing paper workers, Resolute has committed to www.pulpandpapercanada.com

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heating the Northern Ontario mill over the winter in order to protect the equipment. The pulp mill in Fort Frances has been closed for more than a year. However, the union, community and government are exploring options for the mill’s future. Resolute spokesperson Seth Kursman told CBC News that it has cost Resolute $17.5 million to keep the site heated and lit during the last two years while it was in “asset protection mode.”

Verreault family purchases and privatizes GL&V Pulp & Paper GLV Inc. announced November 28, 2014, that it had completed the sale of its pulp and paper business to a corporation owned by Richard and Laurent Verreault. The company name will be GL&V Pulp & Paper Group. GLV Inc. has changed its name to Ovivo Inc. and will now be entirely focused on its core water treatment business. AT GLV Inc., Richard Verreault was the president and CEO and Laurent Verreault was the executive chairman of the board. Both are members of one of the founding family of GL&V’s pulp and paper business. A company statement on the GL&V Pulp & Paper web site says the transaction will allow GL&V the flexibiltiy to move faster and more efficiently. Founded in 1975 by Louis Laperrière and Laurent Verreault, GL&V Pulp and Paper Group designs and markets equipment used in various stages of pulp and paper production.

New editor for PAPTAC’s journal J-FOR PAPTAC has announced that Paul Stuart of École Polytechnique de Montréal will succeed Honghi Tran as chief scientific editor of the association’s technical journal J-FOR. Patrice Mangin, CRML/UQTR and PAPTAC councilor, will take on the duties of deputy editor.

Neucel mill takes market downtime The Neucel Specialty Cellulose mill in Port Alice, B.C., is taking market-related downtime for almost two months, reported the Industry Intelligence Inc. news service. The mill produces dissolving pulp via a sulfite process. Warren Beatty, vice-president of human

resources, told Industry Intelligence the downtime began on Nov. 9 and was expected to continue until Jan. 8, 2015. Planned maintenance will be done during the downtime. Beatty noted that commodity dissolving pulp prices in China are as low as US$840/ tonne. The mill produces both commodity and specialty grades in varying proportions, Beatty said. The Neucel mill was not affected by anti-dumping measures imposed by China last year on several Canadian producers of dissolving pulp.

Catalyst Paper shuts one machine, looking for ways to make Powell River profitable Catalyst Paper has decided to indefinitely curtail the No. 9 paper machine, one of three machines at its Powell River operation. The decision is market-related, says the company, due to a lack of orders and a declining market for the paper manufactured on PM9. The paper machine was temporarily curtailed on October 27. “This is a difficult, but necessary, decision that supports Catalyst’s commitment to align mill operations and production with market demand,” said Joe Nemeth, president and CEO. “We are committed to making the Powell River operation successful for the long term, and will be working with our employees, leadership and the unions on a plan to make improvements to secure our sustainability.” The shutdown is expected to lead to the loss of 50 jobs at the Power River operations and the Surrey Distribution Centre, Catalyst’s product distribution hub. Last fall, community stakeholders and employees of Catalyst Paper’s Powell River mill were told there is a three-year window to bring the mill back to profitability. Eldon Haggarty, president of Local 1, Unifor, told the community newspaper: “We are making everyone well aware that we are going to have to do things differently. [The mill] is not profitable at the moment and we need to turn it around.” According to the story in the Powel River Peak, Joe Nemeth, president and CEO of Catalyst Paper, said in a written statement that he believes the Powell River division can be viable, but, “There is no question that we are facing significant cost escalations such as BC Hydro rates, high

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Industry News overall taxes and fibre availability, which pose a threat to the viability of our manufacturing facilities.”

BC Aboriginal business wins forest industry award Stuwix Resources Joint Venture from the interior of British Columbia has won the FPAC-CCAB Aboriginal Business Leadership Award presented by the Forest Products Association of Canada (FPAC) and the Canadian Council for Aboriginal Business (CCAB). “FPAC is excited to recognize Stuwix Resources for their outstanding business leadership. They are committed to their local community and understand the value and contribution that Aboriginal businesses make in the sector,” said David Lindsay, president and CEO of FPAC. Stuwix Resources Joint Venture is a tenure holder and forest management company wholly owned by eight First Nations Bands.

Fortress Paper announces cost reductions The Fortress Speciality Cellulose mill in Thurso, Que., has implemented several cost reduction measures in 2014, bringing its average cost to $757 per air dried metric tonne (ADMT) of dissolving pulp produced, according to a company update published in late October. The cost reduction measures included projects related to a dissolving pulp gas collector system, a new drum washer, a power generation project and a new dry sodium sulphate project to reduce chemical costs.

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Kadant Inc. has acquired the screen cylinder product line from J&L Fiber Services, Inc. This acquisition further extends Kadant’s product offerings of screen cylinder products applied to recycled fiber lines, thick stock, broke, and other aggressive applications. “The addition of J&L Fiber Services’ screen cylinders to our stock preparation product line advances our strategic initiative to grow our parts and consumables business,” said Jonathan W. Painter, president and CEO of Kadant Inc. “Screen cylinders are the most important consumable for stock preparation systems, and this bolt-on product line acquisition serves to deepen our product offerings and we believe will benefit our customers who require rugged and rebuildable screen cylinders for challenging fiber processing applications.” Kadant Inc. is a supplier of high-value, critical components and engineered systems used in process industries worldwide.

Management changes at CRIBE

Domtar and Unifor reach agreement for Kamloops mill

OUR NAME IS INNOVATION

Kadant adds to stock preparation product line

CRIBE, Northern Ontario’s funding agency for bio-economy research, has made changes to its leadership structure. As of December 1, Scott Wiebe is the new CEO and president of CRIBE, replacing Lorne Morrow who will be stepping down after a successful five year tenure. Although new to the role, Wiebe is not new to CRIBE. He was previously program manager at the agency for two years before joining AV Terrace Bay as business analyst. In October, Michael Willick accepted the position of chairman of the board of directors, replacing Frank Dottori. Dottori will remain as a director on the board. In addition, Thunder Bay’s Douglas Murray has joined the board in the role of Director for a three-year term. Don Campbell and J.P. Gladu are stepping down as directors.

Benchmarking for Success:

Cost: $4,100 plus applicable taxes

As the cogeneration facility is optimized and other initiatives are implemented, management expects the mill to achieve run-rate production costs of $725 per ADMT of dissolving pulp produced by the end of 2015. Although the FSC mill has the capability to produce both hardwood and dissolving pulp, the company is targeting 100% dissolving pulp production for 2015.

An agreement between Unifor Local 10B and Domtar sets the stage for a new working relationship and an expanded commitment to apprenticeship training in Kamloops, B.C. “Unifor believes in partnerships that can have long-lasting positive effects not just for the worksite, but for the communities we live in,” said Jerry Dias, Unifor national president. “We are pleased to have reached this agreement that we believe fosters a new working relationship between Domtar and Unifor that recognizes and builds on our common interests,” said Nels Goddard, Domtar human resources manager. The agreement sets a framework for apprenticeship training at the mill. It also establishes scholarships and bursaries that Unifor and Domtar will administer in pursuit of supporting local trades training schools in Kamloops. www.pulpandpapercanada.com

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Industry News

Robotics, automation, telematics and autonomous vehicles. These advanced technologies might soon be found in the forest and thereby make it possible to provide forest workers with a safer, more efficient work environment. The Forest Machine Technology Conference (FMTC) will be showcasing these technologies on April 21-23 in Montreal. The FMTC will focus on what advanced technologies can bring to the forest industry in terms of productivity and sustainability. This event will bring together stakeholders in the forest industry and other sectors in order to define the challenges of using advanced technologies in the forest, to present the technological potential in other sectors and encourage new partnerships as well as initiatives in R&D. Conference participants will hear from forest industry leaders in Canada and Brazil, from major manufacturers of international forest machinery and from a variety of experts related to the design of forest equipment. The FMTC will also feature technical presentations, technological forums, booths of various advanced technology providers, working groups and presentations of technical and scientific posters. The FMTC is intended for managers of companies in the forest industry, equipment manufacturers, supply chain manag-

