Pulp & Paper Canada March/April 2011

March/April 2011

www.pulpandpapercanada.com

PaperWeek

Canada Biorefining and Traditional Products Share the Spotlight • Safest Mill in Canada Winners • Focus on Refining JOURNAL OF RECORD, PULP AND PAPER TECHNICAL ASSOCIATION OF CANADA PAUL: Bleach Plant Control to Minimize Brightness Variability

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MARCH/APRIL 2011 Vol. 112, No. 2 PRINT EDITION ISSN 0316-4004

A Business Information Group Publication ON-LINE EDITION ISSN 1923-3515

FEATURES

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PaperWeek Canada Report: Biorefining and Traditional Products Share the Spotlight Biorefining topics and the business sessions were the big draws when more than 400 people gathered in Montreal for PaperWeek Canada.

The event incorporated PAPTAC’s annual meeting and technical sessions.

This extensive post-conference report includes coverage of the business and technical sessions, awards and keynote speeches.

Our cover image shows one emerging biorefining technology: Lignol’s pilot lignin production line in Burnaby, B.C. Photo courtesy of Lignol Energy Corp.

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PAPERWEEK CANADA REPORT

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FOCUS ON REFINING

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Technology News: Focus on Refining A collection of technical innovations and new products related to mechanical pulping.

Safest Mill in Canada Contest Winners Two repeat winners demonstrate that a culture of safety protects employees year after year.

TECHNICAL PAPERS

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Minimizing and Sustaining Final Brightness Variability and Reduced Chemical consumption in Kraft Bleaching

By J. Paul (NewPage Corp., Rumford, ME) and A. Rowat (Formerly Metso Automation, Norcross, GA)

MISSION STATEMENT:

To promote the pulp and paper industry in Canada by publishing news of the people and their innovations in research, technology, management and financing, as well as forecasts of future trends.

Authorized to publish papers of the Pulp and Paper Technical Association of Canada, which are identified by the symbol Serving the industry since 1903.

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NEWS

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IN EVERY ISSUE

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News Technology News Events/Previews Classified Ads

March/April 2011 PULP & PAPER CANADA

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EDITORIAL

Give Me One Good Reason for Biofuels

I

’ve attended two pulp and paper industry events with an emphasis on biorefining in the last few weeks — one on each side of the border. While the technical discussions are largely the same, the business development talk is strikingly different.

In the U.S., the push for energy independence is bankrolling development in the biofuels sector. Lignocellulosic biofuels are caught up in that wave. A representative of the U.S. Department of Energy, speaking at TAPPI’s International Bioenergy & Bioproducts Conference, declared biofuels are the only viable alternative to petroleum-based transportation fuels at this time, and the U.S. desperately wants an alternative to imported oil.

Colin South, now chief technology officer of Canadian biotech supplier Lignol Energy Corp., and founder of two other biochem companies, summed up the situation in his keynote speech at the TAPPI event in Atlanta, Ga. South argues that the biofuels and biochem industry should use the current socio-political emphasis on environmental benefit and energy security to secure legislative backing and start-up subsidies, and then use that stable base to move into biochemicals.

There has been discussion on both sides of the border about why pulp and paper companies would want enter the biofuels sector, especially since producing ethanol essentially means entering a commodity market with a low-value product.

South’s proposed solution is to use the biofuels market as a stepping stone to higher value products, “because nobody cares if you create a $5/gallon chemical. It hasn’t got the same national imperative as energy independence.”

He notes that there is a lesson to be learned from the corn ethanol industry. This industry has experienced tremendous growth in the past 20 years, and stands as an example of what can be achieved with a single-minded focus on a single product.

Unfortunately, even just in woody biomass-derived biofuels and biochemicals right now, there are multiple product platforms, multiple transformation technologies, multiple feedstocks and multiple markets; it makes it very hard to stay focused.

To get a market-driven incentive program, we (woody biomass biofuels) need to come in under the energy security issue, South concludes. Success with that would change the way financiers see the market as well.

How does this relate to the Canadian situation? Several biomass technologies are poised to go commercial, and when they do, well, technology knows no borders.

As for incentives, we in Canada have the Forest Products Association of Canada lobbying for “biopathways” and Natural Resources Canada supporting pilot projects, but we’re lacking that “national imperative”, that one simple reason Cindy Macdonald that would coalesce support for Editor wood-derived biofuels.

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PULP & PAPER CANADA March/April 2011

EDITORIAL Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Sustaining member, Pulp and Paper Technical Association of Canada; Member, Canadian Business Press and Audit Bureau of Circulation.

Contributing Editors HEATHER LYNCH ADVISORY BOARD Richard Foucault Greg Hay Dr. Richard Kerekes Barbara van Lierop Dr. David McDonald Dennis McNinch Dr. Yonghao Ni Bryant Prosser Dr. Paul Stuart Ross Williams

Indexed by: Canadian Business Periodicals Index; Abstract Bulletin, The Institute of Paper Science and Technology; Materials Science Citation Index

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INDUSTRY NEWS Paper Excellence to buy Domtar’s Prince Albert site for dissolving pulp conversion

MONTREAL — Domtar Corp. has announced an agreement with Paper Excellence Canada Holdings Corporation for the sale of its Prince Albert, Saskatchewan, assets.

Paper Excellence will convert the former pulp and paper mill to the production of dissolving pulp, a product intended for the viscose textile market.

The transaction is expected to close in the second quarter of 2011, but is contingent on a few conditions. Paper Excellence and the government of Saskatchewan must reach agreement on fibre allocation, the purchase of excess power, and the division of responsibilities between the government and the buyer for past environmental liabilities. Also, the buyer must negotiate a new collective agreement with the local labour union.

According to a statement from the government of Saskatchewan, Paper Excellence will be investing more than $200 million in the conversion of the mill and creating hundreds of construction jobs in addition to the projected 200 mill jobs. The conversion is expected to take between 18 and 24 months to complete.

The Prince Albert mill was permanently closed in the second quarter of 2006 and has not been operated since.

Domtar acquired the assets in 2007 as part of a transaction with Weyerhaeuser Company. Domtar completed the dismantling of the mill’s paper machine and converting equipment in 2008.

The pulp mill portion of the facility was built in 1966. At the time it was shut down in 2006 it had an annual capacity of 145,000 t/y of bleached softwood and hardwood kraft pulp.

Based in the Netherlands, Paper Excellence also owns Meadow Lake Mechanical Pulp (BCTMP) in Saskatchewan and two mills in B.C., Mackenzie Pulp Mill (kraft pulp) and Howe Sound Pulp & Paper (kraft, TMP and newsprint).

Cascades starts up Voith Atmos tissue machine in Candiac

KINGSEY FALLS, QUE. — With the start-up of a new technology at its Can-

diac tissue paper mill, Cascades is the only manufacturer in North America to have the Voith Atmos technology to produce a superior quality tissue paper with recycled fibres. The investment at Candiac, Que., could total more than $30 million.

This new technological addition will allow Cascades to manufacture tissue products with fewer fibres, less energy, less water and fewer chemical products than in any other paper manufacturing process.

According to Voith, the Atmos technology for premium tissue production consumes significantly less energy than through-air-dried (TAD) production.

Instead of hot air drying (as in TAD), the tissue web in the Atmos process runs over a vacuum roll which sucks out the water.

While other tissue machines manufacture ultra quality tissue paper with mostly virgin fibres, this “TAD equiva-

People…

James F. Shepard will retire from his position as president and CEO of Canfor Corp. in May. Don Kayne has been appointed by the Board of Directors to replace Shepard as president and CEO. Kayne has been with the company for more than 32 years.

Dr. Uwe Liebelt becomes president of BASF’s paper chemicals division, located in Basel, Switzerland, effective April 1. Liebelt is currently senior vice-president, dispersions & pigments North America, located in Charlotte, North Carolina.

Mario Plourde has been appointed chief operating officer of Cascades Inc., a producer of packaging and tissue products.

Elissa Meiklem has been appointed executive director of The Northern Bioenergy Partnership, an industryled coalition. Meiklem will be charged with executing the three-year strategic plan to build Prince George and the Northern B.C. region as a forest-based bioenergy cluster.

lent” technology is able to manufacture similar quality tissue paper using a majority of recycled fibres.

This project will benefit from a financial contribution of $4.9 million by Investissement Québec.

Ruptured tank spills pulp at Mackenzie mill

MACKENZIE, B.C. — Production was for about a week at the Mackenzie Pulp Corp. kraft mill in Mackenzie, B.C., after a 22-m tall tank in the bleach plant split open, spilling tonnes of pulp slurry into the building. According to media reports, one of the mill’s five towers split almost top to bottom.

The incident occurred Feb. 16, and production was halted until Feb. 23.

General manager Doug Van Buskirk explains that they restarted production by using an old brown stock bypass line to avoid the damaged tank.

This allows the mill to perform three-stage bleaching and produce semibleached pulp.

Work on removing the tower was still ongoing in early March. Once it is removed, Van Buskirk says the mill will begin four-stage bleaching and should be able to resume target production rates.

An investigation into the cause is ongoing. The tank which split was a carbon steel tank, with mortar and tile lining.

No one was injured in the incident, and the spill was contained in the bleach plant.

The Mackenzie mill resumed operations last August after a two-and-a-half year shutdown.

Mercer studying dissolving pulp option for Zellstoff Celgar mill

RICHMOND, B.C. — Mercer International has completed a preliminary feasibility analysis for its Zellstoff Celgar mill in B.C. and Stendal mill in Germany with respect to enhancing their operations and margins.

The preliminary analysis identified the possibility that the mills could become “swing mills,” producing NBSK (as they currently do) or dissolving pulp, depending on market conditions. The estimated capital cost for this option would be $30 to $40 million per mill.

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PULP & PAPER CANADA March/April 2011

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INDUSTRY NEWS

Green Transformation Program Catalyst spends PPGTP credits on co-gen and boiler upgrades

RICHMOND, B.C. — Catalyst Paper has announced two projects funded under the federal Pulp and Paper Green Transformation Program, for a total of $18 million to be spent at the Port Alberni and Powell River sites.

A $13.3-million green-energy project at Catalyst’s Powell River mill will produce low-carbon electricity and be one of the cleanest waste wood co-generation projects anywhere in Canada. The project is funded entirely by PPGTP credits, earned through production of black liquor at the Crofton pulp operation in 2009.

At the Port Alberni site, a $4.7-million capital upgrade will improve the efficiency and reliability of biomass-based energy generation, while further reducing greenhouse gas and other air emissions.

The project is funded entirely by PPGTP credits.

The Powell River green energy project will involve new waste-wood handling equipment, a sand recycling system and other upgrades to an existing power boiler (PB19), and installation of a steam condenser on the generator (G12). Work is underway and expected to be completed within approximately 12 months.

Manufacturing-related steam requirements were reduced when kraft pulp production ended at Powell River in 2001. The new steam condenser will allow PB19 to once again be operated at capacity, and G12 electricity generation to double from 14-18 megawatts (MW) to a range of 32-36 MW. “This project creates a supplemental

energy product line, and that could translate into significant competitive advantage in an industry that’s under pretty severe pressure,” said Bob Lindstrom, vice-president, supply chain, energy and information technology.

