Pulp & Paper Canada September October 2011

September/October 2011

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APP opens the doors to Hainan Jinhai

Home of the world’s largest fine paper machine

• Norampac steam rebuild • Green Transformation: project updates • Compact ClO2 units for papermaking AN OFFICIAL PARTNER OF THE PULP AND PAPER TECHNICAL ASSOCIATION OF CANADA

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EDITORIAL

Will the U.S. have enough biomass? Yes

T

he much-anticipated “Son of Billion Ton” study of U.S. biomass availability has been released. Why does it matter to us north of the border? Because this will be an important tool for American policy development regarding biofuels.

The original Billion Ton study, in 2005, was conducted to determine if the U.S. had the capability to produce at least one billion tons of biomass annually. The billion tons was considered enough to produce biofuels to meet one-third of the States’ current demand for transportation fuels.

The Billion-Ton Update did confirm that the potential biomass resource is sufficient to meet the country’s renewable fuel standard goals through to 2022, and indeed, that by 2030, the country will have potential biomass feedstock of nearly 1.1 billion dry tons.

I have not read the entire 180-page report, but a few points jumped out at me from the summaries.

Dedicated energy crops are expected to produce as much as half of the total biomass available by 2030, assuming the high-yield scenario in which the productivity of energy crops increases over the twenty-year period, due to gains in planting experience plus breeding and selection programs.

However, the report’s simulations show “a loss of commodity crop acres to energy crops and higher commodity crop prices.”

Uh-oh. Watch for the “son of food vs. fuel debate.”

More interesting to us is the estimate of forest residue biomass potential The report pegs the current amount of forest residue biomass at 33 to 119 million dry tons. By 2030, 35 to 129 million dry tons are expected to be available, depending on the price at roadside. The prices examined in the study, because I know you’re wondering, are US$20 to $80 per dry ton at roadside. The study considers “primary forest residue biomass” from two sources – removal of a portion of the residue logging and removal of biomass from thinning operations.

It also acknowledges that the large amounts of biomass in the form of mill residues and pulping liquors are mostly consumed within the industry, leaving only small amounts available for new bioenergy uses.

So, in the baseline scenario of the Billion-Ton Update, forest resources account for 327 million dry tons, agricultural residues account for 367 million, and energy crops for 400 million of the 1.1 billion dry tons total. In the high-yield scenario, forest resources fade in importance, holding their contribution at 327 million tons, while ag residues grow to 507 million tons, and energy crops double their share to 799 million tons.

That’s the high-level look at the potential amount of forest biomass available for biofuels. If you want to dig deeper, the full report and other resources are available at Cindy Macdonald Editor www.bioenergykdf.net.

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PULP & PAPER CANADA September/October 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.

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SEPTEMBER/OCTOBER 2011 Vol. 112, No. 5 PRINT EDITION ISSN 0316-4004

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

APP-CHINA OPENS DOORS TO HAINAN 14

COVER STORY

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APP-China: Hainan PM2 Raises the Bar On an island in the South China Sea, the world’s most productive fine paper machine combines modern technology and a small environmental footprint.

Watch for more stories from China in upcoming issues Nov/Dec — APP-China’s plantation model Jan/Feb — A tour of Gold East Paper

NO MORE STEAM VENTING

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REDUCE SLIME WITH CLO2

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FEATURES

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Green Transformation Takes Hold A detailed look at how seven companies are spending their Green Transformation dollars.

Reduce Slime and Biocide Stress with Worry-free Chlorine Dioxide Compact ClO2 units are a cost-effective choice for papermakers to control slime on paper machines.

Steam Venting is History at Norampac Trenton A steam and condensate rebuild project at Norampac’s Trenton, Ont., mill results in 16% savings in energy cost per tonne, or $800,000 per year.

Focus on Process Control A round-up of new products and equipment to improve process control.

IN EVERY ISSUE

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Editorial News Technology News Classified Ads

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September/October 2011 PULP & PAPER CANADA

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INDUSTRY NEWS

NewPage granted creditor protection, permission to sell Port Hawkesbury Justice David MacAdam agreed to NewPage Port Hawkesbury’s proposed restructuring plan on Sep. 9, giving the company permission to use funds from its American parent company to shut down operations mid-September and proceed with the sale of the Port Hawkesbury, N.S., mill.

The $25-million settlement will keep the Port Hawkesbury mill open in a “hot idle” state for the next 13 weeks, while the company attempts to find a buyer.

In the U.S., NewPage Corp. received permission from the court to continue operations while under Chapter 11 protections, and received interim approval for $600 million of debtor-in-possession financing.

NewPage Port Hawkesbury has

Deinking equipment improves pulp quality at Cascades’ Breaky Fibres

Cascades officials inaugurated last week $3.7 million in new deinking equipment at the Cascades Fine Papers Group, Breakey Fibres mill. Started in 2010, the project required the addition of several types of equipment, including a flotation cell, washers/thickeners, a disperser, and a clarifier. It also involved the expansion of the building located in Breakeyville, Que. Cascades took its commitment to sustainable development to a new level by sourcing equipment from various plants.

As a result of this investment, pulp quality has greatly improved. Visible dirt and glue residue have each decreased 50%, while the whiteness has slightly increased.

“We consider this to be a very significant benefit, especially as the quality of raw materials — waste paper to be recycled — is declining more and more,” said Luc Langevin, president and COO of Cascades Specialty Products Group.

Johnstone

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agreed to set up a fund to pay forestry contractors, who have not been paid since Aug. 22. The woodsman reserve fund will contain $1.35 million. Without such a fund, the forestry contractors threatened to oppose NewPage’s creditor protection plan.

In addition, the provincial government has stepped in with $15-million investment to keep woodlands workers in the area employed and keep the supply chain to the mill ready for restart.

Documents presented to the court state that the Canadian operation has been losing about $4 million per month for the past year. These operating losses had been covered by its parent company.

The company has been seeking buyers for several months, and a few are said to

be interested in purchasing the mill.

The NewPage Port Hawkesbury mill consists of one newsprint machine and one supercalendered paper machine, plus a thermomechanical pulp mill. The company recently concluded a deal with Nova Scotia Power to build a co-generation plant on the site, and operate the plant on behalf of the utility. The target start date for the co-gen plant was Dec. 31, 2012.

Nova Scotia Power has said it will proceed with plans to build the co-gen plant.

The court documents provide an insight into NewPage Port Hawkesbury’s operating costs. When fully operational, the mill “spends” roughly $1 million per day. Because the TMP process is so energy-intensive, the mill pays about $100 million per year for electricity.

Since 1985, the Breakey Fibres mill has specialized in the manufacture of recycled deinked kraft pulp, mainly used in the production of Cascades’ fine papers, such as the Rolland Enviro100 family of products.

industry that is also poised for growth in the water treatment market. Johnstone is a 25-year member of Buckman’s global leadership team. He led several global teams and was instrumental in designing and building the Montreal manufacturing, laboratory, and office facility.

The leadership of Buckman Canada passes to two veteran Buckman executives. Mehes will serve as general manager - sales and will be responsible for all sales activities for Buckman Canada. Ihab Wassef will serve as general manager operations and will be responsible for all operations for Buckman Canada.

“In retiring as president, I am leaving the leadership of Buckman Canada in very capable hands in the team of Davor Mehes and Ihab Wassef,” says Johnstone. Mehes has 29 years of service with Buckman and was vice-president paper technologies. He will now manage three sales divisions: paper technologies, water technologies and performance chemicals. Wassef has 20 years of service with Buckman and was vice-president - operations.

In a letter announcing the changes, Peredo thanked Johnstone for his dedication, energy, and loyalty to Buckman.

“We will miss his enthusiasm, sense of humor, and marvelous optimism.”

Buckman provides chemical solutions, industry know-how, and collaborative problem solving to the Canadian pulp and paper industry.

Buckman Canada: New leadership, same commitment

Tom Johnstone has retired as president of Buckman Canada, but will stay on as a consultant, and continue his involvement with the pulp and paper industry through his position on the PAPTAC Executive Council.

“Tom has enjoyed a challenging and rewarding 33-year career at Buckman with an extensive and significant list of accomplishments,” says Edson Peredo, president of Buckman International.

