Pulp and Paper Canada July/August 2010

July/August 2010

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SAVE OUR MILL! Kitimat residents won’t give up on Eurocan

JOURNAL OF RECORD, PULP AND PAPER TECHNICAL ASSOCIATION OF CANADA HART: Peroxide Explosion Hazards

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From pulp to paper, water is the connection.

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JULY/AUGUST 2010 Vol. 111, No. 4 PRINT EDITION ISSN 0381-548X

A Business Information Group Publication ON-LINE EDITION ISSN 1923-3396

FEATURES

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The Physics of Paper up for Discussion Researchers gathered in Montreal to share developments in paper physics and assess their implications for papermaking.

COMMUNITY RALLIES FOR EUROCAN

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PAPER PHYSICS

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NANOCELLULOSE OUTLOOK

15

COVER STORY

12 15 30

Residents struggle to save mill Workers, municipal government, and local businesses are pooling their talents and resources to find a buyer for the closed pulp and paper mill in Kitimat, B.C. Nanocellulose steps up on stage A one-tonne per day demonstration plant is in the works, and manufacturers are lining up to explore the potential of nanocellulose.

Pulp Growth Ain’t No Pulp Fiction The man who bought the Thurso pulp mill explains why dissolving pulp has a solid future.

TECHNICAL PAPERS

17 PAPTAC abstracts

A brief introduction to some of the technical papers available from the Pulp and Paper Technical Association of Canada at www.paptac.ca.

19 A Comparative Evaluation of Explosion Hazards in Chemical and Mechanical Pulp Bleaching Systems A kinetic model of peroxide decomposition explains why peroxide bleaching in mechanical pulp mills has lower risks.

By P.W. Hart (MeadWestvaco) and A.W. Rudie (USDA Forest Products Laboratory)

23 Effect of Eucalyptus Kraft Pulp Enzyme Bleaching on Effluent

Quality and Bio-Treatability Enzymatic prebleaching of Eucalyptus pulp was carried out under different conditions. The best pulp quality was achieved at pH 7.

By M.T. Borges, C.M. Silva, J.L. Colodette, L.B. Alves, G.R. Rodrigues, L.C. Lana, (Universidade Federal de Vicosa, Laboratorio de Celulose e Papel), and F. Tesser (International Paper do Brasil)

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July/August 2010 PULP & PAPER CANADA

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EDITORIAL

Canada courted for its forests

I

ngrained in the Canadian consciousness (in the Eastern provinces at least), is the idea of “have” and “have-not” provinces, and the ideal of redistributing wealth to achieve parity between the two. But on a global scale, in the have and havenot accounting of wood fibre, it’s not the have-nots that are lusting after Canada’s natural riches. It’s players in the regions that have substantial fibre available who want more.

Witness the just-announced agreement to sell Howe Sound Pulp & Paper to Netherlands-based Paper Excellence BV. This is the same company that bought an idled Mackenzie, B.C. pulp mill only three months ago.

Paper Excellence is a unit of Indonesia’s Sinar Mas, which already has a significant amount of vertically integrated pulp and paper capacity through its Asia Pulp & Paper subsidiary.

European and Asian businesses also covet our fibre for bioenergy applications. When a dozen Canadian bioenergy and forest companies visited Beijing on a trade mission in May, Kai Johan Jiang, president of DP Cleantech, China’s largest bioenergy power producer, told the Canadians: “China has $20 billion to invest in renewable energy overseas. And Canada, with its ready supply of renewable biomass and the technology to convert it to energy and high-value products, is a very attractive partner for us.”

Mired as we are in bankruptcies and mill closures, it’s good to be reminded that this industry does still have opportunities.

Ours is an industry with a heavy burden of infrastructure and tradition, but it doesn’t have to be moribund.

New investors are cropping up, and they bring fresh ideas, as well as an influx of more tangible resources. Levi Sampson shook things up at Harmac (now Nanaimo Forest Products), and Chad Wasilenkoff is set to do the same thing at Thurso (see page 28).

Domtar, capitalizing on research performed by our own FPInnovations, is getting into a brand new offshoot of forest products: nanotech. See the story on page 15 for details about the demonstration plant being built at Domtar’s Windsor, Que., pulp and paper mill.

We will get a more diversified, more agile industry out of this latest downturn, but not without some pain. At the grassroots level, mills are closing, and efforts to save them are ongoing. The Eurocan mill in Kitimat, B.C. is the most visible rescue effort. Whether or not that group is successful in finding a buyer, the story illuminates some of the frustration and determination of Canadian mill workers.

We are most definitely a “have” country when it comes to resources.

We can rebuild our forest communities on that foundation.

EDITORIAL Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Contributing Editors HEATHER LYNCH

Sustaining member, Pulp and Paper Technical Association of Canada; Member, Canadian Business Press and Audit Bureau of Circulation.

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A10-287

INDUSTRY NEWS Restructured AbitibiBowater could emerge from creditor protection in October

MONTREAL — AbitibiBowater could emerge from bankruptcy protection in October if creditors vote in August to approve the newsprint producer’s restructuring plan, the Canadian Press reports.

Following the creditor’s meeting in late August, the Quebec Superior Court and the U.S. Bankruptcy Court would meet in early September to endorse the restructuring plan.

According to a Canadian Press article which appeared in the Winnipeg Free Press on July 5, the restructuring plan will see AbitibiBowater’s debt decrease from US$6.5 billion to US$1.6 billion as it pays off secured creditors and debtor-inpossession financing. It will also offer up US$500 million in new convertible notes to eligible unsecured creditors.

Unsecured creditors will receive between zero and 48% when their debt is converted to equity, depending on their class. Current shareholders will walk away empty-handed. Others fall somewhere in between, including workers who received no severance when their mills were shut over the past year.

The reorganized company hopes to capitalize on export market opportunities and promising growth markets for paper used in catalogues, magazine inserts, direct mail, inkjet paper, and paper packaging.

CORRECTION

In the article “Technology and Policy Driving Biofuels Growth” (May/June 2010), I made an error regarding B.C.’s renewable fuel targets. In fact, B.C. would need approximately 300 million litres of ethanol per year to feed its current target of 5% ethanol blended into gasoline. A Lignol biorefinery processing 1000 dry tonnes per day of feedstock will produce approximately 100 million litres of ethanol per year, so three such facilities could produce enough ethanol to meet B.C.’s target.

— Cindy Macdonald, editor

AbitibiBowater has streamlined its asset portfolio by closing or idling 3.4 million tonnes of paper capacity since 2007. Newsprint production capacity has been trimmed 36% to 3.6 million tonnes and accounts for 38% of total sales, down from 45% in 2007, according to the Winnipeg Free Press story.

AbitibiBowater sells four closed mills

MONTREAL — AbitibiBowater has completed the sale of three idle paper mills located in eastern Canada to a wholly owned affiliate of American Iron & Metal Company Inc. for $8.7 million and the sale of a paper mill and other assets located in British Columbia to an affiliate of Conifex Inc. for $33.9 million.

The three paper mills sold to American Iron & Metal, together with certain related assets and the property on which these paper mills are situated, are located in Beaupré, Que., Donnacona, Que., and Dalhousie, N.B. As part of the sale, AIM has also agreed to acquire a fourth idle paper mill (Fort William), located in Thunder Bay, Ont. In addition, AbitibiBowater will be paid 40% of the net proceeds from any subsequent sale of paper machines from these mills.

The assets sold to Conifex, all located in Mackenzie, B.C., include a paper mill, two sawmills, including planer mills, as well as timberland operations with a forestry license providing an annual allowable cut of approximately 932,500 cubic meters.

AbitibiBowater has streamlined its asset portfolio to focus on top-performing facilities by closing or idling 3.4 million tonnes of paper capacity, moving from an overall production capacity of 10.4 million tonnes to 7 million tons since 2007.

During this period, the company has also sold aggregate assets and land for total proceeds of over $980 million.

AbitibiBowater is currently under creditor protection in Canada and the U.S.

Cascades plans $10-million pulping line for OCC at East Angus

KINGSEY FALLS, QC — Cascades broke ground June 1 for a $10-million investment at the Cascades East Angus mill in Quebec’s Eastern Townships

region to build a recycled pulp unit that will enable the production of kraft-type recycled pulp.

A new building will be added to the premises to house a pulper, loading platforms, and a warehouse for waste paper.

This unit will be able to convert more than 200 tonnes per day of old corrugated cardboard (OCC) into recycled pulp.

This integration will also enable Cascades to increase the recycled content of its kraft papers from 43% to 70%.

Despite a difficult market, Cascades continues to invest in the production of environmentally sound paper products.

“The East Angus plant initiated a shift a few years ago towards products that were more respectful of the environment,” explains Mario Plourde, president and chief operating officer of Cascades Specialty Products Group. The East Angus mill integrated recycled content and obtained FSC certification, as well as reduced its water and energy consumption.

The old corrugated cardboard for the new pulping line will come from the company’s sorting centers. “This investment integrates perfectly with our desire to include maximum recycled fibre content in our products,” states Alain Lemaire, president and CEO of Cascades. “It is an effective way of reusing local materials that would have probably ended up in a landfill site, while ensuring the longevity of the plant.”

Cascades kraft papers can be used for the production of envelopes, bags, packaging, or construction products.

Smurfit-Stone completes restructuring

CREVE COEUR, MO., and Chicago — Smurfit-Stone Container Corporation has successfully completed its financial restructuring and has officially emerged from Chapter 11 as a reorganized, publicly traded company.

In accordance with the terms of the reorganization plan, Smurfit-Stone’s previous common stock and preferred stock have been cancelled. However, the plan provides that a percentage of the new Smurfit-Stone common stock pool will be distributed to previous stockholders.

FOR MORE DETAILS, VISIT WWW.PULPANDPAPERCANADA.COM ABITIBIBOWATER FINED FOR WORKER INJURIES … CANFOR PROJECT A BREATH s s s

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INDUSTRY NEWS

Canadian forest industry and environmental groups sign world’s largest conservation agreement Twenty-one member companies of the Forest Products Association of Canada (FPAC) and nine leading environmental organizations have reached an unprecedented agreement — the Canadian Boreal Forest Agreement — that applies to 72 million hectares of public forests licensed to FPAC members. The agreement will conserve significant areas of Canada’s vast boreal forest and protect threatened woodland caribou.

Under the agreement, FPAC members commit to the highest environmental standards of forest management within an area twice the size of Germany. Conservation groups commit to global recognition and support for FPAC member efforts.

“The importance of this agreement cannot be overstated,” said Avrim Lazar, president and CEO of FPAC. “FPAC member companies and their ENGO counterparts have turned the old paradigm on its head. Together we have identified a more intelligent, productive way to manage economic and environmental challenges in the boreal that will reassure global buyers of our products’ sustainability.”

The agreement calls for the suspension of new logging on nearly 29 million hectares of boreal forest to develop conserva-

tion plans for endangered caribou, while maintaining essential fibre supplies for uninterrupted mill operations. “Do Not Buy” campaigns by Canopy, ForestEthics, and Greenpeace will be suspended while the agreement is being implemented.

The agreement includes a commitment to world-leading forest management, joint proposals for protected areas; a life cycle approach to carbon management; and support for the economic future of forest communities; and recognition of conservation achievements in the global marketplace.

Signatory environmental organizations, FPAC, and the association’s companies have begun meetings with provincial governments, First Nations, and local communities across the country to seek their leadership and full participation in advancing the goals of the agreement.

Forestry companies participating in the agreement: AbitibiBowater Alberta Pacific Forest Industries AV Group Canfor Cariboo Pulp & Paper Company Cascades Inc. DMI F.F. Soucy, Inc. Howe Sound Pulp and Paper Kruger Inc. LP Canada Mercer International Mill & Timber Products Ltd. NewPage Port Hawkesbury Ltd. Papier Masson Ltée.

SFK Pulp Tembec Inc. Tolko Industries West Fraser Timber Co. Ltd. Weyerhauser Compnay Limited

Environmental organizations participating in the agreement: Canadian Boreal Initiative Canadian Parks and Wilderness Society Canopy (formerly Markets Initiative) The David Suzuki Foundation ForestEthics Greenpeace Ivey Foundation The Nature Conservancy The Pew Environment Group’s International Boreal Conservation Campaign (The Hewlett Foundation’s support for boreal forest conservation has been critical to the collective efforts of these groups.)

H OF FRESH AIR … FRASER PAPERS SELLING U.S. ASSETS … ENERKEM TO DEMO GHG-REDUCING TECH FOR BIOREFINERIES … ELK FALLS SHUTDOW s s s pulpandpapercanada.com

July/August 2010 PULP & PAPER CANADA

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INDUSTRY NEWS Creditor approval brings Terrace Bay Pulp closer to restart

THUNDER BAY, ON — The approval of Terrace Bay Pulp’s repayment plan moves the idled Ontario pulp mill one step closer to resuming production this summer. According to the Chronicle Journal newspaper, 165 of 168 voted in favour of the plan, which represents $35 million in claims.

The paper also reports that the company has reached a separate agreement with about two dozen logging contractors who are collectively owed about $9 million for logs and wood chips delivered before the mill was idled in February 2009.

The mill, located in Terrace Bay on the north shore of Lake Superior, has been under creditor protection since March 2009. A sanction hearing set for July 27 in Ontario‘s Superior Court is expected to set the stage for recalling mill workers and restarting the mill.