Installation of a recycling system will improve the use of sand that is fed into the boiler bed to ensure combustion efficiency. Rather than being trucked away for screening, as is now done, sand will be screened and recycled on-site, reducing the total volume of sand required.

The Port Alberni project involves three upgrades to the main power boiler (PB4): a new secondary air system, a larger “economizer” or heat-exchange system, and a new gas monitoring system. Work will not begin until late in the year, but is expected to be completed during an extended annual boiler maintenance shutdown planned for October.

“This is a multi-benefit project and a big step forward for the Port Alberni operation,” said Lindstrom. “Energy efficiency tops the list of the returns we expect from it. At the same time, it will also reduce environmental impacts and deliver bottom-line benefit from lower fuel consumption and operating and maintenance costs.”

Installation of larger and better-designed air nozzles will result in more efficient boiler combustion and reduce fuel requirements, improving operational reliability of the existing equipment. Fewer economizer outages will reduce the need to use a backup natural gas boiler, and the greenhouse gas emissions associated with it.

The new gas monitoring system will

provide ongoing feedback, which operators will use to continually optimize the performance of the upgraded boiler.

Catalyst Paper manufactures diverse specialty printing papers, newsprint and pulp.

ABERCROMBIE, N.S. — Northern Pulp Nova Scotia will receive $28.1 million from the federal Pulp and Paper Green Transformation Program for three projects that will help the mill reduce odour emissions, increase renewable energy production and improve environmental performance.

The federal investment, together with Northern Pulp’s capital program, enables the company to move forward these projects.

One project will reduce odour emissions from the Abercrombie Point mill by at least 70%. Northern Pulp is doing detailed engineering on the odour emissions project; construction will begin this summer and the completion is scheduled for the end of 2011.

Northern Pulp is also upgrading the mill’s boiler to make it cleaner and more efficient, which helps improve the mill’s operational efficiencies and environmental performance. Project completion is scheduled for the end of 2011.

The mill is also increasing production of renewable energy from black liquor solids. Both of these projects will be operational after the mill’s fall shutdown at the end of 2011.

Dissolving pulp is used to produce rayon, a textile fibre, among other things.

The study notes that the scale, technical age and regional wood pricing would allow Celgar to be a first quartile cost producer of dissolving pulp. The project would take about 16 months to complete, with no expected impact on NBSK production, expect a three-week shutdown near the end of the project.

Mercer states that it would most likely implement the project at only one of the two mills. Mercer expects to make a final decision in mid-2011 about the conversion.

As part of the final technical and feasibility study, the company is implementing a process to select which mill and the timing of the project. The Celgar mill’s use of a continuous digester could be a technical limitation for the project.

“Dissolving pulp is experiencing a very robust market, and while a pullback in pricing is expected, the long term outlook is quite promising,” said Jimmy S.H. Lee, president and chairman of Mercer. “This opportunity is only possible because of our large, modern mills.”

“We believe that we will be able to take further advantage of the excess

Energy production, odour emissions are target at Northern Pulp

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INDUSTRY NEWS energy produced from dissolving pulp to increase our power generating capacity and enhance electricity revenues,” he added.

Nexterra secures $15 million in financing

VANCOUVER — Biomass gasficiation supplier Nexterra Systems Corp. has secured $15 million in equity financing from Tandem Expansion Fund and ARC Financial to accelerate the growth of Nexterra’s business.

“We believe that the market for small-scale biomass heat and power systems is poised to grow rapidly in the next few years to meet rising demand for on-site renewables, energy security and greenhouse gas reduction,” said Sandy Scott on behalf of Tandem Expansion. “When we looked at the biomass energy market, Nexterra clearly stood out due to its innovative and commercially proven technology, strong market position and seasoned management team.”

Alberta Newsprint adopts new technology for beetle-killed wood

WHITECOURT, ALTA. — The Government of Canada has invested $1.05-million at the Alberta Newsprint Company mill in Whitecourt, Alta.

The mill will receive funding under the Transformative Technologies Pilot Scale Demonstration Program to implement technology that will result in substantial reductions in energy and fresh water consumption at the mill.

Alberta Newsprint will contribute more than $1 million to the project, along with an $80,000 investment by Alberta Innovates Bio Solutions.

“This technology will enable Alberta Newsprint to consume larger sawmill residual chip volumes of beetle-attacked pine and threatened green pine while simultaneously reducing our fresh water consumption from the Athabasca River,” said Gary Smith, technical director, Alberta Newsprint Company.

“The technology holds great promise for many pulp and paper producers.

The technology provides for concentrating pitch-laden dark pulp fibres, enabling reductions in water usage, chemical usage and energy savings. We expect to start up the equipment in early March.”

The federal government’s Transformative Technologies Pilot Scale Demonstration Program is administered by FPInnovations.

Metso adds Canadian service centre for roll repairs

MONTREAL — Metso Paper Ltd. has contracted Usinage Bertrem of Sorel, Que., to be an authorized Canadian service centre for roll repairs.

Usinage Bertrem is owned by Pierre Cardin, an ex-Beloit employee with more than 30 years of experience in paper machine and roll manufacturing.

The company operates a 22,000 sq. ft. workshop in Sorel. The services offered at this location will mainly focus on mechanical roll repairs, but because of existing links to the other Metso roll repair and covering

PACWEST CONFERENCE JUNE 8-11, 2011

“Capturing Value – Delivering on Innovation” Join us again at:

SUN PEAKS, BC

to network with peers, industry leaders and technical experts. Enhance professional development learning about new technologies, process improvements and what’s being showcased for the latest industry challenges. We are also pleased to present a full Spousal Program TECHNICAL SESSIONS: • Kraft • Maintenance • Paper Machine Technology • Energy • Environment • New Technologies • Mechanical Pulping • For further information and to register, visit:

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PROGRAM OUTLINE WEDNESDAY, JUNE 8 • Industry Meetings: • PAPTAC Councillors (TBC) • Mill Managers • Short Courses: • PINCH Technology • Kraft Pulp Bleaching • Recaust / Lime Kiln Operations • Pulp Machine Operations • Trade Fair THURSDAY, JUNE 9 • Conference Forum featuring leading Industry Managers: • Joe Nemeth, CEO, Canfor Pulp • Catherine Cobden, FPAC • Tom Rosser, NRCan • Ted Seraphim, COO, West Fraser • Daryl Nichol, VP Pulp Operation, Al-Pac • Mike Edwards, Sr. VP Pulp & Paper Manufacturing, Domtar • Roundtables: • Pulp Machine Superintendents • Maintenance Superintendents • Energy Managers (TBC) • Technical Sessions • Trade Fair FRIDAY, JUNE 10 • Technical Sessions • Panel Discussions • Feature Luncheon with guest speaker, Patricia Graham, Editor-in-Chief, Vancouver Sun • Trade Fair • Awards Dinner Dance • Honorary Peddler Inductee SATURDAY JUNE 11 • Annual Golf Tournament

2011 CALL FOR PAPERS For inclusion in the Program, abstracts should be received by March 31st 2011 with paper completion by April 30th.

Selection of papers is based on several criteria, including originality, technical merit and mill relevance.

Time limit for presentations is 20 minutes with 5 minutes for Q&A ABSTRACTS should be submitted to PACWEST 2011 Program Chair, Randy Reimer Alberta-Pacific Forest Industries Randy.Reimer@Alpac.ca • PROGRAM Committee: Paul Watson - Canfor Pulp Randy Reimer - Al-Pac Bill Adams – Domtar Brian Grantham – Hinton Pulp IBMP ORGANIZING Committee: Ken Harman - ADI Sales Al Parsons - Bancroft Western Tony Vandendool - Oval International Dennis Froats - ERCO Worldwide Che-Man Lee - Kemira Pulp & Paper

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INDUSTRY NEWS facilities in the U.S., this location will act as a true one-stop roll service centre.

New Brunswick establishes task forces to determine timber objectives

FREDERICTON – The chairs of two task forces set-up to establish timber objectives for Crown and private land have been announced.

Norman Betts will chair the Crown Land Task Force, which will make recommendations to the provincial government

by July 1 on timber objectives for New Brunswick’s public forests. Betts is a member of the Faculty of Business Administration at the University of New Brunswick in Fredericton and is a former provincial minister of finance.

Donald Floyd, interim dean of the Faculty of Forestry and Environmental Management at the University of New Brunswick, is the chair of the Private Land Task Force. This task force has a mandate to set timber objectives that provide a stable and predictable wood supply from private land.

Briefly…

A total of $11.2 million in federal-provincial funding will help the University of British Columbia undertake a clean heat and power project. UBC has partnered with Nexterra and GE Energy on a biomass demonstration project that will produce about 1.9 megawatts of electricity.

A new RISI report forecasts that the bioenergy industry will create additional biomass demand of 19 million dry tons by 2015. Called the North America Bioenergy Review, it forecasts North American wood biomass supply, demand and pricing, plus analyzes the cost structure of each sector.

Metso has strengthened its advanced controls groups for chemical pulp-

ing, mechanical pulping, and recycled fibre and paper by forming a new Performance Solutions group, focusing on process improvement and optimization.

The Fiducie de recherche sur la forêt des Cantons-de-l’Est, which promotes sustainable forest management by supporting research projects in forestry, will receive a total of $75,000 from Natural Resources Canada. With the knowledge transfer gained from this project, forest owners will benefit from the small-scale application of an ecosystem management system that supports the planting of fast-growing tree species and species best suited for the restoration of degraded forests.

AnnounCeMent Fibrek Inc. is pleased to announce the appointment of Mr. Gerry Clapperton to the position of Director, Pulp Sales Mr. Clapperton will be responsible to sell NBSK pulp produced at the Saint-Félicien Mill, located in Québec, as well as RBK pulp produced at the Fairmont Mill, in West Virginia, and the Menominee Mill, located in Michigan. “No doubt the Company will benefit from Gerry’s extensive experience in the industry, his network and his knowledge of sales, technical and manufacturing,” declared Jean-Pierre Benoit, Vice-President, Sales and Operations at Fibrek.

Mr. Clapperton holds a degree in chemical/ biochemical engineering from Laval University, combined with several pulp and paper master degree courses from UQTR, and some 25 years of experience in the pulp and paper industry.

Before joining Fibrek, Mr. Clapperton acted as General Manager Pulp Sales at Fraser Papers for Thurso Division. He also worked for Donohue, Domtar and CIP. We wish him well in his new role.

About Fibrek Fibrek (TSX: FBK) is a leading producer and marketer of high-quality virgin and recycled kraft pulp. The Company has approximately 500 employees and operates three mills located in Saint-Félicien, Québec, Fairmont, West Virginia, and in Menominee, Michigan with a combined annual production capacity of 760,000 tonnes. The Saint-Félicien mill provides northern bleached softwood kraft pulp (product known as NBSK pulp) to various sectors of the paper industry in Canada, the United States and Europe, for use in the production of specialized products. The Fairmont and Menominee mills manufacture air-dried recycled bleached kraft pulp (product known as RBK pulp) and primarily supply manufacturers of fine uncoated paper, household paper for commercial and industrial uses, and coated paper in the United States.

www.fibrek.com 10

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PULP & PAPER CANADA March/April 2011

Masaki Aikawa, president of Aikawa Iron Works, and Dr. James Olson, UBC, cut the ribbon to open the new LC Refining Research facility in Vancouver.