Under Johnstone’s leadership, the Canadian operation grew from a very small satellite sales office to what it is today – a key player in the Canadian papermaking

Wassef

PULP & PAPER CANADA September/October 2011

Mehes

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INDUSTRY NEWS AbitibiBowater upgrades pulp cleaning, PM8 at Iroquois Falls

AbitibiBowater will be investing between $12-$17 million in the thermomechanical pulp mill at Iroquois Falls, Ont., and on paper machine number 8, the larger of the mill’s two machines. The pulp mill investment will result in improved pulp quality with the installation of additional pulp cleaning. Paper machine upgrades will result in improved wet-end formation and newsprint quality. As well, chip receiving and chip handling capabilities will be increased to allow the Iroquois Falls facility to operate on 100% externally supplied chips, with the mill’s current wood yard and wood room being phased out.

“Today’s announcement is a critical step in improving the competitive position of our Iroquois Falls operation for the foreseeable future,” said Michel Maillé, vice-president, pulp and paper operations.

The reconfiguration follows consultation with both the town of Iroquois Falls and the employees at the mill and their union representatives. The increase in chip receiving and handling capability and the closure of the wood room and wood yard will occur during the first half of 2012. It will result in a workforce reduction of approximately 60 positions.

“In addition to improving mill economics, the conversion to 100% externally supplied chips will also provide an outlet for chip residuals from sawmills on the Highway 11 corridor. This will be particularly important as markets for Ontario lumber recover,” added Maillé.

“Newsprint remains an important component of our business,” stated Richard Garneau, president and CEO of AbitibiBowater. “While market and economic conditions remain challenging, the company will invest where there is a good resource base, a strong workforce, and a receptive investment climate. The investments announced today reflect our view that the Iroquois Falls mill and its employees are worthy of our confidence and that Ontario is a good place to invest.”

Kadant expands water management product offering

Kadant Inc. recently expanded its product lines with the acquisition of M-Clean Papertech AB, a European supplier of paper machine fabric and roll cleaning pulpandpapercanada.com

systems. The acquisition was completed in May 2011 and the company will be re-named Kadant M-Clean AB. Based in Husqvarna, Sweden, Kadant M-Clean AB manufactures the MultiJet™ modular cleaning system used for fabric and roll cleaning. The acquisition of the highefficiency cleaning product line expands Kadant’s water-management product line.

It will be sold and serviced by Kadant’s existing global sales and service network.

Tembec reaches settlement with employees at Matane pulp mill

Tembec’s Matane, Que., high-yield pulp mill has resumed production, following a three-month strike. The settlement with unionized employees covers a seven-year agreement that will expire in October 2016.

The plant in Matane employs 143 people, of which 99 are unionized. Its production capacity is 250,000 tonnes/year.

Domtar enters personal care market with purchase of Attends

Domtar Corporation has signed a definitive agreement to acquire privately-held Attends Healthcare, Inc., a manufacturer and supplier of incontinence products, for $315 million. Attends’ production facility is in Greenville, N.C., close to Domtar’s Plymouth, N.C. mill, from which it will purchase fluff pulp.

People…

• Bruce Fleming is now president of CD Nova Ltd., replacing Don Bealle, who remains with the company as board chairman. CD Nova is a Vancouver-based manufacturers’ representative/distributor with offices across the country.

• Jeff McLaughlin has joined Bruks Rockwood as the manger of the mobile chipper product line.

• Noted environmentalist Monte Hummel is taking on the job as chairman of the Canadian Boreal Forest Agreement Secretariat.

Andrew Bevan becomes the first full time executive director of the CBFA Secretariat. The two are tasked with translating the goals of the agreement into concrete action on the ground.

Stop, starts, changes….

• Cascades Inc. is permanently closing its Norampac containerboard mill in Burnaby, B.C., blaming high operating costs and a high dollar. Nearly 100 employees will be affected by the Dec. 1 closure. The mill, which produces 100% recycled linerboard, medium and gypsum, has an annual capacity of 128,000 short tons. Norampac said it will redirect that production to other plants.

• Buckeye Technologies Inc. plans to close its Delta, B.C., airlaid nonwovens facility by the end of calendar 2012. Buckeye Chairman John B. Crowe said, “This closure has become necessary due to several factors including unfavorable site location relative to customers and raw material suppliers, a strong Canadian dollar, and low capacity utilization. It is unfortunate that this closure will result in the eventual termination of employment for approximately 95 dedicated employees.”

• Construction relating to the conversion of the Fortress Specialty Cellulose mill at Thurso, Que., from a NBHK pulp to a dissolving pulp operation is proceeding mostly on schedule. However, due to rescheduling of the delivery and installation of specialized equipment, and the enhancement of certain processes, the company has decided to slightly delay the necessary shut down of the mill required to make tie-ins and upgrades on existing equipment for the conversion. The production of dissolving pulp is now scheduled to commence in early November 2011.

• Tembec has secured a $75-million loan through Investissement Quebec to upgrade the energy efficiency of its boilers at the pulp and paper producer’s plant in Temiscaming. Tembec told Canadian Press details of the project are still being finalized.

September/October 2011 PULP & PAPER CANADA

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As Dan says, Compozil is a blend of experience, know-how and business sense. (His High-Speed Video Audit can show all the details, if you like.)

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CAPITAL SPENDING

Green Transformation Takes Hold Much of the federal government’s billion-dollar stimulus program is being put toward boiler upgrades and other projects aimed at producing green energy.

By Cindy Macdonald, editor

A

mill that had a shaky future in 2008 has been revitalized, and will have a cleaner, brighter future thanks to the federal government’s $1-billion Pulp and Paper Green Transformation Program.

Among Canadian pulp producers, Domtar received the largest allocation from the federal program — $143 million — and proceeded to pour more than half that amount into its Kamloops pulp mill.

To a lesser extent, a similar story has been repeated across the country.

Pulp and paper producers are adding their own monies to the federal pool, and proceeding with capital projects that might never have happened without the Canadian government’s response to the now-defunct U.S. black liquor tax credit.

Because of the stipulation that PPGTP projects had to improve the environmental performance of the mill, many of the funded projects incorporate boiler rebuilds, precipitator upgrades, and installation of turbine generators to harness surplus energy.

At Kamloops, the number 2 recovery boiler upgrade was completed in June 2010. For this project, the combustion air system and boiler circulation were upgraded. The boiler received a new generator bank, furnace floor, bull nose, screen tubes, front wall, load burners, start-up burners, soot blowers and port rodders.

Installation of the bull nose and screen tubes was one of the most intricate of the changes, says Dennis Castle, project manager at Domtar Kamloops. Parts of the unit were assembled in a staging area outdoors, and the crane did a few practice lifts to ensure the load was balanced.

A trio of energy conservation projects were to be completed during the summer of 2011. These are a power boiler optimization, pulp machine dryer upgrade, and several PINCH energy conservation projects.

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Speakers at the PacWest green transformation panel took turns spreading the good news about PPGTP projects at their mills.

For the power boiler optimization, Domtar installed new feedwater economizers, increased the superheater surface area, and upgraded the combustion air system and generating bank. New fuel distributors and new ID fan rotors complete the project.

On both pulp machines, new high efficiency dryer coils were installed. This increased the capacity and energy efficiency of both dryers.

An air emissions improvement project is expected to be completed in October.

This includes the installation of new precipitators for the mill’s power boilers.

The overall reduction in emissions will be about 70%.

Capitalizing on green power

Speaking at PacWest in June, Tim Lanteigne described Daishowa-Marubeni International’s green power enhancement project at the Peace River Pulp Division.

The objectives were to increase the capacity of the existing recovery boiler, improve the environmental performance of the recovery boiler precipitator, and increase exports of green electrical power. One benefit of the project is expected to be an increase in softwood pulp production of 22,300 ADMt/yr. Plus, the company will be able to increase its electrical power exports to Alberta’s electrical grid by 126,000 MWh/yr. Recovery boiler particulate matter emissions are expected to

PULP & PAPER CANADA September/October 2011

decrease by 0.87 g/s.

The project required an upgrade to the recovery boiler and precipitator, and the installation of a 25 MW condensing turbine generator. The recovery boiler upgrade was a $15.7-million undertaking, including upgrades to the circulation, combustion air system, primary superheater, and the smelt dissolving tank scrubber.

On the recovery boiler precipitator, switched integrated rectifiers (SIR) were installed on the A and B fields. As well, spiral wire electrodes were replaced with discharge electrodes in the A fields. Captial cost was $4.5 million.

