Pulp& Paper
Inside: 2012 Pulp, Paper and Bio-economy Map
Canada
Over 100 years of serving the industry
JUly/august 2012 www.pulpandpapercanada.com
State of the
Industry: n PacWest warns of labour shortage n Trends & ideas from PaperCon n Bio-economy gaining steam
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July/August 2012 Vol. 113, No. 4 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
12 PacWest: Courting young people
PacWest furthered the discussion of our industry’s looming demographic shift and labour shortage.
14 new ideas in new Orleans
TAPPI’s PaperCon drew all types of papermakers to New Orleans, and served up global trends, production improvements, and “outside-the-box” ideas.
FeATUreS
14
10 Refiner trial hits the sweet spot
A Toronto papermaker will save almost $200,000 per year thanks to a new refiner design coupled with online freeness measurement.
Photo by Sharon Boutwell
ping
PulP P& PaPer Pa PaP Per
22 lignin poised for commercial breakthrough
Attendees at the International Lignin Biochemical Conference were told Domtar will be producing commercial quantities of lignin next year and a production line for lignin/ PAN carbon fibre will be available by the end of 2013.
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IN every ISSUe
Plus Pulp, Paper and Bio-Economy map included with this issue. 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.
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editorial news Safest mill update opinion: FPac Technology news classified ads
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For breaking news, visit www.pulpandpapercanada.com
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Editorial
We’re not out of the woods yet
W
hen the May/June issue reached readers’ hands, publisher Jim Bussiere and I were criticized by some for accepting advertising from an oil and gas company looking to recruit pulp and paper industry personnel. In the context of the strong messaging at PacWest about the shortage of skilled workers, I agree, it is disturbing to see such an ad in our pages. But, it underscores all that we heard at PacWest. Other industries are looking to poach our workers. As several speakers noted, the shortage of people to fill skilled trades and other positions at mills is not unique to the pulp and paper sector. Vale, a mining company, recently placed a half-page ad in Canadian Civil Engineer recruiting engineers to join the company as it undertakes a huge capital expenditures blitz. We are competing with shipbuilding, oil and gas, mining, and construction for a share of the same talent pool. We have to keep the workers we have and look outside the industry for new recruits. See the PacWest coverage in this issue for more Cindy Macdonald discussion of this topic. Editor This month’s issue contains some good news, some bad, some success stories, some dire warnings of problems ahead. Bowater Mersey and Chetwynd have been idled, Terrace Bay and Trenton have been spared. There was good news for Catalyst Paper employees and pensioners, but those at Corner Brook and NewPage are still facing an uncertain future. There’s no simple answer to “How are things in the industry?” I was tempted to make the cover line for the issue: “Not out of the woods yet. Canadian industry struggles to recruit people, re-purpose mills.” From a design point of view, it didn’t really work, but it does sum up the state of the industry. Dear Cindy, I just received the latest (March/April) issue of P&P Canada and was skimming through the article on nanotech when a phrase leapt off the page at me: “The Harper Conservatives contributed $23.2 million via the Pulp and Paper Green Transformation Program…” If this money came from the Conservative Party, I wouldn’t have any problem with this statement but we all know that this money came from the taxpayers of Canada. Therefore, the phrase “The Harper Conservatives” must be replaced with “The Government of Canada” or a specific department or ministry thereof. Let’s keep the politics out of this. Sincerely, John du Manoir Mr. Du Manoir makes a valid point. I’ll watch out for that in the future. CM
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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: cda 800-268-7742; usa 800-387-0273
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PulP & PAPer CANAdA (ISSN 0316-4004) is published by BIG Magazines lP, a div. of Glacier BIG Holdings Company ltd., 80 Valleybrook dr., Toronto, oN M3B 2S9 SubScrIPTION rATES Canada $52.95 per year; $71.95 for 2 years. outside Canada $99.95 per year. Single copy $19.50. (All subscription prices exclusive of taxes.) The editors have made every reasonable effort to provide accurate and authoritative information but they assume no liability for the accuracy or completeness of the text or its fitness for any particular purpose. All rights reserved. The contents of this publication may not be reproduced in part or in full without the consent of the copyright owner. From time to time, we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods. Phone: 1-800-668-2374; fax: 416-442-2191; e-mail: privacyofficer@businessinformationgroup.ca; mail to: Privacy officer, Business Information Group, 80 Valleybrook dr., Toronto, oN M3B 2S9 POSTMASTEr: Please forward 29B and 67B to 80 Valleybrook dr., Toronto, oN M3B 2S9. legal deposit Quebec National library. Publications Mail Agreement No. 40069240 A Business Information Group Publication Print edition ISSN 0316-4004 on-line edition ISSN 1923-3515
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Industry News
Aditya Birla proposes to restart Terrace Bay by october for kraft pulp The Indian corporation purchasing an idled pulp mill in northwestern Ontario says it would restart production of papergrade pulp by October 2012, and gradually convert the mill to dissolving pulp. It was announced in early July that Aditya Birla Group of India has signed an agreement-in-principle to purchase the assets of Terrace Bay Pulp in Terrace Bay, Ont. The transaction is subject to court approvals in Canada and other regulatory approvals in Canada, Thailand and India. The deal was expected to close by July 31, 2012. The new owner will be investing more than $250 million to convert the mill to produce 280,000 tonnes per year of dissolving grade pulp. Until the conversion, which is likely to happen in fiscal 2016, the mill will produce and sell paper grade pulp. Aditya Birla expects the pulp mill to restart by October 2012. “The acquisition of Terrace Bay Mill and its subsequent conversion into a dissolving grade pulp mill is a major strate-
gic move for our business where we are global leaders,” states Kumar Mangalam Birla, chairman of the Aditya Birla Group. “The Terrace Bay Mill upon conversion will provide superior quality pulp for our viscose staple fibre business.” The international company will establish AV Terrace Bay Inc. (Canada) to complete the purchase. An Aditya Birla subsidiary, Grasim Industries Ltd., proposes to hold a 40% stake in AV Terrace Bay, while the remaining 60% would be held by another subsidiary, Thai Rayon Public Co. Ltd. of Thailand. According to a company press release, Grasim would be contributing $44 million over a period of the next three years, out of the total equity contribution of $110 million. The Aditya Birla Group has a significant presence in Canada, including two dissolving pulp mills in New Brunswick, AV Nackawic and AV Cell. The Terrace Bay mill has gone through a series of shutdowns in recent years, in response to the restructuring of its parent
Tembec to close chetwynd mill in September
Chetwynd mill is primarily shipped to Asia. The Chetwynd bleached chemithermomechanical (BCTMP) mill was built in 1990 and has an annual production capacity of 240,000 tonnes. Tembec purchased the mill in 2002. Tembec bills itself as the world’s leading producer of high-yield pulp. It also produces high-yield pulp at Matane and Temiscaming, in Quebec.
Softness in the market for high-yield pulp has prompted Tembec to announce the shutdown of its high-yield pulp mill in Chetwynd, B.C. The mill, which employs 115 people, will be indefinitely idled as of September 16, 2012. “The high-yield pulp market has continued to soften over the past year. At today’s price levels, it is virtually impossible to maintain viable operations given the current cost structure of the Chetwynd mill,” stated Chris Black, Tembec executive vice-president and president of the Paper and Paper Pulp Group. “We will continue to monitor the market and, in due course, reassess the situation accordingly.” High-yield pulp is used in printing and writing papers, paperboard, tissue and towelling. Pulp produced at the www.pulpandpapercanada.com
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Future of Kruger corner Brook still in question Most of the unionized workers at Kruger’s Corner Brook pulp and paper mill in Newfoundland have agreed to a new contract with unspecified pay cuts in a bid to keep the mill operating while Kruger mulls its fate. “It’s a tough contract, but we are tough people, so we’ll manage,” Gary Healey told CBC.ca. Healy is a national represen-
Photo: www.dgphoto.com
company, Buchanan Forest Products. In October of last year, it was shut down after an explosion in a blow tank killed one worker. The mill is able to produce bleached softwood kraft as well as bleached hardwood kraft. An Ontario government announcement of the purchase notes that the re-start will support 275 mill jobs, 335 woodland jobs and an estimated 1,300 indirect jobs province-wide.