UBC and Aikawa open the way for low consistency (LC) refining research “We are now starting up the most state-of-the-art, university-based LC refining facility in the world,” said Dr. James Olson, associate head of the University of British Columbia’s Pulp & Paper Centre. “We are grateful to Aikawa for donating this equipment and being long-term partners with the university.”

Aikawa and its subsidiary AFT (Advanced Fiber Technologies) donated the key process equipment – a state-of-the-art single-disc refiner plus a full complement of FINEBAR® refiner plates – to the University of British Columbia so that the university’s Pulp & Paper Centre could perform research in the area of low consistency (LC) refining to improve the energy efficiency of mechanical pulp production. pulpandpapercanada.com

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Reporter W CONFERENCE

www.pulpandpapercanada.com

PaperWeek Canada: Exchanging Ideas for Transformation Biorefining topics and the business sessions were the big draws as more than 400 industry participants gathered at PaperWeek Canada in Montreal in early February. The three-day event combined the Pulp and Paper Technical Association’s annual meeting with an international symposium on biorefining.

A consistent theme throughout the event was transformation of the pulp and paper industry.

Biorefining of chemicals and other non-traditional products is one approach, but several speakers in a session organized by Natural Resources Canada reminded participants that there are other routes to success. Levi Sampson spoke about the renewal at Harmac Pacific following its buyout by employees and private investors. A cooperative attitude among employee-owners has reduced costs and leaves the mill in a good competitive position.

At Thurso, Que., the route to success involves a new owner and a dramatic change to the mill’s output. Now owned by Fortress Paper, the mill will be converted to produce dissolving pulp this year.

After three days of presentations at the International Forest Biorefinery Symposium, it was evident that there is still no clear path forward for pulp mills entering the bio-refining arena.

Many speakers emphasized that profitability will depend on the optimization of biobased products within existing pulp mills, and that biofuels should be de-emphasized in favor of higher value-added bio-chemical products.

The new format of PAPTAC’s annual conference worked well. Business sessions alternated with technical sessions throughout the day, and a conference lunch with keynote speaker was offered each day. PaperWeek Canada 2012 will once again be held in Montreal in February.

Two Tales of Green Marketing An interesting dynamic developed in the “Green & Authentic Marketing” panel discussion, as representatives from two competing tissue manufacturers shared the podium to offer their expertise on green marketing.

In the business session sponsored by Cascades Inc., experts agreed that operating a green, sustainable enterprise can be challenging, but that the rewards, both tangible and intangible, are worth it.

Hubert Bolduc, vice-president communications and public affairs at Cascades, noted that for his company, being green, being sustainable, is profitable.

From an operational point of view, Cascades uses less water per tonne produced than the industry average, and has many initiatives to reduce energy use. For example, one mill uses methane from a nearby 12

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landfill as an energy source. Cascades fleet of trucks are fitted with “skirts” under the trailers to improve fuel efficiency.

The more intangible benefit of Cascades’ longtime commitment to sustainability is recognition as a leader in the field. Greenpeace and Terrachoice recognize the company’s leadership in this sector. Other companies turn to Cascades for its expertise (Bombardier, Hydro Quebec).

Bolduc also pointed out that being a socially responsible company helps Cascades attract and retain employees.

Steven Sage, corporate director, sustainability and innovation, with Kruger Products Ltd., spoke more pointedly about how green marketing should be performed. He suggested that green marketing must be transparent: “You have to

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tell the truth, the whole truth, even if it hurts.” He said it is okay for companies to talk about their journey and the learning that comes through the process of becoming a more sustainable business.

Another element of green marketing, said Sage, is empowerment. It provides an opportunity to tell your customers how they can make a difference.

It’s not easy being green, said Sage.

Added scrutiny comes with it, it generally requires additional technology or R&D, and the marketing must be authentic.

For its green marketing initiative, Kruger Products has chosen to: pursue EcoLogo for many of its products; produce a sustainability report; and develop a company-wide initiative to enhance the sustainability of its business, called Sustainability 2015. pulpandpapercanada.com

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Right Products and Policies Will Make Biorefining Work

By Shaun L. Turriff After three days of presentations at the International Forest Biorefinery Symposium, it became clear that there are myriad products that Canadian mills could choose to produce in conjunction with pulp — and that it is still anyone’s guess which combination of products and processes will be economically viable. However, some suggestions for shaping the emerging bioeconomy are gaining traction. Many speakers emphasized that profitability will depend on the correct integration of bio-based products with existing pulp mills, and that biofuels should be deemphasized in favor of higher value-added chemical products.

The symposium was held Feb. 1-3, 2011, in conjuction with PaperWeek Canada.

Maria Wellisch’s keynote address offered a snap-shot of the biorefinery landscape as it stands in the Canadian context. Wellisch is a research advisor on sustainable conversion of bioresources for Natural Resources Canada. She noted that Canada is already on its way, with both existing and new businesses forming “a mosaic of different biorefineries.” She also remarked on the challenges facing the emerging industry: unfavourable economic climate for “risky” investments, low energy prices, lack of full cost accounting, and increasing competition for existing biomass resources.

Wellisch closed with the exhortation to tell the whole story — the economic, environmental, and social upsides to the new bio-based economy — and to repeat the message, frequently, in order to cut through the inertia of older economic models.

“Commodity plants scaled to typical forest biomass supplies may be too small to be economically viable, while plants at an economically-sensible size will face large feedstock costs,” notes Browne. “Furthermore, in the absence of significantly higher effective prices for fossil fuels, the revenues per tonne of wood consumed are inevitably going to be lower for commodity chemicals and fuels than existing products such as kraft pulp.

This is independent of plant scale.”

More profitable to make kraft pulp

Browne gives the example of kraft pulp at $825/t, 42% yield, producing revenue of $340 per tonne of wood consumed.

Biodiesel produced by Fischer-Tropsch reactors at $0.65litre, 235 l/t gives revenue of $156 per tonne of wood consumed.

Power production at $100/MWh, 1450 kWh/t gives revenue of $145 per tonne of wood consumed.

Hakim Ghezzaz of École Polytechnique de Montreal presented a paper that examined the impact of feedstock availability and process selection on plant performance and profitability. The study looked at various permutations with different feedstocks (woody residues, agricultural residues, hardwood and softwood) and different biorefining processes, both biochemical (ethanol production, ethanol using organosolv, ethanol using organosolv and PF resin from lignin) and thermochemical (Fischer-Tropsch liquids, F-T liquids and waxes, bio-oil via fast pyrolysis).

The paper examined the possible combinations You can make anything out of lignin… with both single- and mixed-feedstock options.

Tom Browne of FPInnovations continued the Maria Wellisch: Spread Ultimately, Ghezzaz concluded that for biochemibig picture view. With his tongue firmly in cheek, the message of the biocal processes, ethanol with PF resin is the most economy.

Brown summed up biorefining by quoting an viable, using a single feedstock, with hardwood as industry joke: “You can make anything out of lignin, except the best choice. For thermochemical processes, a mixed feedstock money.” His presentation focused on the changing marketplace for scenario works best, again with a value-added product (such as the end products of biorefining, vis-à-vis products based on petro- F-T waxes) in addition to the primary product (such as F-T leum. Browne claimed that in a world where oil costs $20/barrel, liquids). These findings seem to echo statements made by others the old joke is true, but things change when a barrel sells at $85. during PaperWeek Canada.

Overall, Browne examined the economic potential of comLuc LeBel of the Université de Laval discussed market-driven modity chemicals and fuels for Canadian biorefineries, ulti- supply chain strategic planning, using a model developed by he and mately concluding that a biorefinery approach, where “wood is his team. The model seeks to answer questions such as whether disassembled into its constituent parts, and maximum value is to use woody biomass and residue to produce bio-energy or forest obtained from each component” is more resilient. products, which plants, what size, and where, as well as greenfield Profitability depends on the proper sizing of the biorefiner- vs. existing facilities, in order to maximize Net Present Value. ies, in light of the dispersed nature of feedstocks, and on the Using the model in a case study in Québec, LeBel concludes production of high-value chemical products, particularly niche that given current market conditions, pelletization seems to be market products, which preferably cannot be obtained easily the best option, although changes in the price of ethanol could from petroleum-based sources. affect the outcome. pulpandpapercanada.com

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See the Forest in Saved – Mills, Communities, Jobs a New Light An independent Quebec-based publisher has launched a coffeetable book of stories about the forest, with contributions from two well-known figures in the pulp and paper world: Jean Hamel of FPInnovations and Patrice Mangin of CIPP. In Once Upon a Forest, twelve experts talk about the various faces of the forest: the Aboriginals’ forest, the forest as landscape, the healing forest, paper and the forest, and the future forest. The book is beautifully illustrated by the artwork of Marie-Andrée Tardif.

Published by Isabelle Quentin Editeur Inc., the book makes an appropriate gift in this, the International Year of the Forest. It is available through the publisher’s web site, http://iqe.qc.ca/, and at www.amazon.ca. It is also published in French, under the title Il était une fois la forêt.

Contributors to Once Upon a Forest, (from left) Jean Hamel, Marie-Andrée Tardif, Isabelle Quentin, and Patrice Mangin, were present for the book’s launch at PaperWeek Canada.

PAPTAC 2010 Review After two years at the helm of PAPTAC, André Bernier handed the chairmanship of the association to Patrice Mangin at the annual meeting on Feb. 2.

Bernier explained how PAPTAC had made changes to its membership structure in the past year. The new format encourages mills to have many individuals become members. The result: membership grew by more than 430 people last year. This type of “package” deal is also forthcoming for supplier companies and research organizations, says Bernier.

The association had a surplus of $90,000 in 2010.

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The business session sponsored by Natural Resources Canada was an upbeat one, with several success stories from across the country, under the banner: “Partnering for Transformation: Industry, Employees, Government and Communities.”

Marco Veilleux and Levi Sampson gave personal accounts of two success stories: the employee buyout at Nanaimo Forest Products and the purchase of the Thurso, Que., mill by Fortress Paper.

Veilleux is chief operating officer at Fortress Specialty Cellulose, the new owner of the kraft pulp mill at Thurso. He recounted how the mill experienced several temporary shutdowns during 2008. By June 2009, then-owner Fraser Papers declared an indefinite shutdown. Later that summer, as Fraser was going through restructuring, employees were told the mill would be permanently closed.

“We understood that we had an asset that we could reposition,” recalled Veilleux. So union leaders, mill managers, and local politicians began meeting to discuss possibilities for the future of the mill.

Veilleux says the employees were ready to purchase the mill, and had a business plan that hinged on wage concessions, profit sharing, improved efficiency, a simplified organization, co-generation, and potential new products in the biorefining or textile sectors.