Resolute offers details on suspension of two FSC certificates Resolute Forest Products has outlined some of the circumstances surrounding the suspension of two of the company’s Forest Stewardship Council® (FSC) certificates in the Lac-Saint-Jean region of Quebec, and notes that it “will be impossible for the company to obtain reinstatement of the two Lac-Saint-Jean certificates within the allowed time and without significant socio-economic impact.” One of the certificates expired on December 3 and the second, which is currently suspended, was to be revoked on January 1, 2015. Resolute claims that the interpretation of the requirements of the FSC’s Boreal Standard is what sealed the fate of the two certificates, and led to non-conformities associated principally with two issues: a territorial dispute and a caribou habitat conservation plan. “The certificate suspensions in LacSaint-Jean have nothing to do with Resolute’s adoption of leading forest management practices or its compliance with laws and regulations. These are in fact the same sustainable forest management principles and practices that are applied by other current holders of FSC certificates in

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Photo: Tigercat

Robots and autonomous vehicles could soon be part of woodlands operations

The use of robotics and telematics in logging operations will be discussed at The Forest Machine Technology Conference in April.

ers, technology providers in the forest sector and other sectors, members and partners of Unmanned Systems Canada as well as universities and R&D institutions interested in shaping a vision for the future. Event sponsor are John Deere, Ponsse, Tigercat, Caterpillar, Aeryon Labs Inc., Komatsu and Fibria. More information is available at fmtc.fpinnovations.ca.

Eastern Canada,” said Richard Garneau, president and CEO. The company says a complex territorial dispute between the Cree First Nation and the government of Quebec contributed to the FSC auditors’ decision to suspend one of the two FSC certificates. The suspension of several of Resolute’s FSC certificates has had one direct affect on the company’s business. Electronics retailer Best Buy recently announced it would shift its business away from Resolute and require its suppliers to provide FSC-certified paper. “Our intention is to conduct business with companies that support sustainable forestry practices including those in the Canadian Boreal Forest. Clear preference will be awarded to companies that have earned FSC certification,” says a Best Buy news release.

FSC changes processes following Resolute dispute with Rainforest Alliance Following legal action by Resolute Forest Products against Rainforest Alliance to prevent an audit report of Resolute’s activities from being published, the Forest Stewardship Council (FSC) has decided to amend its processes so that similar actions cannot be repeated by FSC cer-

tificate holders in the future. FSC’s Advice Note, released on Dec. 18 to all its certification bodies, requires third-party certification bodies to suspend and subsequently withdraw certificates when they cannot take certification decisions to maintain a certificate within a specified time period, for circumstances beyond the control of the certification body. FSC explains that such circumstances may include, but are not limited to, the client or other parties preventing the use of audit findings and/ or the delayed or declined acceptance of audit findings or the audit report by the client. In April 2014, Resolute’s FSC forest management certificate for the Caribou Forest in Canada was audited by the Rainforest Alliance, as part of an annual assessment. According to FSC’s principles, all audit reports must be made public as verification. However, Resolute gained a legal injunction against any communication of the final audit report for the Caribou Forest. FSC said it takes no side, at the present time, in the dispute between Resolute and Rainforest Alliance. However, FSC “deeply disapproves of Resolute opting for legal action rather than following the dispute resolution process provided by FSC.”

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Industry News Some Port Hawkesbury pensioners have to repay money received in error A decision has been reached in a case involving two pension administration firms responsible for the pensions of former employees of the Port Hawkesbury, N.S., paper mill when it was owned by NewPage. Details of the settlement were not revealed, but the result is that pensioners who were overpaid due to miscalculation by the pension administrator will have to pay back 70% of the monies received in error. According to a CBC News story posted on Dec. 19, Morneau Shepell, which took over the pension in 2012, accused the previous pension administrator, Aon Hewitt, of miscalculating the pensions of about 200 pensioners by roughly $5 million. Paul Chang, speaking for Morneau Shepell, told CBC News: “The affected people received monies – they were overpaid, and they got more prior to 65 than they should have. What we’re asking back from those people is 70% of

those overpayments,” he says. The money owed will be repaid over several years, by reducing the monthly pension payments to the affected pensioners. According to a local newspaper, The Chronicle Herald, the repayment plan will affect 150 people and will result in the reimbursement of $2 million. The Port Hawkesbury mill was sold to Pacific West Commercial Corp. in 2012, and now operates as Port Hawkesbury Paper.

Ontario mill included in Clearwater Paper sale Clearwater Paper Corporation has sold its specialty products business and mills to Dunn Paper, Inc., of Michigan. The transaction includes the sale of five Clearwater Paper specialty tissue and machine glazed paper mills located at St. Catharines, Ont.; East Hartford, Conn.; Menominee, Mich.; Gouverneur (Natural Dam), N.Y.; and Wiggins, Miss. With the sale, 470 specialty products

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employees are now employees of Dunn Paper. “We are very pleased to welcome the exceptional people who lead and work at these specialty mills to the Dunn Paper team,” said Brent Earnshaw, CEO of Dunn Paper. “Combining the unique assets, capabilities and products of these mills with Dunn Paper’s Port Huron mill will lead to a specialty paper company with unmatched product offerings for our diverse customer base.” The five mill locations include nine paper machines with more than 200,000 tons of production capacity across a diverse set of product lines including machine glazed paper, coated paper, specialty napkin, towel and tissue, and wet crepe. Dunn Paper produces a wide array of specialty waxed, coated and uncoated machine-glazed papers used in various food packaging and specialty label applications. Clearwater purchased the St. Catharines mill and several other plants form Cellu Tissue in 2010. PPC

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Opinion

Canada’s Forest Products Industry: Helping to Grow a Greener World By David Lindsay, president and CEO, Forest Products Association of Canada

id you know that Canada’s forest products sector employs almost twice as many people and contributes twice as much to Canada’s manufacturing GDP as auto manufacturing, according to Statistics Canada? Naysayers who write off the forest industry as a sunset sector might be surprised to know that 2014 was a relatively good year with exports up about 10% from a year earlier. It is of course true that some traditional pulp and papers mills have shuttered recently, but there is positive news as well – the sector has been refocusing and reinventing itself. It can look to the future with cautious optimism because of its idealistic vision, pragmatic approaches and smart decisions by both industry and governments. For pulp and paper mills, innovation is emerging as an engine of growth. Wood fibre is now being used in everything from car parts to cosmetics to chemicals and clothing. Turning traditional mills into bio-refineries will help create new growth but also help “green” the economy since these new products, based on a renewable resource, can replace those made from

more carbon-intensive materials. Marketing the new wood-based bio-products as “green” can only enhance the industry’s already strong environmental credentials. Canada is recognized for its progressive forest management practices; we have 40% of the world’s independently certified forests. Pulp and paper mills have cut greenhouse gas emissions by about 70% since 1990. About thirty mills now generate green electricity on-site – enough to power all the houses in Calgary – using residual materials from their operations. Forest companies belonging to the Forest Products Association of Canada (FPAC) continue to work co-operatively with environmental groups in the Canadian Boreal Forest Agreement (CBFA). And under Vision2020, the sector is aiming to further reduce its environmental footprint by 35% by the end of the decade. FPAC is gratified to see that a 2014 international market survey by Leger Marketing showed that Canada’s forest products industry had the best environmental reputation in the world. So even with bumps along the way, the industry is growing and further greening itself as it looks to a future where it continues to support jobs and prosperity, especially in rural Canada.