tative with the Communications, Energy and Paperworkers Union (CEP). Four of the five CEP locals at the mill approved the collective agreement. According to the CBC.ca story on June 22, a local of the International Association of Machinists and Aerospace Workers also turned down the Kruger offer. The new agreement enables the company to have another vote on pension funding relief measures that were voted down earlier this year and to “continue its assessment of the mill’s viability,” Kruger said in a release. The company has previously said the pension funding relief is essential to the mill’s competitiveness. The company expects the voting process to be completed by August 22. In the meantime, Kruger has said it will continue its efforts to reduce the mill’s operating costs by applying necesJuly/august 2012
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Industry News sary cost-cutting measures. Prior to the vote on the collective agreement, Kruger chairman Joseph Kruger made the gravity of the situation clear in a letter distributed to employees. According to Canadian Press, the letter states, “A vote against our proposal would be a vote against maintaining the mill.” The letter describes the mill’s financial situation as fragile, reports Canadian Press, and says the mill has not been profitable in five years and has defaulted on loan agreements since the last quarter of 2009. The Corner Brook mill is the last operational pulp and paper mill in the province. Kruger Inc. is a major producer of publication papers, tissue, lumber and other wood products, corrugated cartons from recycled fibres, green and renewable energy, and wines and spirits.
rare second creditor vote saves catalyst mills from sale Catalyst Paper has received the necessary creditor approval for its second amended plan of arrangement under the Companies Creditors Arrangement Act. Under the new plan, the company’s secured bondholders will own almost all of the equity in the company. They agreed to swap $390 million in notes from for $250
million in new notes plus 96% of the equity in the restructured company, the Vancouver Sun reports. “With the cooperation of employees, vendors, customers, pensioners and investors, Catalyst has been able to make progress through a very complicated situation at an unprecedented swift pace,” said president and CEO Kevin J. Clarke. “We’re now turning our attention to securing our exit financing and satisfying the remaining conditions of the plan with a target timeline to emerge from creditor protection in the near term.” In a previous vote on May 23, not enough creditors supported the restructuring plan, and the papermaker was forced to begin a sales process. According to the Vancouver Sun on June 20, the unusual decision to allow a second vote is the result of a grassroots campaign led by the company’s salaried pensioners. If the company had been sold, the pension plan would have been wrapped up, and because it is underfunded by about $115 million right now, pensioners stood to lose a significant amount of their pension income. Gary McCaig, one of the organizers of the campaign, told the Sun the pensioners agreed to give up their extended medical benefits, which will save Catalyst about
Briefly… • Resolute Forest Products recently certified 3.2 million hectares (7.9 million acres) of forestlands in the Lac-Saint-Jean region of Quebec to the FSC Boreal Standard. This certification raises the total area of Resolute-managed FSC-certified forests in North America to 10.3 million hectares (25.6 million acres), and makes the company the largest manager of FSC-certified forest in the world. • Five technical communities of the Pulp and Paper Technical Association of Canada now have their own “micro-site” within the PAPTAC web site, www.paptac.ca. The first micro-sites are for the following communities: paper machine technology, energy, maintenance, paperboard packaging, and process control. • Kemira was recently awarded the prestigious Grand Slam Award by the Association of American Railroads (AAR). The criteria for receiving this award includes being recognized by at least four class 1 railroads and having zero non-accidental releases (NARS) during a calendar year. In 2011, Kemira’s North American operations had more than 8300 shipments of hazardous materials. • Canadian engineering services firm Genivar Inc. has purchased WSP Group PLC, a multi-disciplinary professional services consultancy based in London, U.K.
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$7 million a year. They also agreed to allow the company a longer term to pay off the pension deficit, a move which is supported by the provincial government.
Bowater mersey not competitive; indefinitely idled by resolute Resolute Forest Products indefinitely idled operations at the Bowater Mersey newsprint mill on June 17, in spite of concessions granted several months ago by employees, provincial and municipal governments, and Nova Scotia Power. The facility in Brooklyn, Nova Scotia, is a joint venture between Resolute (51%) and the Washington Post (49%). Resolute is assessing the feasibility of selling all its assets in Nova Scotia. “The mill produces newsprint primarily for export markets and is unable to compete due to declining prices in those markets, caused mainly by unfavorable currency fluctuations,” stated Richard Garneau, president and CEO of Resolute. The indefinite closure reduces capacity by approximately 250,000 tonnes of newsprint. Approximately 320 employees at the Mersey paper mill, associated woodlands, Oakhill sawmill and Brooklyn Power Corporation will be affected by this action. Last fall, in an effort to keep the mill open, the Nova Scotia government pledged $25 million in forgivable loans to the company ($5 million per year), provided another $1.5 million for training and purchased 10,000 hectares for $23.75 million. According to local media, the loaned funds have been returned, since they were contingent on the continued operation of the mill.
labour deal saves norampac Trenton from closure Almost 130 employees at Norampac Trenton will keep their jobs now that a second vote has resulted in a significant majority of employees deciding in favour of Cascades’ final offer. Owner Cascades Inc. had announced the imminent closure in April, after the union rejected the company’s offer. “The challenges faced by this mill are by no means over. However, reaching this agreement with our employees is a vital pre-condition, and we can now concentrate on identifying an action plan www.pulpandpapercanada.com
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Industry News for achieving long-term viability,” said Marc-André Dépin, president and CEO of Norampac. The Norampac–Trenton facility produces corrugating medium and has an annual production capacity of 150,000 tonnes.
Boreal forest plan would protect caribou habitat, increase wood yield Forest industry and conservation group signatories to the Canadian Boreal Forest Agreement (CBFA) made recommendations in late June for an area of Ontario’s boreal forest almost five times the size of Metro Toronto. The plan applies to approximately 3 million hectares of the Abitibi River Forest. The area in question is managed as a co-operative Sustainable Forest Licence. It extends north and east of Kapuskasing and Timmins to the Quebec border. The two largest shareholders in the cooperative are Tembec Inc. and Resolute Forest Products.
James Lopez of Tembec speaks at the June press conference introducing a Canadian Boreal Forest Agreement plan for protecting caribou habitat. richard Garneau of resolute Forest Products is at his left.
The CBFA has proposed a zonation approach to forestry that includes a no-harvesting zone covering an area of 835,000 ha that complements and includes existing protected areas in the
northern reaches of the Abitibi River Forest; a Caribou Recovery Zone composed of deferrals and harvest areas (985,000 ha); and a Strategic Caribou Recovery Zone where normally approved
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515 Richards PPC Jul_Aug complete.indd 7 Street Vancouver, BC
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CON121004AB_1_PulpPaperCanada.indd
June 15/2012 7" x 4.875"
CREATIVE
LIVE
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INSERTION DATE(S)
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Industry News forestry with supplemental caribou recovery objectives will be undertaken (1,200,000 ha). The plan increases wood supply for industry relative to the current direction by approximately 20% over the next 30 years. Natural Resources Minister Michael Gravelle said the Ontario government supports the collaborative efforts of the CBFA and will review the details of the recommendations.
Buckman wins green chemistry award for papermaking enzymes Buckman was awarded the Presidential Green Chemistry Challenge Award from the U.S. EPA for its Maximyze® enzymes, which are comprised of natural catalysts and used to reduce energy and decrease the amount of wood fibre needed to manufacture high quality paper and paperboard. This technology is now being applied successfully in many paper mills around the world.
deal not closed, but newPage buyer organizing workforce Having cemented its labour contract, the company negotiating to purchase the NewPage mill in Port Hawkesbury, N.S., has advised former employees who will, or won’t, be called back if the mill re-opens. Only about 229 unionized workers will be returning to work at the mill, down from the more than 500 who were employed prior to the mill’s closure in September 2011. The potential buyer, Pacific West Commercial Corp., will restart only the supercalendered paper line, not the newsprint machine. Pacific West has reached a tentative deal concerning its electrical power rate, but the agreement must be approved by the province’s utility review board. The board met in July, and Pacific West expects a decision on the matter before the end of August. A Pacific West spokesman told the Cape Breton Post in May that the company is ready to proceed with
SaFeST mill in canada conTeST Year to date, June 2012
Total Recordable Incidents
Total Hours Worked
Mill Frequency
caTeGory a OVER 80,000 MANHOURS PER MONTH Domtar Inc., Windsor, QC
2
765,192
0.52
Alberta Pacific Forest Industries Inc., BC
5
561,079
1.78
Catalyst Paper, Crofton, BC
12
562,628
4.27
Resolute Forest Products, Thunder Bay, ON
3
463,668
1.29
Resolute Forest Products, Alma, QC
3
419,394
1.43
Resolute Forest Products, Fort Frances Mill, Fort Frances, ON
3
398,688
1.50
HSPP, Howe Sound Pulp & Paper Corp., Port Mellon, BC
4
455,547
1.76
Resolute Forest Products, Baie-Comeau, QC
4
423,702
1.89
Weyerhaeuser Canada, Grande Prairie, AB
0
268,888
0.00
Fibrek, St-Felicien, QC
0
255,884
0.00
Resolute Forest Products, Kenogami, QC
0
204,524
0.00
Resolute Forest Products, Thorold, ON
0
153,845
0.00
Strathcona Paper LP, Napanee, ON
0
147,441
0.00
caTeGory B 50,000 to 80,000 MANHOURS PER MONTH
the restart once the electricity rate agreement is approved. Despite the mill closure, work continues on Nova Scotia Power’s biomass power cogeneration plant at the NewPage Port Hawkesbury site. The plant should be producing power by the end of the first quarter of 2013.
a change of management for Fibrek The board of directors of Fibrek Inc. has been replaced by nominees of Resolute Forest Products. This new Fibrek board appointed Richard Garneau as president and chief executive officer of Fibrek, Alain Boivin as vice president for operations, Jo-Ann Longworth as vice president and chief financial officer, and Jacques P. Vachon as vice president for legal affairs and corporate secretary. Garneau is also president and CEO of Resolute. Longworth is Resolute’s senior vice-president and chief financial officer, and Vachon is its senior vicepresident for corporate affairs and chief legal officer.