In May 2010, Fortress Paper purchased the mill. According to Veilleux, the new owner had a vision for the mill which complemented the employees’ business plan. Fortress’ plan is to convert the facility to a dissolving pulp mill.

Veilleux vividly described the outpouring of emotion that gripped the town when the purchase by Fortress and the imminent restart of the mill were announced. More than 300 people returned to work in June 2010.

The changeover to dissolving pulp is expected in 2011, with co-generation to begin in 2012.

Following Veilleux’s good news story, Levi Sampson, director and president of Harmac Pacific, recalled his role in the worker buyout at Nanaimo Forest Products’ Harmac Pacific mill. Sampson said he had been following the story of a potential employee buyout in the newspaper, and thinking it was a good idea. When it became evident that the buyout idea lacked financing, he called the mill manager and arranged a visit with the buyout group to assess “how serious they were.”

“Could they let bygones be bygones?” he wondered.

Eventually a B.C. Superior Court judge ruled in favor of the bid by employees, Sampson, and two other private investors to buy the mill.

“There were little celebrations all around town,” said Sampson.

“We had managers and the investors invited to the union hall for beers.

Something like that doesn’t happen very often in the forest industry.”

In 2008, when the group purchased the mill, the price of pulp dipped below $500/tonne.

Sampson undertook a complete restructuring of the company, and, he said, the attitude has completely changed. “I’ve seen nothing but amazing things out at Harmac.” Production costs have been reduced by more than $100/tonne.

These two mills are a testament to the Canadian industry’s ability to adapt and react to changing conditions. pulpandpapercanada.com

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PAPTAC TECHNICAL SESSIONS Breaking Up Bacteria Reduces Fertilizer, Polymer Costs

A cell disrupter system could be the key to getting more value from the bacteria used to clarify pulp mill effluent. Paradigm Environmental Technologies is setting up a demonstration facility at Catalyst’s Crofton mill to investigate how its Microsludge technology can reduce fertilizer and polymer costs for pulp mill’s wastewater treatment systems, and create valuable biogas at the same time.

The bacteria found in typical wastewater treatment systems are discarded as sludge once they’ve served their purpose treating effluent. Bacteria tend to have tough cell membranes, but if those membranes can be breached, said Rob Stephenson, mills can produce more biogas, access the nitrogen and phosphorus for re-use, and have less sludge to burn or truck to landfill. Stephenson is Paradigm’s chief technical officer.

Paradigm’s MicroSludge technology uses a high-pressure homogenizer, which it calls a cell disrupter, to break the cell walls and release the liquid from bacteria in the sludge. After the treatment, viscosity of the sludge is reduced by 95%. Nitrogen and phosphate can be returned to the mill’s effluent stream, thereby reducing the amount of fertilizer the mill must purchase. Also, because there are fewer solids to dewater, polymer usage for dewatering can be reduced as well.

“This process can be a real moneysaver for mills,” says Rob Stephenson.

“Polymer costs, for example, are onerous for many mills.”

If a mill has an anaerobic digestion process, Paradigm’s investigations also show that sludge treated by the Microslude process produces more methane and better quality methane than raw waste-activated sludge.

The objective of the demonstration plant at Crofton is to verify the lab results, minimize implementation costs, and maximize the benefits Microsludge has on mill processes.

The technology has been used for several years in the municipal solid waste sector. pulpandpapercanada.com

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New Opportunities for MolybdateCatalyzed Delignification

During the bleaching session, Thomas Dietz of Evonik Degussa discussed the possibilities of molybdate-catalyzed delignification with hydrogen peroxide. He and his co-authors concluded a DPmo stage could be realized with the addition of an upflow tube and downflow tower in existing bleach plants.

This type of delignification provides significant savings in ClO2. For hardwood, it shows no negative effect on properties.

This is not a new technology, but it may become a viable candidate because there is now a recovery and recycle process for the catalyst.

Less Bark and Anti-scale Add Up To Savings at DMI

A mill case study about controlling scale in the bleach plant was presented by M.H. de Oliveira of Daishowa Marubeni Peace River Pulp. The mill was having an issue with scaling. It was causing production losses for cleaning and washing lines, poor quality due to high degree of dirt in final pulp, and higher chemical usage when the washer was plugged.

An investigation determined that one contributing factor was bark content, so the mill set upper limits for bark content and penalizes suppliers if they exceed that level.

Using a simple calcium level test, staff were able to determine that bark content dictates the calcium level coming into the bleach plant.

De Oliveira explained that if the D0 washer is kept clean, there will be low carryover of calcium.

The mill also began using an antiscale product. Scale decreased and chemical savings were noted for ClO2 and NaOH. Following these procedures, the mill had no production losses in 2010 for cleaning related to this issue. The mill is producing better quality pulp, with less chemical consumption. The estimated savings is $1.3 million/year.

Renewable Fuels Standards Pushing Biofuel Developments

By Shaun L. Turriff

The last session of the International Forest Biorefinery Symposium began with the keynote address by Mike Rushton, of Lignol Innovations Inc. Rushton’s talk focused on the current state of biofuel legislation and funding in both Canada and the U.S. Rushton was quick to point out that pulp mills are already biorefineries, in the strictest definition of the word, but that the recent focus has shifted to the specific production of biofuel, even though single product output is rarely viable. Part of the shift in focus lies at the feet of renewable fuels standards imposed by the governments of Canada and the U.S. These standards, along with government funding of biorefining projects, have been a significant driver in the development of biorefineries. This funding, Rushton noted, has been deployed more slowly in Canada, but the sector is becoming more active, with five project applications received, two more expected, and 20 companies being watched as potential candidates.

The US funding situation, according to Rushton, is more robust, which is part of the reason Lignol has a demonstration plant in that country. In the U.S., 29 grants have been issued for commercial, demonstration, and pilot projects.

Largely, these projects expect to begin construction in the next few years.

Rushton reported that financing, feedstock availability, and technology development are the major problems facing these projects. The economic and political climates still present a significant challenge considering the recent recession and low oil prices.

Another problem facing the industry is the lack of a clear winning process or product (amply demonstrated by the variety of papers presented during PaperWeek Canada). The industry structure, with many small start-ups lacking substantial financing, also presents a challenge for the future of the sector. continued on page 16 March/April 2011 PULP & PAPER CANADA

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Multiple Pathways to Bio-based Products

By Shaun L. Turriff Many presenters at PaperWeek’s biorefinery symposium moved away from the broader strategic view and focused more narrowly on some of the myriad technical elements of the biorefinery process, including various techniques (all at the laboratory phase of development) and integration issues (based on simulations).

The keynote address delivered by Thore Berntsson, of Chalmers University, Sweden, entitled “Integration of Biorefining Technologies in Pulp and Paper Mills” dealt primarily with research activities in Sweden, including black liquor and biomass gasification, lignin precipitation and upgrading, ethanol production in converted pulp mills, hemicellulose extraction and the catalytic cracking of lignin.

Like many of the papers presented at the biorefinery symposium, Berntsson’s addressed the differences of the multiple pathways available, and the potential pros and cons of each. Also, like many of the papers, he addressed the importance of integration, and suggests that plants operating below peak efficiency need to be optimized as an integrated facility, not as two separate processes.

Continuing on the topic of integration issues, Zoé Perrin-Levasseur, of Natural Resources Canada, CANMET Energy, discussed the production path for lignin in pulp mills and the effects of lignin production on existing energy and resource use in the mill. PerrinLevasseur’s paper identifies acid precipitation as the best current technology for the extraction of lignin, and examines the integration processes in terms of increased steam demand (up to 23%) for the mill and of increased demand for inorganic compounds added to the process. In each case, Perrin-Levasseur’s research indicates that with careful integration using pinch analysis and the capture and reuse of chemicals produced by the kraft process (CO2 from the recovery boiler flue gases, for instance), 16

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the increased resource consumption associated with lignin extraction can be overcome.

How to make lignin and furfural work

The optimization of the heat system in a biorefinery producing furfural was the subject of a presentation by Ludovic Montastruc, of the Institut National Polytechnique de Toulouse, in conjunction with the École Polytechnique de Montréal. Focusing on kraft pulp mills and the conversion of hemicellulose into furfural, Montastruc’s paper suggests a cluster approach of three mills producing 1000 t/d each. One mill serves as the centre of the cluster, with the biorefinery on site, while the other two supply concentrated hemicellulose pre-hydrolysates for the production of furfural. Ultimately, the simulation of the cluster and the subsequent optimization of the heat network suggest that costs can be cut by up to 45%, making this a potentially profitable process for a kraft mill/biorefinery combination.

A presentation by Eric Connor, of ThermoChem Recovery Intl. (TRI) presented the company’s pilot plant projects in the United States: Flambeau River and NewPage. Both plants are set up as BTL (biomass to liquids) biorefineries with Fischer-Tropsch systems.

Highlights of these projects include integration with existing infrastructures (Flambeau River mill is more than 100 years old), feed stock flexibility and product optionality, depending on market conditions. These elements, Connor maintains, are important to biorefinery integration, as market values (feedstock availability and price, end product market value, energy pricing) change.

Extraction of chemicals holds promise

Pharmaceuticals present another avenue for pulp and paper companies to explore.

Mamdouh M. Abou-Zaid of the Cana-

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“Biofuel Developments” (continued from page 15)

Rushton’s factors for success for biorefineries include: being well capitalized, building on an existing business, thinking big (ability to scale up is important to attracting investment), and reducing emphasis on biofuels (advice heard often during the symposium). Rushton closed by noting that the opportunity is there, despite the challenges, and that the forest industry is well positioned to participate.

Another established Canadian player in the biorefining sector was present to talk about biofuels as well. Randall Goodfellow, senior vice-president, corporate relations, at Ensyn, discussed his company’s long history of biorefining and its future in the forest industry. Ensyn focuses on the production of bio-oil, which can then be sold to a number of industries, including liquid fuel and chemical producers.

The presentation focused on Ensyn’s proprietary system of RTP, or fast pyrolysis, and its advantages.

RTP, according to Goodfellow, is commercially proven, reliable, maximizes yield, reduces emissions and is cost competitive with fossil fuels.

Ensyn’s strategy involves partnering with established businesses (UOP/ Honeywell, for example). The company is currently working with Tolko Industries. Bio-oil is already used extensively in the chemical and thermofuels industries, and by 2012 will be used in the refining of transport fuels as well.

dian Forest Service, Natural Resources Canada, told attendees of the potential for both existing and novel pharmaceutical products extracted from Canadian forests.

Focusing on the research taking place at the Great Lakes Forestry Center, Abou-Zaid discussed the advantages of using Rapid Thermal Process in the extraction of taxanes, used in the treatment of soft tissue cancer, over more traditional solvent extraction.

Abou-Zaid also discussed the potenpulpandpapercanada.com

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PAPERWEEK CANADA REPORT tial of several other compounds extracted from Canadian tress (taxanes are found in yew), such as willow and birch. While these compounds may be many years from market, Abou-Zaid highlighted the importance of the ever-growing library of chemical compounds extractable from Canadian forests being compiled by the lab at the Great Lakes Forestry Center.