Paperweek: FPInnovations Presents at the 101st Annual Conference By Jennifer Ellson, Senior Communications Specialist, FPInnovations

he night is absolutely longer and the weather is undeniably colder in Montreal – it is definitely time for PaperWeek! FPInnovations is proud to be an active participant and sponsor of this premier international conference, which has the theme “Shaping the Future: People, Process and Innovation” for 2015. Paperweek has been graced by generations of papermakers and there are probably 101 reasons to attend this annual event, which is celebrating its 101st year. Hosted by PAPTAC, the event brings together key players from the pulp and paper industry from both the mill and supplier sides.The 2015 conference is all the more special as PAPTAC celebrates its 100th anniversary. Industry leaders will jumpstart the conference with an opening executive breakfast panel where they will discuss the strategy of Canadian industry alignment. FPInnovations’ president and chief executive officer Pierre Lapointe will be one of the panelists, as FPInnovations is an important partner in the industry and as organizations work to advance the forest industry in Canada, we cooperate on many files. Also on opening day, Charles Xu, NSERC/FPInnovations associate industrial research chair in forest biorefinery, will deliver a keynote presentation entitled “BioFuelNet www.pulpandpapercanada.com

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and the Conversion of the Forest Biomass.” For the technical sessions, FPInnovations’ researchers and scientists have been busy preparing presentations to highlight the latest game-changing innovations in the Canadian pulp and paper sector. Without a doubt, Canada is at the forefront of the international race to develop game-changing technology and eco-friendly materials and FPInnovations has been at the center of many of the incredible technological advances. On Feb. 3 in the afternoon, FPInnovations’ Stéphane Larivière and Zhirun Yuan are chairing the tissue and technical tracks, respectively, where technical presentations on the fundamentals of tissue properties and mechanical pulping will be given by distinguished FPInnovations scientists: Jessica Carrette, Joseph Aspler, Alois Vanerek, Daniel Ricard and Quangqing Zha. On Wednesday, February 4, FPInnovations’ research manager Xuejun Zou talks about enhancing tissue manufacturing efficiency and performance using new measurement tools, while FPInnovations researcher Shree Prakesh Mishra will talk about mill implementation of a near neutral chlorine dioxide brightening technology in the afternoon. The complete conference program and schedule are available for download at http://www.paperweekcanada.ca. PPC January/February 2015 PULP & PAPER CANADA

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Packaging

Cascades continues to divest assets

Photo courtesy Cascades.

Having turned 50 years old, Cascades is paring back its operations to focus on sectors in which it is strong: certain core packaging sectors, tissue paper and recovery By Cindy Macdonald, editor

n recent months, Cascades Inc. has been paring back its operations to focus on certain packaging sectors and the tissue market. The Quebec-based paper company has sold boxboard and envelope assets, and withdrawn from the fine papers sector with the sale of the Rolland division earlier this year. The latest move is the planned sale of the company’s North American boxboard manufacturing and converting assets to Graphic Packaging Holding Company for $44.9 million. Cascades’ president and CEO Mario Plourde says this divestment is part of the company’s commitment to focus on sectors in which it excels. “This transaction follows in the wake of a number of other actions taken during the course of the year, with a view to reducing our debt load and focusing our investments in certain core packaging sectors, as well as in the tissue paper and recovery sectors.” The boxboard deal is subject to standard closing conditions and regulatory review and is expected to close in the first quarter of 2015. The Cascades boxboard units affected by the transaction are: • East Angus, Qué., a mill that manufactures recycled coated boxboard for the production of folding cartons. Founded in 1910, it was purchased by Cascades in 1983. • Jonquière, Qué., a mill that manufactures three-ply coated boxboard from virgin or recycled fibre. Founded in 1963, it was acquired by Cascades in 1984. 12

Cascades retains its corrugated packaging business and tissue operations.

•

Winnipeg, Man., a plant that manufactures folding cartons. Founded in 1905, it was acquired by Cascades in 2001. • Mississauga, Ont., a plant that manufactures high-quality graphic packaging. Founded in 1986, it was purchased by Cascades in 1992. • Cobourg, Ont., a plant that manufactures high-quality flexographic boxboard containers. It was built by Cascades in 1993. The five plants affected by the transaction employ approximately 670 workers. “The investments made in past years in these boxboard manufacturing and converting units have led to an opportunity to create synergies with a player such as Graphic Packaging. By exiting this sector of activity in North America, Cascades and Norampac are turning a page in their history. We sincerely thank our employees for their loyal services, and we wish them all the best in the future,” added Marc-André Dépin, president and CEO of Norampac. The transaction gives Graphic Packaging a significant presence in the Canadian market. David Scheible, Graphic Packaging’s chairman, president and CEO, commented: “The acquisition of Cascades’ Norampac paperboard assets enhances our position

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in North American folding cartons and enables us to extend our customer reach in Canada. The transaction is a continuation of our acquisition strategy to grow integrated folding carton converting volumes in key geographies and end-markets.” Graphic Packaging, headquartered in Atlanta, Georgia, provides packaging solutions to food, beverage and consumer products companies.

Twin Rivers buys kraft envelope business Earlier in 2014, Twin Rivers Paper Co. purchased certain envelope assets from Cascades’ East Angus operations. “The recycled natural envelope offering is a great addition to the Twin Rivers product line,” said company president, Ken Winterhalter. “We are confident the environmentally astute customers will find us to be an innovative and value-added future partner.” Cascades and Twin Rivers representatives worked closely through the development process, the company stated, and the two firms will continue this cooperation to ensure a seamless transition of the business. The envelope products are manufactured at Twin Rivers’ Madawaska Paper Mill in Maine. Twin Rivers also operates a pulp mill in Edmundston, N.B. PPC www.pulpandpapercanada.com

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Photo courtesy Cascades.

Cover Story Excerpted from 2013 Global Forest Products Facts and Figures, published by FAO

THE

BIG

PICTURE: global fibre, pulp and paper data

Global production of wood products rose in 2013, but pulp and paper stagnated

lobal production of all major wood products continued to show steady growth in 2013 for the fourth consecutive year, according to new data published by the Food and Agriculture Organization of the United Nations (FAO) in December 2014. While the production of industrial roundwood, sawn wood, wood pellets and wood-based panels has fully recovered from the economic downturn in 2008-2009, global production of pulp and paper stagnated in 2012-13 largely due to a decline in consumption in China, where FAO says electronic publishing is increasingly being used instead of traditional printing processes. In pulp and paper markets, overall growth was very modest over the period 2009-13, with a growth trend of below 1% per year.

Paper markets pause due to weaker demand in China In China, production of paper and consumption of pulp and wastepaper – the two main products used to manufacture paper – declined slightly (by 1%) in 2013 for the first time, after 38 years of uninterrupted growth. The downturn in the world’s largest producer and consumer of paper was largely responsible for the stagnation in global pulp and paper production in 2013. “The developments in Chinese paper consumption are worth noting for the future,” said Adrian Whiteman, FAO senior forest economist. “If people in China are switching to electronic media as so many www.pulpandpapercanada.com

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of us have in the West, this will be the end of one of the few remaining centres of growth in printing and writing paper consumption.” In contrast to this, China continues to increase in importance as a producer and consumer of other forest products. In 2013, the country overtook a number of other major countries in different product groups; for example, it overtook Canada in sawn wood production and the United States in sawn wood consumption. China’s imports of industrial roundwood and sawn wood also surged by 18% and reached record levels in 2013. The country is by far the largest producer and consumer of wood-based panels and paper. China is also highly significant for international trade in forest products, being the world’s largest importer of industrial roundwood, sawn wood and fibre furnish (pulp and wastepaper) and the largest exporter of wood-based panels. China’s imports of industrial roundwood and sawn wood surged by 18% and reached record levels in 2013, but paper production and consumption in China contracted slightly in 2013 for the first time since the 1970s.

