pulp & paper canada december 2010

JOURNAL OF RECORD, PULP AND PAPER TECHNICAL ASSOCIATION OF CANADACHU: Energy Optimization of Tissue Machines

June 2009

www.pulpandpapercanada.com

November/December 2010


New rules bring more voices to forest planning

SEEDS OFCHANGE

• Toward sustainable papermaking

• PaperWeek preview

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pulpandpapercanada.com November/December2010 PULP&PAPERCANADA 3


FEATURES

10 A Reformation in Forest ManagementTenure rules and forest management policies are being revamped in Ontario, Quebec and Nova Scotia. The trend is toward ecosystem-based management, more stakeholder involvement in resource management decisions, and competitive bidding for wood supply.

14 A Détente in the Boreal ForestFrom adversaries to allies: A forest products executive and a conservationist reveal how the agreement protecting Canada’s vast northern forests came to be.

18 The Business Side of SustainabilityThe pursuit of sustainability has benefits for papermakers: products that boost productivity, minimize water use and reduce energy consumption.

20 PaperWeek Returns in 2011In its new format, PAPTAC’s annual meeting and conference alternates business and technical sessions, with plenty of opportunity to mix and mingle.

TECHNICALPAPERS

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

25 Low Consistency Refining of Oxalic Acid Pretreated Wood ShavingsBy T.Kang (Abitibibowater, Liverpool, N.S.), G.Soong (Pulp and Paper Centre, UBC), X.F.Chang (Dept. of Chemical Science, BCIT), R.Beatson (Dept. of Chemical Science, BCIT), J.A.Olson (Pulp and Paper Centre, UBC) and D.M.Martinez (Pulp and Paper Centre, UBC)

30 Multivariable Control and Energy Optimization of Tissue MachinesBy S.Chu,R.MacHattie and J.Backström (Honeywell Process Solutions, North Vancouver, B.C.)

FOREST MANAGEMENT 10

PATH TO SUSTAINABILITY 18

INEVERYISSUE

4 Editorial

6 News

35 Technology News

37 Classified Ads

38 Technology News:Machine Clothing

TERRACE BAY RESTART 6

NOVEMBER/DECEMBER 2010 Vol. 111, No. 6 A Business Information Group PublicationPRINT EDITION ISSN 0316-4004 ON-LINE EDITION ISSN 1923-3515

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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.

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EDITORIAL

4 PULP & PAPER CANADA November/December 2010 pulpandpapercanada.com

Dispatches from the trenches

This month, you’ll find several stories from writers who are not regular contributors to our magazine. They are bring-

ing us the front-line perspective from a few significant events. The stories were originally written for other publications, and often that means they don’t translate well to a trade journal, but in these instances the writers have bridged that gap.

Writing about an industry meeting and the restart of a mill, Monte Paulsen and Carl Clutchey have captured the mood of the occasion, and we can all relate to it.

Clutchey takes us to the heart of the matter in his tale of Terrace Bay Pulp – the frustration of financing deals that fall through, working in B.C. to feed the family in Ontario, and lining up at the food bank when there’s no work to be found. There’s jubilation and profound relief in the entire region when the mill is fired up and money begins flowing.

The situation at Terrace Bay Pulp is not unique, which is what makes it so moving. The lights are out at mills across the country. Some may come on again; others won’t.

Old adversaries bury the hatchetBruce Lourie and Wayne Clogg provided an insider’s view on the drafting of the Canadian Boreal Forest Agreement to attendees at the Sustainable Forestry Initiative’s annual meet-ing in Vancouver in September. Monte Paulsen was there to bring the story to a wider audience.

In this case, it was all about finding a compromise that everyone could live with. In formal and informal meetings, environmentalists and industry reps came up with a deal that benefits both sides.

Also on the environmental front, Carroll McCormick revis-its Quebec’s Sustainable Forestry Act in a round-up of forest management legislation – our cover story this month. Que-bec’s move to take planning away from individual companies and create a competitive market for fibre is being echoed in Ontario. Nova Scotia meanwhile has had lots of input into its plans, but is faced with a “two solitudes” situation. The three authors of a planning report on resource management had such divergent views that the report is really two reports in one: one author supports the status quo, the other two advocate change. Perhaps they should take a hint from the folks who penned the Canadian Boreal Forest Agreement.

Overall, there’s a lot of good news in this issue. Mills are re-starting and there’s been a flood of announcements about projects funded by the feds’ Green Trans-formation Program. All of which bodes well for 2011.

Merry Christmas, and best wishes for the new year.

EDITORIALEditorCINDY MACDONALD [email protected]

Contributing EditorsHEATHER LYNCH

ADVISORY BOARDRichard FoucaultGreg HayDr. Richard KerekesBarbara van LieropDr. David McDonaldDennis McNinchDr. Yonghao NiBryant ProsserDr. Paul StuartRoss Williams

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Conventional thermocompressors use high-pressure steam to compress

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From Toronto to Tokyo,there’s one word for innovation.

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From Toronto to Tokyo,there’s one word for innovation.

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.

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.

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.

The next generation of doctor blade holders features light-weight composite

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tray and there are no items to loosen, twist, or fall into the machine.

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INDUSTRY NEWS


s s s s s s

ALBERTA GAINS GROUND AGAINST MOUNTAIN PINE BEETLE … U.S. TRADE COMMISSION ORDERS DUTIES ON COATED PAPER IMPORTS FROM CHINA AND INDONESIA … SALE OF HOWE SOUND PULP AND PAPER COMPLETED … DOMTAR BREAKS OFF NEGOTIATIONS TO SELL PRINCE ALBERT MILL …

TERRACE BAY, ONT. — Some people believed it would never reopen. But they were wrong. Terrace Bay Pulp is back in business, a fact celebrated at a grand re-opening the afternoon of Oct. 4 as a forklift brought bales of fresh-made pulp into the operation’s giant warehouse. The mill has restarted only one line, with a capacity of 350,000 tonnes/year, producing northern bleached softwood kraft (NBSK) pulp.

“The mill is in good shape, so it’s time to rock ‘n’ roll and make some pulp,” mill manager Bob Bryson shouted out to a crowd of workers, company officials, retirees and local politi-cians. Bryson has worked at the mill for more than three decades.

The upbeat ceremony capped a grinding and often emotional effort to get the 62-year-old plant back on line 19 months after it sought court protection from its creditors while it restructured and paid off about $80 million in debt.

The frustration and angst took hold in February of this year, when a tight credit market was blamed for stalling the com-pany’s restructuring plans and forcing it to postpone a planned restart. In May, another bump in the road resulted in the restart being put off once again.

With summer nearly over and a second lender having backed out of the plan to get Terrace Bay Pulp (TBP) back on line, the company hooked up with a little-known Toronto-based lender — Callidus Capital Corp. Experienced in rescuing cash-strapped companies that still look good on paper, Callidus agreed to provide Terrace Bay Pulp with $30 million.