Canfor Pulp, PCT strike forest carbon offset deal

VICTORIA — Canfor Pulp Limited Partnership has signed a letter of intent with Pacific Carbon Trust for a multiyear deal to sell carbon offsets related to emission reductions at the Northwood pulp mill in Prince George, B.C. The emission reduction project will generate up to 80,000 tonnes in CO2e reductions, announced PCT CEO Scott MacDonald.

The aggregated emission-reduction project at Northwood has three component sub-projects. One is the installation of a side stream scrubber which allows the mill to achieve higher biomass-fuel-burn rates, supporting a reduction in the burning of natural gas.

Also, equipment improvements to the biomass delivery systems will reduce the need to supplement the fuel supply with natural gas, resulting in reduced greenhouse-gas emissions.

In addition, major upgrades to the recovery boiler will increase mill pulp production, improve combustion efficiency, increase internal electricity generation, and reduce steam requirements from the mill’s power boilers.

Collectively, these improvements will also significantly reduce sulphur and particulate emissions.

Under the agreement, Pacific Carbon 8

PULP & PAPER CANADA July/August 2010

Trust will purchase all third-party-verified offsets originating from the project from 2010 to 2012, with future purchases dependent on the parameters of any cap and trade systems developed at the regional or national levels.

Pacific Carbon Trust is a Crown corporation established in 2008 to deliver B.C.-based greenhouse gas offsets.

Fire puts Tembec Chetwynd out of commission for two weeks TEMISCAMING, QUE. — A fire at Tembec’s high yield pulp mill in Chetwynd, B.C., on June 30 caused no injuries, but the mill was expected to be out of service for 14 to 18 days.

The damage is primarily concentrated in the log storage and chip pile area. There was also some damage to the scales, chip receiving and unloading equipment, chip conveyors, and related electrical services.

Assessments by mill personnel and outside resources have indicated that damage to the pulp production area of the mill is relatively minor. In terms of direct loss, it is estimated that roughly 40,000 cubic metres of fibre (chips and logs) were destroyed.

Catalyst Paper pays tax bill in full to three of four municipalities

RICHMOND, B.C. — One year after several B.C. forest products companies rebelled against their municipal taxes, Catalyst Paper announced it will pay its full municipal property tax bill in three of the four municipalities that host its B.C. paper mills. It is seeking leave from the Supreme Court of Canada to appeal a recent court decision involving the fourth municipality.

The company will pay more than $15 million in municipal taxes to Powell River, Campbell River, Port Alberni and the District of North Cowichan. The company continues legal actions against North Cowichan and Campbell River.

Stowe Woodward closes Canadian manufacturing facility NORTH BAY, ON — The Stowe Woodward plant in North Bay, Ont., is closing as a result of reorganization at its parent company, Xerium Technologies, Inc. Xerium manufactures clothing and roll covers used in paper production.

It is expected that production at the North Bay location will cease by August 20, 2010. Local news sources report that 31 jobs will be lost.

Xerium president Dave Pretty lays the blame on paper industry contraction which reduces the demand for roll covers.

Stowe Woodward has eight other facilities in North America and Mexico.

The company went through a brief period of Chapter 11 bankruptcy protection earlier this year.

Cascades’ latest clean sweep

KINGSEY FALLS, QC — The antibacterial paper towel Cascades has been busily working to develop for five years is launching at an opportune time. In the aftermath of H1N1 where concern over the spread of germs remains high, the paper company’s latest offering is specifically designed to slash the amount of bacteria transmitted by hand contact.

The towel is targeted towards the

People….

Richard Garneau has joined the Board of Directors of AbitibiBowater Inc. Garneau most recently served as president and CEO of Catalyst Paper Corporation.

Catalyst Paper has appointed a former printing industry executive, Kevin J. Clarke, as president and CEO. Clarke is an experienced in the print industry, bringing nearly three decades of experience with World Color (Quebecor World) to his new role at Catalyst.

Fortress Paper has chosen veterans of the specialty cellulose field to lead the conversion of Fortress Specialty Cellulose’s Thurso mill to dissolving pulp. Peter Vinall will be president and CEO of Fortress Specialty Cellulose, Vincent Byrne joins the company as vice-president, technical development, and Donald Deer will be projects leader. In addition, Marco Veilleux, the former operations director of the Thurso mill under Fraser Papers’ ownership, has been appointed chief operating officer of Fortress Specialty Cellulose. pulpandpapercanada.com

INDUSTRY NEWS food-processing and restaurant sectors, as well as high-traffic areas including aircraft and cruise ships, medical clinics, schools, and daycares. It will be green in colour.

“This innovation responds to a need for improved hand hygiene that is frequently cited by public health experts in recent years,” CEO Alain Lemaire said of the paper.

Aeration system cuts energy costs at Canfor’s Taylor, B.C., pulp mill

EDMONTON — Canfor’s Taylor Pulp mill has purchased two microbubble aeration systems from Seair Inc. According to Seair, testing confirmed that the Seair system reduces the energy required by the mill’s effluent system by 3,800 megawatt hours per year. Seair notes that the expected savings in energy reduction alone will be in the range of $285,000

annually using current BC Hydro tier 2 pricing, equivalent to a 12-month payback purely on energy savings.

Seair’s aeration systems have a small footprint, which makes them versatile and easy to fit within existing facilities.

Craig Thomson, energy and environmental supervisor at the Canfor mill, notes: “We purchased our first Seair unit three years ago and continue to be impressed with its performance, reliability, and efficiency. With these additional units we believe we have obtained the optimal balance for our aeration system.”

Harold Kinasewich, Seair’s president and CEO, adds, “The Taylor mill is the first full Seair implementation at a pulp mill. However, with BC Hydro’s continued support, we are presently demonstrating Seair’s solutions at a number of other mills and we look forward to additional full implementations.”

Stops, starts, changes…

Fortress Specialty Cellulose Inc. began production and sale of NBHK pulp from the company’s mill in Thurso, Que., on May 28. The mill reopened May 1 after being shut down by its former owner in early 2009. Fortress Specialty intends to produce NBHK pulp while undergoing transformation to become a dissolving pulp producer in mid-2011.

AbitibiBowater is indefinitely closing its newsprint mill in Gatineau, putting 350 people out of work. The mill shutdown began April 19 as a temporary closure.

Kruger Inc. ceased coated and supercalendered paper production at the Trois-Rivières mill and extended the interruption of directory paper production at the Wayagamack Mill for an indefinite period of time. The company cites persistently unfavourable market conditions and the strong Canadian dollar as reasons.

At the Trois-Rivières mill, the No. 1 (coated paper) and No. 6 (supercalendered paper) paper machines, and the No. 8 coating machine were shut down indefinitely, effective June 11, 2010. This measure affected approxipulpandpapercanada.com

mately 320 employees in production, maintenance, and administration. The mill, however, will continue to produce newsprint, employing almost 300 people.

The No. 3 machine at the Kruger Wayagamack mill, which had stopped making directory paper on December 31 and was to resume operations in June, will be idled indefinitely. The extended shutdown will affect approximately 120 employees. However, the mill will maintain coated paper production, which means continued employment for more than 350 employees.

Catalyst Paper will permanently close its Elk Falls paper mill near Campbell River, B.C., in September. This facility has been indefinitely curtailed since February 2009. Catalyst cites the steep decline in commodity paper markets, and uncompetitive labour and tax costs as reasons for the closure. The Elk Falls mill began operation in 1952, and at its peak, produced 784,000 tonnes of pulp, paper and kraft paper annually. The company also announced the permanent closure of its paper recycling operation in Coquitlam, B.C. The facility, which supplied the company’s Crofton mill, was indefinitely idled in February.

Million-dollar forest research program launched by Northern Pulp Nova Scotia

HALIFAX — Northern Pulp Nova Scotia is creating a new Forest Research Program in the province. Northern Pulp’s initiative and $1-million investment over five years will drive research to study the impacts of current forest management practices and help shape and improve forest management strategies in the future.

“As one of Nova Scotia’s largest forest products companies, the health and sustainability of the forest ecosystem is extremely important,” says Michael McLarty, timberlands manager at Northern Pulp Nova Scotia. “We believe the best way to maintain a healthy forest and ecosystem, while producing forest products to meet society’s needs in a safe and economical manner, is to continually gain more knowledge and understanding of the impacts of applied forest management strategies.”

Mike McLarty, Northern Pulp’s timberlands manager, addresses the audience during an announcement at the Otter Ponds Demonstration Forest.

The Forest Research Program will be chaired by Dr. Peter Duinker, director and professor, School for Resource and Environmental Studies and associate dean, research with Dalhousie University’s Faculty of Management.

“I am deeply impressed that a Nova Scotia forest-products company would make such a huge commitment to improving forest management knowledge through research,” said Dr. Duinker.

“There is strong potential to match the company’s research funds with money from Canada’s granting councils, so we are anticipating a vigorous research program on sustainable forest management.”

Over the next several months, Dr. Duinker, along with Northern Pulp, will invite members of industry, academia and other stakeholder areas, including government, to join the Forest Research Program Advisory Committee.

July/August 2010 PULP & PAPER CANADA

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INDUSTRY NEWS NB hands out Crown forest biomass to eight companies, primarily for co-generation

FREDERICTON — Eight allocations for Crown forest biomass have been awarded to New Brunswick companies, to be used for renewable carbon-neutral energy or to be incorporated into value-added products.

The biomass material consists of branches, tree tops, and foliage not traditionally used by the forest industry. The allocations total 1,276,000 cubic metres of biomass, which the government estimates is enough to displace about 200 million litres of oil.

“Most of the biomass will be used in co-generation facilities to produce energy for use by these companies in their own facilities, and potentially surplus electricity for sale to the provincial power grid,” said Natural Resources Minister Wally Stiles.

Twin Rivers Paper Co. Inc. received the largest allocation, 308,000 cu. m. The biomass will be used to produce carbon-

Green Transformation Fund Lake Utopia Paper uses federal funding for biomass boiler

A $22-million cash infusion for Lake Utopia Paper Mill in New Brunswick will go a long way towards helping the facility boost its production of clean energy. The funding comes as part of the federal Green Transformation Program and will allow the mill to install a new biomass boiler that will be fuelled by wood waste from the company’s own forestry operations in the province.

The boiler is expected to churn out enough steam to meet the facility’s energy needs, thus reducing its reliance on fossil fuels for power. The installation will also scale back the mill’s greenhouse gas emissions by more than 66,000 tonnes per year and will displace the equivalent of 180,000 barrels of fossil fuel.

The $22-million investment represents a substantial chunk of the $32.9 million total the project will cost. The outstanding project costs will be covered by a $10.8 million repayable loan from the Government of New Brunswick, in addition to a $500,000 grant from Efficiency NB.

Hinton’s pressure diffusion washer will boost energy efficiency

West Fraser has announced its intention to purchase and install a pressure diffusion washer at its Hinton Pulp division. The project, which is expected to cost $15 million, will be funded by credits earned under the Canadian government’s Pulp and Paper Green Transformation Program.

The installation of a pressure diffusion washer will allow Hinton Pulp to improve its energy efficiency by reducing the volume of natural gas consumed and increasing the facility’s production of green power. The project will also improve environmental performance through reduced and cleaner mill effluent.

The successful completion of this project is expected to be an important step for Hinton Pulp in improving its overall competitiveness and long-term outlook.

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July/August 2010

neutral energy for its Edmundston mill.

The other allocations were: 272,000 cu. m to AV Cell Inc. for energy production at its mill in Atholville; 221,000 cu. m to AV Nackawic Inc. for a planned co-generation facility for its mill in Nackawic; 139,000 cu. m to Lake Utopia Paper to help fuel a planned co-generation facility at its mill in St. George; 138,000 cu. m to Irving Pulp and Paper Ltd. for co-generation at its Saint John plant; 76,000 cu. m to Irving Paper Ltd. of Saint John for co-generation; 62,000 cu. m to Groupe Savoie Inc. to integrate into value-added products produced at its plant in St. Quentin; and 60,000 cu. m for the J.D. Irving Ltd. sawmill in Chipman for co-generation.

Stiles said the Department of Natural Resources has developed a Crown Land Forest Biomass Harvesting Policy and related assessment tools to ensure that biomass material is harvested in a sustainable manner.

Cold winter was hard on Alberta’s mountain pine beetles, but threat of in-flight from B.C. remains

Cold temperatures last winter and extreme temperature fluctuations this spring combined to cause significant mortality to mountain pine beetles infesting trees in Alberta. Mortality surveys completed by the Government of Alberta show beetles had low survival throughout areas of the province where trees are infested, with the exception of some hot spots in northwest Alberta.

“At the same time, the cold weather did not completely eliminate the beetles and there is still the threat of additional in-flights from British Columbia,” says Alberta Sustainable Resource Development Minister Mel Knight.

As well, the Minister explained, the trees the beetles infested before dying are also dead and work must be done to allow regeneration of new forests to replace those lost to attacks.

As a result, the Alberta government is continuing its action plan to minimize the spread of infestations by a variety of methods, including single-tree removals, stand-level harvest, and controlled fires.

Considering the 2010 over-winter mortality surveys and the risk of in-flight from B.C. this summer, the government has determined the following areas are a high priority for beetle control: Whitecourt/Slave Lake, Grande Prairie, Banff/Canmore/ Kananaskis, Oldman River/Crowsnest Pass.

The Alberta government’s objectives are to minimize the spread of beetles north and south along the Eastern Slopes and to prevent beetles from spreading east in the boreal forest.

In related news, a study underway at the University of Alberta is looking at the effect of tree loss caused by beetles on water levels and new forest growth, the Edmonton Journal reported in June.