The condensing steam turbine generator, condenser, cooling tower, and auxiliaries had a price tag of $38.3 million.

The total for the green power enhancement project was $59.1 million, of which $40.5 million was PPGTP credits, and $18.6 million was invested by DMI. Lateigne said the plan was to have all the new equipment up and running by mid-October.

As pulp producers branch out into producing green power, there are also infrastructure considerations. AlbertaPacific, for its green power project, constructed a 28-km power transmission line and built a new on-site substation, in addition to installing a steam turbine generator and implementing steam saving initiatives at the mill.

Daryl Nichol expects the final installed pulpandpapercanada.com

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CAPITAL SPENDING

cost to be $74.9 million. Currently, the mill only exports 52,000 MWh/yr. By the end of phase 2 of the project, the mill will be able to export 300,000 MWh/yr.

Al-Pac was expecting delivery of the turbine in July.

Nichol noted that the PPGTP funding, indirectly, allowed the company to move forward with a replacement of the distributed control system with Honeywell’s Experion process knowledge system.

Sharing resources works for neighboring Canfor mills

At Canfor, a stock transfer line between the Prince George Pulp (PG Pulp) facility and the neighboring Intercontinental mill has allowed the mills to increase green power production. The company was able to increase black liquor production to fully utilize the recovery boiler capacity at PG Pulp and take advantage of that mill’s condensing turbine generator.

Chuck Walls also recounted Canfor’s other green transformation projects for the PacWest crowd.

At PG Pulp, a boiler feed water upgrade is underway. PG Pulp does not have demineralizers as most mills do, but uses hot lime softeners instead.

With this upgrade, blow down rates will be reduced from 8% to 1.5%. Energy use will decline by 650,000 GJ/yr and effluent temperature will be reduced by 0.50C on average.

The company is also installing a precipitator on the No. 1 power boiler at PG Pulp. The result will be a decrease in particulate of about 100 to 130 t/yr.

This mill also undertook an odour reduction project to collect DNCG from various sources that were not previously collected.

Work at Canfor Pulp’s Northwood mill concentrated on the #1 recovery boiler. An indirect contact concentrator replaced the direct contact cascade evaporator, and the wet bottom precipitator was supplanted by a new electrostatic precipitator.

The boiler received a new long tube economizer and air system upgrade.

The upgrade allows Northwood to shut down one of two hog fuel boilers on the site, and is expected to reduce TRS emissions by 35 t/yr and particulate emissions by 240 t/yr. In addition, it will 12

reduce the mill’s consumption of natural gas. Start-up is planned for the fourth quarter of 2011.

Mining effluent for methane

AV Cell in Atholville, N.B., is turning to biogas as its source of green energy. The mill expects to have an aerobic reactor up and running in a few months. The reactor transforms mill effluent into a methanerich biogas.

Shankar Ray, CEO of AV Group, told the Fredericton Times & Transcript that the technology used at the Atholville mill will remove about 50% of the sulphur dioxide from the effluent, which makes the transformation into a biofuel more efficient. Using a filtration system, the reactor can create biogas with 65% methane content, high enough for use in the mill’s boilers, reports the paper.

The $18-million, closed-loop system will be a renewable energy source, able to account for 25 to 30% of the mill’s energy, said AV Group’s corporate energy manager, Rajeev Goel. He calculates that the new reactor will displace 2.2 million litres of oil and 7,000 green tonnes of biomass each year.

Small projects add up

At Nanaimo Forest Products’ Harmac Pacific site, the company’s $27-million in PPGTP credits was allocated to a variety of small projects. Doug Barbour explains that 11 projects consumed the bulk of the funding.

Among those were the installation of hog presses and hog conveying equipment to decrease moisture content in the hog fuel. Since coming online in Jan. 2011, these changes have eliminated the need to supplement hog fuel with natural gas, improved the power boiler efficiency, and resulted in higher boiler feed rates.

Upgrades to two of the lime kilns have resulted in more stable operation, less natural gas use, and more uniform white liquor. For the number 3 kiln, instrumentation was upgraded and supervisory control implemented. At the number 2 kiln, Harmac Pacific installed a discharge end dam, replaced the lime mud filter showers, and upgraded the chain section.

Pulp machines 1 and 3 will get a slight boost in capacity due to upgrades of the drainage table, new felt on the lump

PULP & PAPER CANADA September/October 2011

breaker, new felt on the third press, and an upgrade to the third press nip intensity. On machine #3, the changes have resulted in a drier sheet, which in turn, means less steam demand.

Altogether, the small projects will add up to energy savings of 160 GJ/yr in natural gas usage, 250 MW/yr of electricity, and 50,000 lb/hr of steam use.

More pulp, more power

For West Fraser, the PPGTP project list included a 28 MW/hr cogeneration plant and ClO2 generator energy upgrade for Cariboo Pulp, plus investments in low consistency refining for Quesnel River Pulp and Slave Lake Pulp, reported Brian Grantham. At Hinton Pulp, he told the PacWest audience, a pressure diffuser and an upgrade to the pulp machine were on the list.

The pressure diffuser installed at Hinton Pulp is a PD100 Metso unit, which has a capital cost of about $15 million.

The investment is expected to achieve a 3.8% reduction in BOD and TSS, and to increase WBL solids 1.1%, causing an 8% reduction in evaporator steam usage.

The pressure diffuser should also contribute to less defoamer usage; reduced consumption of ClO2 and NaOH; and better pulp quality.

Grantham explained that the major components of the pulp machine energy upgrade were the top former, combi press section, 10 dryer decks, the dry end repulper and the cutter/layboy.

Capital cost of the project was about $37.5 million. The Flakt dryer was converted to 80 lb. steam, which permits more power production. Mill production capacity increased to historic levels, and, as a result, Hinton Pulp is firing more black liquor, leading to more power production. The net energy benefit is calculated to be 2.0 MW/hr.

The environmental benefits of all the PPGTP-funded green transformation projects are laudable. There have also been operational benefits that will last for many years, and the projects provided a shot in the arm to the local economy of many mill towns. But the intangible benefit is the sense of renewal, and the optimism that stems from seeing construction crews at work at mills across the country.

PPC pulpandpapercanada.com

Green Our Color. Our Commitment.

Buckman Green, our comprehensive approach to environmental stewardship, social leadership and financial responsibility, is making significant progress toward a sustainable future:

STEWARDSHIP: Tapping into our better nature.

We are protecting the Environment by— • Creating new biodegradable, nontoxic, naturally derived chemistries.

• Finding innovative ways to help our customers save energy, reduce waste, and conserve water.

• Reducing our own environmental footprint.

Over the past 10 years, Buckman has slashed their own emissions to air by 70%, curtailed emissions to water by 30%, cut emissions to landfills by 95%, and reduced water consumption by 30%.

LEADERSHIP: Bringing chemistry to life.

Sustainability is about achieving and maintaining a high quality of life for our local and global communities as well as our own associates. For Buckman, that means: • Supporting volunteer service organizations.

• Encouraging our associates to volunteer their time and talent.

• Sponsoring educational opportunities for youth.

RESPONSIBILITY: Making a future, not just a living.

Buckman has positioned itself for long-term business success by establishing everything from global and supply chain management to worldwide financial and accounting standards. We employ the most up-to-date tools and plans to ensure our financial sustainability.

Find out more.

To get a copy of our 2010 Sustainability Report, call 1-877-BUCKMAN (877-282-5626), or read it online at buckman.com.

©2011 Buckman Laboratories International, Inc.

COVER STORY

Hainan PM2

raises the bar for speed,

water conservation Hainan PM2, the world’s most productive fine paper machine, sits in a building more than half a kilometer long. Its combination of modern technology and small environmental footprint is typical of its owner, APP-China.

By Cindy Macdonald, Editor

A

PP-China is a relative newcomer to the pulp and paper market.

A subsidiary of Asia Pulp & Paper, which in turn is owned by the privately-held Sinar Mas Group of Indonesia, APP-China began building mills in China 20 years ago. It now has more than 20 pulp and paper mills, including the largest single line fine paper machine in the world (at Hainan Jinhai), the fastest coated fine paper machine in the world (Gold East Paper) and the largest pulp mill in China (at Hainan Jinhai). By its own calculation, APPChina’s parent company, Asia Pulp & Paper Group, is the third largest pulp and paper producer in the world. APPChina’s revenue in 2010 was US$5.8 billion. By the standards of the Chinese industry, it is a giant, setting an example with state-of-the-art equipment and world-class environmental performance.

