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PAPERCON WRAP-UP MOTORS: REPAIR OR REPLACE PACWEST IN REVIEW HOW TO OPTIMIZE RECOVERY BOILERS
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Strong bonds lead to unique possibilities – in business as well as in chemistry. And that’s precisely why we’ve acquired AkzoNobel’s paper chemicals business. Additional expertise. A broader technology base. Greater presence where you need us most. It all adds up to a winning partnership with a shared commitment to innovation. We’ve extended our capabilities so you can extend yours. Let’s work together to build value into paper. www.kemira.com/extend-your-capabilities
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July/August 2015 Vol. 116, No. 4 An Annex Business Media Publication PRINT EDITION ISSN 0316-4004 ON-LINE EDITION ISSN 1923-3515
OVER 100 YEARS OF SERVING THE INDUSTRY
COVER STORY 11 The Way Forward
What will influence your core business in the next ten or twenty years? Here are some predictions for various sectors that intersect with pulp and paper production.
FEATURES 13 PacWest in Review
Ideas flow when several hundred talented people get together for PacWest. Coverage of Western Canada’s industry gathering includes award winners, highlights of the executive panel, bio-products and technical sessions.
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18 Insights and Foresight at PaperCon
TAPPI’s PaperCon combined strong technical sessions on papermaking, maintenance and packaging with short- and long-range industry forecasts.
19 Canfor Mills Install Online Measurement of Fibre Wall Thickness
With data on fibre wall thickness readily available, Canfor can pass it on to customers for product optimization.
24 Should You Repair
Energy-Efficient Motors?
This article provides a decision-making process to help you determine whether to repair or replace a failed motor.
TECHNICAL PAPER 20 First Maximize Then Optimize the Reduction Efficiency in a Kraft Recovery Boiler
A two-wall primary air system is proposed as a low-cost method of increasing penetration of the primary air jets, resulting in better combustion and higher reduction efficiency. By Colin MacCallum, Boiler Island Air Systems
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MISSION STATEMENT: To promote the pulp and paper industry in Canada by publishing news of its people and their innovations in research, technology, management and financing, as well as forecasts of future trends.
Serving the industry since 1903.
For breaking news, visit www.pulpandpapercanada.com Cover photo: Thinkstock
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EDITORIAL
Re-imagining research and product development
H
ow will possible future developments and events impact research and technology management over the next 25 years? That was the central question behind the Industrial Research Institute’s IRI 2038 Futures Study. One of the primary outputs of this project was the creation of four plausible scenarios about the future of R&D and innovation management. I attended a presentation about the project during PaperCon in April. This was a strategic foresights project, using methods commonly used by futurists. Here are the four scenarios the group developed, as described on the IRI web site. 1. Africa Leapfrogs Developed Countries – An inability to build new capacity in the developed world due to increasing environmental regulations creates a new flexible and localized manufacturing process. This process churns out the highly customized products consumers demand at an ever-faster pace. With less of an installed asset base and the ability to better leverage its natural resources, Africa jumps ahead of the developed world in growth and economic dynamism. 2. Everything’s In Beta – The collapse of the complex global manufacturing ecosystem leads to a bifurCindy Macdonald cated economy underpinned by local manufacturing. Editor At the low end there is massive churn of new products that are introduced as beta products with little market research. On the other end stand premium products that are socially reputable and deploy R&D resources towards tackling the big challenges of the 21st century. 3. Three Roads To Innovation – In an era of virtual work and prize-driven motivation, society creates three paths toward innovation. Many choose to directly connect their brains together in a community in which the network runs project management. Another path is to intentionally form insular communities that work in secrecy. With the entire workforce now freelance, many corporations adopt a model similar to Hollywood movie studios, where a small production team manages a large pool of freelance talent. 4. Death Of Distance vs. Megacities – Cities become the major political force in countries due to their embrace of smart technologies to manage transportation, energy, and waste. They grab natural resources through giant public/private partnerships and grow into city-states. Technology and connectivity make distance irrelevant at last, restoring some balance to individuals and enabling scientists to do and teach at the level of entire corporations or universities of the past. All of these scenarios suggest a diminishing role for intellectual property, and an increasing role for simulation and artificial intelligence. While these scenarios are speculative, the evolution of intellectual property practices is relevant, given that pulp and paper companies are now actively engaged in the development of forestbased bioproducts.
Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com
Director of Soul/COO ANNEX PUBLISHING & PRINTING INC. SUE FREDERICKS
Publisher JIM BUSSIERE 416-442-5600 ext. 3606 jim@pulpandpapercanada.com
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INDUSTRY NEWS
Resolute will enter tissue market by adding tissue machine to Calhoun mill Resolute Forest Products has decided to enter the tissue market. Traditionally known as a producer of newsprint and forest products, Resolute will diversify into the tissue business with a state-of-theart facility at its mill in Calhoun, Tenn., that will manufacture premium private label bath tissue and towel. “This is an important step forward for Resolute as we execute on our growth strategy in a way that maximizes our ability to capture synergies and deliver superior value,” said Richard Garneau, president and chief executive officer. “We have been studying this option to diversify into the tissue business for quite some time, and we will continue to look at opportunities to expand our presence in this growing market.” Garneau said the tissue paper machine and converting operations to be built at the Calhoun mill site will be one of the most competitive and efficient tissue operations. This $270-million project represents the largest investment made by Resolute since 2010. At full capacity, the new tissue and converting facilities will produce approximately 60,000 tonnes per year of at-home, premium bath tissue and towel, focused on the growing private label market. Market feasibility studies, technology selection and project engineering are nearly complete. Construction is expected to begin shortly, with ramp-up expected to start in the first quarter of 2017. The tissue machine will use excess slush pulp over and above the additional dried market pulp capacity associated with a previously announced continuous pulp digester project at the Calhoun site.
Competing papermakers announce strategic alliance Mohawk and Arjowiggins Creative Papers have announced a first-of-its-kind partnership in the fine paper industry. The two papermakers will share manufacturing facilities, expertise and proprietary technologies. Mohawk is North America’s largest privately-owned manufacturer of fine papers, envelopes and specialty substrates for commercial and digital printing. 6
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Arjowiggins Creative Papers is a leading manufacturer of creative and technical papers with manufacturing facilities in Europe and Asia. According to Thomas D. O’Connor, Jr., chairman and CEO at Mohawk, the alliance is “a groundbreaking move to grow our businesses through better utilization of our respective sales, operational, marketing and manufacturing assets, without requiring a lot of additional investment. Ultimately, this union creates the largest premium paper and luxury packaging manufacturing entity in the world.”
Metsä Board will be first to harness foam forming technique Metsä Board, a European producer of folding boxboards and linerboards, will test foam forming technology on a production scale at its Kyro mill in Finland. The company has already done extensive development work to commercialize the new technology. In foam forming technology, the waterfibre suspension is aerated with a stream of tiny bubbles. By using foam forming, the paperboard structure becomes bulkier,
Forest industry interns begin the Green Dream Fifteen students are receiving a scholarship and an iPad mini from the Forest Products Association of Canada as part of the 2015 Green Dream Internship program. The students will blog about their adventures as interns in Canada’s forest products industry. The blogs will be posted on TheGreenestWorkforce.ca, an online tool highlighting the future direction of the forest products industry and job opportunities available across the country. “The scholarship award given to this year’s 15 Green Dream Interns will go a long way toward supporting each student’s education and career aspirations within the forest products industry,” said David Lindsay, president and CEO of FPAC. “And, the blogs the students will be writing over the summer will offer rich insight into the adventures young millennials get to experience in the sector.”
Finnpulp seeking approvals for another million-ton pulp mill in Finland Finnpulp Oy has submitted an environmental impact assessment program regarding a pulp mill project in Sorsasalo, Kuopio. The annual production capacity of this pulp mill, designed specifically to produce raw materials for the tissue and packaging board industries, is 1.2 million tons. In addition, it will produce bioelectricity and wood-based biochemicals such as tall oil and turpentine. It is estimated that the mill will use roughly 6.7 million m3 of wood raw material per year.
In foam forming technology, the water-fibre suspension is aerated with a stream of tiny bubbles.
Former GM of Corner Brook mill joins board of Soundview Paper
lightening the board’s weight. In addition, fibres are distributed more evenly in the web, improving formation of the board and resulting in more consistent properties and appearance, states Metsä. “We have already seen that the technology works in a laboratory environment as well as on pilot machines,” says Mika Joukio, CEO of Metsä Board. “Following promising laboratory scale results and our detailed feasibility studies, we reached a decision to invest in further development of the technology on a production machine.” Valmet is installing the technology at Metsä Board’s Kyro mill.
Soundview Paper Company has announced senior management changes, including the addition of longtime tissue and paper industry executives Steve Ziessler and Bob Snyder to the Board of Managers. Company president Karl Meyers has been appointed chief executive officer, and senior vice-president of strategy Rob Baron has been named the company’s new president. Snyder served as CEO and president of Orchids Paper Products from 2007 to 2014. From 2002 to 2005, he worked for Kruger, Inc., where he served as vicepresident and general manager of Corner www.pulpandpapercanada.com
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INDUSTRY NEWS
Domtar’s Windsor mill gets approval for customs self-assessment
Pictures taken in November 2014 showing the building foundations, structural steel, and placement of the first wall for Northern Pulp’s electrostatic precipitator upgrade.
Northern Pulp completes install of air pollution equipment Northern Pulp in Abercrombie Point, N.S., has resumed operation after a onemonth shutdown to install a new electrostatic precipitator. The new equipment is necessary to meet the air pollution reductions required by the mill’s new operating permits. “With this precipitator, we have entered a new era of improving the mill’s environmental performance significantly,” general manager Bruce Chapman said in a press release. “Northern Pulp now has a progressive owner committed to continue investing in the mill, a dedicated workforce and a client base that continues to grow.” The Nova Scotia Department of Environment confirmed on June 25 after an inspection of the mill’s new electrostatic precipitator that the mill had met the terms and conditions for startup and commissioning, as outlined in a ministerial order issued May 28, 2015. According to a CBC report, the $22 million precipitator project has faced some challenges. Winter storms caused delays, and the U.S. supplier for the project, Clyde Bergmann Group, backed out of its contract to install the precipitator. Northern Pulp is appealing its industrial approvals from the Nova Scotia government, which impose new environmental standards on the mill, including the air pollution reduction expected from the precipitator. The Herald reports that the maintenance shutdown will also include several other projects. Boiler inspections and repairs are expected to cost $1.5 million, and $500,000 each has been budgeted for digester repairs, pulp machine roll changes and pump replacements. Another $400,000 will be spent on steel repairs and inspections of critical equipment, valves, tanks and pipes. Brook Pulp and Paper in Newfoundland. Soundview Paper Company is a manufacturer of recycled and virgin fiber towel and tissue products located in Elmwood Park, N.J.