With the $25 million TBP already had promised from the province, the green light went on and 350 workers — many of whom had run out of employment insurance and had become regulars at food banks — prepared to re-enter the inside of a mill they hadn’t seen for nearly two years. On Sept. 24, a tiny window that offers a peek into the mill boiler turned red-hot orange. The plant was being fired up. Steam billowed out of the stack, and the roughly 2,000 people who live in Terrace Bay and nearby Schreiber let out a collective sigh of relief.

“Nothing can beat the sight of coming down here again, and seeing smoke coming out of the stack,” remarked Ontario’s Northern Development, Mines and Forestry Minister, Michael Gravelle, who called the plant’s re-opening “the highlight of my political career.” Many workers who had spent the last two years making ends meet by commuting to contract jobs as far away as British Columbia couldn’t agree more.

“I’m happy for our town, and it’s just nice to be able to come home at night and see my two daughters,” said TBP boiler operator Jim Fournier, 39.

Terrace Bay Pulp founder Ken Buchanan Sr. paid tribute to Callidus president Sam Fleiser, who was among the crowd. “Sam worked diligently to help us get where we are today,” Buchanan said. “He helped lift this mill off the ground.”

Four years ago it was Buchanan himself who was seen as the saviour, after his company took over the Terrace Bay mill from former owner Georgia-based Neenah Paper, which was making

plans to scrap it. At the celebration, Buchanan quipped: “This is the second opening we’ve had, and I hope it’s the last. It’s been a very hard grind to get where we are.”

Traditionally, Terrace Bay’s pulp has gone mostly into the U.S. — to the other side of Lake Superior, as locals like to say. That’s expected to change, with the company’s sales team seek-ing new customers overseas.

Locals celebrate the restart of Terrace Bay PulpBy Carl Clutchey, Thunder Bay Chronicle-Journal

Terrace Bay Pulp recovery boiler operator Jim Commisso keeps an eye on the control board during startup procedures.Photo: Carl Clutchey/The Thunder Bay Chronicle-Journal

Smurfit-Stone La Tuque resumes production after 11-day lockout A conflict between Smurfit-Stone Container Corp. and one of the unions at the company’s La Tuque, Que., facility is resolved. The situation began with a 48-hour strike on Nov. 8 by Unik Local 34, which represents 140 paper machine workers at the containerboard mill. Smurfit-Stone proceeded to halt produc-tion and implement a lockout, saying it would not restart pro-duction until the union signed a new collective agreement.

The work stoppage lasted 11 days, with workers returning to the facility on Nov. 19. Workers from Local 34 initially rejected the company’s contract offer, but a second vote several days later swung in favor of the deal.

There was no change in the offer between the two votes, but local newspapers report there was tremendous pressure on the locked-out workers to accept the deal. Unik Local 34 represents only about one-third of the workers at the mill; 270 other workers represented by the Communications, Energy and Paperworkers Union Local 530 had accepted the contract offers months earlier. As well, the Smurfit-Stone mill is one of the largest enterprises in the region and locals were concerned about the effect the lockout would have on the local economy.

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INDUSTRY NEWS

pulpandpapercanada.com November/December 2010 PULP & PAPER CANADA 7 s s s s s s

ALBERTA GAINS GROUND AGAINST MOUNTAIN PINE BEETLE … U.S. TRADE COMMISSION ORDERS DUTIES ON COATED PAPER IMPORTS FROM CHINA AND INDONESIA … SALE OF HOWE SOUND PULP AND PAPER COMPLETED … DOMTAR BREAKS OFF NEGOTIATIONS TO SELL PRINCE ALBERT MILL …

Award-winning packageOntario-based Strathcona Paper LP has won the 2010 Pulp & Paper International (PPI) Award for Innovative Product of the Year for its GreenChoice 100 recycled paperboard. Frank Dorrington, Strathcona Paper’s environmental supervisor (centre), accepted the Innovative Product award.

AbitibiBowater gets go-ahead from courts, pension regulators to exit creditor protectionMONTREAL — AbitibiBowater has cleared the last legal hurdle of its restructuring process. The U.S. Bankruptcy Court for the District of Delaware has confirmed AbitibiBowater’s plan of reorganization under chapter 11 of the U.S. Bankruptcy Code, clearing the way for the papermaker’s emergence from creditor protection in December.

The reorganization plan already has creditor approval in both the U.S. and Canada, and has been approved by the Quebec Superior Court.

AbitibiBowater recently finalized agreements with the gov-ernment of Ontario related to funding relief for the solvency deficits in its pension plans. The company had earlier reached a similar agreement with the government of Quebec. The agree-ments will allow the company to meet its future pension obliga-tions to beneficiaries in full.

In addition, the Ontario government has reached a five-year agreement with what will become one of AbitibiBowa-ter’s Canadian subsidiaries post-emergence, AbiBow Canada, regarding investment levels, governance, and sustainability at its pulp and paper operations in the province.

The company directly employs approximately 8,500 work-ers and has in the order of 20,000 pensioners in Ontario and Quebec.

St. Marys secures $8.8 million loan for restart plus biomass co-gen dealSAULT STE. MARIE, ONT. — With the assistance of a loan from the provincial government and promises of an appropriate wood supply, St. Marys Paper Corp. in Sault Ste. Marie, Ont., is gearing up to restart by early December. The groundwood mill has been closed since March.

“This is important news for St. Marys, and for the local econ-omy,” said Dennis Bunnell, chairman and CEO of St. Marys.

“Our market studies confirmed that St. Marys Paper should continue producing supercalendered paper as its base product,” Bunnell noted. “As a result of the provincial support we can now implement our plans to transform the business by joining the expanding forest bio-economy business sector.”

The transformation in underway. St. Marys Paper has signed a 10-year, 30-megawatt power-purchase agreement with the Ontario Power Authority for the electricity produced by a bio-mass-fueled co-generation plant to be built adjacent to the St. Marys Paper mill in Sault Ste. Marie. The plant will be operated by St. Marys Renewable Energy Corporation.

The company still needs to finalize funding for the $175-mil-lion project. The co-generation plant will replace St. Marys’ aging boilers and allow wood waste, in this case, forest industry residuals, to be used as fuel in the new a bubbling fluidized bed boiler.

The construction phase is expected to begin in 2011 and generate 400 jobs. About 30 people will work at the co-gen plant once it is operational, and another 125 will be employed provid-ing biomass fuel and logistics.

St. Marys has negotiated a commitment of up to 400,000 tonnes of biomass annually from the Algoma and Northshore Crown Forests for the life of the project. The company also will engage in nano-technology product development partnerships and studies with the University of Toronto, and other bio-economy projects with private sector partners and the Sault Ste. Marie Innovation Center.

West Fraser announces $37-million Hinton Pulp upgrade of boiler and pulp machineVANCOUVER, B.C. — West Fraser will proceed with an energy efficiency upgrade of the pulp machine at its Hinton Pulp operation in Hinton, Alta. The project, which is expected to cost approximately $37 million, will be funded with credits earned under the Canadian government’s Pulp and Paper Green Transformation Program.