is due to increased production in the AsiaPacific region (an increase of 13% from 2009 to 2013). Production in the other four regions remained roughly the same. In 2013, the regional distribution of production was as follows (Figure 1): AsiaPacific – 184 million tonnes (46%); Europe – 105 million tonnes (26%); Northern America – 85 million tonnes (22%); Latin America and Caribbean – 20 million tonnes (5%); and Africa – 4 million tonnes (1%). With respect to international trade, about one-quarter of paper and paperboard production is exported (roughly the same as the proportion of fibre furnish that is exported). Exports increased slightly over the period from 102 million tonnes in 2009 to 108 million tonnes in 2013. Thus, the current changes in global demand (e.g. high demand growth in Asia-Pacific and declining demand in Europe and Northern America) appear to be having more of an impact on international trade in fibre Fig. 1

Asia-Pacific leads growth in paper and paperboard Paper and paperboard production has increased over the period 2009-13 from 371 million tonnes in 2009 to 398 million tonnes in 2013. Production in 2013 remained roughly the same as in the previous three years. Almost all of this growth January/February 2015 PULP & PAPER CANADA

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Cover Story Fig. 2

furnish than on trade in paper and paperboard. The figures for net trade between the regions show some growth in the period 2009-13 (Figure 2). Europe and Northern America are net exporting regions, with net exports of 12 million tonnes and 8 million tonnes respectively in 2013. Asia-Pacific, Latin America and Caribbean and Africa are all net importers. The two largest paper and paperboard producers in 2013 were China (105 million tonnes) and the United States (74 million tonnes). Together, their production accounted for 45% of global production. The other three largest producers were Japan (26 million tonnes), Germany (22 million tonnes) and Republic of Korea (12 million tonnes), which accounted for another 15% of global production. China and Republic of Korea were the only major producers where production increased over the period 2009-13 (by about 20%). Production in the United States, Japan and Germany remained about the same.

Canada is a leading exporter of paper and board Exports from the five largest paper and paperboard exporters are roughly the same

(between 8 million tonnes and 13 million tonnes). These five countries – Germany, the United States, Sweden, Finland and Canada – exported 53 million tonnes in 2013 (49% of global exports). Figure 3 also shows that exports are quite variable from year to year. However, it seems that exports from the United States are on an upward trend (e.g. an increase of 33% over the period 2009-13), while they declined or remained unchanged in the four other countries. Exports from Canada have declined by 14% over the period 2009-13. Consumption in China increased over the period 2009-13 (by 14%, from 90 million tonnes in 2009 to 103 million tonnes in 2013). However consumption (and production) declined slightly (by 1%) in 2013 for the first time after 38 years of uninterrupted growth in this country. Consumption in India grew by 35% and in Germany by 8% over the same period.

Newsprint production declined, packaging paper increased Figure 4 shows the distribution of paper and paperboard production among the five different product types that are included in this group. As the figure shows, wrapping and packaging paper accounted for over half of all production in 2013 (216 million tonnes, or 54% of the total). Printing and writing paper was the next largest (105 million tonnes or 27% of the total), followed by household and sanitary paper (8%), newsprint (7%) and other paper and paperboard. The two main trends in the different products are the gradual decline in newsprint production (a fall of 10%, from 32 million tonnes in 2009 to 29 million tonnes in 2013) and the 13% increase in wrapping and packaging paper over the period (from 191 million tonnes to 216 million tonnes). Household Fig. 3 and sanitary paper production also increased over the period (an increase of 12%, from 28 million tonnes to 31 million tonnes). Printing and writing paper has increased marginally by 2% (from 103 million tonnes to 105 million tonnes), while production of other paper remained roughly the same over the period from 2009 to 2013.

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Fig. 4

Global fibre furnish remains stable In FAO’s forest products statistics, the fibre used to manufacture paper and paperboard is referred to as “fibre furnish.” This includes recovered paper (wastepaper), other fibre pulp and the wood pulp used to make paper. The latter includes mechanical, chemical and semi-chemical wood pulp, but does not include dissolving pulp (which is used for other purposes). Global production of fibre furnish in 2013 amounted to 397 million tonnes. This was a very small (1%) decrease compared with the previous year. At the global level, the production of fibre furnish increased in 2010 and remained quite stable thereafter. The increase (from 377 to 397 million tonnes in 2009-10) occurred in only that year; the other years over the period 201013 show a quite stable production level at about 400 million tonnes.

Fibre furnish growth varies by region The regional distribution of fibre furnish production in 2013 was as follows (Figure 5: Asia-Pacific – 141 million tonnes (36%); Northern America – 114 million tonnes (29%); Europe – 105 million tonnes (26%); Latin America and Caribbean – 33 million tonnes (8%); and Africa – 4 milFig. 5

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Cover Story lion tonnes (1%). The Asia-Pacific region is now the largest producer of fibre furnish due to consistent growth over the period (with production in 2013 about 10% higher than the figure of 130 million tonnes in 2009). Production in Europe and Latin America and Caribbean has also grown consistently over the period, although at a much lower level. In contrast, production has not changed or slightly declined in Northern America and Africa. About one-quarter of fibre furnish production was traded in international markets in 2013. This trade has increased consistently over the period (from 99 million tonnes in 2009 to 110 million tonnes in 2013, equal to an increase of 11% in total). Net trade also remained at quite stable over the period 2009-13. The Asia-Pacific region is the only net importing region and net imports of fibre furnish have increased over the period by 10%, from 44 million tonnes in 2009 to 48 million tonnes in 2013. Net imports have also increased at about the same rate as consumption in the AsiaPacific region. The main net exporter is

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Northern America, with net exports of 30 million tonnes in 2013, followed by Latin America and Caribbean (13 million tonnes) and Europe (5 million tonnes). Net exports have increased over the period in Latin America and Caribbean and Northern America, but declined by half in Europe. The main producers of fibre furnish are the United States, China, Japan, Canada and Brazil. Together, these countries produced 231 million tonnes of fibre furnish in 2013 (58% of the global total). As Figure 6 shows, production has remained roughly the same the over the period 2009-13 in the United States, Japan and Canada. This is due to declining paper production and consumption in these three countries, which is now a common trend in many developed countries where people are using more electronic communication media. Production in China increased by 18% over the

Fig. 6

period 2009-11 (from 58 million tonnes to 69 million tonnes) and remained quite stable in the following years.

Canada a major exporter of fibre furnish Four of the main producers of fibre furnish are also the main exporters (United States, Japan, Canada and Brazil) and the fifth largest exporter is Chile (Figure 7). These five countries exported 57 million tonnes of fibre furnish in 2013 (52% of the global total). Exports increased over

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Cover Story of fibre furnish in 2013 (62% of the global total). Figure 8 shows that recovered paper and chemical wood pulp are the two main products used to manufacture paper, accounting for 55% and 33% (respectively) of all fibre furnish consumption in 2013. Mechanical pulp is the next most important (7%), followed by other fibre pulp (3%) and semi-chemical wood pulp (2%). The trends in consumption also show that not only does recovered paper account for more than half of all fibre used to make paper, but it is also increasing in importance. In 2009, recovered paper consumption amounted to 201 million tonnes (54% of the total) compared with the figure of 216 million tonnes (55% of the total) in 2013. In contrast, consumption other fibre Fig. 7

the period 2009-13 in Canada (by 16%), Brazil (by 15%), Japan and Chile (by 5% in both countries). In the United States, after an increase in 2009-11, exports in 2013 came back to the level of 2009. The five main consumers of fibre furnish are China, the United States, Japan, Germany and Republic of Korea. These countries consumed 246 million tonnes

Fig. 8

pulp has declined (both in absolute and percentage terms). Wood pulp consumption increased slightly (5%) and its share remained unchanged over the same period. Excerpted from 2013 Global Forest Products Facts and Figures, published by FAO, December 2014. FAO’s forest products statistics present figures for the production and trade (quantity and value) of forest products, covering 54 product categories, 21 product groups and 245 countries and territories. At the end of each year, final statistics are released for the previous year.

We don’t just talk about innovation.