Telecom company to run trial of wheat straw paper Sprint will test the use of paper made from wheat straw in a two-month pilot project, a company executive said recently during the Sustainable Brands conference. According to a report in the Guardian newspaper on June 4, Sprint is seeking an alternative to wood-based paper. “Wheat straw is ready for prime time. Hopefully we will pave the way for creatwww.pulpandpapercanada.com
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ing national demand,” said Keanon Swan, manager of strategic partner relationships and postal alliance at Sprint, according to the Guardian story. Sprint is buying 20 rolls of paper through Prairie Papers for its pilot project. The paper is made of 80% wheat straw and 20% wood fibre. For the pilot project, Sprint is planning to send out about 2.5 million notices over August and September, Swan said. The project will use wheat straw and paper made in India, but Sprint wants to buy the products from within the U.S., Swan said. Buying local would reduce the cost and the carbon footprint of shipping from paper Asia.
Domtar’s pulp and paper mill in Windsor, Que., has streamlined the importation of fibre to the mill by qualifying for a selfassessment program. The mill is the first facility in the Canadian forestry industry to be approved under the Customs Self Assessment Program (CSA) of the Canada Border Services Agency for the importation of wood, wood chips and biomass coming from the United States. “The Customs Self Assessment Program streamlines the current process for suppliers and transporters of fibre from the United States passing through Canadian customs. It reduces the time it takes to cross the border and improves the Windsor mill’s ability to compete,” notes André Gravel, fibre procurement director at Domtar’s Windsor mill. A Domtar press release explains that under the CSA program, inspection and control of the product is entrusted to the facility. This makes it easier for Domtar to import fibre, which represents 25% of the deliveries to the Windsor mill.
Catalyst upgrading recovery boiler at Rumford mill Catalyst Paper has announced an investment of nearly $16 million in the Rumford pulp and paper mill in Maine. It will constitute the company’s single largest maintenance expenditure in 2015. Approximately $11.4 million will be invested in various maintenance projects including upgrading the Rumford mill’s Recovery Boiler C. This includes the complete replacement of the 35-year-old generating bank. An additional $4.5 million in capital investments will be made in the second quarter of 2015.
Forestry research facility receives $5.6 million in federal funding A federal infrastructure funding announcement on May 15 included $5.6 million to upgrade the Pacific Forestry Centre in Victoria, a research facility that supports Canada’s forest sector by advancing forest management policy and conducting important research in fields including forest pests, genomics and bioenergy. This year marks the 50th anniversary of the Pacific Forestry Centre. July/August 2015
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INDUSTRY NEWS
Unifor members at Domtar Dryden sign new agreement
On the occasion of the re-start of Paper Excellence’s Chetwynd pulp mill, the media-shy company opened up a bit in an interview with Business in Vancouver. The firm’s deputy CEO, Pedro Chang, said the company is in Canada for the long haul. “Many pulp manufacturers look at the pulp industry [to be in] sunset,” Chang told the magazine. “Paper Excellence, our vision is different. We look at it as sunrise. We will be here for a century – as far as Asia continues emerging.” While there is a family connection between Paper Excellence and Asia Pulp and Paper (Jackson Widjaja is the son of Teguh Widjaja, chairman of Sinar Mas Group, which owns APP), Chang told Business in Vancouver that Paper Excellence is not a subsidiary of either company. It is 100% owned by Jackson Widjaja, and headquartered in Richmond, B.C. According the article, about 100 people work at the Richmond headquarters. Across Canada, Paper Excellence employs more than 2,000 people, and owns seven mills in British Columbia, Saskatchewan and Nova Scotia. However, Paper Excellence does have the benefit of selling its pulp to APP mills, not on the open market, so it is not as vulnerable to pulp price fluctuations, Chang explained. Asked why the company is so bullish on the Canadian pulp mill sector, Chang said one reason is capital cost. He noted that a modern pulp mill can cost $2 billion to build, whereas Canada has idled or underused pulp and paper mills. The company spent $115 million modernizing the Howe Sound mill after buying it, and recently invested $50 million before re-starting the Chetwynd facility.
in early January 2015, at which time the company generated its first electricity sales. In late January, Tembec successfully met the “commercial-in-service” test set forth in the power purchase agreement and began selling electricity at the higher “green” power rate. During February, Tembec began the firing of pulp mill residual liquor in the new boiler, which forms part of the cogen system. The quarterly report states: “A significant amount of effort and resources were dedicated to ramping up the volume of liquor burned and optimizing the exhaust gas scrubber system and related equipment. The commissioning work occurred during a period of very cold temperatures and necessitated the purchase of a significant volume of natural gas, which offset the energy cost benefit of firing the liquor in the month of February.” During the month of March, operating efficiency of the boiler, the scrubber and the turbine continued to improve, Tembec reports. At that time, the cogen system was approaching targeted levels of performance and provided a net energy cost benefit of $2 million in the month. Based on boiler and turbine operations to date, the company expects to attain the $28 million of projected annual energy benefits. The company had also set a target of $7 million per year in operating and maintenance cost reductions due to the new boiler and cogen system, but notes that during the March 2015 quarter, the Temiscaming site continued to periodically operate the old boilers and was required to maintain them on operational readiness when not in operation. As such, very little of the projected operating and maintenance savings were realized in the March 2015 quarter. The ability to take the older boilers permanently “offline” will dictate the timing of these savings.
Chetwynd BCTMP mill back in business
CelluForce names new CEO
The pulp mill in Chetwynd, B.C., is back in operation, after an investment of $50 million by its new owners, Paper Excellence. The BCTMP mill was previously owned by Tembec, and had been shut down since September 2012. Pedro Chang, deputy CEO for Richmond-headquartered Paper Excellence, told Business in Vancouver that the mill restarted on May 1, 2015. The Chetwynd pulp mill now employs a total of 136 people, Chang said. This mill is one of four in British Columbia owned by Paper Excellence. Prior to its upgrade, the mill had an annual production capacity of 240,000 tonnes of bleached chemi-thermomechanical (BCTMP) hardwood pulp.
CelluForce Inc., a producer of nanocrystalline cellulose (or cellulose nanocrystal), has announced the appointment of Sebastien Corbeil as chief executive officer. Acting president René Goguen returns to his position as vice president, manufacturing. Corbeil has extensive international business experience spanning more than 20 years in a wide range of sectors. He has Bachelor’s and Master’s degrees in chemi-
More than 550 Unifor members employed at the pulp mill and woodlands operations of Domtar’s Dryden, Ont., site have ratified new collective agreements. “We’re proud that these agreements meet all elements of Unifor’s Eastern Canada pulp and paper pattern,” said Jerry Dias, national president of Unifor. Unifor established the Eastern Canada Pulp and Paper pattern last year when it reached an agreement with Resolute Forest Products. Key elements of the new four-year Domtar mill and woodlands deals are 2% annual wage increases, a 75 cents/ hour pay increase for trades, and a 9.3% increase in employer woodlands pension
contributions along with a 25% increase in retirement bridging. Employees receive a $1000 signing bonus and improved health and dental benefits.
Tembec’s cogen project is online, at budget In its quarterly report for the period ending in March 2015, Tembec relates some of the challenges of bringing the company’s new turbine online. Total construction cost for the cogen project at the company’s Temiscaming pulp and paper complex in Quebec had reached $272 million by the end of March 2015, versus the expected construction cost of $273 million. The cogen project is now producing green electricity for the provincial grid. Commissioning of the turbine began
Paper Excellence will be here for a century, says executive
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INDUSTRY NEWS cal engineering from McGill University, as well as a Master’s in business administration from DePaul University in Chicago. CelluForce manufactures NCC/CNC at a demonstration plant located in Windsor, Que. Its shareholders are Domtar Inc., FPInnovations and Schlumberger Canada Ltd.
Fairfax Financial acquires block of Tembec shares Fairfax Financial Holdings has acquired, through its subsidiaries, almost 20 million common shares of Tembec Inc., representing approximately 19.9% of the issued and outstanding shares. The shares were purchased in a private transaction at a price of $2.25 per share. The company states that it holds the shares for investment purposes. Fairfax is a Toronto-based holding company which, through its subsidiaries, is engaged in property and casualty insurance and reinsurance, and investment management.
Kemira adds AkzoNobel’s paper chemicals business Kemira has completed the acquisition of AkzoNobel’s paper chemicals business that was announced last July. The value of the transaction is EUR 153 million. The acquisition solidifies Kemira’s global reach and strengthens the company’s presence in the Asia-Pacific region, says Jari Rosendal, president and CEO. “It also enables substantial efficiency improvements in our global paper chemicals manufacturing network. Most importantly, we gain new competencies and technological capabilities through 350 paper chemical experts and six manufacturing facilities,” he continues. Kemira will also increase the production capacity of its own paper chemical manufacturing sites in order to capture production synergies.
Genome BC receives funding to support resource development Western Economic Diversification Canada (WD) is contributing $715,000 to Genome BC. This funding will be used by Genome BC to address the federal government’s economic priority of responsible resource development and to support priorities that natural resources industries www.pulpandpapercanada.com
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have identified as being critical to longerterm success. Two of the partners that Genome BC will be working with to advance the uptake of genomics technologies include Canfor and FPInnovations. Genome British Columbia is a catalyst for the life sciences cluster on Canada’s West Coast, and manages a cumulative portfolio of more than $710 million in 254 research projects and science and technology platforms.
Wood costs push Tembec to suspends sawmill operations in Quebec Tembec suspended operations for two weeks at its three sawmills in Quebec due to the high cost of wood supply in the Abitibi-Témiscamingue region. The company says the wood costs make its sawmills uncompetitive given the persistent weak market prices for lumber in North America. “Tembec has already expressed its concerns, on many occasions, to the Québec government regarding wood costs at its sawmills in Abitibi-Témiscamingue,” said James Lopez, president and CEO. “Unfortunately, these costs have increased more than 20%.” Tembec is still trying to obtain from the Québec Ministry of Forests, Wildlife and Parks an additional annual volume of some 300,000 m³ of softwood to ensure the long-term operations of its three Abitibi-Témiscamingue sawmills. Tembec is a manufacturer of forest products – lumber, pulp, paper and specialty cellulose.
Briefly…. • The Board of the Forest Products Association of Canada (FPAC) is launching an executive search for a new president and CEO to replace David Lindsay, who will leave the position by the end of 2015 to return to the Toronto area to be closer to his family. • Metsä Fibre has decided to proceed with a previously announced plan to build a massive 1.3 million tonne/year pulp and bioproducts mill in Äänekoski, Finland. The construction work will begin immediately, and the mill is scheduled to be completed during the third quarter of 2017. In addition to premium pulp, the mill will produce much more electricity than it will need, as well as tall oil and turpentine, among other bioproducts. Valmet and Andritz will be responsible for the main equipment deliveries. • Charles Gagnon has joined the FPInnovations research organization as vice-president of business development. Gagnon comes to FPInnovations after a 17-year career in the fields of engineering design and project management, business and market development, and strategy delivery for large renewable energy commercial enterprises.