PPGTP funding will be used to install new components and upgrade an existing boiler and pulp machine in order to increase energy efficiency and renewable electricity generation at the mill. Combined, these capital improvement projects will produce more than 10,000 megawatt hours of additional green power per year. These projects will also enable the mill to reduce its natural gas consumption by more than 112,000 gigajoules per year and cut greenhouse gas emissions by more than 5,600 tonnes annually.

“The upgrades to the recovery boiler and pulp machine will allow the mill to produce more green power, reduce its natural gas consumption, and lower its carbon footprint. The successful completion of these projects is an important step for Hinton Pulp in improving its overall competitiveness and long-term outlook,” said Brian Grantham, general manager, Hinton Pulp.

As a result of this project and other initiatives, pulp produc-tion is expected to increase to 420,000 tonnes, returning the mill to levels achieved when it ran two production lines.

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INDUSTRY NEWS


Tolko invests Green Transformation funds in power and recovery boilersTolko Industries’ kraft paper mill in The Pas, Manitoba, will receive $2.26 million in funding under the Pulp and Paper Green Transformation Program to improve the mill’s energy efficiency and increase renewable energy production. The altera-tions to the power and recovery boilers will promote better fuel combustion.

The new equipment will increase the production of thermal energy from wood waste and black liquor by close to 114,000 gigajoules a year. This increase will reduce the mill’s need to use fossil fuels to compensate for renewable energy shortfalls, lowering the mill’s greenhouse gas emissions by around 10,000 tonnes per year.

By reinforcing its environmental stewardship, Tolko is better able to meet market demands for sustainably manufactured pulp and paper products. “We thank the government for actively sup-porting the pulp and paper industry’s advancement in applying green technologies,” said Bob Snow, technical manager, Tolko’s Manitoba Kraft Papers Division. “These Green Transformation Program projects will provide both environmental and socio-economic benefits for our employees and our community.”

BC Hydro purchases power from Zellstoff CelgarCASTLEGAR, B.C. — BC Hydro is now purchasing clean electricity from the Zellstoff Celgar’s Green Energy Project as a result of a series of upgrades that allow the pulp mill to direct more steam to energy production. A new 48-megawatt condensing turbine is now generating electricity for use in the BC Hydro power grid.

Zellstoff Celgar’s cogeneration facility will produce 238 giga-watt hours of electricity annually for sale to BC Hydro under the terms of a 10-year electricity purchase agreement. The new clean energy generating capacity at the Zellstoff Celgar mill was made possible through a series of upgrades funded by $40 mil-lion from Natural Resources Canada’s Pulp and Paper Green Transformation Program and $17 million from Mercer Inter-national, Zellstoff Celgar’s parent company.

The investments at the mill include upgrading the wood waste boiler and installing a new condensing turbine and other steam-saving equipment to allow the mill to generate energy in excess of its own needs that it can sell to BC Hydro. The mill

generates the steam it uses for its operations by burning wood waste and black liquor, a byproduct of the pulp-making process.

In addition to the electricity purchase agreement with Zell-stoff Celgar, BC Hydro has bioenergy agreements with Canfor Pulp in Prince George; PG Interior to Waste to Energy Ltd. in Prince George; and Domtar in Kamloops.

Norampac puts Green Transformation funding to use on paper machineThe Government of Canada’s investment of $83,000 in Noram-pac, a division of Cascades Canada Inc., will be used to improve the energy efficiency of the paper machine at Norampac’s Tren-ton pulp and paper mill.

To increase energy recovery, Norampac has made improve-ments that have increased the efficiency of the mill’s heat exchangers. The recovery of this additional energy will reduce the mill’s energy requirements and its use of natural gas by more than 20,000 gigajoules per year.

“This $481,000 project, in which the Pulp and Paper Green Transformation Program will invest $83,000, will allow Norampac Trenton to improve its environmental performance by reducing the use of fossil fuels,” said Marc-André Dépin, president and CEO of Norampac.

White Birch sale approved by Quebec court, still needs U.S. approvalThe US$236-million sale of White Birch Paper Company, which owns three newsprint mills in Canada, to BD White Birch Investment, LLC, has been approved by a Quebec court. The company has been in bankruptcy protection since February.

The sale of White Birch’s assets also includes a mill in Vir-ginia, and the deal still needs approval of the U.S. bankruptcy courts.

The majority owners of BD White Birch are funds managed by Black Diamond Capital Management, and its affiliates, with Caspian Capital Advisors also participating as equity owners.

B R I E F L Y …

SKF has agreed to acquire US-based lubrication sys-tems provider Lincoln Holdings Enterprises, Inc. Lincoln Industrial is complementary to SKF’s existing lubrication systems business. In addition, Lincoln Industrial provides SKF with improved access to the lubrication tools and equip-ment aftermarket in North America.

Metro Waste Paper Recovery Inc. has changed its name to Cascades Recovery Inc. As a member of Cascades Specialty Products Group, Metro Waste has become an integral part of Cascades’ supply chain and supports its sustainability goals and responsible products.

P E O P L E …

Chad Wasilenkoff of Fortress Paper Ltd. has been named Ernst & Young Entrepreneur Of The Year for the Pacific region.

Peter Rippon has been appointed vice-president, pulp and energy, at West Fraser Timber Co. Rippon was previously operations manager, mechanical pulp and energy.

Jim Futcher passed away on Sept. 26, 2010, in Ottawa from a form of cancer caused by exposure to asbestos. Futcher was a long-time member of PAPTAC.

André Tremblay will take over as CEO of the Québec For-est Industry Council (CIFQ) in January. Tremblay has a career in law and has been general manager of Produits For-estiers Saguenay Inc. since 2004. Tremblay will also oversee the CIFQ’s communications and public affairs portfolio.

p 06-8 news.indd 8 03/12/10 2:07 PM

A10-550

There’s no doubt about it: big energy can cost big money. That’s why smart businesses don’t pay for wasted power. And that’s why we help BC pulp and paper mills make great energy management a part of doing business, every single day. To find out more about our expert resources and major financial incentives call 1 866 453 6400 or visit bchydro.com/industrial.

BEING SMART WITH YOUR POWER IS SMART BUSINESS.

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SUSTAINABILITY

Tenure rules and forestry regulations are being revamped in Ontario, Quebec, and Nova Scotia. The trend is toward

ecosystem-based management, more stakeholder involvement, and competitive bidding for wood.

Nova Scotia and Ontario are in the discussion stage of the development of their new for-est management programs, while Quebec

has already turned its new policies into law. Already, there are a few common themes in this current round of tenure reform: a preference for competitive bidding over single-company licences; a nod to ecosystem-based resource management; and an opening of the planning process to a broader variety of stakeholders.

Despite some recent examples of co-operation between the forest industry and conservation groups, the provincial forest management policies under devel-opment still show echoes of the traditional environment vs. industry paradigm.