We innovate. See how FPInnovations takes part in the

technological advances of the pulp,

paper and bioproducts sector. fpinnovations.ca Follow us

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www.pulpandpapercanada.com

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Operations Sponsored Technical Paper

Nanotechnology Raises Doctoring Performance to New Level

hroughout the modern history of papermaking, significant advances have been made in roll cover and press and dryer fabric materials. The materials used to make doctor blades have also evolved over the past century to reflect other technology developments in papermaking. The consistent demand for new and better-performing doctoring materials has accelerated in recent years as machine speeds pushed higher and recycled fibre usage increased. Demanding operating conditions led to the continuous development of ever more sophisticated composite materials to carry out the roll cleaning and dewatering functions combined with a constant drive to reduce operational costs for the papermaker. Because a doctoring failure in a critical position can cause significant down time and irreparable damage to roll surfaces and dryer fabrics, properly designed, adjusted, and maintained doctors can significantly enhance machine efficiency and lower operating costs. Kadant’s most recent doctoring development shifts from a conventional product upgrade to a step-change in doctor blade materials featuring patented and patentpending nanotechnology-enhanced resins applied to doctor blades. Nanotechnology, in terms of doctor blade materials, is the inclusion of micro particulate materials into the resin matrix. The nanotechnology-enhanced resin provides a more homogenous structure than can be achieved by conventional filler particles alone, with the composite resin matrix being manipulated on a molecular scale to produce high-performing, wearresistant doctor blades. The resulting blade products are denser and provide increased stiffness, increased resistance to chipping, and improved interlaminar bonding. They also have a lower coefficient of friction compared to traditional doctor blades. Roll surface cleaning is improved and doctor blade life has been shown to increase significantly compared to conventional doctor blades. For the papermaker, this means longer blade life, www.pulpandpapercanada.com

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Figure 1. Brand X doctor blade after two days.

Figure 2. Kadant blade after two days.

Figure 3. Stock penetration into conventional blade material. Figure 4. A strong leading edge ensures best performance.

fewer blade changes, and the potential for reduced operating costs while enhancing overall machine efficiency. Since its introduction, the nanotechnology-enhanced doctor blade offering has shown impressive performance in critical and demanding positions. Because a doctor blade’s cleaning effectiveness depends on a strong leading edge, special attention was given to the new nanotechnologyenhanced resin matrix to ensure maximum longevity. Figures 1 and 2 show the difference between the leading edge of the Kadant nanotechnology-enhanced blade and a competitor’s blade after running on the same position. The nanotechnologyenhanced blade maintained a strong bevel edge, showed light dusting, and no visible wear. Note the contrast with the incumbent blade, which has a poor leading edge that allowed considerable pitch to pass and form into ribbons on the back of the blade. Aggressive recycled furnish applications with high stickies and high levels of abrasives will cause delamination and characteristic penetration of the blade edge in conventional blades, shown in Figure 3. The operational result with nanotechnology-enhanced blades performing in the

same position, shown in Figure 4, is that the sharp doctoring edge is maintained and no delamination or bevel penetration occurs. The nanotechnology-enhanced doctor blades have introduced a step-change in blade performance and are now setting a new bar for blade performance. Not since the early 1900s, when composite blade materials were introduced to address new roll surface materials and finishes, has there been such a radical innovation in blade material to cost-effectively address contaminants removal and machine runnability. As a new standard in doctor blade performance is being established using nanotechnology, paper mills around the world are benefiting. Cylinder cleanliness, machine runnability, heat transfer, and product quality are all being affected in various ways, and papermaking operations are finding a new source of value from their doctoring systems. PPC For more information, visit www.kadant. com/nano-blade. Or contact your local Kadant specialist to discuss how your machine could benefit from nanotechnology-enhanced doctor blades.

January/February 2015 PULP & PAPER CANADA

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Technology: Bleaching

Is Conductivity the Best Measurement of Bleach Plant Carryover? By Niclas Andersson, BTG Instruments; Caroline Wilke, BTG Instruments and Karlstad University; Tom Biazzo, BTG Americas Inc.; Rick Van Fleet, BTG Americas Inc.; Ulf Germgård, Karlstad University; Sandra Beder-Miller, BTG Americas Inc.

ABSTRACT Kraft pulp mills have struggled with how to quantify black liquor carryover into the bleach plant. Current on-line kappa testing measures only lignin bound to the fiber from a washed pulp sample. The dissolved lignin in the filtrate accompanying the pulp into the bleach plant has been measured in-line by indirect methods such as pulp conductivity, D100 residual measurement or D100 washer brightness. These methods are only surrogates of the true measurement that is needed for D100 chlorine dioxide chemical control. Conductivity measures inorganic sodium salts. An assumption is made that the inorganic to organic compounds ratio remains stable with the majority of organic material being dissolved lignin. From this conductivity measurement, we infer the amount of dissolved lignin or the organic portion because there is currently no direct measurement of dissolved lignin. A new sensor has been developed that can directly measure dissolved lignin content in the pulp slurry using a unique principle based on optical measurements. It has the ability to perform the measurement of the dissolved lignin inline even at medium consistency condition. The dissolved lignin concentration is highly correlated to COD and filtrate kappa. The sensor has two major applications: (i) improving efficiency in washing stages, and (ii) optimizing bleach plant chemical charges. Results from several mill trials have shown that the contribution from dissolved lignin in the filtrate portion of the pulp is up to 30% of the total bleach load, i.e. fiber and filtrate kappa number combined into the bleach plant. Correlations between the new sensor and filtrate kappa exceed 0.96 R-squared whereas the correlation of conductivity and filtrate kappa is only 0.46. Inaccurate measurement of dissolved lignin would lead to overuse of chlorine dioxide at the D100 stage.

Introduction

leach plant operators have been long been challenged with how to process variable quality pulp entering the bleach plant for the lowest cost. The pulp can have high or low “carryover”, which is the amount of black liquor solids entering the plant along with the pulp. The amount of carryover is due to a variety of reasons such as: - Upsets in brown stock washing in advance of the bleach plant - Shower flow limitations - Recovery limitations. The literature has shown that black liquor in the bleach plant adds to chemical costs. Consumption has been expressed as (1): - 1 kg of chlorine per 1 kg black liquor measured as sodium sulfate - 2 kg of chlorine per kg of carryover as lignin - 0.5 kg equivalent chlorine per kg of total dissolved solids 18

The best solution is not to send carryover to the bleach plant. This is not always possible due to aging washing equipment and the operational considerations cited above. The challenge is to accurately quantify the amount of black liquor accompanying the pulp into the bleach plant. The chlorine dioxide dosage calculated from kappa factor control does not include carryover since it is based on a washed pulp sample. Operators have employed a variety of methods to account for the dissolved lignin since it is the first to consume the chlorine dioxide dosed at the D0 stage. Measuring conductivity at the end of the brown stock washing or incoming to the bleach plant has been used as indicator of pulp cleanliness due to its low cost and ease of use. There is a flaw in using conductivity as an indicator of carryover. Conductivity is based on the measurement of the ionic sodium species in the liquor, inorganic phase. Conductivity does not directly

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measure the organic phase, the dissolved lignin. It is assumed that the inorganic/ organic phase remains constant so a relationship can be built between the conductivity and dissolved lignin. In short time frames this ratio assumption is good enough but over time it is believed that the relationship does not hold up. This is due to changing white liquor concentration (TTA/EA), liquor-to-wood ratios in digesters, the extent of delignification in the digester, wood species changes and other seasonal effects. Sodium measured in the pulp leaving the brown stock washers has also been used to evaluate cleanliness of the pulp entering bleach plant. This test is reported to the bleach plant operator who will factor this result into how much extra chlorine dioxide must be added to account for dirty pulp entering the bleach plant. Sodium does not consume chlorine dioxide but the dissolved organic component carried over in the pulp does. Stromberg, www.pulpandpapercanada.com

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Technology: Bleaching

Experimental Inline dissolved lignin measurement

Figure 1. Stromberg: Washing for low bleach chemical consumption (2).