In recent years, the company has pulled back the veil on its operations, and even had a group of North and South American journalists tour some of its mills and forestry operations in July.

Pulp and Paper Canada was among this group, who were the first Western journal-

14

ists to see the new PM 2 at Hainan Jinhai Pulp & Paper Industry Co. Ltd. Completed in May 2010, this Voith machine is the largest fine paper machine in the world.

Big fish in a crowded pond

APP-China is one of a new breed of pulp and paper producers in China. “We

have changed many, many things about the paper industry in China,” says Sophy Huang, PR director for APP-China. The company bought and built modern, efficient mills with up-to-date environmental controls, in contrast with China’s thousands of small, inefficient, outdated producers.

The wastewater treatment system at Hainan Jinhai can handle 100,000 m3 per day.

PULP & PAPER CANADA September/October 2011

pulpandpapercanada.com

COVER STORY

APP-China has also shown good corporate citizenship throught donations, encouraging volunteerism among employees, and raising the standard of living in communities in which it operates. At Gold East Paper, for example, the average salary is twice what the citizens of Zhenjiang can earn at other employers.

“Twenty years ago, you couldn’t find good coated fine paper in China. It used to cost twice as much as it does now,” says Huang. “And, you couldn’t get good quality tissue.”

At that time, the industry was populated with smaller paper producers, and had an abominable environmental record. APP-China entered the scene as the industry was beginning to clean up its act, and larger mills were starting to emerge.

China still has thousands of small mills, but in the past two years the government has been eliminating the socalled “backward” production facilities by enacting more stringent environmental laws and shutting down non-compliant facilities. “Backward” production

Waste water discharge for pulp production Tonne waste water/tonne pulp Hainan Jinhai 2007

16.4

Hainan Jinhai 2008

16.50

Hainan Jinhai 2009

16.52

Hainan Jinhai 2010

16.63

capacity refers to outdated equipment which uses large amounts of energy to produce low value products. Many of those that fall into this category would be producing straw pulp.

Still, disparity in the industry continues. According to the China Paper Association, the production capacity of 3,600 small and medium Chinese paper companies is less than the output of China’s 100 largest paper companies.

APP-China’s parent company, Asia Pulp & Paper, has come under fire from Greenpeace and other environmental NGOs, but the Chinese firm insists it is operating legally, and is working toward a vertically-integrated business model that combines plantations, pulp, and paper, in a way that balances social, environmental, and economic goals.

While the plantation model is displeasing to some environmental groups, others are recognizing that the development of high-yield, planted forest is an effective way to meet fibre demand in countries without a large fibre basket, explains Dr. Wending Huang, deputy CEO of APPChina’s forestry operations.

Dr. Huang notes that in China, the plantation model spares the natural forest and discourages illegal logging by meeting the industry’s need for wood fibre in a productive way.

Mix in a little Canadian fibre

The leading example of APP-China’s principle of integrating forestry, pulp,

COD discharge for pulp production kg/tonne pulp Hainan Jinhai 2007

2.16

Hainan Jinhai 2008

1.93

Hainan Jinhai 2009

1.5

Hainan Jinhai 2010

1.56

Chinese standard prior to May 2009

220

Chinese standard prior to May 2009

88

Chinese standard effective May 2009

80

Chinese standard effective May 2009

16

Chinese standard effective July 2011

50

Chinese standard effective July 2011

5

pulpandpapercanada.com

September/October 2011 PULP & PAPER CANADA

15

COVER STORY

and paper is Hainan Jinhai Pulp & Paper Co. Ltd. APP-China has a nursery and plantations of eucalyptus and acacia on Hainan Island, which sits off the southernmost tip of mainland China. Also on the island, the Hainan Jinhai pulp mill gets much of its fibre from the local plantations. The sulphate pulp mill, the largest in China at 1.2 million tonnes per year, has now been joined by a fine paper machine.

The Hainan Jinhai complex has a 420 -MW private coal-fired power station, wharfs, and an R&D centre, plus housing and facilities for about 4000 employees.

Discharge of waste water and emissions from the pulp mill are lower than national standards of China, Europe, and North America.

The pulp produced at Hainan Jinhai is a mix of eucalyptus and acacia from plantations, plus imported softwood fibre.

To feed the behemoth pulp line, about 2 million tonnes of chips are stored on site.

Much of the wood comes from APPChina’s own plantations on the island, supplemented with imported fibre from Cambodia and Vietnam, plus imports of pulp from Canada and Brazil for the necessary long-fibre component.

Owing to APP-China’s close relationship to Paper Excellence, much of the softwood pulp comes from Canadian mills owned by Paper Excellence. The warehouse at Hainan Jinhai is filled with bales from Howe Sound, Meadow Lake, and Mackenzie.

The Hainan Jinhai complex employs about 6500 people: 1300 for a small tissue machine, 2500 for the pulp mill, 2700 for the paper mill.

The newest addition at Hainan Jinhai, PM2, is massive. The Voith paper machine is 428 m long; the building that houses it is 660 m. It is 11.6 m wide, producing paper that is 10.96 m wide.

PM2 has four coating stations, and 61 dryers (87 total dryer cylinders).

The machine has a design speed of 2000 m/min. In just 30 minutes, it can produce a jumbo roll of paper, weighing 90 tonnes, with a diameter of 3.55 m.

Voith Paper had already manufactured three high-performance paper machines for APP-China and installed them at the company’s mill in Dagang. The machine design of the PM2 at Hainan is similar to that of PM3 in Dagang, one of the fastest fine paper machines in the world.

Outside the administrative offices of Hianan Jinhai is a dragon statue, with the recovery boiler in the background.

The tandem NipcoFlex press for Hainan PM2 has a design width of 11 m, a length of 20 m and 10.5-m height.

This press section is the largest Voith Paper has ever built. It weighs approximately 500 tonnes.

The fish pond is evidence of the effectiveness of the mill’s water treatment. The pond’s water source is treated mill waste water.

The mill grounds are lush and well-tended.

APP-China performance versus emission standards Measures

Water consumption

Tonne water/tonne paper Waste water discharge Tonne waste water/ – paper tonne paper COD discharge – paper Kg/tonne paper Water consumption Tonne water/tonne pulp Waste water discharge Tonne waste water/ – pulp tonne pulp COD discharge – pulp Kg/tonne pulp 16

PULP & PAPER CANADA September/October 2011

APP-China 2011 Q2 commitment discharge data

Chinese standards effective May 2009

Chinese standards effective July 2011

10

8.85

9

7.31

20

20

0.61 28

0.47 23.38

2

1.6

17

16.55

80

50

2.16

1.54

16

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COVER STORY

Water matters

APP-China strives to minimize fresh water consumption and the use of fresh fibers in its papermaking process. The latter is achieved through an increase in coating application via pigments (mainly ground limestone). Hainan PM2 is equipped with three speedsizers, one for starch, two for pigment coating. Paper from PM2 ranges from 150 to 250 g/ m2. It generally has about 55% fibre content.

Actual figures are not available, but Voith anticipated that the fresh water consumption of the PM2 production line would be about 6 liters per kilogram of paper produced. This is much less than the maximum allowable consumption of 10.5 L/kg prescribed by the Chinese government, and also less than APP-China’s company-wide average of 8.85 L/kg. According to Voith, comparable fine paper machines in Europe consume about 8 L/kg on average.

With the lower of fresh water consumption, waste water volume is also reduced. The water conditioning system at APP’s mill in Hainan has a capacity of 100,000 m³/day to serve the pulp and paper lines. After mechanical and biological treatment’ the wastewater is so pure that the State Environmental Protection Administration of China allows for it to be piped straight into the sea.

Siemens supplied all the drives and electrical equipment for the fine paper line at Hainan. That included 185 Sinamics drive systems with a total connected power output of more than 40 MW for PM2, as well as the drives for roll cutters, re-winders, and offline calenderers. The electrical equipment supplied by Siemens encompasses the entire medium-voltage distribution system for 35 kilovolts and 6 kilovolts as well as all motors and converters.

One unique aspect of Hainan PM2 is the CarboTec rolls from Voith Paper.

CarboRun CS rolls are used for the center supported rolls (CSR) and have a positive influence on the fabric performance.

Voith CarboTec rolls are made of carbon fiber reinforced plastic. The benefits 18

Wood chips and other commodities can be delivered to the wharf at Hainan Jinhai.