Quebec: Government takes over planningQuebec’s National Assembly adopted its new Sustain-able Forest Development Act last April. The goals of taking forest management away from the forest industry and putting it in government hands seems to have been achieved, as well as a strengthening of local, regional and First Nations interests in the forest planning process.

By Carroll MCCorMiCk

A reformation in

FORESTMANAGEMENT

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SUSTAINABILITY

tices within the “intensive forest management” approach. Greenpeace is very preoccupied by the lack of environmental guidelines. Our main concern is that most of the concrete changes are not described in the Act, but will be in the SADF, now under revision.”

NovaScotia:AdoptintegratedresourcemanagementIn May, 2010, following community meetings attended by more than 2,000 residents, a resulting Phase One working paper, then feedback from stakeholders, then more paperwork, Nova Scotians finally got their hands on a report intended to re-evaluate the Department of Natural Resources’ (DNR) policies on forests, minerals, biodiversity and parks. Phase Two of the DNR strategy process is a report entitled A Natu-ral Balance: Working Toward Nova Scotia’s Natural Resources Strategy. The section on forests contains more than 160 rec-ommendations.

In abbreviated form, these are: adopt a multi-aged forest management paradigm; implement an Integrated Resource Management Program; i.e., promote synergy among multiple uses of Crown land, and possibly some private lands; take a bal-anced approach between harvesting and ecosystem objectives; encourage stewardship and education initiatives to improve land use; and amend regulations to stop whole tree harvesting and phase out clearcutting. The recommendations also include improving tenure-of-supply arrangements.

Still to come is a strategy based on the Phase Two report, which will guide future DNR policy and program decisions. According to Mike Hutchinson, project coordinator, Fed-eration of Nova Scotia Woodland Owners, the Phase Two report, coming from the three experts tasked to write the recommendations was actually two reports, or viewpoints: one written by two panel members who took an environmental, “change required” angle, the other by the third panel member from an industry, “maintain the status quo because there’s no problem” perspective.

Both viewpoints are compelling and the government is having a “heck of a time” combining them, says Hutchin-son. “We do not know how far and in which direction the strategy will go.”

Hutchinson is particularly supportive of some of the final report’s conclusions. “We have to reduce clearcutting. It does not mimic natural disturbances. Right now it is not used as a forester’s tool. It is used as an economic tool to generate wood supply and is being overused. Reducing clearcutting and changing harvesting methods is definitely part of the strategy, but we do not know to what extent.”

In October, Natural Resources Minister John MacDonell announced the province was backing off on its earlier plan to introduce a mandatory licensing system for controlling clearcutting. According to Hutchinson, “The forest industry had been pushing hard on MLAs that they do not want man-datory licensing, saying that it will not work.”

Whole tree harvesting is also under the magnifying glass. “Our soils are not fertile enough for it. I support the banning

Jean-Pierre Dansereau, the director of the Fédération des producteurs de bois du Québec (FPBQ), which represents Quebec wood producers, is still worried that the new Act will place private wood sellers at a disadvantage.

He expressed concern last year that Bill 57 (the proposed forest act) did not require that wood be purchased from private wood lot owners first and then from public lands only as a last resort. He reported that wood cut from private lots on contract was rotting on the ground while mills procured cheaper wood from public land.

The new Act stipulates that a Wood Marketing Board for wood from public lands will be implemented in 2013. “Our Federation still agrees with the principle but also still ques-tions if the conditions will be there for the Board to draw enough competitive buyers to set fair benchmark prices for wood being cut on public lands, particularly in depressed markets. We are very much afraid that woodlot owners we represent will keep facing unfair competition from the public lands, as they are now.”

The “residuality principle” — which means that access to wood from public land is given to mills once what they can get from primary sources such as private lands has been taken in account — has been kept in the Act but the article that allowed the Minister to enforce ad hoc adjustments to wood allocation on public land twice a year has been dropped. “We feel this is an important weakening regarding the residuality principle enforcement,” notes Dansereau.

Nicolas Mainville, Greenpeace Canada’s specialist in for-estry campaigns, outlines what he regards as some of the new Act’s good features. “It abolishes the CAAF [timber supply and forest management agreements] and government takes over all planning and management: As of 2013, Quebec and the regions will decide where, how and when public forests can be logged. Ecosystem-based management (EBM) is part of the Act and should play a central role for future forest practices.”

Greenpeace salutes this essential reform but questions how the Ministry of Natural Resources (MNR) plans to concretely apply EBM on the ground. “Will EBM become the new “sus-tainable development”, a great concept that is now profoundly violated by many stakeholders seeking greenwashing?” Main-ville wonders.

On the down side, he says, “Protection of forests and cre-ation of protected areas is still excluded from the new Act, thus stopping conservation projects and allocating all the wood for industrial purposes. It briefly refers to the SADF (manage-ment strategy) for conservation purposes and joint work with MDDEP (Ministry of Sustainable Development, Environ-ment and Parks), but without concrete tools to make sure that the new Act ensures conservation.

“There is no intact forest protection strategy. The govern-ment will allow the destruction of the last virgin areas of our productive forests (about 10-15% of total allocated land),” Mainville continues. Greenpeace considers this as a major fail-ure from MNR and MDDEP.

“The door is open for large scale tree farming, intensive monocultures and other environmentally non-friendly prac-

A reformation in

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SUSTAINABILITY

of industrial whole tree harvesting,” Hutchinson says.Hutchinson hopes the strategy will include an

incentive program for small wood lot owners for developing forest management programs. “What we are encouraging people to do is develop a manage-ment plan, documenting ways to achieve your goals, much like a financial plan,” Hutchinson says.

He points to a fundamental problem with forest use that, in his opinion, really should change, but which would take time to correct. “There is no point trying to compete for paper on the world market. When you are competing on a world market where there is cheap labour and fast-growing trees, you are beating a dead horse. Why not look at value-added wood industries? For those of us who are looking at forests for what they will provide, and not what we can make them provide, it is a simple choice.”

Ontario: Competitive bidding not fibre allocationIn 2009 the Ministry of Northern Development, Mines and Forestry (MNDMF) released A Pro-posed Framework To Modernize Ontario’s Forest Tenure and Pricing System, designed to “stimulate discussion on how the forest tenure and pricing system could be improved and updated to support a revitalized forest industry,” according to MNDMF. It was open for comment from April to the end of June this year.

The framework has three main elements: New local forest management corporations (LFMC), would assume responsi-bility for the management, marketing and competitive sale of wood from Crown land, with the goal to maximize the value of the forests for Ontario. The second element is competitive markets; i.e., selling timber at market prices via competitive processes such as tendered and negotiated sales, rather than relying on government commitments that allocate fibre to indi-vidual mills or harvesters. The third element is what MNDMF calls a new revenue model: Each LFMC would be a stand-alone business whose revenues would come from Crown timber sold from its own management area.