Fig. 1, has shown that at the same saltcake loss, the dissolved organic component can vary up to 4 times when compared between several mills. The organic component, or dissolved lignin, can be quantified by chemical oxygen demand (COD) or filtrate kappa. Until recently, there were no on-line sensors to measure these parameters. The operator would run COD on a periodic basis and relate to an in-line conductivity meter. COD tests are time consuming and take several hours to complete. The test results are reported long after the pulp condition was sampled and the operator is left to guess at the amount of additional chemical to add to the incoming pulp at the D0.

The strong light absorption of the lignin molecule in the UV-VIS (ultraviolet and visible) region due to its aromatic structure is well known and it is employed in currently used technology for automatic fiber lignin content measurement typically expressed as kappa number. It can also be used for determination of dissolved lignin by light transmittance measurement. However, such a measurement can only be performed on a filtrate i.e. without fibers and can thus only be conducted on a pure filtrate stream where the fibers have been filtered off (3). The new sensor for measurement of the concentration of dissolved lignin, presented in this paper, employs a unique principle capable of resolving the filtrateâ&#x20AC;&#x2122;s light absorbance in the presence of pulp fibers. As shown in Fig. 2, using a small measuring volume, the time periods corresponding to measurement of only the filtrate portion can be identified and used to calculate the light transmittance and absorbance, and subsequently to determine the dissolved lignin concentration. A common understanding is that determination of lignin should be performed in the UV region. Under the assumption that the absorbance measured by the new sensor is directly related to the dissolved lignin concentration, no calibration is required unless for scaling into, for example, filtrate kappa number using one reference sample only (see next section).

Furthermore assuming that the chemical oxygen demand (COD) correlates with the dissolved lignin concentration, one can choose scaling into COD output, again using only one reference (COD) sample. Hence the sensor is operative principally immediately after installation.

Filtrate kappa number measurement The so-called filtrate kappa number has been used as a measure of the concentration of dissolved lignin of the filtrates. This parameter has thus been used for calibration and follow-up of the performance of the new sensor. The filtrate kappa number method is very similar to the standard (fiber) kappa number method of Tappi and SCAN but uses a certain volume of filtrate as the basis and thus provides filtrate kappa number per ml of filtrate (compared with kappa number per gram of fiber). In order to relate to the fiber kappa number, and to calculate the total kappa number (fiber + filtrate kappa number), the consistency of the pulp is used for weighing the two sources. In a feed to bleach position the total kappa number can be expressed as the total bleach load. However, this assumes that the permanganate consumption is a relevant measure of the remaining bleaching chemical demand for both the fibers and the filtrates.

Results and discussions The presented work was focused on mill studies but some basic laboratory trials were also made to verify the principle of the new sensor, and to understand the characteristics compared with current technologies used in mill applications.

Laboratory investigations

Figure 2. Probe with measuring gap (left) and principle signal extraction (right) of new dissolved lignin sensor. www.pulpandpapercanada.com

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In order to understand how currently used technologies are affected by the content of inorganic matter in the studied black liquors, changes were made of the NaOH and the NaCl concentrations in mill filtrate samples. In Fig. 3, it can be seen that the conductivity and refractive index show a significant dependence on the chemical additions. It should be noted regarding refractive index that very small absolute changes occur in general and a difference January/February 2015â&#x20AC;&#x192; PULP & PAPER CANADAâ&#x20AC;&#x192;

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Technology: Bleaching

Figure 3. Effect of pH (left) and addition of NaCl (right) to mill pulp samples on refractive index and conductivity.

of only 0.0010 units corresponds to half of the total range of filtrate kappa number variations for the laboratory samples taken (being 4-10 filtrate kappa number units in this position; pre-O2). The new sensor for dissolved lignin, as expected, was practically unaffected by the chemical additions; less than 0.5% relative to the range of variation of the filtrate kappa samples.

Mill investigations The new sensor has been installed in several pulp mills and in different positions. Two cases are described in the following. Case 1. Brown stock washing control This softwood sulfite pulp mill has nine batch digesters which feed a single blow tank. Depending on the pulp grade, the digesters can yield between 18 and 24 batches per day, over a large kappa number range. Pulp is pumped from the blow tank to a horizontal belt washer. The consistency of this pulp feed is controlled by a consistency controller which manipulates the flow of dilution water. Figure 4 shows data from the new sensor versus the corresponding filtrate kappa number for a brownstock washing installation. It is clearly seen that there is a very good linear correlation between the sensor signal and the filtrate kappa number. Thus, it is possible for the pulp mill to regularly obtain information on the amount of dissolved lignin in the pulp slurry. Combining this information with 20â&#x20AC;&#x192;

Figure 4. Filtrate kappa (per ml, filled symbols, left axis) and COD (mg/l, circles, right axis) vs. the new sensorâ&#x20AC;&#x2122;s raw signal output. Data from case 1.

the liquor volume per ton of pulp and production rate it is possible to calculate the dilution factor (DF) in this fiber line position. Figure 4 also shows the new sensor signal vs. COD for the same fiber line position and in this case also there is a linear correlation. Thus, it is possible to replace the tedious, costly and environmentally problematic COD test with the signal from the new sensor. The mill uses the value of the dissolved lignin to modulate the wash water applied

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to the brownstock washing system. The dissolved lignin value is also indicative of a certain final product specification. This allowed the mill to maintain final product specification for numerous grades of pulp produced at the mil as well as optimize the liquor solids to the spent liquor recovery system (4). Case 2: Feed to bleach carryover measurement The inline sensor was installed before a wash press prior to the D0 stage of a softwww.pulpandpapercanada.com

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Technology: Bleaching

wood kraft pulp mill, at a pulp consistency of 4-5%. Figure 5 trends the sensor output during a period of 70 days, scaled to filtrate kappa number, along with laboratory reference data (69 samples). The fit between the sensor trend and the reference data is very good. This is also seen in Fig. 6, showing both filtrate kappa number and COD vs. the sensor’s raw signal, both with correlation coefficients r2 above 0.97. The variability of the dissolved lignin concentration is also quite remarkable. Assuming an average pulp consistency of 4.5% and a filtrate density of 1 g/ml, one filtrate kappa number unit (i.e. per ml filtrate) corresponds approximately to a kappa number of 21 on fiber basis i.e. even more than the fiber kappa number which typical level is indicated in Fig. 7. The sensor was also installed after the wash press before the D0 stage where the inlet pulp consistency to the stage was 8-10%. The filtrate kappa number on laboratory samples varied between 0.06-0.23 with an average of 0.16 (per ml). At 9% consistency this corresponds to an average of 1.6 kappa number units on a fiber basis, i.e. approximately 10% of the total kappa number or bleach load. However, the variability of the filtrate kappa number corresponds to approximately +/-1 kappa number unit (on fiber basis) which must be considered significant relative to the fiber kappa number variability. Based on data for fiber kappa number variability in this position, approximately one-third of the total bleach load variability originates from the filtrate kappa number variability, i.e. carryover, and subsequently approximately two-thirds from the fiber kappa number variability.

Figure 5. A 70-day trend of the new sensor-predicted and laboratory-determined filtrate kappa number of the pulp. The data is from case 2.

Figure 6. Filtrate kappa number (per ml, filled symbols, left axis) and COD (mg/l, circles, right axis) vs. the new sensor’s raw signal output. The data is from case 2.

Practical implications of the current results, scope of further studies he conditions determined in a pre-O2 T position show filtrate kappa number averaging at 7 and ranging between 4-10 (kappa number units per ml filtrate) for laboratory samples. With 10% consistency this filtrate kappa number corresponds to 63 kappa number units on fiber basis (ranging 36-90). The target cooking kappa number is 30 at this mill. The findings from studying the preO2 position, where evidently most of the www.pulpandpapercanada.com

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Figure 7. Pre-D0 fiber kappa number vs. time (days), indicating typical variability. The data is from case 2. January/February 2015 PULP & PAPER CANADA

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Technology: Bleaching

‘total’ kappa number (i.e. permanganate consuming compounds) are in the filtrate portion of the pulp, also requires further investigation. Even though chemistry is quite different, such high levels imply it will affect the conditions.