From McGill University, Robert Marchessault followed up with a paper presenting the extraction of water soluble

xylans from wood using liquid ammonia.

Holocellulose from hardwood chips is pre-treated with liquid ammonia and then treated with hot buffered water to extract O-acetylxylan, which can then be used either in extruded plastics or to produce water cast film, which offers barrier properties for use in packaging. Marchessault’s presentation did not directly cover the potential uses of this technology in the pulp and paper industry, or the economic potential of such a process.

Mangin to Lead PAPTAC; Dufresne, Dal Monte Join Council

New Bio-economy Will Grow Hand-in-Hand with Traditional Forest Products

Patrice Mangin, general director of CIPP (Centre intégré en pâtes et papiers) and professor of chemical engineering at University of Quebec in Trois-Rivières, took the reins as chairman of the Pulp and Paper Technical Association of Canada at the group’s annual meeting on Feb. 2.

“This is my chance to give back to the association that has given so much to me,” said Mangin.

The Forest Products Association of Canada (FPAC) released at PaperWeek Canada a second study related to its Bio-pathways project that shows how the Canadian forest sector can thrive in the bio-economy.

The study, called The New Face of the Canadian Forest Industry: the Emerging Bio-Revolution, demonstrates how the forest products industry of Canada is uniquely positioned to take advantage of the new bio-economy and exploit a potential global market of around $200 billion for bio-energy, bio-chemicals and bio-materials that can be extracted from trees. These products include everything from renewable fuels to lightweight plastics to non-toxic chemicals and food additives.

The Bio-pathways study examined 36 different technologies, and traced their various permutations and combinations. The answers were astonishingly clear – “Yes, there is a robust market, and we can compete in it,” said Avrim Lazar, president and CEO of FPAC The bio-economy will not replace the traditional forest products industry, said Lazar, because it is woody residue that is the most attractive feedstock.

Economically, it is most feasible to add new products to the existing industry.

Socially, he adds, in terms of job retention, it is also best to tag onto the existing industry.

Environmentally, harvesting wood

Patrice Mangin, chairman, PAPTAC

His 38-year career with the pulp and paper industry includes roles as CEO of Centre Technique du Papier (CTP, Grenoble, France); Quebecor chair holder at UQTR, Stora Enso chair holder at the Royal Institute of Technology (KTH, Stockholm), scientific director of the Swedish Print Research Network, and various positions at PAPRICAN. Also joining the PAPTAC Executive Council this year are Robert Dufresne, general manager of Canfor Pulp’s Northwood mill, and Carlo Dal Monte, corporate energy director with Catalyst Paper. pulpandpapercanada.com

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Valerie Bisong, from the University of Manitoba, presented another new technology in the form of cellulose fermentation with the goal of ethanol production.

Bisong’s process, using a single bioreactor, presents the potential for a continuous process and low cost production of ethanol (and hydrogen as a co-product).

Bisong pointed out, as did many of the other presenters at the symposium, that ethanol is not yet cost-effective, given today’s oil prices.

Avrim Lazar, Patrice Mangin and Theo Van de Ven at PaperWeek Canada.

solely for bioproducts is not as favorable.

“To go from standing on the threshold to fully occupying this possibility requires that we develop openness to new partnerships, for example, chemical, energy, textile, biotech,” said Lazar.

The report is the second phase of an exhaustive research study on how to best position the next generation forest products industry by extracting maximum value from every tree.

The project was guided by FPAC, in partnership with FPInnovations and the Canadian Forest Service, with help from experts in fields such as bio-technology and carbon analysis.

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Buckman Gibson Puts Sustainability into Perspective Kathy Buckman Gibson has a more personal vision of sustainability, more personal than the three-legged stool metaphor (economically, environmentally, socially sustainable) heard so frequently in industrial discussions. As chairman of the board for Buckman, a chemical manufacturer, she has had much exposure to ideas about sustainability, and she shared her thoughts with PaperWeek Canada participants.

Buckman Gibson believes sustainability is about long term thinking. She feels organizations should make decisions based on the “right” thing to do. Buckman Gibson said organizations have to step away from day-to-day thinking, and think of the longer term.

She noted that the recent global financial crisis was caused by short-term thinking, ignoring risk for short-term gain.

“I would hope that we can begin to think about the issue of sustainability

Kathy Buckman Gibson with Tom Johnstone of Buckman Canada.

for our organizations in much the same way we think about what is best for us as individuals on a day in, day out basis.

Each day we as individuals make decisions about our families, our homes,

where we send our children to school, our career choices, and each of those decisions, for the most part, is guided by what we think is the right thing to do for our families — not for next week, or the next month, but for the long term, for the rest of our lives.”

As a company, Buckman has significantly reduced its emissions, strives for one recordable incident per year, and subscribes to the 12 principles of green chemistry.

Last year, Buckman decided to support volunteerism in education, environment, health and human services. In 2010, the company logged 4780 hours of Buckman-sponsored community hours.

“True sustainability for our industry and our organizations requires that we step back from the day-to-day, that we think longer term, that we think about what decisions we would make if we were making them for our family,” she concluded.

2011 PAPTAC Awards Awards for research, technical papers and service to the Canadian pulp and paper industry were conferred during the PAPTAC Annual Meeting, held February 1-3 in Montreal.

Dr. R. Crotogino was presented with the John S. Bates Memorial Gold Medal for long-term contributions to the industry.

The I.H. Weldon Award for the best paper went to ZhiHua Jiang and Richard Berry (both of FPInnovations) for their paper, “Near-Neutral Final Chlorine Dioxide Brightening: Theory and Practice. The two were also awarded the

Weldon Award

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Howard Rapson Memorial Award for the best chemical pulp bleaching paper.

The Douglas Atack Award for the best paper presented at the mechanical pulping sessions at the previous Annual Meeting was awarded to Xue Feng Chang, Colin Bridges, David Hu, Lena Kuang, James Olson, Antti Luukkonen (all of UBC) and Rodger Beatson (BCIT), for their paper, “Saving Electrical Energy by Alkaline peroxide Pretreatment of TMP Prior to Low Consistency Refining.”

The F.G. Robinson Community Service Award was conferred upon Sammy Di Re of Voith, chairman of the Paper Machine Technology Community.

The Douglas Jones Environmental Award for the best paper in the field of environment improvement went to Sébastien Migneault, Hamid Nadji, Bernard Riedl (all of Université Laval), James Deng, Tony Zhang (both of FPInnovations) and Ahmed Koubaa (UQAT), for their paper, “Properties of Binderless Fibreboard Made from Primary and Secondary Paper Mill Sludge from Three Pulping Processes.”

The Jasper Mardon Memorial Prize for the best paper contributing to the advancement of papermaking was presented to Geneviève Gauthier, Ivan Pikulik and Jean Hamel (FPInnovations) for their paper, “PAPRIDRY™ - Continuous Operation of Two Pilot Plant Units of PAPRICAN.” pulpandpapercanada.com

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Top PAPTAC honour goes to Dr. Ron Crotogino Jones Award

Pedram Fatehi (UNB) received the C. Howard Smith Award for the best paper submission by a member under age 33. His paper is entitled, “Importance of Change Density of Cationic Additives on Increasing Paper Strength.”

The Gadget Competition is judged by the members of PAPTAC’s Engineering and Maintenance Community.

Prizes and certificates are awarded by the sponsor, Pulp & Paper Canada. This year’s first prize winner is Jean Paradis of UQTR-CIPP for “capuchons enveloppants”. The second

Gadget Competition: Paradis

prize winners are George Korhonen and Grant Douglas of Catalyst Paper for their pressure filter tube puller.

The Energy Conservation Opportunity Awards are presented for the best examples of energy conservation opportunities applied in Canada. First prize went to Surendra Singh of Alberta Newsprint for A Chain Reaction of Energy Reduction in Boiler Water Feed Pump. Second prize was presented

Energy Conservation Award: Singh

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The 2011 John S. Bates Memorial Gold Medal, the highest honour offered by the Pulp and Paper Technical Association of Canada, has been awarded to Dr. Reinhold (Ron) Crotogino. He has been associated with the forest products industry for more than 50 years, as a student, researcher, consultant, and teacher.

Crotogino is currently the network director, president and CEO of ArboraNano, the Canadian Forest NanoProducts Network.

The award was presented during PaperWeek Canada in Montreal. Accepting the award, Crotogino said of his long career in pulp and paper: “Throughout my career, I kept getting hooked by incredibly interesting challenges, and the incredibly interesting people I’ve been able to work with.”

Crotogino is a graduate of the University of British Columbia (B.A.Sc. 1966) and McGill University (Ph.D. 1971), both in chemical engineering. He worked with Voith for a few years after graduating, but spent much of his career as a researcher and research manager with Paprican (now FPInnovations).

In 2008, he prepared the successful application for funding of ArboraNano, and took charge of the organization when it was incorporated in March 2008.

Crotogino joined the Technical Section of the Canadian Pulp and Paper Association (now PAPTAC) as a student member in 1964. He has served as a member of various committees, and became involved in organizing several international conferences sponsored by PAPTAC and TAPPI. He is a Fellow of TAPPI and of the Canadian Academy of Engineering. to Dilesh Thurai of Cascades Tissue Group for Steam and Condensate Optimization. Pierre Daneault of AbitibiBowater Baie-Comeau received third prize for Thermostatic Trap on Deaerator Vent.

The Energy Conservation Opportunity Awards are sponsored by Pulp & Paper Canada.

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BLEACH PLANT

Minimizing and Sustaining Final Brightness Variability and Reduced Chemical Consumption in Kraft Bleaching

By J. Paul and A. Rowat Abstract: NewPage Corporation in Rumford, Maine installed and calibrated an on-line Metso Kappa Q Analyzer to measure kappa number and brightness after the first extraction stage, and brightness after the D1 stage of their bleach plants with sequence D0 Eop D1. This paper describes how these measurements, along with a predictive and adaptive control strategy, have reduced brightness variability by 50% while at the same time have sustained a reduced monthly chlorine dioxide usage of between 15 and 25%.

T

he NewPage Corporation pulp and paper mill in Rumford, Maine has two fibre lines designated for hardwood and softwood pulp production, respectively. Each fibre line has a three-stage bleaching sequence: D0 Eop D1.

Hardwood makes up 75% of the mill’s total pulp production and its brightness target is 88.5 ISO. The mill planned to reduce their total ClO2 usage in both fibre lines by implementing Metso’s mBLEACH™ Control, which uses on-line kappa number measurements, on-line extracted and post D1 brightness, and in-line sensors in a control strategy to apply chlorine dioxide to the D0 and D1 stages and hydrogen peroxide to the extraction (Eop) stage in a predictive and adaptive control strategy.

Metso’s D0/Eop bleaching solution includes: • Validation on all measurement inputs (min, max and maximum deviation); • Bumpless transfer from control off to control on; • Control of oxidative agents in D0/Eop model (ClO2 + H2O2); • Uses derivatives for in-line sensor control input – this compensates for sensor drift if it occurs as it is the rate of change and not the raw value that is used;

Fig. 1: D0/Eop control model

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PULP & PAPER CANADA March/April 2011

• Targets for D0/Eop are Eop brightness and CEKappa number. Closing the loop uses weighted error (measurement minus target); • Grade and species tracking, clean transitions between grades; • Remote monitoring and support.

Metso’s D1 bleaching solution includes: • Validation on all measurement inputs (min, max and maximum deviation). Automatic switch to laboratory tests if analyzer measurement invalid; • Bumpless transfer from control off to control on; • Uses derivatives for in-line sensor control input – this compensates for sensor drift if it occurs as it is the rate of change and not the raw value that is used; • Uses CEKappa number and Eop brightness in weighted sum; • Target for D1 is D1 final brightness. Closing the loop uses error (measurement minus target); • Grade and species tracking, clean transitions between grades; • Remote monitoring and support.

Fig. 2: D1 control model.

J. PAUL NewPage Corp., Rumford, ME

A. ROWAT Weyerhaeuser Co. (formerly Metso Automation, Norcross, GA) pulpandpapercanada.com

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T2

BLEACH PLANT Table I: Results before and after mBLEACH™ controls.

Before After % controls* controls** reduction

Final brightness average 88.5 ISO Final brightness STDEV 1.14 Final brightness coeff of var. (%) 1.30 D1 after tower residual (g/L) 0.10 Total ClO2 usage X

88.5 ISO 0.59 0.66 0.05 0.78X

48% 49% 52% 22%

*Feb. 1 – April 30, 2009 ** Feb 1 – April 30, 2010

RESULTS

Hardwood pulp bleaching at Rumford had considerable challenges: an inlet kappa 14.7 σ 1.1, 88.5 ISO brightness target, and a short (three-stage) bleaching sequence. Before the mBLEACH controls were in place, there were episodes of high residuals out of the D1 stage, and episodes of low brightness as operators tried to treat the pulp to meet their brightness target with only pre-bleach kappa number information. Online brightness measurements before and after the D1 stage and the control model virtually eliminated these quality problems. Table I summarizes the results before and after mBLEACH implementation.

Figure 3 shows the ClO2 usage versus baseline for both pre-implementation and post-implementation of mBLEACH. The results of mBLEACH have sustained ClO2 usage well below baseline values.

Figure 4 shows that the kappa number variability coming into the bleach plant during this time was similar to pre-mBLEACH timeframe.

Figure 5 shows the process capability of the final brightness with a lower specification limit (LSL) of 87.8 and an upper specification limit (USL) of 88.8. Before mBLEACH implementation 64.46% of the total dataset is outside of the specification limits, and 30.85% below LSL. Figure 6 shows the process capability of the final brightness after the implementation of the mBLEACH controls. Again, with a LSL of 87.8 and USL of 88.8 the total percent of data outside of the specification limits dropped to 22.6% with only 9.04% less than the LSL.

INTEGRATION

Metso’s mBLEACH Controls are easily integrated with a mill’s DCS and come with ready-made displays for each bleaching stage. A four-hour class on the process and controls and one shift of control room hands-on training is all that is required for operators to confidently use the control strategy.

Remote access allows immediate customer support if needed.

All measurements used in the mBLEACH controls go through validation verifications. If a validation is violated the measurement is not used in the controls. Depending on what the measurement is, the controls either use the last measurement that was validated, or stop using the measurement in the controls

Fig. 3: ClO2 usage compared to baseline.

Fig. 5: Final brightness capability pre-mBLEACH.

Fig. 4: Kappa number variability entering bleach plant.

Fig. 6: Final brightness capability post-mBLEACH.

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T3

BLEACH PLANT altogether and use all other validated measurements. This is important for control uptime. At Rumford the average mBLEACH control usage has been 97%.

Other benefits at Rumford

Other than chemical and brightness variability reductions, the measurements and controls have intangible benefits: • Controlling a three-stage bleach plant to high brightness can be challenging and can lead to high residuals and safety issues. This is a safety issue that has been alleviated: the post D1 residual level has been halved.

• Having 15-minute final brightness measurements from the Kappa Q is another unquantifiable metric.

Operators like to see the “real time” brightness every 15 minutes compared to a laboratory brightness test

on pulp that was taken from the process more than one hour prior.

• Operators are no longer concerned about their chemical additions; they can focus on other duties.

CONCLUSION

On-line kappa number and brightness

measurements with Metso’s mBLEACH control system have reduced chemical usage, stabilized final brightness, and eliminated high residual safety issues in NewPage, Rumford’s bleach plant.

Control uptime is greater than 97% on every bleaching stage, with no operator interventions.

Résumé: NewPage Corporation de Rumford, Maine, a installé et étalonné un analyseur Metso Kappa Q afin de déterminer la blancheur et l’indice Kappa après le premier stade de l’extraction, et la blancheur après le stade D1 des ateliers de blanchiment avec la séquence D0 Eop D1. La présente communication décrit la façon dont ces déterminations ont, en conjonction avec une stratégie de commande adaptative et prédictive, réduit la variabilité de la blancheur de 50 %, tout en maintenant la consommation réduite de dioxyde de chlore à 15 % à 25 %.

Reference: PAUL, J., ROWAT, A. Minimizing and Sustaining Final Brightness Variability and

Reduced Chemical Consumption in Kraft Bleaching. Pulp & Paper Canada 112(2): T1-T3 (Mar/Apr 2011). Paper presented at PacWest 2010 in Sun Peaks, B.C., June 9-12, 2010. Not to be reproduced without permission of PAPTAC. Manuscript received June 2010. Revised manuscript approved for publication by the Review Panel January 2011.

Keywords: KAPPA ANALYZER, K NUMBER, KAPPA NUMBER, BRIGHTNESS, PROCESS VARIABILITY, BLEACH PLANT CONTROL

FOCUS ON REFINING Metso starts up two new-generation refiners

In November 2010, Metso successfully started up the first two OptiFiner Pro refiners at Koehler Greiz KG’s mill in Greiz, Germany, and Sappi Fine Paper’s Biberist mill in Switzerland. OptiFiner Pro is a revolutionary low-consistency refining concept.

The first start-up at the Greiz mill was on deinked pulp for trim refining/deflaking.

The Greiz mill produces colored recycled papers and board for office, school and graphics applications. The mill’s target is to break fibre bundles, shives, and other impurities with minimum refining degree change. “Currently we are running the optimization phase, but compared to the old machine we have already observed significant energy savings,” says Ulrich Mallon, technology and quality assurance manager in Greiz.

The second OptiFiner Pro started in mid-November at Sappi’s Biberist mill, replacing four conventional conical refiners in a eucalyptus stock preparation line on a coated fine paper machine. The Biberist mill produces coated woodfree paper for the graphic arts and offset printing industry, as well as woodfree uncoated pre-printed paper for office, pre-printed and offset applications. Stefan Franke, development engineer at Sappi Biberist, says the mill’s targets of energy savings and quality improvement have been met. “Energy savings are as expected with good strength development and strength improvement

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with same specific refining energy.”

The OptiFiner Pro is a new low consistency refiner with a very compact design. In conventional refiners, fibres travel the full length of the refining zone suffering excessive impacts that lead to increased fines and weakening of the refined fibres.

Many fibres, as much as 70% of the total, may not be treated at all. To combat this, 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 higher refiner loadability and better energy efficiency.

Metso Paper 514-335-5426, www.metso.com

Optimize and modernize to reduce operating costs

Invensys Operations Management is focused on providing tools and solutions that help thermomechanical pulp (TMP) mills reduce operating costs by closely monitoring power consumption, production quality, and heat recovery.

Invensys’ unique InFusion Enterprise Control System (ECS) platform provides unified access across any automation platform so that data can be manipulated into useful real-time decision-making information for all stakeholders from operators to mill managers.

Dashboards allow operators to make informed decisions in full knowledge of their cost or performance implications and contribute to meeting plant objectives.

PULP & PAPER CANADA March/April 2011

The dashboards are designed to help achieve quality and throughput targets at minimum power consumption and cost, and to monitor optimal heat recovery for use elsewhere in the mill.

Invensys Operations Management also supplies advanced control solutions to stabilize and optimize refiner operations, taking into consideration quality, pulpandpapercanada.com

22/03/11 10:32 PM

TECHNOLOGY NEWS

FOCUS ON REFINING throughput and economic objectives. The mesh control backbone of the company’s continuously current Foxboro I/A Series distributed control system has effectively removed limitations on transferring information from one part of the plant to another and facilitates the cost-effective modernization of existing systems.

Other innovations have enabled tighter integration of PLCs at the I/O board level to provide increased reliability and data throughput at a much reduced cost.

Additionally, Invensys Operations Management’s Avantis asset performance and condition monitoring solutions work in unison with the ECS to track equipment usage, maintain uptime, and avoid unscheduled downtime.

Invensys Operations Management 469-365-6400, http://iom.invensys.com

LC refining: Half the energy, increased strength

The installation of a new Andritz low consistency refiner at Holmen Paper’s Braviken mill in Sweden is part of a public project to demonstrate dramatic reductions in energy consumption for mechanical pulp production. The concept for the new line at Braviken is a combination of three process steps: RT-pretreatment, high consistency (HC) mainline refining, and low consistency (LC) secondary refining. Not only is the process unique, but the huge Andritz TwinFlo 72 refiner (72-inch) is a totally new machine and the largest in the world.

The groundwork for the development project started 10 years ago when Holmen

experimented with LC secondary and reject refining in a TMP line. The results were so good that Braviken installed its first low consistency TwinFlo refiner in 2003. “The big advantage to LC is the low energy consumption,” says Christer Sandberg, development project manager for Holmen.

“It has about half the energy consumption

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Saving energy is smart business

quality monitoring hardware and model predictive control algorithms. Together, these systems may provide a dramatic increase in pulp sampling frequency combined with the capability to build advanced process models. The result will be better product, reduced variability, and reduced costs.

BC Hydro’s Power Smart Partners Industrial Program, Monitoring Targeting & Reporting (MT&R) initiative is being implemented at several BC pulp and paper mills to support the evolution of continuous process monitoring and control.

This initiative provides the customer with a basic MT&R energy management and information package and adds to it the information provided by continuous pulp quality monitoring and the unit process control capabilities of model predictive control. This is applied to all key mechanical pulp mill subsystems including chip washing/conditioning, mainline refining, mainline screening and rejects refining system. This system will give operators an unprecedented ability to directly control pulp quality development while optimizing the contribution of each subsystem and minimizing process inputs like chemicals and refining energy.

New information systems and data mining can help industry enhance process understanding, and provide new solutions using existing data and processes.

BC Hydro 866-453-6400, www.bchydro.com/industrial

for a given increase in strength properties compared to HC single-disc refining.”

What is achieved at Braviken could benefit TMP producers around the world, according to Rikard Wallin, mill manager.

“From a practical point of view, the front line of mechanical pulping research is in Braviken for the next two or three years,” he says. “If the technologies here can be applied in other places, we can contribute to lowering energy consumption and emissions globally.”