The Framework document implies that the existing pric-ing, tenure, licensing model is not working. Is this so? “We struggled with that question ourselves. We think the chal-lenge in Ontario is that there has been an underutilization of wood. Somehow the government has suggested that this unused wood means that we need a new tenure system. But the underutilized wood is a sign of the times, not of a flawed system,” says Jamie Lim, president and CEO, Ontario Forest Industries Association (OFIA). “When we went to the town meetings, with the exception of three or four people, there was no support for this Framework.”

OFIA says there is no “dog in the manger” attitude about unused wood in Ontario. Tenure systems are sometimes criti-cized for this; i.e., tenure holders sitting on their wood while new players cannot get access to any. “OFIA, for the past two

years, has put out a position statement that we support putting Ontario’s 26 million cubic metres of industrial wood fibre back to work.”

Lim refers to the Provincial Wood Supply Com-petition (PWSC) launched in November, 2009, as proof that there is a good system already in place working to allocate wood to companies with viable plans and simultaneously protect the wood supply for mills and plants that have survived the recession and continue to employ Ontarians. “It hit the reset button to open up the underutilized wood supply to competition, but also to protect the wood supply that was allocated and being used,” Lim says.

“There has been a move away from single-entity Sustainable Forest Licenses (SFL) to a more inclusive enhanced shareholder co-op model. This means that wood is not being managed by a single company anymore. We asked government that instead of the Framework, it should finish what it started with the PWSC and accelerate the move from single entity

SFLs to enhanced co-ops. We just completed one this summer: the Abitibi River Enhanced Co-op. This

ensures that wood is being used in an effective and effi-cient manner by industry,” Lim says.

The head scratcher, according to Lim, is that the PWSC is already dealing with the concerns voiced in the Framework. The Framework would simply undermine the mills that are still open, because they would continually have to bid and compete for supply. “It is that simple,” Lim says.

Too, Lim explains, OFIA does not want forests run by people with no vested interests. “The Algonquin Forest Corpo-ration, a Crown corporation, has some of the highest fibre costs and significantly higher staffing than any shareholder co-op.”

Scott Jackson, manager, forest policy, OFIA, adds, “We have said that if the government is so convinced that its model is competitively sound, we would tolerate them introducing two pilot programs in areas that lack leadership and eco-nomic activity. Run them for five years, take what they have learned, have them independently assessed and compared to the enhanced co-ops. We really think the government should set up the pilot programs, finish the PWSC and support the enhanced co-ops elsewhere on the land base. That would be enough for this province and the tenure system status quo would be changed.”

As for how this process could play out, Lim notes that, “Our members and us have been meeting with government. We are hopeful. We believe that there is an openness to reform tenure by testing these pilot projects against the revised tenure co-ops.”

Regardless of what you call it, the clear direction of these reforms in the East is away from single-company forest licenc-es, toward multi-stakeholder decision-making and integrated resource management. Competitive bidding for wood supply is will soon be the reality for pulp and paper companies in Que-bec, and looms on the horizon for Ontario. PPC


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SUSTAINABILITY

A détente in the

BOREAL FORESTBy Monte Paulsen

From adversaries to allies: A forest products executive and a conservationist reveal how the Canadian Boreal Forest Agreement redefines the relationship between industry and activists.

The Canadian Boreal Forest Agreement, which covers 72 million hectares of the coldest dirt on

Earth, has spawned strange bedfellows. It brought the forest products industry and environmental groups to a mutually agreeable protection plan for Canada’s boreal forest. It has resulted in a regional ceasefire in the sprawling battle among rival certifiers of “green” wood and paper products: the Sustainable Forestry Initiative (SFI), which was created by the forest products industry, and the Forest Stewardship Council (FSC), which was founded by a coalition of forest conservation activists.

Two gentlemen involved in hammering out the agreement shared a stage in September at the Sustainable Forestry Initiative’s annual conference in Vancouver.

Wayne Clogg is a senior vice president at West Fraser Timber Company, a loyal SFI member and sometime target of environmental protest in British Columbia.

Bruce Lourie is president of the Ivey Foundation, a Torontobased family charity that has funded much of the activism targeted at companies such as West Fraser.

Their comments both illuminated and illustrated the fragile truce that promises to remake Canada’s vast northern forest.

A tradition of ‘throwing tomatoes’Clogg appeared at ease speaking to the overwhelmingly male audience of timber industry executives and consultants. He summed up the boreal experiment succinctly in response to an audience question.

“The traditional model is: government sets up a table. Bruce comes in. He sits at one end. I sit at the other. We spend our time throwing tomatoes at each other. We walk out. We both give a different recommendation to government; they come out with something in the middle,” Clogg said. “And then we both dump all over them.”

A throaty chuckle gurgled across the ballroom of the Renaissance Hotel. The West Fraser executive continued.

“That’s the traditional model. What we’re trying to test here is: can these two sides get together, try and find that balance — it won’t be easy — bring some outside experts in and try and give a recommendation to government that we both support.”

Lourie, playing Daniel to the lion’s den, spoke more formally.

“This is essentially a culmination of probably 10 to 20 years of a much more adversarial relationship between conservation organizations and forest compa

nies,” Lourie began. “At the Ivey Foundation, we’ve been

more associated with supporting what you would call the other side of the issue, supporting the conservation groups. So for many years we’ve supported groups like the Nature Conservancy, World Wildlife Fund, and we also support — I should be careful what I say here — more aggressive groups like ForestEthics.”

Some audience members shifted uncomfortably in their seats. ForestEthics has lobbed some big tomatoes at SFI.

Lourie continued, “It was probably one of the most professional, the most nerve wracking, and really the most exciting gatherings of businesses and conservation groups that I’ve ever participated in.”

Big goals, ‘big gives’The Canadian Boreal Forest Agreement is between 21 member companies of the Forest Products Association of Canada (FPAC) and nine leading environmental organizations. Together, they plan to present recommendations to federal, provincial and First Nations governments.

The agreement applies to 72 million hectares of public forest licensed to FPAC companies. That’s about a quarter of Canada’s 307 million hectare boreal forest.

“Just to put it in perspective, Canada’s boreal forest, if it was overlayed on the U.S., it would be about 40 per cent of the size of the continental U.S.,” Clogg said.

“If you look at the northern fringe of that band of boreal forest, it’s pretty marginal from an economic forestry perspective,” Lourie said, “but it is still very important from an ecological perspective

Bruce Lourie and Wayne Clogg told participants at the Sustainable Forestry Initiative’s annual meeting the tale of how activists and industry reached a truce on the boreal forest issue.

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SUSTAINABILITY

and increasingly from a carbon stor-age perspective... By many accounts, the boreal forest stores more carbon than any other ecosystem in the world.”