Conductivity versus COD Tests were conducted in a Scandinavian mill prior to oxygen delignification to demonstrate the relationship between COD, filtrate kappa and conductivity, Figs 8 and 9. The weak correlation is shown to be slightly over 0.40 for COD versus conductivity. The industry has long accepted the relationship that carryover expressed as COD potentially will consume 1 to 1.5 kg of chlorine dioxide per kg of COD (3). The economic impact using this relationship on a 1000-ton per day mill with 350 operating days and chlorine dioxide at $1.00 per kilogram would result in $350,000 of additional chemical costs per year. Now consider that an inaccurate quantification of COD is used in the kappa factor control strategy at the D0 stage. The simple linear relationship shown in Fig. 8 will over-estimate the amount of COD 67% of the time and under-estimate the amount of COD 33% of the time. This will lead to a misapplication of additional chlorine dioxide. A similar weak relationship holds for filtrate kappa expressed on a per gram basis and conductivity. Because of this inaccuracy using conventional sensors, the new sensor will have a payback of two months compared to a conventional conductivity measurement. The COD and filtrate kappa tests were compared to the in-line dissolved lignin transmitter, Figs. 10 and 11. The correlation was very strong and well over 0.90 R-squared. A single point calibration was required to relate the UV absorbance signal from the dissolved lignin transmitter to the desired laboratory test.

Conclusions The key conclusions based on the present study are as follows: • An inline sensor for dissolved lignin has been validated in laboratory and mill trials in several mills and in positions from pre-O2 to pre-D0. The sensor’s cor22

Figure 8. Pre-O2 delignification data from Scandinavian mill.

Figure 9. Pre-O2 delignification data from Scandinavian mill.

relation with dissolved lignin as filtrate kappa number and COD is very high. • The sensor operates inline in the pulp stream, at LC and MC conditions. It is principally pre-calibrated and requires only one sample for scaling for desired output. • The investigations using the sensor have revealed that the dissolved lignin in the filtrate has a significant share of the total kappa number and that it contributes to

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a large part of total variability thereof. • The sensor can be applied for washing control, i.e. for optimization of the use of wash water with respect to, for example, energy consumption in evaporation and pulp cleanliness. In a mill application the sensor output is used as a valuable tool for modulation of dilution factor and the overall control of the brown stock washing system. www.pulpandpapercanada.com

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Technology: Bleaching

• The sensor can be applied for control of charging of bleach chemicals. Together with the fiber kappa number the total bleach load can be calculated for optimizing process performance. • According to the present findings the dissolved lignin is likely a key process parameter but so far not possible to measure inline for control purposes. The new sensor for dissolved lignin opens up new opportunities in optimizing fiber line operation. • The new sensor directly measuring dissolved lignin in the filtrate is a more accurate and reliable measurement for process control purposes than other current technologies e.g. conductivity and refractive index. Figure 10. Dissolved lignin transmitter predicting COD

Acknowledgements The excellent cooperation with Honeywell is acknowledged in Case 1, “Brown stock washing control” for developing and implementing the APC solution. References 1. Dence and Reeve, Pulp Bleaching, Principles and Practice, pp 583-584 (1996). 2. Stromberg, C.B., “Washing For Low Bleach Chemical Consumption”, Tappi Journal 74(10), pp.113-122 (1991). 3. Mao, B., et al., “Continuous on-line determination of the concentrations of dissolved lignin and hydrogen sulfide ions in kraft cooking liquors”, Nordic Pulp and Paper Research Journal, 11(4), pp. 266272 (1996). 4. Wasik, L.S., Mittet, G.R. and Nelson D.J., “Controlling brownstock washing during production rate changes”, Tappi Journal 83(3), pp. 94-101 (2000). PPC

Figure 11. Dissolved lignin transmitter predicting filtrate kappa.

AstenJohnson acquires Eagle Nonwovens business AstenJohnson, a supplier of paper machine clothing, filaments, specialty and filtration fabrics, and equipment for the paper industry, has acquired Eagle Nonwovens, Inc. Eagle Nonwovens is known for producing consistent, highquality products and has gained a reputation for creative problem solving by developing innovative needlepunch solutions for the aerospace, automotive, healthcare, filtration, and home furnishings industries.

www.pulpandpapercanada.com

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“We are excited to welcome Eagle Nonwovens into our family of businesses,” says Dan Cappell, president and CEO of AstenJohnson. “This is yet another opportunity to offer customers an array of high performance products, technical expertise, and innovative solutions. The workforce at Eagle Nonwovens is highly engaged and professional, and shares our commitment to lean manufacturing and quality.” Eagle Nonwovens’ facility in St. Louis, Missouri, uses stateof-the-art Dilo Systems production equipment with in-line calendering, heat setting, singeing, glazing, etc. AstenJohnson, www.astenjohnson.com

January/February 2015 PULP & PAPER CANADA

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Technology News

ABB will supply a 34.5kV power distribution system, based on gas-insulated switchgear (GIS) technology, for Klabin’s major new pulp mill being constructed in Ortigueira (Paraná State), Brazil. The contract is valued at US$20 million and includes design, supply, commissioning and startup services. Klabin is a producer and exporter of packaging paper. The new mill will have an annual capacity of 1.5 million tons of pulp. ABB’s solution features leading edge technology such as the Is-limiter, the world’s fastest power switching device, and cabinet modularity. The mill in Ortigueira will be self-sufficient in electrical power, generating 270MWh of energy. Of this total, 120MWh will be used for its own consumption and a surplus of around 150MWh – enough energy to supply a city of half a million inhabitants – will be delivered to the market. ABB, www.abb.com

Valmet’s OptiBin chip bin used at Nordic Paper’s Bäckhammar pulp mill

Valmet has developed a new chip bin, OptiBin, for digester chip feeding at pulp mills. The first OptiBin was recently started up at Nordic Paper’s Bäckhammar pulp and paper mill in Sweden. The innovations in the OptiBin design bring several benefits. The design allows chips to flow smoothly and results in even presteaming and less runnability problems. The flow design allows a cold top to be used. This means that the bin itself will form a lid of chips that disables gases to flow to the atmosphere which

Well-lit, beautiful, functional and cost-effective laboratory space…. Combines lab/warehouse/pilot plant and class “A” office space. Fully furnished, ready to move in for sublease. Office building with 10ft ceilings, 15+ windowed, closed door offices, including a large conference room, and a kitchen. Located in the Technoparc district in Montreal, close to all amenities, including bus stop/ metro and just a 10 minute drive from Montreal Trudeau airport, with ample parking available. Sub-Lease includes shipping, receiving and business services. Ideal for Pulp and Paper related business, either supplier or manufacturer. Lab is fully equipped with all pulp and paper lab equipment, in pristine condition, including handsheet machines, a paper calendar and a wet chemistry lab, with 3 fume hoods and full paper testing. Total space available is flexible from 5000 sq.ft to 10,000 sq.ft. Also, for sale as a separate option is the possibility of pulp and paper equipment purchase. Please contact elizabeth.cacchione@norbord.com for photos and details. Low cost rent is possible due to shared space.The space is available April 1, 2015 for a 4-year sublease.