Fortress completes acquisition of lebel-sur-Quévillon mill Fortress Paper has completed the acquisition of the buildings, equipment, and ancillary property related to the nonoperating pulp mill located in Lebel-surQuévillon, Que. The mill was purchased from a numbered company owned by Domtar Inc. and the Quebec ministry of economic development. Collective agreements with the unionized employees of the LSQ mill have been ratified. Fortress Global Cellulose, a subsidiary, will invest about $222 million to convert the former NBSK mill to dissolving pulp production. The acquisition also includes a 30-MW co-generation facility, which Fortress intends to restart.
caTeGory c LESS THAN 50,000 MANHOURS PER MONTH
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People… • CD Nova Instruments in Calgary has appointed Kevin Cyr as Canadian product manager of their Power & Energy Division.
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Opinion
Vision2020: The Future Face of Canada’s Forest Products Industry
T
he Canadian forest products industry is decisively on the move. The sector has already been transforming itself by becoming more innovative, more environmentally friendly and more global in its reach. Now member companies of the Forest Products Association of Canada (FPAC) are building on the momentum with the unveiling of Vision2020 which sets ambitious goals to propel By Catherine Cobden, the industry forward in the area of President and CeO, products, performance and people to FOrest PrOduCts assOCiatiOn OF Canada ensure a vibrant path for the sector in the years ahead. Our first goal is to generate an additional $20 billion in economic activity from new innovations and growing markets by 2020. Canada needs to build on the work already underway to research and develop new products made from trees such as rayon for clothing or specialty cellulose pharmaceuticals. The forest products industry has also had remarkable success in diversifying markets. For example, forest products are now Canada’s number one export to China. Still the industry is setting its sights much higher in the area
of new innovations and growing markets. The second goal is in environmental performance – to deliver a further 35% improvement in the industry’s environmental footprint. Already the Canadian industry is emerging as the “greenest” forest products sector in the world. For example, Canada has the most third-party certified forests on the planet, and the industry has cut its greenhouse gas emissions by two thirds since 1990. Now FPAC has identified 12 parameters, including caribou planning and air contaminants, where the industry will attempt to further its environmental credentials. The third goal relates to “people” and a desire to hire at least 60,000 new recruits including women, Aboriginals and immigrants. After a decade of decline in the workforce, the Canadian forest products industry is now recruiting and offering solid careers for those with the skills and desire to work in the sector. It won’t be easy. We recognize the need to refresh the image of the forest industry, and we will have to compete for workers with other sectors, including the oil patch. We cannot achieve these goals alone but will have to work with partners including governments and researchers. But let there be no doubt. The Canadian forest products industry is aiming high and determined to succeed. We fully intend to be a global leader that will create new jobs and prosperity for Canada well into the future.
Excellence.Assured.
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www.saiglobal.com/assurance/forestry 1 800 465-3717 | certiication.americas@saiglobal.com
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refiner trial hits the sweet spot A Toronto papermaker will save almost $200,000 per year thanks to a new refiner design coupled with online freeness measurement. By Cindy Macdonald, editor
T
he prototype for a new single-disk refiner, combined with online freeness sensing technology, is showing positive results at Atlantic Packaging in Toronto. The refiner and freeness monitoring system were installed in April 2011 and tweaked during the summer. By October, the new improved linerboard/corrugating medium line was breaking production records and demonstrating remarkable process stability. Chris Demler, vice-president at Kadant Black Clawson, says the company has been studying ways to achieve small labtype refiner precision from a commercialsized refiner. “Recently, a commercial 42-inch diameter, 100 hp, prototype refiner capable of lab refiner precision began operation and is currently being used to produce base ply refining for a 750 BDST/D linerboard machine,” he said in presentation at PaperCon 2012. A technical paper outlines the refiner development and experiences at Atlantic Packaging: Refining Case Study: Using Improved Refiner Control to Increase Pulp Quality and Paper Machine Performance, was authored by Demler, Sandra E. Beder-Miller, of BTG Americas Inc., and Rick Aldridge, of Atlantic Packaging, Inc. Demler notes that low consistency refiners are “very large machines trying to mechanically alter very small fibres.” Shorter fibres and recycled fibres need the most precise refining. “We see this as an opportunity to target these areas with a very precise machine,” he adds. The new Pure refiner being devel-
oped by Kadant Black Clawson is a selfaligning, single-disk design capable of achieving 0.015 mm (0.0005 in.) plate gap positioning accuracy. The design promises to be more energy efficient and stable than other commercial refining options, says Demler. Kadant’s strategy has been “to improve accuracy and repeatability of the proven disk refiner and then fully integrate that capability with the latest online pulp quality sensing technology…”, the paper states. With the new refiner combined with BTG Americas’ online freeness sensing technology and a motivated papermaker like Atlantic Packaging, it is possible to make a significant performance improvement in the refining system, which can impact the mill’s profitability, the paper concludes.
Stable and repeatable sheet strength The Atlantic Packaging mill in Toronto manufactures up to 750 BDST/D of twoply linerboard and corrugating medium from 100% AOCC. A common highdensity chest feeds the refining system of each ply. Each ply has one active and one spare refiner, with net specific energy control systems in place. The top ply (liner) is served by 30-in. Beloit DD 4000 refiners (two). The new 42-in. Pure refiner by Kadant is used for the base ply (filler) in parallel with a 42-in Pilao RTD double-disk refiner. The online freeness monitoring is intended to help control refining and
Power Savings at Atlantic Packaging old refiner setpoint
New refiner setpoint
Liner
600-800 hp
260-500 hp
Medium
800-1000 hp
260-500 hp
result: average savings of about $190,000 per year 10
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minimize process variation. For refiner control on the new unit, the upper and lower freeness limits were set at 500 CSF and 460 CSF, respectively. The system has the ability to increment the net specific energy set-point by 0.06 HPD/BDT. Rick Aldridge of Atlantic Packaging says the mill can use the DCS and freeness sensor feedback to adjust the quantity of refining whenever necessary. “We have found that when our freeness values fall below 420 CSF, we are able to bypass the entire refiner and still maintain test [strength], whereas before we would not have known of the raw material change and we would generally over-refine the poor furnish and miss our strength targets.” He continues: “Once we identified the sweet spot for our plant, we can now run there all the time with maximum stability. The wet line stays in a constant spot, along with moisture and steam rates, giving us a more stable and repeatable sheet strength.” Last October, once the control strategies had been optimized, the mill broke its monthly production record, reaching 20,600 tons, from a previous high of 18,900 tons. Now, machine tenders “live and breathe” the freeness information, says Aldridge. “That information is the best [data] to run the mill.” Atlantic Packaging also uses the prerefiner freeness measurement to provide feedback to the yard workers, allowing them to identify good quality furnish.
Precise alignment gives repeatable performance As Demler explains it, Kadant’s work on the Pure refiner has focused on using new technology to address the need for precise plate positioning and alignment, which is needed to achieve homogeneous and repeatable performance. www.pulpandpapercanada.com
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Operations
A typical freeness feedback control strategy. Courtesy of BTG Americas.