The agreement, which was announced in May, is being implemented over the next three years. It is framed around six specific goals:

world-leading sustainable forest man-agement practices;

creation of a network of protected areas that represent the diversity of eco-systems within the boreal region;

recovery of species at risk within the boreal forest, including species such as boreal caribou;

reducing greenhouse gas emissions along the full life cycle from forest to end-of-product life;

improved prosperity of the Canadian forest sector and the communities that depend on it; and

recognition by the marketplace (e.g., customers, investors, consumers) in ways that demonstrably benefit FPAC members and their products from the boreal forest.

Lourie, who described the sixth goal as the “pot of gold at the end of the rainbow,” said, “Our hope is that [the boreal agreement] will deliver a com-petitive advantage as the world becomes more focused on green products and more focused on a low-carbon economy.”

The path to such a future was paved by a controversial quid pro quo under which the forest companies agreed to suspend logging on nearly 30 million hectares so that caribou conservation plans can be enacted.

“The deferral of logging on 30 million hectares was the big give from the forest companies’ side,” Lourie said. “In return, the big give from the conservation groups, and particularly from the more activist forest groups, was that they would end all of their campaigns that were targeted at signatory companies.”

Those include high-profile ‘do not buy’ campaigns by Canopy, Greenpeace and ForestEthics.

Certification nearly derailed agreement Clogg and Lourie agreed that the first goal — defining the forest management

practices that would be certified by orga-nizations such as the Sustainable Forestry Initiative and Forest Stewardship Council — was the most difficult.

“It may not surprise you to hear that this was one of the more contentious areas of the discussion,” Lourie said.

“This was one point we had a few tense moments over,” Clogg concurred. “And it even threatened, I think, to derail the process.”

Clogg described the process for the SFI audience. He said the environmental groups at the boreal table insisted on high forest management standards.

“And for them, this meant embracing FSC in the boreal... However, for the FPAC member companies, this was a major stumbling block,” the West Fraser executive and SFI stalwart explained.

“We had no appetite for a major con-version to FSC,” Clogg continued. “And the environmental interests felt that only FSC could give them the assurance that they sought about our performance on the ground.”

Beer broke the standoff. “We had a discussion over a beer

one night — and this was one of the benefits of this process, is that we began to break down the traditional barriers between the two sides — and we started to discuss the real objectives we were trying to achieve. And it turned out that our real objective was about forest man-agement performance on the ground,” Clogg said.

“So we hit upon the idea... of develop-ing a set of on-the-ground forest practices in the boreal. The idea was to develop a boreal standard of practice which could be adopted and verified under any of the three certification systems in Canada,” he continued.

They agreed to hire outside experts to help indentify best practices.

“Finally, and this one has been con-troversial, we agreed to use the FSC boreal standard as a reference point. Not as a starting point. Not as a benchmark. But as a reference point, so that envi-ronmental proponents could support the new standards by comparing these to the standards they were most comfortable with,” Clogg said.

“For us this truly is a win-win. We will incorporate this element into our SFI audits of the boreal, and retain all of the other positive benefits that we like about the SFI program,” he continued.

Better than the status quo“Why did West Fraser support the boreal agreement?” Clogg asked. It was a front-of-mind question for many in the indus-try audience.

“After all, our company has a long history with forest campaigns. This goes way back to the Great Bear Rainforest campaign on the B.C. coast,” Clogg said. “So over the years, even though this hasn’t been a whole lot of fun — and I’ve had my share of scars — in fact we’ve learned to deal with campaigns and we’ve learned to carry on our business successfully.”

“Quite simply,” Clogg replied to his own question, “we saw a window of opportunity to negotiate an outcome in the boreal that we thought was better than the status quo. Not just better for us, but better for both parties.”

Both Clogg and Lourie described the boreal agreement as “in early days,” and both stressed that it will need the active support of governments, First Nations and other resource sectors (such as min-ing and oil) in order to succeed.

Lourie noted that he had recently met with Syncrude, one of several oil sands operators now under pressure from the same sorts of conservation groups that had previously campaigned against the FPAC companies.

“We met with the CEO of Syncrude. He was really excited about the model of the Boreal Forest Agreement, and I imagine there will be more of those kinds of conversations with different industry sectors going forward,” Lourie said.

The Ivey Foundation president con-cluded with a puckish bit of good news for the timber industry audience.

“Happily, I should tell you that all of the forest activists are now fighting the tar sands, so you guys won’t have to worry about them too much longer.”

(This article first appeared on TheTyee.ca, on September 28, 2010.)

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ENVIRONMENT

Traditionally, the focus for a wide range of paper producers had been to deliver high productivity

with little concern for the amount of raw materials and energy employed; just get as much product as possible to the mar-ketplace and keep things running. Many did this very effectively.

Today’s expectation is still high pro-ductivity, but the difference is a change in the definition of success. Success today also requires a reduction in raw mate-rial usage, reformulations to lower costs, minimization of energy employed, and tighter control of water usage.

Beyond the mill, fine paper grades must meet the needs of digital presses running with entirely new inks. Packag-ing grades must be lighter but stron-ger, and eliminate proven coatings in favor of new, green formulations. Add in the pursuit of increased quality of life for communities and employees at the mill — profitable for stakeholders and shareholders alike — and you can see the sweeping reach of the sustainability equation.

Because of the increasingly important business dimension of sustainability, top management from many global compa-nies is actively weaving the “less is more” concept and the bigger picture dimen-sion of sustainability into their long-term plans, often measured by each operation’s carbon footprint.

“Mapping the carbon footprint of production facilities has become com-monplace and part of the cultural change at pulp and paper mills,” says Fred Clark, vice-president, sustainability at Eka Chemicals, the AkzoNobel pulp and paper division. “Often the reduc-

tion targets are challenging. At Eka and the other AkzoNobel business units, we have taken the initiative seriously and are aiming to reduce our carbon footprint by 10% in 2015 relative to 2009. Our ambi-tion is to achieve a 20-25% reduction by 2020. Partnering with leaders in the pulp and paper industry, including NGOs, to support sustainability efforts and helping them reach ambitious goals is fundamen-tal to our own success.”

With this approach, Eka Chemicals joins a forward-thining cadre of chemical companies that are addressing their own carbon footprint, and compiling sustain-ability data about their products for cus-tomers. Sun Chemical, for example, has just made carbon footprint data available for its product lines.

At Eka Chemicals, “more and more customers ask for eco-profiles of our products,” confirms Clark.

High-performance chemistrySustainability challenges usher in a new role for chemistry, which requires a holis-tic view from the forest through pulp and papermaking, as well as the processes that follow, always working in innovative ways to meet continuously increasing demands for a more sustainable industry.

As Tom Lindstrom, a professor at the Swedish Royal Institute and a guru in sustainable packaging and innova-tion sees it, “Reducing the use of fibre remains on the forefront of this effort, through basis weight reduction in pack-aging grades, or filler substitution in fine papers. This means a greater role for chemistry, including utilizing retention, drainage and strength enhancements in new ways, or taking advantage of new

product or application technology in these areas.”