Pulp baling line.

of carbon fiber material in this application are low weight, low energy consumption, and low vibration tendency, leading to high stability and no susceptibility to corrosion.

Compared to steel rolls, these rolls are 40% lighter, reducing loads on the framing, which in turn, has a positive effect on the vibration level.

So in fact, PM2’s massive size is not its only claim to fame. The jewel in APP-China’s crown is notable for its advanced technology, minimal environmental footprint, and tight integration of plantation, pulp and paper.

PPC

PULP & PAPER CANADA September/October 2011

Anthony Chang, vice-director, pulp production division (left), and several members of the press tour watch treated waste water (under the grate) flowing out to sea. pulpandpapercanada.com

PAPERMAKING

Reduce Slime and Biocide Stress with Worry-free Chlorine Dioxide Compact ClO2 units are a cost-effective choice for controlling slime on paper machines.

By Martin Koepenick, Innova

T

ighter control of the microbiological activity in incoming and process waters will always bring higher efficiency in pulp and paper production, as well as contributing positively to sheet quality and printability.

A simple conversion to chlorine dioxide (ClO2), delivered by a compact generator, addresses these issues, and consequently eliminates persistent deposits on forming fabrics, press felts and equipment. Foul odors, increased calcium levels, and high conductivity can also be drastically reduced.

“Compact ClO2 units are a wise move for the Canadian papermaker; they are the most cost effective slime control option for paper machines,” says Jim Anderson, market specialist Purate, Eka Chemicals. “Typically, payback is less than six months because Eka Chemicals takes responsibility for installing and operating the generator. The initial cost for the customer is limited to PVC piping, electrical and DCS connections, including tote bin handling and containment.”

Scott Auger, market manager for Purate, continues, “When you form your sheet with cleaner, pretreated water, the focus is on optimizing performance, not on the interferences caused by traditional biocides. In addition, downtime caused by corrosion is not an issue.”

While treating papermaking process water for slime control offers the greatest benefits, applications such as fluorescence reduction, broke bleaching, and incoming water treatments can also be of considerable value.

Getting ahead of the slime

Microorganisms enter process water with fresh water, various additives, and other raw materials. Under alkaline/neutral papermaking conditions, at temperatures of 40°–50°C, and in closed white water systems, slime can seriously interrupt operations.

When the growth takes off, corrosion, sheet holes, odor, and poor machine performance can seriously threaten wet-end stability and machine runnability.

The slime-like deposits, which attach to surfaces on machines, piping, and tanks are caused by aerobic bacteria that produce a mucous capsule consisting of polysaccharides. The capsule protects the cell against harmful conditions such as variations in temperature, pH, and lack of nutrients.

Fiber fines and colloidal particles adhere to biofilm and contribute to rapid growth of deposits. When the slime layer thickens, parts of that layer can break loose and cause runnability and paper quality problems. Anaerobic conditions that can occur under thick layers of slime also can cause corrosion problems.

ClO2 attacks and penetrates these deposits in their formation stages, and eliminates issues that are caused by “slough off”. pulpandpapercanada.com

Just as on-site generation of chlorine dioxide has become a preferred approach to disinfecting drinking water and industrial wastewater treatment, Purate® technology is becoming a preferred approach for papermaking processes, because of its bactericidal and slimicidal efficiency.

What used to be a troublesome and costly process has now become worry-free.

ClO2 can be made available to all users safely, efficiently, and at a much lower cost than ever before. What’s more, the paper industry version of Eka Chemicals’ Purate has gone one step further by introducing a state-of-the-art control system that can distribute ClO2 safely to four different feed points in relation to known parameters. Each point is controlled individually and can dose ClO2 on a continuous, shock, or proportional mode.

All of this can be integrated with the mill’s DCS, or function as a stand-alone unit.

Cleaner clothing and other benefits

The negative effects of deposits on paper machine clothing are well known. Often, sheet defects and process upsets are the direct result of build-up on forming fabric and felts. Because ClO2 is highly reactive and can penetrate biofilm, it’s only logical that fewer deposit issues are the result of its application. In addition, longer clothing life is achieved, as wear is reduced by a smoother, less contaminant-ridden flow across the wet-end and beyond.

September/October 2011 PULP & PAPER CANADA

19

From Toronto to Tokyo,

there’s one word for innovation.

Across the globe, papermakers face tough challenges. They are looking for new ways to reduce energy consumption, increase fibre yield, and boost operational efficiency.

And they continue to turn to the company that, for more than a century, has led the industry with innovative products, process-knowledge, and a dedication to understanding papermaking needs. The company that consistently delivers the best solutions, in every language and market. That company is Kadant.

Discover how Kadant innovations in fibre processing, water management, doctoring, and drying are making a difference to papermakers around the globe. Discover Kadant.

w w w . k a d a n t . c o m

Š 2010 Kadant Inc. All rights reserved.

Increase thermocompressor efficiency up to 25% and reduce high-pressure steam consumption.

Conventional thermocompressors use high-pressure steam to compress and recirculate uncondensed steam in the dryer section. Kadant’s new high-efficiency thermocompressor has been shown to reduce motive steam consumption and increase overall thermocompressor efficiency by up to 25%. Using advanced computational fluid dynamics modeling, Kadant thermocompressors are designed to maximise steam utilisation.

New UniSet™ doctor blade holder delivers robust performance and simple replacement.

The next generation of doctor blade holders features light-weight composite and carbon-reinforced construction integrated with the UniTrak™ T-rail.

The UniSet™ blade holder offers easy removal, replacement, and upgrades to improve doctoring performance. All blade retention and pivoting components are formed and reinforced within the top-plate and tube tray and there are no items to loosen, twist, or fall into the machine.

ErGo™ filtration system removes contaminants while enhancing safety.

Kadant’s innovative ErGo™ filtration system is designed for protecting shower nozzles and process equipment from contaminants while increasing energy efficiency and contaminant removal. The automatic internal backwash barrel filter design features a safety cap allowing rapid filter media access and a “bottomless” barrel for easy cleaning and element removal.

PAPERMAKING Chlorine application can be quite harmful to clothing, especially because a higher dosage is needed to have the desired killing effect.

Because of chlorine dioxide’s ability to minimize slime at the onset, the important interactions between nanoparticle retention and drainage systems, minerals, additives, and sizing agents can occur with less interference. Not only can chemicals function more effectively, but also they can reach high levels of performance at potentially lower dosages, because traditional biocides are not clouding their effectiveness.

Strong unappealing odors are not only undesirable but they are also potentially explosive, and are usually a sign of harmful substances in the air or on surfaces. ClO2 also minimizes slime in mist areas, and improves the cleanliness of railings, flooring, and steps. This can result in a big improvement in safety.

Proven over many years

A wide range of papermakers now employ compact chlorine dioxide generators. Most applications are in Europe, but the technology is catching on in the Americas and Asia.

One paper and board producer in Northern Europe was losing productivity because of excessive sheet holes, especially at high grammage. Slime was suspected as the main cause of the sheet holes problem. A non-oxidizing biocide was added to the whitewater system and evaluated as a means to control the microbiological activity and improve the productivity.

Significant amounts of slime had accumulated in the clear filtrate tank. Measurements also indicated a high level of bacte-

The SVP Pure® Technology is a patented generator that uses a proprietary solution of hydrogen peroxide and sodium chlorate (Purate®) and sulfuric acid to generate chlorine dioxide solution.

The fast reaction speeds of this chemistry are one advantage. In addition, the absence of harmful by-products, such as chlorine and chloride are notable. The small-scale generator enables a ClO2 supply from 0.5 kg/hour up to 100 kg/hour.

rial activity in the broke tower, probably due to long residence time. The non-oxidizing biocide was ineffective at controlling slime and keeping the broke from “rotting”.

The chlorine dioxide treatment at the chosen dosage points was effective in the water system and on the paper machine.

Measurements on microbiological activity in process waters and the broke tower showed a significant reduction in aerobic count and ATP (adenosine triphosphate) activity. In the white water tower, one effect of the treatment was a visible difference in the clear filtrate tank. Over a period of time this addition of chlorine dioxide kept the tank slime free.

The most important observation with chlorine dioxide treatment was the effect on the productivity and quality. The improvements following chlorine dioxide addition were significant. Sheet holes on average were reduced by more than 50%. Treatment cost of the system was comparable to the nonoxidizing biocide system and delivered significant additional quantifiable value to the papermaker.