“Our design uses a rigid and fixed rotor position and a multi-axes servocontrolled adjusting stator plate. The system has high accuracy encoders that allow for the stator plat to self-align to the rotor with 0.01 mm (0.0005-in.) accuracy so there is no run-in required and any operating condition can be repeated,” the technical paper explains. “Additionally, for the trial unit, the actuator systems have load cells built in and a stand alone torque and speed sensor was added to the main drive shaft.” This development project builds on earlier work by Levlin and Ouellet that quantified very narrow plate gaps and “the fact that any misalignment of the refiner results in significant force variation and reduced processing homogeneity.” According to the technical paper, the actuators and refining surfaces must be very stiff and precise. As well, the structure of the refiner must allow deflections resulting from pump through pressures and temperature changes to be reacted in a structure that moves perfectly along the refiner’s principle axis without distorting the relationship between rotor and stator. Installed at Atlantic Packaging, the self-aligning, 1072-hp refiner immediately achieved a 25% power reduction compared with the conventional 42-in. double disk refiner. Further development of the controls achieved an optimized system with less than 0.02 mm (0.001-in.) alignment error. www.pulpandpapercanada.com
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Freeness measurement for refiner control The second component of Atlantic Packaging’s successful upgrade is the online freeness monitoring system. The technical paper states that “Mills have improved refiner processing and reduced energy costs by using closed loop control that relies on good consistency control in advance of the refiner and a freeness measurement pre- and post-refining. “Online freeness control adds the ability to account for incoming pulp furnish variations.” In this control approach, the final freeness after refining is measured online and is incorporated as a key control variable. This requires a fast, accurate and reliable online measurement to get a meaningful freeness signal. At Atlantic Packaging, in-line freeness analyzers were installed in three positions to automatically measure freeness of the base ply inlet (same as top ply inlet), base ply accepts and top ply accepts. Sandra Beder-Miller of BTG Americas notes that the freeness analyzer results are dependent on the accuracy of the laboratory tests used for calibration. This is where Atlantic Packaging had a need for improvement. Beder-Miller explains that the goal for this application was to have no more than a 15-point difference between a lab test and the online measurement. The initial results showed much larger deviations, so BTG and Atlantic Packaging worked together to find the cause. “Opportunities for improvement were found with the
sampling collection method and the scale used in testing which affected the consistency used in the freeness calculations,” the paper states. BTG Americas also made sure to incorporate a wide range of process conditions into the calibration process, including start-up, shutdown and process upsets. While older online freeness monitoring systems had some inherent problems, the current measurement tools “can be
BTG freeness analyzers and water filter system at Atlantic Packaging.
very accurate, and are suitable for closed loop control to reduce refiner outlet variability,” Kadant’s Demler concludes. Using online freeness sensors, producers of linerboard and corrugated medium can pursue lower basis weights while still achieving strength targets. Atlantic’s Rick Aldridge is enthusiastic about the cost savings and knowledge provided by the new refining and monitoring system at his mill. “This has been one of our mill’s most successful projects. It has provided us with an understanding of the fibre quality that we did not have before, that now allows us to more strategically develop and use it productively.” It also allows the mill to consistently run in that sweet spot, achieving the best balance of process stability and productivity. July/august 2012
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PacWest: Courting young People Bringing almost 250 industry representatives together, PacWest furthered the discussion of our industry’s looming human resources problem. By Cindy Macdonald, editor
P
eople – how to find them, how to keep them – was the chief topic of discussion at PacWest. Both presenters and participants showed a deep concern about our industry’s current employment demographics, and about the increasing competition with other sectors for skilled trades workers. There was general agreement among the speakers that we need to quickly change our workplace culture to accommodate young people. Several also commented that pulp and paper’s transformation with regard to the bio-economy and groundbreaking new products will change our industry image and attract talent, but that the industry needs to “shamelessly” promote itself to achieve that goal.
labour shortage is a problem for many sectors Putting the employment shortage into a national perspective, John Wright, senior vice-president of Ipsos-Reid, commented that the skilled labour shortage is a
micro-crisis for a whole series of sectors. “Focusing on high schools and universities will not get you there,” Wright counseled. Alberta, he said, by 2021, is expected to have a cumulative labour force deficit of 114,000. Andrew Casey, vice-president public affairs and international trade, with the Forest Products Association of Canada, agreed. “The biggest problem is that we’re not the only ones looking for people.” “I think there will have to be a triage process for the industry,” said Casey. Start locally, tapping into aboriginal communities and those who used to work in the forest products sector, he suggested. “We need to bring our own people back. We need to find them and reach out.” In addition to aboriginals and “come homers”, immigrants and young people just entering the workforce are frequently cited as talent pools the industry should explore. Programs like Alberta’s Work Wild initiative have had some success raising the industry’s profile. Cam Rollins,
Honeywell and BTG made BLT sandwiches for friends old and new in celebration of their new bleach load transmitter (BLT) that measures total bleaching load to the bleach plant. Above, richard van Fleet of Honeywell (left) and Sandra Beder-Miller of BTG present Brennan Dubourg of Caribou Pulp & Paper with his sandwich.
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of Work Wild Alberta, says his team has been able to change some people’s perceptions, especially among youth. The Work Wild effort included a web site, video, and tour. However, for youth pursuing skilled trades, there are impediments in the current apprenticeship model. Geoff Stevens of Resource Training Organization, part of the apprenticeship training system in B.C., reported: “Trades occupations are very significant for the resource sector, and all the provinces are worried. There’s mounting evidence that the traditional sponsorship model (of an apprentice working four years with the same employer) will not work going forward.” Stevens said B.C. is looking to launch Skill Source for the resource sector, a group training organization that would likely undertake recruitment and screening of apprentices, and take some of the burden off individual employers. The oil and gas sector has traditionally been the major siphon on pulp and paper’s employment pool, but Stevens
reandy reimer, conference chair (left), and Bill Adams, program chair, present Shawn russell with the H.r. MacMillan Trophy for Best Mill Paper (co-authored with ralph Lunn and Jim McLaren).
As keynote speaker, John Wright of Ips his insights into Canadian demograph is conference co-chair Al Parsons (left) conference chair.
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advised PacWest participants that this known foe is not the only one we’ll have to fight off. The West Coast shipbuilding industry has a plan to target mature workers in other sectors to meet its growing need for tradesmen, he warned
retirement/attrition more severe than expected For Canfor Pulp, the exodus of older workers has been more quick and thorough than expected, said Martin Pudlas, general manager, PGI Pulp Mills, Canfor Pulp. At its three mills in Prince George, B.C., the company employs 1100 people, and generally enjoys a stable workforce. “We have had the luxury of keeping our experienced workers,” said Pudlas. But the rate of attrition has been faster than anticipated. “Now, we’ve become very good at doing retirement parties.” Pudlas reported that in 2011, Canfor Pulp hired just shy of 100 people, about 2 people a week. The same pace continues in 2012. “We will see the extinction of baby boomers at our company within the decade. This situation is not unique to Canfor.” His question to the audience was: “Is your organization actively changing to meet the expectations of talented millenials?” Gen Y needs strong leadership, orientation and training, and communication
eaker, John Wright of Ipsos-reid (center) shared o Canadian demographics. Show with John o-chair Al Parsons (left) and randy reimer, air.
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skills, as well as the opportunity to be part of a team.
Treat social media more seriously To foster a more appealing image of pulp and paper jobs, several organizations are turning to social media. “We’re tying to create a conversation about what it means to work in this industry,” explained Alistair Hain, of the Forest Products Sector Council. The sector council has performed several studies over the last few years, characterizing the industry’s labour force, and making recommendations for improvement. The group’s federal funding ends March 2013, but its work will likely be transferred to the Forest Products Association of Canada (FPAC), Hain reported. In its remaining months, FPSC will work on a social media marketing through greenestworkforce.ca, including a presence on Twitter, Facebook, Linkedin, and YouTube. Hain also noted that he is willing to work with companies to develop their social media efforts. Andrew Casey of FPAC agrees that the industry needs to communicate through social media its participation in the bioeconomy. FPAC has launched the Forest Industry People group on Linkedin. “Not all kids should go to university,” said Casey. “We need to get kids to look at other options.”
The International Brotherhood of Migratory Peddlers welcomed Carlo dal Monte (right) of Catalyst Paper as an honorary member with a suitcase full of “necessities” for any travelling businessman.
Technology still drives the industry The PacWest agenda was not solely focused on human resource issues. There were plenty of technical papers, many written by mill staff. There was a tour of the neighbouring Hinton pulp mill, graciously offered by West Fraser. The mill managers meeting, pulp mill superintendants roundtable, and a roundtable for maintenance managers provided plenty of opportunity for discussion of operational matters with peers. James Olson and the Pulp & Paper Resarch Centre of UBC organized a session on energy conservation in mechanical pulping with an international input. Tom Buckman gave a motivational speech about building organizational health, noting that teamwork is a company’s ultimate competitive advantage. He explained how Buckman had adopted and applied Patrick Lencioni’s principles of effective teams. PacWest is the annual conference of the Pacific and Western branches of PAPTAC. The conference is organized in large part by volunteers from a loose-knit organization of suppliers known as the International Brotherhood of Migratory Peddlers. Mary Barnes presides over the whole event as coordinator. Next year’s event will be held at Sun Peaks, B.C., June 12-15.