“On another front,” he contin-ues, “nano-cellulose developments are advancing quite rapidly to enhance strength to entirely new levels, which will bring about all kinds of innovations in formulations. It’s interesting to note the keen interest from entrepreneurs in the cosmetics, medical, food and many other industries who are contacting us from all over the world to tap into the inherent properties of nano-cellulose for their own performance and sustainability reasons.”

Lindstrom also notes that there’s a lot of interest in the use of clays for bio-barriers, which also fit into the sustain-ability model.

Process improvement through better chemistry is not a new phenomenon. “We have been developing and promot-ing sustainable products and providing sustainability benefits since our inven-tion of the microparticle-based retention system 30 years ago,” says Mark Zempel, paper chemicals marketing manager for Eka Chemicals. “The modern versions of this concept are now allowing unprec-edented filler levels in graphic grades, maintaining or improving productivity and quality at the same time. Similarly, use of new retention, dewatering and strength concepts is allowing board pro-ducers to reduce basis weights, optimize furnish mix, and increase productivity. These each contribute positively to a mill’s sustainability metrics — improved productivity, for example, can result in fewer resources (energy, water, etc.) con-sumed for each ton produced.”

In concert with advances in chemistry, much has been happening on the paper

The Business Side of Sustainability

For papermakers, the pursuit of “sustainability” has produced innovations in chemistry that boost productivity, and minimize water and energy consumption.

By Martin Koepenick, Innova

p 18-19 Environment story.indd 18 03/12/10 1:52 PM


equipment side to attain the same goals. Alain Lascar, director of applications

and marketing for Kadant’s fiberline group, explains: “In the recycled fibre sector, we are helping customers utilize contaminated, but high quality fibre, gaining a high yield, reducing energy costs, and minimizing the chemicals employed. While we do try to help lower chemical costs, we have a high respect for high performance chemistries, because they deliver advantages needed to pro-duce a sheet with fewer imperfections. Just as we deliver more fibre from waste paper, effective nanoparticle systems retain more of the fibre, minerals and additives in the sheet.”

Better,lighterbasesheetGlobally, today’s base sheet is typically more uniform, even though it’s produced at very high speeds. The ratio of filler to fibre has shifted notably in the direc-tion of filler, sometimes to nearly half the content of the sheet. Ranging from newer alternatives such as eucalyptus fibre to heavily contaminated waste fibre, or even bamboo, bagasse and straw, paper formulations in the new millen-nium are entirely different, continuing to evolve to incorporate fibre from sustain-able resources.

Complimentary to the fibre changes, applications of advanced chemistries at the wet end have become standard prac-tice. But there is nothing standard at all about the effect they have had on retention of fibre, minerals and other additives. Greater knowledge of the sheet on a nano level allows for impressive productivity at lower dosages of advanced chemistry. What’s more, the base sheet can be designed to be single-, double-, or

triple-coated more precisely.Consider the sustainability implica-

tions of Eka Chemicals’ fourth genera-tion nanoparticle, anionic colloidal silica. The product has a high structure and sur-face area and is typically added after the screen. It dramatically reduces chemical addition because of its strong interaction with polymers and starch. As with the previous generations, this nanoparticle silica product is in and of itself a sustain-able chemistry: an inorganic colloidal mineral in water with no VOC impact and requiring very simple dosing equip-ment.

The true sustainability impact, howev-er, is on the paper or board process itself: even small amounts of this new product allow reductions in other, less sustainable additives, and provide new maximum levels of performance in retention and dewatering. In one case, production rate increased more than 10%, while sewer losses were reduced due to improved retention of fines and filler. In other cases, dramatic reductions in wet strength resin or retention polymer have been possible along with the productivity gains.

According to Eka Chemicals’ Zempel “When you combine these new additives with best-in-class injection technology like Wetend Technologies’ TrumpJet systems, you maximize their performance while also making huge impacts on water and energy savings. Using thin stock as the dilution medium reduces water con-sumption and also prevents the need to heat it to process temperature.”

Faster-dryingsheethasenergybonusIn addition to a reduction in raw materi-als costs, another benefit of increased

filler content is energy savings. Clay and carbonates dry much more easily and quickly than wet fibre.

The addition of filler can dramatically increase the drainage rate and the water removal rates during pressing and drying. With 20% filler addition, the drainage time often decreases by 20% compared to the unfilled paper. Energy gains are the inherent result. Indeed, in mill trials, 4 -5% starch encapsulated kaolin clay was shown to have no statistical impact on strength and slide angle, to provide faster drainage and drying, and to reduce steam demand by 10%.

SustainabilityasustainabletrendforpaperSustainability progress will continue to accelerate throughout the pulp, paper-making, converting and printing process-es, especially as alternative value-added solutions make “attainability” happen sooner and at lower overall costs.

In addition to its own goals regard-ing greenhouse gas reduction and water management, Eka Chemicals has a busi-ness goal of having 30% of revenue from eco-premium solutions by 2015. Eco-premium refers to those solutions which are superior to the mainstream com-petitive solution with respect to energy efficiency, use of natural resources, emis-sions, toxicity, waste, and land use.

Clearly, papermakers can expect more options in their pursuit of sustainability.

PPC

Martin Koepenick of Innova has written about the paper industry and innovations in technology for more than 25 years.. He can be reached at [email protected]

By having employees participate in Robert Swan’s Leadership on the Edge 2008 Antarctica expedition, AkzoNobel encouraged the company’s future leaders to act as real ambassadors for sustainability in their jobs and everyday life.

p 18-19 Environment story.indd 19 03/12/10 1:52 PM


PAPERWEEK PREVIEW


The new format for the Pulp and Paper Technical Associ-ation of Canada’s (PAPTAC) annual meeting and con-ference alternates business and technical sessions, with

plenty of opportunity to mix and mingle. Luncheons, coffee breaks and end-of-day receptions are arranged to give attendees time for the face-to-face discussions that are so important in our geographically-dispersed industry. Although the format of the meeting has changed from conference-plus-EXFOR® trade show to conference-plus-networking, the exchange of knowledge and camaraderie continue to be the core values of this annual event.

PaperWeek Canada 2011 runs from Feb. 1-3 at the Fair-mont Queen Elizabeth in Montreal.

For up-to-date details on the event, please visit www.paper-weekcanada.ca. What follows is a preliminary schedule (as of Nov. 30), and is subject to change.

Prior to the official opening of PaperWeek, on Monday, Jan. 31, there will be meetings of various industry groups plus the mill managers’ roundtable, an invitation-only event.

Opportunities to learn and conversePaperWeek’s first day is Tuesday, Feb. 1. The schedule is packed, so things get off to an early start with a welcome event at 7:30 a.m. and then the business session starting at 8:00 a.m. The first business track is presented by FPInnovations, and will focus on innovation. This is followed by concurrent technical sessions on mechanical pulping and research, as well as the first session of the Forest Biorefinery Symposium.