Tree planters aim to break a record People of all ages and backgrounds from across Canada and the U.S. came together in May to break the Guinness World Record for the most trees planted in one hour by small teams. Organized by the Sustainable Forestry Initiative Inc. (SFI), more than 200,000 trees were planted simultaneously in 28 different communities. The record attempt involved more than 1,100 participants. Each team of 25 to 100 people planted trees simultaneously from 1:00 to 2:00 pm EDT. One team of 100 people, led by J.D. Irving Limited, even exceeded the existing record by planting 52,598 trees. PPC
Cadence Halfnights (left) and Emily Swan are proud to have carefully planted 35 trees on behalf of West Fraser Mills – Williams Lake Plywood Division. July/August 2015
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OPINION
The Russian ruble: Lessons for Canada’s forest sector By Nancy Tupper, economic analyst, Forest Products Association of Canada
F
or an export industry, fluctuating exchange rates can create a lot of buzz. And recently there’s been speculation about the significant shifts in currency rates for three big forest industry producers: Canada, Brazil and Russia. For example, Canada increased its wood exports to China by about 1000% over the last decade but industry insiders were worried that Canadian success in the Chinese market could be undermined by the plummeting Russian ruble. There’s no doubt that the Canada’s forest products industry is an export powerhouse, each year exporting more than $30 billion of forest products to more than 180 countries. Canada’s forest sector operates on a global stage and distant forces influencing foreign currencies play a big part in Canada’s competitiveness. In December of 2014, the value of the ruble dropped as much as 19% in a single day, falling nearly 50% in just a
year. The political and economic forces sending Russia into a downward spiral include falling oil prices and economic sanctions as a result of Russia’s continued aggression in Crimea and Eastern Ukraine. Bloomberg Business says the oil and gas industry generates about half of Russia’s revenue, so Russia got hammered by a combination of the shale gas boom in the U.S. and the dramatic drop in oil prices last year. Many speculated that with the ruble’s fall, China would snatch up the opportunity to import cheaper forest products from Russia while nations like Canada, with less dramatic currency devaluation, would be squeezed out of the highly lucrative Chinese market. However early statistics have shown Russia’s log trade with China only increased 2-3% from year-ago levels. Why would this be? Why wouldn’t the Chinese pounce on an opportunity for cost savings when it arises? Evidence seems to indicate that Russia is unable to capitalize on this export promise because
of logistical hold-ups in every step of its supply chain. This includes an inability to promptly increase timber harvests, limited access to logging equipment, insufficient infrastructure, a lack of loggers and truckers, and bottlenecks in every step from forests to ports. There’s a lesson in this for Canadian manufacturers of forest products – there’s more to export competitiveness than a favorable exchange rate. With the U.S. economy showing growth in new housing construction, Canadian producers will need to ramp up production to meet increased demand south of the border while continuing to serve oversea markets. Our cheaper dollar will help exports but it’s not enough – there needs to be a reliable supply chain from forests to mills to ports. Collaboration between producers, suppliers, transportation systems and governments is required to successfully and dependably deliver world-class products to our customers. That’s the way to remain an export powerhouse regardless of currency fluctuations. PPC
FPInnovations hosts training courses By Jennifer Ellson, senior communications specialist, FPInnovations
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n a very competitive, fast-moving industry like ours, the best way to get ahead is through continuing education courses. FPInnovations holds numerous training opportunities throughout the year so that industry people can stay up-to-date with the latest research, technical advancements and the best available technology. One example is the Absorbent Hygiene Products training course that was recently conducted at FPInnovations’ Pointe-Claire laboratory, with 37 participants increas10
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ing their knowledge of hygiene products. Water absorption capacity is one of the key performance attributes for hygiene products. FPInnovations has developed a new automated water absorption tester that provides measurements that are faster and more reproducible than existing methods. The instrument has the ability to measure average absorption rate, water retention, and total water absorption capacity. This information helps monitor and control water absorption properties and develop new products. The one-day training course allowed participants to learn about the different
July/August 2015
designs and requirements for diapers, female hygiene and adult incontinence products. Interesting discussions also took place among participants. For example, the group discussed wood fibres being a big part of these hygiene products but facing competition from superabsorbent polymers (SAP), and the different opportunities for modified fibres and non-wovens that can help improve the performance of hygiene products. To learn more about the numerous training opportunities offered by FPInnovations, please visit www.fpinnovations.ca. PPC www.pulpandpapercanada.com
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COVER STORY
The way forward
What will influence your core business in the next ten or twenty years? Here are some predictions for various sectors that intersect with pulp and paper production. By Cindy Macdonald, editor The Future of Forestry panel: Aran O’Carroll, executive director, Canadian Boreal Forest Agreement - Secretariat; Glenn Mason, assistant deputy minister, Canadian Forest Service; Janette Bulkan, assistant professor, UBC; Ben Cashore, Yale University.
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o one has a 360 degree view of the forces that could influence the pulp and paper sector going forward, but the following specialists each offer a unique perspective from their field of expertise. These forecasts and commentary were presented at recent North American industry events.
Photos courtesy of Public Policy Forum.
DOING BUSINESS IN A RESOURCE-CONSTRAINED WORLD On the subject of natural resources, Peter Berg of the management consulting firm McKinsey & Co., said small changes are not enough. “We need to be more than incremental going forward.” Berg is the director of knowledge for McKinsey’s global paper and forest products practice, and was a speaker at PaperCon 2015. It has been well documented that as global population grows and the middle class expands, supply challenges in minerals and water can be expected. Water, Berg noted, is becoming more and more inter-connected with other resources, such as food and energy. For example, in India in 2012, shortages of water led to blackouts. “We need to get into a regime of higher productivity of resources,” said Berg. To achieve that higher level, McKinsey’s view is that these items – nanotechnology, biology, software, systems engineering, interchangeable parts – will be required in management’s toolkit. McKinsey also identifies five levers for more effective use of resources: • reduce waste, • substitute (use less resource-intensive choices) • circularity (reduce, rework and recycle) • optimize (by networking, for example, peer-to-peer rentals) • virtualize (one speaker at Papercon appeared by video, for example) Berg highlighted North America’s love affair with the car as one system that engenders a lot of structural waste. He noted that the typical American car spends 96% of its time parked, www.pulpandpapercanada.com
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86% of the fuel it consumes is not delivered as power to the wheels, and peak throughput on the road network is achieved only 5% of the time. In pulp and paper specifically, he said fibre yield improvement seems to be slowing and we can expect more strict regulations in land use, water conservation and waste. “We need to pull other levers to maximize the use of fibre,” he said. Berg noted possibilities in smart packaging and non-wood fibres for paper. He also suggested more holistic system thinking. “Arguably, our biggest contribution could be from the bioeconomy.” According to Berg, if 5% of the world’s pulp lines were to extract hemicellulose as sugar, it could boost the world bio-polymer supply by 50%.
“We may be the only country that has the challenge of managing an immense national forest sustainably. The danger for us, I think is …being defined by others.” – Pierre Bernier, Canadian Forest Service Berg was not complimentary about the pulp and paper industry’s ability to meet the challenges of a resource-constrained economy. He said what most pulp and paper companies are doing now is materials development. In comparison, for the plastics industry, he noted that “time to adoption” studies have shown it takes 24.8 years to get a product into complex value streams. “I would argue that many pulp and paper companies don’t have the skills to do this,” Berg concluded. “The way forward will require large strides in process, product and business model development.”
NANOTECHNOLOGY FOR PACKAGING WITHIN 10 YEARS Sean Ireland, a former chair of TAPPI’s Nano Division, boldly stated at Papercon 2015 that nanocellulose will be widely availJuly/August 2015
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COVER STORY able within 10 years. During a conference session on the future of packaging, Ireland outlined the potential benefits that the addition of nanocellulose materials can bring to packaging. He described how nanocellulose applied to the surface of a sheet can make it suitable for printed electronics, by making it more smooth. But he also noted that these materials will require changes to board- and box-making machinery. Substrates made of or with nanocellulose materials could be orders of magnitude thinner that what packaging equipment can currently handle. Nanocellulose-enhanced substrates are also stronger, said Ireland. “We’re talking gigapascals of strength improvement, while getting thinner, smaller and smoother. “That changes everything.” Ireland believes that traditional research labs trying to treat CNC as pulp are taking “the wrong tack.” Currently, industry is reaching “up to 40% of the strength potential of nanocellulose,” said Ireland. He predicted the price of these materials will drop. “I can tell you, CNCs (cellulose nanocrystal) will be less than $2/kilogram.” He said to boxmakers and packaging manufacturers: “I guarantee it’s going to hit your market. If you’re not planning for it, you’re behind the curve already.”
PUT YOUR MONEY ON BIOFUELS AND BIOCHEMCIALS Biofuels are more attractive to strategic investors than biomass electricity, said Don Roberts in a keynote address at the BioEnergy Exhibition and Conference, held in Toronto on May 20-21. Roberts, an expert on financing the bioeconomy, commented that “the relative attractiveness of biomass-based electricity is going to going to get worse,” compared with other forms of renewable electricity. With advances being made in power storage, the competitive advantage that biomass has as an “on-demand” power source is diminishing. “There is a role here for biomass, but we need to focus on what’s unique about biomass. Liquid fuels and chemicals, that’s where the game is.” Roberts is president and CEO of Nawitka Captial Advisors Ltd. He has been an analyst of the resource sector and financial services executive for many years, and was 12
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a key contributor to the Forest Products Association of Canada’s Future Bio-pathways project, which evaluated paths for the Canadian forest products industry to participate in the bio-economy. Roberts suggested to that companies seeking investors should focus on technologies that create “drop-in” biofuels which use the existing petrochemical refining and fuel infrastructure. Choose technologies that use multiple feedstocks, because investors want flexibility, he said. Avoid ethanol, because of the blend wall and the high cost of forest biomass relative to nonwood feedstocks. Roberts’ firm has continued to do the type of analysis that characterized the FPAC biopathways project. This type of analysis is highly localized, and examines the return on capital employed (ROCE) of various technologies and combinations of technologies. Using the example of an analysis for the B.C. Interior region, Roberts concluded that stand-alone kraft pulp mills could improve ROCE by about 50% by integrating selected biofuels technologies. Roberts suggested that the biomass cost must be less than about $60 per ODMT for a bioenergy project to succeed. This can likely only be achieved by mixing a variety of sources. Sawmill residue and chips, for example, doesn’t even come close to this cost. Forest residues and hog fuel come closer, but to really bring the costs down, it will likely be necessary to bring municipal solid waste or fast-growing energy crops, such as miscanthus, into the mix. Speaking as an investment counselor, he said, “If you don’t have a weighted average cost less than $60, I won’t look at it.”
DATA VS. INFORMATION IN FOREST MANAGEMENT In late March, a policy dialogue convened by the Public Policy Forum and project partners brought together corporate, environmental and First Nations leaders, as well as academics and policymakers from across Canada.