PacWest, returning to Jasper, Alta., had more than 250 delegates this year. The trade show was a hub of activity. July/august 2012
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TaPPi’s Papercon drew all types of papermakers to new orleans in may, and taught them about global trends, production improvements, and thinking outside the box
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Photo courtesy of TAPPI
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By Cindy MaCdonald, editor
s a mélange of many events, PaperCon 2012 in New Orleans had something for everyone, from executives to shift supervisors. Organized by TAPPI, the PaperCon conference program was supplemented by another TAPPI event, Control Systems 2012, and the Production-Technical Seminar of the Recycled Paperboard Technical Association (RPTA). With a theme of “Growing the Future,” the April event drew more than 1400 registrants. Sessions addressed the business challenges facing the industry, the global paper industry outlook, innovations, and developments in papermaking, procurement, and sustainability. Within PaperCon were special themed events, such as the Sustainability Forum. The PaperCon the trade show spread about 100 exhibitors over two floors of the Sheraton New Orleans.
Paper properties not a concern for readers During an end-user panel, Guy Gleysteen, senior vice-president of production at magazine publisher Time Inc., described how his organization used focus groups to research how a magazine’s physical characteristics affect consumer satisfaction. They found that physical properties were not top-ofmind. Content and layout were the primary determinants of magazine quality. “I think we overvalue the physical properties of the paper itself,” Gleysteen said of the magazine industry. For magazines in general, he noted newsstand sales are slipping (down 9.6% for the second half of 2011 vs. the same period in 2010), although total circulation only declined 1% from 2010 to 2011. Advertising continues to be a challenge as marketers 14
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gravitate toward digital platforms. What can papermakers do? Focus on product innovation, especially lower cost approaches, he recommended. Gleysteen said there’s very little interest in sustainability from advertisers or consumers. In terms of the purchasing behaviour of advertisers and media decisionmakers, sustainability has “zero” impact, said Gleysteen, even if these same advertisers espouse sustainability in their own manufacturing process. Sustainability does appear to be a concern among young consumers. Mark Pitts of the American Forest & Paper Association summarized some research the association has done with 16-26 year-olds. The study found this age group is concerned about paper consumption and the environment. Eighty percent of AF&PA’s respondents believe paper usage is wasteful. However, these young people are also concerned about technology’s impact on the environment. This age group is active on an expansive online network, but their feeling about paper is that it represents trust. They perceive paper as more official, more secure, more sentimental. The takeaway message, said Pitts, is that the industry “needs to use social media to supply facts, and give paper a presence.” Photo by Sharon Boutwell
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uBc presents pulping research Mechanical pulping was the focus of a paper by Nina Rajabinasab and her colleagues from the University of British Columbia. Rajabinasab noted that the aim of her work was to understand the effect of operational and plate design parameters on noload power in refining. The paper, entitled Experimental Study
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THE UNIVERSITY OF BRITISH COLUMBIA Department of Chemical and Biological Engineering
Photo courtesy of TAPPI
Mercer International Industrial Research Chair in Advanced Engineering for the Forest-Products Based Bio-Economy The Department of Chemical and Biological Engineering and the Pulp and Paper Centre at the University of British Columbia invite applications for the new Mercer International Industrial Research Chair in Advanced Engineering for the emerging forest-biomass based bio-economy. The Chair is expected to provide leadership within the university and Canada through a field-defining program focused on establishing the technological breakthroughs and educational advances needed to improve or create commercially viable opportunities for sustainably converting Canada’s forest-fibre resource into traditional and new value-added products. Through internationally recognized research and an appointment at the rank of Associate or Full Professor, the chair is therefore expected to expand upon UBC’s considerable expertise in pulp and paper science and technology, including lignocellulose biorefining engineering related to the forest-based chemical industry and green engineering of processes and products. Applicants must have a Ph.D. in Chemical Engineering or in a closely related field, and have a strong commitment to high-quality undergraduate and graduate teaching. Relevant industrial and teaching experience are assets. Applicants must also either have, or be eligible to register within five years with the Association of Professional Engineers and Geoscientists of British Columbia. The successful candidate must possess the skills, background and motivation needed to quickly build an independent research program of international calibre within the area defined above that leverages current strengths within the Department of Chemical and Biological Engineering and the Pulp and Paper Centre, as well as within complementary and affiliated interdisciplinary centres such as the Clean Energy Research Centre and the Michael Smith Laboratories. Review of applications will begin on August 21, 2012 and continue until the position is filled. Applications, including a curriculum vitae, a short statement of teaching and research interests, and the name and contact information of four qualified referees must be submitted online at http://www.hr.ubc.ca/careers-postings/faculty.php by August 20, 2012. The successful candidate will be nominated for a Natural Sciences and Engineering Research Council of Canada (NSERC) Industrial Research Chair (IRC). An application will be submitted to the IRC program of NSERC in the Fall of 2012. The anticipated start date of the position is January 1, 2013. The Department of Chemical and Biological Engineering offers programs leading to the Bachelor of Applied Science (B.A.Sc.) degree in Chemical Engineering and to the Bachelor of Applied Science (B.A.Sc.) degree in Chemical and Biological Engineering. Graduate programs leading to the degrees of M.Eng., M.A.Sc., M.Sc., and Ph.D. are offered in important areas of chemical and biochemical engineering, including fluidization, pulp and paper, biotechnology, environmental engineering, clean energy, biomedical engineering, thermodynamics, transport phenomena, electrochemical engineering, polymer processing, catalysis and process control. Details about the Department and its current research programs are available at http://www.chbe.ubc.ca, and information on the activities and mandate of the Pulp and Paper Centre are available at http://www.ppc.ubc.ca. The University of British Columbia hires on the basis of merit and is committed to employment equity. All qualified persons are encouraged to apply. We especially welcome applications from members of visible minority groups, women, Aboriginal persons, persons with disabilities, persons of minority sexual orientations and gender identities, and others with the skills and knowledge to engage productively with diverse communities. Canadians and permanent residents of Canada will be given priority.
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About Mercer InternAtIonAl Inc. Mercer International Inc. is a global leader in the production of high quality Northern Bleached Softwood Kraft (NBSK) pulp, renewable bio-energy and other bio-products. The company operates three large and very modern softwood pulp mills, with two in Germany, and one in British Columbia, Canada. The three mills have a combined pulp production capacity of over 1.5 million tonnes per year, and a combined electrical generating capacity of 259 MW. Mercer’s David Gandossi, Executive Vice President, Chief Financial Officer and Secretary said; “Our strategy of continuously striving for world class performance, and of implementing new and innovative technologies which improve our social, environmental and economic sustainability, is at the core of why Mercer International is proud to support this research chair in Advanced Engineering for the Forest-Products Based Bio-Economy at UBC”.
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Conference report
of Low Consistency Refiner No-load Power, was produced in cooperation with J.A. Olson, J. Heymer (now with AFT), and D.M. Martinez. No-load power goes to overcome the hydraulic and mechanical losses in the refiner, Rajabinasab explained. Her study demonstrated that no-load power depends on the plate gap which implies that the net power at a specific gap requires that the no-load power is known at that gap. Rajabinasab stated that hydraulic power is only dependent on rotational speed. Pumping power, which is the difference between the total no-load power and hydraulic power, depends on gap size, rotational speed and flow rate. In the course of their work, the group developed a new plate roughness parameter.
Performance monitoring in the age of “big data” Canadian research was also highlighted at Control Systems 2012. The keynote address was presented Dr. Sirish Shah, professor with the department of chemical and materials engineering, Univeristy of Alberta. Dr. Shah is the NSERC-MatrikonSuncor-iCORE senior industrial research chair in computer process control. He spoke of the challenge of “big data.” To handle various kinds of data found in manufacturing – business data, spectral data, binary data, numerical data, vibration data – you need the right analysis tools, said Shah. The world is becoming data centric, he noted. In a manufacturing operation, engineers may use 5-10 metrics to measure the performance of one loop. (In a separate presentation on energy conservation opportunities, Andrew Denasiewicz, Siemens Industry Inc., commented that a modern, 500,000-ton-per-year pulp mill typically has 9000 instruments and 14,000 instrument loops.) Shah noted there is a lot of research attention right now on the subject of connectivity data being the missing link between process data and alarm data. For causality detection, we need process knowledge because correlation does not imply causality, said 16
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Shah. One approach he suggested is direct transfer entropy, a relatively new approach that captures material flow and information flow. Shah recommended that businesses should “incorporate process connectivity into process data analysis.” To do so, multi-variate analysis is suggested, and process topology or connectivity information is needed.