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Our technology-driven services are focused towards solving the problems of owners and operators.

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22

PULP & PAPER CANADA September/October 2011

The MD Papéis’ Santista mill, located in Cubatão, São Paulo State, Brazil, decided to switch from a monochloramine-based system. The mill produces 60,000 tpy of printing and writing grades and flexible packaging.

Caio Mori, Eka’s business development manager in Brazil, explains, “Because monochloramine is a persistent chemical and can be harmful to waste treatment, MD Papéis Santista began looking for a way to reduce the toxicity of their effluent. Purate, now in place for nearly two years, provided the level of treatment efficiency desired without the persistency problems in the effluent, and also helped with paper machine runnability.”

Several units are employed in trials in the U.S., and look to be fully commercialized in the near future.

PPC Thanks to Jim Anderson, Bruno Bolduc, Scott Auger and Caio Mori for their valuable contributions to this article.

Martin Koepenick of Innova has written about the paper industry and innovations in technology for more than 25 years. He can be reached at mkoepen@gmail.com pulpandpapercanada.com

greening

Canada’s Forestry Sector If you have an innovative clean technology for the forestry industry, we want to hear from you.

Talk to us now about submitting a Statement of Interest.

SDTC supports the commercialization of clean technologies by Canadian companies. sdtc.ca/applications

REBUILD

Steam venting is history at

Norampac Trenton A steam and condensate rebuild project at Norampac’s Trenton, Ont., mill results in 16% savings in energy cost per tonne, which translates into a cost saving of more than $800,000 per year. Dryer section runnability has also improved.

By Mark Williamson, journalist/engineer

T

he sight and sound of vented steam outside a paper mill are sure signs of wasted energy inside. But, if that clearly visible problem can be solved, a good return can be achieved at today’s energy prices. With the steam venting problem put to rest by a paper machine steam and condensate system rebuild, the environment outside the Norampac mill in Trenton, Ont., is a little quieter and that formerly wasted steam is now being put to good, efficient use in the dryers.

The rebuild project, completed in early 2011 by Kadant Canada, has generated a significant return on investment by reducing the steam energy cost per tonne by 16%. Considering the mill’s steam costs, that results in a saving of more than $800,000 per year on the 180,000 tonne/year PM2 corrugating medium machine. Better cross-direction moisture uniformity and reduced sheet break downtime add to the return.

The venting of steam from the PM2 drying section was a chronic problem, says Gérald (Gerry) Nolin, production manager. “Since I have been at the mill it seems we have always been venting. When dryer amps rose (indicating a dryer flooding condition) the operators had to open one or more steam vent valves to get proper condensate removal. We have four manually-operated vent valves – one for each steam section – and it seemed that one was open all the time,” he explains.

Part of the problem was that the old cascading thermocom-

All dryers were fitted with new stationary syphons and PTX steam joints.

24

PULP & PAPER CANADA September/October 2011

Proud partners: Mike Soucy (left), president of Kadant Canada, and Gerry Nolin, production manager, Norampac.

pressor steam and condensate system was unstable and hard for operators to control. “It was not a well-designed system; the valves seemed to be fighting each other,” adds Nolin.

So mill staff approached Kadant Canada for a proposal to eliminate the steam venting problem, improve energy efficiency in the dryers, stabilize the drying system, and improve paper quality. It was expected the moisture profiles could be improved by uniform condensate removal and heat transfer to the sheet.

First, a thorough system audit

Before making a firm proposal, Kadant engineers performed a thorough audit of the existing steam and condensate system, including measurements of dryer surface temperatures and condensing rates, as well as an evaluation of drying and condensate handling deficiencies, control procedures, and bottlenecks. Control valve sizing, tank sizing, piping design, and instrumentation were included in the audit. Pocket ventilation was also reviewed.

Some of the dryers had been updated to stationary syphons on a case-by-case basis but most were equipped with original rotary syphons. Computer models were used to predict the steam and condensate system performance if the system were redesigned with matching stationary syphons and individuallycontrolled re-circulating thermocompressors for each of the four sections.

The delivered scope of supply by Kadant included; • Stationary syphons and PTX steam joints for all dryers.

The stationary syphons provide maximum condensate pulpandpapercanada.com

VISIT/VISITEZ

WWW.PAPERWEEKCANADA.CA

World-renowned technical program and highly popular business track

Programme technique de renommée internationale et volet affaires des plus populaires

2012

Greg Hay, Executive Director / Directeur Éxécutif PAPTAC

WELCOME!

BIENVENUE !

PaperWeek Canada 2012 - the Annual Conference of the Canadian Pulp and Paper Industry, will be held from Januray 31 to February 2, at the Queen Elizabeth Hotel in Montreal. Please visit www.paperweekcanada. ca regularly to find information on the event and to stay abreast of regular updates regarding the annual gathering of our industry.

Please note that detailed information regarding the business and technical programs, registration, hotel reservations, activities and other useful tips will be uploaded to the site regularly.

Please make sure to check you inbox for update notifications.

L’édition 2012 de PaperWeek Canada - la conférence annuelle de l’industrie canadienne des pâtes et papiers, aura lieu du 31 janvier au 2 février à l’hôtel Le Reine Élizabeth à Montréal.

Assurez-vous de consulter www.paperweekcanada.ca de façon régulière pour toute information relative à l’événement et pour obtenir des mises à jour au sujet de ce grand rendez-vous de l’industrie papetière canadienne. Veuillez noter que les informations détaillées au sujet du programme technique et du volet Affaires, de l’inscription, des réservations d’hôtel et des autres activités entourant l’événement seront disponibles sur le site de façon régulière. Assurezvous de vérifier vos messages et de prendre connaissance des avis de mise à jour.

We are also very excited to announce the return of the PaperWeek tradeshow which will be held in conjunction with the business and technical sessions, allowing you to increase your networking and business development opportunities.

Nous sommes également heureux de vous annoncer le retour du Salon commercial de PaperWeek qui aura lieu conjointement aux sessions de PaperWeek Canada, vous permettant ainsi d’accroître vos opportunités de réseautage et de développement d’affaires.

Be sure to mark your calendars! We look forward to seeing you in Montreal in February!

Notez ces dates à votre agenda dès maintenant !

Nous vous attendons avec impatience à Montréal en février !

Come and Exhibit at PaperWeek Canada, THE major Canadian gathering for the advancement of the pulp and paper industry.

Profitez de la vitrine PaperWeek Canada et participez à titre d’exposant dans le cadre de ce RENDEZVOUS canadien pour l’avancement de l’industrie des pâtes et papiers.

Information : Thomas Perichaud, PAPTAC 514392-6956 / tperichaud@paptac.ca

Also featuring / Aussi de retour : Second International Forest Biorefinery Symposium To offer to the pulp and paper professionals and scientists from around the world a platform for the presentation of recent advancements and technological breakthroughs in the field of forest biorefinery.

REBUILD First dryer section power consumption

pounds of steam per tonne

Steam consumption per tonne of paper

Fig. 1: Steam consumption per tonne has been reduced by 16%.

removal and operate with lower blowthrough steam at much lower differential pressures. This is because the stationary syphons do not have to overcome the rotational forces of the dryer shell.

• Full width Turbulator® bars for all dryers. Flush with inside of the dryer shell, the bars provide turbulence in the condensate layer, thereby improving the uniformity of heat transfer. Since the heat transfer is even across the shell, moisture profiles can be improved.

• Converting the older cascading-thermocompressor steam system to a re-circulating thermocompressor design with individual steam section control. The new thermocompressors with a lower motive pressure (220 psig) were matched to the lower blowthrough steam and differential pressure requirements of the new syphons.

• Regrouping of the steam sections to match the drive sections.

• Automated vent valves.

• Updating and recalibrating transmitters with new, more accurately engineered impulse lines.

• New steam and condensate piping, including stress analysis.

The entire project was completed within a very tight one-and-ahalf month time window.

Venting vanquished

Since project completion Nolin has been checking the external steam vents for any signs of the previous problems and has found none. So the major objective of the project has been conclusively achieved. Actually, a small amount (less than 500 lb/hr) of steam venting is required to bleed non-condensable gases from the system, but that is a far cry from the 15,000 lb/hr previously wasted. With little venting, better heat transfer, and more efficient drying, the consumption of steam per tonne has been reduced substantially, by about 16%, as shown in Fig. 1.