Following the conference luncheon, a business session pre-sented by KPMG runs until 3:30 p.m. The technical track then resumes with further sessions on research, bleaching and biore-fining. The day concludes with a cocktail reception.

Wednesday, Feb. 2, follows a similar format. A business session presented by Cascades will discuss the benefits of green marketing, followed by concurrent technical sessions on paper machine technology, environment, and biorefining. After lunch, the business topic is partnerships between industry, government and communities, presented by Natural Resources Canada. Technical topics on Wednesday afternoon are paper machine

technology, energy, and biorefining. A cocktail reception wraps up the day’s events.

Thursday is a half-day, opening with a session on energy conservation presented by Hydro Québec. Technical sessions will cover paper machine technology and process control. A luncheon will follow.

Biorefinery symposium draws on global knowledgeThe biorefining sessions at PaperWeek Canada are part of the International Forest Biorefinery Symposium organized by École Polytechnique in Montreal. The symposium will cover biorefining technologies, conversions of kraft pulp mills, energy and water integration and optimization, supply chain design, sustainability and energy efficiency, bioproducts, and markets.

Speakers and presenters at the poster session hail from Canada, U.S., Sweden, Finland, Iran, and India.

There will be two biorefining keynote speakers: M. Wellisch, research advisor, sustainable conversion of bioresources, Natu-ral Resources Canada, and T. Berntsson, a professor with the Department of Energy and Environment, Chalmers University of Technology, Sweden.

Montreal welcomes youThe Fairmont Queen Elizabeth Hotel is offering a special rate of $165/night to conference attendees. Please see the Paper-Week web site for details.

Registration fees for PaperWeek are $620 for PAPTAC members, and $900 for non-members, with discounted rates available to presenters, retired PAPTAC members, students, and representatives of PAPTAC supplier company members.

The registration fee grants access to all PAPTAC-sponsored events, including lunches and receptions.

As in the past, awards for research and technical papers and for service to the Canadian pulp and paper industry will be presented at the beginning of sessions and during PAPTAC’s annual general meeting.

Stay tuned to www.paperweekcanada.ca for the detailed PaperWeek program. PPC

PAPTAC Annual Meeting 2010

PaperWeek returns in 2011PAPTAC has expanded the scope of its annual meeting

to become a three-day conference and networking eventBy Cindy Macdonald, Editor

p 20 Paperweek preview.indd 20 03/12/10 2:08 PM

http://www.paper-weekcanada.ca



http://www.paperweekcanada.ca

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©2010 Buckman Laboratories International, Inc.

p 21 Buckman ad.indd 21 03/12/10 1:52 PM

http://www.buckman.com

PAPTAC ABSTRACTS


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

Whole Log Chipping of Mountain Pine Beetle Killed Wood for the Pulp and Paper IndustryBy B. Dalpke and P. Bicho

Déchiquetage de grumes entières détruites par le dendroctone du pin ponderosa destinées à l’industrie des pâtes et papiersAbstract: To alleviate the current chip supply shortage in the province of British Columbia, and to make use of mountain pine-beetle-killed wood that is unsuitable for lumber production, whole log chipping of heavily checked, grey-stage beetle-killed wood to provide an additional chip supply for the pulp and paper industry is explored. Chipping productivity, hog fuel and fibre recovery, and chip quality of a satellite chipping yard are evaluated. Whole log chipping of heavily checked grey-stage trees resulted in high ratios of pins and fines, but otherwise good quality chips. Kraft

and TMP pulps made from such whole log chips did not show any quality concerns. Heavily-checked, grey-stage mountain pine beetle-killed wood thus provides a suitable source of raw material for whole log chipping operations and the resulting chips can be used to supplement the chip feed of kraft and TMP mills.Paper presented at the PAPTAC Annual Meeting 2010 in Mon-treal, Que., February 2-3, 2010.Full manuscript available at www.paptac.ca.

The Impact of Wood Species on the Treatment of Brownstock with Hydrogen Peroxide By D. Davies, G. Pageau, H.U. Süss

Effets des essences de bois sur le traitement de la pâte brune avec du peroxyde d’hydrogène Abstract: The Howe Sound mill uses an ODEopDD sequence to produce fully bleached kraft pulp from northern softwood. Tests of ClO2 consumption by the liquid portion of the 3.5% consistency stock feeding the Do stage were generally under 10% of total Do stage usage but did reach that level on occasion. Hydrogen per-oxide (H2O2) was added to the bleach feed just minutes prior to ClO2 addition in the hopes of reducing overall bleaching cost. Key findings of the trial were that costs can indeed be reduced as long

as there is only trace ClO2 residual in the filtrate used for dilution and peroxide dosage is kept low enough to ensure it is completely consumed before ClO2 is added.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.

Refining of Long Fibre Fractions after FractionationBy Q. Zha, R. Lanouette, K.-N. Law, J.-P. Bousquet, S. Bussières

Raffinage des fractions de fibres longues après fractionnementAbstract: In this work, a primary-stage black spruce TMP was fractionated into long and short fibre fractions using two-stage screening. The long fraction (secondary reject) was further frac-tionated with a two-stage slotted screen to obtain earlywood and latewood enriched fractions. These fractions were refined to evalu-ate the efficiency of fractionation in order to improve the overall pulp quality. We observed that refining consistency, number of refining stages and the fraction itself inf luenced the refining behavior of the long fibre fractions. The latewood-enriched frac-tion had a better fibre development potential than the earlywood-

enriched fraction but it required higher energy consumption. Low consistency refining consumed less refining energy but it led to lower mechanical properties. Separate refining could reduce refin-ing energy and increase handsheet’s light scattering coefficient. Recombination of these refined fractions indicated that energy saving without too much strength loss is possible.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.

p 22-24 PAPTAC abstracts.indd 22 03/12/10 1:53 PM





PAPTAC ABSTRACTS

pulpandpapercanada.com November/December 2010 PULP & PAPER CANADA 23

Decontamination of Whitewater Fines by Laboratory-Scale FlotationM. Ricard, G. Dorris, C. Lapointe, N. Pagé, Y. Ben

Décontamination de fines d’eau blanche par flottation en laboratoireAbstract: To our knowledge, mills have not yet developed strate-gies to selectively remove contaminated or aged fines from the wet end of the machine. To alleviate some of the drawbacks associated with non-selective means of cleaning whitewater, we have explored the use of dispersed air f lotation. We carried out f lotation tests on nine process water samples that were obtained from six different mills producing various types of paper or board. We found that laboratory f lotation improved the quality of mill process water solids and increased the brightness of the handsheets made from whitewater fines by up to 2.4 units while reducing their extractives

and ink content by up to 59% and 48%, respectively. Flotation selectively removed the smallest and most contaminated solids from paper machine waters. Decontamination of whitewater by f lotation may lead to improved sheet properties, reduction in the use of papermaking and bleaching chemicals, improved paper machine runnability, and increased water system closure.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.

Understanding the Effect of Chemical Pretreatment on Properties of Aspen CTMPBy Z. Yuan, