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STRENGTH RESIN TECHNOLOGY THAT REALLY STACKS UP Kemira legacy companies introduced the first commercial synthetic strength resins more than 50 years ago. Today, over 100 researchers in our global R&D centers continue to develop new generations of strength resins and other innovative paper technologies. Kemira’s FennoBond dry strength and FennoRez temporary wet strength products help our customers enhance sheet properties, reduce basis weight, optimize furnish costs, and increase machine speeds. It is no wonder Kemira is the North American market leader for glyoxylated polyacrylamide (GPAM) technology. Kemira’s FennoStrength resins are the highest solids products commercially available, delivering unbeatable cost efficiency for permanent wet strength applications.
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Editorial
Companies still recovering from abnormal cold, truckers’ strike
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rarely report the quarterly financial results of forest products companies in this magazine, partly because of timing, and partly because they require so much explanation and context to have any real meaning. However, there are often nuggets of non-financial information within the quarterly results press releases. The news item I posted to our web site about delays and rising costs for Tembec’s cogen project at Temiscaming, for example, was culled entirely from the company’s quarterly statement. That same quarterly statement, issued in late July for Tembec’s fiscal third quarter ended June 28 (see what I mean about lengthy explanations?), yielded some insights into the cost structure of pulp and paper companies that might be interesting to those of us not currently occupying executive offices. Here’s some of the commentary regarding the newsprint market from Tembec’s press release: Cindy Macdonald Editor “The US $ benchmark price for newsprint was unchanged at US $605 per tonne. The stronger Canadian dollar resulted in a $7 per tonne decline in newsprint realizations.” That’s the influence of currency fluctuation. Now, witness the influence of the weather. “Manufacturing costs at the Kapuskasing newsprint mill decreased by $10 million, primarily for energy. The prior quarter’s costs had been negatively affected by the abnormally cold weather that led to a shortage of natural gas, which in turn caused significant increases to the cost of purchased electricity in the province of Ontario. The newsprint mill also took six days of unplanned downtime in the prior quarter to mitigate the impact of the higher electricity rates.” Operators of mills in Alberta can sympathize. The result: “The Paper segment generated operating earnings of $7 million, compared to an operating loss of $2 million in the prior quarter.” Out on the west coast, at Canfor Pulp Products, pulp shipments were up were up 11% from the previous quarter, “largely attributable to improved transportation performance following the challenges experienced in the prior quarter.” Said challenges would be the Vancouver Port truckers’ strike. Although more pulp was shipped, the strike still had a negative effect on sales in the second quarter: “…pulp unit sales realizations experienced a small decrease compared to the previous quarter due to a combination of weaker prices to China, a slightly stronger Canadian dollar and a higher proportion of shipments to lower-margin markets, including Asia, mostly tied to constraints in the previous quarter due to the Vancouver Port truckers’ strike.” All told, these insights make me glad to be a worker bee, not an executive.
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
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PULP& PAPER
September/October 2014 Vol. 115, No. 5 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
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Sharing the Land
A Supreme Court decision regarding a First Nation’s land claim changes the landscape and forest products companies may get caught up in the turmoil.
FEATURES
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Barriers to Growth for Paper and Board
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Ian Lifshitz of APP Canada explains how bioplastics and water-based barrier coatings will make paper and board more competitive in packaging applications.
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Nanocellulose: Tweaking the Process
While making sample quantities of crystalline nanocellulose for others to test applications, the team at Alberta Innovates Technology Futures is focused on how to make this new material more cheaply.
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The Magic of Whitecourt Pulp
Millar Western’s BCTMP mill in Whitecourt, Alta., is a mill of outstanding versatility with a broad product range, coupled with a team of skilled employees.
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Bioeconomy: Kruger, Mercer, Resolute, West Fraser Step Onto the Field
Kruger and FPInnovations begin production of cellulose filaments, while Mercer and Resolute pair up to sell it. West Fraser commits to commercial scale production of lignin at Hinton Pulp.
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IN EVERY ISSUE 4 8 12 12 14 26 29 28
Editorial News
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Opinion: FPAC
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Opinion: FPInnovations Technology News Classified Ads
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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 image: Thinkstock
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Increase thermocompressor efficiency up to 25% and reduce high-pressure steam consumption. Conventional thermocompressors use high-pressure steam to compress and recirculate uncondensed steam in the dryer section. Kadant’s new high-efficiency thermocompressor has been shown to reduce motive steam consumption and increase overall thermocompressor efficiency by up to 25%. Using advanced computational fluid dynamics modeling, Kadant thermocompressors are designed to maximise steam utilisation.
New UniSet™ doctor blade holder delivers robust performance and simple replacement. The next generation of doctor blade holders features light-weight composite and carbon-reinforced construction integrated with the UniTrak™ T-rail. The UniSet™ blade holder offers easy removal, replacement, and upgrades to improve doctoring performance. All blade retention and pivoting components are formed and reinforced within the top-plate and tube tray and there are no items to loosen, twist, or fall into the machine.
ErGo™ filtration system removes contaminants while enhancing safety. Kadant’s innovative ErGo™ filtration system is designed for protecting shower nozzles and process equipment from contaminants while increasing energy efficiency and contaminant removal. The automatic internal backwash barrel filter design features a safety cap allowing rapid filter media access and a “bottomless” barrel for easy cleaning and element removal.
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Industry News
Cascades exits fine paper business, sells Rolland assets A private equity investment firm has teamed up with management to acquire the Cascades Fine Papers Group from Cascades Inc. for $39.5 million. The units covered by the transaction with H.I.G. Capital are: • Rolland Division, an uncoated fine papers and security papers plant located in Saint-Jérôme, Que. • CTC Converting Centre, a fine papers processing and distribution plant built in 1998, also located in Saint-Jérôme. • Fibres Breakey, a de-inked bleached kraft pulp manufacturing plant located in Sainte-Hélène-de-Breakeyville, Que. “This transaction provides stability and growth opportunities for all Rolland employees, customers, and suppliers. We are excited about the future of the business and the partnership with H.I.G.,” said Daniel Parrot, president and COO of Rolland Enterprises. The three units employ about 425 workers. The business will be re-named Rolland Enterprises, taking back the former name of the business prior to its purchase by Cascades in 1992. The current management team will remain in place in order to ensure an orderly transition.
Cascades to close kraft paper operations in East Angus Cascades is withdrawing from the kraft paper sector and closing its kraft paper manufacturing activities at the East Angus, Que., plant because of unfavourable market conditions and the failure of discussions concerning the plant’s transfer to new owners. Close to 175 employees will be affected by the closure, which will come into effect by October 3, 2014. The coated boxboard plant in East Angus is not affected by this announcement. “With the arrival of new competitors that convert newsprint paper machines to produce kraft paper, and the ongoing weakening of market conditions for our products, the East Angus plant has not managed to maintain a competitive edge in the market despite significant investments and serious recovery efforts,” explained Luc Langevin, president and chief operating officer of Cascades Specialty Products Group. “Last November, we announced to employees our decision to withdraw from the industry. At the time, we offered them the plant debt-free. After several months of ongoing efforts on the part of buyer Gino Lévesque, the Québec government and Cascades to come up with a financial package, the project was abandoned because of a lack of new investors. With the failure of the turnaround project and the loss of numerous key employees, today we are forced to announce the end of these activities.” Founded in 1964, Cascades produces, converts and markets packaging and tissue products that are composed mainly of recycled fibres.
Kimberly-Clark releases tube-free bathroom tissue
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Compliance order issued to Northern Pulp Nova Scotia’s Environment Minister Randy Delorey has issued a Ministerial Order to ensure that Northern Pulp takes measures to reduce air quality emissions that exceed approved limits under the Environment Act. The mill, however, has had well-publicized plans in place since April to replace its electrostatic precipitator, which should address the emissions problem. The NBSK pulp mill is located near Pictou, N.S., and has been owned by Paper Excellence for about three years. Local residents have been vocal in their concern about emissions from the mill for several months. “They are voicing their concerns because they want a healthy, safe and prosperous Pictou County. We all want the same things,” said Premier Stephen McNeil. “This order makes it clear to Northern Pulp what this government expects of the company so we can clean up the air for residents and the industry can continue to prosper.” The order says Northern Pulp Nova Scotia Corporation is in violation of a term and condition of its approval, by exceeding air quality stack emissions from a recovery boiler. The compliance order specifies that Northern Pulp takes measures to come into compliance before May 30, 2015. “This ministerial order outlines several actions that I expect the company to complete between now and next spring,” said Delorey.
After a test period in some U.S. markets, Kimberly-Clark has made bath tissue rolls without the inner cardboard tube available across the U.S. This innovative product eliminates the cardboard tube that has been the central fixture of rolled toilet paper for more than 100 years. The company claims that 17 billion toilet paper tubes are thrown away each year, which is enough to fill the Empire State Building twice. Thus, it is billing tube-free bath tissue as a way for consumers “to take small steps to make a big impact on the environment” “Kimberly-Clark is thrilled to be able to release Scott Naturals Tube-Free bath tissue nationally, providing consumers across the country with a product that contributes to a better, cleaner world, without sacrificing quality,” said Jared Mackrory, brand manager for Scott Brand. The national launch of the tube-free product is supported by advertising and an online consumer pledge. Consumers are encouraged to take an online pledge to “toss the tube” at www.ScottBrand.com and share their commitment on social media using the hashtag #TosstheTube. Kimberly-Clark brands inlcude Kleenex, Scott, Huggies, Pull-Ups, Kotex and Depend.
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Industry News The order requires Northern Pulp to ensure an electrostatic precipitator is built, installed and commissioned on the recovery boiler by May 30, 2015, to bring the mill’s air emissions into compliance. The company must also submit a schedule for installing the new precipitator and provide weekly progress reports in writing. A local paper reported in June that Clyde Bergemann Power Group Americas of New Jersey was awarded the turnkey contract for design, fabrication and installation of a new precipitator for the Northern Pulp mill. A local news site, Daily Business Buzz. ca, reported the levels of particulates in the mill’s plume in a July test were 25% lower compared with results last fall. But according to statements by the mill’s owner, the particulate level in July was 500 mg/m3, while the legal limit is 375.
Biomass power plant at Prince Alberta Pulp indefinitely closed The biomass-to-energy operation at the Prince Albert Pulp mill in Saskatchewan has been indefinitely shut down, according to the local newspaper, the Prince Albert Herald. The pulp mill and wood energy plant are owned by Paper Excellence. The biomass burning facility had been providing about 10 MW of electrical energy to the provincial grid while the pulp mill is being readied to re-open, but local officials have been told it is too expensive to operate the biomass-to-energy facility without waste wood from the pulp mill. Paper Excellence stated at the end of 2013 that the mill would be re-fitted to produce fluff pulp and should be operational in 2015.
Babcock & Wilcox among suppliers for Irving upgrade As part of a modernization announced in March of this year, Babcock & Wilcox Canada Ltd. has received an order from Irving Pulp & Paper to design, fabricate and field-erect a pulp discharge tank at the West Side pulp mill site in Saint John, N.B. In addition, E.S. Fox Ltd. of Saint John, N.B., has been awarded a contract of more than $2 million. The local company is undertaking the design, fabrication, delivery, site installation, and testing of modular utility racks. The stainless steel discharge tank will www.pulpandpapercanada.com
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Briefly….. • Fortress Paper Ltd. will sell all of the shares of its subsidiary Fortress Optical Features Ltd. to Nanotech Security Corp., for an aggregate purchase price of up to $17.5 million. Fortress originally acquired the optical features business to complement its security papers business at Landqart. The new owner will continue to supply optically variable thin film material to Fortress Paper’s Landqart Mill. • Finnish forest products producer UPM has agreed to become the exclusive distributor of Domtar’s BioChoice™ lignin in Europe, effective Aug. 1, 2014. BioChoice™ lignin is produced at Domtar’s biorefinery in Plymouth, North Carolina. • Sonoco has signed an agreement to acquire Weidenhammer Packaging Group, a leading provider of composite cans, composite drums and rigid plastic containers, for €286 million, or approximately US$383 million, in cash. Weidenhammer operates 13 production facilities globally. Sonoco has two Canadian paper mills, in Brantford and Trenton, Ont. • Resolute Forest Products Canada has been fined $55,000 after a worker was injured in 2012 at the company’s Fort Frances paper mill. According to a statement by the Ontario Ministry of Labour, the worker was helping to move a stack roll when the stack roll shifted and pinched the worker’s arm. The person suffered a crushed arm and wrist. be 45 ft. in diameter, 100 ft. tall and constructed of large modules which will be assembled on site, combined with traditional tank construction methods. The modules are designed to reduce site construction time and accelerate the work to be executed in the field. The modular racks fabricated by E.S. Fox are comprised of a structural steel frame with long pipe sections and will connect the existing facilities with the new continuous cooking plant.
Renewable materials specialist joins UBC Dr. Scott Renneckar will be joining the Department of Wood Science at the University of British Columbia as an associate professor in advanced renewable materials. Prior to joining UBC, Renneckar was a faculty member in the Department of Sustainable Biomaterials at Virginia Tech. Renneckar’s research program focuses on creating advanced renewable materials. He uses materials such as high performance fibres, transparent films and coatings, and nanocomposites in applications for automobile, aerospace, building, and the emerging additive manufacturing industries.
Metis groups form joint venture to commercialize Alberta forests Active Energy Group Plc, an international supplier of industrial wood chip, timber products and forestry management services, has entered into a joint venture agreement to exclusively commercialize in excess of 100,000 hectares of mature forestry assets in Alberta, which are expected to yield more than 20 million m3 of commercial standing timber. The forests are owned by three indigenous aboriginal groups: the Alberta Métis Settlements of Peavine, Paddle Prairie and East Prairie. The Métis Settlements and Active Energy Group will each hold a 45% equity interest in the joint venture company, which will be incorporated in Canada and headquartered in Kelowna, B.C., with the remaining equity to be held by Grand Chief Ronald M. Derrickson. Derrickson, who is also chairman of RMD Group, commented: “In AEG, the Métis Settlements have finally found a partner with the experience, vision and international network to enable them to properly and fairly commercialize their assets for the long-term benefit of their communities.” Under the agreement, the Métis Settle-
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Industry News
Supplier news..... • Kemira is planning to acquire AkzoNobel’s global paper chemicals business, which includes products for retention and sizing, as well as other paper chemicals, including wet strength and coating products. The two companies will also enter into a distribution agreement for AkzoNobel’s colloidal silica business for retention and drainage applications for the paper industry. The transaction does not include AkzoNobel’s Pulp Bleaching business. • Export Development Canada (EDC) announced a US$2 million loan for a subsidiary of Montreal-based GLV Inc. to grow its operations in India. GL&V India produces equipment parts for the pulp and paper industry, and will expand and modernize its existing production unit. • Ashland Water Technologies has a new name – Solenis. The name change coincides with the acquisition of Ashland Water Technologies by a fund managed by private investment firm Clayton, Dubilier & Rice (CD&R). The sale closed July 31, 2014, and included the Industrial Water and the Pulp and Paper business units. Solenis’ product portfolio includes a broad array of process, functional and water treatment chemistries, as well as state-of-the-art monitoring and control systems. 10
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Resolute permanently closes Laurentide mill in Shawinigan Resolute Forest Products Inc. will permanently shut down its Laurentide paper mill in Shawinigan, Que., saying the mill’s competitiveness has been affected by the restart of a competitor’s mill at the end of 2012 and the high cost of fiber, as well as higher transportation and fuel costs. “We made every effort to find a way to improve the Laurentide mill’s performance. Unfortunately, due to its cost structure and challenging market conditions, there is no economically viable option for the mill,” stated Richard Garneau, president and CEO of Resolute. The Laurentide mill has been in operation for more than 126 years. It employs 275, with an annual production capacity of 191,000 tonnes of commercial printing papers. The permanent closure will take effect on or about October 15, 2014. Resolute has committed to work with union representatives and government officials to respond to the needs of affected employees and encourage a smooth transition. As many employees as possible will to be transferred to other company facilities. “We will do our utmost to ensure employee safety during the transition. We will also work closely with our customers to continue to meet their needs,” added Garneau. Resolute Forest Products produces a diverse range of products, including newsprint, specialty papers, market pulp and wood products.
Blanchet leaves Tissue Group for corporate role with Cascades After more than 17 years at the head of Cascades Tissue Group, Suzanne Blanchet, president and CEO, is passing the torch and leaving the Tissue Group to join the Cascades management team as senior vice-president, corporate development. Jean Jobin will succeed her at the Tissue Group and add the title of president to that of chief operating officer which he already holds. “I am very proud of how far we have come since we began our activities in the tissue paper sector. Starting with a single mill, we have managed to climb to the rank of fourth largest producer in North America and to become a key player, not only in the retail sector, but also in the commercial and industrial sectors,” declared Blanchet.
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Photo: Waneta dam, BC Hydro
ments will, in exchange for their equity interest in the joint venture company, grant exclusive rights over all their forestry assets to the joint venture company; and AEG will commit to commercialize those forestry assets in exchange for its equity stake. The joint venture company will be allowed to enter into sub-leases with third parties for periods of approximately 200 years. All commercial transactions that the joint venture may enter into will include an obligation to provide local employment for Métis citizens, and a commitment to contribute to corporate social responsibility programs which benefit Métis communities.
BC Hydro provides incentives for mechanical pulp producers SURREY – The B.C. Ministry of Energy and Mines and BC Hydro have introduced a new energy efficiency program aimed at reducing the power costs of mechanical pulp producers. The Power Smart program provided an injection of $100 million over three years. The program is expected to reduce electricity consumption by 300 gigawatt hours per year, which is calculated to save pulp and paper producers $17.5 million in annual power costs. There are seven thermo-mechanical pulp and paper operations in B.C. operated by four companies: Canfor (Taylor), Catalyst Paper (Crofton, Port Alberni and Powell River), Paper Excellence (Chetwynd and Howe Sound) and West Fraser (Quesnel). “We are pleased with this outcome after several months of open dialogue examining all sides of this complex situation,” says Catalyst president and CEO Joe Nemeth. “This program improves the viability of the energy-intensive mechanical pulping industry and will help ensure the economic benefits we generate throughout the province will continue.” Catalyst Paper is in the advanced stages of planning for a project in Powell River that utilizes waste steam to reduce its electrical load on the BC Hydro system. The project has an expected capital cost in excess of $25 million, of which Power Smart funding will cover 75%, and reduces energy cost by an estimated $5 million annually. PPC
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Committed to moving your performance forward
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Pulp, paper and energy producers worldwide rely on Valmet’s advanced and competitive technologies and services. Every day, our 11,000 professionals work close to our customers to reach sustainable results. Read more and find out how we can help move your performance forward at valmet.com
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Opinion
Confronting the Challenges of a Greying Workforce By Carmie Lato, project manager, PAPTAC
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he aging workforce is an issue of prevalent concern to all current businesses. As baby boomers move closer to being retirement-eligible, it is no longer an emerging issue; rather, it is today’s reality, yet many companies are ill prepared to meet the challenges of this greying workforce. Managing this demographic certainty is much more complicated than simply facing a mass retirement exodus and replacing these skilled workers with less experienced ones. It’s about crucial knowledge being drained out of companies in all sectors; not only cognitive/intellectual knowledge, but practical knowhow as well. Thankfully, though, retirement patterns will vary significantly depending on where one is in the cycle and will play out differently from one geographical area to another, from company to company, and even from function to function, thus affording us a small window of opportunity to plan. For obvious reasons, we can’t fully predict how these confluence of factors will actually play out. All we can do is prepare and be ready to act when the need to do so arises. So, how do we prepare? Training. Many companies view employee training and development as more optional than essen-
tial, and many training budgets are planned solely as a function of a company’s current economic status. In good times, companies are more apt to spend money on training, while in bad times it is seen as an expendable commodity and eliminated altogether. Yet more than ever, business survival will be correlated to an investment in its human capital. Companies will have to define their business wisdom and intellectual knowledge and establish a workforce planning strategy to ensure the transmission of proprietary, collective, and practical knowledge to the new generation. Training and development must play an imperative role in today’s modern workplace. Companies are looking to their professional orders and associations, which have embraced this challenge and are working to put affordable training programs back on the map, and are addressing the obstacle of cross-industry competition and skilled human resource depletion and retention. PAPTAC offers many training initiatives in the form of webinars, technical and management forums, local technical days, international conferences, etc., that promote the exchange of such knowledge and experience. The association is also working on developing training modules addressing the current manpower training challenges. Human capital is your principle business asset – invest in it strategically. PPC
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By David Lindsay, president and CEO, Forest Products Association of Canada
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he environmental group Canopy is again targeting the forest products industry in its “Fashion Loved By Forest” campaign, aimed at clothing sourced from so-called “endangered forests” such as the Canadian boreal. Canopy has asked fashion designers and manufacturers to sign a pledge to not use such fabrics and has contacted newspapers throughout the world urging the public to stop buying clothing made from rayon or viscose made from dissolving pulp. Of course Canopy has it all wrong. The Canadian boreal forest is not endangered – only 0.2% of the boreal is harvested each year. Fire, insects and disease destroys about 1% of the total acreage annually or five times the area affected by commercial harvesting. We also know that by law, all harvested areas are regenerated so the boreal will be there for generations to come. Fabrics made from wood fibre also have a lower environmental footprint than competing synthetic materials such as polyester or natural fibres such as wool and cotton. For example, studies have shown that cotton production using irrigation requires 15 to 35 times more water than cellulose fibre production based on wood pulp. Canada’s renewable forests do not use arable land 12
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which is needed for food production for an increasing global population. Synthetic fibres do not come from a renewable resource, and are not biodegradable. We also know that Canada’s forest products industry has leading environmental credentials – in fact a recent global survey by Leger found that the Canadian industry had the best environmental reputation in the world. We know that Canada has about 150 million hectares of certified forests, or about 40% of the world’s certified forests. This is independent confirmation that companies follow sustainable forest management. Forest companies belonging to the Forest Products Association of Canada and major environmental groups have joined forces in the Canadian Boreal Forest Agreement, the largest conservation agreement ever signed. The CBFA is built on the premise that conserving habitat and protecting jobs go hand in hand and it changed the paradigm from confrontation to co-operation. FPAC feels that protection of the boreal forest is better secured through working together. We remain confident that savvy consumers will discount the Canopy propaganda. In reality anyone designing or buying “forest fashions” can feel confident they are choosing one of the most environmentally friendly materials used in clothing. PPC www.pulpandpapercanada.com
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iRoll provides data that moves your runnability forward
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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 caliber, 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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Opinion
Printing problems: Addressing operating and runnability issues By Jennifer Ellson, Senior Communications Specialist, FPInnovations
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hen FPInnovations introduced the Roll Testing Facility (RTF) at its Web and Roll Centre, the industry could not get enough of the service that helps papermakers solve printing problems. Nothing resembling it exists elsewhere in the world. When paper rolls leave the mill for the pressrooms, engineers hope that the paper quality evaluated at the mill site is sufficient to predict the performance on the press. However, experience shows that this is not always the case. This is why FPInnovations developed its world-class Web and Roll Centre – a unique suite of tools and expertise dedicated to understand and solve paper and roll quality problems that affect web uniformity, dimensional stability and pressroom performance. With RTF, a roll of paper is unwound while a mass of data about both the roll and the outgoing sheet are recorded. The data is then analyzed which gives a complete study of roll quality, sheet uniformity and stability. This gives a clear indication of how the roll would have performed on a press or any other conversion equipment. RTF’s distinctive feature is the high resolution measurement of web bagginess profile in cross direction. This way, papermakers can accurately quantify drops in tension in the sheet. Soft or
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baggy edges impact sheet stability and can cause misregistration, wrinkles and tearing. The RTF is well-known to Canadian mills, which turn to it without fail as soon as a problem with roll structure or web uniformity arises. In recent years, American mills have begun using this unique service. In doing so, they witness a decade’s worth of accumulated expertise and become acquainted with the extent of FPInnovations’ knowledge base. The RTF has so far tested some 3,000 rolls, with up to 650 studies completed on a wide variety of paper and cardboard types. This cumulative experience has allowed us to resolve several web and roll performance issues. The RTF has built an enviable reputation among the biggest experts in the field, like the world-renowned authority in web handling and converting, Dr. David Roisum, who said that the RTF, which is unique to FPInnovations, “may be the best or only place to turn to because they have web-handling equipment and people resources that are almost without equal.” FPInnovations’ expertise in roll testing is explained very well in this Youtube video by Dr. Roisum: http://ow.ly/A5Aez. For more information, contact Frédéric Parent, research leader, Web Performance Group, at 514-782-4653 or frederic.parent@ fpinnovations.ca. PPC
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Point of View
BARRIERS TO GROWTH FOR PAPER AND BOARD Bioplastics and water-based barrier coatings will make paper and board more competitive in packaging applications. By Ian Lifshitz, Asia Pulp & Paper Group
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e are seeing huge growth in food packaging demand, with a shift in the industry away from producing paper and board for print media and a shift toward specialty products such as foodcontact paper and board. As a material type, paper and board is popular for foodcontact use, with the latest inventions in barrier technology becoming the material of choice in most packaging applications. There will however, be some challenges to the future of paper and board. Paper and board only work safely and effectively for food contact if used together with a barrier coating of some form. Traditionally, this has been a paraffin wax coating where grease resistance is required, or as in a juice carton or coffee cup, when full oxygen and liquid barriers are necessary. Food contact barriers created from plastic are also important in enabling heat sealing, an essential requirement for many of the current packaging formats. While these traditional barrier coatings work well, their use involves minute quantities of non-renewable materials – something the latest advances in accurate coating application technologies are reducing even further. However, the main issue with barrier coatings is not the use of a non-renewable material, but the impact on end-of-life. Barrier-coated boards and papers tend to require specific recycling technologies to separate materials. Due to insufficient infrastructure and available technology, this is an issue in emerging markets, where demand will also be strongest in the coming years. www.pulpandpapercanada.com
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Bioplastics vs. water-based coatings
case, is safe for the landfill. IntroducDue to the recycling challenge, recent ing water-based efforts have focused on developing new coatings is imporbarrier technology that is either renewably tant again for sourced, readily recyclable, biodegradable product applicaor all three. tions where comBioplastic-based technology is growing plete liquid and at a rapid rate. Technology has advanced oxygen barrier to a point where it can compete with tra- technology is not ditional plastics in functional terms – just necessary. This is look at Coca-Cola’s Plant-Bottle™ as an seen in the fast food sector, where packexample. aging is so high volume and often misses Bioplastic barrier technology faces some the recycling stream all together. of its own challenges. First, brand owners In the future, we’ll likely see ongoing are wrestling with confusion over termi- development of bioplastics as a barrier nology which is holding the technology coating, with the questions centered on back. Is it “renewable” or “biodegradable” comparative costs and the type and quanor something else? Bioplastics can also tities of feedstock consumed, instead of confuse consumers who are unsure about debates about technology or functionality. their end-of-life disposal. Should they be Furthermore, the use of water-based coatseparated? Can they be recycled? Can ings will likely increase, particularly for they be put in the compost bin? There’s products that only require a grease-barrialso a question of the lifecycle issue, with er. This technology will make paper and first generation bioplastics in particular. board even more competitive. While it Is the feedstock used for production dis- competes well with alternative materials in placing food intended for human con- packaging efficiency and lifecycle terms, sumption? What’s the climate impact? when it comes to the barrier technology of Advances in bioplastic technology will the future, paper and board could potensoon make use of waste materials as a tially be the material of choice in nearly feedstock. In the pulp and paper industry all packaging solutions. PPC especially, work is currently underway to determine how lignin – an organic by- Ian Lifshitz is North American director of product of the pulping process – could sustainability & stakeholder relations at Asia Pulp and Paper Group (APP), the world’s be used as a feedstock. Another approach sees movement second largest pulp and paper company. towards water-based coatings, meaning To learn more about APP’s community the coating can be readily removed in initiatives and sustainability efforts, visit recycling, is compostable or, in the worst http://www.asiapulppaper.com September/October 2014
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Market Trends
NANOCELLULOSE:
AITF is tweaking the process The production process for crystalline nanocellulose is being optimized at an Alberta pilot plant while external clients develop applications. By Cindy Macdonald, editor
F
or the last 12 months, a pilot plant at Alberta Innovates Technology Futures has been producing crystalline nanocellulose (CNC), the nano-scale reinforcing agent made from cellulose fibres. Samples have been sent to more than 50 clients, and a field trial of a CNC-enhanced product for the oil and gas Tosto, Dunumah, Liyan Zhao and Ahvazi stand in front of the reactors at AITF’s pilot plant. industry has been completed. The next steps in bringing this new product to market are year, CelluForce has temporarily ceased production and is pursucost reduction of the pilot process, application development and ing financing to restart.) Both plants use acid hydrolysis to produce commercial development, says Behzad (Benji) Ahvazi, AITF’s CNC, but the pre-treatment steps are likely different, says Ahvazi. program lead for the CNC pilot plant. Optimizing the pilot-scale The AITF process uses two glass-lined reactors. The incoming production process is the focus of Ahvazi and his team at AITF. fibre is mixed with acid at 140ºC. After two hours, it is diluted The yield on the digester in the pilot plant is currently less than and sent to tanks. There it is neutralized to pH 7. The crystalline 50%, says Frank Tosto, the program’s lead technologist. nanocellulose starts to settle out, and is separated by centrifuge. “The reality is that production cost has to be below $25/kg,” The next stage for the CNC is ultrafiltration to remove salts says Tosto. In one application, CNC could be competing with and other impurities. Once purified, the CNC can go to a spray Kevlar®, which sells for about $60/kg, he notes. dryer. Some clients request the material in suspension; others The team has drawn some conclusions about the process want a dry form. already. If the feedstock could be received as a slurry, it would Tosto says the process will work with any pulp, but some diminish costs and reduce the number of steps in the process. will produce better yields than others. Right now, what AITF Energy consumption also needs to be addressed. produces is essentially one grade, with similar properties despite “We make the material early in the process. The challenge is the species of pulp. to deal with the by-products,” explains Tosto. To get an idea of the scale of the final product, Tosto tells people He says sulfuric acid is used to hydrolyze the cellulose, creating to imagine a pen (representing a rod-shaped CNC particle) on a particles that are 150-200 nanometres in length. Then sodium hockey rink (representing a cellulose fibre). Softwood fibres can hydroxide is used to neutralize the acid. It would be helpful, in be up to 2 cm in length; CNC is typically 200 nm long. Another terms of process efficiency, if the plant was able to regenerate the reference commonly used to explain the nano size range is the acid used in the process. human hair, which is generally 50,000 to 100,000 nm in diameter. The team has been working with FPInnovations and visiting AITF is also working in concert with FPInnovations on the mills to explore ideas. characterization of CNC. Application development is generally On the plus side, some of the by-products could have value. in the hands of clients and researchers who are working with the Some sugars, for example, are formed prior to acidification. sample material. Within the oil and gas sector, CNC has potential as a reinforcing agent, as a coating for transporting slurries, Fine-tuning here reduces risk for commercialization and as a dispersant and process aid in oilsands extraction and in There are essentially two objectives set out for the pilot plant, tailings ponds. says Ahvazi. First, get good quality CNC out the door. Second, Applications for CNC in wood-based composites are probably fine-tune the process to reduce the risks for commercialization. the closest to commercialization, says Christophe Danumah, one The AITF pilot plant is based on a process developed by FPIn- of AITF’s CNC researchers. novations. It is similar to that used by CelluForce, a joint venture The possibilities seem endless, but the team at AITF has a more between FPInnovations and Domtar with a demonstration CNC concrete goal. For the next year, Ahvazi says the group will focus plant in Windsor, Que. (After producing CNC for more than a on improving the performance of the pilot plant. PPC 16
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ilot plant.
Cover Story
COURTING FIRST NATIONS A recent Supreme Court decision changes the landscape for Aboriginal land right disputes and forest products companies may get caught up in the turmoil. By Carroll McCormick
T
his June the Supreme Court of Canada (SCC) validated the Tsilhqot’in Nation’s claim that it is the owner of a roughly 1,700-square kilometer parcel of land in British Columbia. The ruling could have far-reaching implications for the resource sector. “The decision is the first time that an Aboriginal group has proved Aboriginal title over a significant land base in Canada,” writes Vancouver-based law firm Miller Titerle + Company LLP, in Impacts of Tsilhqot’in Part 1: A Layperson’s Guide to Tsilhqot’in Nation V. British Columbia. The SCC judgment doesn’t only raise red flags in B.C., where resource companies may have thought they were safely installed on Crown land. First Nations treaty and land claims are in play across Canada. The Tsilhqot’in land title issue went critical in 1983 when the B.C. government gave Carrier Lumber Ltd. a tree cutting licence on what the Tsilhqot’in regarded as its land. The subsequent court battle eventually landed before the SCC. It determined that the area in dispute was Tsilhqot’in land and that, “governments and others seeking to use the land must obtain the consent of the Aboriginal title holders.” The SCC notes that in most of Canada, “indigenous peoples gave up their claim to land in exchange for reservations and other promises, but, with minor exceptions, this did not happen in British Columbia.” Some people read this to mean that B.C. resource industries are most at www.pulpandpapercanada.com
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risk of finding themselves unwelcome trespassers on private land. For example, when asked to comment on the SCC ruling, Susan Murray, executive director, public relations for the Forest Products Association of Can ada, said, “We are monitoring it, but we are not publically commenting on it. We know that it mainly impacts B.C.” James Gorman, president and CEO, Council of Forest Industries (COFI), comments, “B.C. is the only province in the federation that does not have a large number of signed treaties …”
Ruling has implications across Canada The reality, however, is far larger than B.C. “A lot of people are saying that the Supreme Court ruling applies just to B.C. The significance [of the SCC decision] is way, way wider,” says James O’Reilly, a lawyer with O’Reilly & Associes Inc., in Montreal. “In parts of the Northwest Territories there are no treaties. The Metis have special rights. All the Maritime provinces are unsettled. Agreements are not entirely settled in the Yukon. There are unsettled lands in Quebec. A lot of Aboriginal groups across Canada were missed in treaties; for example, in Ontario and Alberta. In the areas with treaties there are a number of groups saying ‘we were not caught in treaties and assert Aboriginal rights.’ “For all of Canada I’d say that for twenty to twenty-five per cent of the land, title
claims are unsettled. [Resource companies] are at peril to have their rights suspended, for sure.” O’Reilly has nearly 50 years of experience as a specialist in Aboriginal rights, treaty rights and the self-governing rights of Aboriginal peoples. His many cases include landmark resource development cases brought on behalf of First Nations in Quebec and Alberta. His clients include the James Bay Crees, the Lubicon Lake Cree Nation and Stoney Tribe in Alberta, and the Mohawk Nation and Miawpukek Micmac in Newfoundland. As for his insistence that this is a panCanadian phenomenon, O’Reilly says, “A lot of people would say we are ranting and raving, but this is what is actually taking place. I am involved with a number of these cases across Canada.” Doubters should note several announcements by First Nations this summer: In early July the Gitxsan First Nation in B.C. served notice to CN Rail, logging companies and sports fishermen to leave their territory along the Skeena River. The Gitxsan also announced its intention to challenge Ottawa’s highly controversial approval of the Northern Gateway pipeline. The Kwikwetlem First Nation has claimed title to some lands in Vancouver. The Neskonlith Indian Band announced it would hand an eviction notice to Imperial Metals Corp., whose tailing pond dam breached on August 4, sending millions of cubic metres of waste into lakes and rivers. The Band
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also ordered Imperial Metals to stay away from the site of its proposed Ruddock Creek zinc and lead mine northeast of Kamloops. A group of First Nations chiefs in New Brunswick has filed for an injunction against the controversial forestry plan the provincial government announced earlier this year. And how long might it be before First Nations ask the courts in that province to shut down all exploratory work for unconventional gas fields and hydraulic fracking that taps them?
Rights and relationships The land claims story goes all the way back to Europeans’ assertion of sovereignty over Canada. “Is Cartier’s planting of a flag on Mount Royal an assertion of sovereignty? No,” says O’Reilly. Then there are those supposedly done-and-dusted treaties. “A lot of groups are challenging the true meaning and intent of treaties. I’m involved with one with the Stoney near Banff. They are saying that this was supposed to be a treaty of friendship and sharing of the land, not giving up all claims,” he adds. Much more recently the courts established requirements for consultation with First Nations but, says O’Reilly, “It is not working at all. Governments were sending out notices and went ahead and did what they wanted. One of the flaws in this whole system …[is that] the duty of consultation is only on government. [Companies] have no obligation whatsoever to engage in consultation. The governments caught on right away. Before they issue permits,
Photo: Tsilhqot’in National Government
Cover Story
Tsilhqot’in Chiefs drumming together after hearing the Supreme Court of Canada decision.
they get companies to do the work of consultation. But companies have not.” O’Reilly describes ways that matters can go well or badly in relationships between resource companies and First Nations. “The more forward-looking companies, particularly mining, have entered into “impact benefit” agreements, with jobs and revenue sharing. Whether governments want to do it or not, the sane way is to approach the Indian people and say, ‘We want an impact benefits agreement.’ If they don’t do that, they [proceed] at their peril. The courts could say, ‘you stop [resource extraction] temporarily.’” Important keywords are reconciliation, consultation and accommodation. The many agreements and partnerships that already exist between resource companies and First Nations make it clear that resource development on their lands is possible. Continued on page 22
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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Photo: Tsilhqot’in National Government
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Cover Story
First Nations and forest products industry have strong economic relationship
Continued from page 18
Following the federal government’s rejection of the New Prosperity gold and copper mine in B.C. in January 2014, Tsilhqot’in Tribal Chair Joe Alphonse said in a press release, “I think [Taseko The Forest Products Association of president and CEO of FPAC. Lindsay made Mines Limited, which proposed the mine] has put Canada (FPAC) estimates that the forest his comments as part of the announcesuch a spin on things, you know, portraying us as products industry in Canada works with ment that nominations are open for the being anti-industry. We welcome opportunity. We about 1,400 Aboriginal-owned business- 2014 Aboriginal Business Leadership welcome logging. Some of our communities are into es, and employs about 17,000 Aborigi- Award offered by FPAC. logging. We own a sawmill. We’ve worked with nal people, making this sector the largAlso commenting on the award, JP other exploration firms in the area. There [are] other est employer for First Nations workers. Gladu, president and CEO of the Canadian projects that we would deem acceptable.” “Under Vision2020, we are aiming to Council for Aboriginal Business, said, “The COFI’s Gorman says, “Our members have all refresh our workforce with an additional forest products industry continues to contaken a leadership role in establishing relationships 60,000 recruits by the end of the decade, tribute to the health and vitality of our with First Nations communities. We have built real and this includes increasing Aboriginal Aboriginal communities while the sucrelationships over the years.” engagement through employment, busi- cess of Aboriginal businesses in this sector On the other hand, Aboriginals can ask the court to grant what is called interlocutory relief while a ness development, and entrepreneurship demonstrates our enormous accomplishland claims case is in court. This is an injunction within our sector,” said David Lindsay, ments and economic potential.” against development from the time a court procedure is instituted to the time the case is finished. “You can go to court and get, fairly quickly, interlocutory relief provisionally suspend forestry operations with interlocutory relief. or injunction. It can take a few weeks to a few months. I predict Hydroelectric, forestry and mining companies are next on the list that because it takes so long to prove [title] in trial, a lot of groups of the Indians. Yes, forestry companies can expect that Aboriginal will go for interlocutory relief. Companies that think they can get groups will challenge virtually every timber licence if it interferes away with nothing will be surprised,” O’Reilly says. “Courts could with their traditional activities or [search] for title.” Gorman realizes that the SCC ruling upsets the status quo, but he remains confident. “We’ve seen First Nations become entrepreneurial and resource-development focused. Their interests line up with our interests. Our forestry companies are continuing to invest. Our partnerships and relationships between First Nations and the forest industry continue to evolve.” Get your FPInnovations What effect might the ruling have in Quebec, for example, where, O’Reilly estimates, the SCC ruling could apply to some 20% Report on Bleached of the province north of the St. Lawrence, from the Saguenay River Kraft Market Pulps east to the Labrador coast? O’Reilly suggests, “In the Tsilhqot’in case [the land] was relatively undeveloped. In Quebec the develop Compare your performance ment of resources in most of Quebec has been going on for sixty Defend the quality of your pulp years or more, even a century. You have instances where you have Position yourself mines, railways, ports … traditional activities have diminished. against competitors for With schooling, a lot of families have stayed home and are only papermaking potential doing part-time hunting and fishing activities. Get access to a wide data “For Indian people to come along at this point and say, ‘We bank of information from an want to stop forestry development,’ in, say Abitibi, forestry comindependent ISO-accredited panies can say that there has been development for many decades, laboratory. this is unfair to us … [But] I’m talking about the area within a Includes the data for all pulps few hundred kilometres of the Canada/US border. Above that, and illustrates the relationships between several property pairs. the Indians are in a pretty good position.” To order: Contact us at But can’t a government override Aboriginal title, claiming the Cost: $4,100 plus applicable taxes publications@fpinnovations.ca greater good? For this to happen, three conditions must be met Quebec: 418 659-2647 in a test: (1) the government has meaningfully consulted with Vancouver: 604 222-5743 the Aboriginal group; (2) there is a compelling and substantial Montreal: 514 630-4100 public objective and; (3) the government has acted in a manner consistent with its fiduciary obligation to the Aboriginal group. OUR NAME IS INNOVATION Governments do not have the power that some think they do, O’Reilly says. “[Aboriginal rights] can be infringed by governments, Follow us but it is a tough test.” PPC
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Mill Profile
THE MAGIC OF
WHITECOURT PULP
Millar Western’s BCTMP mill in Whitecourt, Alta., has outstanding technical versatility coupled with a team of skilled employees. By Cindy Macdonald, editor
W
hen you design a process not knowing exactly what the demands of the end market will be, you end up with equipment that can handle almost anything. That’s what happened at Millar Western’s Whitecourt Pulp mill. The mill was designed in the late 1980s to produce high-yield pulp from aspen and softwoods. Ron Ries, senior vice-president, pulp with Millar Western, explains that the pulp was moving into new markets, so the designers of the mill didn’t know what product characteristics would be needed. The result is that the Whitecourt mill has two lines which can make completely different products concurrently, and it can blend chips to create just about any recipe. “There’s equipment in this mill that you could never justify these days,” says Dale Holloway, operations manager. “We can make grades that nobody else can make.” In addition to its technical capabilities, the mill maintains rigorous product quality standards and has skilled, motivated staff.
Always improving Holloway expects production of 325,000 admt of pulp this year, from a mill that was originally designed to produce 210,000 admt. The staff strives for continuous improvement, says Holloway. In 2014, the mill has set daily and monthly production records and expects to set an annual record at year-end. This, while maintaining a strong focus on environmental and safety performance (mill staff reached the milestone of two years without a lost-time accident in July) and at a time when the mill is working to design, construct and integrate a new bioenergy project. Millar Western is installing an anaerobic hybrid digester system at the pulp mill that will convert organics in the effluent stream into biogas to generate green electricity as well as waste 24
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heat to replace natural gas. The bioenergy project, which should be completed in 2015, will contribute a 10% reduction in electricity purchased from the grid in a mill that has, since startup, already reduced its total electrical energy use per tonne of pulp produced by about 20%. Millar Western also recently upgraded Whitecourt Pulp’s distributed control system to the 800XA system from ABB. Standing in the control room, Holloway says, “Every valve, pump, motor, is run from here.” To maintain its reputation for high-quality pulps, its pulp testing lab operates 24/7. There is a direct return on investment, says Holloway, because the pulp’s selling price can be higher based on its quality. Moreover, Holloway notes that the international consulting firm Poyry has previously rated Whitecourt Pulp as one of the lower cost high-yield pulp mills worldwide. “To be both high quality and low cost – that’s magic,” he says.
Changing with the times Bleached chemi-thermomechanical pulp is valued for its bulk, stiffness and opacity, says Holloway. It is used in a variety of paper products, including fine papers, paperboard, tissue and toweling. www.pulpandpapercanada.com
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Mill Profile The mill currently produces about 25 grades of hardwood, softwood and blended pulps, with an on-grade rating of 99.8%. “This is the most flexible, versatile mill I’ve ever seen,” Holloway comments. The team manages about 300 grade changes per year. Whitecourt’s BCTMP process incorporates up to three stages of chemical impregnation and flexible refining and screening configurations on either line, “which allows us to squeeze out every little ounce of capacity and quality,” states Holloway. Reis says that when the pulp division began in 1988, it had contracts with Scott Paper for tissue and towel for about 50% of the mill’s output. By the late 1990s, the highest proportion of the output had shifted to coated woodfree grades for magazines. Now, the largest end-use is coated folding boxboard. During the 25 years the mill has been in production, the geographic distribution of its markets has changed substantially as well. In the 1990s, sales were split roughly equally between Asia, the Americas and Europe. Now, only 8% stays in the Americas, 17% goes to Europe, and 75% goes to Asia. The current challenges facing Whitecourt Pulp, according to Holloway, are Alberta’s deregulated electricity market and the competitive labour market. The company is combating volatile, high ener-
gy costs by reducing usage and investing in projects like the bioenergy plant, which will allow the mill to meet more of its own energy needs. With regard to the labour market, Holloway notes that Millar Western is supporting industry-wide marketing efforts, such as the Greenest Workforce and Work Wild campaigns. In addition, the mill strives to be an employer of choice, by maintaining a
collaborative work environment and providing flexibility and opportunity to employees. Millar Western hires or develops multi-ticketed tradesmen (i.e. those holding certification for more than one trade); its control room operators are trained as power engineers and for all operating positions. “People at this mill are good at what they do,” states Holloway. That’s part of the magic. PPC
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In the control room are (left to right) Graeme Davidson, Jean-Guy Denis and Bryce Uttley.
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Technology News Kadant Johnson to offer Donahue steam products
Kadant Johnson Inc., a subsidiary of Kadant Inc., has expanded its corrugator steam and condensate handling systems to include Donahue steam systems, Donahue steam traps, and corrugator and boiler audit services. With the retirement of John and Maureen Donahue from Donahue & Associates International, Inc., the former employees of Donahue & Associates have joined Kadant Johnson. “John Donahue and his staff have built a solid reputation for corrugator steam systems and plant optimization. We are pleased to now be able to offer our ThermoMax™ steam system complemented by Donahue steam technologies as part of our core offering to corrugator plants,” said Greg Wedel, president of Kadant Johnson. Donahue products include the Donahue steam system with high-pressure condensate receiver, recognized for its high energy efficiency; Donahue steam traps; and the variable moisture steam shower. Donahue systems, components, and spare parts will now be offered exclusively by Kadant Johnson. Kadant Johnson Inc. is a leading provider of rotary sealing devices, precision unions, and steam handling systems to process industries. Kadant Canada Corp. 877-369-6111, www.kadant.com
Resolute selects Andritz fibreline for Calhoun upgrade
Resolute Forest Products broke ground on a US$105 million upgrade project at its Calhoun, TN, pulp and paper mill on Aug. 19. The project includes a continuous cooking system and additional fibreline equipment from Andritz. According to Resolute, the new digester replaces eight older ones, and will help the mill produce more pulp at higher quality. The Lo-Solids digester from Andritz will be designed to switch between hardwood and softwood pulp production, producing 1,400 ADST of bleachable softwood and 1,659 ADST of bleachable hardwood pulp per day. When the investment was announced in March, Resolute president and CEO Richard Garneau said: “This investment will make a good mill even better. It will improve the mill’s long-term competitiveness by lowering its costs and giving it the flexibility to adjust grade production to changing market dynamics.” Andritz will supply equipment, engineering, and field services for a new Lo-Solids continuous digester including Andritz’s patented TurboFeed chip feeding system, which will replace an existing displacement batch pulping process. Start-up is scheduled for the third quarter of 2015. Andritz will also supply a blowline pressure diffuser and will upgrade the mill’s oxygen
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U.S. greenfield linerboard mill chooses Valmet OptiConcept M
Valmet will supply the first OptiConcept M board production line in North America to Pratt Industries for its new greenfield paper mill in the Valparaiso area of Indiana. The mill will use recovered paper in the production of recycled linerboard and corrugated medium. The start-up of the new paper machine, PM16, is scheduled for 2015. The value of the order was not disclosed. “OptiConcept M is a new and modular way to design, build and operate a paper machine. Its modular approach enables short delivery times, quick start-up and low project costs,” says Mike Gray, senior vice-president, sales, with Valmet North America. “This will be Valmet’s first OptiConcept M installation in North America and we are all proud to work with Pratt on this project.” The new machine will have a wire width of 6.25 meters and a design speed of 1,200 m/min. Valmet’s scope of delivery will comprise a complete OptiConcept M board production line from headbox to winder. Pratt Industries is America’s fifth largest corrugated packaging company. Valmet Ltd., 514-335-5426, www.valmet.com
Stellar Materials acquires refractory companies
Stellar Materials Inc. has acquired three companies: Stellar Canada Inc. and Refractory Resources Ltd. of Ontario, and Cardinal Refractories of Ohio. These three companies have built a substantial business reaching well beyond the borders of Canada, offering unique, high quality solutions to the refractory consuming industry. “Combining our resources will benefit the entire group of companies,” said Stellar Materials president, David Mintz, “and will help Stellar continue its growth and expansion as a premier solution provider to the industry.” Stellar Canada Inc. has been a long-standing and important strategic partner to, and re-seller for, Stellar Materials. “The combining of companies is advantageous to the Canadian group as it brings resources that will help foster a quicker market expansion of the unique products that they offer,” said Mintz. The companies will continue to operate under the same names. Refractories are heat-resistant materials that can be used in various pieces of process equipment in the pulp and paper industry, including waste heat boilers, lime kilns, black liquor boilers, gasifiers, and any other moderate- to high-temperature or abrasion applications. Stellar Canada Inc. 905-631-1156, www.stellarcanada.com delignification and bleaching systems. In terms of automation, the order also includes advanced process control and IDEAS dynamic simulation software. The upgrade is also expected to have a positive impact on the mill’s environmental performance, particularly in the area of its discharge. According to Resolute, the mill’s measurable environmental impact will be 30% less to the receiving stream once the new continuous pulp digester comes on line. Andritz Pulp & Paper, www.andritz.com
September/October 2014
www.pulpandpapercanada.com
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Technology News Södra picks GL&V for fibreline upgrade at Mörrum
Södra Cell has appointed GL&V to supply a major upgrade of the softwood pulp line at its Mörrum mill. GL&V will be responsible for screening and washing equipment in the unbleached area of the pulp line. Södra recently announced that it would spend SEK 700 million for a comprehensive refurbishment of the pulp mill at Mörrum. “We have had a good and close co-operation with GL&V while planning this project and we are convinced it will continue in the execution phase,” said Jörgen Lindström, operations engineer at Södra Cell Mörrum. “The Mörrum mill will be equipped with what in our opinion is undoubtedly the industry’s best technology. We focus on innovation and we are glad that Södra Cell, which itself is one of the industry’s most innovative companies, has chosen to partner with us,” commented Fredrik Björck, sales manager at GL&V. The investments in Mörrum will increase production capacity from 380,000 tpy to 425 000 tpy of pulp. The mill produces both softwood pulp and dissolving pulp (textile pulp). GL&V Canada Inc. 819-371-8265, www.glv.com
PROCESS CONTROL Brazil mill orders simulation software to test control logic, train operators
Andritz Automation has received an order to supply dynamic simulation solutions for Klabin’s Puma pulp mill project in Ortigueira, Paraná, Brazil. The scope of supply encompasses the simulation models, DCS checkout, and operator training simulator (OTS). These solutions will be used to test and verify process design concepts, identify and correct errors in the control logic, and provide realistic, hands-on training for the operators with the aim of helping Klabin achieve a fast and smooth start-up. The start of pulp production is scheduled for the end of the first quarter of 2016. Andritz Automation will use its proprietary simulation tool, IDEAS, to model the key process areas of the pulp mill: two digesters, two fiber lines, two bleach plants, and the white liquor plant supplied by Andritz Pulp & Paper, as well as the recovery boiler, evaporation plant, and power boiler delivered by other companies. Klabin is the largest producer and exporter of packaging paper in Brazil. The new mill will have an annual production capacity of 1.5 million tons of pulp, of which 1.1 million tons will be short fiber and 400,000 tons will be long fiber, part of which will be converted into fluff pulp. Andritz Automation 604-214-9248, www.andritz.com
Metso receives patent for automated root cause analysis
The U.S. Patent office has issued a patent for Automated Determination of Root Cause to Metso Automation USA, Inc. The patent was developed by Metso’s ExperTune team, and is used in their PlantTriage Control Loop Monitoring software. The key to assessing a control loop is to locate the original root cause of upsets, Metso explains. The new patented method determines the most likely root cause using a “big data” technique, eliminating several costly and time-consuming steps in the problem-solving process. According to Metso, the new automated determination of root cause does not rely on process models, which enables major operational benefits across most complex process plants. “‘Our clients see the benefits in energy savings, production increases, Rotor reduces energy consumption and quality improvements. With the proper training and methodology, a by up to 30% single engineer can perform like a large team of engineers,’’ says George Voith has brought a new IPV Rotor for virgin pulp Buckbee, general manager, automation, and the inventor of record. onto the market. The new component has already The newat tools are available in the current release of Metso ExperTune Södra picks GL&V for fibreline upgrade Mörrum proven itself for some months under mill conditions. PlantTriage software. Its strength: energy consumption of the new rotor The new automated method gathers real-time data from hundreds can be up to 30% less than that of conventional techor thousands of controllers. Then, it looks at correlations between nologies. controllers, and especially at the effect of time-shifting on correlations. The IPV Rotor is part of the LowEnergy rotor famSince root causes usually appear as the first in a series of similar events, ily and was developed for application in the Intenthe software is able to identify the most likely root cause from this saPulper by Voith as well as a retrofit component combination of correlation and time shift. for existing Voith pulper and third party systems for Results of the automated analysis are displayed in a Process processing virgin pulp. But the rotor can also be used Interaction Map. The Process Interaction Map shows the relationship to slush other clean raw materials like broke or fresh graphically, using bands of color to highlight the strongest correlations. fiber. For oscillatory interactions, the PlantTriage software also includes the The substantial reduction in energy consumption Oscillation Details Problem-Solver. is achieved by an innovative design that improves the Metso ExperTune PlantTriage software is the foundation for Metso’s flow characteristics inside the pulper. In addition, the Control Performance Business Solution. This customized service program pulping process can be further improved through pairs PlantTriage software with experienced control performance integration of a so-called bale breaker. The bale specialists, who collect and analyze real-time performance data, identify breaker loosens the hard-pressed pulp bales before the root cause of underperforming loops, make and prioritize corrective the actual dissolution in the pulper and thus disburaction recommendations and report progress. dens the rotor, which has a further positive effect on Metso Automation, www.metso.com, www.expertune.com/ energy consumption. plantTriage Voith Paper Inc., www.voith.com www.pulpandpapercanada.com
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Bio-Economy
Kruger, FPInnovations start up cellulose filament plant
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scant six months after it was announced, the cellulose filament demonstration plant at Kruger’s Trois-Rivières mill is a reality. The demo facility will produce up to 5 tonnes per day of cellulose filament, enough to permit commercialization and application development of this new, bio-based strengthening agent. The production of cellulose filament is a Canadian innovation and the Trois-Rivières. Que., facility is the first in the world to manufacture this product. Media, government officials and guests attended the official launch of the plant on June 17. The demo plant is a collaboration between Kruger Inc. and FPInnovations. An intensive concurrent R&D program will support the industrial scale-up for applications in different commercial pulps, papers, packaging grades, tissues and towels, as well as thermoset plastics, thermoplastics, coatings, construction panels and non-wovens. “This project is about more than saving jobs and ensuring the future of one paper mill. It’s about Canada taking the lead in a technology,” said Daniel Archambault, executive vice-president and COO of Kruger’s industrial products division. “I have a lot of admiration for our owner Joseph Kruger. I thank him for pushing us and making this happen.” Little has been revealed about the manufacturing process for cellulose filament, except that it is a completely mechanical process that uses existing equipment in thermomechanical pulp mills. The analogy that FPInnovations likes to use to explain cellulose filaments is the Cheesestrings children’s snack. Cheesestrings are rod-shaped pieces of cheese that can be pulled apart into smaller strings.
Kruger’s Daniel Archambault (far left) answers questions from the media at the opening of the cellulose filament demonstration plant in Trois-Rivières, Que. On display at the opening celebration was towel made of from 94% TMP and 6% cellulose filament.
In financial terms, the demo plant is part of a $43.1 million, three-year project to commercialize cellulose filament technology. Natural Resources Canada contributed $15 million through the IFIT program, Investissement Quebec made a refundable contribution of $11 million (repayable by royalties), Kruger invested $3.75 million, and the government of British Columbia invested $2.25 million. A portion of the funding will come from the sale of cellulose filament to the 13 member companies of FPInnovations. Archambault noted that more than 57,000 hours of work went into the implementation of the cellulose filaments plant. At one point, 90 contract workers were on site. Capital expenditures for the project are estimated at $9.9 million, while operating costs should be $8.2 million for the entire three-year duration of the project. About 40 researchers are assigned to it. PPC
Hinton Pulp to install commercial-scale lignin recovery West Fraser’s Hinton pulp mill will be the first in Canada to extract lignin from its black liquor recovery stream at commercial scale using the LignoForce process developed by FPInnovations and NORAM Engineering. The technology has been operating successfully at a pilot-scale demonstration plant in Thunder Bay, Ont. Initially, West Fraser will pursue the use of lignin as a renewable, natural replacement for certain glue components used in the manufacture of plywood and engineered wood products such as laminated veneer lumber (LVL) and oriented strand board (OSB). The company is an integrated wood products company producing lumber, wood chips, LVL, MDF, plywood, pulp and newsprint. The Hinton pulp mill pro28
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duces 370,000 tonnes per year of NBSK. The lignin recovery project at the Hinton pulp mill will benefit from a contribution of $10 million from Natural Resources Canada under the IFIT program. The LignoForce technology can provide a kraft mill with a new revenue stream while increasing pulp production. FPInnovations’ research combined with NORAM Engineering’s commercial process and technology development resulted in what the companies call “an efficient, low-capital system capable of producing high quality, dry lignin.” “Lignin recovery offers the potential for high-value, bio-based chemical alternatives that could have wide application in industrial use,” said Ted Seraphim, president and CEO, West Fraser. “Developing high-
September/October 2014
value products from our existing production reinforces the competitiveness of our operations and supports rewarding careers in our business.” Potential uses for lignin include: adhesives in wood products, surfactants and binders, polyol in polyurethane foams, chemicals, thermoplastic composites, packaging, carbon black, activated carbon, dispersant/flocculant, epoxy resins, adhesive in foundry resins and adhesives in pellets. Pierre Lapointe, president and CEO of FPInnovations, noted: “This project, a result of a significant collaborative effort between West Fraser, FPInnovations and NORAM Engineering, will once again position Canada as a world leader in developing new bioproducts using one of our most abundant natural resources.” PPC www.pulpandpapercanada.com
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Bio-Economy
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Resolute and Mercer team up to commercialize cellulose filaments
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ess than one week after a five ton/day cellulose filament demonstration plant started-up in Quebec, two other Canadian forest products companies announced a joint venture to develop applications for this new biomaterial. Resolute Forest Products and Mercer International have formed Performance BioFilaments Inc. to commercialize uses for cellulose filaments in markets other than pulp and paper. “The significance of this new biomaterial, derived from wood fibre, is tremendous from both an environmental perspective and the range of possible applications. It holds the potential to make a variety of products stronger, lighter, more flexible and more durable, while leveraging a sustainable and renewable resource,” said Gurminder Minhas, managing director of Performance BioFilaments. Performance BioFilaments’ cellulose filaments are made from wood pulp, processed using a proprietary technology licensed from FPInnovations Inc. The resulting cellulose filaments have exceptional strength and purity, with an extraordinarily high aspect ratio that is unique when compared to all other high-value, cellulose-based biomaterials. Initially, Performance BioFilaments will use material produced at the demonstration plant operated by FPInnovations and Kruger in Trois-Rivières, Que. As a member company of FPInnovations, Performance BioFilaments has access to all current and future cellulose filaments research, including production processes and applications, as well as the process
technology, findings and production quantities being advanced at the Trois-Rivières mill. This plant is expected to supply sufficient quantities of cellulose filaments to enable a significant research and development effort into new applications while providing commercial quantities for sale to the Canadian pulp, paper and bioproducts members of FPInnovations. “Performance BioFilaments is looking to identify joint development partners for novel product applications of cellulose filaments, whereby we can together leverage
diverse range of products, including 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. “Today’s launch highlights our ongoing effort to drive innovation in the forest products industry,” said Richard Garneau, president and CEO of Resolute. “Resolute will provide funding and expertise to Performance BioFilaments, supporting the
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FPInnovations foundational research and our own proprietary work to create new and exciting products,” said Minhas. He told Pulp & Paper Canada that the new joint venture really has two goals. The first is to develop commercial applications for cellulose filaments. Once some markets for the product are secured, Performance BioFilaments will assess possibilities for manufacturing the material, potentially at sites owned by Mercer or Resolute Forest Products. Mercer International Inc. is the world’s largest producer of NBSK market pulp and has modern, large-scale pulp mills in both Germany and Canada. Resolute Forest Products produces a
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venture’s research and development capabilities that aim to bring sustainable products to a broad spectrum of industries.” Minhas says the strength of cellulose filaments can be compared to that of synthetic reinforcement fibers made from non-renewable petroleum inputs. “The difference is that cellulose filaments are entirely renewable, with a very low carbon footprint.” Cellulose filaments are obtained by peeling the filaments from wood fibres using a mechanical process that uses no chemicals or enzymes. They can be used to improve traditional pulp and paper products and incorporated into new applications outside of the forest sector. PPC
Södra finds partner to promote pulp-based bio-composite material
Photo: Södra
Södra is taking the first commercial step into the international market for its bio-composite material DuraPulp in collaboration with UK-based James Cropper PLC, a speciality paper and advanced materials group. “James Cropper’s extensive technical competence and global market reach will mean that we will be able to speed up the commercialization of DuraPulp,” said Anna
Altner, Södra’s project manager for DuraPulp. “Initially, the collaboration will involve niche and high-end packaging-related applications but we do see wide potential opportunities, including the horticulture market,” explained Jacqueline Redman, strategic marketing and innovation manager at James Cropper. DuraPulp is a bio-composite material that consists of specially-selected pulp from Södra Cell and a renewable biopolymer. After additional processing, these two components take on special properties, such as moisture resistance, strength and rigidity.
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nts
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Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice. OM Official Mark of the Ontario Power Authority.
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