The study authors, Uldis Silins and Ellen Macdonald of the Department of Sustainable Resources, note that pine trees use up massive quantities of precipitation. “Once these forests die, that water has to go somewhere,” said Silins. “It’s basically going to go into the ground, and you’re going to see increased run-off.” That run-off could leech nutrients from the soil into groundwater, potentially lowering water quality downstream. That could also result in algal blooms, which can choke lakes and kill off fish.

The three-year study is currently at its halfway point. pulpandpapercanada.com

CONFERENCE REVIEW The group enjoyed a dinner cruise on the St. Lawrence River

What’s new in paper physics?

H

ow do you quickly measure cell wall thickness or simulate fibre network deformation? These were among the questions addressed at the Progress in Paper Physics Seminar in Montreal in June. Organized by FPInnovations, the event attracted about 60 delegates from universities, research institutes and various segments of the paper industry.

Topics included paper structure modeling, experimental methods, manufacturing and characterization of tissue, lignocellulosic composites, paper properties, and ink-paper interactions.

According to Norayr Gurnagul of FPInnovations, one of the seminar organizers, the technical highlights of the event are: • A novel and rapid technique for determining cell wall thickness and S2 fibril angle of intact wood pulp fibres using circularly-polarized-light microscopy has been developed. This patented technology is now being commercialized in the new generation of on-line fibre quality analyzers and will allow mills to relate pulp quality variations to fibre properties. pulpandpapercanada.com

• Simulations of wet fibre network deformation show that sheet stretch shows very significant statistical variations and the variations are affected by specimen size and fibre geometry. Since the stretch variations control wet sheet breaks in the open draw, the result has an important implication to paper machine runnability.

• Surface topography and formation can only account for 55% of the total variance of print density in flexo printing of packaging paper. In fact surface topography alone accounts for 49% of the total variance; this suggests that formation alone is not a dominant factor in controlling print mottle.

Keynote addresses and special sessions covered topics such as new nanostructured functional materials based on cellulose, a review of successes and failures in paper physics, a review of what has been learned from new characterization tools over the last decade, as well as new and emerging fields in materials science and engineering.

A boat cruise on the St. Lawrence River was the spectacular setting for the seminar banquet.

PPC

Dr. Derek Page was the keynote speaker at the Progress in Paper Physics Seminar.

Attendees learned about developments in paper physics and their practical application in papermaking.

July/August 2010 PULP & PAPER CANADA

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COVER STORY

On the outside looking in: Mary Murphy (left), Trafford Hall (centre), and Randy Dobson (right) have poured time and energy into finding a buyer for the shuttered Eurocan mill.

When a mill closes, how can citizens get it reopened? If the owner says it is not a viable business, why would someone else buy it? Where do you turn for advice, for manpower, for funding? The experience at Eurocan provides some insight.

By Carroll McCormick

W

hen West Fraser Timber Co. Ltd. announced on October 28, 2009, that it would permanently close its Kitimat paper mill, the last pulp and paper mill on British Columbia’s north coast and the town’s second-largest employer at more than 500 men and women, it was like driving a steel-toed boot into a bee hive.

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Within days Local 298 of the Communications, Energy and Paperworkers Union (CEP), the national CEP representative, the District of Kitimat and the community began strategizing about how Eurocan Pulp & Paper Co. could somehow be kept open. For Local 298 though, this was unexplored territory. “We didn’t know where to go,” recalls Mary Murphy, its president.

PULP & PAPER CANADA July/August 2010

Somehow, Local 298 found, then sought, early counsel from the Calgarybased Canadian Worker Co-operative Federation (CWCF) which describes itself, in part, as a “grassroots membership organization of and for worker cooperatives”. An essential part of its mandate is to provide information to worker groups on the many aspects of starting worker co-ops, such as preparing feasibility studpulpandpapercanada.com

Photo: G. Patzelt

Community rallies to save Eurocan mill

COVER STORY ies and business plans, and obtaining government assistance. As a first step in trying to figure out what was even possible, Local 298 looked at the possibility of employee buy-in at the mill.

Employee buy-out considered

The CWCF and worker groups in trouble learn about each other partly from monthly conference calls among members of the Western Labour/Worker Co-op Council, which includes unions. Although CWCF has been around since 1991, it has a zero-for-two track record with mill worker groups. It should be noted that the successful Ohio Employee Ownership Center, which does similar work in various industries in that US state, finds that one of six attempted buy-outs proceeds.

To improve the chances of success in Western Canada, the Western Labour/ Worker Co-op Council, which began having formal meetings in 2006 and incorporated last fall, specializes in this area. “The Council is what is helping employees keep mills open,” says CWCF executive director Hazel Corcoran. “It was created in large part to provide a closer relationship between the worker co-op movement and the unions. At the moment one of the Council’s goals is to get a first successful buyout, and so far the demand has been coming from the pulp and paper industry.” CWCF is a member of the Council.

As for who pays for the help and advice of CWCF and the Council, Corcoran explains, “At this stage, the Council’s resources are coming from a federal government program called the Co-operative Development Initiative (CDI). We have sent in co-operative developers paid for by the CDI.” While Local 298 was picking up some speed from the Co-op Council, Kitimat’s municipal government, the District of Kitimat, also hooked its peavey into the issue. “Given the jobs and tax base that was at stake, the municipal government decided it had to spend some time looking at saving Eurocan,” says municipal manager Trafford Hall.

Throughout November, meetings were held to enlist support. A team formed and called itself the Eurocan Industrial Viability Group (EIVG). It had its first formal meeting on November 28. pulpandpapercanada.com

Aerial view of the 40-year-old Eurocan integrated pulp and paper mill.

“EIVG started being formed almost immediately after the mill closure was announced. The union, the District, the Chamber of Commerce were naturals for being on it,” Hall says.

EIVG originally had six members, including Envision Financial Kitimat.

Then the District sought funding assistance from the provincial government; it also joined EIVG. However, Hall stresses, the initiative is not being spearheaded by the government; it is being spearheaded by the local EIVG members.

There was some reluctance to have the provincial government sit on EIVG, as some local members where unsure where its allegiances lay. With the employees?

With West Fraser? “We don’t always know who our allies are. You can sometimes find that a member has a conflicting objectives,” Hall explains, while stressing, “The mission of EIVG is to make the mill viable.”

Despite his invaluable business expertise in this ongoing saga, Hall plays down his own importance in the effort to reopen the mill, which shut its doors at the end of this January. “I can’t take credit as a civil servant. Mary has been a key leader here; she has energy and integrity. Other than that we have to share the leadership amongst the members of our group.”

Drawing from the community

Murphy explains how Local 298 got buy-in from the town: “We requested support from individual citizens, community groups, town businesses and the Chamber of Commerce. We met with the mayor and council of the District of Kitimat, the mayor of [nearby] Terrace and several Terrace councillors. We made presentations to the Canadian Labour Council and received support from the president of the Canadian Auto Workers and other unions. We met with local First Nations, with provincial government officials and the Northwest British Columbia Forest Coalition representatives.”

Buy-in has meant support, manpower and resources, including $60,000 from the provincial government to help fund a $175,000 study on alternative business models to make the mill viable. “We were learning to put one foot in front of the other. We decided we needed a professional review of the mill. So we hired Pöyry, a global consulting and engineering firm,” Murphy says. “West Fraser was totally on board because they have the utmost respect for Pöyry.”

Hall underlines the importance of this move. “It’s rather arrogant to assume that we could succeed where West Fraser could not.” After all, in the October 28, 2009, July/August 2010 PULP & PAPER CANADA

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COVER STORY press release announcing the mill’s imminent closure West Fraser CEO Hank Ketchum stated, “Unfortunately, even with the most optimistic projections the business fundamentals of the operation have deteriorated to the point where permanent closure is the only reasonable alternative.”

Before and after Pöyry issued its Eurocan Mill Viability Assessment, Summary Report on March 31, Local 298 and EIVG jumped hurdle after hurdle. “In the beginning I had no idea what to do,” Murphy recalls. “West Fraser claimed that the mill was not viable and that they would simply close it. But after putting a lot of pressure on them, they agreed to [the proposal] of letting a buyer buy the mill.

“To date CEP 298 has put $65,000 into trying to find a buyer. CEP national has contributed. It has been a huge expense to everyone, including personal money Local 298 vice-president Randy Dobson and I have spent. The commitment consumes you full time. We are all working very hard, but I have a life.”

Boiling down the 21-page Pöyry summary report to a nugget, the mill might be viable if it closes one line and runs only the single sack kraft line. However, it would have to secure 600,000-700,000 cubic metres of pulp wood at a price that deferred some of the cost to regional coharvested logs.

In a stark example of “know thy region”, EIVG approached the Northwest British Columbia Forest Coalition, which has too many decadent trees (those with rotten cores) in and among its perfect trees.

“The good trees must bear the whole cost of the logging operation. This has driven the cost very high, to more than $100 per cubic metre,” Hall explains. In fact, the Coalition has what amounts to an advertisement on its website: “2,700,000 cubic meters of annual fibre available for wood processing investors.”

EIVG approached the Coalition, asked whether it could supply 700,000 cubic metres of pulp wood at $40-$45 a cubic metre. The Coalition said it could, according to Hall. As for the skill required to conduct such impromptu negotiations, Hall explains, “We think it is pretty straightforward to determine the broad (average) price we can pay and ask the supplier if they can supply. But any investor will have specific negotiations with the several individual members of the Coalition which will no doubt be more complex.”

As of late June, workers and the town of Kitimat were still far from being out of the woods. West Fraser has been redistributing equipment from the mill, although, says Murphy, “West Fraser notified us of each removal and assured us these assets

would be returned if we found a buyer.”

Still, Murphy has concerns about these removals. “If they bring the assets back, who will pay to reinstall them?”

Hall notes, “We got West Fraser’s cooperation because we haven’t derailed its plans to sell individual components. West Fraser said, ‘Fine, look for buyers, because our process of removing machinery will take time.’ They are giving us time.”

The Viability Group has been trying to stir up investors, and by June had entertained four potential buyers, according to Murphy. Too, she says, “We are working with the government to see if there is government funding for a union buyout. I am going through the CWCF venture to develop a business plan. If we have people come to the table we might be able to put down a deposit and keep the assets. This is a full-time job, looking for investors.”

West Fraser gave EIVG till the end of the June, but if a serious potential investor comes forward, they are willing to extend that deadline.

Although individuals like Murphy and Hall can make all the difference, at some point big guns must be brought on deck. Hall reports, “We are going to hire Poyry to look for a buyer. Hire some horsepower. Pöyry can do this from eight to five. I can’t do it.”

PPC

IT TAKES A COMMUNITY EFFORT TO RE-OPEN A MILL Nanaimo Forest Products and Mackenzie Pulp, stand as proof that it can be done – an idled mill can be saved, but it takes a lot of people pulling in the same direction to make it happen.

These two former Pope & Talbot mills in Nanaimo and Mackenzie, B.C., were idled when the company declared bankruptcy in 2008. One was bought by a group of employees and private investors, the other by an international pulp and paper company.

It took the cooperation of many parties to get both mills up and running again.

But one difference between the situation at the Eurocan mill and that of Nanaimo Forest Products and Mackenzie Pulp is that the two Pope & Talbot sites were

14

closed as part of a bankruptcy proceeding.

For Eurocan, its owners said, the “business fundamentals” dictated permanent closure.

In the case of Mackenzie Pulp, the list of those who helped to make the sale a reality is long. Worthington Industries bought the mill from receivership, but never reopened it and ceased paying workers in January 2009. The provincial government stepped in to pay workers and keep the mill warm during the winter so that pipes would not freeze and crack, releasing chemicals into the air and water. Mackenzie Pulp Mill Development Corporation preserved the mill’s physical capability to resume production. The provincial government and the District of Mackenzie consolidated and

PULP & PAPER CANADA July/August 2010

reduced the mill’s debt load.

The McLeod Lake Indian Band worked with the Ministry of Forests and Range to help secure the fibre needed to start the mill. And the Communications, Energy and Paperworkers Union (CEP) negotiated a new collective agreement that enabled the mill to reopen with significant cost reductions.

For Nanaimo Forest Products, 200 mill employees invested in the mill, along with several private investors. The new owners attribute the mill’s ongoing success to a long-term fibre supply with Western Forest Products, a longterm marketing deal, a positive attitude among the worker/owners, and an entrepreneurial attitude.

pulpandpapercanada.com

MARKET TRENDS

Nanocellulose steps up on stage

pulpandpapercanada.com

small. Mother Nature has been using NCC in plants since long before dinosaurs woke up hungry and its tremendous strength is one of the reasons trees can soar as high as 379.1 feet (115.56 metres) — the world record, incidentally — without collapsing on themselves.

Also called cellulose nanocrystals, the material was first isolated in 1949, according to Berry. The cellulose in pulp is up to 70% NCC, which is a crystalline cellulose, and about 30% amorphous cellulose, give or take.

Liberate the crystalline from the amorphous cellulose and, voilà, you have NCC to go.

Production scaling up

Photo :B om

C

anadian researchers and manufacturers are leading the world in learning how to create new uses for nanocellulose, a major component of trees. Industries from aerospace and automotive to pharmaceutical and security are lining up, paying up and teaming up to learn how to use this strong and versatile material to improve existing products and develop new ones.

Canada is “absolutely” on the front of the world stage in the ability to industrialize the production of this material, according to Dr. Richard Berry, a program manager at FPInnovations, a private, not-for-profit Canadian forest research institute. There, he pioneered the effort to liberate nanocellulose in industrial quantities from pulp.

To avoid confusion, FPInnovations coined the term nanocrystalline cellulose (NCC) for the particular form of nanocellulose it makes; the crystallites it produces are uniformly 150200 nanometres long and 5-10 nanometres in diameter.

“A lot of other people are talking about nanocellulose, but we don’t always know what their versions of it are,” says Dr. Ron Crotogino, president and CEO of the Canadian Forest Nanoproducts Network. Officially called ArboraNano, it was created last year

by Industry Canada’s Business-Led Network of Centres of Excellence program. ArboraNano has almost $9 million and a fouryear mandate to bring together researchers and industry to develop new products based on forest-based nanomaterials, particularly NCC. Other public and private sources are providing matching funding.

Unlike nanorobots, say, NCC is not a mysterious human invention, purposefully made tiny for working in small places. The crystallites just happen to be vanishingly

Photo :S he r

A one-tonne per day demonstration plant is in the works, and manufacturers are lining up to explore

By Carroll McCormick the potential of these tiny particles. w

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The nut that Canadian researchers have cracked is how to extract NCC from wood in industrial quantities. At the FPInnovations laboratory in Pointe Claire, Que., a batch process is capable of producing kilogram quantities per day. A commerical-scale, one-tonne per day demon- Nanocrystalline cellulose stration plant is now under could be used in a construction at Domtar’s variety of products.

Windsor pulp and paper facil- (Photo courtesy of ity. The $32-million facility is FPInnovations) a joint venture between Domtar and FPInnovations, with Natural Resources Canada and Quebec’s Natural Resources and Wildlife Ministry contributing $10.2 million each to FPInnovations’ portion of the venture.

A whole sack of nuts that FPInnovations and its university and industry partners are busy cracking is how to use NCC and its properties to enhance existing products and contribute to the manufacture of new ones.

The National Sciences and Engineering July/August 2010 PULP & PAPER CANADA

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MARKET TRENDS Research Council lists 18 product areas in which NCC could have applications.

Here are some possibilities: • Add NCC to varnish, perhaps just 3% of its volume. This makes it about three times harder, and more abrasionresistant than ordinary varnish. This improvement could directly help those in the wood products industry, such as manufacturers of hardwood floors and cabinetry. NCC could also improve the strength of adhesives.

• Add NCC to water-based paint. Just sitting there, in the can, the NCCenhanced paint will be a bit jelly-like.

Agitate it, however, and it becomes liquid — perfect for brushing and rolling. But once applied, the paint will re-gel and not drip from the ceiling onto your glasses.

• Add NCC to a liquid in just the right way, then dry it. The resulting material will have a shimmering iridescent colour. It’s not a dye though. Rather, the arrangement of NCC crystals reflects visible light so that we see pretty colours.

Possible ways to exploit this property include security marks on paper and pigments for nail polish or lipstick. NCC can also be made to reflect radiation in the ultra-violet and infra-red parts of the electromagnetic spectrum. “We are initiating work with the Institut National d’Optique,” Berry says.

• Manipulate the surface of NCC so it bonds with other polymers, and the result, for example, could be stronger plastic. This, plus the possibility of making stronger, possibly lighter cellulosebased car parts, excites manufacturers.

Other potential applications include aircraft, textiles, optics, gels, composites, pharmaceuticals, bone replacement, tooth repair, food additives and electronic products.

Bell Helicopter Textron Canada Limited, NanoLedge Inc., Kruger Inc., the Ontario Bioauto Council and NanoQuebec — are from the private sector.

Le Fonds québécois de la recherché sur la nature et les technologies (FQRNT) and Alberta Innovated — Bio Solutions provide provincial funding support.

“The wonderful thing that is happening is that every company we visit sees a use for its properties. We have more than 65 companies that we have different levels of relationships with. Even getting to the discussion point in this economy is significant. People’s time is precious,” says Berry.

“We are putting together joint agreements with manufacturers. Our expertise is making and modifying the materials, and they know best how to formulate their materials in products.”

Research is heating up at the university level, says Crotogino, who notes that the exact number of participating universities is a moving target. “As projects are approved, more universities come on board. There are now four universities receiving research funding with four more universities involved in the administration of the network.”

In partnership with FQRNT, one of its public funding members, ArboraNano launched a research partnership program.

Four grant recipients at the universities of McGill, Sherbrooke, Laval and Quebec (at Trois-Rivieres) now have a total of $965,000 to work on NCC projects in the wood processing and pulp and paper sectors until 2013. Targets of their investigations include wood coatings and composites, improving NCC’s compatibility with polymers, applications of its optical properties and its use to improve pulp and paper processes.

Manufacturers are interested

Not salvation, but stimulation for the industry

Imagining potential applications of NCC, inspired by its great strength and other known properties, is the easy task.

Proceeding to products is a far more complex undertaking. It is impressive then, given the real risk of failure, the amount of private industry interest and money behind the effort to commercialize NCC. Of the eight funding members of ArboraNano, six — FPInnovations, 16

Pulp mills will be involved in the production of NCC, but it remains to be seen, however, what the demand for pulp to produce NCC might be once the nanocellulose market matures. Claims that NCC may be the salvation of the wood products industry are exaggerated.

Rather, says Crotogino, “the salvation of the forest products industry is innovation. NCC will be part of this as a

PULP & PAPER CANADA July/August 2010

key to the development of higher-value forest products. It will not save a paper mill that makes traditional products, but NCC creates new opportunities for the manufacture of innovative, high-value paper products, as well as a new generation of building materials.”

Berry adds, “I look at NCC as a way of diversifying the sectors in which wood products are used, rather than turning it back into the industry.” What he means by this is that the wood products industry should not think only about making better wood products with NCC. Rather, it should be thinking of totally new applications for the materials harvested from our forests.

“The whole purpose of ArboraNano is to extend these materials into other areas, newer directions, new marketplaces, and get us out of the box we have been living in. We need to look at the full spectrum of possibilities from the components, talk to the companies we have never spoken to before,” Berry declares.

Construction on the demonstration plant should be completed in about 20 months, capping 15 years of research by FPInnovations. “We need to have products ready to use NCC by then. We will start with materials that are easier to take to the marketplace. Industrial materials are easier than consumer materials.

Wood products are easier than aerospace,” Berry explains.

Introducing NCC to products containing water will be the easiest to master, because NCC likes water. Hydrophobic materials will come later. Industrial uses will likely come before consumer products, because of regulatory issues. Automotive applications will precede those in aerospace, with its stringent and lengthy certification processes.

One day, Berry muses, aircraft manufacturers might come full circle to using NCC-enhanced wood products in aircraft again: fancier versions of plywood sheathing and the wooden stringers of old. Call it wild speculation, but perhaps spacecraft will one day be made of nanocrystalline cellulose-containing parts. After all, the registry number for Star Trek’s USS Enterprise, the most famous spaceship in the universe, was NCC-1701.

PPC pulpandpapercanada.com

PAPTAC ABSTRACTS

Introducing a New Decision Tool Using MPC for the Production Line Evolution

By M.-P. Pinard and L. Laperrière

Nouvel outil de décision par contrôle prédictif à base de modèle (MPC) pour l’évolution de la chaîne de production

Abstract: The presented decision tool links management decisions to production optimization. It identifies the possible lacks of flexibility and/or agility in a production environment that is under the influence of some global turbulence factors and for which profitability objectives have to be maintained. In this context, flexibility and agility act as performance measures and quantitative definitions using DCS data are proposed. The tool is implemented using MPC, Cadsim Plus™ dynamic simulation software and DeltaV DCS. Paper presented at the 2008 Control Systems Pan-Pacific Conference in British Columbia, June 16-18, 2008.

Keywords: FLEXIBILITY, AGILITY, MPC, OPTIMIZATION, SIMULATION, CADSIM PLUS™, DELTA V, TURBULENCES, PROFITABILITY OBJECTIVES Full manuscript available at www.paptac.ca.

On-Line Determination of Green-Liquor Reduction Efficiency and Total Titratable Alkali Using FourierTransform-NIR Spectrometry

By T. Trung, D. Osmond, B. Allison, V. Uloth, and J. Porter

Détermination en ligne de l’efficacité de la réduction de la liqueur noire et de l’alcali titrable total à l’aide de la spectrométrie infrarouge à transformée de Fourier

Abstract: In this paper, we describe the use of Fourier-transform

pulpandpapercanada.com

(Full peer-reviewed manuscripts available at www.paptac.ca)

Energy Analysis of a Canadian Kraft Pulp Mill

By J.-C. Bonhivers and P.R. Stuart

Analyse énergétique d’une usine de pâte kraft canadienne

Abstract: A study to reduce the steam consumption in a kraft pulp mill was conducted using simulation, process analysis, pinch method principles and optimization. Results showed that retrofit of the heat exchanger and water networks would result in a 15% energy reduction. Opportunities were identified in brown stock washing, the bleaching area, the pulp machines, the water heating system and tank management.

Paper presented at the PAPTAC Annual Meeting 2010 in Montreal, Que., February 2-3, 2010.

Keywords: KRAFT PULP PROCESS, PINCH ANALYSIS, WATER NETWORK, TANK MANAGEMENT, OPTIMIZATION, STEAM, ENERGY REDUCTION Full manuscript available at www.paptac.ca.

Near-Infrared spectrometry (FT-NIR) for on-line measurement of green liquor compositions, such as TTA, EA, carbonate, sulphide, sulphate, thiosulphate, and reduction efficiency (RE) in raw green liquor. The technical feasibility of using this analyzer as an on-line monitoring system for dissolving tank TTA control as well as for reduction efficiency monitoring has been demonstrated during normal mill operation as well as for simulated upset conditions.

FT-NIR data for TTA has tracked well with dissolver density values. In addition, FT-NIR reduction-efficiency data has been correlated to changes in black-liquor solids content, primary air flow and black-liquor firing rate. Online TTA control could help stabilize TTA which will stabilize recaust operations. The ability to monitor reduction efficiency online will provide operators with better understanding of boiler conditions that lead to “poor” conditions with high TRS and dead-load.

Paper presented at the 2007 International Chemical Recovery Conference in Quebec, Que., May 29 - June 1, 2007.

Keywords: GREEN LIQUOR, FT-NIR, TTA, REDUCTION EFFICIENCY, SULPHATE, THIOSULPHATE, ONLINE MONITORING, TTA CONTROL, SMELT DISSOLVING TANK, RECOVERY BOILER OPTIMIZATION, LIQUOR COMPOSITIONS Full manuscript available at www.paptac.ca.

July/August 2010

PULP & PAPER CANADA

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PAPTAC ABSTRACTS

Papridry™ – Continuous Operation of Two Pilot Units at Paprican

By I. Pikulik, G. Gauthier, and J. Hamel

Papridry™ – Fonctionnement en continu de deux unités pilotes à Paprican

Abstract: Incremental developments have increased the speed of the conventional dryer section, but have not eliminated its shortcomings, such as its enormous size, high capital and operating costs, and its failure to improve product quality. Papridry™ is a novel method for drying paper and board; it is designed to provide substantially higher drying rates and

Reduction in Quality Variation in a Continuous Kamyr Using Model Predictive Control

By A. Malhotra, M. Rahm, and M.T. Brown

Réduction de la variation de la qualité dans un lessiveur Kamyr en continu par contrôle prédictif à base de modèle (MPC)

Abstract: There is a growing need within the industry to cut operating cost by reducing variability in pulping operations and optimizing chemical and energy utilization. Better control of digester house operation is therefore considered to be at the center of pulp mill optimization, especially considering that many pulp mills are digester limited.

This paper details an implementation of a model predictive range

to improve the product quality. Two key elements of this technique are: pressing the wet web onto the surface of a large-diameter, heated, drying cylinder; and impingement of hot gas directly onto the uncovered paper from a hood surrounding the cylinder. Extensive pilot paper machine trials were conducted to test the method at nearly commercial speed in a series of long continuous trials. These trials, mostly conducted at 1000 m/min, demonstrated that the technique can reliably dry paper over an extended period of time. The drying rates measured in these trials ranged from 60 kg/h/m2 to 240 kg/h/m2. This work demonstrates that the technology is now ready for commercial application. The Papridry™ system could be installed on new machines or retrofitted into existing machines.

Paper presented at the PAPTAC Annual Meeting 2010 in Montreal, Que., February 2-3, 2010.

Keywords: DRYING, IMPINGEMENT DRYING, PRESSING, YANKEE DRIERS, YANKEE MACHINES, RUNNABILITY, NEWSPRINT, PAPER MACHINES, PAPER PROPERTIES, QUALITY Full manuscript available at www.paptac.ca.

control (MPRC) based approach on a continuous digester utilizing Honeywell’s Profit® controller. The robust range control algorithm of this controller helps to give good control despite model plant mismatch, which is inherent when using linear models to control a nonlinear process. This is particularly useful for dealing with nonlinearities due to different production rates. The goal has been to develop a solution to improve yield, reduce white liquor demand, and minimize Kappa variability. The MPRC design has focused on controlling cooking time, temperature and chemical concentration. Quality control was added by including Kappa feedback control and residual alkali feedback control.

This digester control solution has yielded excellent results in two digesters in a southeast United States mill, where we were able to meet and exceed all performance guarantees.

Paper presented at the PAPTAC 95th Annual Meeting 2009 in Montreal, Que., February 3-4, 2009.

Keywords: CONTINUOUS DIGESTER, KAMYR DIGESTER, PULP, MODEL PREDICTIVE CONTROL, MODEL PREDICTIVE RANGE CONTROL, MPC, MPRC, ADVANCE PROCESS CONTROL, APC, PROFIT CONTROLLER, RMPCT Full manuscript available at www.paptac.ca.

Scanner Path as a Manipulatable variations dans le sens travers Abstract: Typically quality at paper machines online is measured Variable for Optimal Control with a scanning gauge. This paper presents two approaches of irregular scanning to improve the diagnostics and control of the and Diagnostics of CD variations of the paper web: changing the scanning routine based on detection of variations degrading CD/MD separation perVariations formance, and continuous path optimization. A 2D estimation

By J. Ylisaari, K. Konkarikoski, R. Ritala, T. Kokko, M. Mäntylä

Chemin suivi par l’analyseur comme variable pouvant être manipulée pour le diagnostic et le contrôle optimal des 18

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method that is applied to both regular and irregular scanning is described.

Paper presented at the 2008 Control Systems Pan-Pacific Conference in British Columbia, June 16-18, 2008.

Keywords: SCANNING GAUGE, IRREGULAR SCANNING, 2D ESTIMATION Full manuscript available at www.paptac.ca.

pulpandpapercanada.com

HYDROGEN PEROXIDE

A Comparative Evaluation of Explosion Hazards in Chemical and Mechanical Pulp Bleaching Systems

By P.W. Hart and A.W. Rudie Abstract: Three pulp mills in North America using 50% hydrogen peroxide have suffered explosions of pumps, mixers, and tanks. In two instances, alkali-catalyzed decomposition of peroxide is implicated in the explosion. Although many mechanical pulping facilities use hydrogen peroxide to bleach pulp, no alkalicatalyzed explosions have been reported. This research uses a kinetic model of peroxide decomposition to explain why the peroxide bleaching process used for mechanical pulps has lower risks than processes used to bleach chemical pulps.

H

ydrogen peroxide is a well-known bleaching agent in both chemical and mechanical pulp mill bleach plants.

It can be and has been used safely for many years, but like any strong oxidant, it must be handled with respect. The major safety problems related to hydrogen peroxide use are the potential for rapid pressurization from catalyzed decomposition, fire due to oxygen formed in decomposition, and peroxide/organic vapor phase explosions. Within the past 15 years, at least three chemical pulp bleach plants in North America experienced catastrophic equipment failures associated with the use of 50 wt% peroxide [1,2]. People were badly injured in two of these instances, and these two mills were fortunate to have avoided fatalities in these events. Both bleach plants experienced a peroxide-induced pressure burst when peroxide and caustic were added to a medium-consistency pump and pulp flow did not start due to operating problems. The third incident was a contamination case that occurred at the UniforĂŞt mill in Port Cartier, Quebec, in 1993 [3].

Several significant differences in chemical and mechanical pulps have led to very different bleaching processes. Mechanical pulps typically contain high enough concentration of manganese and iron to decompose a significant portion of the peroxide used in bleaching pulp [4]. To minimize decomposition, mechanical pulp mills usually use a bleaching solution containing sodium silicate and magnesium sulfate as peroxide stabilizers. In comparison, most trace metals are removed in the first stage of bleaching for chemical pulps, and addition of peroxide stabilizers is usually not necessary.

Mechanical pulps use peroxide as the primary bleaching agents and typically require 1% to 3% charge on pulp. In comparison, peroxide is a supporting delignification reagent in most chemical pulpandpapercanada.com

pulp bleach plants and is used at less than 0.5% on pulp. The high chemical charge in the case of mechanical pulps justifies more capital and the result is a stage optimized for peroxide bleaching: a press to enable bleaching at 20% consistency and a specialized mixer to mix chemicals efficiently in the absence of free water. The low charge of peroxide in most chemical bleaching systems does not justify significant capital expense, and these stages are usually very similar to other chemical bleaching stages such as chlorine dioxide and caustic extraction.

The high consistency used in bleaching mechanical pulp benefits the process in two ways.

Mechanical pulps are low drainage pulps and generally have had very little washing that could remove trace metals before peroxide bleaching.

Pressing the pulp from 3% to over 20% consistency removes as much as 88% of the soluble metals, providing significant benefit in peroxide stability and bleaching efficiency. For a case using 3% peroxide on pulp at 20% consistency, the initial peroxide concentration is over 0.2 M, more than twice the concentration and consequently more than twice the reaction rate obtainable at a more conventional 10% consistency. This also provides a noticeable improvement in the performance of the bleaching stage. For chemical pulps, the preceding stage washer discharges at 12% to 14% consistency and chemicals are added either by simultaneous injection into a medium-consistency pump or mixer or by mixing caustic in the repulper of the preceding stage and adding peroxide at the mixer.

The two different systems have resulted in different standard practices in supplying peroxide to the pulp mixer. The additional chemicals and the need to provide sufficient volume to obtain uniform chemical distribution in the high-consistency mixer necessitate considerable dilution for mixing July/August 2010

P.W. HART MeadWestvaco Corp., Atlanta, GA

A.W. RUDIE USDA Forest Products Laboratory, Madison, WI PULP & PAPER CANADA

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HYDROGEN PEROXIDE

Fig. 1. Temperature and adiabatic volume of oxygen and steam resulting from the decomposition of a single volume of hydrogen peroxide solution. Volumetric expansion is liters of gas produced per liter of peroxide solution.

Fig. 2. Pressure change when 50% peroxide is added to a CSTR-type mixing chamber containing 3.25 gallons of 25% caustic—first 1/10 s. Note that reaction pressure has stabilized at the first time increment.

peroxide with mechanical pulps and the resulting solution is typically about 10% peroxide.

Chemical pulp mills have few requirements, and this has resulted in a lack of standardization for handling peroxide. Without installing the specialized equipment used in mechanical pulp bleaching, the only way to increase the peroxide concentration in a chemical mill is to start at a higher peroxide solution strength.

Some mills or suppliers have taken this approach, supplying 50% peroxide direct from storage to the pulp mixer. Most have elected to dilute to 10% strength for distribution in the mills. Although the approach is sound in theory, in practice the higher peroxide strength appears to have little benefit. Assuming the washer is discharging at 14% consistency and the peroxide charge is 0.5% on pulp, the final peroxide stage consistency and peroxide concentration are 13.9% and 0.0237 M when peroxide is added as a 10% solution, and 13.98% and 0.0239 M when it is added using a 50% solution. This is not a large enough difference to have a noticeable impact on stage efficacy.

In an effort to understand the hazards associated with hydrogen peroxide use in both chemical and mechanical pulp bleaching systems, the current work employs a dynamic kinetic model of caustic-induced hydrogen peroxide decomposition to determine conditions that lead to potentially explosive situations. The hazardous conditions identified are then examined relative to typical procedures for bleach liquor preparation and addition in both mechanical and chemical pulp bleaching systems. The potential hazards for each type of system can then be evaluated.

from inorganic contamination and base catalysis are similar.

These are a disproportionation reaction recombining two moles of peroxide to produce one mole of oxygen and two moles of water [6,7]:

PEROXIDE DECOMPOSITION

Gas generation, volumetric expansion In general, peroxide is a stable chemical, decomposing slowly at a rate less than 1% per year [5]. If mishandled, peroxide can decompose rapidly and becomes a serious chemical hazard. The most serious peroxide accidents usually involve one of three types of decomposition processes: • decomposition resulting from organic contamination, • decomposition resulting from inorganic contamination, or • decomposition under alkaline conditions.

The peroxide reaction with organic materials is an oxidation reaction much like combustion. The decomposition reactions 20

PULP & PAPER CANADA July/August 2010

2 H2O2(aq) fi 2 H2O(g) + O2 (g) ΔH = –14.3 kcal/g-mol [1] The reaction is highly exothermic and the temperature rise from decomposition increases the rate of decomposition—a critical condition for a runaway reaction.

Using the heat of reaction [7] and ideal gas law, the adiabatic volumetric expansion can be calculated for hydrogen peroxide at various strengths (Fig. 1) [3,8]. Between the 1.5 mol of gas evolved from the decomposition and the water vapor produced from the heat of reaction, extremely large volumes of gas can be produced at the higher peroxide concentrations. The water produced by the decomposition remains liquid until the temperature reaches 100°C. At about 10% peroxide concentration, the heat from peroxide decomposition is sufficient to raise the solution from room temperature to 100°C, and the decomposition begins to generate steam. At about 60% concentration, insufficient water is available to carry away the heat of reaction as steam, and the gas temperature rises above 100°C, causing additional thermal expansion. Use of dilute solutions provides an inherent risk reduction although it cannot remove all risk.

Alkali-catalyzed peroxide decomposition kinetics Alkali-catalyzed decomposition of hydrogen peroxide follows second-order reaction kinetics as shown in equation 2 [7]. The rate of decomposition depends on both the acid (HOOH) and base (HOO–) forms of peroxide: dP/dt = –k[HOO–][HOOH]

[2]

where P is total peroxide concentration (both acid and base forms) and t is time.

The apparent rate constant reported by Makkonen is 8 × 10–3 L/mol/s at 45°C [7]. The apparent rates follow the Arrhenius theory within the temperature range of Makkonen’s experiments, giving an activation energy of 13.1 kcal/mol [7]. The rate is pulpandpapercanada.com

PEER REVIEWED

Fig. 3. Concentration of acid and base forms of peroxide for the first 100 s. There is never sufficient acid form to accelerate the reaction.

Fig. 4. Estimated pressure for a scenario using 50% peroxide and 25% sodium hydroxide. The vented mixing vessel contained 25 L of peroxide prior to alkali addition.

flow was estimated using the square root relationship between mass flow and differential pressure [10] and assuming a 10-cmdiameter orifice.

(P

M/s = 0.0252

Fig. 5. Concentrations of H2O2 and HO2– as estimated by the kinetic model for the situation in Fig. 4.

reported as an apparent rate since it is condition dependent and the decomposition from alkaline catalysis cannot be completely separated from decomposition due to trace transition metals, which is also pH dependent [9]. As examples, Makkonen measured slower decomposition for reactions stabilized with magnesium or silicate [7], and Galbacs and Csanyi reported rates as low as 10–6 L/mol/s using extreme efforts to minimize inorganic contamination [9]. Because mill conditions are invariably heavily contaminated, the Makkonen kinetic measurements provide a conservative estimate of the apparent decomposition rate and a convenient basis for developing a dynamic kinetic model.

Dynamic kinetic modeling To evaluate conditions that could lead to catastrophic peroxide decomposition, a kinetic model was prepared in an Excel spreadsheet (Microsoft Corp., Redmond, Washington) integrating the reaction kinetics using Euler’s method. Details of the model were published elsewhere [3, 8]. The model can vary peroxide and caustic concentration and evaluate pressure build-up for closed systems or situations with some gas escape, as would occur in a pump or mixer.

Several design configurations were evaluated using the kinetic model developed earlier. Early scenarios had included adiabatic conditions and gas-vented conditions. For the vented cases, gas pulpandpapercanada.com

h

– 10100)P h T

[3]

where M is mass, Ph pressure at the high-pressure side of the orifice, and T temperature in kelvins.

All dynamic scenarios for evaluating mill mixing systems in this paper used the 10-cm-diameter vented model. The model involves a number of approximations. First among these is the orifice constant, which is typically around 0.85. The model also assumes no significant rate acceleration from equipment surfaces or contaminants and estimates kinetic rate at temperatures well beyond the range evaluated by Makkonen [7]. The errors in these assumptions can be substantial. Additionally, the presence of sodium silicate and/or chelant reduces the reaction rate.

Because the purpose was to evaluate worst-case scenarios, these mitigating factors were not considered. The value of the model is in demonstrating features of the process that can predispose the process to catastrophic decompositions but not in identifying conditions that are certifiably safe. The model is also capable of determining the impact of order of chemical addition and change in concentration of the acid and base forms of peroxide as the decomposition reaction progresses. The model was used previously to identify specific system failures that contributed to the runaway reactions experienced by the two chemical pulp mills [3].

Scenario 1: Simultaneous mixing of 50% peroxide and 25% sodium hydroxide The first scenario examined the decomposition for a startup condition mixing diluted caustic with 50% hydrogen peroxide. As shown in Fig. 2, the peroxide caustic solution rapidly reaches a decomposition equilibrium condition that results in a very slight pressure rise easily contained within the system. Maintaining flow rates simply results in a steady increase in the base form of the peroxide (HOO–), and the low residual concentration of acid form controls overall rate and causes the reaction to become selflimiting. Figure 3 shows the gradual build-up of the base form of hydrogen peroxide over the first 100 s of adding peroxide to the mixing tank. The acid form of peroxide remains below 0.01 M. July/August 2010 PULP & PAPER CANADA

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HYDROGEN PEROXIDE Scenario 2: Delayed addition of sodium hydroxide When caustic is added to a preexisting pool of high concentration (50%) hydrogen peroxide, the pressure rise is quite sudden and very substantial (Fig. 4). This reaction scenario is no longer self-limiting. Instead of a steady or declining rate dictated by the limited concentration of the acid form of peroxide, as the caustic increases, the reactant ratios approach ideal. Temperature and kinetic rate rise, causing an acceleration of the reaction rate and much higher gas and steam pressures. Because the reaction rate does not begin to slow until the acid form of the peroxide is nearly exhausted, the ultimate rate, temperature, and pressure are limited principally by the initial concentration and volume of peroxide (Figure 5). This scenario mimics the conditions thought to have preceded at least one of the two catastrophic mill incidents.

Other scenarios examined Several other systems were evaluated. All scenarios using dilute peroxide (10% or less) fail to produce the unmanageable pressure spikes observed in the second scenario (Fig. 4). This is primarily because there is sufficient water to prevent boiling, and welldesigned peroxide storage systems provide sufficient vent area to prevent a significant pressure build up. Low peroxide strength therefore provides an inherent improvement in safety to peroxide mixing systems. Unvented vessels and pipe supply systems can still encounter substantial pressures. A scenario with delayed peroxide addition provided an outcome similar to that of Scenario 1. When the hydrogen peroxide starts to enter the reaction system, it rapidly converts to the base form. Because the alkali is not consumed in the reaction, any increase in the kinetic rate of decomposition quickly consumes the residual acid form peroxide, which becomes the limiting reagent that controls reaction rate.

CONCLUSIONS

The general arrangement of typical mechanical pulp bleaching liquor preparation systems makes them relatively safe to operate. Concentrated hydrogen peroxide is added into a flowing or mixed stream of diluted caustic. The presence of sodium silicate, magnesium sulfate, and/or chelant help to slow the decomposition reaction, and the dilution water reduces concentrations and adds a large thermal mass that absorbs the heat from decomposition that does occur. Once the peroxide concentration is below 10 wt%, the potential for catastrophic pressure rises is substantially reduced although not completely eliminated.

Chemical pulp bleaching systems do not always have this designed-in safety. Some systems use caustic and peroxide as received or stored, resulting in very high concentration mixing.

These mills can generally operate safely, but under upset condition where the pulp flow is interrupted and caustic flow starts late, the pool of high concentration peroxide can decompose at accelerating rates and overload the vent capability of the system and in worst-case scenarios, the pressure handling capability of the equipment. The reason this scenario results in a significant pres-

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sure spike is that the reservoir of peroxide continues to feed the reaction while temperature and kinetic rate increase. By contrast, there is no reservoir of reactive peroxide when the caustic is diluted in the mixing tank and used as dilution for peroxide being added into an exit stream of a cascade mixer or series of static mixers.

The dynamic kinetic model of alkali-catalyzed peroxide decomposition used in this evaluation appears to mimic mill experience nicely. It has identified one specific set of conditions that should result in significant pressure spikes and potentially catastrophic consequences. This scenario appears to match the conditions thought to have preceded one of the two catastrophic failures that have been recorded in chemical pulp bleaching systems. Although eliminating all hazards in working with energetic chemicals is impossible, experience and the kinetic model both suggest that the risk of catastrophic pressure spikes can be greatly reduced by diluting the peroxide to 10% strength for distribution to the bleach plant.

LITERATURE

1. HOEKSTRA, G., “Explosion Rocks Mill, Two Workers Injured by Blast” Prince George Citizen, Feb. 8, 2007.

2. “Ruptured Pump May Figure into Evadale Mill Explosion”, Beaumont Enterprise, Beaumont Texas, Aug. 18, 2001.

3. HART, P.W., RUDIE, A.W., Hydrogen Peroxide—An Environmentally Friendly but Dangerous Bleaching Chemical, TAPPI EPE Conference, Jacksonville, FL, Oct. 2007.

4. PRESLEY, J.R., HILL, R.T., “Peroxide Bleaching of (Chemi)Mechanical Pulps” Chapter 1, Section V of Pulp Bleaching, Principles and Practice, Dense, C.W. and Reeves, D.W. editors, TAPPI Press, Atlanta, 1996.

5. SCHUMB, W.C., SATTERFIELD, C.N., WENTWORTH, R.L., Hydrogen Peroxide, ACS Monograph No. 128, Reinhold Publishing Corporation, New York, 1955, pg. 526.

6. RAINES, J.C., SCHMIDT, J.P., BURELACH, J.P., FAUSKE, H.K., “Assessing Contaminated Hydrogen Peroxide for Safe Storage and Transportation Using the FTAI”, Journal of Thermal Analysis and Calorimetry, 85(1):53-55 (July 2006).

7. MAKKONEN, H.P., Decomposition of Hydrogen-Peroxide in Dilute Alkaline Aqueous Solutions, Ph.D. Thesis, University of Washington, 1971.

8. HART, P.W., RUDIE, A.W., “Modeling an Explosion: The Devil is in the Details”, submitted to Chemical Engineering Education.

9. GALBÁCS, Z.M., CSÁNY, L.J., “Alkali-induced decomposition of hydrogen peroxide”, J. Chem. Soc., Dalton Trans., 2353-2357(1983).

10. Perry’s Chemical Engineers’ Handbook, 6th ed., McGraw-Hill, Inc, New York, 1984, pp. 5-13.

Résumé :

Des pompes, des mélangeurs, et des réservoirs ont explosé dans trois usines de pâte chimique nord-américaines qui utilisaient du peroxyde d’hydrogène à 50 %. Dans deux de ces cas, la décomposition du peroxyde catalysée par l’alcali a été la cause de l’explosion. Bien que bon nombre d’usines de pâte mécanique utilisent du peroxyde d’hydrogène pour blanchir la pâte, on n’a rapporté aucune explosion catalysée par de l’alcali. La présente recherche emploie un modèle cinétique de la décomposition du peroxyde pour expliquer pourquoi le procédé au peroxyde utilisé pour blanchir la pâte mécanique comporte moins de risque que les procédés utilisés pour blanchir la pâte chimique.

Keywords: HYDROGEN PEROXIDE EXPLOSION, DECOMPOSITION, KINETIC MODEL, MECHANICAL PULP, BLEACHING.

Reference: HART, P.W., RUDIE, A.W. A Comparative Evaluation of Explosion Hazards in Chemical and Mechanical Pulp Bleaching Systems.

Pulp & Paper Canada 111(4): T60-T63 (July/Aug 2010). Paper presented at the PAPTAC Annual Meeting 2010 in Montreal, Que., February 2-3, 2010.

Not to be reproduced without permission of PAPTAC. Revised manuscript approved for publication by the Review Panel April 19, 2010.

pulpandpapercanada.com

ENZYME BLEACHING

Effect of Eucalyptus Kraft Pulp Enzyme Bleaching on Effluent Quality and Bio-Treatability

By M.T. Borges, C.M. Silva, J.L. Colodette, L.B. Alves, G.R. Rodrigues, L.C. Lana, F. Tesser Abstract: The filtrate and pulp quality of different enzymatic pre-bleaching conditions were characterized.

Bio-treatability of the effluents was evaluated. Enzymatic pre-bleaching of Eucalyptus pulp was carried out in 4 different conditions of pH and enzyme dosage. The best pulp quality was achieved at pH 7, when smaller kappa number, higher pulp brightness and smaller amount of hexenuronic acid were observed. However, in this condition a higher yield loss and effluent COD load were observed. For all bio-treatment assays, the COD removal was higher than 85%.

T

he bleaching sector of a kraft pulping process is responsible for the high effluent volume generated in modern mills. The effluent is rich in organic matter and contaminants such as organochlorine compounds when chlorine based chemicals are used [1]. The industry has been looking for novel processes in order to minimize the impact of these effluents in the environment.

In the 90s, the use of enzymes in pre-bleaching stages aimed at the improvement of effluent quality, particularly the reduction of organochlorine compounds (AOX) in the effluent [2].

Currently, the enzymatic pre-bleaching stages are used mainly for economical reasons. It reduces the consumption of bleaching chemicals, particularly the chlorine dioxide in ECF (elemental chlorine free) sequences [3, 4]. However, when enzymatic pre-bleaching stages are used, an increase of the filtrate’s organic load has been observed, compromising the effluent treatment plants [5].

Enzymes are protein molecules capable of catalyzing specific chemical reactions. Specificity of enzymes is generally very high [6]. They are commercially produced by fungi and bacteria.

Currently, it has been possible to produce stable enzymes by genetic manipulation with high effectiveness for pulp bleaching processes [7]. Industrially, they are commercialized in concentrated liquid suspensions and are applied in small dosages in the pre-bleaching reactor. Two types of enzymes are often used for kraft pulp bleaching: xylanases and laccases [8].

Xylanase has been the most common type of enzyme used for this purpose. It is very efficient and reduces considerably the use of bleaching chemicals [3]. In some cases, where chlorine or chlorine dioxide is used, it can lower the AOX in pulpandpapercanada.com

the filtrates by as much as 25% [9].

Due to the specific nature of enzymes, several conditions can affect the enzymatic reaction, such as the application rate, pH, temperature, retention time and mixing [10].

In the 90s, the typical pre-bleaching conditions with xylanase were: temperature varying from 40°C to 55°C, pH from 4 to 6, pulp consistency from 2.5 to 12% and a time reaction from 0.5 to 3 hours. Initial studies demonstrated that the wood type, the bleaching sequence and the type of xylanase could affect the enzymatic treatment [11]. Better conditions of xylanase application have been developed, allowing the use of enzymes in common mill conditions, such as alkaline pH, higher temperatures and shorter retention time [8, 12].

Some advantages of xylanase application are the low capital investment, the reduction of bleaching chemicals (15-20%), the low AOX concentration in the final effluent and the higher pulp brightness [13, 14, 15]. However, the effect of xylanases is limited, because they do not replace more than 20% of the bleaching chemicals. Moreover, the cost of xylanase is high [2, 7] and there is a possibility of pulp yield losses [15]. Electronic microscopy studies of oxygen bleached pulps followed by enzymatic pre-bleaching had shown some fiber morphologic changes such as holes, cracks, formation of filaments and peeling [16].

Senior and Hamilton, 1991, showed that the BOD (biochemical oxygen demand) of the filtrate after xylanase pre-bleaching of softwood increased almost two times compared to a reference. Similarly, COD (chemical oxygen demand) and TOC (total organic carbon) also increased. On the other hand, BOD/COD ratio was significantly higher for the xylanase pre-bleaching filtrates, i.e., the

M.T. BORGES Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG C.M. SILVA Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG J.L. COLODETTE Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG L.B. ALVES Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG G.R. RODRIGUES Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG L.C. LANA Universidade Federal de Vicosa, Departamento de Engenharia Florestal, Laboratorio de Celulose e Papel, Viçosa — MG F. TESSER International Paper do Brasil Ltd

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ENZYME BLEACHING TABLE I: Pulp characterization for the different treatments Treatment

Fig. 1: Enzymatic pre-bleaching diagram in 85°C for 2h.

Reference pH 7 Reference pH 9 25 g adt-1 pH 7 25 g adt-1 pH 9 200 g adt-1 pH 7 200 g adt-1 pH 9

Kappa Number

Brightness % ISO

10.81 ± 0.08 ab 10.89 ± 0.05 a 9.79 ± 0.12 c 10.44 ± 0.06 b 8.60 ± 0.16 d 9.93 ± 0.08 c

52.03 ± 0.01 d 51.92 ± 0.02 d 53.12 ± 0.08 b 52.03 ± 0.12 d 54.81 ± 0.05 a 52.55 ± 0.09 c

Values are mean of three replicates; ±standard deviation; Averages followed by the same letter in the columns do not differ significantly from each other by the Tukey test at 5% probability.

TABLE II: Pulp characterization for the different treatments Treatment Reference pH 7 Reference pH 9 25 g adt-1 pH 7 25 g adt-1 pH 9 200 g adt-1 pH 7 200 g adt-1 pH 9

Hexa’s (mmol kg-1)

Yield Loss (%)

50.99 ± 0.03 b 52.15 ± 0.34 a 45.76 ± 0.04 d 51.10 ± 0.34 b 42.62 ± 0.37 e 48.48 ± 0.18 c

0.73 ± 0.16 d 0.76 ± 0.24 d 2.66 ± 0.11 b 1.74 ± 0.28 c 3.20 ± 0.05 a 2.19 ± 0.16 bc

Values are mean of three replicates; ±standard deviation; Averages followed by the same letter in the columns do not differ significantly from each other by the Tukey test at 5% probability.

Fig. 2. Kappa number versus enzyme dosage

effluents seemed to be more biodegradable [17].

In fact, there are only a few studies about the influence of enzyme pre-bleaching on effluent quality [17, 5, 9]. The objectives of this study were to characterize the filtrate and the pulp quality of different enzymatic pre-bleaching conditions and to evaluate the bio-treatability of the effluents.

MATERIAL AND METHODS

Enzymatic pre-bleaching of eucalyptus pulp was carried out in four different conditions using an endo-1, 4-b-xylanase: enzyme dosage of 25 and 200 g adt-1 and pH 7 and 9 for each dosage. A test without enzyme was also carried out as a reference [Fig. 1].

The dosage of 25 g adt-1 was based on the commercial use of the xylanase, while the dosage of 200 g adt-1 was obtained from a decreasing kappa curve obtained in lab conditions [Fig. 2]. The pH 7 was chosen for being the ideal value for enzymatic reaction, and the pH 9 was chosen because it could favor mill conditions avoiding acid application. The bleaching conditions were 85°C for 2h, and a pulp consistency of 10%. The pulp was characterized by kappa number, brightness, hexenuronic acid and yield loss.

About 14 L of filtrate was generated in each enzymatic prebleaching assay. The filtrates were characterized and the biotreatability determined. The parameters were: COD, BOD5, color and electric conductivity. The filtrates generated in the enzymatic pre-bleaching treatments were kept at 4°C for two weeks approximately. The bio-treatability was conducted in sequencing batch bioreactors. The effluent characterization was based on the Standard Methods for the Examination of Water and Wastewater, 1998 [18].

The sequencing batch bioreactor consists of a complete mixture reactor operating in cycles where all phases of treatment occur: filling, reaction (aeration), sludge settling and sludge waste.