Andritz Ltd. 514-631-7700, www.andritz.com

reduced energy consumption – using a combination of sub-processes and targeted chemical treatments. ATMP consists of unit

Excellent processes are efficient processes. With this in mind, BC Hydro, in conjunction with industry partners, is supporting a series of information-based studies, demonstration projects and Power Smart Partner Industrial Program initiatives intended to assist the pulp and paper industry to drive process improvement and reduce waste.

BC Hydro is supporting benchmarking studies in order to provide companies with a database of industry best practices that will subsequently support development of energy models for various unit process operations and areas.

BC Hydro is also supporting several demonstration projects on data mining. Through these projects, mills are learning how to harness the power contained in vast amounts of stored process information.

Data collection systems in pulp and paper facilities continuously gather data that is seldom used as feedback to improve the process. It is becoming clear that energy issues, both in the pulp and paper industry and more broadly, often involve the analysis of complex systems. These demonstration projects use software that can analyze all this process data and find useful correlations to generate simple operating rules and setpoints that can be used to improve plant operation While existing data can tell one story, BC Hydro is also supporting the demonstration of continuous pulp

Advanced TMP – energy savings and better mechanical fibers

Andritz Advanced TMP (ATMP) is a method for producing well-bonded softwood thermomechanical pulps with significantly

The Andritz Advanced TMP (ATMP) process significantly reduces energy consumption (in excess of 25%) on softwoods. The three major modules, which can be retrofitted to existing installation, include: RTFibration, highintensity RTS refining with chemical treatment, and HC or LC refining.

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TECHNOLOGY NEWS

FOCUS ON REFINING operations formulated to better separate the defibration and fibrillation steps in TMP refining with the goal of improved pulp fibrebonding at the lowest possible energy consumption. The targeted chemical treatment with sodium bisulfite is important for maximizing the efficiency of this process.

Results indicate significant energy reductions (in excess of 25%) can be achieved for a given pulp strength. Andritz has also confirmed that it is possible to produce high quality mechanical pulps from spruce, fir, and various pine species with enhanced properties suitable for production of wood-containing printing papers.

Andritz Ltd. 514-631-7700, www.andritz.com

Refiner plate MiniSegment™ extends value, saves money for LC refining AFT Finebar®, part of the global Aikawa Group, has developed the MiniSegment™ refiner plate – the latest advancement in diffusion bonded refiner plate technology.

The MiniSegment allows mills to replace only the working surface of the refiner plate, reducing the overall cost of ownership.

“Our customers have been thoroughly impressed by the performance of the FibreWall cylinder,” says Daniel Parenteau, general manager of Kadant Black Clawson’s Montreal office. “We are able to reach significantly higher efficiencies for demanding DIP and mechanical pulp applications, even on high consistency applications. In some cases, this has allowed for shutting down equipment, such as cleaners, to save energy and reduce maintenance cost. The excellent strength of the FibreWall screen cylinder allows us to retrofit existing screen cylinders with a high level of confidence, particularly on mechanically demanding applications.”

The patent-pending Fibrewall screen cylinder design features non-welded construction, built in the round, to minimize stress and distortion and allow for maximum screening efficiency. The robust mechanical assembly and high-precision

AFT Finebar® refiner plate MiniSegment™ reduces plate replacement costs.

wire positioning system allow for tight slot width tolerances and a high degree of consistency. As a result, the Fibrewall cylinder maximizes screening efficiency and provides for a high capacity flow through the pressure screen in virgin, recycle and mechanical pulp applications.

Kadant Black Clawson Inc. 514-620-4441, www.kadant.com

Refiner upgrades cut energy consumption more than 25%

A Wisconsin-based specialty paper mill reports continued success with refiner upgrades.

The mill has four refining systems. The first conversion project started in 2003 on one line of three 34-in. DD®3000 refiners operating in mono-flo. This system was upgraded to GL&V’s DD®3500 spline technology and the refiners were converted from mono-flo to duo-flo mode which changes the flow path within the refiner and increases the hydraulic capacity of the unit. The refiner plate patterns were also optimized.

A duplicate of the first conversion was completed in 2004.

The final two lines were upgraded and optimized starting in 2008 and completed in 2010. In all, the mill updated these specific refiners: nine 34-in. DD3000s to DD3500s, one 34-in. DD4000 to DD4600, and one 38-in. DD4000 to DD4600.

Data was compared over a 40-month period with two years of data prior to the installation and 16 months of data after the installations. The mill is pleased to report an overall reduction in kW consumption of just over 25% for the refiners.

GL&V USA Inc., refiners@glv.com, www.glv.com

The MiniSegment is installed on an adapter plate, which is bolted to the mounting surface using the existing refiner bolt holes. In addition to saving money by replacing only the fibre-contacting portion of the refiner plate, the MiniSegments weigh considerably less than a traditional plate, making them easy to position when bolting and safer to handle.

AFT Finebar Inc. 914-391-0878, www.aikawagroup.com

FibreWall™ screen cylinders suit demanding applications

FibreWall screen cylinders are quickly gaining new customers and applications, as the product is now an integral element of Kadant’s fibre processing product offerings.

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TECHNOLOGY NEWS Canfor selects FITNIR analyzer to improve efficiency of bleaching operation

Canfor Corp. has selected FITNIR Analyzers Inc. to supply and install advanced infrared measurement technology at their Intercontinental pulp mill in Prince George, B.C. FITNIR’s analyzer will enable Canfor to monitor and control key chemical data to optimize the solution composition of its chlorine dioxide (ClO2) generator. The improved generator efficiency and pulp production levels will provide tangible financial and environmental benefits.

The decision to implement FITNIR was made on the heels of the successful completion of the system upgrade at the Northwood mill site in October 2010. With the accurate measurements that the analyzer will provide, Canfor’s Intercontinental pulp mill can expect significant savings on chemical costs. Furthermore, anticipated system reliability and efficiency improvements will result in considerably less downtime and lost pulp production, as well as a higher quality product.

The first of its kind capable of measuring ClO2 generator compositions, FITNIR’s analyzer provides pulp mills with data to enable optimization of their control parameters, including chemical requirements.

This new technology utilizes near infrared (NIR) spectrometry to analyze liquor content throughout the pulp mill process.

Providing a comprehensive set of process analyzers, FITNIR can analyze liquor samples at various stages throughout the recovery, recausticizer and digester areas, as well as the chlorine dioxide (CLO2) generator.

“We are very excited to be working with yet another Canfor mill,” said Tom Sands, CEO of Vancouver-based FITNIR Analyzers Inc. “Canfor is a true industry leader and we believe our cutting-edge analyzer will add to its strong competitive position in the market.”

Implementation is underway and expected to be completed in the spring of 2011.

FITNIR Analyzers Inc. 604-204-2531, www.fitnir.com

Premium fluff pulp debonder has minimal impact on absorbency

The Industrial Specialties business line of Evonik has introduced Arosurf® PA 780, a new debonder for use in fluff pulp manufacturing that raises the bar in debonder absorbency, significantly minimizing its impact on fluff pulp absorbency and ultimate capacity. The result is superior absorbency in demanding end products such as baby diapers, feminine hygiene pads and pulpandpapercanada.com

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airlaid absorbent products.

Arosurf® PA 780 is a blend of nonionic and cationic surfactants, a highly effective debonder despite a reduced cationic content. It provides a superior initial and ultimate capacity index to fluff pulp.

According to Evonik, fluff pulp treated with Arosurf® PA 780 has been found to have a 25% greater absorbency rate than fluff pulp treated with a competitive product.

Arosurf® PA 780 can be applied as a lowsolids dispersion into stock chests or suction pumps or through continuous inline mixing of the concentrate pumped from storage.

Nalco Company, 630-305-1246

Burner retrofit boosts boiler efficiency

Hamworthy Peabody Combustion offers a new Q-jet™ Low NOx Burner Optimization Kit that can be retrofitted to practically any existing burner, regardless of manufacturer, to increase efficiency and reduce maintenance.

The Q-jet™ Kit achieves NOx reductions up to 35% on gas firing, and up to 40% on oil firing when equipped with the SPIROjet™ low NOx atomizer.

The optimization kit is an economical and practical alternative to installing completely new burners. It works with single burner boilers up to multi-burner utility boilers.

Hamworthy Peabody Combustion Inc. 877-PEABODY, www.hamworthy-peabody.com

Precision FotoFiber honored for impact on productivity

Honeywell’s Precision FotoFiber solution has won the Paper Industry Technical Association’s (ATIP) Silver Palm Award, which recognizes innovation in the French paper industry.

“Precision FotoFiber is a true breakthrough in high-speed image analysis that saves paper and board makers time

and money,” said Jack Ross, marketing director, Pulp & Paper, Honeywell Process Solutions.

Precision FotoFiber is a fibre orientation-angle sensor. It is ideal for manufacturing large product runs of newsprint, fine paper, containerboard, and folding boxboard, and minimizes the need for manual monitoring by mill personnel. Its camera and powerful illumination technology automatically adjust to varying machine speeds and sheet surface characteristics to capture high-quality sheet surface images.

This automated approach helps reduce variations in web fibre orientation profiles.

Honeywell International, www.honeywell.com/ps

Energy-saving forming fabric technology

Developed by Xerium and its research partners, EnerStar is an exclusive energysaving paper machine clothing (PMC) technology designed to both reduce energy consumption and extend the economic life of forming fabrics that are vital to the manufacturing of paper.

EnerStar technology is produced with the highest-grade, modified polymers and is available as an optional feature for selected fabric designs from Xerium’s Huyck.Wangner and Weavexx PMC companies.

EnerStar technology provides unprecedented reduction in friction across the forming and vacuum element resulting in significantly lower energy requirements, and is already helping customers reduce costs.

Xerium Technologies Inc., www.xerium.com

Biocide approved for use in process water

Eka Chemicals’ Purate® technology has been approved for use as a paper machine biocide by Canadian regulatory authorities.

The Canadian Pest Management Regulatory Agency has given permission to use Purate technology to produce chlorine dioxide for applications to control microorganism contamination in pulp and paper mill process water.

“Purate is proven technology with more than 300 on-site chlorine dioxide production units around the world,” explains Mario Houde, president, Eka Chemicals Inc. “We are really excited to be able to offer this technology to the Canadian pulp and paper Industry as it is the most cost effective chemistry to control biofilm in the papermaking process.”

Eka Chemicals Inc., www.eka.com March/April 2011 PULP & PAPER CANADA

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CONFERENCE PREVIEWS PacWest: Capturing value, delivering on innovation

For four days in June, PacWest will offer pulp and paper personnel an exceptional learning and networking opportunity. The annual conference and trade show incorporates technical presentations, short courses and round table discussions for maintenance and pulp mill staff.

The event takes place June 8-11, in the beautiful setting of the Delta Sun Peaks Resort, near Kamloops, B.C. The opening forum on Thursday, June 9, will follow the conference theme: Capturing Value – Delivering on Innovation. Speakers include: Joe Nemeth, CEO, Canfor Pulp; Tom Rosser, Natural Resources Canada; Catherine Cobden, FPAC; Ted Seraphim, COO, West Fraser; Daryl Nichol, VP Pulp Operation, Alberta-Pacific Forest Industries; Mike Edwards, Senior V-P pulp and paper manufacturing, Domtar.