With this significant energy saving, the successful project has caught the attention of Union Gas, the local gas utility, who has committed to a partial funding of the project.

26

PULP & PAPER CANADA September/October 2011

Fig. 2: The stability of the first section dryer amps has been improved, indicating more stable dryer loads and condensate removal.

Reduced breaks, improved control

The original venting problem was initiated by high dryer amperage loads which indicated a flooded dryer condition. Dryer amperage data shown in Fig. 2 indicate that this problem has been reduced since the project completion. The drive stability has had a positive effect on dryer-related breaks and lost time due to sheet re-threading on the hot dryer cans. As well, the dryer sections are now matched to the drive section, thereby improving draw control.

Nolin estimates the lost time due to draw problems, high dryer amps, and dryer pickouts has been reduced by more than 13%, even though the number of breaks was reduced by a modest 2.8%.

“The dryer section is much more stable and easier to control,” he says. In fact, the differential pressure required to drain condensate through the new syphons is now much lower. “They are 3 to 5 psig compared to 20 psig, if you could trust the measurements before,” quips Nolin. The pressure transmitters are now accurately measuring the correct pressure, as that was one of the issues to address with the project.

The operators can now control the first section to a lower pressure to get a gradual increase in the drying rate in the sheet and not trap moisture at the beginning of the drying cycle, therefore making drying less efficient. The drying is now more evenly distributed throughout the dryer section. Nolin believes the improved stability of the dryers has contributed to cleaner dryers in some sections. “There is less sticky buildup and they seem to clean themselves,” he says.

Projects aimed at energy efficiency can also have some side benefits, and that has been the case at the Trenton mill. Quality improvement was one of the original goals which has been realized thanks to the even CD heat transfer provided by the Turbulator bars. The 2-sigma CD variation from the QCS system has been reduced by 19%. Energy efficiency and quality improvement; that’s a win-win.

PPC Mark Williamson is an accomplished writer of technical articles, based in Thornhill, On pulpandpapercanada.com

TECHNOLOGY NEWS

PROCESS CONTROL Infrared sensor boasts improved machine and process diagnostics

Some tissue mills are now replacing nuclear basis weight sensors with Metso IQFiber infrared sensors which measure both weight and moisture. The new combined sensors are easy to service with extensive diagnostics. Furthermore, certain costs are eliminated if a tissue mill is nuclear-free.

Until now, nuclear basis weight sensors have been the standard for scanning the tissue web. Today, infrared technology has been developed by Metso and refined to the point where it can take over the task of measuring oven dry basis weight (fibre weight) with the same precision as a nuclear sensor and, furthermore, measure moisture simultaneously at the same spot.

IQFiber uses a four-channel infrared detection system in which there are no rotating filters. The IQFiber is a new application of previous Metso multichannel infrared sensors for moisture.

A single semiconductor detector in IQFiber senses the absorption of infrared energy by the tissue sheet at wavelengths specifically sensitive to water and fibre content of the sheet. Two reference measurement points ensure the readings are absolute.

Unlike nuclear sensors whose source strength decays and measurement sensitivity is diminished over time, the infrared measurement sensitivity is constant.

Side-by-side sensor comparison trials in a tissue mill have confirmed that the infrared measurement of fibre and the oven dry weight measurement derived from the nuclear sensor minus the moisture measurement were essentially the same. The fibre measurement and the on-control stock flow changes tracked closely during normal production periods and grade changes, and the profiles were equivalent. Data shows the online fibre reading was slightly closer to the laboratory result than the nuclear reading.

Customers report more precise control and improved machine operations with the sensors installed with new PaperIQ Select QCS systems.

The speed of response and signal to noise ratio of the dry fibre weight measurement is significantly better than traditional nuclear sensors, making it most appropriate for online web variability analysis and more precise control. The MD and CD variability in a sheet are measured at exactly the same spot with a pulpandpapercanada.com

small 5 mm streak resolution and very fast response, with sampling rates of 1 KHz. The frequency components of these fast-responding online measurements are determined by the spectral analysis capability built into PaperIQ Select. This adds a significant diagnostic and machine troubleshooting capability to the system.

Metso, www.metso.com

Solenoid valve cost-effective for pulp and paper uses

Parker Fluid Control Division introduces the High Flow direct mount NAMUR solenoid valve, part of its expanding line of valve actuation products.

The High Flow product line provides new, cost-effective solutions for generalpurpose valve actuator applications including water and sewage, and pulp and paper.

Compact in its design, the High Flow NAMUR valve is built with an anodized aluminum body and a stainless steel spool, as well as internal parts made of brass. It operates in a pressure range of 30 – 150 psi.

A spring return allows fail-safe operation in the event of a power loss, and a screened exhaust nut protects valve function during outdoor use. Additionally, the O-ring seal design increases sealing force at higher pressures and offers less breakaway resistance at lower pressures.

Parker Fluid Control Division 800-Valve05, www.parkerfluidcontrol.com

ORP sensors offer better control for making bleach

Commonly, bleach making consists of mixing sodium hydroxide (caustic) with chlorine to produce sodium hypochlorite of various strengths. The initial strength of the caustic determines the overall concentration of bleach and its stability.

The amount of chlorine will determine the pH value and the bleaching effectiveness

of the solution. Measurement and control of the solution’s oxidation-reduction potential (ORP) serves as an effective way to achieve specific ratios of the two bleach components.

ORP and pH sensors are similar.

The difference is that the ORP sensor measures the electrochemical effect of all ions in solution, while the pH sensor looks only at hydrogen ion concentration.

For bleach making, ORP sensors offer more resolution and tighter control. They also last longer because pH sensors lose efficiency more quickly in the strong caustic solutions.

Excess caustic produces low, negative ORP readings (in millivolts). Chlorine, on the other hand, raises the ORP readings.

An ORP measurement and control loop can effectively achieve whatever bleach strength is desirable. The graph shows ORP values of various concentrations of sodium hypochlorite solutions. The steep step change in an ORP reading indicates the completion of the desired reaction.

The Endura TBX587 is the latest addition to ABB’s successful line of industrial pH/ORP sensors. The sensors are renowned for their ability to outperform conventional gel filled sensors in the toughest process applications.

The TBX587 electrode design eliminates failures due to thermal stress caused by rapid temperature excursions. Unlike other sensors that use a large inner air bubble for expansion absorption, the TBX587 electrodes use a unique inner plunger that provides more effective protection against temperature fluctuations.

ABB, www.abb.com

IR sensor reduces defects in coated products by up to 15%

Honeywell has introduced new infraredsensing technology designed to help

September/October 2011 PULP & PAPER CANADA

27

TECHNOLOGY NEWS packaging makers significantly reduce defects in their coated products, as well as reduce the amount of raw materials used to produce them.

The Reflectance Infrared Spectrometer (RIS) uses proprietary array detector technology to provide the industry’s highest resolution and the broadest IR spectrum range, which allows mills to achieve unsurpassed quality by measuring multiple components of

N.Y. containerboard mill gets Voith stock prep, Siemens electrics Cascades and partners broke ground for a greenfield containerboard mill in early September. The Greenpac facility in Niagara Falls, N.Y., will manufacture a light weight linerboard, made with 100% recycled fibers, on a single 8.33m machine with an annual production capacity of 540,000 short tons. This machine will be one of the largest in North America.

The building and the machinery will be designed for optimal energy efficiency and many operations will be automated.

Also, process water will be treated and reused in order to reduce consumption as much as possible, and the state-ofthe-art management system for recycled fibres will have a positive effect on the environmental performance of the mill.

The paper machine will be manufactured by Metso, Voith will provide the stock preparation equipment and anaerobic effluent treatment plant, and Siemens will provide the power and control technology.

Voith Paper Fiber & Environmental Solutions will supply the entire OCC recovered paper system. Cascades notes that the high efficiency of Voith equipment with regard to energy consumption, minimal fibre loss, and low water consumption will contribute to achieving the project goals.

The equipment includes an energy efficient IntensaPulper R furnish pulper, complete coarse cleaning and screening systems, fine cleaning with EcoMizer Technology and fine slotted screening with C-bar slotted baskets and MF powersaving rotors.

Siemens received a multi-million dollar order to supply the complete electrification and service for the US$430-

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coatings, even on reflective or printed substrates.