Tools to increase paper production Voith and Metso presented two retrofit ideas for the forming section that may be especially relevant to board producers. A new approach to single-side dewatering for fourdrinier formers can be achieved by using tools like a vacuumassisted forming board, such as Metso’s VacuBalance, say four specialists with Metso Paper Inc. Juan Cecchini et al.
ensures stable sheet forming from the beginning of the drainage process, noted Kast. As well, the flexible wire merging with three pneumatic-loaded blades allows smooth initial forming on the top side of the sheet. In this enhanced hybrid former, a curved top wire suction box ensures a stable run of the wire sandwich. “We have studied quite a bit on reducing energy consumption, how to get a drier sheet going into the press,” said Kast. He explained that the new design produces a cost-efficient increase in solids. The use of high vacuum boxes contributes to increased solids without using a suction couch roll. “Replacing the suction/couch with high vacuum reduces energy costs by 20%,” Kast stated. Both pump size and drive horsepower are reduced. According to Kast, this new former
“replacing the suction/couch with high vacuum reduces energy costs by 20%.” – Thomas Kast, Voith
describe how formation is achieved by increasing shear from the jet-to-wire speed difference as well as strong water removal over the shorter table length. In a fourdrinier equipped with a vacuumassisted forming board, the orientation and formation can be simultaneously controlled, Cecchini noted. This can be an advantage when considering MD strength development. The vacuum-assisted forming board expands the operating window of fourdrinier-type formers. It gives paper and board makers an opportunity for rebuilding existing machinery with benefits related to production capacity and quality control capabilities. Thomas Kast of Voith described for PaperCon attendees the development of an improved hybrid blade former driven by the demand for increased production capacity. This new concept allows the Duoformer D II hybrid blade former to operate in a range that was previously only occupied by gap formers, said Kast. The optimized arrangement of drainage elements in the pre-drainage area
design allows a production increase of more than 30% for the filler ply at a total board weight of more than 400 g/m2 produced with a three-ply board machine. Using this former, the machine speed for board machines can be increased up to 1200 m/min or even 1400 m/min. The benefits of the iTable from IBS were presented by Andy Forester. According to Forester, this adjustable forming table has been shown, on average, to produce a 6% reduction in basis weight for 35 lb. linerboard, and a 10% increase in speed. IBS has 16 units in operations: three on virgin fibre machines, and 11 on recycled linerboard or medium machines.
chemicals suppliers champion a holistic approach To maintain higher filler levels and maintain or improve paper quality, Eka has introduced the EcoFill system. The filler modification system, including an online filler treatment system with charge control additives and an engineered cellulose additive, was described by Patrik www.pulpandpapercanada.com
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Cover Story
Simonson, et al., of Eka in the paper Challenges and demands towards higher filler levels in white top liner and fine paper. The paper was presented at Papercon by Mark K. Zempel. Simonson notes that the engineered cellulose additive improves the bonding at the interface between the filler particles and between the filler and fibre in the sheet. This gives significant internal bond improvements. The role of the charge control additives is to contribute to the physical interaction between the binder and the filler particle surface, but also to be the active control of the charge balance in the wet end, he explained. Brian Altherr of Ashland Water Technologies described how a holistic specialty chemical approach can be useful in overcoming the challenges associated with using recycled furnish. He presented a summary table outlining newer chemical technologies and their benefits. Included are NVF-based polyvinlyamine for strength, retention and drainage; ammonium bromide for microbiological control; and synthetic detackfiers for stickies control. In one example, he described how a mill producing 100% recycle linerboard was struggling with high production costs and poor runnability. This mill was running ASA sizing and glyoxylated polyacrylamide (GPAM). Sizing costs had been steadily increasing for several years. A new approach involved replacement of the GPAM dry strength resin with N-vinylformamide-based (NVF) polyvinylamine technology. “The new chemistry impacted the system significantly, primarily through reduced cationic demand, improved ring crush, increased drainage, and a 15% boost in first pass retention,” Altherr writes in 100% Linerboard manufacturers use advanced specialty chemicals to save money and overcome multiple challenges. Daniel Glover and Rosy Covarrubias of Buckman described an advancement to GPAM dry strength resins technology that improves shelf life and stability, reduces freight costs and has improved efficiency. They note that first-generation GPAM products were characterized by www.pulpandpapercanada.com
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rockTenn plans more investment to be low-cost producer James A. Rubright, chairman and CEO of RockTenn, freely acknowledges that his company is aiming to be the “last man standing” in the North American containerboard market. With the merger last year of RockTenn and SmurfitStone Container, the company expanded its production capacity to more than 9 million tons per year – 80% in containerboard and 20% in consumer packaging. Rubright was presented with the PIMA Executive of the Year award during PaperCon. James A. rubright In recent years, RockTenn has pursued a course of acquisition and investment. In the face of offshore competition in many of its product categories, “we looked for sustainable competitive advantage,” he explained. That advantage turned out to be higher utilization of assets, becoming the lowest cost producer, and the strategy commonly known as “last man standing.” “Even though you have an absence of growth [in your market], you can grow profitably,” Rubright noted. He recalled that even though some experts were telling the company not to invest in its existing assets, management decided to invest in its facilities and people. “So we embarked on hundreds of projects to take costs out of the old recycled mills.” This year, RockTenn has allotted $500 million in spending on its “acquired asset base.” “The majority is focused on taking cost out,” said Rubright. RockTenn bought Smurfit-Stone in May 2011, shortly after that company emerged from bankruptcy protection. “We acquired an asset base that will allow us to grow profitably,” Rubright noted. The purchase included 12 mills and 10 converting facilities. With the acquisition, RockTenn became owners of a linerboard mill in La Tuque, Que., a corrugating mill in Matane, Que., and converting facilities across Canada. RockTenn quickly closed the Matane containerboard mill, saying it was the highest cost mill in the RockTenn containerboard mill system.
low solids, low shelf life and low charge. In Buckman’s second generation GPAM, percent solids rises to 10-12.5% from its former level of 6-8%. Its shelf life at 30 degrees C is 30-60 days, compared with 12-15 days for first generation materials. The charge density per unit is significantly higher, explain Glover and Covarrubias, which will give an advantage for drainage in highly anionic furnish such as OCC. John Xu of AstenJohnson Inc. presented The effect of non-woven base on press felt properties and dewatering. He noted that compared with conventional and multi-axial felts, the non-woven felts tend to have lower air permeability after conditioning. They also have higher compressibility, less void volume, and better pressure uniformity. In a pilot
trial on a paper machine, it was observed that non-woven felts perform differently when compared with conventional and multi-axial felts. When a non-woven felt was used, the sheet solids increased and the Yankee dryer steam condensation rate decreased. There was more water discharged from the pressure roll tray and less water removed from the uhle box.
