Pulp & Paper Canada April 2009

April 2009

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POWER PLAY Mills analyze energy consumption and non-traditional sources to find bottom-line benefits

Capital expenditures report Spending focuses on energy conservation and maintenance

Safety in a recession Don’t be short-sighted

PacWest preview JOURNAL OF RECORD, PULP AND PAPER TECHNICAL ASSOCIATION OF CANADA VAN HAM: Pulp and Paper Sludge as a Barrier Layer in Landfill Closure: A New Opportunity

The Chemistry of Paper and Water You can’t make paper without water and at Kemira, we know both. Built on our expertise in water and fiber chemistry management, we offer a complete product portfolio designed to provide value for our customers. Our solutions not only help enhance your paper processes, but also help you make better use of scarce resources like water, energy, and fibers.

Ready to create chemistry? Just add Kemira.

1380 Country Road #2, P.O. Box 615 Maitland, Ontario KOE 1PO www.kemira.com

February 2009

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april 2009 Vol. 110, No. 4 a Business information Group publication iSSN 0316-4004

FEATURES

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Power Play

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Funds on hold

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sludge as a barrier layer

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Power Play Traditionally, electricity has been relatively inexpensive for mills. But now energy sources and energy costs are frequently on the agenda.

Funds on Hold There is a sharp decrease in spending for equipment and upgrades this year, but mills are proceeding with maintenance and energy projects.

Preview: PacWest Explores Opportunities for “Green” Profits PacWest 2009 provides a balance of business and technical sessions, with an emphasis on the profit potential of being “green”.

Managing Safety in a Recession John Little takes a look at the problems of maintaining safety programs during tough times, plus suggests some cost-effective solutions.

A Fond Farewell to Mackenzie Tom Boughner has managed the Mackenzie mill through good times and bad.

TECHNICAL PAPERS

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The Influence of an Integrated Pulp and Paper Mill on Ambient Levels of TRS and PM2.5 in the Community Results suggest that wood-burning stoves and industrial sources contribute to particulate matter concentrations.

By B. O’Connor (FPInnovations- Paprican) and C. Walton (AbitibiBowater) Pulp and Paper Sludge as a Barrier Layer in Landfill Closure: A New Opportunity Landfill closure could be a low-cost, beneficial application of sludge.

By M. Van Ham (Sylvis Environmental), L. Dampier, K. Morton, and S. Mullen Final Pulp Bleaching by Ozonation: Chemical Justification and Practical Operating Conditions Several model compounds were submitted to various charges of chlorine dioxide and ozone.

By D. Lachenal , G. Pipon, and C. Chirat (all of Grenoble INP-Pagora)

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PulP & PaPer Canada April 2009

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editorial

Carbon market revenue stream starts as a trickle

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s carbon trading gains momentum, the shape of carbon markets for the North American forest products industry is emerging. As an introduction to the topic, I like the blunt honesty of this explanation, found on Ecotrust’s web site: “In a forest carbon offset program, landowners may sell credits for the storage of carbon in their forests. For every credit sold, representing a ton of carbon stored in the forest, a polluter is able to emit an extra ton of carbon dioxide.”

Pacific Carbon Trust, a British Columbia Crown corporation, is kick-starting the creation of forest-based carbon offset projects in B.C. PCT issued a request for information on April 3 to gauge interest in projects based on three types of silviculture investments: creating more forests through afforestation; planting seedlings grown from superior seeds; and fertilizing.

For those considering offset projects, be advised that one generally-accepted characteristic for offset projects is “additionality.”

According to Ecotrust, “additionality in a forest offset requires that the carbon stored by the project came as a result of the incentives provided by the greenhouse gas markets, voluntary or mandatory – that the storage was, in essence, additional to usual business practices.”

So, for example, reforestation projects that are mandated by law are not “additional.” However, planting seedlings in abandoned pasture land might meet the criteria.

The selling price of carbon offsets will also be a factor for companies to watch.

Editorial Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Contributing Editors HEATHER LYNCH ELYSE AMEND advisory Board Richard Foucault Greg Hay Dr. Richard Kerekes Barbara van Lierop Dr. David McDonald Dennis McNinch Dr. Yonghao Ni Bryant Prosser Dr. Paul Stuart Ross Williams administration Publisher EILEEN WALTERS eileen@pulpandpapercanada.com President, Business Information Group BRUCE CREIGHTON Vice President, Publishing ALEX PAPANOU Editorial and salEs officEs: 12 Concorde Place, Suite 800 Toronto, ON M3C 4J2 Phone: 416-442-5600.

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In early April, carbon offsets were trading for US$2 per ton on the Chicago Trading Exchange. At that rate, it was estimated by one news report that landowners in Oregon could receive US$3.50 to $7 per acre per year by selling carbon credits.

Balancing the revenue potential is the cost of setting up a recognized carbon offset project. At the PAPTAC annual meeting in February, Frédéric Gagnon-Lebrun of EcoRessources estimated that the preparation phase, including feasibility studies and marketing, could cost about $70,000. The validation phase is in the range of $30,000, which includes third-party verification, certification, and product registration.

While being a provider of carbon offsets may not be profitable yet, in a strictly dollars-and-cents assessment, it does give pulp and paper companies a chance to wear the white hats among the eco-conscious community.

Scandinavia and Finland: Jyri Virmalainen, Exomedia Oy, Latokartanontie 7A, 4 krs, 00700, Helsinki, Finland; Phone: +3589-61500100; Telex 121394 tltx sf (Att: Exomedia); Fax 358-9-61500106.

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April 2009 PulP & PaPer Canada

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Indexed by: Canadian Business Periodicals Index; Abstract Bulletin, The Institute of Paper Science and Technology; Materials Science Citation Index PULP & PAPER CANADA (ISSN 03164004) is published by a division of Business Information Group Magazines, Limited Partnership, 12 Concorde Place, Suite 800, Toronto, ON, M3C 4J2. suBscriPtion ratEs: Canada – $90Cdn/1 year; $133Cdn/2 yrs.

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industry news LABOUR RELATIONS

FINANCIAL ANALYSIS

Montreal – With their collective agreements set to expire april 30, members of Canada’s largest pulp and paperworkers’ union from mills in ontario, Quebec, and the atlantic region are inviting pulp and paper companies to come to the table with a “new approach.” local representatives from the Communications, energy and Paperworkers Union of Canada, representing some 15,000 workers, held a three-day meeting in Montreal where they discussed strategy and chose a pattern company – abitibiBowater – for this round of pattern bargaining. the union is seeking a three-year agreement.

“CeP will continue to address the survival issues that all companies face and negotiate a responsible industry-wide agreement that is fair for all companies, but we expect our employers to join with us in an effort to protect jobs and to save our industry,” says a statement prepared by the union.

“We believe firmly that jobs and mills cannot be saved by attacking workers’ wages and pensions, or by breaking the common industry standards that have been established by our pattern bargaining system. We propose a three-year agreement with labour stability and productivity increases.”

CeP President Dave Coles says the union is putting the industry on notice that it must start “thinking bigger.”

VanCoUVer — according to PricewaterhouseCoopers’ (PwC) quarterly net earnings review, aggregate fourth quarter 2008 net earnings of 13 of the largest Canadian forest, paper and packaging companies plummeted to -$1.3 billion from -$226 million in Q3 2008 and -$438 million in Q4 2007.

Western Canadian companies’ net losses increased across the board to -$641 million in Q4 of 2008 from -$368 in Q4 of 2007, excluding timberWest who actually saw improved results in Q4 2008 due to a $340 million net gain from its fair value adjustment on modification of debt. eastern Canadian companies saw losses deepen dramatically from -$106 million in Q4 2007 to -$954 million in Q4 2008. However, it was Domtar who skewed numbers by suffering the most significant drop due to a C$700 million impairment charge.

CEP expects upcoming talks to be challenging

FORESTRY

Cold may have killed 90% of the mountain pine beetles in Alberta

Computer simulations done by the Canadian Forest Service indicate frigid temperatures this winter have killed off more than 90% of the mountain pine beetle population in alberta, but it won’t be known until later this spring whether that is enough to stop the bugs from destroying more trees in the province. the computer models show about 95% of the beetles have died in southern alberta, and 90% have died in the northern part of the province.

However, a 97.5% death rate is needed

Net earnings for Canadian forest and paper industry drop even further: PricewaterhouseCoopers

Western Canadian Company Performance $ millions Quarter ended Dec. 31, 2008 Canfor $(229.8) Ainsworth (156.7) Mercer International (94.2) West Fraser (69.5) Catalyst Paper Corp.

(48.5) Western Forest Products (24.3) Interfor (18.5) TimberWest 330.1 Total (311.4)

Quarter ended Dec. 31, 2007 $(237.0) $(184.5) 10.3 (2.9) 12.4 42.9 (8.9) 35.8 (331.9)

Q change $

Eastern Canadian Company Performance $ millions Quarter ended Dec. 31, 2008 Domtar $(819.2) Tembec (60.0) Norbord (36.4) Fraser Papers (19.4) Cascades (19.0) Total $(954.0)

Quarter ended Dec. 31, 2007 $(25.5) (60.0) (12.8) (19.9) 12.0 $(106.2)

Q change $

to keep the mountain pine beetle – which produces a natural anti-freeze to protect itself during the winter – from infecting more trees. according to a number of reports, the experts expect to know more about the state of the infestation once crews head out to inspect forests in May. TRADE DISPUTE

U.S. imposes tariffs on Eastern Canadian softwood lumber

WaSHInGton, D.C. – the United States is imposing 10% customs duties on imports of softwood lumber products from ontario, Quebec, Manitoba, and Saskatchewan, in response to what it views as Canada’s failure to cure a breach of the 2006 Softwood lumber agreement

7.2 27.8 (104.5) (66.6) (60.9) (67.2) (9.6) 294.3 20.5

(793.7) 0.0 (23.6) 0.5 (31.0) (847.8)

by imposing the compensatory measures determined by an international tribunal. the duties will remain in place until the United States has collected US$54.8 million. earlier this year, the tribunal found that Canada had breached the Sla by failing to calculate quotas properly during the first six months of 2007.

Canada has not imposed the compensatory measures determined by the tribunal – a 10% export charge until $68.26 million (US$54.8 million) has been collected. Instead, the Government of Canada has offered a payment of $46.7 million to the United States. “at this difficult time for the industry, Canada chose this payment alternative instead of imposing an additional export charge, which would result in further mill

Visit www.pulpandpapercanada.com for details: B.c. wood waste questioned…noVa scotia lends pictou mill a hand…f s s s

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April 2009 PulP & PaPer Canada

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industry news closures and job losses in communities,” says International Trade Minister Stockwell Day. Canada is asking the tribunal to confirm that its $46.7-million lump sum payment cures the breach in a manner consistent with the SLA. This payment is equal to the revenue the U.S. claimed their industry lost due to the breach.

The United States does not consider that such an offer cures the breach identified by the tribunal, and the U.S. government formally rejected Canada’s offer on April 2.

MILL CLOSURE

Cascades closes Norampac corrugated plant in Quebec

KINGSEY FALLS, QUE. — Cascades will cease production at the Quebec City facility of its Norampac division by the end of 2009. Nearly 145 employees will be affected by the closure of the corrugated production plant.

Sales and distribution services at the Quebec plant will remain intact, and production will be redirected progressively towards the other Norampac Quebecbased plants.

PAPERCLIPS

“This decision was taken as a result of a significant decline in demand for corrugated products while taking into account the high number of Quebec-based plants owned by Norampac,” explains MarcAndré Dépin, president and CEO of Norampac.

“The economic context has forced us to proceed with nearly 1,000 temporary or permanent layoffs in our plants and mills in the past year, either by major reorganizations or by plant closures,” he adds. fInAnCIAL AnALySIS

AbitibiBowater pursues new restructuring alternatives

MONTREAL — AbitibiBowater Inc. announced in early April that the company is evaluating new restructuring alternatives and is currently in active discussions with lenders and debt holders of its Bowater Inc. subsidiary to restructure Bowater’s debt and implement alternatives for maintaining adequate liquidity levels. These developments follow the expiration and termination of Bowater’s previously announced exchange offers.

“We are optimistic that we will be able to work constructively with all of our lend-

ers, debt holders and other constituencies to successfully implement an alternative restructuring of our overall debt,” states David J. Paterson, president and CEO. According to a Reuters report on April 7, some of AbitibiBowater lenders have granted its Abitibi-Consolidated unit a waiver, after it failed to meet the requirements under a $210 million receivables purchase agreement. The waiver and amendment granted by Citibank and Eureka Securitisation extends the termination date of the loan to Sept. 1.

RESEARCH

Nanotechnology research receives government support

FPInnovations announces that ArboraNano — the Canadian Forest NanoProducts Network — will receive $8.9 million over four years from the federal government. The research and development network brings together nanotechnology and forest sector expertise.

Dave McDonald, vice-president, pulp and paper, FPInnovations says “many of the new products will be based on a plantderived nanomaterial — nanocrystalline cellulose (NCC) — while others will use continued on page 8

Breaking the rules for ruled notebooks Whitelines stationery could turn the standard for ruled writing paper on its head. The new line of paper products features white ruled lines on a light grey background, instead of black or blue lines on white. The concept is based on the premise that the dark lines of ordinary paper tend to visually interfere with the markings of pens and pencils. In contrast, Whitelines supports the composition or sketch because there is no visual competition between the lines on the paper and the written or artistic work on the page.

“The idea of Whitelines came to me by accident when I was creating a sketch of another invention,” says creator Olof Hansson. “I was frustrated because the lines on the copy made a mess of my design, and then it hit me: Using a paper with white lines instead of dark ones would not be visible on a photocopy, leaving only my drawing.”

Originally sold in Sweden, Whitelines notebooks will be available in the U.S. this month.

Hansson received Stockholm’s 2008 Innovator of the Year award for Whitelines.

fpca award recognizes aBoriginal leaders…startup underway for lignol Biorefinery…B.c. loggers on prime time tV… s s s pulpandpapercanada.com

PulP & PaPer Canada April 2009

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industry news continued from page 7

STARTS/STOPS/CHANGES

other nanomaterials in the development of new forest products.

Research by FPInnovations scientists has shown that NCC has many remarkable properties, some of which are unique and others that are comparable to those of other well-known nanomaterials.”

ON THE MOVE Having seen the shuttered Worthington pulp mill in Mackenzie, B.C., through the hazards of winter, general manager Tom Boughner has announced his resignation, effective May 8, after ten years on the job.

Boughner

Wall Colmonoy announces the appointment of Craig Johnson to the position of vice-president, Alloy Products Group.

Johnson has more than twenty years of service at Wall Colmonoy, most recently as commercial director for the Alloy Products Group.

Johnson

Domtar Corp. will idle its Dryden, Ont., pulp making facility for approximately ten weeks, effective April 25, in response to continued weak global demand.

The temporary shutdown at Terrace Bay Pulp in Ontario may go on longer than the original six-week period, considering that the mill’s owner, Buchanan Forest Products, filed for court protection from its creditors. With about $80 million in debt, the mill hopes the protection period will give it enough time to restructure its finances and keep operating.

Montreal-based Tembec Inc. will be shutting its Kapuskasing, Ont., operations beginning April 9 for a minimum of four weeks due to the challenging market conditions for both newsprint and lumber. The move will take 20,000 tonnes of newsprint and 8 million board feet of construction lumber off the market About 40 employees of Nanaimo Forest Products’ Harmac mill reportedly will be back to work within four months as the pulp mill plans to begin a second line of operation. According to the Nanaimo Daily News, the mill is also proceeding with its plan to start a chipping operation to reduce its dependence on sawmills for its fibre supply.

The 240 workers at Marathon Pulp Inc. in Marathon, Ont. have lerarned their mill is shutting its doors for good. The mill, which is owned by Tembec and Kruger, is more than $50 million in debt, and filed for bankruptcy protection in February. The Canadian Press reported bankruptcy trustee PricewaterhouseCoopers currently controls the mill and will try to find a buyer.

White Birch Paper Company, North America’s second largest newsprint manufacturer, took market related downtime at its Stadacona L.P. Division in Quebec City, Quebec beginning March 20. The shut was planned to last until April 6 and will result in a reduction of about 30,000 tonnes of newsprint.

About 30 unionized employees at Corner Brook Pulp and Paper in Newfoundland are facing temporary layoffs after the mill’s parent company, Kruger, announced the No. 4 paper machine will be shut down for an eight-week period. The move is part of Kruger’s plan to cut production by 32,000 tonnes at its three Canadian newsprint mills in response to poor market conditions.

While reporting net earnings of $17.1 million for 2008, Quebec-based SFK Pulp will stop production for six weeks and temporarily lay off up to 225 workers at its Saint-Félicien, Que. mill in response to market demand.

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April 2009 PULP & PAPER CANADA

pulpandpapercanada.com

YES, WE’LL ACTUALLY PAY YOU TO SAVE MONEY. Saving a bundle on your energy costs is obviously a reward all its own.

But our job at Power Smart is to make sure there are no major barriers to great energy management at your pulp and paper facility - even if that means pitching in to help kick-start your efficiency initiatives.

Our experts can show you straightforward, low-cost ways to reap major savings in every corner of your operation, from your energy management processes to your light switches. If you decide that you want to reap even bigger savings, our financial incentives are ready to help you take action, all with minimal risks and maximum returns.

Of course, saving energy isn’t just about saving money. It’s about insulating yourself against volatility in the market. It’s about getting the best possible performance out of your equipment and procedures.

And it’s about showing everyone - your peers, your employees, and the communities in which you do business - that you’re ready to be a leader in our province’s bright, sustainable energy future.

Get in touch today and we’ll get you started.

bchydro.com/pulp

Look for us at PacWest 2009 and learn how BC Pulp and Paper companies are using Power Smart programs to gain a competitive edge.

A09-134

cover story

POWER PLAY Power is no longer cheap, nor plentiful, so mills are turning to non-traditional sources and taking a hard look at consumption patterns.

W

ith cost cutting and environ environmental stewardship as two top boardroom concerns, discussions of ener energy sources and energy costs come up far more frequently that they did in the past.

“Traditionally, electricity had been relatively inexpensive,” says Dennis Fitzgerald, a British Columbia-based private consultant to the pulp, paper, and utilities industries. Fitzgerald recently retired from a 32-year career with Catalyst Paper,

most recently as director of energy. He explains that a lot of mills were built with hydro-electric facilities nearby, such as the Catalyst site at Powell River, B.C., located on the Sunshine Coast north of Vancouver on Powell Lake.

“That lake provides the water for turbines that have basically operated the mill for close to 100 years,” he notes. “Powell River was not hooked up to the grid, I think, until about the ’60s.”

B E A

While this may not be the case for all mills in Canada, the economic reality of energy costs – be it for electricity, natural gas, or others – has certainly changed over the years. As demand rises, so does the need for new energy supplies. And energy prices inevitably follow suit.

“I don’t think we have ever considered that energy was expensive in circumstances like those [at Powell River],” Fitzgerald says. “I think that’s the attitude we’ve come from.”

Photo: Columbia Power Corp.’s Brilliant Generating Station near Castlegar, B.C.

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April 2009 PULP & PAPER CANADA

pulpandpapercanada.com

cover story Nexterra’s gasification up to 60% moisture content.

technology converts wood waste to synthetic “syngas” that can be used like natural gas. Syngas is consumed by the boiler, which provides process steam for the Kruger tissue mill.

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Gas from biomass replaces gas at Kruger

In addition, the industry has suffered a succession of hard hits over the past years, so many mills are reluctant to invest in large-scale projects aimed at reducing energy use. Kruger Products Ltd. is an exception. The company is moving forward with a biomass gasification system at the Kruger tissue mill in New Westminster, B.C. The gasification system, supplied by Nexterra Energy Corp., will turn locallysourced wood residue into clean burning syngas, which will be fired directly into a boiler in place of natural gas. The installation, which is projected to start up in December 2009, will produce 40,000 lb./hr. of process steam, and displace about 445,000 GJ of natural gas per year.

Kruger’s vice-president of technology, Frank van Biesen, says installing this new system is part of their goal to improve the mill’s energy position.

“The first driver was really to get

“I’m happy to be a part of a company that wants to do this.”

– Frank van Biesen, Kruger

away from fossil fuels to an alternative.

The easiest one that’s available to anyone these days is hog fuel,” says van Biesen.

However, he adds that ordinary hog fuel burners have some negative sides to them, such as a significant amount of particulate emissions.

The gasification process uses about pulpandpapercanada.com

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20% to 30% of the oxygen needed for complete fuel combustion. The amount of air supplied to the gasifier is carefully controlled so only a small portion of the fuel burns completely. This process provides enough heat to pyrolyze and chemically break down the balance of the fuel into “syngas”, which is primarily made up of carbon monoxide, hydrogen, and methane.

According to van Biesen, the primary benefit of this technology is a significant reduction in particulate emissions. “The second thing is that it affords greater flexibility in terms of fuel choice. You can burn drier wood; you could source construction waste that conventional hog fuel burners would not accept.”

In addition to making the mill less reliant on fossil fuels and reducing emissions, this biomass gasification installation – the first of its kind in the pulp and paper industry — is projected to save the New Westminster facility millions of dollars a year in energy costs.

“I’m happy to be part of a company that wants to do this,” van Biesen states.

Wait-and-see attitude prevails

Given that there are new technologies out there that can help mills produce their own energy and cut down on costs, why is it that more aren’t jumping on board?

“This industry is renowned, I’ll say, for its unwillingness to take risks and chances on new technology. As an industry, we’re very old school in terms of wanting to try something new,” van Biesen comments.

Dino Mili, vice-president of business development at biofuels developer Enerkem, echoes that sentiment: “The

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The primary motivation for Kruger’s biomass project is reduced reliance on fossil fuels. industry is not necessarily what you would call first movers. So there’s going to be more of a wait-and-see position from most of the larger companies to figure out how the technologies will affect them in terms of if the technology performs well, and then how will they be able to access the technology.” Enerkem has two notable projects in process now: a production plant in Westbury, Que., that will use wood from utility poles to produce ethanol, and a joint venture with Greenfield Ethanol that will see Edmonton become home to the first industrial-scale facility to produce ethanol from municipal solid waste. The ethanol is planned to go into fuel distribution to help Canada meet its 5% renewable fuel content requirement by 2010.

These projects may also have some significance in the pulp and paper industry. “We leave, sometimes, more in the forest than can be used. It can’t be used to make pulp and paper, but it can be used to make materials like biofuels,” says Mili.

Frank Dottori is the founder and former CEO of Tembec Inc. and current managing director of Greenfield Ethanol’s cellulosic ethanol division. He says using biomass to generate energy is something the pulp and paper industry should look at. However, there is an obstacle.

PULP & PAPER CANADA April 2009

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cover story

“There’s going to be more of a “wait and see” position from most of the larger companies.”

– Dino Mili, Enerkem

To reduce its reliance on fossil fuels, Kruger’s tissue mill in New Westminster, B.C., is installing a biomass gasification system.

“Companies have to be in a position where they have the money to invest in these kinds of technologies,” says Dottori, adding that most companies today are fighting for survival. “There are good technologies available. They just need the support to get them going.”

He suggests that governments should get involved in helping one of Canada’s largest industries invest in biomass technologies.

“The government should really support that. It would help the pulp

and paper industry, it would help sawmills, it would displace fossil fuels,” he says. “A lot of the infrastructure is there. It’s really a viable economic option. I don’t understand why the governments don’t make that a priority for the industry.”

Make conservation a priority

On a smaller scale, Dennis Fitzgerald notes that there are a few steps mills can take to be more energy efficient without investing a lot of money.

The first step is to measure and

Proven tools to measure and control energy use The Quebec Forest Industry Council’s (CIFQ) Energy Conference provided numerous examples of how pulp and paper mills are monitoring their energy habits and finding ways to reduce consumption.

By John E. Little

An analysis of the plant’s energy use was the jumping off point for most of the real-life energy conservation examples presented at the Quebec Forest Industry Council’s (CIFQ) energy conference held last spring in Bécancour, Que. Cascades Groupe’s two-stage approach to cutting down on energy consumption for plant heating was described by AndréAnne De Gagné, an engineer with Cascades Énergie. The first stage involved determining the real, or baseline, cost of heating in their pulp and paper mills. It was a two-step process that examined the method of calculating energy used for heating and the problems of distinguishing the energy used for heating from overall mill energy consumption.

The second stage then implemented measures to reduce heating costs after an examination of the available technologies for this purpose.

The first problem to resolve in establishing overall mill energy consumption was to determine a method or model to 12

April 2009 PulP & PaPer Canada

Using an intelligent alarm to track performance of the TMP regenerator, AbitibiBowater determined that uncorrected anomalies were costing $1,000 a day. isolate the impact on energy consumption caused by external ambient air temperature fluctuations. The model was based on the total of three variables: production demand plus degree-days of heating plus the base energy load. Calculations demonstrated that for a paper mill, heating represented a cost of $4 to $13 per tonne of product and from 2% to 10% of the overall energy costs for the mill. In a conversion plant, heating costs represented

10% to 15% of total energy costs.

In one example, De Gagné explained that the automation of the Cascades Jonquière mill economizers at a cost of $65,000 yielded savings of $35,000 for ROI of 1.9 years. It also avoided costs of $170,000 per year.

De Gagné also discussed heating by glycol at Cascade Papers Kingsey Falls.

An expenditure of $215,000 led to savings of $85,000, for an ROI of 2.5 years.

Another example was the installation of natural-gas powered, infrared radiant heaters in another mill to replace electric, steam, and standard natural gas heaters and fans.

Energy management minimizes electricity purchases

P.A. Bessette, an advanced control specialist with SFK Pulp of St. Félicien, Que., described the advanced controls used at the plant in kraft pulp production, with a unique twist — electricity demand management. pulpandpapercanada.com

cover story

understand how energy is being used at the mill. Putting in a metering system, for example, can help to understand how energy is being consumed at the mill, and why changes occur. “If you don’t take steps in that direction, you probably can’t be very effective at reducing consumption,” he states.

Second, mills should also look at how energy is purchased and what options are available from their utilities and suppliers that may add value, which in turn can be passed back to the mill to reduce costs.

Next, Fitzgerald suggests the creation of a team made up of people from all mill areas and levels whose objective is to monitor consumption and spearhead process changes or other conservation measures to

SFK uses advanced controls in six applications. From an energy management point of view, the turbo-generator advanced control setup installed in 2007 is probably the most intriguing. The principal goal was to maximize utilization of the turbo-generators, minimize the use of make-up bunker oil, and maximize the profitability of mill electricity production.

The mill’s strategy was to limit total outside purchases of electricity as a function of its capacity to produce steam.

SFK Pulp had a cogeneration contract with Hydro-Québec, whereby the mill sold 15% of electricity from Turbo #1 and 100% from Turbo #2. It purchased electricity from Hydro-Québec under a “sale plus total consumption less internal production” arrangement subject to three tariff levels: Tariff L for 5 MW, Tariff H for off-peak demand (nights and weekends), and Tariff H for weekday peak demand — quite a headache for the operating team to optimize! The trick was to balance the supply of electricity from both turbo-generators to satisfy mill demand, while optimizing electricity purchases from Hydro-Québec under the complex tariff terms of the contract.

The mill was able to achieve this and provide the operator with an interface for pulpandpapercanada.com

Enerkem’s facility in Westbury, Que., will produce ethanol from scrapped utility poles.

For its pulp and paper mills, Cascades calculated that heating represented a cost of $4 to $13 per tonne of product and from 2% to 10% of the overall energy costs for the mill. the steam network in the control room that confirmed the actual cost of power on a continuous real time basis.

Data mining: Seeking the big picture

A further approach to mill energy management using data mining has been adopted at AbitibiBowater. As explained

by Sebastien Lafourcade of Pepite Technologies and Martin Fairbanks of AbitibiBowater, data mining is the practice of analyzing process information to reveal process performance information and to generate understanding. In this case, the companies were able to extract added value from historical process data

meet their collective energy goals.

“I think [energy] has to be given the priority it deserves,” Fitzgerald said, pointing out that many mills already take similar steps when it comes to mill safety and quality control. “It’s something that people should do on a day-in, day-out basis, just like every day they make sure their work areas are safe.”

While this industry may not be known as early adopters of technology, the momentum toward conservation of energy and investigation of alternative sources is building. Cheap, plentiful power is no longer taken for granted. Now, energy has become a topic of discussion at all levels of forest products companies – from the boardrooms to the mill floor.

PPC

already available to AbitibiBowater, to provide different levels in the mills with better decision making tools for energy management, with little or no financial investment.

The production process can involve more than 3,000 variables. The challenge is to reduce this to fewer than 10 key process variables through preliminary analysis, data exploration, invariate and multivariate analysis, modelization, and advanced multivariate analysis.

At AbitibiBowater, the benefits were substantial: in the first mill they were able to optimize the quantity of dirty TMP steam sent to the regenerator with potential savings of $1 to $4 per tonne. Using an intelligent alarm to track performance of the TMP regenerator, they determined that the uncorrected anomalies they identified were costing $1,000 a day. In a second mill, they observed wide variations in specific steam consumption for a paper machine with three specific consumption peaks, revealing potential savings of $3 to $6 per tonne.

These examples demonstrate that there are efficiencies to be found in mills, and that, once found, these problem areas can be transformed to real savings that flow directly to the bottom line.

PulP & PaPer Canada April 2009

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capital expenditures report A major upgrade to Catalyst’s Port Alberni TMP mill was announced in February 2008.

It should be completed in May.

Funds on hold Checking in with mills across the country, Carroll McCormick finds a significant decrease in spending for equipment and upgrades this year. Expansion plans are almost non-existent, but mills are proceeding with maintenance and energy-related projects.

I

n the midst of a global economic crisis, the idling of paper machines across Canada, and out-and-out mill closures, pulp and paper companies from coast to coast report a dramatic reduction in capital spending this year.

Last October, Minas Basin Pulp and Power was poised to begin building a $20-million, 110,000 lb./hr. hog fuel boiler. This was to be its fifth-largest capital project since Roy A. Jodrey founded the company in 1927. With the market downturn and the drop in the price of Bunker C fuel from 70 cents down to the low thirties however, the company put the project, which will take 12-16 months to complete, on hold.

“All the engineering and studies were done, the vendors were chosen, and the 14

April 2009 PulP & PaPer Canada

environmental permitting is in progress,” says Terry Gerhardt, vice-president of operations for Minas Basin. “We are still continuing the engineering and site preparation. But at this point we are not spending on the labour or equipment.”

The paperboard mill in Nova Scotia burns 14.5 million litres of Bunker C a year. “This year we need to get off fossil fuels,” Gerhardt acknowledges. “The project will go ahead, but we are not certain when.”

Also on hold is $500,000 worth of work to make the mill more of a closed loop; e.g., installing more equipment for recycling waste process water. “This will go ahead sometime in 2009. When you do projects that affect the environment, you have to do them. Projects to improve

By Carroll McCormick product costing or machine efficiencies are still being considered, but additional tonnage capacity in the current market conditions is not in our plans,” Gerhardt says.

The company will continue to spend smaller amounts on some environmental, procedural, and safety projects. As well, some government-funded studies on electrical consumption may result in additional projects this year.

Daishowa-Marubeni International reports that this year’s capital spending is just 30-35% of what it was in 2007 and 2008. Its plans were whipsawed between the higher cost of capital in Alberta’s hot oil boom market and the subsequent need to conserve cash in the current recession. For the next couple of years capital pulpandpapercanada.com

Photo by Ken Miner, courtesy Catalyst Paper

capital expenditures report plans will focus on replacing worn out and obsolete equipment, according to Stu Dornbierer, general manager, human resources, and director of corporate communications. “Examples in 2009 include ClO2 absorption tower replacement ($812,000), evaporator impingement plate and nozzle replacement ($500,000), 980 loader replacement ($588,000), digester scraper arm replacement (500,000), boiler tube replacement ($300,000), and control equipment obsolescence ($289,000).”

Also in Alberta, Weyerhaeuser reports that no capital expenditures are in progress or planned for its Grande Prairie mill.

Exceptions to the rule

This January Cascades announced it would spend $5 million at its Norampac plant in Kingsey Falls, Que., the first stage of a $20-million investment over the next three to five years. The unit that manufactures linerboard from 100% recycled fibre will be streamlined.

The building expansion that is required to replace the winder and create additional space for future investments has been completed. Equipment will be installed this year.

“The way to compete and stay alive is to continue to invest in the quality of the product and the future of the mill,” says Alain Lemaire, president and CEO of Cascades. That said, he notes that capital expenditures this year will be below $100 million, down from an average outlay of $170 million a year for the past five years.

“We have cancelled and postponed

different programs because of the market uncertainty, but we hope that we will be able to spend enough money. But if you are cutting just to improve the bottom line, that is not a good decision. We try and rationalize our units, and invest in the units that we think will be the best,” Lemaire explains.

The company is also finishing up many projects it began in 2008, including a $15-million acquisition of a high-tech conversion line for its Lachute tissue paper plant and a $20-million biomass plant in Trenton, scheduled to begin operating by the end of 2009; the boiler will be able to produce 100,000 tonnes of steam an hour. Cascades is also spending $10 million a year on other energy reduction projects.

Irving’s Pulp & Paper Division is also continuing with planning and engineering on various initiatives.

Having already spent $100 million since purchasing the Port Alice, B.C. pulp mill from Domtar Industries in 2005, Neucel Specialty Cellulose plans to invest $10 million to $15 million on capital projects this year. These include $2 million on two hog boilers and two oil-fired boilers, $1 million to $2 million on the liner and associated equipment for its number ten digester (Neucel relined other digester liners last year), and an undetermined amount of money on the evaporators (Neucel spent $2 million on the evaporators in 2008). In 2010 Neucel may build a new $15-million wood plant.

The mill produces 500 tonnes a day of chemical-grade cellulose feedstock

Positive steps encourage investment

“In the current economic circumstances [P&P] companies in general are trying to conserve cash until conditions improve. The 2009 federal budget extended the straight line accelerated Capital Cost Allowance to 2011. This CCA increase from 30% to 50% was introduced in the 2007 budget. This is a measure that will be helpful to companies that are investing, but I expect that it will be swamped by the current economic conditions.

“The biggest issue for our members vis á vis the budget was the availability of credit. The budget announced a number of measures to expand financing through Export Development Canada, expand its mandate, and improve its ability to fill gaps in the credit market. These are positive initiatives that go some way to addressing the primary concerns of our members, which is access to credit.” — Marta Morgan, vice-president trade and competitiveness, Forest Products Association of Canada

pulpandpapercanada.com

At Catalyst Paper, Lyn Brown says the company is focused on maintenance expenditures in 2009.

for products such as paints, plastics and explosives. It has been relatively immune to the market turmoil experienced by mills that produce pulp for paper products. “Some of our major customers are in major expansions,” says Robert Barbour, manager of engineering. “We had customers that used to switch back and forth between pulp and oil but they got so burned [by high oil prices] that they switched to pulp and are staying. We see nothing but a positive future.”

Energy conservation projects move ahead

Fraser Papers senior vice-president and chief financial officer Glen McMillan reports that there are no capital expenditures of significance to report at its pulp and paper mills. In a June 25, 2008 press release however, Fraser announced a $40 million loan from the New Brunswick government to support the upgrade of its facilities in the province, to “improve energy efficiency, increase throughput, upgrade technology, and enhance environmental performance.”

Fraser is supporting its Edmunston paper mill indirectly through a $17.5-million project to install a biomass boiler and modernize its Plaster Rock sawmill. The continued viability of the sawmill will ensure a continued supply of wood chips to the paper mill.

Noting that AbitibiBowater is quite “restricted” in its capital expenditures, Alain Bourdages did comment that the company is currently investigating biofuels. Bourdages is director of energy development and strategy for AbitibiBowater.

PulP & PaPer Canada April 2009

15

capital expenditures report “We are on a fact-finding mission about biofuels. We are trying to understand everything about them – the technology and end products – and are looking at what Abitibi has for hardware, infrastructure, and assets, and what we can use for fuel. The key there is the value of access to feedstock and avoiding capital exposure. We have some [biofuels] projects under development, but nothing I can talk about now.”

Mercer in a January 30 press release it announced that its Celgar mill had, “commenced upgrades to its generation facilities, which will include the installation of a 48 MW condensing turbine, that will bring Celgar’s installed generating capacity up to 100 MW.”

Cost reduction projects worth the investment

In spite of reduced capital budgets, several companies are pursuing projects that promise to lower production costs.

other old one and the new one Al-Pac bought last year.”

Catalyst spent $42 million on capital projects in 2008, about half of its 2007 level of $80-$100 million. This year, says Lyn Brown, company vice-president, corporate relations and social responsibility, “We are concentrating purely on maintenance and business-required capex for maintenance. No big projects are on the horizon at this stage.”

That said, its February, 2009 Management’s Discussion and Analysis notes that a $12-million capital upgrade to Port Alberni’s thermomechanical pulp facility, announced a year earlier, is expected to be completed by May 2009. The upgrade will “increase TMP capacity and displace recycled de-inked pulp, further improving the cost competitiveness of the Port Alberni mill.”

The 2009 capital expenditure program at Howe Sound Pulp & Paper includes upgrading the bleaching capacity on its

In spite of reduced capital budgets, several companies are pursuing projects that promise to lower production costs.

Alberta Pacific Forest Industries spent $54 million on capital projects in 2007, well above its annual average of $20 million. This year the figure is just $13 million, targeted for projects that will yield cost reductions, according to Al Ward, president and chief operating officer. The biggest project is a major, $4-million rebuild of the 13-MW backup turbine, which was due to be completed by the end of March.

Another is a metal spray of a recovery boiler, due to be carried out in May. Worth $6 million over five years, it is an example of a cost-reduction move: waiting until the tubes needed replacement would cost $25-30 million. Al-Pac will spend $1.2 million to pave some existing roads and $800,000 to build new roads.

This will reduce maintenance costs and increase truck cycle times.

Ward cited one deferred purchase: a $1 million-plus chip caterpillar. “We decided to keep the old spare, and use the 16

April 2009 PulP & PaPer Canada

TMP lines. This project began in January and should be completed by May. “It will allow us to make sure we meet the brightness requirements of our customers, even when we use darker wood,” explains Al Strang, manager of environment and external relations. He did not provide a dollar figure for this project, but did say that the mill will be spending $2 million to continue the expansion of its landfill for ash from the power boiler and other process waste, begun last year and due for completion in 2010.

The rest of this year’s capital expansion program is minimal; e.g., $80,000 to complete the replacement of the halon in the fire suppression system in the motor control centre rooms, and unspecified expenditures to upgrade the controls in the lime kiln to reduce natural gas use and improve lime quality.

There’s interest in going green

Kruger announced in November that it

Al-Pac president and COO Al Ward says investments this year are targeted at projects that will reduce costs.

would implement a biomass gasification system at its New Westminster, B.C., facility. The system will reduce its greenhouse gas emissions by 22,000 tonnes annually and reduce its natural gas consumption by 445,000 GJ per year. Kruger, Vancouver-based Nexterra Energy, and FPInnovations formed a consortium to build the new system. (For more details on the system, see “Power Play”, page 10.)

The project is valued at $13 million, $7 million-plus of which comes from Kruger, $1.7 million from National Research Canada, and $1.5 million from the Innovative Clean Energy Fund (B.C.). The plant is in the final design stages and the site selection is being finalized. It will use fuel such as sawdust and shavings, to be delivered to the plant from various sources. Construction will begin in 2009, and it will be finished and ready to operate by September 2010, according to FPInnovations executive vice-president Jim Dangerfield.

FPInnovations will gather benchmark data and do the post-performance aspects of the project; e.g., energy efficiency, economics, and carbon footprint.

Other pulp and paper companies have expressed interest in the technology. Nexterra Energy director of communications, Raymond McAllister, says, “There is a lot of interest in the technology that Kruger purchased. But with the state of the economy and the lack of capital, a lot of PPC projects are on hold.” pulpandpapercanada.com

conference preview

PacWest explores profit potential of being green PacWest is once again providing a balance of business and technical sessions, with a national roster of speakers. The annual conference of PAPTAC’s Pacific Coast and Western branches will be held from June 10-13 at the Delta Sun Peaks Resort, near Kamloops, B.C. This year’s theme is “Closing the Loop: Profiting from our Green Potential.” That will also be the topic of the conference forum on Thursday morning, featuring Jacquelyn McNutt, Center for Paper Business & Industry Studies; Paul Lansbergen, director energy, economics and climate change, FPAC; Thomas Browne, FPInnovations-Paprican; Ron Ezekiel, Fasken Martineau; Nicole Rycroft, Markets Initiative; and Michael Weedon, BC Bioenergy Network.

In a later session on green opportunities, Rycroft will discuss how papermakers in Canada are not supplying the “green” paper which publishers in North America are seeking. Also on the subject of market opportunities, Lyn Brown of Catalyst Paper, Patrick Armstrong of Moresby Consulting, and Michael Bradley of Canfor Pulp LP will take part in a panel discussion on product certification.

A number of case histories will be presented as part of the technical sessions.

On tap are a pulp machine upgrade at Canfor Pulp LP, energy reduction initiatives at Alberta Newsprint with an emphasis on pumping systems, and a case study of efficiency improvements on renewable fuels usage.

Wednesday, June 10 Closed meetings of mill managers and senior executives Short course: Pulp Machine Operations, 8 a.m. - 4 p.m.

Short course: Energy Conservation, 8:30 a.m. - 4:30 p.m.

Short course: Continuous Cooking, 8:30 a.m. - 4:30 p.m.

Registration, 1 p.m. - 9 p.m.

Trade Fair, 3 p.m. - 9 p.m.

Welcome Reception, 5 p.m. - 7 p.m.

Thursday, June 11 Short Course: Pulp Machine Operations, 8 a.m. - 4 p.m.

Trade Fair, 8 a.m. - 5 p.m.

Conference Forum, 9 a.m.

Technical Session: Pulping and Recovery, 1:30 p.m. - 4:30 p.m.

Panel Discussion: Monetizing Sustainable Energy, tba Technical Session: New Technologies, 4:30 p.m. - 5:30 p.m.

pulpandpapercanada.com

Two papers on the subject of pulping of mountain pine beetle-infested wood will also be of interest to pulp mills in affected areas.

The technical program at PacWest is supplemented by short courses on pulp machine operations, energy conservation, and continuous cooking, as well as a trade fair that runs Wednesday through Friday.

The social aspect of the program begins Wednesday, June 10, with a welcome reception. Friday wraps up with the awards banquet and dance. There’s also a 5K run/walk on Friday, and golf on Saturday.

For additional information and to register, visit www.pacwestcon.net.

Friday, June 12 5K Fun Run/Walk, 7:00 a.m. - 8:00 a.m.

Short Course: Pulp Machine Operations, 8 a.m. - 4 p.m.

Trade Fair, 8 a.m. - 3 p.m.

Technical Session: Control, Mixing, and Green Opportunities, 8:45 a.m. - 12:00 p.m.

Panel Discussion: Energy Management, tba Keynote Feature Luncheon, 12:15 p.m.

Technical Session: Pulp & Paper Machine Technology, 2:15 p.m. - 4:30 p.m.

Panel Discussion: Product Certification, 2:15 p.m. - 4:30 p.m.

Conference Reception, 6:30 p.m. - 7:30 p.m.

Awards Banquet & Dance, 7:30 p.m.

Saturday, June 13 Golf Tournament, 8 a.m.

Golf Awards BBQ, 1 p.m.

PULP & PAPER CANADA April 2009

17

safety matters

Managing Safety in a Recession A look at the issues and problems that can arise when a company is in a tough financial situation, plus some cost-effective solutions to boost safety in trying times.

R

ecently, American Society of Safety Engineers president Warren K. Brown cautioned employers against cutting back on workplace safety in times of economic difficulty.

“We realize these are tough times, but during economic downturns, employers seeking to cut expenses may target variable operating costs such as travel, training and safety,” Brown said. “Money cut from safety processes now could have an enormous cost later; this can be from injury and health care costs, fines, lost production time, employee morale, or worst of all, employee injury or even death. There are better and smarter ways to protect the bottom line.”

Amen!

The issues

While economic hard times may be a more recent concern for many North American manufacturers, the pulp and paper industry has been living with this problem for the last 10 years or more. But in 2008-09 it reached critical proportions.

At some point the situation will level off and the surviving mills will see better times. Until then, mills still face difficult challenges. All employees fear mill closures. Corporate liquidity is severely affected; cash is short. Anxiety and stress are rampant, employees are overworked in some cases, and work routines are disrupted. Jobs are at risk and employee morale is extremely low.

Can mills deal with these issues? What problems do they create for employee safety?

The problems: weak sales, liquidity, and safety

Many mills desperately need cash. Cash shortages lead to more cost cutting and the mill safety budget is not immune.

Accidents and illness rates often escalate.

Stress and/or fatigue stem from overtime, downsizing, new tasks, fear of job and income loss, etc. Reduced or ineffec18

April 2009 PulP & PaPer Canada

By John E. Little

tive spending on accident prevention and plant maintenance generate new or additional hazards in the workplace. In some instances, employees who fear imminent job loss may resort to fraudulent workrelated injury/illness claims to receive workers’ compensation benefits to replace their expected lost income.

But there may well be a silver lining.

Simple, targeted, cost-effective initiatives that address employee insecurity and safety during recessions can even contribute to corporate liquidity in both the short and long term.

Cost-effective solutions

Most mills have fairly comprehensive safety efforts in place. During good times, they are well funded but are rarely subject to intensive scrutiny. They accumulate fat. Rather than blindly defending existing safety spending, now is the time to take a quick, hard look at identifying and reinforcing those safety activities that actually add value, deleting those that don’t, and maybe adding one or two that are missing. Now is the time to cut out the fat in the safety process. Above all, keep it simple.

But first, addressing the low morale and financial anxieties of employees is a prerequisite to any other initiatives. If not already done, management should be open with employees about the true status of the enterprise, all possible outcomes, and the seriousness of the situation. Layoffs, severance, and relocation procedures should be clearly established to reassure employees that the employer cares about their welfare, whatever the outcome. All this is vital to reduce employee stress and anxiety to a manageable level. This establishes management credibility, improves employee receptiveness, and sets the stage for exceptional recession-based safety initiatives.

The secret to world class safety is essentially that it is process-focused and employee-managed. Management and employees work together to identify those

safety activities that truly add value and those that don’t. During the good years, a lot of fat can accumulate on the safety process because nobody is really scrutinizing it. But where mills have fairly comprehensive safety management systems, the additional improvements in safety performance usually come from activities that involve a high level of employee participation and ownership. These are characterised by the ability of the employees to perform risk management individually and/or as teams. They continuously perform some form of pre-task planning and risk assessment procedure, mental or written, before performing a task.

They also provide management with continuous feedback on hazards and incidents in order to improve the upstream hazard filtering activities of the safety management systems. This reduces the hazard burden at the workface where the employee is exposed to risk. The key feature of this type of activity is that it focuses on forward looking, pre-emptive practices that emphasize seeing the risks and exposures that lie ahead as opposed to those that lay behind. To quote Ron Dembo on risk management, “Risk lies where we’re going, not where we’ve been!”

Employees need sound, pressure-proof work performance methods and skills in order to work safely in a dynamic, uncertain, changing environment. The beauty of this approach is that it can be implemented at little or no extra cost to the enterprise during a recession when cash is tight. Cutting the fat may well reduce overall safety process costs and budgets.

Two excellent examples of this thinking come to mind.

First, the AbitibiBowater Beaupré, Que., mill, which has a good safety record, implemented in 2008 a risk assessment procedure for 100 maintenance workers.

The procedure uses a simple checklist on a single, double-sided card to help employees identify hazards and adequately prepare for the safe, productive perforpulpandpapercanada.com

safety matters

P&P

mance of every maintenance task. This procedure can take seconds, minutes, or hours, depending on task complexity. Yet the training time required was only one hour per employee.

Incidents dropped 30% in 2008, the first full year of its application. In addition, the process was developed, not by management, but by an employee task force composed of two electricians and five mechanics with support from a unionized foreman! The mill now plans to expand the approach to all 200 remaining mill employees.

The second example comes from a U.S. company. This money-saving safety initiative is one that focused on a shift from measuring safety by OSHA incident rates to valuing safety in hard dollars. A former risk manager for the Häagen-Dazs Co. found his most immediate challenge was to reduce high workers’ comp costs generated the California HALF ADS 2 by1/16/09 2:44facility.

PM Page 1 Larry Hansen recounted this tale on ehstoday.com: “Corporate-imposed incident rate measurements had frustrated supervisors because they were held account-

During good times, safety programs are well funded but rarely subject to intensive scrutiny. Now is the time to cut out the fat. able for something over which they had little control, had created employee cynicism because workers knew that numbers were suspect, and had driven real problems and near-miss events underground until they ultimately surfaced as costly injuries.

His solution was to implement what he calls the ultimate safety metric — an average loss cost calculated by the following formula: Average loss cost = total cost of all incidents/total number of all incidents.

By “incidents,” he meant incidents of all types: near-misses, first aid, medical only, restricted duty, and disabling.

His goal was to build trust and remove cynicism by removing the negative consequences associated with reporting, which

in turn would expose real problems and foster real safety progress.

The genius of this metric is that the only two ways it can be improved is by increasing the number of incidents reported (exposing hidden problems), or by reducing total costs (forcing better management of employee claims).

By the end of the first year, the plant reported 33% more claims, but produced a 30% reduction in claim costs. The risk manager went on to a Dole Foods division where he applied the same approach and reduced loss costs from $385,000 to $30,000 in the first year.”

In conclusion, by emphasizing employee management of safety and concentrating on those activities that focus on the safety processes that reduce exposure to risk, mills can still succeed in maintaining safe operations while cutting prevention costs and contributing to corporate liquidity.

John E. Little is a risk management consultant and can be reached at jelittle@videotron.ca or 418- 826-0541.

TELL US YOUR STORY! ...from the mill to the board room Has a story you’ve read in Pulp & Paper Canada helped you solve a problem or inspired you and your team to make changes at your operation?

Whether it’s about safety, environmental issues, new technologies, or anything else, we’d like to hear about it.

Send us a photo of your team and a short comment on how an article you read in Pulp & Paper Canada has impacted you. If selected, you could be featured in an upcoming issue.

Email your entries to:

media@pulpandpapercanada.com www.pulpandpapercanada.com

SEE YOUR STORY FEATURED IN AN UPCOMING ISSUE

We look forward to hearing from (and seeing) you! pulpandpapercanada.com

PulP & PaPer Canada April 2009

19

T37

monitoring

WINNER OF THE JOHN S. BaTES aWaRD

The Influence of an Integrated Pulp and Paper Mill on Ambient Levels of TRS and PM2.5 in the Community

By B. O’Connor and C. Walton

Abstract: Three ambient monitoring stations for TRS and PM2.5 were operated for a period of 1.7–2.2 years in a large city near the vicinity of an integrated pulp and paper mill. The stations were carefully located so as to differentiate the influence of the mill from other sources. For ambient TRS, the mill’s installation of a dilute non-condensable gas collection system midway through the study resulted in a significant reduction (43–82%) in the TRS levels in the community. For ambient PM2.5, statistical analysis of the data clearly indicated that mill emissions were not the most important contributor to the ambient levels that were measured at the three stations. During poor air quality episodes, it was clear that the elevated values were due, in large part, to sources other than mill emissions. This strongly suggests that wood-burning stoves, other town and industrial sources, and residential activities are important contributors to the ambient PM2.5 concentrations that are measured in the airshed.

I

B. O’CONNOR, FPInnovations – Paprican, Pointe-Claire, Que.

C. WALTON, AbitibiBowater Inc., Thunder Bay, Ont.

20

n communities where pulp and paper mills operate, the key areas of concern continue to be odours and particulate matter. Odours are usually attributed to total reduced sulphur (TRS) compounds which can originate from kraft mills (via process stacks and the treatment system) and thermomechanical pulp mills (via the treatment system). For kraft mills, the TRS compounds include hydrogen sulphide, methyl mercaptan, dimethyl sulphide, and dimethyldisulphide, whereas for thermomechanical pulp mills, the TRS is typically hydrogen sulphide, as a result of anaerobic activity.

From a regulatory standpoint, odours are also receiving increased attention from both the federal and provincial governments. Environment Canada has added TRS to the National Pollutant Release Inventory (NPRI) and hydrogen sulphide is being evaluated for toxicity under the Canadian Environmental Protection Act (CEPA). In addition, the Ontario Ministry of the Environment has recently prepared an information draft for the development of air standards for TRS [1] in order to develop health-based guidelines for the protection of communities.

With respect to particulate matter, regulatory agencies in Canada and other countries have begun to place increased focus on particulate matter less than or equal to 10 microns (PM10) in size as well as its PM2.5 subfraction (< 2.5 microns). In 1999, a federal/provincial working group issued a Science Assessment Document which examined the effects of particulate matter on the community [2]. The assessment concluded that PM10 and PM2.5 were associated with a range of serious health effects of which the PM2.5 fraction was thought to be potentially responsible for having

April 2009 PulP & PaPer Canada

the largest impact on human health.

As a result of this assessment, Canada-Wide Standards (CWS) were ratified in June of 2000 for PM2.5 [3]. The CWS for PM2.5 is based on ambient concentrations and was set at 30 µg/m3, over a 24-h averaging time, to be achieved by 2010. Over the past 15 years, Environment Canada has also operated a particulate monitoring program (NAPS, or National Air Pollution Surveillance) examining PM10, PM2.5, and particulate composition in major Canadian cities [4]. While Environment Canada’s database contains a wealth of information for major cities and several rural locations, data for pulp and paper mill towns are lacking [5].

The objective of this study was to collect ambient TRS and PM2.5 data from three monitoring stations in the vicinity of a large integrated pulp and paper mill in an attempt to more fully examine the potential contribution of the mill toward air quality in the community. In addition, the mill has been implementing various air quality improvement projects over the monitoring period and it was of interest to document the impact of these changes.

RESULTS AND DISCUSSION

The city chosen for the ambient air quality study contained numerous industrial and residential inputs and a relatively large population of approximately 110,000 people. The monitoring stations were located in the vicinity of an integrated pulp and paper mill. At the time of the study the facility operated two kraft mills, producing hardwood and softwood market pulp, a thermomechanical pulp mill, a deink mill, and two paper machines producing a variety of paper grades including newsprint, directory, book, and coated paper basestock. pulpandpapercanada.com

peer reviewed The site also operates an oxygen activated secondary effluent treatment plant. The equipment used to monitor the ambient air quality for particulates has been described in detail in previous reports [6,7]. One station was provided by Paprican, while the two additional stations were set up for the mill by an independent consultant. The three ambient monitoring stations were located at distances of 1.5â&#x20AC;&#x201C;3.1 km from the mill. For ambient TRS, the integrated kraft mill was the predominant source that was contributing to the release of these components into the airshed. In contrast, for ambient PM2.5, the airshed contained input from a number of industrial and residential sources.

In addition to the contribution from the integrated pulp and paper mill, other industrial sources included a coal-generating power station, mechanical pulping operations, and several sawmills and lumber-drying kilns. Transportation sources (rail, automobiles, diesel trucks, and airport), other types of manufacturing facilities, as well as residents with woodburning stoves, were also prevalent in the community.

The ambient monitoring stations were placed at three strategic locations in order to best capture the potential influence of the mill emissions on ambient air quality.

The location of the ambient monitoring stations is provided in Figure 1. The direction of north (0 degrees) is identified on the map. Site #1 (denoted by S1) was located in a residential sector 2 km northwest of the mill. Site #2 (S2) was located at the start of the residential section of the town, 1.5 km northeast of the mill. Site #3 (S3) was situated in the adjacent First Nations community 3.1 km east of the mill. For this report, since the trends at the three stations were similar, data will be shown primarily for Site # 2.

TRS monitoring at the three ambient stations Since the integrated pulp and paper mill was the only significant source of TRS in the community, the TRS data set was quite useful in identifying the specific wind directions (at the stations) that corresponded to emissions from the mill sources. A depiction of the ambient 1-h TRS concentration versus the wind direction, for Station #2 is provided in Figure 2. It is important to note that the 1-h average data pulpandpapercanada.com

points shown in the figures do not include those produced under conditions of calm winds. Wind conditions are assumed to be calm when the wind speed is below 1 m/s (3.6 km/h). The rationale for removing these data points is that under calm wind conditions, the correlation between the ambient TRS and the wind direction would lose its significance as the wind direction has little bearing on the original source, since the wind monitor will swing randomly due to small puffs of air.

For the 1-h TRS data from Station #2, a clear relationship between the 1-h ambient TRS concentrations and wind direction was noted. At this location, the mill was found to influence the station when the wind was coming from a direction of between 200â&#x20AC;&#x201C;240 degrees. For the nineteen-month period that the TRS data were generated, we had an interesting opportunity to examine the extent to which capital projects at the mill impacted the ambient levels of TRS in the community. Ambient TRS data were available from all three stations for the period from February 6, 2004 until November 2, 2005.

During this period (specifically, on November 30, 2004), the mill finished the installation of a dilute non-condensable gas (DNCG) collection system. The facility conducted advanced emission modeling to determine which sources were the major contributors to odours in the community and based on this assessment the DNCG system collected a total of 11 emission sources which discharged from 38 different process points in the kraft mills. The process points collected included chip bins, black liquor storage tanks, brown stock washers, soap tanks, and various seal tanks.

The collected gases are burned in one of the chemical recovery boilers located on site.

The 1-h TRS data from the three monitoring stations were analyzed statistically using Sigmaplot. For each station the TRS data collected when the wind was coming from the direction of the mill were sorted into pre-DNCG and post-DNCG installation. A box plot representation of the data is provided in Figure 3. The box plot diagram separates the data into various percentiles. The figure illustrates that the installation of the DNCG system caused a significant reduction in the ambient level of TRS in the community. For Station #1 and #2, the reduction in the average TRS level was found to be 82%

FIG. 1. Location of the three ambient air monitoring stations in relation to the integrated kraft pulp and paper mill (encompassed by the box).

and 70%, respectively. For Station #3 the reduction in the ambient TRS level was observed to be 43%. It is not surprising that Station #1 and #2 showed the largest TRS reductions since they are closest to the mill and hence would be most affected by the low-level sources that were targeted by the DNCG installation. Given that Station #3 is farther from the facility, it is expected that the taller combustion stacks would have a greater influence than the lower level sources.

In May 2006 the mill shut down the older chemical recovery boiler located at the site and there was an additional reduction in TRS noted in the far field station (data not shown in this report). From the data in Figure 3, it is also interesting to note that the spread in the data was smaller and the 95th percentile was significantly reduced after the installation of the DNCG system. Clearly, at this facility, the DNCG system targeted the key TRS sources and led to a significant improvement in ambient air quality for TRS. PM2.5 monitoring at the three ambient stations For an analysis of ambient PM2.5 levels, since there are numerous other sources contributing to the overall burden of this contaminant into the airshed, identification of the potential contribution of the mill was more complex than was the case for TRS. Two approaches were utilized for the analysis of the data. The first approach examined the statistical changes in the 1-h average PM2.5 values (excluding calm wind data points) for different wind directions.

This would allow the contribution of different sectors to be more fully elucidated.

Of course, this approach has some limitations since there could be other sources, near or far, that are also aligned with a given wind direction. For example, when the PulP & PaPer Canada April 2009

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FIG. 2. Ambient 1-h TRS concentrations versus wind direction for Station #2.

wind is coming from the direction of the mill, the influence of background levels, other sources located farther downstream from the mill, or long-range transport could also be having an input on the levels of PM2.5 that are measured at the ambient monitoring trailer. The second approach focused on an examination of the data generated during periods when the daily (i.e., 24-h) ambient PM2.5 concentrations were elevated. Since the overall goal is to reduce these episodes and hence improve air quality, what is occurring on these elevated days is extremely important. Statistical analysis of the database, for these elevated conditions, could potentially help identify the sources or regions in the town that were contributing to these higher ambient levels.

Statistical analysis of 1-h PM2.5 data versus wind direction at Station #2 Given that Station #2 was situated at the southern edge of the city, it was ideally located so as to compare the impact of the city in relation to the kraft mill and other industrial sources. This station would be impacted by emissions from the town for winds coming from 0–90 degrees. Industrial sources (coal power plant, newsprint mill, sawmill, and lumber kilns) originated from wind directions of 90–180 degrees.

The kraft mill emissions came from wind directions of 200–240 degrees (as indicated by the TRS data in Figure 2). The remaining wind directions of 240–360 degrees were mostly affected by residential activity and the influence of the airport.

A comparison of the ambient 1-h PM2.5 concentrations versus wind direction is 22

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FIG. 3. Comparison of the ambient 1-h TRS concentrations at the three monitoring stations, before and after the installation of a dilute non-condensable gas (DNCG) collection system.

provided in Figure 4. At this location, the 1-h ambient PM2.5 levels demonstrate obvious elevations for winds coming from the direction of the town/industrial sectors (45–135 degrees) and the mill/residential sectors (200–295).

Interestingly, some of the highest 1-h values (1-h PM2.5 concentrations approaching 120 µg/m3) originated from the residential sector corresponding to wind directions of approximately 250–290 degrees. The reason this sector occasionally shows such high values was thought to be due to the proximity of a house that has a chimney on the roof and a wood-burning stove in the garage. An examination of the data related to this area was further examined to see if there were seasonal effects, which would occur if the source responsible for the high values was indeed the wood burning stove. During the cold winter months (i.e., November to February), when the wood stove would be in use, the bulk of the elevated 1-h PM2.5 values was found to be from the direction of the house and the wood stove. Particularly noteworthy were the data for December 2004 and January 2005 when there were 21/22 and 44/44 periods of elevated PM2.5 that were due solely to the house and woodstove, respectively.

Obviously, the operation of a single wood burning stove has the potential to cause a significant impact on the ambient air quality at the monitoring station. Of course, the reason for this is the proximity of this particular unit to the monitoring station, but it raises the question of the community impact when several thousand wood burning stoves are operating in the community.

A more in-depth analysis of the collected 1-h data points, broken into 22.5 degree segments around Station #2, was also performed. There was found to be considerable variability amongst the different sectors with average 1-h concentrations ranging from 1.9–10.2 µg/m3. The highest 1-h average was associated with winds coming from the direction of the mill (10.2 µg/m3), followed by the town and industrial sectors (6.0–7.1 µg/m3). The lowest 1-h averages of 1.9–3.3 µg/m3 were associated with residential areas. For the 99th percentile analysis, the highest values (48.1 and 49.1 µg/m3) were observed for winds coming from the direction of the woodburning stove and the chimney on the nearby house. The mill direction was the third highest (43.3 µg/m3) followed by the town and industrial sectors (42.1 and 40.6 µg/m3). For this site, the mill emissions, wood-burning stoves, several other sources from the town, and the industrial sectors were found to be important contributors to the ambient air quality for PM2.5.

Statistical analysis of periods when the ambient levels of PM2.5 were elevated The second statistical approach that was employed to compare the influence of the mill to other sectors/sources was an examination of the data generated during periods of poorer air quality (i.e., when the 24-h ambient PM2.5 concentrations were elevated). In order to examine the data set during these periods, the ambient 24-h levels were considered elevated if they exceeded 15 µg/m3. This corresponds to half the typical provincial standards for 24-h PM2.5. For the three stations, the pulpandpapercanada.com

peer reviewed

FIG. 4. Ambient 1-h PM2.5 concentrations versus wind direction

number of days that exhibited levels > 15 µg/m3 were 26 out of 625 days for Station #1, 51 out of 629 days for Station #2 and 44 out of 752 days for Station #3. An examination of the 1-h data points versus wind direction, for the above mentioned days, would provide an indication as to the sources that were having the greatest influence on the poorer air quality.

The analysis of the elevated data points for Station #2 is provided in Figure 5. At this location, the town/industrial sectors accounted for the bulk of the elevated periods (63%). The emissions from the direction of the wood stove/chimney gave the highest daily readings and accounted for 20% of the elevated periods. The emissions from the direction of the mill were lower and accounted for only 16% of the elevated periods. Analysis of the elevated data points for Station #3 was also examined (figure not shown). At this location, the town/industrial sectors were again the most significant contributors, accounting for 42% of the elevated levels. The emissions from the First Nations community and rural areas were the second highest accounting for 31% of the values. The emissions from the direction of the mill were found to be responsible for 22% of the higher data points.

In terms of ambient air quality, the approach of examining the poorer air quality days allows for a much better understanding of the importance of the various sectors/sources. At the stations, it is clear that the elevated 24-h values that were measured were, in large part, due to sources other than the emissions from the mill.

This strongly suggests that wood-burning pulpandpapercanada.com

FIG. 5. Examination of 1-h data points collected when the daily PM2.5 levels were > 15 µg/m3 for Station #2.

stoves, other town and industrial sources, and residential activities are important contributors to the ambient PM2.5 concentrations that are measured in the airshed.

Hence, any community approach toward improving air quality would have to take a number of these sources into consideration.

Comparison of ambient monitoring data to federal and provincial ambient air criteria A comparison of the 1-h ambient concentrations versus wind direction, as discussed previously, is useful when attempting to examine the influence of various sectors on ambient air quality. In terms of ambient air standards or criteria, however, the average value that is typically considered is based on a 24-h time period. Several provinces have set ambient air criteria solely based on a 24-h time period [8], such as Ontario and Quebec, which have ambient limits for 24-h PM2.5 of 30 µg/m3. For the CanadaWide Standard for PM2.5, achievement of the 30 µg/m3 standard is based on the 98th percentile of the 24-h values, averaged over a three-year period. For the data that were generated in this study, although the stations were not in place for a period of three years, the yearly data are useful in predicting potential compliance with the Canada-Wide Standard.

A box plot of the 24-h average PM2.5 concentrations, for the various locations, is provided in Figure 6. The data in the figure represent all the 24-h values that were calculated during the year. At all three stations, the average 24-h PM2.5 concentrations over the course of one year were found

to be low with values ranging between 4.7 µg/m3 to 7.2 µg/m3. The dotted line in the figure represents the provincial ambient air criteria of 30 µg/m3. At Station #1, this value was not exceeded over the course of one year (100% compliance). At Station #2, the criteria was exceeded three times over a one-year period (99.2% compliance).

At Station #3, two complete years of data were available. In 2004, the provincial criteria were not exceeded (100% compliance) and in 2005 they was exceeded only twice (99.5% compliance). Again, it is important to note that the previous examination of days when the ambient PM2.5 was elevated indicated that the pulp mill emissions were not the primary factor affecting the poorer air quality.

To determine compliance with the Canada-Wide Standard, the 98th percentile is obtained from a complete year’s worth of data. What this means is that for 365 days of operation, the 98th percentile would refer to the 7th highest data point that was generated during that time period. In 2005, the 98th percentiles were 20.7 µg/m3, 24.7 µg/m3 and 20.1 µg/m3, for Stations #1–3, respectively. The 98th percentile for Station #2 was higher than the other two stations, presumably due to the influence of the wood-burning stove. As stated previously, compliance with the Canada-Wide Standard is based on three years of data.

From the data that were generated to date, the trend would strongly suggest that the town would not be expected to exceed the Canada-Wide Standard.

In Canadian cities, Environment Canada operates a range of ambient monitoring stations as part of its National Air PulP & PaPer Canada April 2009

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monitoring Pollution Surveillance (NAPS) network [4]. While none of these stations are present in pulp and paper mill towns, a comparison of their results to our monitoring stations would be quite interesting. The NAPS network examined PM2.5 data in the main urban areas of Canada and several rural areas, providing measurements from coast to coast. The mean 24-h concentrations for PM2.5, generated at the NAPS urban sites, were observed to range from 8.6–17.1 µg/m3. The three rural sites in the NAPS network recorded mean 24-h concentrations ranging from 4.0–6.6 µg/ m3. The mean 24-h PM2.5 data from Stations #1–3 in the pulp mill town ranged between 4.7–7.2 µg/m3. The data therefore indicate that the air quality in the pulp and paper town is very similar to what has been observed in rural areas in Canada and is consistently lower than what has been measured in urban towns.

It is also clear from the NAPS network data that all of the urban sites would be expected to exceed the Canada-Wide Standard for PM2.5, while the pulp mill town would be expected to be well below the regulated level.

SUMMARY

Ambient monitoring of TRS and PM2.5 in a large city near the vicinity of an integrated pulp and paper mill was instrumental in order to better understand the potential impact of the mill emissions on ambient air quality. For ambient TRS, the data demonstrated a 99.9–100% compliance with the province’s ambient air regulations. In addition, the mill’s installation of a dilute non-condensable gas (DNCG) collection system midway through the study resulted in a significant reduction (43–82%) in the levels of ambient TRS in the community. For ambient PM2.5, statistical analysis of the data clearly indicated that the emissions from the mill were not the most important contributor towards the ambient levels that were measured at the three stations. During poor air quality episodes, it was clear that the elevated values were, in large part, due to sources other than the emissions from the mill. Any community approach towards improving air quality would, therefore, have to take a number of these sources into consideration.

ACKNOWLEDGEMENTS

The author wishes to thank Serge Genest and Steve Ellis for their excellent technical assistance, Talat Mahmood for his review of the manuscript, Paprican’s shops and electronics staff for assisting with the construction of the ambient monitoring trailers, and the mill for providing support during the monitoring period. This work was supported by the Maintaining Members of the Pulp and Paper Research Institute of Canada. Partial financial support for the work was provided by Natural Resources Canada, Environment Canada, and Technology Partnerships Canada.

REFERENCES

1. Ontario Standards Development Branch, EBr registry Number PA05E0030, available at: www.ene.gov.on.ca/envision/env_reg/er/documents/2005/airstandards/PA05E0030.pdf.

2. A report by the CEPA/FPAC Working Group on Air Quality Objectives and Guidelines, “National Ambient Air Quality Objectives for Particulate Matter: Science Assessment Document”, April 1999. Available from: Director, Science Assess-

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FIG. 6. Comparison of the 24-h PM2.5 averages at the three monitoring stations (the box plot illustrates all the data points that were generated). ment and Policy Integration Division Atmosphseric Environment Service, 4905 Dufferin St., Toronto, ON., M3H 5T4 or online at: www.hc-sc.gc.ca/bch.

3. Canada-Wide Standards ratified by the Canadian Council of Ministers of the Environment, June 5–6, 2000. Document available at: www.ccme.ca/3e_ priorities/3ea_harmonization/3ea2_cws/3ea2.html.

4. BrOOk, J.r., DANN, T.F., and BurNETT, r., “The relationship among TSP, PM10, PM2.5 and inorganic constituents of atmospheric particulate matter at multiple Canadian locations”, J. Air Waste Manage. Assoc., 47:2–19, 1997.

5. O’CONNOr, B., “A survey of PM10 and PM2.5 emissions from the Canadian pulp and paper industry”, Paprican, Mr 390, November 1998.

6. O’CONNOr, B., “Monitoring of Ambient PM10 and PM2.5 in the Vicinity of kraft Pulp and Paper Mills”, PAPTAC Midwest Branch Meeting, Harrison Hot Springs, Sept. 24-26, 2003.

7. O’CONNOr, B., “Determining the Potential Influence of kraft Mill Operations on Ambient PM2.5 Concentrations”, PAPTAC Pacific Coast Branch Conference, Parksville, April 16-17, 2004.

8. Multi-pollutant Emission reduction Analysis Foundation (MErAF) for the Pulp and Paper Sector, Prepared by AMEC Forest Industry Consulting, June 12, 2002.

Résumé: Trois stations de surveillance du SRT et des MP2,5 dans le milieu ambiant ont fonctionné durant une période de 1,7 à 2,2 ans dans une grande ville près d’une usine intégrée de pâtes et papiers.

Les stations ont été soigneusement installées afin de permettre d’établir une distinction entre l’influence de l’usine et celle d’autres sources. En ce qui a trait au SRT ambiant, l’installation par l’usine, à mi-chemin de l’étude, d’un système de collecte de gaz non condensables dilués a permis de réduire de façon importante (43 à 82 %) le niveau de SRT dans la communauté. Quant aux MP2,5, l’analyse statistique des données indique clairement que les émissions de l’usine n’étaient pas le plus important contributeur aux niveaux ambiants mesurés aux trois stations. Lors des épisodes de mauvaise qualité de l’air, il était évident que les valeurs élevées étaient attribuables, en grande partie, à d’autres sources que les émissions de l’usine, ce qui suggère fortement que les poêles à bois, d’autres sources communautaires et industrielles, et les activités résidentielles contribuent de façon substantielle à la teneur en PM2,5 du milieu ambiant déterminée dans le bassin atmosphérique.

Reference:

O’CONNOr, B., WALTON, C. The Influence of an Integrated Pulp and Paper Mill on Ambient Levels of TrS and PM2.5 in the Community.

Pulp & Paper Canada April 2009: T37-41. Paper presented at the 2008 PACWEST Conference in Jasper, AB, Canada, June 18-21, 2008. Not to be reproduced without permission of PAPTAC. Manuscript received October 21, 2008. revised manuscript approved for publication by the review Panel January 2009.

Keywords:

MONITOrING, PArTICuLATE EMISSIONS, TOTAL rEDuCED SuLPHur, AMBIENT CONDITIONS, PuLP MILLS, PAPEr MILLS, AIr QuALITY, POLLuTION, ODOrS

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pulp sludge

Pulp and Paper Sludge as a Barrier Layer in Landfill Closure: A New Opportunity

WINNER OF THE dOuglas jONEs ENVIRONMENTal aWaRd

By M. Van Ham, L. Dampier, K. Morton, S. Mullen Abstract: Abitibi-Bowater Inc. (formerly Abitibi-Consolidated Company of Canada), with the guidance of SYLVIS and the authorization of the British Columbia Ministry of Environment, closed a 1.4 hectare on-site ash landfill using a compacted sludge barrier system. The compacted sludge barrier layer appears to be performing in a manner equal to that of the conventional barrier systems. The use of compacted sludge in landfill closure presents a new opportunity for mills to use pulp and paper residuals in a low-cost, beneficial-use option.

P

ulp and paper sludge has historically been regarded as a waste material destined for disposal, traditionally through combustion or landfilling.

Allocating space and resources to the disposal of this material has become an increasing burden for many in the industry. Recently, beneficial use options have been developed, most involving the application of these residuals to land for soil amendment and fertilization.

Research has identified new opportunities for the use of pulp and paper sludge as a low permeability landfill barrier layer where the sludge material possesses similar engineering properties as clay [1,2].

The function of the barrier layer is critical as it isolates the contents of the landfill from the environment.

Compacted sludge has been used successfully as a barrier layer in landfill closures elsewhere in North America but is not commonly practiced in Canada.

In 2006 Abitibi Bowater Inc. closed a 1.4 hectare (ha) ash landfill using compacted pulp sludge as a barrier layer. This paper presents the study undertaken that assessed and compared the use of pulp and paper sludge to conventional barrier layer materials, and summarizes the activities in the ultimate landfill closure.

Regulatory framework In British Columbia (B.C.), design, closure and post-closure criteria for landfills are specified in the Landfill Criteria for Municipal Solid Waste from the BC Ministry of Environment (MoE). Final cover criteria require that the final cover include a minimum of 1 m of low permeability (hydraulic conductivity < 1 x 10-5 cm/s) compacted soil and 0.15 m of topsoil [3]. These are minimum requirements; quite often more complex closure systems are required to restrict infiltration of precipitation, support vegetation, control landfill gas, restrict access by wildlife, and promote surface drainage.

A landfill closure plan submitted to the MoE must outline the specifics of the closure and be approved prior to commencement of closure activities.

Typical materials used for barrier layers are compacted clay and geosynthetics. While both of these materials can attain very low hydraulic conductivity desirable for landfill closure, material availability and cost can be prohibitive. The beneficial use of pulp sludge in this capacity diverts the material from less desirable disposal alternatives, promotes environmentally protective recycling of readily available product, and could provide cost savings in closure construction activities.

LANDFILL DESIGN CRITERIA

THE ABITIBI BOWATER ASH LANDFILL CLOSURE

Once a landfill has reached capacity, closure activities are undertaken. Closing a landfill serves a multitude of purposes, all with the objective of protecting the environment beyond the active lifetime of the landfill. These objectives include: isolating the refuse from the environment, including animals and humans; preventing vertical infiltration of water into wastes that could create contaminated leachate; controling gas emissions from underlying wastes; creating a land surface that can be used to support vegetation; and reducing or eliminating erosion of the cap surface. pulpandpapercanada.com

Abitibi Bowaterâ&#x20AC;&#x2122;s paper mill is located near the community of Mackenzie, B.C., approximately 185 km north of Prince George. The mill is an integrated thermomechanical pulp (TMP) and paper mill that generates approximately 50 wet tonnes of combined sludge per day (60% primary and 40% secondary), some of which is incinerated in the power boiler for energy with the remaining volume generally landfilled. The average annual rainfall for Mackenzie is 0.36 m, with an average snowfall of 3.26 m. In January and July, the mean

M. VAN HAM, SYLVIS Environmental, New Westminster, BC

L. DAMPIER, formerly of SYLVIS Environmental, New Westminster, BC K. MORTON, formerly of AbitibiConsolidated Company of Canada, Mackenzie Division S. MULLEN, Environmental Consultant, formerly of AbitibiConsolidated Company of Canada, Mackenzie Division

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pulp sludge Fabricated Soil

Fabricated Soil

Drainage Sand

Drainage Sand Geomembrane Drainage Sand

Compacted Barrier Layer (clay or pulp sludge)

Ash Substitute

Drainage Sand Ash Substitute

FIG. 1. Barrier layer comparison profiles.

daily temperatures are -11.4 and 14.9°C respectively [4].

Under permit from MoE, a landfill closure plan was submitted for a 1.4 ha onsite ash landfill owned by Abitibi Bowater.

The plan included the use of compacted pulp sludge in place of clay or geotextiles as the barrier layer. As this type of closure had not previously been undertaken in B.C., the MoE requested an evaluation of the barrier system to run concurrently with closure activities. A barrier layer evaluation study was initiated in fall 2004 and was completed in fall 2006.

STUDY DESIGN

The purpose of the study was to identify whether compacted pulp sludge would perform equally well as a barrier layer as compacted clay and a geomembrane. A barrier plot was constructed for each of the following three treatments: • Treatment 1 – Compacted Sludge • Treatment 2 – Compacted Clay • Treatment 3 – Geomembrane Barrier system treatments The study consisted of a system of above ground barrier plots (Photograph 1). Each plot was 3.0 m by 4.5 m and was constructed with interlocking concrete lock blocks acting as walls. Above the existing soil and inside each plot a geomembrane liner was installed to create a closed system.

The barrier plots were designed to resemble as closely as possible actual conditions in the ash landfill. Each barrier plot was composed of a top cover of fabricated soil, an upper drainage sand layer, a barrier layer, a lower sand drainage layer and a 26

April 2009 PulP & PaPer Canada

Photo 1. Interlocking lock blocks provide the structure of the barrier layer plots. two of three plots are shown here prior to installation of the geosynthetic liner and closure strata.

bottom layer of fabricated soil (ash substitute). A schematic of these strata is found in Figure 1.

While the actual landfill design includes a dome shaped slope to avoid water ponding and reduce surface infiltration, the barrier plots were sloped moderately into the centre to prevent the movement of water off the surface and down the edge of the profile, bypassing the barrier layer.

The top cover was composed of a vegetated layer of fabricated soil. Wood chips, pulp sludge, sand, and ash available on the site were used to fabricate the top cover soil. The soil provides the necessary plant nutrients to quickly establish vegetation.

The vegetated cover reduces water inputs to the landfill system by increasing evapotranspiration. The fabricated soil layer was placed to a minimum of 0.3 m in each barrier plot.

The upper drainage sand layer is designed to act as both an intermediate cover layer and as a drainage layer. The sand protects the underlying barrier layer by restricting the intrusion of plants and animals and by reducing the effects of freezing and thawing. The upper drainage sand layer was 0.3 m deep.

The barrier layer is a critical component of a landfill system as surface water that flows through waste may become impacted with constituents of concern. The pulp sludge used was a mixture of both primary and secondary sludge. Multiple assessments showed the pulp sludge had saturated hydraulic conductivity ranging from 5.36 x 10-7 cm/s to 3.82 x 10-8 cm/s. The clay had a saturated hydraulic conductivity of 1.8 x 10-7 cm/s.

Both the clay and pulp sludge were installed to a depth of 1 m of compacted material.

Any water that permeates the barrier layer must then move through a second sand layer, referred to as the lower drainage layer. As described above, a hydraulic gradient exists between the sand and the underlying fabricated soil which promotes drainage along the surface of the underlying material.

The fabricated soil layer at the bottom of the plot simulates the ash in the landfill.

Any water movement through this layer is of interest as it may become impacted with constituents of concern. The water can then move out of the landfill system and into the underlying soil and groundwater.

Data collection To examine the performance of the barrier systems, soil water samplers (lysimeters) were installed at two depths within each treatment: one in the upper sand drainage layer directly above the barrier layer and one below at the sand/ash substitute interface. Tubing leading from the lysimeters was fed through the concrete lockblocks and into a central sample collection box.

The location of the lysimeters is shown in Figure 2.

Water collected from the upper lysimeter represents water that has moved through the fabricated soil layer and into the upper drainage layer. This water has the potential to move through the barrier layer. Water from the lower lysimeter represents either water already in the system from construction, or water that has moved from the surface to the lower sections of the system.

Gypsum blocks were also installed near the lower lysimeters as a surrogate measure for soil moisture. Gypsum blocks measure pulpandpapercanada.com

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Fabricated Soil Upper Lysimeter

Upper Drainage Sand

Compacted Barrier Layer

Lower Lysimeter

Lower Drainage Sand

FIG. 2. Cross section of a barrier layer comparison profile showing location of lysimeters.

in-situ resistance which can be used to calculate soil water content. These gypsum blocks were wired into a datalogger that was connected to a weather station which collected meteorological data from the site throughout the study period. Weather station data such as rainfall and temperature were utilized in the final assessment.

INSTALLATION

The barrier plot installation was initiated in the fall of 2004 and completed in the spring of 2005. Inclement weather caused construction to be continued into the second year.

Concrete lock blocks were assembled to create three above ground plots (Photograph 1). Holes were drilled into the concrete blocks to create a conduit for tubing in order to collect water samples and link the gypsum blocks to the weather station.

The geomembrane liner was inserted into each plot and secured to the concrete wall.

The landfill cover strata were installed in a similar manner. Material was placed into the plot using a small backhoe and was then contoured to the correct grade and depth by hand (Photograph 2). Material for layers requiring compaction was deposited in three lifts, and was compacted with a vibrating tamper and/or plate compactor after each lift.

Silicone was used to seal any holes in the geomembrane (e.g. where lysimeter tubing exited the system). Clay was placed around the perimeter of the compacted barrier layers and silicone was placed between the liner and the geomembrane barrier layer to minimize the potential for a â&#x20AC;&#x153;short circuitâ&#x20AC;? whereby water travels down the side of the pulpandpapercanada.com

PHOTO 2. Material was placed by a backhoe and contoured to the desired levels by hand.

geosynthetic liner without moving through the barrier system.

The compacted pulp sludge was installed in 2004 while the clay and geomembrane were installed in 2005 (Photograph 3).

It was noted in the spring of 2005 that the exposed compacted pulp sludge had dried out on the surface and that it had undergone further compaction over the winter. Additional pulp sludge was placed and compacted in the plot in the spring to maintain a depth of 1 m.

Measures were taken to keep the plots clear of snow throughout the winter of 2004/05. However, severe winds exposed the barrier plots to snow that entered the system after the liners were installed and before all strata had been installed.

An irrigation system was installed in the event that dry summer weather would not produce any soil water for analysis. The barrier plots were irrigated with approximately 250 mm of water in 2005 and 120 mm in 2006. A weather station was installed adjacent to the test plots to collect meteorological data for the duration of the study (Photograph 4).

MONITORING

To quantitatively evaluate the performance of the barrier layers, lithium bromide (LiBr), a common soil water tracer, was applied to the surface of the barrier plots in the summer of 2005. Lithium bromide is used extensively in soil water studies in a number of different disciplines. Lithium bromide is considered a conservative tracer, meaning that it is not typically sorbed to colloidal surfaces nor is it significantly chemically or biologically altered by soil. It

is relatively simple to quantify and it occurs at low natural concentrations. In addition, LiBr is a salt which does not adversely affect the environment. Lithium bromide is often considered an effective, relatively low cost tracer for use in soil water studies [5,6].

A second soil water tracer, pentafluorobenzoic acid (PFBA), was applied to the soil surface in the summer of 2006. PFBA was selected for its resistance to degradation, low potential for aquatic toxicity and its lack of occurrence in the natural environment [7,8]. Pentafluorobenzoic acid has been used extensively in soil water studies in a number of different disciplines and is often used as a substitute for bromide. PFBA has also been found to be a more suitable non-reactive tracer than bromide in the presence of plants [9].

Soil water collection events for the upper and lower lysimeters of each treatment were conducted on five occasions in 2005 and six occasions in 2006 including purge events. Soil water was extracted using a vacuum pump system and collected in clean glass sample bottles. Samples were analyzed for a number of parameters depending upon sample volume including pH, conductivity, nitrate and nitrite, bromide, PFBA and trace elements.

A soil pit was dug in each of the treatments in the fall of 2005 and the fall of 2006 at the eastern edge of the treatments.

These pits were used to qualitatively assess barrier layer performance and to collect soil moisture from the upper strata just above the barrier. The eastern edge was selected as it was the farthest from the lysimeters and would minimize disturbance to the PulP & PaPer Canada April 2009

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pulp sludge

PHOTO 3. Clay and pulp sludge were compacted in three lifts using a vibrating plate tamper. The level of compaction was confirmed prior to sand placement.

system. Although a single sample per year does not provide an exhaustive inspection, the concern over plot disturbance limited the extent of this physical inspection.

RESULTS AND DISCUSSION

At each sampling event an attempt was made to extract exfiltrate from all treatments. Exfiltrate volume data are provided in Table I. Periodically the treatments either did not yield a sample, or yielded an insufficient volume to conduct analysis. As such, a complete data set consisting of an equal number of samples collected from each treatment both above and below the barrier layer was not possible. A general discussion of the observable trends is discussed in the following sections.

Exfiltrate quantity Water was collected from above and below the barrier layer in each treatment. Although there is some variation between the values obtained both between and within treatments, it is important to note that these volumes are extremely low when compared to the total input of water to the system through irrigation and precipitation.

Less water was collected from above the barrier layer than was anticipated, despite irrigation events. This was likely a result of greater than anticipated assimilation by plants and atmospheric evaporation.

Established vegetation on the barrier treatments was significantly greater in density and biomass than adjacent natural vegetation indicating that the vegetation was capitalizing on the readily available soil nutrient and utilizing water inputs.

It was anticipated that very little water would be extracted from the lower sec28

April 2009 PulP & PaPer Canada

PHOTO 4. The final barrier layer plots showing sample collection box at centre and the weather station.

Table I: exfiltrate volume (ml) from 2005 and 2006 sampling events.

Sample Date

20-Jul-05 24-Aug-05 25-Aug-05 4-Oct-05 5-Oct-05 7-Jun-06 13-Jul-06 1-Sep-06 6-Sep-06 14-Sep-06 6-Oct-06 Total(c) (a) (b) (c)

Treatment 1 Pulp Sludge Upper Lower 50 n/a(a) n/a 395 345 585 650 - (b) 280 375 2,680

60 n/a n/a 250 45 900 260 100 100 50 1,765

Treatment 2 Clay Upper Lower 440 n/a n/a 485 175 400 10 20 1,530

320 n/a n/a 410 175 100 400 700 625 500 750 3,980

Treatment 3 Geosynthetic Membrane Upper Lower 260 n/a n/a 475 170 300 350 50 625 2,230

350 n/a n/a 485 55 200 350 200 720 380 550 3,290

n/a - not available due to internal lab error.

Dash indicates no sample volume was collected.

Estimated total does not include exfiltrate collected during the August 24 and 25 sampling events.

tions of the barriers; however, detectable volumes were extracted in almost every sampling event. Some of the water in the lower sections originated as precipitation entering the system prior to final compaction and closure of the barrier layer.

Overall for the sampling events where data are available, less water was collected from below the pulp sludge than the other two treatments.

Tracer applications Lithium bromide was applied in the summer of 2005 immediately preceding an irrigation event. Results of the LiBr monitoring were inconclusive with virtually no bromide detected above any of the barrier layers and with bromide found in each of the lower treatments during at least one sampling event. There was evidence of a possible short circuit causing elevated bro-

mide levels in the pulp sludge treatment.

Results were less ambiguous with the PFBA tracer. Due to the concern over short circuiting the PFBA was applied only to the centre of the plot with subsequent irrigation covering only the centre of the plot as well. Pentafluorobenzoic acid was detected in exfiltrate collected from above the barrier layers in all treatments; none was detected below the barrier layers.

This indicates that PFBA was present in detectable concentrations above the barrier layer but did not move through the profile to the lower sample collection point by the sample collection period.

Soil water content Gypsum block data indicated that all three treatments exhibited some seasonal variability in soil moisture content and showed a spike from the 2005 irrigation event. pulpandpapercanada.com

peer reviewed

PHOTO 5. Pulp sludge compacted by dozer.

The 2006 irrigation event where water was applied only to the central portion of the plot did not yield a spike. This indicated that there was a short circuit along a portion of the edge of the barrier plots.

Soil was collected in soil tins from above the barrier layers in 2005 and 2006 to assess moisture content. The soil was dried in an oven at 105째C for 24 hours. In both 2005 and 2006 a wetting front was observed where more moisture is found at the sand/barrier interface than the soil/ sand interface. In the 2006 sampling event standing water was observed on the surface of the pulp sludge barrier layer (at the sand/pulp sludge interface). During both events an anaerobic odour was detected indicating a lack of oxygen and saturated conditions.

Exfiltrate quality Although an assessment of exfiltrate quality does not necessarily imply level of function of the barrier layer, it was conducted in order to better understand the processes within the barrier system.

In both 2005 and 2006, analytical results indicated that the electrical conductivity was higher in the water collected from below the compacted pulp sludge than that observed in the other two treatments. This is likely attributable to the higher salt content in the pulp sludge as compared to the other barrier layers. As the pulp sludge was compacted it is likely that some water containing these salts would have moved out of the compacted material and into the bottom of the barrier plot where it was sampled.

Nitrate and nitrite levels in the soil water varied substantially by treatment and pulpandpapercanada.com

PHOTO 6. Placement of soil above the upper sand drainage layer.

by the position above or below the barrier layer. This may be due to varying rates of nitrification. Nitrification is the process by which ammonium or ammonia is oxidized via nitrite to produce nitrate.

In 2005, both the pulp sludge upper and clay upper treatments had extremely low levels of nitrate and nitrite. The lack of nitrate and nitrite in these two treatments can be explained by several processes. Physical sorption can occur between ammonia molecules and the surface of clay minerals or humic colloids. In addition, significant amounts of ammonia can also be fixed in non-exchangeable forms by organic matter. The pulp sludge upper and clay upper treatments have a multitude of potential sorption or fixation sites for ammonia ions.

The remaining ammonia may undergo nitrification to become nitrite and nitrate.

However nitrate is the predominant form of plant-available nitrogen, therefore the nitrate produced in these two treatments was likely quickly assimilated by the rapidly growing vegetation.

The membrane upper treatment, on the other hand, had much higher levels of nitrate and nitrite. Unlike the clay and pulp sludge barrier layers, the geosynthetic membrane does not provide any sorption or fixation sites for ammonia. Available sites are limited to the soil layer above, therefore the majority of the ammonia in the system can be nitrified, resulting in increased concentrations of nitrite and nitrate.

For samples collected from below the barrier layer, higher levels of nitrite and nitrate were observed in the clay and geomembrane treatments. Oxygen is a critical component of the nitrification pro-

cess and the lack of oxygen is rate limiting.

In the pulp sludge treatment the barrier layer was installed and compacted in October 2004 while the clay and geomembrane treatments were open to the atmosphere until late June 2005. Limited oxygen available for nitrification in the pulp sludge lower may explain this difference between treatments.

In 2006, insufficient sample volume for nutrient analysis did not provide data across all treatments for the upper profile.

However, foliar analysis of the overlying vegetation showed elevated nitrate levels in plant tissues, particularly in the clay and pulp sludge treatments. Below the barrier layers, nitrate and nitrite concentrations were below the detection limit for each sampling event.

STUDY CONCLUSIONS

Compacted sludge was evaluated as the barrier layer of a landfill closure system, and assessed to determine the ability to use this material as a substitute for clay or geosynthetic membrane.

The quantity of exfiltrate collected from above the barrier layers in each treatment was lower than anticipated overall due to uptake by plants, atmospheric evaporation, and low inputs as precipitation. While collection of exfiltrate below the barrier layers in each treatment was variable, it was generally greater than anticipated, while remaining low in comparison to water inputs both by rain and artificial precipitation inputs. All three barrier systems restricted water inputs to the subsurface layers.

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pulp sludge content over time, these changes are primarily seasonal and observed across all treatments. Spikes related to heavy irrigation events existed for the irrigation event in August 2005 but not the event in September 2006. This indicates that the application of irrigation water to the central section of the treatments may have prevented the movement of water through a short circuit.

While the LiBr tracer study in 2005 yielded inconclusive results, PFBA was identified in the upper profile of all treatments and was not found in the lower profile of any. Other exfiltrate analyses failed to identify a performance failure in any of the barrier systems.

Without a sloping drainage and barrier layer, the precipitation inputs – through artificial irrigation and rainfall/snowfall – have no opportunity for run-off, creating a significant hydraulic pressure on the barrier systems. It appeared that some volume of water entered the lower part of the system in all three treatments. The resistance recorded by the gypsum blocks as a surrogate for soil moisture did not consistently show an immediate response to heavy irrigation events through a drop in resistance (increase in soil water content). As care was taken to reduce the potential for short circuiting during events that do not show a resultant spike in resistance (or soil water content), it is possible that a minor short circuit was present in isolated sections of the barrier plots. Observations of soil water content and the integrity of the barrier layer in each treatment indicated that water was held above the barrier.

Vegetation establishment was dense over all the barrier systems and resulted in significant moisture storage and evapotranspiration losses. Soil nutrient (nitrogen) concentrations appeared to be influenced by the barrier layer, with less available nitrogen in the membrane barrier layer. This is attributed to moisture and nitrogen cycling dynamics.

The compacted sludge barrier layer performed in a manner equal to that of the other barrier systems.

LANDFILL CLOSURE

The closure of the 1.4 ha ash landfill proceeded concurrently with the study and was initiated in the spring of 2005 with the placement of the intermediate sand cover layer. A single lift of pulp sludge 30

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PHOTO 7. Grasses were seeded in October 2006 and germinated in the spring of 2007.

was placed in the fall of 2005 (Photograph 5). In the summer and fall of 2006 the remaining pulp sludge barrier layer, sand drainage layer, and topsoil layer were completed (Photograph 6).

The pulp sludge was delivered to the site using end dump trucks and placed with a wide track bulldozer. The material was compacted by passing over it multiple times with the bulldozer. Both fresh (as produced) and aged (removed from sections of the pulp sludge landfill) pulp sludge was used to complete the barrier layer in multiple lifts. Compaction testing of the pulp sludge was conducted on five separate occasions and indicated that the described application methods attained the required level of compaction.

Overwinter consolidation of material previously compacted was observed, similar to observations from the barrier layer test plots. Construction challenges centered about delivering materials to sections of the landfill where sludge had already been placed. Vehicle ruts required ongoing repair to avoid contamination of the different strata.

The landfill was closed in October 2006 and seeded with vegetation. Vegetation germinated in spring 2007 (Photograph 7).

REFERENCES

1. KRAUS, J.F., BENSON, C.H., VAN MALTBY, C., WANG, X. Laboratory and field hydraulic conductivity of three compacted paper mill sludges. Journal of Geotechnical and Geoenvironmental Engineering July (1997).

2. VAN MALTBY, C. Compilation of alternative landfill cover experience using wastewater treatment plant residuals. NCASI Technical Bulletin No. 900, Kalamazoo, MI (2005).

3. British Columbia Ministry of Environment. Landfill Criteria for Municipal Solid Waste, Section 6.3. www. env.gov.bc.ca/epd/epdpa/mpp/lcmsw.html (1993).

4. Environment Canada. Climate Data On-line, www.climate.weatheroffice.ec.gc.ca/climateData/ canada_e.html (2005).

5. LEVY, B.S. and CCHAMBERS, R.M. Bromide as a conservative tracer for soil-water studies. Hydrological Processes 1:385-389 (1987).

6. BOWMAN, R.S. Evaluation of some new tracers for soil water studies. Soil Science Society of America Journal 48:987-993 (1984).

7. MCCARTHY, J.F., HOWARD, K.M., and MCKAY, L.D. Effect of pH on sorption and transport of fluorobenzoic acid ground water tracers. Journal of Environmental Quality 29:1806-1813 (2000).

8. HU, Q. and MORAN, J.E. Simultaneous analyses and applications of multiple fluorobenzoate and halide tracers in hydrologic studies. Hydrological processes 19:2671-2687 (2005).

9. PEARSON, R.J., INSKEEP, W.P., WRAITH, J.M., COMFORT, S.D., and GABER, H.M. Observed and simulated solute transport under varying water regimes: I. Bromide and pentafluorobenzoic acid.

Journal of Environmental Quality 25:646-653 (1996).

Résumé: La société Abitibi-Consolidated Company of Canada, Division Mackenzie (Abitibi), sous la conduite de SYLVIS et avec l’autorisation du ministère de l’Environnement de la ColombieBritannique, a isolé une décharge de cendres de 1,4 hectare avec une barrière de boues compactées. Ce type de barrière semble agir de la même manière qu’une barrière classique. L’utilisation de boues compactées pour fermer une décharge permet d’utiliser les résidus des pâtes et papiers des usines comme une option avantageuse à faible coût.

Reference: VAN HAM, M., DAMPIER, L., MORTON, K., and MULLEN, S. Pulp and paper sludge as a barrier layer in landfill closure: A new opportunity. Pulp & Paper Canda, April 2009: T42-47. (April 2009). Paper presented at the 2008 PACWEST Conference in Jasper, Alta., June 18-21, 2008. Not to be reproduced without permission of PAPTAC. Manuscript received April 04, 2008. Revised manuscript approved for publication by the Review Panel November 12, 2008.

Keywords: PULP SLUDGE, ASH, LANDFILL CLOSURE, BARRIER LAYER pulpandpapercanada.com

pulp bleaching

Final Pulp Bleaching by Ozonation: Chemical Justification and Practical Operating Conditions

WINNER OF THE I.H. WELDON AWARD

By D. Lachenal, G. Pipon, and C. Chirat Abstract: In an attempt to understand why, in pulp bleaching, the final brightness points are so difficult to gain despite the very low content of residual chromophores, several model compounds representing chemical structures which may still be present in semi-bleached pulp were submitted to various charges of chlorine dioxide and ozone. Depending on the model (quinones or lignin fragment) and on the reagent, different results were obtained. ClO2, when it reacted with the lignin fragment, generated new coloured chromophores which were resistant to further degradation. O3 also produced new coloured groups. However, the latter were entirely degraded with an excess of reagent. Moreover, the quinone models were very reluctant to degradation

by ClO2. On the contrary they were easily destroyed by O3. These results may explain the pulp resistance to chlorine dioxide in final bleaching and the better efficiency of an ozone treatment for this purpose.

The conditions of an ozone stage performed at the end of a bleaching sequence were not as critical as when ozone served as delignifying agent. It was shown that the ozone stage could be advantageously conducted at high temperature (80°C).

T

he colour of unbleached pulp is mainly due to chromophores which are formed on lignin during kraft cooking.

Even though wood carbohydrates may in theory form coloured substances, their presence in unbleached pulp has never been proved. Moreover, a recent study showed that such chromophores, if they exist, should be easily destroyed and should not survive the first bleaching stages [1]. It has been proposed that the last chromophores still present in the pulp at the end of the bleaching process would contain quinone groups possibly attached to phenolic residues [2, 3]. Considering the tiny quantities in which those chromophores must be, the reason why a relatively large excess of reagents must be applied to get rid of them is difficult to understand. Also, no justification really exists as to the rationale of using chlorine dioxide at that position.

Bleaching sequences of the D (EO) DED type are today considered the reference. Because some pulps did not respond very well to this treatment it has been proposed to add some peroxide in the extraction stages. Very often this solution is more economical than increasing the chlorine dioxide charges [4]. More recently ozone was proposed to replace or complement the last D stage [5]. Spectacular results were observed, with ozone quantities as low as 0.05% being claimed to increase the final brightness by several units [6]. Applying ozone at this position was different from its previous uses.

In particular an acidic pH was not required which represented a definite practical advantage. It also indicated that the chemistry of final bleaching was not the same as that prevailing in the first stages

and was likely more related to colour removal than to delignification. Finally, if one admits that two different chemistries are required during the whole bleaching process, one may argue about the justification of using one single reagent (ClO2) in the whole bleaching process.

Actually, very few basic investigations have been carried out so far to understand the chemistry involved at the very end of the pulp bleaching process [2, 3].

One way to approach this understanding is to investigate the effect of the bleaching agents on the chemical structures likely to be present at the latest stage of the process. A lot of work has already been done on the mechanism of lignin degradation during chlorine dioxide or ozone stages [7, 8]. Ring opening and resulting introduction of carboxyl groups on the lignin moieties offer reasonable explanation for lignin removal.

Even though the formation of new chromophores has been mentioned, like quinones in the case of chlorine dioxide [7, 9], no particular attention has been paid to the evolution of colour during bleaching nor to the chemistry of some coloured groups such as quinones.

In the first part, this paper will concentrate on the evolution of colour when chromophores models react with chlorine dioxide and ozone. In a second part it will be shown that ozone bleaching can be performed under conditions which improve its efficiency.

EXPERIMENTAL

Pulp samples Two mixed hardwood kraft pulp samples (bright-

D. LaChenaL Grenoble INP-PagoraSt. Martin d’Hères, France

G. PiPon Grenoble INP-Pagora St. Martin d’Hères, France

C. Chirat Grenoble INP-Pagora St. Martin d’Hères, France

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pulp bleaching ness 83.7% and 85.1% ISO) were provided by the Alizay mill in France. The pulp had been bleached in the mill by the D0 (EP) D1 sequence and sampled ahead of the final D2 stage.

6 mmol l-1 (except for naphthoquinone: 1 mmol l-1). These concentrations were chosen in order to be in the suitable range of absorbance of the spectrophotometer (Unicam UV500, Thermospectronic).

Reagents and bleaching stages Ozone was produced in a laboratory ozone generator (LN 103, Ozonia) from pure oxygen at a concentration of 50-60 mg l-1.

Chlorine dioxide was produced in the laboratory from the reaction between sulphuric acid and sodium chlorite at a concentration of 8 g l-1 in water. For practical reasons the Z stages were carried out at high consistency. The mill pulp was diluted in process water, then centrifuged to 35% consistency and fluffed. The ozone treatment was carried out in a rotating spherical glass reactor at the desired temperature (from 20 to 80°C). Ozone charges varied up to 0.2% on pulp. D stages were carried out at 10% pulp consistency in plastic bags placed in a thermoregulated water bath. D Stages were performed at 80°C for 3 hours.

After bleaching, brightness and cellulose state of polymerization (DP) were measured according to the ISO standards (ISO 3688 and 5351 respectively). Prior to DP measurement the pulp was reduced with 2% NaBH4 and 1% Na2CO3 at 10% consistency and room temperature for 30 min. Post colour number was the difference (x100) between K/S after aging at 105°C for 24 h and before.

Ozone treatment 1.5 mmol (0.25 mmol for naphthoquinone) of the compounds were dissolved into 250 ml of deionized water. This solution was ozonated in a glass flask by injecting directly gaseous ozone at 20°C. This temperature is low enough to favour ozone solubility. The quantity of ozone that was introduced in the solution at a flow rate of 1 l min-1 was measured by an ozone analyzer (BMT 961). The residual gas was directed to a 400 ml trap solution of 20 g l-1 potassium iodide (Roth) where it was titrated by iodometry. Thus, the exact quantity of ozone consumed by the solutions of the model compounds could be calculated by difference.

Model compounds Para-benzoquinone (Lancaster Synthesis), sulphonated naphthoquinone (1,2 naphthoquinone-4-sulfonic acid, sodium salt, Aldrich), and sulphonated softwood lignin (lignosulfonic acid sodium salt, Aldrich) were commercial products. The molar mass of the “phenylpropane unit” of the sulphonated lignin was 247 g mol-1 as indicated by the supplier. The formulas of the three models are the following: CH2CH O

CH

O

SO3Na CH

O

O Parabenzoquinone

SO3Na 1,2 Naphtoquinone-4sulfonic acid sodium salt

OMe OH Lignosulfonic acid sodium salt

Reaction of model compounds Aqueous solutions of the model compounds were treated at a concentration of 32

April 2009 PulP & PaPer Canada

Chlorine dioxide treatment 1.2 mmol (0.2 mmol for naphthoquinone) of the compounds were dissolved into 100 ml of deionized water. Then, a given quantity of deionized water and of chlorine dioxide was added to reach 200 ml. This solution was maintained in a closed and opaque reactor at 70°C and under agitation during half an hour. Then, it was cooled in an ice bath till its temperature reached 20°C. As chlorine dioxide has a yellow colour which can interfere in the visible spectra, the residual chlorine dioxide was removed by a flow of nitrogen gas injected directly in the solution. The extracted chlorine dioxide was directed into a 350 ml trap solution of 20 g l-1 potassium iodide where it was titrated by iodometry.

The effects of ozone and chlorine dioxide on the model compounds were followed by UV-Vis spectrophotometry at 457 nm. The advantage is that this wavelength is used for the measurement of the brightness of pulp and paper. An exception was para-benzoquinone for which the analysis was performed at 427 nm since the absorbance at 457 nm was very low. The pH was monitored in all cases.

RESULTS AND DISCUSSION

Final bleaching with chlorine dioxide and ozone The mixed hardwood kraft pulp of 85.1% brightness was treated with chlorine diox-

Table I. Final bleaching of a kraft mixed hardwood kraft pulp: brightness against chemical charge.

Reagent,% 0 0.05 0.10

0.20 0.27

ClO2 O3

87.2 88.0 89.5 -

85.1 85.1 87.8

86.0 88.7

ide (D stage) and with ozone (Z stage).

The results in Table I clearly show the superiority of the ozone over chlorine dioxide in final bleaching. The reason for such a difference must be related to the nature of the chromophores still present in the pulp before final bleaching.

Even though those chromophores are not precisely known it seems reasonable to assume that they should contain phenolic and quinone groups belonging to residual lignin fragments [2, 3]. Three models were chosen to cover these possibilities: a commercial lignin (lignosulphonate was preferred in order to enhance the solubility in neutral conditions), para-benzoquinone, and naphtoquinone (sulphonated for the same reason). Solutions of the models in water were submitted to D and Z conditions and the colour of the solution was followed by measuring the absorbance at 457 nm or 427 nm. The results are given in Figures 1-3.

Figure 1 shows that the colour of the lignin solution first increased during the treatment. Then colour removal took place. It was interesting to notice that colour was not completely eliminated when ClO2 was used in large excess, contrary to what happened with O3 which ultimately led to a colourless solution. In the case of ClO2 treatment, colour formation may result from the formation of quinones as described in many studies dealing with the ClO2 oxidation of the phenolic units in lignin [7]. Quinones should not be formed during ozonation. However new carbonyl groups are created which may increase the light absorption of the existing chromophores. Further application of the reagents reduced the colour. Total destruction of the original and new chromophores was possible with O3 only. Some of them resisted the ClO2 treatment.

Figure 2 confirms that quinone groups were rather resistant to ClO2 oxidation but were degraded by O3. Both Figures 1 and 2 clearly suggest that ozone would be more appropriate to destroy pulp chromophores, which is in accordance with the bleaching results in Table I. pulpandpapercanada.com

peer reviewed Ozone treatment as final bleaching The use of ozone in pulp bleaching has been implemented in more than 30 bleaching lines worldwide. The justification of introducing ozone in a bleaching sequence is mainly economical.

The fact that in theory one mole of ozone (48 g) can exchange 6 electrons against only 5 for 67 g ClO2 makes it a cheaper alternative. Moreover ozone reactivity is such that any unsaturated group in lignin readily reacts with ozone, which is not the case with chlorine dioxide.

Ozone operating conditions have been carefully looked at in order to minimize ozone decomposition, favour lignin degradation, and avoid cellulose depolymerization. It is well documented that ozone delignification should most favourably take place at acidic pH (between 2 and 3) and at the lowest temperature possible. When used in final bleaching the level of pH was not found critical [5] and close to neutral conditions gave good results. This may have something to see with the fact that the target of ozone reaction is then some resistant chomophores, rather than lignin, which would require a different chemistry. In this new application the effect of temperature has never been investigated. However this parameter is of interest since the pulp at this stage must be at least around 70°C. The following figures refer to the influence of temperature in the ozone final bleaching of the hardwood kraft pulp of initial brightness 83.7% ISO. Figure 3 shows that, contrary to what was expected, brightness development was better at the higher temperatures, despite the fact that ozone stability should have been less. One reason could be that the oxidized chromophores are more soluble at higher temperature. However attempts to obtain the same effect by submitting the pulp treated by ozone at 20°C to a water extraction at 80°C for 30 min. failed. Therefore it is likely that the higher the temperature the better the chemical degradation of the chromophores by the ozone, which remains to be understood.

The better bleaching is obtained at the expense of some cellulose depolymerization (Figure 4). However, the loss in DP was moderate and should not modify the mechanical properties of the hardwood pulp significantly.

Finally, the increase in temperature improved the brightness stability of the pulp (lower PC number) (Figure 5). At low temperature (20°C) some loss in brightness stability accompanied the bleaching effect of ozone. At 80°C brightness stability was the same as the original one before the ozone treatment. Explanation for this effect has not been found yet.

CONCLUSIONS

ECF bleaching sequences are based on the extensive use of chlorine dioxide. No other reagent is necessary in the sequence to obtain fully bleached pulps, provided that sufficient charges of chlorine dioxide are applied, even though some oxygen or hydrogen peroxide are added in the extraction stages to reduce the bleaching cost. However a close examination of the ClO2 requirements in the successive D stages shows that ClO2 becomes less and less efficient as the bleaching progresses. In fact, considering the tiny quantities of coloured matters in the pulp before the last bleaching stage, much lower charges of ClO2 should be required.

This study demonstrates that phenolic lignin fragments may pulpandpapercanada.com

FIG. 1. Behaviour of lignin solution when treated by increasing amounts of ClO2 and O3.

FIG. 2. Colour removal during ClO2 and O3 treatment of quinones in water solution. (a) naphtoquinone (b) parabenzoquinone.

actually develop some new colouration when they react with small quantities of ClO2. These new chromophores will not be then entirely destroyed with further quantities of reagent. Moreover, this study illustrates the fact that quinones, which are also claimed to be possible residual chromophores, are very reluctant to react with ClO2. Therefore, reasons for the low efficiency of chlorine dioxide in last bleaching stages could be either the formation of stable chromophores (possibly quinones) when ClO2 reacts on lignin fragments, or the presence of quinones already in unbleached pulp, which will not readily react with ClO2.

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pulp bleaching

FIG. 3. Effect of ozone stage temperature on pulp brightness (pH 3, 0.18% ozone charge, original brightness 83.7%).

FIG. 5. Effect of ozone stage temperature on pulp brightness stability (conditions as on Fig. 3, original PC number 0.74).

The behaviour of ozone was shown to be very different.

Although new chromophores are also formed when ozone reacts on lignin fragments, those coloured groups will not resist further ozonation. Also, the quinones models used here were easily degraded by the ozone. Those chemical considerations would explain why the potential of ozone in final bleaching was found better than that of chlorine dioxide.

Ozone delignification is known to work better at lower temperature. However, pulp temperature in final bleaching is usually between 70 and 80°C. Contrary to what was expected, ozone bleaching worked much better at 80°C than at 20°C. Several brightness units could be gained only by such an increase in the reaction temperature without substantial consequence on cellulose depolymerization. Moreover, brightness stability was found better after bleaching at 80°C. Therefore ozone final bleaching, which requires neither pH nor pH adjustments, is indeed a very simple and promising process.

ACKNOWLEDGEMENT

This work was carried out in partial fulfilment of the requirements for Guillaume Pipon’s PhD in pulp and paper science at Grenoble INP-Pagora. Wedeco is thanked for their financial and technical contributions to the project.

LITERATURE

1. VOIRON, S., KULIGOWSKI, C., and LACHENAL, D. Contribution of various

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FIG. 4. Effect of ozone stage temperature on cellulose degradation (conditions as on Fig. 3, original DP 1550). coloured groups in pulp to bleachability problems, Cellulose Chem. Technol., 40(34):243-248 (2006).

2. MATEO, C., CHIRAT, C., and LACHENAL, D. The chromophores remaining after bleaching to moderate brightness. J. Wood Chem. Technol., 24(3):279-288 (2004).

3. ROSENAU, T., POTTHAST, A., KOSMA, P., SUESS, H.U., and NIMMERFROH, N. Isolation and identification of residual chromophores from aged bleached pulp samples. Holzforschung, 61:656-661(2007).

4. LACHENAL, D. Hydrogen peroxide as a delignifying agent, in Pulp Bleaching, Principles and Practice, C.W. Dence and D. Reeve Editors, Tappi Press, Atlanta, :349-359 (1996).

5. CHIRAT, C. and LACHENAL, D. Other ways to use ozone in a bleaching sequence. Tappi J. 80(9):209-214 (1997).

6. CHIRAT, C., LACHENAL, D., and MATEO, C. Final bleaching with ozonated water, Revue ATIP, 57(2):12-16(2003).

7. BROGDON, B.N., MANKCOSKY, D.G., and LUCIA, L.A. New insights into lignin modification during chloride dioxide bleaching sequences (I): chlorine dioxide delignification. J. Wood Chem. Technol. 25:133-147(2005).

8. ERIKSSON, T. and GIERER, J. Studies on the ozonation of structural elements in residual kraft lignins. J. Wood Chem. Technol. 5(1):53-84 (1985).

9. BROGDON, B.N. Influence of oxidized lignin structures from chlorine dioxide delignified pulps on the kappa number test. J. Pulp Paper Science 27(11):364369(2001).

Résumé: Pour mieux comprendre pourquoi les derniers points de blancheur sont si difficiles à obtenir lors du blanchiment des pâtes chimiques, alors que les quantités de chromophores résiduels sont extrêmement faibles, plusieurs composés modèles des structures chimiques vraisemblablement présentes dans les chromophores des pâtes mi-blanchies ont été traités par différentes charges de dioxyde de chlore et d’ozone. Selon le modèle (quinones, fragment de lignine) et le réactif utilisé, des résultats différents ont été obtenus. Lorsqu’il réagit avec des fragments de lignine, ClO2 forme de nouveaux chromophores colorés qui vont résister à une attaque ultérieure. L’ozone O3 forme également de nouveaux chromophores mais ceux-ci sont entièrement dégradés par un excès de réactif. De plus, les modèles quinoniques se sont avérés très résistants vis-à-vis de ClO2 alors qu’ils sont facilement dégradés par O3. Ces résultats peuvent expliquer la moindre efficacité du dioxyde de chlore en fin de blanchiment par rapport à l’ozone.

Les conditions d’utilisation de l’ozone en fin de blanchiment sont moins critiques que lors d’une délignification. Ainsi il est montré que le stade d’ozonation peut être avantageusement réalisé à haute température (80°C).

Reference: LACHENAL, D., PIPON, G., and CHIRAT, C. Final Pulp

Bleaching by Ozonation: Chemical Justification and Practical Operating Conditions. Pulp & Paper Canada, April 2009:T48-T51. Paper presented at the 2008 International Pulp Bleaching Conference in Quebec City, Que., Canada, June 2-5, 2008. Not to be reproduced without permission of PAPTAC. Revised manuscript approved for publication by the Review Panel January 5, 2009.

Keywords: PULP BLEACHING, CHLORINE DIOXIDE, OZONE, CHROMOPHORES, TEMPERATURE

pulpandpapercanada.com

events calendar PULPTECH 2009 May 25-29 FPInnovations-Paprican, Pointe-Claire, Que. Nikki Roussanidis, 604-222-3205, nikki.roussanidis@fpinnovations.ca

International Mechanical Pulping Conference June 1-4 Sundvall, Sweden G. Hay 514-392-6964

CMM International June 1-4 Rosemont, Ill. www.cmmshow.com

International Paper and Coating Chemistry Symposium June 10-12 McMaster University, Hamilton, Ont. G. Hay 514-392-6964

PACWEST Conference June 10-13 Delta Sun Peaks Resort, Kamloops, B.C. M. Barnes 604-988-9829; barnesmm@shaw.ca

International Symposium on Wood and Pulping Chemistry June 15-18 Oslo, Norway G. Hay 514-392-6964

International Conference on Nanotechnology for the Forest Products Industry June 23-26 Edmonton 800-446-9431, memberconnection@ tappi.org, www.tappi.org/09nano

International Conference on Woody Biomass Utilization August 4-5 Mississippi State University, Starkville, Mississippi www.forestprod.org/confbiomass09. html

XIVth Fundamental Research Symposium Sept. 13-18 Oxford, UK frc14oxford2009.org.uk; www.frc14oxford2009.org.uk

TAPPI Engineering, Pulping, Environmental Conference Oct. 11-14 Memphis, TN www.tappi.org

15th Asian-Pacific Corrosion Control Conference Oct. 18-21 Manila, Philippines

Events

Fluid-driven tank washer for large tanks

High-impact cleaning of tanks up to 30 m is now available from Spraying Systems Co. The TankJet 4 Tank Washers provide high-impact cleaning of tanks up to 30 m are now available from Spraying Systems Co. The units provide consistent impact over the entire pressure range to ensure superior cleaning.

TankJet 4 Tank Washers are equipped with special nozzles that minimize turbulence and improve stream integrity for increased impact and greater cleaning effectiveness. The nozzles rotate 360° in horizontal and vertical planes creating a crisscrossing pattern that thoroughly cleans tanks of even difficult-to-remove residues.

The units are sleek and compact and fit in tank openings of 16 cm. Pin and clutch versions are available to accommodate both permanent installations and portable operation.

The TankJet 4 is ideal for cleaning chemical reactors, tanker trucks, pulp storage tanks, blenders, and more.

Spraying Systems Co., 630-665-5000, www.spray.com pulpandpapercanada.com

products Lubricants meet environmental and performance goals

Petro-Canada has launched the EcoSia brand, a suite of products from the company’s current line-up which possess environmentally-friendly characteristics. The product offering spans a diverse range of applications and customer segments including lubricants and fluids for forestry.

“With increasing enthusiasm and need for environmentally-friendly lubricants, we also wanted our customers to be aware of the fact that many of our products, that they already use, are environmentally responsible without compromising product performance,” explains Randy Koenig, vice-president lubricants, Petro-Canada.

Petro-Canada’s EcoSia products are inherently or readily biodegradable, and are not environmentally toxic.

Petro-Canada, 800-268-5850 or 800-576-1686, www.lubricants.petro-canada.ca/ecosia PULP & PAPER CANADA April 2009

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products Embedded sensors provide real-time nip profile

Stowe Woodward unveiled its new SMART roll technology during EXFOR and representatives of the company and its parent company, Xerium Technologies Inc., are certain it will make waves in the industry.

The SMART technology has sensors embedded within the roll cover that measure the nip profile while the machine is operating. Through a wireless link, data is communicated from the sensors to a computer, which gives the nip profile in real time.

William Butterfield, Stowe Woodward vice-president, global rolls technology, explained how this allows operators to make immediate adjustments. The technology, he added, eliminates the need for shutdowns to take the nip profile, and also results in a lower cost per tonne, reduced consumption of raw materials and energy, and increased machine efficiency and product quality.

In addition, Butterfield pointed out the return on investment is not measured in years, but in months – as “early as the first shutdown,” he said.

Stowe Woodward www.smartrolltechnology.com

Hand-held monitor provides early warning of potential failures

The SKF Machine Condition Advisor (MCA) is a rugged, easy-to-use, hand-held device that measures vibration signals and temperature simultaneously to indicate machine health or bearing damage, and provides early warning of machine problems before a costly breakdown occurs.

According to Torsten Bark, product line manager at SKF Reliability Systems, “The SKF Machine Condition Advisor is a good fit whether a facility is just beginning a predictive maintenance program or wants to supplement their existing condition monitoring program. New users can have increased confidence because their readings are automatically compared to established standards or backed up by experienced analysts using SKF data analyzers for further analysis.”

The SKF MCA automatically compares the velocity measurements to preprogrammed International Organization of Standardization (ISO) guidelines and uses industry-proven Enveloped Acceleration technique to measure vibration against established bearing vibration guidelines.

These features provide time savings and diagnostic confidence, and can improve machine reliability.

SKF, www.skf.com/mca

Professional Connections Equipment

Splice detection technology protects sensitive equipment

Sentinel splice (joint) detection technology will detect any splice or joint that may exist within web-based processes, and can monitor up to 16 webs of material. It is applicable to manufacturing processes that require the culling out of splices or joints prior to shipment. As a control in subsequent conversion processes, it prevents damage to sensitive equipment, such as soft rolls, print heads, coater applicators, and print blankets. Immediate detection, rejection, and control of splices or joints create savings of up to tens of thousands of dollars per year.

Unaffected by printed surfaces, material colour, grade changes, and process speeds, the Sentinel guarantees 100% reliable detection every day; every shift. It is a selfcalibrating system powered by 24 V DC. The Sentinel can be connected directly to PLC control devices or interfaced into existing marking systems.

Splice Detection Technologies/R.K.B. Opto-Electronics, 315-455-6636

Advertiser Index Andrew Merrilees Ltd. . . . . . . . . . . . . . www.merrilees.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 BC Hydro . . . . . . . . . . . . . . . . . . . . . . . . . www.bchydro.com/pulp . . . . . . . . . . . . . . . . . . . . . . . . .9 Buckman Ltd. . . . . . . . . . . . . . . . . . . . . . www.buckman.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Fluoron Inc. . . . . . . . . . . . . . . . . . . . . . . . www.fluoron.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Freeman Staffing Inc. . . . . . . . . . . . . . . www.freemanstaffing.com . . . . . . . . . . . . . . . . . . . . . .37 Gamajet Cleaning Systems . . . . . . . . www.gamajet.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Indeck Power Equipment Co. . . . . . . www.indeck.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Kadant Canada Corp. . . . . . . . . . . . . . . www.kadant.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Kemira Chemicals Inc. . . . . . . . . . . . . . www.kemira.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PAPTAC . . . . . . . . . . . . . . . . . . . . . . . . . . . www.paptac.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Phoenix Process Equipment Co. . . . www.dewater.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Poyry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.poyry.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Sandwell Inc.. . . . . . . . . . . . . . . . . . . . . . www.sandwell.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Wabash Power Equipment Co. . . . . . www.wabashpower.com . . . . . . . . . . . . . . . . . . . . . . . .37

36

April 2009 PULP & PAPER CANADA

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Careers 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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37

point of view

A Fond Farewell to Mackenzie Tom Boughner shares his thoughts on leaving the storied British Columbia mill he has managed through good times and bad.

April 1, 2009

I told president Tim Roots this morning that I plan to end my employment with Mackenzie Pulp Mill Environmental Management Inc. on Friday May 8, 2009. Today is my tenth anniversary on the job. The previous record holder was a bit short of five years so my record may stand for a while.

Across the industry, ten years is not a record but it’s up there; and doing it for a succession of six different employers in the same mill may be a record!

By early May, the risk of winter freezing will be over. We will have done what we said we would do, as far as ensuring the safety of our employees and the community, and protecting the environment from chemical spills is concerned. We will have also resisted the pressure to cut spending on asset preservation, at least to the extent that we have not let the mill freeze up or burn down.

I’m proud of what our team has achieved. Of course, there will be tremendous pressure to get through next winter at reduced cost. That’s obvious. It will take a lot of methodical management at the mill level, rather than creative leadership; I will get out of the way and let someone else handle that.

Before I accepted this position ten years ago, I told Fletcher Challenge that it was time for them to stop viewing Mackenzie as an entry point to the bigger mills at Crofton and Campbell River on Vancouver Island. It was time to hire a manager for Mackenzie who wanted to live in Mackenzie, provide the kind of leadership that was necessary, and participate actively in community life for three to five years. I made that commitment, knowing that three years was the average tenure of my nine predecessors.

In 1999, I was intensely motivated to demonstrate that shrewd team building and fired-up, trust-generating leadership could make a big difference in performance. After five consecutive annual production records (from 2001 to 2005) we’d proved that. Eight months into 2006, we were ahead of 2005, en route to a sixth consecutive annual record. Then we were hit by the perfect storm of the escalating pine beetle resin levels and the fibre shortage resulting from the collapse of the lumber market.

Corporately, the collapse came at us in stages: in April, 2007, Pope & Talbot’s CEO, who I much admired, retired; in October 2007, the corporation filed for protection from creditors; in May 2008, the company declared bankruptcy and PricewaterhouseCoopers was appointed receiver. In September 2008, after PwC had taken an amazing four months to do what should, in PwC’s own assessment, have taken three to six weeks, Worthington Industries assumed ownership. Two weeks later, when Worthington announced that the startup was to be delayed, the writing was on the wall.

My objective has always remained what it was when I first came here: to help lift this mill to new levels of achievement.

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April 2009 PULP & PAPER CANADA

B T B

The commitment to people’s safety and to the environment caused me to change gears over the past winter, recognizing there were powerful decision makers who did not understand the devastating potential consequences of what they might do.

Now spring is coming. Right now, it may look just the opposite, but I believe Mackenzie Pulp Operations has a bright operating future. Like the Cariboo and Taylor pulp mills, Mackenzie was built to serve the regional lumber mills by making a valuable product out of what used to be waste streams. When the lumber industry comes back in 2010, sawmills will need an outlet for chips and sawdust. With a fine-tuned configuration that typically consumes 55% chips and 45% sawdust – yet remains able to revert to processing 100% chip furnish – Mackenzie is beautifully suited to the fibre supply from the Mackenzie region.

Rebuilding the team, restoring equipment performance, and completing a small number of specific minor modernization projects for improved competitiveness is going to be a long-term challenge again. By the time the mill is contemplating restart, I will be approaching my 64th birthday. I’m not suggesting I’m slowing down. What I am suggesting is that at 64, I’m not going to be making another three- to five-year commitment, which is exactly the kind of commitment that our employees and the community need, expect, and deserve. It will be time for a new leader to step up.

My wife Cecille has supported me in my career demands for nearly 37 years, starting when I was a production area supervisor, with those nighttime calls, and now she’s been married to a pulp mill manager since 1989. So now it’s time for us to shift priorities. We will leave Mackenzie with no regrets and an abundance of great memories. The opportunities we’ve had to get involved in a number of community activities and the many great people we have met have made our ten years in Mackenzie a tremendous, enriching experience.

I plan to change pace and find some other ways to keep myself busy, including sharing the experience I’ve been fortunate enough to accumulate over four decades.

My best wishes for all the best to the Mackenzie team and community.

R. Thomas Boughner, P. Eng., MCIC, General Manager, Mackenzie Pulp Mill Environmental Management Inc. TomBoughner@tetrahedron.ca pulpandpapercanada.com

Featured presentations 12:00 – 14:00 (EDT) 14:30 – 16:30 (EDT) Wood & Chip Quality Tuesday, May 19th Presented by: John Wood, Info-Wood Inc.

Theory of Mechanical Pulping and Testing of Mechanical Pulps Tuesday, May 19th Presented by: Ingunn Omholt & Wayne Bichard FPInnovations-Paprican

Description: Follow the detailed journey of logs and chips from the Woodyard through to the various Mechanical Pulping processes.

Description: Discover the leading edge science behind mechanical pulping processes and the description of most tests done on mechanical pulps, many with videos of tests being carried out.

Screening Wednesday, May 20th Presented by: Steve Hawkes, Andritz Inc.

Cleaning and Thickening of High Yield Pulps Wednesday, May 20th Presented by: Guy Doucet, Voith

Description: Screen types, configurations, pulp properties, maintenance.

Description: Equipment types, layouts, effects on pulp properties.

Refining Plates & Equipment Friday, May 22nd Presented by: Tina Lawton, J&L Fibre Services

Groundwood & Pulpstones Friday, May 22nd Presented by: Bill Bernier, St. Gobain Canada Inc.

Description: Everything you ever need to know about refiner plates and their metallurgy. Description of major pieces of refining equipment.

Description: Pulpstone composition, manufacture, maintenance and resultant effects on groundwood properties.

Peroxide Bleaching & Hydrosulphite Brightening Monday, May 25th Presented by: Martin Fairbank, AbitibiBowater

Rejects Refining Monday, May 25th Presented by: John Wood, Info-Wood Inc.

Description: Detailed chemistry and resultant pulp properties achieved by these processes and their many configurations.

Description: State-of-the-art rejects refining systems for all types of mechanical pulping processes.

High Yield Pulping Wednesday, May 27th Presented by: Dave Mackie, Nexterra Inc.

Advances in TMP Wednesday, May 27th Presented by: Marc Sabourin, Andritz Inc.

Description: Pulp properties achieved from all of the alphabet high-yield pulping processes. Impact on energy and pollution.

Description: Up to date information on all of the newest technology available in the TMP process.

Process Control Friday, May 29th Presented by: Ellen Palmer, Entech Controls Inc. Description: Theory and practical examples of how best to apply process control to mechanical pulping processes.

Other Species Friday, May 29th Presented by: Marc Sabourin, Andritz Inc. Description: Pulp properties and process modifications needed when using Southern Pine, Western Hemlock, Jack Pine and other species.

PAPTAC strongly believes in improving corporate profitability through its members’ individual development. Let us help you achieve your training goals and be of service to you for all your training needs. For pricing and other information on this series of webinars as well as other upcoming events and training courses, please contact Carmie Lato at 514-392-6969 / clato@paptac.ca Pulp & Paper Technical Association of Canada (PAPTAC), 740 Notre-Dame W., Suite 1070 | Montréal QC | H3C 3X6 (514) 392-0265 | Fax: (514) 392-0369 | www.paptac.ca

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Š2008 Buckman Laboratiories