July/August 2015
The findings from this discussion are synthesized in a report by the Public Policy Forum, developed in partnership with the Forest Products Association of Canada and Natural Resources Canada, which identifies the need for greater collaboration among sectors to help improve the forest industry for generations to come. In recent years, the availability of forest and conservation data and its dissemination by the Internet has changed the conversation, said Wynet Smith, executive director of Forest Watch Canada, during the #FutureofForestry discussion. She believes that publicly available data is crucial to managing our forests, but noted that non-standardized definitions are an issue and so are vague data. “The danger for us, I think is … being defined by others,” said Pierre Bernier, research scientist with Natural Resources Canada, Canadian Forest Service. For example, he said, groups such as the World Resources Institute, the Japanese and the Europeans interpret our data, and that interpretation becomes public dialogue. “We may be the only country that has the challenge of managing an immense national forest sustainably,” said Bernier. “We have 70 years, at most, of sciencebased management.” Bernier explained that forestry information exists at multiple scales. At the smallest scale, researchers measure trees, take soil samples, and gather field data. At another level is the landscape data, traditionally gathered through photo interpretation, measuring height, density, species. Now the industry has satellite date and LIDAR, creating datasets that are an almost unimaginable size. The #FutureofForestry: Sustainable Solutions report summarized the situation this way: “Open data can be a dynamic and innovative way to engage the public as it enables reporting on forestry practices, facilitating communication and the sharing of best practices around the world. Although an open platform increases the global profile of Canada’s forests, sometimes data may be repurposed, stripping the material of its context… As a result, a well-intentioned researcher may inadvertently compare two datasets that have little in common.” PPC www.pulpandpapercanada.com
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CONFERENCE REVIEW
PacWest: Our competitive advantage is people Ideas flow and knowledge is freely shared when hundreds of talented people get together for PacWest. By Cindy Macdonald, editor
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he allure of visiting Whistler, B.C., and a strong technical program drew more than 350 people to the PacWest industry conference in June. This year’s attendance surpasses last year’s total of 280. Conference chairman Stew Gibson of Catalyst Paper attributes the higher attendance to PacWest’s growing reputation among the pulp and paper community. PacWest offered an executive panel, technical sessions, short courses and roundtable meetings for mill managers. A table-top trade show featured 20 exhibitors. The conference and trade show are organized by PAPTAC and the IBMP, a group of suppliers to the Western pulp and paper industry.
“We know our mills” The theme of this year’s PacWest conference was Leveraging our Competitive Advantage, and the executives speaking on the opening panel generally agreed that our competitive advantage in the pulp and paper industry is our people. Brett Robinson, president and CEO of Canfor Pulp, reflected on the changes in the industry over his 26-year career, and noted that things seem impossible until someone pushes, and then they aren’t impossible anymore. His personal favorites among the competitive advantages of the Canadian industry: fibre, sustainability and people. “We have decades of experience operating our assets, and we know our mills, the technology and the business as well as anyone else in the world. We know how hard we can push, we know how tight we can run our costs, we know how to push this business to its limits. “Anybody can buy a pulp mill, but at the end of the day, it’s the people who make the difference. I believe our number one competitive advantage today is our people, who dream about the www.pulpandpapercanada.com
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impossible, dare to try, and deliver the change,” said Robinson. Carol Lapointe, mill manager of Domtar’s Kamloops, B.C., pulp mill, spoke about Domtar’s journey since it merged with Weyerhaeuser’s uncoated freesheet business in 2007. Lapointe noted that Domtar in its current form incorporates employees from: E.B. Eddy, Georgia Pacific, Great Northern, Weyerhaeuser, Willamette, Indas and Associate Hygienic Products. “We are very successful at getting our employees working together,” he concluded. “We are developing and implementing a “One Domtar” approach to how we operate as a system.” Domtar is moving resources into critical performance gaps across the system, said Lapointe. One example is bringing employees from other mills to assist during a shutdown at the Kamloops site. Five or six years ago, that would not have happened, he said. Discussing diversification at Alberta Newsprint, general manager Mike Putzke said, “Engaged people and community are our competitive advantage.” During the industry downturn in 2009, Alberta Newsprint had to re-think its assets, recalled Putzke. He deemed those assets to be: supportive owners who invest for the long term; engaged, entrepreneurial employees; strong government partnerships; and the mill’s location in the heart of oil and gas country. Alberta Newsprint made it a goal to have a portfolio of five thriving businesses by 2018. The company ran a two-day session for employees to introduce the concept and do some brainstorming on what those new businesses might be. Now, mid-way through 2015, Alberta Newsprint has also developed ANC Timber, ANC Power and ANC Transload.
The power of electricity Robert Dufresne, vice-president of Resolute Forest Products and chairman of PAPTAC, commented on the role of power producJuly/August 2015
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CONFERENCE REVIEW tion in his company’s product mix. “For Resolute, power is an important product. It would be tough to survive in the market without power sales.” He noted that the Dolbeau and Gatineau mills were able to restart because power sales lowered the production costs at those facilities. Similarly for the St. Felicien pulp mill – having an extra 10 MW to sell changed the cost structure to make the mill more profitable.
Industry transformation: in the trenches
Stew Gibson, Shannon Fehr and Kelly Parfitt.
PacWest 2015 Executive Committee.
A session on bioproducts provided updates from mill personnel on various projects. Jamie Percy reported that Alberta-Pacific’s methanol purification project has been in operation for about 340 days, achieving about 6 t/d of production. The methanol does not meet the desired specifications for sale so it is being used internally in the kiln. She described several trials that have been done to try and reach the desired suphur content and achieve appropriate odor control. A bio-methane project at Slave Lake Pulp was described by Shannon Fehr. The mill is the first in Canada to use a lowrate anaerobic BVF® reactor for anaerobic effluent pre-treatment to generate biogas for energy production. The system has been in operation for six months or so.
Fehr reported that it has increased overall process stability for the waste-water treatment system by mitigating variations in the organic load discharged to the conventional activated sludge system. The mill has been able to decommission two of its four aeration basins. As well, switching to the BVF® digester and decreasing use of the aeration system has resulted 43% savings in electrical usage. The new system has also achieved its objectives for lower use of nutrient chemicals and lower generation of waste sludge. Kyle Wells reported on the LignoForce lignin separation system being installed at Hinton Pulp. Construction was expected to be complete and commissioning to begin in June. Wells and his co-authors calculated the CO2 impacts of commercial scale lignin production and lignin substitution into petroleum-based prod-
ucts. In terms of the Hinton plant, the anticipated CO2 increase of 3,724 t/y for lignin production would be countered by a reduction in CO2 emissions of 13,881 t/y assuming that lignin is used in formaldehyde-based resins in wood composites such as plywood and particleboard, for a net reduction of 10,157 t/y. Wells concluded that “lignin substitution of has the potential to displace substantial amounts of fossil carbon with carbon derived from wood products.”
The intricacies of kraft pulping
Speakers for the Bio-products and Energy session.
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The technical session on kraft pulping included Sandra Beder-Miller of BTG discussing brown stock washer optimization, by sensor-based control. She described sensor-based control of the dilution factor as “a completely new system of measurewww.pulpandpapercanada.com
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CONFERENCE REVIEW
2015 AWARD WINNERS H.R. MacMillan Trophy for Best Paper: Teddy Townsley, Canfor Pulp Implementation of an Energy Management Information System at Northwood Co-authors: Clair Meger, Canfor Pulp; Chris Roberts, Spartan Controls Runner Up: David Eapen, Valmet Benefits of Advance Process Control Solutions on Power Boilers
duction. The problem has been ongoing (in various degrees) for almost 18 months now, said Lunn. Several approaches were tried with mixed results, but no single “smoking gun” has been identified. The mill changed to a less reactive lime, investigated whether green liquor dregs were making their way to the filter (which they were), and changed to a fixed flow control. In addition, at one point, an open valve
was found that was allowing air to the green liquor lines. All of the changes have had some effect, but none has brought the operation of the filter back to its previous levels. There were many other insightful and informative papers presented at PacWest. See the full program at www.pacwestcon. net. Next year’s event will be held at June 8-11 at Jasper, Alta. PPC
Best Supplier Paper: Bruce Allison, FPInnovations A Kinetic-Dynamic Model of the Causticizing Process Suitable for Control Best Novice Paper: Shannon Fehr, Slave Lake Pulp, division of West Fraser Mills Slave Lake Pulp Biomethanation with Power Generation Project Co-authors: Megan DiJulio, Slave Lake Pulp; Peter McCarthy, Daniel Bertoldo, ADI Systems Best Student Paper: Ruhul A. Khan, University of British Columbia, Pulp & Paper Centre Effect of Chitosan and Calcium Hydroxide on the Mechanical and Microbial Properties of Paper Co-authors: Helon Law, Reza Korehei, James A. Olson, University of British Columbia, Pulp and Paper Centre, Department of Mechanical Engineering; D. Mark Martinez, University of British Columbia Pulp and Paper Centre, Department of Chemical and Biological Engineering ment directly based on the cleanliness of the pulp mat leaving the washer system, and the dissolved solids in the weak black liquor going to the evaporators.” Mill trials of this approach are beginning and the actual results are expected to be presented in future technical papers. Ralph Lunn of Zellstoff Celgar discussed the challenges his team has experienced troubleshooting a white liquor pressure filter at the mill. The pressure filter has required more frequent acid cleaning and had begun to impact proJuly/August 2015
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CONFERENCE REVIEW
Insight and foresight mix at PaperCon PaperCon combined strong technical sessions on papermaking, coating, maintenance and packaging with short- and long-range industry forecasts. By Cindy Macdonald, editor
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APPI, a U.S.-based pulp and paper industry association, is celebrating its 100th anniversary this year, so its annual conference and trade show reflected a strong sense of history as well as interest in what the next 100 years will bring. PaperCon was held in TAPPI’s hometown of Atlanta, Ga., in April. More than 2,500 people registered for PaperCon 2015 and TAPPI’s Centennial Celebration, by far the largest number in recent years. Several seasoned executives offered insights during PaperCon about how their companies are dealing the demographic and cultural shifts that affect our industry, in particular, digital technology, urbanization and workforce renewal. John Panichella is CEO of Solenis, a supplier of specialty chemicals and technology. He quoted a TAPPI forecast that predicts 33% of the pulp and paper industry’s management will retire in the next 10 years. Panichella suggested that companies must leverage big data, digitization and automation as “different ways to transfer knowledge.” As chairman and CEO of Graphic Packaging International, David Scheible is keenly attuned to cultural changes. He commented that 80% of the North American population will be urban by 2030. That changes the way people consume, he said. It may change their storage use, and we will likely see more “grab-and-go” products. “Snacking and meals on the go are a growing part of today’s busy way of life,” he noted, but he underlined that there is a mega-shift from fast foods to healthy convenience foods, and that packaging must respond to this change. Graphic Packaging is a vertically integrated manufacturer of folding carton and 18
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packaging, with several locations in Canada following its purchase of Cascades’ boxboard assets. Scheible said the company recently revamped its innovation centres. Commenting on global trends, he said: “European trends translate very quickly to the U.S. It didn’t used to be that way.” A message of hope for the future came from Steven Voorhees, CEO of packaging manufacturer RockTenn. “I think we are the core of the American economy. Our industry is very important to the fabric of our cities.” Voorhees pointed out that 11 mills within the RockTenn organization are more than 100 years old, including the mill in La Tuque, Que., which has been in operation for 107 years. He sees this as a testament of our industry’s ability to adapt and withstand adversity. In a session entitled “The box plant of the future,” Verso Paper’s Sean Ireland presented the findings of a survey of 30 industry professionals. The respondents envisioned converting facilities that ship direct to the consumer, have minimal staff and high levels of automation. The box plant of the future will also have minisized machinery and will perform onmachine digital printing, they predicted. On the subject of innovations in materials, some believe “super performance” liners may eliminate fluting, and “intelligent” adhesives, which can be activated as needed, will be commonplace. There is a need for standards for “smart” packaging, Ireland said. “Intelligent” coatings and adhesives that can be “set” by UV light, chemicals, or lights of a certain wavelength, are coming, he said, but “it’s not going to be easy to adapt the technology to the machinery.” He coun-
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Two Canadians took home awards from PaperCon A researcher and a mill manager from Canada were among the winners at TAPPI’s awards night, held during PaperCon 2015 in Atlanta. Eric Ashby, the mill manager at Domtar’s integrated pulp and paper mill in Windsor, Que., was selected as PIMA’s Mill Manager of the Year. Ashby was selected for his outstanding leadership, management, and organizational skills. Dr. Michael Paleologou, a group leader with research institute FPInnovations, was presented with the 2015 Research and Development Technical Award and William H. Aiken Prize by TAPPI’s International Research Management Committee (IRMC). This award is given for outstanding contributions which have advanced the technology of the paper and related industries in the field of research and development. See www.pulpandpapercanada. com for more coverage of these awards. seled that manufacturers, converters and end-users can’t be silos; they need crosstalk to get things moving. Bringing an international perspective, Elizabeth de Carvalhaes told attendees that 2014 was a difficult year for Brazil, with an adverse macroeconomic scenario, little investment and a crisis of credibility. De Carvalhaes is executive president of Iba, an association representing the Brazilian forest products industry. She noted that Brazil continues to have a competitive advantage in terms of productivity, measured as m3/ha/year. According to de Carvalhaes, the U.S. achieves 15 m3/ha/y compared with Brazil’s average of 40 m3/ ha/y. Top players in Brazil achieve nearly 60 m3/ha/y, she said. “Brazil delivers wood three to four times faster than any other competitors.” De Carvalhaes says the country plans to expand its forest plantings, and has labs working on all uses for forest biomass, including cellulosic ethanol and lignin.PPC www.pulpandpapercanada.com
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OPERATIONS
Canfor pulp mills install first online measurement of fibre wall thickness With data on fibre wall thickness readily available, Canfor can pass that information on to customers for product optimization
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successful collaboration between FPInnovations, Canfor Pulp and PulpEye has resulted in the world’s first technology for online measurement of fibre wall thickness. Canfor is the first pulp producer in the world to install the fibre wall thickness module, FWT, in four PulpEye units at its pulp mills in British Columbia. The Canadian research institute FPInnovations patented in 2007 a technology for determining fibre wall thickness and fibril angle of individual fibres. The rapid and robust technology is based on an innovative light system for colorimetric-based quantification of the desired properties. PulpEye, a measurement technology company serving the pulp and paper industry, has the worldwide rights to the technology and is now commercializing it as an add-on technology for the PulpEye online pulp and fibre analyzer system. Fibre wall thickness is an important parameter for pulp manufacturing, as it influences the strength properties of the pulp, but until now it had not been possible to measure it online. “Fibre wall thickness is a fundamental kraft pulp quality attribute,” says Paul Watson, director of research and innovation, Canfor Pulp. “Having now developed a routine and robust online measurement for our PulpEye, FWT information delivered to Canfor customers should assist their product development and optimization initiatives. This has been an extremely positive collaboration which has defeated a very challenging and longstanding technical issue.” Öjvind Sundvall, managing director of PulpEye, says this Swedish-Canadian cooperation is a good example of bringing the best from each partner to develop a ground-breaking technology. “Ho Fan Jang at FPInnovations has developed and patented this technology. PulpEye has the equipment where the FWT www.pulpandpapercanada.com
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module is perfectly integrated and Canfor Pulp took part in the development with their pulp knowledge and made the first mill installations.” Literature from PulpEye notes that there are a number of reasons to measure fibre wall thickness online. It is an efficient method for raw material control to make sure that the mix of
Above: The measurement result is an image where the fibres are visualized and wall thickness is shown in different colours. Left: In the FWT module, LED light of specific wavelengths is sent through the fibre stream and the resulting light is picked up by a colour camera.
fibre from different sources contributes to consistent pulp quality. The FWT module can control the efficiency of a fibre fractioning process. Also, by measuring fibre wall thickness it is possible to calculate strength data and suggest the level of refining to pulp customers, helping them achieve the requested paper and board strength properties. The FWT module is based on optical measurement of a continuous fibre stream of a controlled concentration passing the patented module. Cellulose is an anisotropic material and polarizes light in two wave planes perpendicular to each other, with different refractive indices. In the FWT module, LED light of specific wavelengths is sent through the fibre stream and the resulting light is picked up by a colour camera. The result is an image where the fibres are visualized and wall thickness is shown in different colors. PPC Submitted by PulpEye, FPInnovations and Canfor Pulp. July/August 2015
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Technical PaPer
ABSTRACT
FIRST MAXIMIZE THEN OPTIMIZE THE REDUCTION EFFICIENCY IN A KRAFT RECOVERY BOILER The key determinant of reduction efficiency in kraft recovery boilers is the temperature at the char bed. A two-wall primary air system has a payback time of about six months and is a low-cost method of increasing the penetration of the primary air jets, which are mainly located on two opposing walls. The more powerful jets flatten the char bed and improve gas mixing at the surface of the char bed, resulting in better combustion, a hotter lower-furnace, higher reduction efficiency, less excess air, higher thermal efficiency, more combustion on the char bed, less suspension burning and less carryover, thus reducing the tendency for build-ups in the precipitator, fewer dregs and a quieter dissolving tank. More than 15 years of operating experience supports the technology. A short boiler trial, if desired, will confirm that two-wall primary air will improve the reduction efficiency. Two-wall primary air should be employed to maximize the reduction efficiency and improve mill profitability, then a system for optimizing the reduction efficiency should be installed.
By Colin MacCallum, P.Eng.
Condensed from papers presented at the Western Canada BLRBAC meeting in Vancouver in April 2014 and BLRBAC meeting in Atlanta in April 2015.
Introduction The principal finding of Jeff Butler’s(1, 2) testing of the Metso system which continuously optimizes and increases the reduction efficiency (RE) of a recovery boiler, was that the RE can be increased by 2 to 3 percentage points, saving US$300,000 to US$400,000 annually on a 1000-t/d recovery boiler. Budget costs for equipment and installation would range from US$425,000 to US$650,000, i.e. a payback time of one to two years.
Reduction efficiency and potential for improvement Reduction efficiency increases with boiler load and the char bed temperature. At low temperatures the reduction reaction is very slow and the RE increases slowly in response to increases in temperature. At high temperatures, further increases in temperature have very little impact on the RE, but bringing the fireball down lower in the furnace increases heat absorption by the furnace walls, thus lowering the furnace exit gas temperature and reducing the stickiness of particulate carryover. Pantsar(3) reported that, on a Finnish boiler, reduction efficiency increased from 90% to 95% when the temperature in the lower furnace increased by 150º C. The reduction efficiency at full load is 20
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generally much higher than at low loads, because the char-bed temperature is higher at higher loads. An increase in temperature at the char bed increases the RE over the entire load range, but the increase in the RE at the lower loads (and lower temperatures) is more pronounced.
Char-bed shape and control In a conventional recovery boiler, the low-pressure primary air jets from all four walls (4wp) generally do not penetrate more than 2 m into the furnace and tend to throw up a char rampart which deflects the air jets upwards, creating a central gas column in the furnace which is further reinforced in the corners of the furnace by the interference of the air jets from adjacent walls. This gas column carries particulate up into the upper furnace and has been extensively modelled both physically and mathematically. In a low-bed situation, the char rampart prevents the primary air from reaching the centre of the hearth, where a low-temperature zone exists on the char bed, especially in large furnaces. This low-temperature zone of poor combustion generates CO, TRS and H2S and lowers the reduction efficiency. In a high-bed situation in a boiler with secondary air 1-2 m above the primary air, the char bed is pyramidal and the top of the bed is cut off and flattened by the large secondary air jets. Because of the wide spacing of the secondary air jets, the secondary air cannot be distributed evenly over the surface of the top of the truncated pyramidal portion of the char
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bed, so the temperatures at the surface of the char bed cannot be even. There is twice as much fume generated from a char bed having uneven temperatures than from a bed with even temperatures(4).
Recovery boilers with multiple elevations of combustion air Modern designs with multiple elevations of combustion air typically operate with primary air as low as 25% of the total air. Less liquor is burned on the char bed and more is burned in suspension. Dust flow potentially increases and there are possible detrimental changes in the properties of the dust going to the precipitator, resulting in potential increased build-ups of dust there(5). More suspension burning moves the fireball upwards in the furnace. That is, the temperature at the char bed is lower than it could be and the expensive heating surfaces of the furnace are underutilized. The furnace needs to be higher or the furnace exit gas temperature will be unnecessarily high and the resulting stickier dust particles will require more sootblowing to remove them from the downstream heating surfaces. More-effective primary air is needed to provide better gas mixing and to bring the fireball down lower in the furnace
Two-wall primary air For a full explanation of the two-wall primary air technique (2wp), see MacCallum(6). The same total quantity of primary air is used in both the four-wall system www.pulpandpapercanada.com
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OPERATIONS
Technical PaPer
(4wp) and the two-wall system. The same O2 is maintained. Most of the primary air is introduced at a higher pressure through the original ports on the two “active”, opposing walls. The higher-velocity jets penetrate at least to the centre of the furnace. The central gas chimney is allowed to spread out, so, with the same flue gas quantity in the larger chimney, there is about one-third of the original upward gas velocity and significantly less carryover. The carryover is proportional to the upward velocity to the power 2.3, thus with 66% lower upward velocity the carryover is reduced by about 90%. So, if a boiler has excessive carryover, moving to two-wall primary air will greatly relieve the problem. The more powerful air jets in the twowall set-up have much greater momentum and entrain and burn combustible gases from the surrounding environment. Also, because the port velocity is higher, the ports stay cleaner. These stronger jets from each air port combine to form a powerful slab of primary air which carries oxygen and blasts char horizontally in to the centre of the furnace, thus providing better, hotter combustion over the entire surface of the flat char bed, thus increasing the reduction efficiency. Such a char bed is extremely stable and its shape changes very little.
almost all the combustion air from the front and rear walls, in a two-wall fullyopposed primary air configuration. Subsequently, 20 of the original 36 primary air ports on each sidewall were blocked with refractory and the associated port rodders were removed and placed in storage. The boiler then operated with two-wall fully-opposed primary air (2wp) from 4 December 2002 until February 2007. Unfortunately, after these four years, some of the refractory broke down and char entered a register and burned through. For reasons which are unclear, the blocked ports were unblocked and the boiler reverted to conventional four-wall primary air (4wp) and promptly experienced a deterioration in performance. The char-bed temperatures are displayed in Fig. 2. Contrary to expectations, when the ports were blocked with refractory, there was a significant difference in the char-bed temperatures at the left, centre and right focus points registered by the Quadtek camera. This spread is attributed to the small sample size. About 10 days into the 2wp trial, the HT/HP steam airheater was shut off and was eventually converted to use IP steam. Using the four-wall primary air (4wp)
Fig. 2: Quadtek char-bed temperatures at RB4 Crofton, B.C. (Number of data sets in parentheses) Fig. 1: Primary air jets combining
Data from boilers with fully-opposed 2wp A report from Paprican (now FPInnovations)(7) discusses the operation of RB4 at Crofton, B.C., in February 2003. The boiler was operating with 56 of the primary-air sidewall ports shut off, using the register dampers, basically running with www.pulpandpapercanada.com
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condition as the base condition, Table 1 shows the increase in the mean char-bed temperatures, the reduction efficiencies and the number of reduction efficiencies recorded. It can be seen that an increase of 45º C (161 – 116 = 45º C) in the char bed temperature leads to an increase of 3.8 percentage points in the reduction efficiency. This increase is similar to the increase reported by Pantsar (3), following the boiler upgrade in Finland, mentioned above, but in the Crofton case, only a minor modification was involved to block off the selected ports. With a hotter lower-furnace, the liquor temperature can be reduced slightly. More of the larger droplets thus obtained reach the char bed and are burned there; this also reduces the carryover. Our experience at other mills is that gas temperatures in the lower furnace are always higher with two-wall primary air than with four-wall primary air operation. A three-day test by Paprican, as part of a five-week trial on another Canadian recovery boiler, found that the average charbed temperature at 79% MCR (maximum continuous rating) with 2wp was higher than the average char-bed temperature with 4wp at 100% MCR. The reduction efficiency was slightly higher with 2wp despite the lower load with 2wp. This confirms that higher char-bed temperature, not higher load, is the key factor driving the reduction efficiency. In the course of that trial, heavy smelt run-offs occurred when the boiler was operated with conventional four-wall primary air. With two-wall primary air, the heat was spread more evenly over the surface of the char bed and the char-bed temperature
Four-wall primary air, all ports open (5 months)
56 sidewall ports dampered shut (5 months)
40 sidewall ports blocked with refractory (3.5 years)
Temperature
Base
Base + 116º C
Base + 161º C
Red. Effy, %
n/a
90.9
94.7
15
2
No. of reduction None efficiency recorded
Table 1. Increase in mean char-bed temperature above the base 4wp set-up when sidewall ports were shut off July/August 2015
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OPERATIONS
Technical PaPer
was higher; only one heavy run-off was reported during the five weeks of operation with 2wp.
Partially-interlaced primary air Partial interlacing and its advantages and physical modeling are described by Sandwell Swan Wooster and MacCallum(8, 9). Eventually it was appreciated that partial-interlacing would also be advantageous at the primary elevation. The scavenging jets shown in Fig. 3 solved the problem of char piling in the corners. New patents were obtained (10). The change from a fully-opposed arrangement of primary air to a partiallyinterlaced arrangement is made simply by adjusting the appropriate primary air dampers. When a partially-interlaced arrangement of jets is adopted, with each large jet opposed by a smaller jet, as shown in Fig. 3, the large jets can then penetrate beyond the centre line of the furnace and create a pattern of jets that minimizes the upward velocity extremes and minimizes carryover. There is no ridge of char and the bed is flat. A significant advantage of the arrangement is that the air jets can be introduced from the front and rear walls when the smelt spouts are on the front or rear walls, or from the sidewalls when the spouts are on one or both sidewalls, without significantly affecting the zone above the primary air.
preliminary in as much as an air pressure of 25-40 mm w.g. was maintained in the sidewall ports to ensure that char did not enter any of the sidewall registers. During the trial, only the primary air was adjusted. The Fig. 4: Large Metso furnace operating with partiallyfurnace was 11 m square and interlaced primary air. Note the primary air ports and the char bed was flat and well the shape of the char bed as shown by the two cameras. controlled, as shown in Figure 4. The large jets from the active walls Operating experience with were created with windbox pressures of two-wall primary air 90-100 mm w.g. and the small jets by More than 15 years of operating experipressures of about 50 mm w.g. The pri- ence with two-wall fully-opposed primary mary air was 25% of the total combustion air jets have been accumulated at various air and the CO was around 20 ppm during mills, Fig. 6. All of these boilers have most of the trial, with one spike to 50 ppm the primary air ports directed at about and another to 60 ppm. 5 degrees downwards, except the boiler Significantly, the char-bed pyrometers at Mackenzie which was a B&W boiler recorded a mean temperature approxi- with steeply-sloping primary air ports. mately 50º C higher with partially-interThe unnecessary ports on the inaclaced primary air than with the conven- tive walls were dampered off on all units tional four-wall primary air. except Crofton where the extraneous ports were blocked with refractory. In several extended trials, char entered one or more primary air registers. We now recommend only short-duration trials with the ports dampered, to confirm improvements. For effective and safe operation with two-wall primary air, the selected ports must be blocked, either with refractory or with inserts – a simple modification Fig. 5: Char-bed temperatures on large with a payback time of very few months. Metso boiler showing temperature increases with partially-interlaced and fully-opposed primary air.
Furnace rebuilds, air-system upgrades and cost savings
The average RE for the three months Conventionally, few changes are made to before the trial was 91.6% with only 4 val- the four-wall primary air system when a ues in the 92-92.5% range. The RE when furnace is rebuilt. running with fully-opposed primary air The cost savings are considerable if jets was 92.4%. two-wall primary air is adopted. Two-wall No RE was measured during the partially-interlaced (PI) test, but as noted in Fig. 5, the mean char bed temperature was 38º C Fig. 3: Fully-opposed and partially-interlaced jets. higher with PI than it was with fully-opposed primary air jets, so, based on the RE increase Partially-interlaced primary at Crofton, we estimate that air experience In the fall of 2011, a large Metso boiler the RE with PI primary air jets in Canada operated for several days in could have been 2 or 3 percenta successful trial with two-wall partial- age points higher, that is, 94% Fig. 6: Operating years with fully-opposed primary air. ly-interlaced primary air. This trial was to 95%. 22
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OPERATIONS
Technical PaPer
primary air offers better operation with less equipment. For example, the boiler at Crofton was built with 108 primary air ports. Operating with 2wp for four years, only 68 ports were used – i.e. 40 ports were blocked with refractory. Thus, if the boiler had been built for 2wp only 68 primary air ports would have been required – i.e. only 63% of the total number of primary ports, port rodders, registers and register dampers that were actually installed.
Advantages of 2wp The main advantages of two-wall primary air are that the arrangement: 1. improves gas mixing at the primary elevation and allows the boiler to operate with lower excess air and less CO, thus improving thermal efficiency; 2. increases the temperature in the lower furnace and improves reduction efficiency; 3. eliminates the need for a HP/HT steam airheater for the primary air, thus providing more steam for power generation and allowing more solids to be burned; 4. improves char bed control; 5. allows more solids to be burned on the char bed and minimizes suspension burning, thus reducing the dust loading to the precipitator; 6. reduces the amount of fume at any given mean char-bed temperature by levelling out the temperature across the surface of the char bed; 7. allows good operation with a low char bed which minimizes burndown time prior to a shutdown; 8. minimizes the risk of blackouts; 9. minimizes spiking of CO, TRS and SO2; 10. utilizes the furnace heating surfaces more fully by bringing the fireball down, lowers the furnace exit gas temperature and reduces the stickiness of the particulate carried over into the pendent heating surfaces in the upper furnace; 11. provides smooth flow of smelt, thus minimizing the risk of explosions in the dissolving tank; www.pulpandpapercanada.com
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12. minimizes carryover by spreading the flue-gas chimney over more of the plan area of the furnace and minimizing the upward-velocity extremes; 13. reduces dregs; 14. can use fewer, larger ports on the two active walls in a new or rebuilt furnace; 15. allows the port-rodding frequency to be reduced on the active walls because the higher air velocity keeps the ports cleaner; 16. employs fewer primary air ports and associated equipment, so boiler operation is simplified and the capital cost of a new or rebuilt boiler is lower. By the simple expedient of blocking selected air ports on the inactive walls, the reduction efficiency is increased over the entire load range. Figure 7 shows how 2wp moves the temperature range at the char bed farther up the temperature curve than the range created by a conventional four-wall system. When reduction efficiencies are high at full load, only a small increase in RE
Fig. 7: Reduction efficiency as a function of temperature
will be obtained at full load with twowall primary air, but at lower loads the improvement will be greater and the cost savings will be significant.
Operating cost savings Operation with two-wall primary air is a significant cost-saving opportunity. As Metso indicated, a reduction efficiency increase of 2-3% alone saves US$300,000 to US$400,000 annually on a 1000 t/d recovery boiler.
Conclusion On the basis of the investment costs and the payback times, the logical sequence is, first, to operate the boiler with two-wall primary air since the payback time is of the order of a few months, then, second, install a reduction efficiency control system to optimize the reduction efficiency. The payback for the control system could be of the order of two years.
Acknowledgements The author wishes to acknowledge that Jeff Butler’s papers, quoted above, bring our attention to the Metso system for optimizing reduction efficiency and the significant operating cost savings that are obtained when the reduction efficiency in a recovery boiler is increased. Further, Bob Ericksen’s efforts to recover more information at the Catalyst Paper mill in Crofton, B.C., and the interest displayed by Blair Rydberg at Tolko, The Pas Operations, are much appreciated. Continued on page 26
Item
Operating cost savings
Reduction efficiency increase
$300,000 to $400,000
Thermal efficiency increase
$70,000 to $150,000
No need for a HP/HT steam airheater for primary air
unknown
Fewer dregs to landfill
unknown
Less carryover
unknown
Less sootblowing steam used
unknown
Lower maintenance on port rodders
unknown
Less risk of dissolving tank explosion
unknown
Order of magnitude operating cost savings
$370,000 to $550,000
Table 2. Order-of-magnitude operating cost savings resulting from the use of two-wall primary air. The unknown amounts vary from boiler to boiler and can be significant. July/August 2015
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MAINTENANCE
Should you repair energy-efficient motors? Thomas H. Bishop, P.E.
M
ost plant engineers and maintenance staff can attest to the reliability of standard-efficiency motors that have been repaired or rewound using industry best practices. They also know repair can cost far less than replacement, especially when the motor has special features. Despite this, some of them hesitate to have failed energy-efficient motors (NEMA Premium models, in particular) repaired because they’ve heard it degrades efficiency. So, what’s the right answer? Is the decision to repair, rewind or replace a failed energy-efficient motor as simple and straightforward as you may have heard?
What makes a motor more energy-efficient? Some energy is always lost (to heat, friction and windage) when motors convert electricity into useful (mechanical) work. To improve motor efficiency, manufacturers have found ways to reduce these losses – not by changing raw materials or production methods, but through design modifications: first with higher-efficiency EPAct motors and, more recently, with NEMA Premium models. Compared with standard-efficiency motors, for example, some higher-efficiency models have longer stator and rotor cores to reduce core losses, and more copper wire area in the windings to decrease copper losses. Using the smallest fan that can keep the winding temperature within design limits also minimizes windage losses in totally enclosed, fan-cooled (TEFC) models.
Repaired motor efficiency The mistaken view that motors – including energy-efficient and NEMA Premium 24
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models – cannot be repaired or rewound without a loss of efficiency was scientifically disproven by a study in 2003 that identified good practices that maintain the energy efficiency of repaired motors. Commissioned by the Electrical Apparatus Service Association (EASA, United States) and the Association of Electrical & Mechanical Trades (AEMT, United Kingdom), the study tested the efficiencies of motors ranging from the original EPAct level to NEMA Premium and IEC IE3 levels. Conducted at the University of Nottingham under the direction of engineering executives from motor manufacturers in the U.S. and U.K., the study measured the efficiencies of 22 motors ranging in size from 50hp to 200hp (37kW to 150kW) before and after multiple winding burnout processes and rewinds. A 1998 study by AEMT also proved that the efficiency of motors with lower hp/kW ratings can be maintained during repair, dispelling the notion that, of themselves, winding burnout and removal damage the core. Among the good repair practices identified by the two studies were making certain the overall length of the turns in the winding does not increase (more resistance increases loss), and increasing the
July/August 2015
wire area (lower resistance means lower loss) when slot fit allows it. These steps maintain, or may even reduce, the copper losses (I2R) in the winding. Service centres that follow the guidelines in ANSI/EASA AR100-2010 “Recommended Practice for the Repair of Rotating Electrical Apparatus” and the more-specific recommendations of the EASA/AEMT Rewind Study’s “Good Practice Guide” will provide repairs that have a proven record of maintaining motor efficiency. Both documents are available as free downloads at www.easa.com/energy to assist service centres, end users and energy advocates in obtaining this critical information. (To further ensure efficiency and reliability are maintained during repair, service centres accredited under the EASA Accreditation Program [introduced mid2014] are independently audited to verify they adhere to the good practices from ANSI/EASA AR100 and the Rewind Study.)
Repair/replace decision-making process A well-informed decision to repair or replace a failed motor often involves more than might be readily apparent. Even the rather complex flowchart on page 26 doesn’t encompass every possiwww.pulpandpapercanada.com
15-07-07 11:22 AM
MAINTENANCE bility, because each application has unique characteristics.
Review the application When a motor fails, the first step is to determine its suitability for the application. A motor with an open enclosure, for example, may not be practical for a paper mill application with a great deal of airborne moisture and debris. Rather than repair, a better choice in this instance would be a TEFC (totally-enclosed, fancooled) replacement. Processes and duty cycles can change over time, so it’s always best to reassess the application when deciding whether to repair or replace a failed motor. An even better approach would be to assess all critical applications prior to failure as part of a motor management plan. When the failed motor suits the application, assess the condition of its stator core. Is there significant damage? Prior to failure, did the motor exceed its rated temperature rise (e.g. due to high core losses)? Unless the motor has special features that
might affect replacement price or availability, it may be more economical to buy a new motor than to repair a seriously degraded stator core. Next, consider these decision points simultaneously: • Has catastrophic failure occurred during this failure? • Is there evidence of a prior catastrophic failure? • Is the rotor damaged? • Are other mechanical parts severely damaged? • Is it an EPAct, NEMA Premium or IEC IE3 motor?
Catastrophic failure (present) When the motor has had a catastrophic failure, compare the cost of repair and replacement. Such failures typically do extensive damage to the stator core, windings and other parts of the motor, including the rotor, shaft, bearings and end brackets. In such cases, replacement may be the most economical option, especially when the motor’s suitability for
the application is questionable.
Catastrophic failure (prior) Evidence of a prior catastrophic failure may be apparent only after disassembling the motor. Examples include damaged stator core laminations; a damaged rotor core or damaged rotor bars or end rings; and a bent shaft that has bent again.
Rotor condition Rotor damage varies widely, from surface smearing due to contact with the stator to melted bars and end rings on die-cast designs, to broken bars or broken barto-end ring joints on fabricated designs. Surface smearing of the outside diameter can often be repaired economically. Other types of rotor repair may not be cost-effective, however, unless the motor is very large or has special features.
Mechanical parts condition The shaft, frame or other mechanical parts may also be damaged beyond repair. Here, again, the cost of buying or making a new
Use an SKF Certified Rebuilder for your electric motors
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The select shops that participate in the SKF Certified Rebuilder Program for Electric Motors are trained to use best-in-class practices and SKF components to: • Improve motor reliability and availability • Reduce unplanned downtime and energy bills • Eliminate recurring failures • Reduce total ownership costs
The Power of Knowledge Engineering
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July/August 2015
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MAINTENANCE shaft, or of purchasing a new frame, may make replacing the motor the logical choice, unless the motor is very large or has special features. Whether the choice is to repair or replace the motor, be certain to identify and address the underlying causes of failure to prevent a recurrence.
Higher-efficiency motors The factors discussed so far have shaped motor repair/replace decisions for more than a half-century. A consideration added more recently is whether to replace the failed motor with a more energy-efficient model. Broadly speaking, higher-efficiency motors are those covered by earlier U.S. federal regulations (EPAct, 1992), IEC motors labelled IE3, as well as NEMA Premium motors covered by newer Canadian (NRCan, 2011) and U.S. federal regulations (EISA, 2007). Repair considerations for these motors are the same as for standard-efficiency models. Following the good practices from ANSI/EASA AR100 and the EASA/AEMT Rewind Study, qualified service centres can repair any of these motors and maintain the efficiency rating. Before repairing a standard-efficiency motor, consider the return on investment for a more energy-efficient replacement (e.g. NEMA Premium) based on the expected life of the motor or process, hours of operation and energy costs. When the analysis favours replacement, determine whether the cost fits within your budget. If not, the best option may be a good-practice repair (so long as it costs less than a new motor). Assuming funds are available for a new motor, the next decision point is availability. Motors such as those that fall under EISA and NRCan rules are predominantly stock items. Delivery times for larger motors or those with special features often range from a few weeks to several months. When the delivery time Recovery Boiler continued from page 23
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A regular contributor to Electrical Business magazine, Thomas H. Bishop, P.E., is a senior technical support specialist at the Electrical Apparatus Service Association (EASA, www.easa.com), an international association of more than 1900 firms in 62 countries that sell and service electrical, electronic and mechanical apparatus.
Why is two-wall primary air not universally adopted?
References 1. Butler, J. Metso Recovery Analyzer or METRA, Product overview and applications, Western Canada BLRBAC Fall Meeting 2013. 2. Butler, J. Metso Recovery Analyzer or METRA, Step change adjustment tests at Stora Enso Veitsiluoto, Western Canada BLRBAC Fall Meeting 2013. 3. Pantsar, O. Computer control for recovery boiler is success at Finnish mill, Pulp and Paper, 53(8):142, 1979. 4. Tavares, A.J., Tran, H., Reid, T. Effect of char bed temperature and temperature distribution on fume generation in a kraft recovery boiler, TAPPI Journal, September 1998. 5. Samuelsson, I.-L., Johansson, F., Levesque, D., van Hattem, V., Effect of black liquor firing conditions on salt cake properties, International Chemical Recovery Conference 2014, Tampere, Finland. 6. MacCallum, C. How partially-interlaced primary air works and improves recovery boiler operation, Western Canada BLRBAC, Vancouver, March 2013. 7. Uloth, V., Duo, W., Trung, T.,MacCallum, C.
exceeds your requirements, a qualified service centre can usually provide a good-practice repair of the original motor in far less time. Alternatively, the service centre may be able to add the special features needed to a stock higher-efficiency motor e.g. by converting it to a C- or D-face mounting. PPC
Colin MacCallum: “No other new technology has ever had this much positive operating experience before being generally adopted. The question arises: why is the system not employed on every boiler? The answer lies partly in our complacency that “our” boiler is running well and its operation can not be improved, and partly in our herd mentality. No one likes to be first into the water when crocodiles may be lurking. Also, some will wonder, “Can the boiler manufacturers be wrong? Obviously all these primary ports must be needed.” The operation of all recovery boilers can be improved. The advantages and cost savings of the two-wall primary air technology are very clear.” Combustion air system evaluation tests on Norske Canada, Crofton’s number 4 recovery boiler, February 24-26/2003. Report for Norske Canada. 8. Sandwell Swan Wooster Inc. (principal investigator: Blackwell, B.R.) Improved gas mixing in kraft recovery boilers, for British Columbia Science Council, 1988. 9. MacCallum, C., Towards a superior recovery boiler air system, International Chemical Recovery Conference, Seattle, WA, USA, 1992.
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10. US Patent 7,694,637 and Canadian Patent 2,429,838 Method and apparatus for a simplified primary air system for improving fluid flow and gas mixing in recovery boilers issued April 13, 2010 and February 17, 2009, respectively.
Colin MacCallum, P.Eng, is president of Boiler Island Air Systems Inc. He can be reached at maccallu@shaw.ca, or 604-913-1604. www.pulpandpapercanada.com
15-07-07 11:22 AM
TECHNOLOGY NEWS
Valmet chosen for Domtar paper machine conversion
Valmet has been selected by Domtar to supply the equipment and technical services to convert a paper machine from uncoated freesheet to fluff pulp at the mill located in Ashdown, Arkansas. The delivery is part of Domtar’s US$160million project to re-purpose the A64 paper machine. The rebuilt machine is scheduled to begin operation in the third quarter of 2016. “Valmet has been a trusted vendorpartner of ours, one that understands our business and delivers top-quality equipment and services that help our company succeed,” says Jack Bray, Domtar’s vice-president manufacturing, Region 2. The scope of the Valmet delivery includes a new wet end, upgrades to existing cylinder dryer section, a new fully automated reel and a new OptiWin pulp winder. Also included is a bypass run to a new cutter-layboy with an automated bale handling line. “Valmet has extensive experience in repurposing pulp and paper assets, especially in the production of fluff pulp,” says Frank Swietlik, general manager, pulp dryers and baling, Valmet. Domtar’s Ashdown mill has three pulp lines and three paper machines. It produces uncoated freesheet papers and bleached kraft market pulp. Valmet Ltd. 514-335-5426, www.valmet.com
Polyurethane roll cover technology for demanding applications
Blue Diamond is a new generation of advanced polyurethane roll cover technology for superior performance on the harshest of press nip conditions. Produced by Xerium Technologies, Blue Diamond roll covers are specifically engineered to deliver exceptional stability, providing superior resistance to groove closure, which is critical for consistent venting performance. “The rolls technology team has developed this new generation of polyurethane for those demanding nip conditions where conventional covers suffer from premature groove closure. Blue Diamond’s exclusive formulation delivers stable performance and long life, which is especially important on covers with grooved and drilled patterns for enhanced dewatering performance,” said Bill Butterfield, executive vicewww.pulpandpapercanada.com
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president and CTO of Xerium. The new roll covers are available in grooved and drilled patterns and include the company’s exclusive Fusion bonding system for additional life. They offer superior resistance to hydrocarbons and other chemical attack that can contribute to cover swelling. Xerium Technologies, Inc., www.xerium.com
Secure seat design for knife gate valve
DeZurik’s new KGC-BD bi-directional resilient seated knife gate valve features a unique, patented perimeter seat design
that provides bubble-tight shutoff in either direction, even on dead end service. The valve is designed for isolation and on/ off applications in the paper, chemical, power and waste water industries. It is designed to handle clean, dirty, viscous and corrosive liquids, sludge, and fibrous slurries. The KGC-BD combines a one-piece rubber molded seat with an insert, a spline and a puck that work together to lock the seat securely into the valve body. This unique seat design prevents buckling or dislodging that can occur with other perimeter seat designs. DeZurik Inc., www.dezurik.com
Honeywell process automation implemented at Stora Enso Europe’s largest pulp, board and paper manufacturer will use process automation, safety tools and manufacturing optimization technologies from Honeywell Process Solutions to modernize one of its mills and help it meet rising demand for packaging board. Stora Enso is implementing Honeywell’s technologies as part of a modernization and optimization effort at their paper mill in Varkaus, Finland. Honeywell’s contributions coincide with the conversion of the facility to produce kraftliner, a virginfibre-based containerboard. Upgrades to the Varkaus mill include: • Migrating the plant from its previous control system to Honeywell’s Experion® PKS (Process Knowledge System), which has one unified architecture for process control, safety systems and automation software. • Experion Process, Machinery and Drives (PMD) controllers, which use a single, consistent set of engineering tools that Honeywell says can lower capital costs and provide more cost-effective execution of production-line and plant-wide control. • Uniformance® Process History Database (PHD), which helps users make better and faster decisions, and offers superior data management and high levels of data security and reliability. • Safety Manager, which integrates process safety data, applications, system diagnostics and critical control strategies. • OptiVision® Manufacturing Execution System (MES), an advanced orderto-cash solution designed for pulp and paper companies and flat sheet manufacturers. Honeywell Process Solutions, www.honeywellprocess.com
July/August 2015
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TECHNOLOGY NEWS
PAPER MACHINE CLOTHING
Optimizing runnability by nip analysis In addition to innovations in the materials and design of roll covers and fabrics, manufacturers of these products are making strides in analyzing how their products work together as a system. Many offer services and equipment to optimize the runnability of this segment of the paper machine. Xerium’s SMART technology and TIPS service, Valmet’s iRoll™ and Voith’s NipSense2 are a few examples. “We try to look at the system as a whole, and then try to optimize a package of rolls and fabrics,” explains Ian Meinke of Voith Paper. Voith’s NipSense2 system facilitates static measurement in the roll nip. Meinke says it’s a real time-saver when working on rolls during paper machine shutdowns. He describes NipSense2 as an electronic sensing blanket that is placed within the nip to provide measurement. “Advances in sensing technology and data transmission allow it to be a more powerful tool now. It has helped us to create a lot of value for customers,” says Meinke. NipSense2 allows Voith to visualize and measure, in real time, the invisible nip conditions of two rolls. The system performs corrective calculations of the nip profile and thereby, according to
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Voith, contributes to a substantial improvement of the reliability and quality of the paper manufacturing process. The new measurement technology is able to measure several nips at the same time and so discover previously unknown interdependencies. The nip width can be determined with a high degree of measurement accuracy. With NipSense2, the sensors transmit data wirelessly to the analytical software. The closing process of the press rolls and every change in nip width becomes visible on the screen. The entire measurement process can be stored on video and later replayed. An expert report with crown recommendations completes the service. Voith states that optimizing the nip profile can lead to more uniform paper and moisture profiles, and that the profile optimizations lead to a longer service life of the roll covers. Valmet’s iRoll™ performs a similar optimization function. It is a roll-mounted sensor that makes use of new developments in polymer electret films. iRoll can be used to improve runnability in a wide variety of applications including tension profile measurement, nip load profile measurement and roll profile measurement.
Use profile measurement to solve problems
An iRoll can be used in place of a reel drum to measure the nip load profile and the roll profile online. This capability facilitates the online control of roll profiles and web tension profiles in permanent installations. The portable version of this system allows almost any roll to be converted into an intelligent roll by using tape-mounted sensors. This technology enables temporary roll profile, nip load profile, and tension profile analysis to be performed by field technicians. The portable system enables the line to be equipped with several profile measurements simultaneously. In this way, says Valmt, economic benefits can be achieved by solving difficult problems without major capital investments. An iRoll acts like a conventional roll in the process, making it possible to measure how the web tension or nip profile behaves online in real time. Moreover, it can be located in various positions in the process, wherever the tension profile is critical or the nippaper roll profile needs to be measured. The iRoll intelligent roll system can be installed in one of three ways: as a permanent nip load measurement tool, as a permanent tension profile measurement tool, or as a temporary nip load and/ or tension measurement tool. SMART Technology from Xerium was the first system to provide dynamic nip measurement. It is now available with new functionality for use in more positions and applications. It produces dynamic 3-D MD and CMD nip width analysis, even on shoe presses. Using embedded sensors in the roll cover, SMART Technology dynamically measures and displays: MD nip width, MD pressure profile, and CD pressure profile. The latest version supports multiple-nip positions for unprecedented simultaneous analysis. It also offers enhanced connectivity software for mill DCS and PI systems, and an enhanced user interface reports real-time nip width, historical trends, and standard deviation. SMART Technology has an expanded pressure range that now enables installations from lumpbreakers and soft press nips to high intensity calender stacks. PPC www.pulpandpapercanada.com
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PulP & PaPer Jobs Freeman Staffing, Inc. specializes in the placement of engineers (all disciplines), production type supervisors, managers, mill and/or plant managers and corporate executives in the pulp & paper industry, North America-wide. For specific current job searches call us or contact our web site. All resumes are treated with complete confidentiality.
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web site: www.freemanstaffing.com July/August 2015
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BIO-ECONOMY
Rayonier and Borregaard to produce lignin in Florida Rayonier Advanced Materials and Borregaard ASA have declared their intent to form a joint venture that will produce lignin-based products at Rayonier’s Fernandina Beach facility in Florida. The new materials will be marketed as an additive for concrete. According to Borregaard, the project increases the company’s sales capacity for lignin products by 30%. “The Fernandina Beach project represents an excellent growth opportunity for our lignin business in a global market which for some time has been supply-constrained,” stated Per A. Sørlie, president and CEO of Borregaard. The Fernandina Beach mill manufactures specialty cellulose and lignin as co-products from softwood. Using Borregaard’s technical expertise, the new company will initially manufacture lignin products suitable for concrete admixture and similar applications. The companies are estimating capital investment of US$110 million for a capacity of 150,000 tonnes per year. The first phase is expected to begin commercial operations in 2017. Completion of the new operation is subject to board approval by both companies and conclusion of definitive agreements, as well as final engineering, permitting and other approvals
Europe’s first pilot facility for nanocrystalline cellulose A pilot facility for the production of nanocrystalline cellulose is being planned by MoRe Research, with the Swedish pulp and paper company Holmen, and SP Technical Research Institute of Sweden. The facility will be the first of its kind in Europe and will allow interested companies to develop nanocrystalline cellulose from cellulose-based material on a large scale. The pilot plant will be based on technology developed by an Israeli start-up company, Melodea. “The investment in nanocrystalline cellulose is important in order to realize sustainable material solutions and to advance the field of bio-economy,” says Maria Khorsand, CEO of SP. “We are helping to make the pilot facility an environment that is open to all. SP operates in many different sectors and will also be able to pave the way for commercially interesting applications beyond the forestry sector’s traditional boundaries.” Holmen is participating as a catalyst in the creation of the facility and in its role as a co-owner of Melodea. MoRe and SP will have central roles in the construction and operation of the facility, which is expected to be in place during the first half of 2016. Melodea is developing an industrial process for the extraction of nanocrystalline cellulose (known as NCC or CNC) from the sludge produced by pulp and paper mills. A major component of the sludge is tiny cellulose fibers that are washed away during paper manufacturing. The company is also developing unique technologies to assemble the NCC into ecologically friendly foams. Melodea’s NCC production process incorporates controlled acid hydrolysis. It can also produce NCC from bleached pulp, and other cellulose sources such as flax and hemp In co-operation with fibers. 30
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July/August 2015
Kruger’s cellulose filament plant has reached its target production level of 5 tonnes/day.
Cellulose filament makes the leap to commercial products Kruger announced at the PacWest conference that its cellulose filament product, FiloCell, is now being used as an additive in two commercial applications within the paper industry. Balazs Tolnai, general manager, technology, made the announcement as he brought participants up to date on the progress of this all-Canadian biomaterial. Kruger and FPInnovations solidified their partnership for the development of cellulose filament in Sept. 2013. Cellulose filament production at the pre-commercial plant in Trois-Rivières began in the first half of 2014. In addition to the commercial applications, as of June 2015, cellulose filament has been used in two market pulp trials and 16 paper machine trials, as well as 20 dispersion trials. Tolnai says the fact that potential users can receive truckload quantities is quite an advantage, compared with other biomaterials that may still be only at the lab-scale or pilot phase. The Kruger plant achieved its target production level of 5 t/d in March 2015. Tolnai said FiloCell has been shown to reduce basis weight while maintaining tensile strength for some paper grades, and functions as a reinforcement for tissue grades.
Biomass-based chemicals achieved by gasification: VTT The Finnish research institute VTT has demonstrated that lignocellulosic biomass can be successfully converted into industrial biochemicals, in this case, pure BTX chemicals (benzene, toluene and xylene). The aim of this research, reports VTT, is to enable the use of wood-based chemicals to replace crude oil in, for example, plastics, fuels, medicine and paints. VTT has developed a method of manufacturing BTX chemicals by combining gasification of lignocellulosic biomass, FischerTropsch synthesis and aromatisation. More than 85% of the separated benzene exceeded 90% purity and about 50% of the separated toluene was over 70% purity, the institute reports. VTT has calculated that the estimated price of pure BTX fractions derived by gasification is EUR 1.40 per litre. This price is higher than the current price of raw material derived from crude oil, but significantly more www.cleantechnology.ca competitive than the price of other bio-based routes. www.pulpandpapercanada.com
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