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Photo: Valmet

ABB to provide power solutions at new pulp mill in Brazil

Nordic Paper and Valmet successfully started up the first OptiBin chip bin.

results in less odors to the surroundings. Thanks to the new chip bin, Nordic Paper estimates an increase in production of about 1,000 Adt/yr. In addition, the OptiBin has led to substantial fiber savings. “The startup was very successful. We started production according to our schedule,” says Jonas Lindqvist, deputy director of production and project manager at Nordic Paper. “A week after the shutdown, we reached full production.” Valmet, www.valmet.com

PulpEye online analyzer sold to SCA R&D centre

SCA R&D Centre in Sweden has bought a PulpEye fibre analyzer unit with a built-in CrillEye unit. It replaces their present fibre analyzer equipment. The equipment will be used in product development as well as in a project called “Improved fines material control” in which SCA, Mid Sweden University and PulpEye are partners. SCA R&D Centre, located in Sundsvall, conducts mill and market-driven R&D mainly for SCA Forest Products units. Öjvind Sundvall of PulpEye comments: “The contribution of crill to paper and board properties have been known for a while but it has not been possible to measure it online in a reliable way. However, with our CrillEye module coupled to ExtractEye calculation module, this is now reality and it was a contributing factor for SCA R&D Centre to buy PulpEye.” “We have close cooperation with SCA R&D Centre and PulpEye and I am very satisfied with the additional research we can develop with the CrillEye module,” says Per Engstrand, a professor at FSCN, Mid Sweden University. PulpEye AB is a measurement technology company, focusing on online applications and services for the pulp and paper industry. PulpEye, www.pulpeye.com

Precise viscosity measurement

During the pulping and bleaching processes, Dynatrol® viscosity systems provide fast, precise viscosity measurement using a unique vibratory principle to provide continuous measurement at on-line process conditions. This eliminates the need for sampling and provides exceptional accuracy. With no moving parts it is virtually wear-free – ensuring a long operating life. Dynatrol® viscosity meters are being used for: alkaline waste black liquor, black liquor, black liquor sludge and black liquor interface. They have also been used to measure pulp slurry additives, resins from tissue and paperboard making and terpene resin. Automation Products Inc., DYNATROL® Division, 713-869-0361 or 800-231-2062, www.DynatrolUSA.com www.pulpandpapercanada.com

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January/February 2015 PULP & PAPER CANADA

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Bio-Economy

Pulp and paper industry use of biomass Quebec cellulose filament plant ramps up considered carbon neutral: EPA

omtar Corp. quickly announced its support of the position taken by the U.S. Environmental Protection Agency that carbon dioxide emissions from sustainably-managed sources of biomass should be considered “neutral” when accounting for greenhouse gas emissions. The Nov. 19 memorandum from EPA’s Acting Assistant Administrator for Air and Radiation, Janet McCabe, recognizes that not all biomass is created equal when it comes to regulating greenhouse gas emissions, according to Domtar company officials. “Just because a resource is renewable does not automatically make it sustainable. Today’s memorandum helps make that important point,” said David Struhs, vice-president, corporate communications and sustainability. Domtar also noted the importance of EPA recognizing the environmental and economic value of utilizing biomass feedstocks derived from waste materials. “EPA’s direction on this issue promotes the idea of extracting

as much value as possible from sustainably harvested biomass, which brings together economic and environmental interests,” according to Struhs. Domtar manufactures and markets a wide variety of products based on wood fibre, including communication papers, specialty and packaging papers and absorbent hygiene products, at facilities in Canada and the U.S. American Forest & Paper Association president and CEO Donna Harman also issued a statement about the EPA’s release of its proposed Accounting Framework for Biogenic CO2 Emissions and policy memorandum. “It appears that EPA has recognized our industry’s sustainable use of manufacturing residuals as carbon neutral. This is consistent with scientific studies showing the use of manufacturing residuals provides greenhouse gas reduction benefits equal to removing 35 million cars from the road when taking into account fossil fuel displacement and avoidance of additional methane emissions from disposal.”

U.S. report outlines path to commercialization of cellulosic nanomaterials The U.S. Forest Service has released a report that details the pathway to commercializing affordable, renewable and biodegradable cellulose nanomaterials from trees. Cellulosic nanomaterials are tiny, naturally occurring structural building blocks The report, titled “Cellulose Nanomaterials – A Path towards Commercialization,” is a result of a workshop held in 2014 that brought together a wide range of experts from industry, academia, and government to ensure that commercialization efforts are driven by market and user needs. “These environmentally friendly materials are extremely attractive because they have a unique combination of high strength, high stiffness and light weight at what looks to be affordable prices,” explains Ted Wegner, assistant director at the U.S. Forest Service Forest Products Laboratory in Madison, WI. “Creating market pull for cellulose nanomaterials is critical to its commercialization.” U.S. Forest Service Chief Tom Tidwell says the Forest Service “plans to generate greater public and market awareness of the benefits and uses for these naturally-occurring nanomaterials.” Issues identified by workshop participants included the need for more data on materials properties, performance, and environmental, health, and safety implications, and the need for a more aggressive U.S. response to opportunities for advancing and developing cellulose nanomaterials. 26

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production

The cellulose filament (CF) demonstration plant at Kruger’s Trois-Rivières facility has been producing a high quality, world-class strengthening bioproduct equivalent to that produced in the laboratory environment, the company reported in November. Since the plant’s inauguration in June 2014, while optimizing the process equipment, high quality cellulose filament has been produced and used in various mill trials and R&D projects. The trials showed that the reinforcing strength of the material from Trois-Rivières is as efficient as that produced in FPInnovations’ pilot plant. “Large-scale production is well under way and we are confident that we can continue to provide premium-quality CF, which will help develop the market and find new commercial applications for this revolutionary biomaterial,” says Daniel Archambault, executive vice-president and COO, Industrial Products Division, Kruger.

Kruger wins innovation award for cellulose filament demonstration plant

CMY

Kruger Inc. was presented with the “Open Innovation” Award by the Québec association for research and innovation development (ADRIQ) in recognition of its cellulose filament demonstration plant in Trois-Rivières. ADRIQ presents this annual award to a company that “has distinguished itself by creating and implementing world-class equipment in the field of collaborative innovation.” The world’s only cellulose filament (CF) demonstration plant, developed as part of an R&D partnership with FPInnovations and dedicated in June 2014, can produce five tons per day of this new-generation biomaterial. The demo plant operates on a simple and efficient chemical-free process developed by FPInnovations after four years of intensive work. Dellulose filament is obtained by mechanically peeling the filaments from wood fibres. The resulting filaments are extremely thin at about 500 nanometres wide, but they can be as long as half a millimetre and are extremely light and flexible. PPC

www.pulpandpapercanada.com

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Valmet_Ad_iRoll_P&P.pdf

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iRoll provides data that moves your runnability forward

CMY

iRoll is an online measurement system for board, paper and tissue machines. In iRoll, sensors are installed on the roll body to detect load profiles. e load profiles can be a direct result of paper tension, paper caliper, size press rod loading, nip pressures, or number of other variables. iRoll is much more than just a monitoring system, it controls product quality to tight tolerances. Learn more at valmet.com

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Unpack the power of Maximyze for packaging. ®

Let Buckman help you improve sheet strength and increase productivity. Buckman announces new Maximyze enzymatic technology for recycled packaging. It can significantly improve sheet strength and drainage, so you can increase machine speeds. With a customized Maximyze program you can reduce fiber costs, steam consumption, transportation costs and your environmental footprint too. No wonder it’s an EPA Presidential Green Chemistry Challenge Award winner! Find out more. Contact your Buckman representative or visit buckman.com. Better drainage Production on a recycled linerboard machine was limited due to drainage. Buckman’s Maximyze application improved drainage, so machine speeds could be increased by as much as 100 mpm. Steam use was reduced 8%, and CO2 emissions were reduced by 1806 metric tons per year. Reduced energy A core and tube producer wanted to increase production, have greater flexibility in its fiber selection and reduce energy use. Buckman applied Maximize to the pulper, which conditioned the fiber faster with less refining energy, preserving fiber strength. Speed increased 10%. Refining energy decreased 30%. And tensile strength increased from 20 to 26 kgf/15mm.

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Commitment makes the best chemistry.

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