Big business in the Big easy While New Orleans may be known for its good times and laissez-faire attitude, during PaperCon it was all business. The broad range of topics and substantial trade show ensured everyone came home with tips and fresh ideas for their job. PaperCon 2013 will be held in Atlanta, April 28-May 1. July/august 2012
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Technology News
FOCUS ON DEINKING/RECYCLING Flotation system minimizes energy consumption Andritz has received an order from EcoPaper JP to supply a flotation system for its Nagoya mill in Japan. According to Andritz, with the new system, power consumption will be significantly reduced, the quality of the pulp produced will be improved, and the fiber losses will be minimized. Start-up is scheduled for the end of 2012. Andritz will deliver a SelectaFlot flotation system (type SFL1D), including piping, pumps, and installation work. The new flotation system will replace old flotation cells in a deinking plant for graphic papers operating at a capacity of 150 t/d. In Andritz SelectaFlot systems, the pulp suspension is pumped through the multi-injectors into the flotation cells. Inside the patented injector, the pressure energy is used to pull air into the feed stock. The right amount of air, as well as the optimized injector geometry, leads to an optimal bubble size distribution, which Andritz says is the key to the superior performance of the cell. This, coupled with the optimized geometry for the flow conditions inside the cell, allows the SelectaFlot cell to deliver maximum dirt speck removal and optimum brightness increase with low fiber loss. andritz, www.andritz.com
Vision system pinpoints origin of web breaks Aylesford Newsprint Ltd. has expanded its advanced web inspection system delivered by Metso in 2010 on PM14 to include cameras for web break analysis. Metso Process and Quality Vision system (Metso PQV) enables improvements in runnability and production by finding the origins of web breaks and analyzing the defect map of even the smallest defects from the whole web. Metso PQV system integrates the web inspection and web break analysis capabilities using the most advanced high-resolution, high-speed digital imaging technology available. The extension at Aylesford Newsprint includes 15 fixed position web break cameras and 1 portable camera. The successful cooperation between Aylesford Newsprint and Metso is also marked by recent replacement of PM14’s distributed control systems with Metso DNA automation system. Aylesford Newsprint recycles 500,000 tonnes per year of used newspapers and magazines in the manufacture of Renaissance – a 100% recycled, publishing quality newsprint which is used by many of the UK and Europe’s regional and national newspaper publishers. Aylesford Newsprint is a joint venture company between SCA Forest Products and Mondi. metso automation canada 514-908-7045, www.metso.com
tolko equips staff with mobile access to geographic data Knowing where to cut trees is essential to running sustainable and safe forestry operations. Field operators need up-todate and accurate forest information so they can intelligently develop their harvest strategy. Tolko Industries Ltd., a forest products manufacturer based in Vernon, B.C., addresses this challenge with Esri’s mobile geographic information system (GIS) solution. Through the mobile GIS, field staff can now identify where they are relative to cut block boundaries and efficiently conduct harvest operations. Esri Canada recently presented Tolko with an Award of Excellence for this outstanding GIS application. “Location plays a significant role in forestry,” says Alex Miller, president, Esri Canada. “GIS helps foresters leverage location intelligence to make the best decisions about where to perform their work in support of their business and environmental priorities, while increasing their safety. Tolko’s mobile GIS is a cost-effective solution for managing information about complex forest systems, as well as their dispersed assets and workforce. It strengthens the groundwork for sustainable operations and growth.” “Worker safety and environmental compliance are both important aspects of our business,” says Rob Kennett, Tolko’s Okanagan Regional Forester. “Our field operators work in all types of conditions.
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This mobile GIS application gives them the confidence to proceed because they know exactly where they are on the cut block. It helps them understand the challenges they’ll face in the field.” Tolko has been using Esri’s ArcGIS technology in its Okanagan Woodlands operations for many years to support essential business processes including forest data management, harvest planning and analysis. Previously, field staff relied on static, printed maps and found it difficult to pinpoint their exact location as they carried out their work. In 2011, Tolko deployed the ArcGIS for Mobile solution on ruggedized tablet computers mounted on feller buncher equipment used to harvest trees. The tablets’ built-in GPS signal allows field operators to determine their exact location and work within cut block boundaries displayed on the GIS. “Our field operators are not necessarily GIS savvy, but they find ArcGIS for Mobile easy to use,” says Leon Medema, GIS analyst, Tolko. “The solution was easy to implement and we deployed it virtually out of the box. The uptake was easy and about 30 field operators now use the application. We’ve since received several requests to add more data to the application because our field staff find it very useful for decision support. The mobile GIS application has become a company best practice.”
esri canada 416-441-6035, esri.ca/ products/arcgismobile www.pulpandpapercanada.com
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Technology News Process measurement equipment donated to Calgary university
adjustable speed drive uses rotating magnets
andritz Primeline chosen for high-strength paper line
Endress+Hauser Canada is investing in the next generation of skilled workers by making a $1.4 million donation to the new SAIT Polytechnic Trades and Technology Complex in Calgary, Alberta. The donation from the process measurement and automation supplier will fund the Endress+Hauser Process Lab. The lab will be outfitted with the latest flow and interface measurement technologies, in addition to guided-wave radar instruments and nuclear density profiling systems. The company will also provide guest lecturers and various training materials that explain the different measurement technologies. endress+Hauser canada, www.ca.endress.com
Flux Drive technology utilizes portions of induction motor theory combined with recent improvements in permanent magnets to create a breakthrough design for flexible soft-start couplings and adjustable speed drives. Coupling torque is transferred across an air gap by means of magnetic induction. This unique magnetic circuit eliminates high-peak power demands during start-up and provides significant energy savings during reduced speed operations. Flux Drive products allow the motor to run at a constant speed, and at its best efficiency point, while having the ability to provide speed control to the load. The Flux Drive Adjustable Speed Drive (ASD) is a soft-start coupling with the ability to configure the linear engagement between the rotating magnet can and rotor. Adjustable speed is achieved by controlling the overlap of the can and rotor. As the can and rotor are disengaged, the slip increases allowing the output speed to decrease proportionally. In centrifugal applications, system power requirements vary with the cube of the pump speed. Small decreases in speed or flow can significantly reduce energy use. For example, reducing the speed by 20% can reduce input power requirements by as much as 50%. The Flux Drive system creates no harmonics and therefore requires no complex filtering systems. Unlike variable frequency drives, no air conditioning or other devices are needed. Flux drive inc. 250-718-0841, www.fluxdrive.com
Andritz has received an order from Zellstoff Pöls AG, Austria, for the supply of a PrimeLine plant for production of specialty paper. The 5.4-m machine will produce very high-strength paper grades used primarily for shopping bags, high-grade medical packaging, and food packaging. Start-up is scheduled for the end of 2013. The machine will have capacity of 80,000 t/a with a design speed of up to 1,000 m/min. The scope of supply includes the stock preparation plant, an approach flow system, the PrimeLine fourdrinier machine, a high-precision steel yankee to increase drying (diameter: 6.5 m), a calender, and the automation systems. With this investment, Zellstoff Pöls is extending its paper production capacity at the Pöls mill. The company is also the largest manufacturer of high-quality, elemental chlorine-free (ECF) sulfate pulp from softwood in central and southeast europe. andritz, www.andritz.com
Buckman wins green chemistry award for papermaking enzymes Buckman was awarded the Presidential Green Chemistry Challenge Award from the U.S. EPA for its Maximyze® enzymes, which are comprised of natural catalysts and used to reduce energy and decrease the amount of wood fibre needed to manufacture high quality paper and paperboard. The award, the second for Buckman, is in the Designing Greener Chemicals Award category. The Maximyze enzymes are derived from renewable resources and produced by fermentations, rather than typical chemical reaction methods. “Buckman is dedicated to serving our customers by providing innovative product and process solutions, while at the same time maintaining a culture committed to a sustainable future,” said Kathy Buckman Gibson, chairman of the board for Buckman. The Maximyze group of products developed and sold by Buckman is comprised of carefully selected and designed enzymes, derived from natural sources, that modify cellulose fibers. This technology is now being applied successfully in many paper mills around the world. In one application, the basis weight of the paper product was reduced by three pounds per 1,000 square feet with no loss of quality, resulting in a 1% reduction in the amount of wood pulp required. Maximyze enzymes can also improve water removal in the papermaking process so less steam is required to dry the paper on the paper machine. Buckman 800-Buckman, www.buckman.com www.pulpandpapercanada.com
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environmentally-compatible process additives Clariant’s “Sustainabilty meets Performance” products deliver energy savings, productivity improvements and high quality finished paper materials. They give papermakers the opportunity to integrate more environmentallycompatible process materials into their operations. Pitchbent® is a complementary additive
new debarker for aV nackawic improves fibre yield A single Fuji King debarker has replaced two rotary-style debarkers at the AV Nackawic dissolving pulp mill in Nackawic, N.B. The Fuji King KD6/120DT was supplied by Carmanah Design and Manufacturing Inc., of Surrey, B.C. According to Carmanah, the change has resulted in higher capacity, improved bark removal, increased fibre yield and les maintenance and downtime. Start-up was October 2011. Carmanah designs and manufactures equipment for the panel and engineered wood products, pulp and paper, and sawmill industries. The Canadian company has a license agreement with the Fuji Kogyo Company of Japan to manufacture and sell the Fuji King Rotary debarker. More than 200units of this debarker have been sold worldwide. Carmanah is also a major service centre for pulp and paper equipment repair and refurbishment. carmanah design & manufacturing inc. 604-268-1676, www.carmanahdesign.com