The bioreactor consisted of a 2000 ml beaker, equipped with air diffusers for aeration and mixture. The temperature was kept at 24

PULP & PAPER CANADA July/August 2010

TABLE III: Effluent characterization for the different treatments Treatment

COD (mg L-1)

Reference pH 7 Reference pH 9 25 g adt-1 pH 7 25 g adt-1 pH 9 200 g adt-1 pH 7 200 g adt-1 pH 9

933 ± 25 f 1169 ± 30 e 3368 ± 78 b 1833 ± 58 d 5051 ± 133 a 2431 ± 140 c

Values are mean of three replicates; ±standard deviation; Averages followed by the same letter in the columns do not differ significantly from each other by the Tukey test at 5% probability.

TABLE IV: Effluent characterization for the different treatments Treatment

Color (mg L-1)

Conductivity (µS.cm-1)

Reference pH 7 Reference pH 9 25 g adt-1 pH 7 25 g adt-1 pH 9 200 g adt-1 pH 7 200 g adt-1 pH 9

331 ± 28 e 345 ± 15 e 761 ± 13 b 487 ± 36 d 1012 ± 21 a 656 ± 25 c

235 238 386 199 450 246

± ± ± ± ± ±

29 c 25 c 18 b 11 c 14 a 5c

Values are mean of three replicates; ±standard deviation; Averages followed by the same letter in the columns do not differ significantly from each other by the Tukey test at 5% probability.

35°C. Each bio-treatability assay had 14 cycles of 12 hours each [10 hours for filling and reaction and 2 hours for sedimentation and sludge waste). The reactors were fed with a constant volume of 500 ml of effluent.

Aerobic sludge seeding from an activated sludge of a pulp mill was used in order to adapt the biomass to the effluent. The system efficiency was determined by the COD removal rate. The BOD:N:P ratio was kept 100:5:1. The minimum level of dissolved oxygen in the reactor was 2 mg L-1. Sludge waste was based on the mixed liquor volatile suspended solid (MLVSS) concentration being kept constant at 3000 mg L-1. pulpandpapercanada.com

PEER REVIEWED TABLE V: COD removal during bio-treatability assays Treatment

Initial COD (mg L-1)

Final COD (mg L-1)

COD removal (%)

Reference pH 7 Reference pH 9 25 g adt-1 pH 7 25 g adt-1 pH 9 200 g adt-1 pH 7 200 g adt-1 pH 9

933 ± 25 f 1169 ± 30 e 3368 ± 78 b 1833 ± 58 d 5051 ± 133 a 2431 ± 140 c

121 137 419 233 639 321

85.3 85.3 87.3 87.3 85.5 85.7

± ± ± ± ± ±

4.55 e 11.03 e 14.17 b 10.09 d 19.87 a 20.53 c

± ± ± ± ± ±

3.44 8.01 1.00 0.68 2.87 1.76

ns ns ns ns ns ns

ns: non-signicant by the F test at 5% probability; Values are mean of three replicates; ±standard deviation; Averages followed by the same letter in the columns do not differ significantly from each other by the Tukey test at 5% probability.

Fig. 3. COD (mg L-1) versus Yield Loss (%) for the reference and the different enzyme dosages

RESULTS AND DISCUSSION

Tables I and II present the pulp characterization after the different enzymatic pre-bleaching treatments. Compared to the reference, the lowest kappa number [8.6] and the highest brightness of the pulp (54.81% ISO) were obtained for the enzyme dosage of 200g adt-1 in pH 7. A lower hexenuronic acid concentration was also observed in this condition (42.62 mmol kg-1), which might reduce pulp brightness reversion. However, the yield loss was higher in this condition (3.2%) when compared with the other treatments.

The pulp sample corresponding to the enzyme dosage of 25 g adt-1 in pH 9 presented the highest kappa number of all treatments [10.44] and the lowest brightness (52.03% ISO), which were similar to the reference pulp sample. The quantity of hexenuronic acid was also similar to the reference in pH 9 (51.10 mmol kg-1 and 52.15 mmol kg-1). This could be explained by the unfavorable pH to the enzymatic reaction. The 1.74% yield loss was higher than the reference (0.73%).

The enzyme dosage of 25 g adt-1 in pH 7 had the effect on the pulp characteristics of reducing the kappa number and the hexenuronic acid content and increasing pulp brightness. However, a higher yield loss was observed compared with the reference. These effects were more pronounced when a higher enzyme dosage of 200 g adt-1 in pH 7 was applied.

Interestingly, the pulp samples corresponding to the enzyme dosage of 25 g adt-1 in pH 7 presented similar kappa number and brightness to the samples of enzyme dosage of 200 g adt-1 in pH 9. However, the pulp samples of 25 g adt-1 in pH 7 showed lower concentration of hexenuronic acids and presented higher yield loss when compared to the pulp samples of 200g adt-1 in pH 9, demonstrating the essential influence of pH in the enzymatic reaction. pulpandpapercanada.com

Tables III and IV present the effluent characteristics from the enzymatic pre-bleaching stages. A significant increase in the COD load of the filtrates was observed when enzymatic treatment was used.

The highest effluent COD concentration was observed for the treatment with 200 g adt-1 in pH 7, in which the COD concentration (5051 mg L-1) was more than 5 times higher than the reference (933 mg L-1). For conventional industrial enzyme dosages of 25 g adt-1 in pH 7, the filtrate COD was significantly higher (3368 mg L-1) than the reference.

Also, for all treatments in pH 9, a significant increase of COD concentration in the filtrates was observed, although they were smaller than the COD concentrations of the treatments in pH 7. It is clear that the COD load increases as the pulp yield loss increases (Fig. 3).

The increase in the organic matter content of the filtrates will have a strong impact on the mill’s overall effluent quality and also on the effluent treatment plant. A higher oxygen demand would be necessary for the aerobic treatment processes.

Similar to the COD concentration, increases in the filtrate color and electric conductivity were also observed in the enzymatic treatment assays. The increase in color may also have an important effect on effluent quality because normally a conventional biological treatment process does not remove color from the effluent.

Figure 4 and Table V present the results of the bio-treatability assays. Figure 4 shows the results of each cycle of initial and final COD. It can be observed that there were no significant changes during the bio-treatability assays. After the first cycle the biomass was completely adapted to the effluent characteristics and a high COD removal was obtained for all filtrates. Table V shows that COD removal was similar, in the range of 85 to 88%, for all filtrates. Therefore, it is clear that the final COD concentration of the treated effluent was higher for the filtrates that had higher initial COD. The organic matter content of the filtrates generated by the enzymatic pre-bleaching stage is mainly biodegradable and can be efficiently removed by aerobic treatment systems. The increase in the organic load of the effluent will lead to a higher demand for oxygen and energy in the treatment plants. Besides, the treated effluent from enzyme pre-bleaching stage will have a higher final COD concentration that could violate environmental legislation standards of some countries.

CONCLUSIONS

The enzymatic pre-bleaching had a significant effect on pulp quality. It decreased kappa number and the hexenuronic content of the pulp and increased pulp brightness. However, it also increased pulp yield loss. The enzyme dosage of 200 g adt-1 and pH 7 was the most effective condition of the pre-bleaching stage for Kappa number and brightness.

A substantial increase in the organic matter content (COD) in the filtrates was observed in the enzymatic pre-bleaching stage.

The COD concentration in the filtrates was three times higher than the reference when enzyme dosages of 25 g adt-1 in pH 7 was applied; and five times higher than the reference for enzyme dosages of 200 g adt-1 in pH 7.

In spite of the increase on COD load of the enzymatic prebleaching stage filtrates, the generated effluents were efficiently July/August 2010 PULP & PAPER CANADA

25

T66

T67

ENZYME BLEACHING treated in aerobic bioreactors. The COD removal was always superior to 85%, similar to the reference.

The increase in the organic matter content in the filtrates will lead to a higher aeration and energy demand in the treatment plant. Moreover, the final COD concentration of the treated effluents from enzymatic pre-bleaching stages will be higher than conventional bleaching sequences.

Brazilian forest fungal species in bleaching of Eucalyptus kraft pulps,” Journal of Biotechnology 136S. (2008) 17. SENIOR, D.J., HAMILTON, J., “Use of xylanases for the reduction of AOX in Kraft pulp bleaching,” CPPA Environmental Conference, Quebec, ICI CANADA INC., p. 310 – 314 (1991).

18. APHA, Standard Methods for the Examination of Water and Wastewater. 20th Ed. Washington. AWW – WPCF, 1325p (1998).

ACKNOWLEDGEMENTS

We thank CNPq (Conselho Nacional Científico e Tecnológico) and FAPEMIG for the financial scholarship that helped us to carry out the experiments. This work was also supported by International Paper do Brasil Ltd.

LITERATURE

1. VIDAL G., SOTO M., FIELD J., MÉNDEZ-PAMPÍN R.; LEMA J. M. Anaerobic biodegradability and toxicity of wastewaters from chlorine and total chlorine-free bleaching of eucalyptus kraft pulps. Water Research. 31(10):2487-2494 (1997).

2. FALEIROS, M. Chemicals come to an alliance with the sector eco-efficiency. O PAPEL. 30-35 (2008).

3. CALL H.P., MŸCKE I. History, overview and applications of mediated lignolytic systems, especially laccase-mediator-systems (Lignozym®-process). Journal of Biotechnology. (53):163–202 (1997).

4. BEG, Q.K, KAPOOR, M., MAHAJAN, L., HOONDAL, G.S. Microbial xylanases and their industrial applications: a review. Appl Microbiol Biotechnol.56:326–338 (2001).

5. DANEAULT, C., LEDUC, C., VALADE, J. L. The use of xylanases in Kraft pulp bleaching: a review. Tappi Journal, 77(6):125 – 131 (1994).

6. MADIGAN, M. T., MARTINKO, J. P., PARKER, J., “Brock Biology of Micoorganisms”, Prentice Hall, Upper Saddle River, New Jersey. 8 Ed. 986p (1997).

7. SAVITHA, S., SADHASIVAM, S., SWAMINATHAN, K., “Modification of paper properties by the pretreatment of wastepaper pulp with Graphium putredinis, Trichoderma harzianum and fusant xylanases”, Bioresource Technology. (100):883–889 (2009).

8. VALLS, C., RONCERO, M.B. “Using both xylanase and laccase enzymes for pulp bleaching,” Bioresource Technology, (100):2032–2039 (2009).

9. MANJI, A.H., “Extended usage of xilanase enzyme to enhance the bleaching of softwood kraft pulp,” Tappi Journal, 5(1):23-26 (2006) 10. FARRELL, R. L., “Status of enzyme bleaching R&D and mill work. In: Non-Chlorine Bleaching” PROCEEDINGS... South Carolina, Pulp and Emerging Technology, March 2 – 5, s.p. 234 – 291, (1992).

11. TORRES, A.L., RONCERO, M.B., COLOM, J.F., PASTOR, F.I.J., BLANCO, A., VIDAL T., “Effect of a novel enzyme on fibre morphology during ECF bleaching of oxygen delignified Eucalyptus kraft pulps,” Bioresource Technology, (74):135-140 (2000).

12. KHANDEPARKAR, R., BHOSLE, N.B., “Application of thermoalkalophilic xylanase from Arthrobacter sp. MTCC 5214 in biobleaching of kraft pulp,” Bioresource Technology (98):897–903 (2007).

13. ATIK, C., IMAMOGLUB, S., BERMEKC, H., “Impact of xylanase pre-treatment on peroxide bleaching stage of biokraft pulp,” International Biodeterioration & Biodegradation, (58):22–26 (2006).

14. SALEEM, M., AKHTAR, M.S., “Biobleaching of kraft Pulp by Xylanase Produced

by Bacillus subtilis.” International Journal of Agriculture & Biology, 4(2) (2002).

15. HART, P.W., HARRY, S.F., “Statistical determination of the effects of enzymes on bleached pulp yield,” Tappi Journal Source, 4(8):3-6 (2005) 16. MEDEIROS, R.G., SALLES, B.C., SILVA, L.P., HANADA, R., SILVA, JR, F.G., BÁO, S.N., AZEVEDO, R.B., FILHO, E.X.F., “Application of xylanases from

Résumé:

Nous avons caractérisé la qualité du filtrat et de la pâte dans divers milieux de pré‑blanchiment aux enzymes et nous avons évalué la capacité de biotraitement des effluents. Nous avons effectué un pré‑blanchiment aux enzymes de pâte d’eucalyptus dans quatre milieux différents de pH et de dosage d’enzymes. La meilleure qualité de pâte a été obtenue à un pH de 7, où l’indice Kappa était plus faible; le degré de blancheur de la pâte, plus élevé; et la quantité d’acide hexénuronique, plus faible. Toutefois, dans ce milieu, la perte de rendement et la charge de DCO de l’effluent étaient plus importantes.

Dans tous les essais de biotraitement, l’élimination de la DCO était supérieure à 85 %.

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PULP & PAPER CANADA July/August 2010

Fig. 4: Initial and final COD during the bio-treatability of the effluents: a) enzymatic pre-bleaching in pH 7; b) enzymatic pre-bleaching in pH 9.

Keywords: ENZYME BLEACHING, EFFLUENT, BIO-TREATMENT

Reference: BORGES, M.T., SILVA, C.M., COLODETTE, J.L.,

ALVES, L.B., RODRIGUES, G.R., LANA, L.C., TESSER, F. Effect of Eucalyptus Kraft Pulp Enzyme Bleaching on Effluent Quality and BioTreatability, Pulp & Paper Canada 111(4): T64-T67 (July/Aug 2010). Paper presented at the PAPTAC Annual Meeting 2010 in Montreal, Que., February 2-3, 2010. Not to be reproduced without permission of PAPTAC. Manuscript received August 1, 2009. Revised manuscript approved for publication by the Review Panel December 9, 2009.

pulpandpapercanada.com

TECHNOLOGY NEWS

Direct Steam Injection Rapidly Heats Pulp Stock, Biomass Kadant Canada Corp. now offers a direct steam injection water heater product line.

Direct steam injection water heaters, also referred to as direct injection heaters, are used to rapidly and accurately heat water and water-based slurries by injecting steam directly into the fluid.

Direct injection heaters can be used in boiler feedwater preheating, fibrous slurries such as pulp stock and biomass pretreatment, paper starch processing, sanitization and tank cleaning, and anaerobic treatment of organic waste, among other applications.

Direct injection heating uses all the sensible and latent heat of steam to heat the fluid. It can provide equal heating to

that of an indirect heat exchanger process with 20% to 30% less energy. The improved energy efficiency results in less steam consumption with no reduction in output.

Kadant direct steam injection water heaters are available in sizes 1.5 in. through 16 in.

Kadant Canada, 613-931-2305 www.kadant.com

Powerful, Compact Low Consistency Refiner Uses Less Energy The refining stage in stock preparation plays a crucial role in developing fibre properties for paper production, greatly affecting the runnability of the paper machine and paper quality.

Unlike conventional refiners, Metso’s new low consistency refining concept, OptiFiner Pro, feeds the stock evenly across the bars directly in the refining zone where fibre treatment occurs. All of the stock is treated equally, providing a higher refiner loadability and better energy efficiency.

In its optimal configuration, one OptiFiner Pro can replace two traditional refiners and still deliver 40% electrical energy savings.

The new design is suitable for all kinds of LC refining applications including short hardwood fibres as well as recycled fibres requiring fibrillation at low refining intensities.

In conventional refining, fibres have to travel the full length of the refining zone and suffer excessive impacts leading to increased fines, weakening of the refined fibres and inefficient delivery of energy to the fibre. The new OptiFiner Pro increases the number of fibres that receive proper refining treatment and, because of the high utilization of the whole refining area and all refining bar lengths, refiner pulpandpapercanada.com

treatment intensity is much higher than any other refiner.

OptiFiner Pro uses a smaller rotor because of the improved fibre flow, reducing the no-load power by almost half. The design permits higher installed power and throughput, further raising the refining efficiency.

The improved performance of OptiFiner Pro enables refining with a reduced number of more compact refiners, thus reducing investment and maintenance costs significantly.

Metso www.metso.com

Sensor Automates Surface Monitoring to Improve Paper and Board Printability Launched at the PulPaper 2010 exhibition, Honeywell’s Precision FotoSurf reduces the need for laboratory measurements by using high speed, on-line surface topography measurement. Precision FotoSurf is a surface topography sensor that helps paper and board makers improve product quality while reducing waste and lowering production costs.

The system’s camera and powerful illumination technology automatically adjusts to varying machine speeds and sheet surface characteristics to capture high-quality sheet surface images.

This automated approach helps reduce variations in web smoothness/ roughness profiles which can cause a range of imperfections in paper and board products – and in turn cause printability problems. The sensor allows mill personnel to electronically monitor web surface characteristics throughout the entire production process, facilitating immediate corrective action if a product deviates from standards.

“Precision FotoSurf saves paper and board makers time and money, and boosts their competitiveness,” said Marko Jamsen, Honeywell’s EMEA business leader for pulp, paper, printing, and CWS. “The solution maximizes productivity by reducing the need for laboratory analysis of smoothness/ roughness profiles, minimizes time needed for corrective action when flaws are detected, and ultimately results in higher-quality products with less waste.

It provides an entirely new method for diagnosing process problems.”

In addition to providing numeric values for surface smoothness and roughness, the sensor displays images of the product surface to determine the root cause of the problem so that corrective action can be taken.

Honeywell Honeywell.com/ps

July/August 2010 PULP & PAPER CANADA

27

TECHNOLOGY NEWS

Urea-free Paper Brightener Produces High Whiteness Levels Clariant offers paper manufacturers new opportunities to achieve the highest possible whiteness levels for printing and writing paper with the launch of Leucophor® VHR liquid. The optical brightening agent (OBA) is the latest addition to Clariant’s innovative Leucophor range. Leucophor VHR is a urea-free, brilliant, high white OBA. Designed primarily for size-press applications, Leucophor VHR gives state-of-the-art performance with ColorLok™ Technology in size-press applications to make ColorLok™ Paper. The OBA also maintains excellent performance with standard size-press applications. ColorLok Paper is a new standard developed by HP and International Paper that improves ink drying speed and definition on office papers.

Andrew Jackson, global product manager at Clariant comments: “Leucophor VHR is unique not only in giving the market a new level in whitening performance, but its compatibility with papers containing ColorLok Technology is second to none. We fully expect ColorLok Technology to become the standard in office and printing papers. We are excited to be at the forefront in offering a brightening agent that is compatible with ColorLok Technology’s capabilities.”

Clariant, www.paper.clariant.com

Machine Vision Systems Ordered for High-Speed Paper Machines Shandong Chenming Pulp & Paper Co., Ltd. has placed an order for two Procemex-TWIN integrated web monitoring and web inspection systems for mills in China. One will be used for a 10.4-metre-wide coated fine paper machine and two supercalenderers, the other on a 10.5-metre-wide fine paper machine.

These deliveries cover web break analyzing and paper quality inspection. The units use Procemex-Flex high speed matrix camera technology together with strobe LED illumination. The technology has been specially developed for fast running paper machines. The deliveries include almost 300 cameras.

The start-up of the both lines will take place in first quarter of 2011.

Procemex, www.procemex.com

Heavy-duty pulpwood grapples Northshore Manufacturing has added a new group of wood handling attachments to its Builtrite product line-up: PG Series Pulpwood grapples. These grapples are designed for bulk handling of short wood at wood processing facilities. Key features include 360° continuous rotation on a heavy duty bearing with advanced, high torque motors and a high pressure hydraulic swivel, and oversize hardened cylinder and arm pivot pins with replaceable bushings.

Arms have optimum curvature for gathering and handling the maximum amount of logs, and arm tips are made from hardened, abrasion resistant material. The grapples also have hard facing on inside of lower grapple arms.

Options include heavy duty bunching chain for holding partial loads and bolt-on butt plates on one or both sides for evening out stacks of wood.

Northshore Manufacturing 218-834-5555, www.builtritehandlers.com.

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July/August 2010

Equipment

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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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Announcement NOMINATION OF MR. MICHEL CRÊTE Mr. Michel Crête, engineer, has been recently promoted President and General Manager of Hydro Technologies (Canada) Inc. Before his nomination, Mr. Crête had been serving as Vice-President of operations, a position he occupied since his arrival at Hydro Technologies in 2007. Previous to his arrival, Mr. Crête has had numerous managerial and strategic positions within the chemical industry.

Hydro Technologies develops and produces HyBrite®, sodium hydrosulfite bleaching compounds tailor made to individual paper mills. Hydro Technologies is also the sole producer of the active Zinc Oxide grade for the rubber and construction industry in North America.

Hydro Technologies (Canada) Inc. is a member of the SILOX group, with locations in Belgium, France, The Netherlands and India.

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July/August 2010 PULP & PAPER CANADA

29

POINT OF VIEW

Pulp Growth Ain’t Pulp Fiction Dissolving pulp has solid future as a building block for rayon.

By Chadwick Wasilenkoff, chairman and CEO, Fortress Paper Ltd.

W

hile “pulp fiction” may resonate with capacity in 2008, but closures of many higher-cost the hearts and minds of people, the dissolving mills resulted in limited capacity to fill wood pulp business sector sometimes the increasing demand. results in a hollow response. While readers would Driven by overall textile demand and increasnot be able to turn the pages of their pulp fiction ing preference for rayon over cotton, more than books or enjoy their cotton and rayon clothing one million tonnes of additional rayon capacity without their wood pulp brethren, the pulp sector (dissolving pulp customers) was built in China in is often looked upon as sleepy.

2009 and an additional 0.5 to 0.7 million tonnes Though the pulp sector may appear quiet, the in China is planned to start-up in 2010. There market players are “yawning” all the way to the is a current shortfall of approximately 0.5 million bank. “Between 2002 and 2006, world exports of tonnes in annual rayon supply which is expected to Entrepreneur Chadwick wood, pulp and paper products grew at an average continue during the next several years.

Wasilenkoff invests annual rate of 10.6%,” reports Global-produc- in sectors considered Rayon’s future is looking very promising, which tion.com, Inc., a business economics consultancy. to be “depressed”, is why we sought to invest in this sector. With our Despite the volatile economy, the upward price to obtain assets at Quebec facility, we are transforming an asset which discount prices. trend in market pulp continues across the world. was previously underutilizing its potential by oper“The fundamentals of the pulp market continue ating as a high-cost producer into a specialty prodto be very strong,” reports PulpWatch, a leading provider of uct producer which is low-cost and globally competitive. Over business information and consultancy services to the interna- 90% of the existing mill equipment is ideally suited to produce tional pulp and paper industry. high-quality specialty cellulose for the rayon textile industry.

As a contrarian investor, I keep focused on industries widely The consumer advantages of rayon are clear: it is woven into considered to be depressed with an eye on purchasing world soft, absorbent and comfortable fabric which supports vibrant class assets at deeply discounted prices. My company recently colors and wears well. Rayon is one of the most widely used paid $1.2 million to Fraser Papers for a facility in Quebec with fabrics in the world which can be blended with man-made or an insured replacement cost of $851 million in assets. We are natural fabrics. converting this mill into a specialty dissolving pulp operation.

For many centuries, people have relied on plants and animals, Dissolving wood pulp is chemically refined bleached pulp com- such as silkworms, sheep and buffalo, to provide the materials posed of pure cellulose fibres extracted from trees. Dissolving needed for clothing. In our 21st century world, we look to techpulp is the major source for the natural cellulose used in the nology and chemistry to create our fabrics. Rayon, dubbed “labproduction of rayon. oratory’s first gift to the loom”, is widely considered to be one I believe rayon demand is at a tipping point around the of the most versatile and economical man-made fibres available. world. The declining global production of cotton is insufficient to meet global textile industry demand; particularly with the As Fortress Paper’s Chairman, Chief Executive Officer and Director, rapidly expanding middle class in China and India. Industry Chadwick Wasilenkoff, age 37, oversees the company’s production of analysts indicate that the rayon market has grown at 7% globally security and other specialty papers. In August 2006, Mr. Wasilenkoff and over 10% in China for the last five years. Rayon is typically headed up a group of investors to purchase the Landqart Mill in blended with other fibres and can logically displace the cotton Switzerland which produces high quality security paper including bank shortfall. Rayon has high uniformity which leads to significant notes and passports, and Germany’s Dresden Mill, and created Fortress improvements in productivity in spinning and textile plants.

Paper Ltd., www.fortresspaper.com, which he took public in July 2007 Rayon demand has revealed a gap in supply. Total dissolving with a $46-million offering. Based in Vancouver, Canada and Palm pulp capacity in late 2007 was 2.4 million tonnes according to Springs, California, Wasilenkoff is an established entrepreneur with the CCF Group (China Chemical Fibers & Textiles Consul- extensive capital markets experience specializing in the resource industry tancy). Expansions and conversions with plants in Brazil, South and currently serves as a director with various publicly listed companies.

Africa and Canada added 0.6 million tonnes of dissolving pulp He can be reached at: chadw@fortresspaper.com.

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PULP & PAPER CANADA

July/August 2010

pulpandpapercanada.com

ANNUAL MEETING 2011 Call for papers

The Association’s 97th Annual Meeting will be held in Montreal early February 2011 and is the flagship event for the Canadian pulp and paper industry. Paper submissions are requested in the areas of bleaching, papermaking, pulping, process control, research, engineering, environment, recycling, energy cost savings, business, and other emerging industry topics.

At the time of submission, authors are requested to designate the category under which they would want their paper to be evaluated. If more than one category is designated, the submission will go to the first program committee that accepts it.

Submissions are welcome in English and French.

The deadline for abstract submissions is September 10, 2010.

For further information, please contact Greg Hay at ghay@paptac.ca or 514.392.6964.

Sponsored by:

GADGET COMPETITION For information on how to enter, contact : Jennifer Lemieux / tech@paptac.ca

1st Prize:

$400

Administered by PAPTAC’s Engineering and Maintenance Community.

2nd Prize:

$200

All Entries must reach the Pulp and Paper Technical Association of Canada (PAPTAC) by the deadline.

Prizes and awards will be presented

by Cindy Macdonald, editor, Pulp & Paper Canada, at PAPTAC’s 2011 Annual Meeting.

DEADLINE: NOVEMBER 12, 2010 For Successful Ideas Impacting on Energy Reduction Sponsored by:

ENERGY CONSERVATION OPPORTUNITY AWARDS

The awards are presented on an annual basis to the individuals working in Canadian pulp, paper and board mills who submit the best examples of energy conservation opportunities or successful projects, justified by whatever means, e.g. production, quality, environment, etc., as long as there are significant impacts on energy reduction.

1st Prize:

$400

2nd Prize:

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3rd Prize:

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Prizes and awards will be presented by Cindy Macdonald, editor, Pulp & Paper Canada, at PAPTAC’s 2011 Annual Meeting.

DEADLINE: NOVEMBER 12, 2010

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