RIS can be used in quality control systems like Honeywell’s MXProLine™, which uses an array of scanners and sensors to monitor the quality of coated products such as liquid and aseptic packaging. The total solution helps producers more accurately measure and control multi-layer or barrier coatings and adhesive layers, discriminate million containerboard mill.

Siemens will provide a fully-integrated automation solution and the complete electric power distribution equipment for the new 250,000-square-foot mill, including drives, motors, gear boxes, and stock preparation, as well as paper machine equipment and services.

The equipment will include medium and low voltage switchgear, power transformers, variable speed drives, and medium and low voltage motion control centers.

The process control system will provide a single view of the entire facility, which will help minimize development, implementation and life cycle costs, and reduce engineering resources.

Start-up is scheduled for the summer of 2013.

Siemens Industry Inc., www.usa.siemens.com/pulpandpaper Voith Paper 613-632-4163, www.voithpaper.com

Domtar purchases another stacker reclaimer The Domtar mill at Ashdown, AR, has recently awarded Bruks Rockwood a contract to supply an over pile stacker reclaimer. This will be the ninth machine of this design installed in the Domtar equipment portfolio. This type of machine has been the choice for Domtar since the early 1990s and will have a live storage capacity of 4 million cubic feet.

Bruks Rockwood Inc. 770-849-0100, www.bruks.com

Less expensive cleaning of small tanks The new TankJet® 75 fluid-driven tank cleaner from Spraying Systems Co. provides thorough impingement cleaning of small tanks without the expense of high impact tank cleaners.

The unit uses external gears to reduce

PULP & PAPER CANADA September/October 2011

components with very similar spectral characteristics, measure on printed and reflective backings, and quantify variations in additives and fillers such as Ti02 and CaC03.

This approach can reduce defects by up to 15% and raw material usage by up to 8%. Additionally, the calibration tools can save time by cutting the calibration effort by up to 40%.

Honeywell, www.honeywell.com/ps

nozzle speed for better impact and cleaning efficiency.

TankJet 75 features rotating solid stream nozzles that complete a 360° indexing pattern every 45 revolutions for complete coverage of the entire tank. TankJet 75 is ideal for cleaning chemical containers, dairy tanks and totes, food and beverage tanks, pharmaceutical tanks and process tanks up to 30 ft. (9.1 m) in diameter.

Spraying Systems Co. 630-665-5000, www.tankjet.com

Spray for machine clothing repels “stickies” Cartaspers® PSM liquid from Clariant prevents the clogging-up of machine clothing with “stickies”— the resin and adhesive particles inherent in waste paper.

Downtime due to stickie contamination is practically eliminated and the amount of hydrocarbon cleaning solvent for dissolving and removing the contaminants is reduced by up to 90%. pulpandpapercanada.com

PROFESSIONAL CONNECTIONS

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

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September/October 2011 PULP & PAPER CANADA

29

TECHNOLOGY NEWS Clariant’s patented Cartaspers® PSM liquid is added to the shower water during the paper production process and adsorbs on the machine clothing to provide a repellent protective layer. This allows the “stickies” to be rinsed away before they can build up and contaminate the fabrics.

Cartaspers® PSM is a nonionic, readily biodegradable, hydrophilic polymer with high affinity for hydrophobic surfaces.

The product is a water-based polyester dispersion, with the ability to modify the surface energy of non-polar substances.

It can be combined easily with other papermaking additives and is suitable for use in hard and soft water.

It can be used in pulping and fibre preparation, wet-end applications and for the surface treatment of paper to increase inter-surface adhesion and improve printability.

Clariant, www.paper.clariant.com

Vehicle scales built for forest conditions

Model VTS101 is a steel deck truck scale that is supported by orthotropic ribs that are completely sealed from the elements by automated continuous welds. The ribs are shaped to distribute concentrated loads better than I-beam designs, leading to a longer life of the scale.

Model VTC101 combines a concrete driving surface with a robust orthotropic understructure. It eliminates a common cause of premature deck failure: voids in the deck that occur when pouring concrete around I-beam flanges and sharp corners.

Mettler Toledo (800) 523-5123, www.mt.com/vehicle

extended run times.

Hypercoat delivers superior overall performance, combining outstanding mark, dent and scoring resistance with superior wear resistance. With higher material strength, Hypercoat improves reliability and maximizes machine performance for extended operating life.

Hypercoat’s advanced properties allow deckling, and minor coating build-up can be sanded off by hand with minimal effect on the profile.

Xerium Technologies, www.xerium.com

Metso will supply six TwinRoll Evolution wash presses to Swedish pulp mills

Celanese introduced its BriteCoat™ line of emulsions for paper and paperboard coatings at PaperCon in May. “BriteCoat emulsions will revolutionize the way paper manufacturers think about vinyl chemistry for their paper coatings,” said Rick Cazenave, market segment manager.

Celanese presented various data, including findings from pilot coater trials using multiple formulations at Western Michigan University.

“BriteCoat 2730 is a fully commercialized product that offers improved fibre coverage of the sheet. This results in a smooth sheet and a potential for coat weight reduction and less TiO2 in the coating formulation,” said Chris Lazaroff, paper coatings specialist.

BriteCoat emulsions also offer advantages to both papermakers and downstream users. Paper mills will appreciate the runnability in the plant along with a low odor. Printers have remarked on the crisp print quality, gloss, and whiteness of the sheet while converters like the glueability and stiffness of the board.

“BriteCoat VAE emulsions offer an exciting alternative to current technologies such as styrene acrylic (SA) or styrenebutadiene (SBR),” said Cazenave. “In today’s tumultuous raw material environment where chemistries derived mainly from oil are escalating in price faster than vinyl chemistries primarily derived from natural gas, the paper and board manufacturers are looking at this viable alternative and are being pleasantly surprised by the quality characteristics of the finished sheet,” he said.

Celanese Emulsion Polymers, www.Celanese.com/BriteCoat

Metso will supply six TwinRoll Evolution wash presses to four Swedish pulp mills.

The wash presses, scheduled to start up between end of 2011 and mid-2012, will help the mills to increase their production capacity, optimize the fiberline and reduce the environmental impact.

To the Södra Cell Mörrum pulp mill, Metso will supply two new TwinRoll Evolution wash presses as a part of the mill’s investment to convert one line to dissolving pulp production.

At Rottneros Vallviks Bruk AB the new wash presses will allow Vallvik to reduce the effluent flow from the bleach plant to the new biological water treatment plant.

Metso’s patented TwinRoll Evolution wash press is the fifth generation in a line of wash presses first introduced in 1954.

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

Advanced roll cover technologies improve machine performance

Mettler Toledo has released two vehicle scales for weighing applications in the forestry industry. The VTS101 (steel deck) and the VTC101 (concrete and steel composite deck) incorporate the newly released Powercell® PDX® load cell network. The Powercell PDX load cell is the first digital load cell of its kind to feature a network with absolutely no junction boxes — the most common source of scale failure.

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The new Multicoat HCX and Hypercoat roll covers from Xerium are high strength, extremely tough rubber materials ideal for the most demanding coating applications.

Multicoat HCX improves machine reliability and coater backing roll cover performance. Its improved mark resistance and outstanding tolerance to impacts and wraps help maintain high coater efficiency and coating quality. In addition to minimizing scoring and edge wear, its outstanding abrasion resistance enables Multicoat HCX to maintain profile longer than standard covers and to deliver

PULP & PAPER CANADA September/October 2011

Emulsion coating provides better fibre coverage

pulpandpapercanada.com

Mac Palmiere, President and CEO

MANAGING YOUR ENERGY IS SMART BUSINESS. “OUR PARTNERSHIP WITH BC HYDRO HELPS US REDUCE OUR COSTS AND OUR NEED FOR ELECTRICITY. WITHOUT THEIR SUPPORT, IT WOULD BE DIFFICULT FOR US TO TAKE ADVANTAGE OF THESE GREAT OPPORTUNITIES.” Howe Sound Pulp and Paper always knew they had big opportunities to save electricity—they just needed the right moment to move forward. That’s exactly what the mill’s leadership saw in Power Smart’s expert resources and financial incentives. Now they have an on-site, co-funded energy manager, backed by a team of people drawn from every corner of the company. With that kind of commitment to continuous improvement, they’ll be seeing many more success stories to come.

Find out more about Power Smart opportunities for the pulp and paper industry at bchydro.com/industrial A11-450

Pack more performance into your paperboard.

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