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Technology News to prevent impurities from raw materials and the build-up of secondary substances in the water re-circulating in papermaking machines. Through passivation, it achieves a clear reduction in glue deposits on machine parts and machine cloth. Printosil® supports the production of multi-purpose paper primarily without the use of binders. The mineral coating creates an even surface at low coating weight. Paper made with Printosil is suitable for all printing processes, and prevents quality issues for optimal production speed and output. “Clariant’s innovative paper solutions address the industry’s need for costsavings and increased use of recycled fiber, while also achieving the highperformance paper strengths, color shades or the brilliant whites end-users expect,” comments Helmut Wagner, head of Clariant’s paper specialties business unit. clariant Paper Specialties, www.paper.clariant.com
eurocon analyzer acquires dynamic drainage analyzer
a retrofit solution for electrical discharge current damage The new range of SKF Shaft Ground Ring Kits have been developed as a solution to help prevent bearing failures due to electrical discharge currents, which can occur when variable frequency drives (VFDs) are used to control AC motors. The kits have been specifically designed for retrofitting on existing IEC frame size industrial electric motors, reducing the need to spend time, effort and cost in replacing the existing bearings. The TKGR series kits are primarily suitable for common applications such as fans, pumps and compressors driven by motors up to 75kW. Compared to non-protected VFDcontrolled motors, TKGR’s help prevent electrical discharge current damage in rolling bearings and protect both motor bearings and the bearings in attached equipment. Designed to be maintenance free, they improve system reliability, helping to avoid motor repair and unplanned downtime. SKF canada ltd. 866-832-6753, www.skf.ca
Powerful tank cleaner for tanks, barrels, drums
Eurocon Analyzer has acquired the Dynamic Drainage Analyzer, DDA, from Akribi Kemikonsulter, Sweden. The agreement covers sales as well as upgrades and support of existing units. The first two orders for DDA equipments since the acquisition have already been booked. The drainage analyzer is designed to give an accurate simulation of the conditions on a modern paper machine. A PC controls the whole analysis and calculates drainage time and permeability. A DDA can be used to measure retention, formation and dry substance simultaneously. Since 1996, about 85 units have been sold worldwide. eurocon analyzer inc. 613-590-0222, www.eurocon.se
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The powerful TankJet 55 from Spraying Systems Co. operates at low flows and fast cycle times, to enable cleaning of multiple tanks, barrels and drums in minutes. It is easy to use and can be repaired in the field. TankJet 55 is compact and fits in openings as small as 1-3/4” (44.5 mm). Two models are available: standard models for faster rotation and shorter cycle times and slow, rotational models which allow excellent dwell time for cleaning tougher residues. The fluid-driven, turbine-driven TankJet 55 cleans using narrow angle full cone sprays rotating in multiple axes for 360° coverage. Spraying Systems co. 630-665-5000, www.tankjet.com
Honeywell expands partnership with sKF SKF, a global leader in vibration-based machinery protection and monitoring systems, has expanded its partnership with Honeywell as part of the Honeywell PKS Advantage™ Program. The PKS Advantage Program is a collaborative program that engages other
best-in-class suppliers of automation solutions and allows them to integrate and apply data and information products with Honeywell’s Experion® Process Knowledge System (PKS), giving end users greater flexibility in choosing complete solutions for their businesses. The results include improved asset availability and effectiveness, optimized process throughput and work processes, and lower costs of ownership, operations and maintenance. Gary M. Foster, SKF, commented, “We joined the PKS Advantage Program to provide high-value integrated machinery protection and vibration monitoring solutions to users of Honeywell’s Experion PKS. Our improved real-time monitoring approach reduces the time required to resolve equipment problems, minimizes unplanned downtime, and lowers maintenance costs while preserving process safety.” Honeywell, www.honeywellprocess.com
Unique partnership warns of doctor blade chatter A product that helps tissue makers optimize production is the first result of a strategic partnership between Nalco and SKF. The Nalco Early Warning Chatter Detection (EWCD) system provides tissue machine operators the ability to detect potentially harmful vibrations that can result in doctor blade chatter. “Our customers are asking for suppliers to work together to provide more advanced solutions, and we’re delivering,” said Scott Morris, SKF global marketing manager, Pulp and Paper Keys to the effectiveness of the system are Nalco’s approach to early chatter detection through analysis of various parameters, an easy-to-use graphic user interface and best-in-class online monitoring technology from SKF. Unlike other condition monitoring software, Nalco’s EWCD system is designed specifically for the creping application. In addition to its critical early warning purpose, the technology has proven to provide additional insight regarding coating stability on the Yankee dryer, thus allowing improved troubleshooting for other creping problems. Ongoing pilot projects already have resulted in successful “saves,” proving the value and reliability of the system. ecolab, www.ecolab.com
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Bio-Economy
lignin poised for commercial breakthrough Attendees at the International Lignin Biochemical Conference were told Domtar will be producing commercial quantities of lignin next year and a production line for lignin/PAN carbon fibre will be available by the end of 2013.
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ith lignin as the focus of varied process and product development efforts on both sides of the Atlantic, it appears that commercial applications for lignin as a substitute for petrochemicalbased polymers are likely in the 20132014 time frame. Speakers at the International Lignin Biochemical Conference in Toronto on June 21 described a variety of product trials, and Domtar confirmed that its Plymouth, N.C., mill should be producing commercial quantities of kraft lignin early next year. The use of lignin as a binder for wood products such as oriented strand board (OSB) is one of the closer-to-market applications, commented Kirsten Maki, associate research leader with the BioEconomy Technology Center in Thunder Bay, Ont. Another promising market for lignin is carbon fibre. The use of lignin as a precursor for carbon fibre would be an entry to a high-value, quickly growing, worldwide market. “(The concept of) carbon fibre from lignin is not new, but if we can make it low cost, we can change the market,” said Mohini Sain, director of the Centre for Biocomposites and Biomaterial Processing, University of Toronto. In his presentation, Sain noted that the commercialization of lignin will require multidisciplinary teams and partners to bring the product to market. Notably, Weyerhaeuser has teamed up with carbon fibre producer Zoltek Companies Inc. to develop a method for producing carbon fibre from lignin. They are using a wet spinning technique and blending the lignin with the most commonly-used carbon fibre precursor, polyacrylonitrile (PAN). George Husman, chief technology officer, Zoltek, explained that both materials are soluble in the same solvents, but the process needs a very high-purity lignin and a higher molecular weight PAN than 22
usual. So far, Zoltek has found the process to be limited to about 45% lignin, but even so, this direct substitution of a lower-cost material for the PAN has a strong positive effect on costs, and may improve throughput. Husman says the blended lignin/ PAN carbon fibre process will undergo commercial-scale validation this summer. Then it’s on to phase two, the design and construction of a commercial production line for lignin/PAN carbon fibre, which is expected to be completed by the end of 2013. Husman noted that the total world market for carbon fibre is currently 50,000 tons, which requires about 100,000 tons of precursor material. The forecast is that world demand for carbon fibre will double or triple in the next five years. So, once the process is commercial, “we should be able to use most of what Weyerhaeuser could produce.”
domtar on track for producing lignin in 2013 The installation of a LignoBoost lignin extraction system in North Carolina is proceeding on budget, on time, and injury free, reported Bruno Marcoccia, director of research and development with Domtar. The line under construction at Domtar’s Plymouth, N.C., site is expected to start-up in the fourth quarter of this year, and begin production early in 2013. Marcoccia provided an update on the Metso-supplied LignoBoost project for participants at the lignin conference. The Plymouth mill will produce 50-100 tons per day of lignin. “One hundred tons per day is a significant amount,” he noted. “You do not just pile that up.” Since there are not yet any customers for such a large, continuous supply of lignin, Domtar will use it as fuel. Domtar’s facility will be the first commercial source of lignin to enter the market in about 25 years.
Dr. Amar Mohanty and Dr. Mohini Sain, discussing lignin, no doubt.
Through collaborative product development, Marcoccia expects to eventually exploit higher value applications for lignin. The R&D executive explained that the Plymouth mill was uniquely suited for the lignin project because it has been recovery-boiler limited for several years. He said the LignoBoost process will costeffectively remove lignin from the black liquor stream, and reduce loading on the recovery boiler. That, in turn, will allow an increase in production for the pulp line. “The vast majority of mills are more balanced (in terms of energy) than Plymouth. This is the only mill in our company that can justify the cost of the lignin plant based solely on its debottlenecking benefits.” Marcoccia noteed that if the mill does begin selling the lignin, it will need a replacement, low-cost fuel to use in the pulp manufacturing process.
moving up the value chain As Mike Rushton of Lignol, commented: Lignin is bio-derived, and trying to get it into a world dominated by synthetic and petro-derived materials is a challenge. “To provide value, lignin has to be more than just a renewable chemical,” he said. “It has to enhance the product.” A number of speakers made it clear that the keys to success for lignin will be the development of consistent supply with repeatable properties, maximizing the use of lignin’s chemical functionality, and partnering with organizations that have the appropriate market knowledge for each sector.
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