Friday’s keynote presentation will explore downstream uses for paper, as Patricia Graham, editor-in-chief of the Vancouver Sun, discusses “Today’s Newsroom: Keeping Pace with the Digital Revolution.”

Technical paper presentations will take place Thursday and Friday. The short courses vary in length from onehalf day to three days, while the maintenance roundtable is spread over three days and the pulp machine superintendants’ roundtable takes place Thursday and Friday.

The trade fair runs for three days, Wednesday to Friday.

For more details, visit www.pacwestcon.net.

Short course schedule – PacWest 2011

Kraft Pulp Bleaching – Fundamentals and Practices, Paul Earl, $200, Wed., June 8 (1 day) Troubleshooting and Optimization of Recaust and Lime, Vic Uloth, $200, Wed., June 8 (1 day) Fundamentals of PINCH Technology for Pulp and Paper, Bob Belling, $125, Wed., June 8 (1/2 day) Pulp Machine Operations, Alexander Mardon, $1090, June 8-10 (3 days) 28

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Rethink the paper industry at PaperCon

PaperCon delivers four days of concentrated technical content and networking opportunities for papermaking professionals. The 2011 event will challenge attendees to rethink paper by focusing on lean manufacturing, operational excellence, and environmental performance.

The conference will be held May 1-4 in Covington, Ky., near Cincinnati.

Organized by TAPPI and PIMA, PaperCon includes three distinct tracks, PIMA Management, Papermaking and Coating. New for 2011, special forums are planned on tissue making, sustainability and maintenance.

John D. Williams, president and chief executive officer of Domtar Corporation, will be the keynote speaker at PaperCon 2011. He will speak on Monday, May 2. Williams will talk about Domtar’s business approach and the integral role sustainability plays in its activities.

Jack McAneny, associate director global sustainability for Procter & Gamble Co., will give the keynote address at the welcome session for TAPPI’s PaperCon conference on Sunday, May 1. This session will provide an overview of P&G’s current sustainability efforts, their long term sustainability vision, and highlight issues that may be particularly relevant for the pulp and paper industry.

“Sustainability is a very important issue for TAPPI, our industry and its customers,” notes James P. Niemiec, PaperCon 2011 conference co-chairman and senior manager, product development for NewPage Corporation.

For more information, visit www. papercon.org.

Mechanical pulping experts meet in China

The biennial International Mechanical Pulping Conference takes place this year in China, from June 27-29. Organizers have made it easy for international visitors by offering a hotel reservation service, arranging post-conference tours, and organizing transportation and accommodation for a two-day mill visit.

This year’s event is sponsored and organized by the Pulp and Paper Technical Association of Canada (PAPTAC), Chinese Academy of Forestry, and

PULP & PAPER CANADA March/April 2011

Shaanxi University of Science and Technology. Topics for the conference include: • fast-growing plantation of hardwood and softwood trees, pulp wood qualities evaluation; • chemimechanical pulping technologies; • bleaching technologies; • end uses of mechanical pulps; • energy-saving technologies; • water management and effluent treatment; • process control.

For more information, visit http:// impc-2011.org.

Intensive biorefining course focuses on implementation strategies

PAPTAC and TAPPI are co-sponsoring a week-long biorefinery course, Designing the Forest Biorefinery, specifically for decision-makers in the forest industry. Held from May 16-20 at the TAPPI offices in Norcross, GA, this course will shed light on the key issues facing forestry companies considering biorefinery implementation.

The course is intended for corporate personnel in forestry companies who wish to become more knowledgeable about biorefinery implementation strategy and design methods, as well as mill managers and technical staff who seek to evaluate the best biorefinery strategy at the mill level. Consultants and other suppliers to the forestry sector will also take home important information regarding the evolution of the sector.

The course format is designed to facilitate exchange between faculty and participants. The course is led by Paul Stuart, a professor at Ecole Polytechnique and Chairholder of the NSERC Design Engineering Chair, Process Integration in the Pulp and Paper Industry. Sessions will be delivered by more than 20 experts from across North America, treating both strategy-setting and design issues related to transformation to the biorefinery.

Among the presenters are: Virginie Chambost, EnVertis, Inc.; Chris Gaston, Andrew Goodison and Tom Browne, FPInnovations; Adriaan van Heiningen, University of Maine; and Warren Mabee, Queen’s University.

The deadline for early-bird registration is April 15. Visit the TAPPI website for details. pulpandpapercanada.com

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PROFESSIONAL CONNECTIONS

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To inquire about advertising in Pulp & Paper Canada contact

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Careers Global Know-how and Local Service for the Forest Industry Pöyry (Montreal) Inc. Montreal, QC 514 341 3221

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PulP & PaPer Jobs Freeman Staffing, Inc. specializes in the placement of engineers (all disciplines), production type supervisors, managers, mill and/or plant managers and corporate executives in the pulp & paper industry, North America-wide. For specific current job searches call us or contact our web site. All resumes are treated with complete confidentiality.

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web site: www.freemanstaffing.com March/April 2011 PULP & PAPER CANADA

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SAFETY

Safest Mill in Canada Winners Two repeat winners demonstrate that a culture of safety protects employees year after year.

T

he 2010 results of Pulp & Paper Canada’s Safest Mill in Canada contest clearly show that safety can become a way of life for employees. Many of last year’s top performers lead their categories again this year. Domtar’s Windsor, Que., integrated pulp and paper mill won in the large mill category again, AbitibiBowater’s Thunder Bay, Ont., mill won Category B, and Sonoco Canada’s Brantford, Ont., mill held on to the top spot in Category C. Sonoco Canada continues its stellar performance, with a perfect score of zero recordable incidents for its recycled-fibre board mill in Brantford, Ont. The mill has won its category consistently since 2006, and maintained that perfect score for five years as well.

Similarly, Domtar Windsor has dominated the top spot in the large mill category, winning since 2007.

The AbitibiBowater operation at Thunder Bay previously won Category A in 2006.

The Safest Mill contest had 40 participating mills in 2010, but due to changing market conditions, very few fell into Category A, which is defined by more than 100,000 man-hours per month.

There were several mills that achieved a substantial improvement in their safety numbers, compared with 2009. Canfor’s Northwood Pulp Mill rose from 12th place last year to third place in category B in 2010. In 2009, the mill frequency was 3.57. Last year, that dropped to 2.03.

Howe Sound Pulp & Paper Corp. (Port Mellon, B.C.) placed fourth this year in Category B. In 2009, the mill was 13th in that category. Employees at HSPP reduced the mill frequency from 3.74 in 2009 to 2.12 in 2010, and worked more hours.

The contest continues in 2011. Please contact Cindy Macdonald at cindy@pulpandpapercanada.com if you would like to participate.

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PULP & PAPER CANADA March/April 2011

Each year, Pulp & Paper Canada oversees the Safest Mill in Canada Contest to rank Canadian pulp and paper operations according to their safety performance. Mills are evaluated according to the number of recordable

incidents each month. We thank these companies for their participation.

TOTAL TOTAL MILL

RECORDABLE HOURS FREQUENCY

INCIDENTS WORKED CATEGORY A

OVER 100,000 MANHOURS PER MONTH Domtar Inc., Windsor, QC 7 1434984 0.98 NewPage Port Hawkesbury, Port Hawkesbury, NS 17 1203200 2.83

2010 Safest Mill in Canada Results

CATEGORY B 50,000 TO 100,000 MANHOURS PER MONTH AbitibiBowater Inc., Thunder Bay, ON Alpac, Alberta Pacific Forest Industries Inc., Boyle, AB Canfor, Northwood Pulp Mill, Prince George, BC Howe Sound Pulp & Paper Corp., Port Mellon, BC Kruger Inc., Bromptonville, QC Hinton Pulp (Div. Of West Fraser Mills), Hinton, AB Zellstoff Celgar Limited, Castlegar, BC Canfor, Prince George Pulp & Paper, Prince George, BC Irving Pulp & Paper Ltd., Saint John, NB Kruger Wayagamack Inc., Trois-Rivières, QC Kruger Inc., Trois-Rivieres, QC Twin Rivers Paper Co. (formerly Fraser Papers), Edmunston, NB Catalyst Paper, Crofton, BC Catalyst Paper, Powell River, BC CATEGORY C LESS THAN 50,000 MANHOURS PER MONTH Sonoco Canada Corporation, Brantford, ON Weyerhaeuser Canada, Grande Prairie, AB AbitibiBowater Inc., Iroquois Falls, ON JD Irving Ltd., Lake Utopia Paper Ltd., St. George, NB Quesnel River Pulp, Quesnel, BC AbitibiBowater Inc., Thorold, ON Northern Pulp Nova Scotia Corp., Abercrombie, NS Canfor, Intercontinental Pulp, Prince George, BC Meadow Lake Mechanical Pulp Inc., Meadow Lake, SK Alberta Newsprint Company, Whitecourt, AB AbitibiBowater Inc., Clermont, QC Millar Western Forest Products, Whitecourt Pulp, Whitecourt, AB Slave Lake Pulp Corporation, Slave Lake, AB JD Irving Ltd., Irving Tissue, Saint John, NB Kruger Inc., Montreal, QC Daishowa Marubeni International, Peace River, AB Norampac Inc., Trenton, ON Tolko Manitoba Kraft Papers, The Pas, MB Strathcona Paper LP, Napanee, ON Catalyst Paper, Port Alberni, BC Tembec – Kapuskasing Operations, Kapuskasing ON. Cascades Groupe Carton Plat East Angus, East Angus, QC AbitibiBowater Inc. (Mersey Paper), Liverpool, NS Minas Basin Pulp & Power, Hantsport, NS

5 9 9 10 8 8 11 12 14 14 18 16 27 23

877222 1043782 888792 944045 723559 648701.75 793560 660447 750275 748508 924225 706504 1000912 686668

1.14 1.72 2.03 2.12 2.21 2.47 2.77 3.63 3.73 3.74 3.90 4.53 5.40 6.70

0 1 1 1 1 2 4 4 3 4 7 3 3 3 4 8 6 12 7 14 18 5 16 14

131,740 586065 569298 291564.75 249004 425376 550436 501901 373417.1 468158 594496 240612 218684 217,561 284754 547972 266722 519003 277910 536565 595819 161,842 484311 327505

0.00 0.34 0.35 0.69 0.80 0.94 1.45 1.59 1.61 1.71 2.35 2.49 2.74 2.76 2.81 2.92 4.50 4.62 5.04 5.22 6.04 6.18 6.61 8.55

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GREEN. Our Color. Our Commitment.

At Buckman, the most important commitment we can make is to a sustainable future.

We know it isn’t

just good for the planet; it’s good for business. And we know it isn’t just about the environment; it’s about people, too.

You can depend on Buckman to find the sustainable path forward. And to help you do the same.

For more information call 877-BUCKMAN (877-282-5626) or visit buckman.com ©2010 Buckman Laboratories International, Inc.

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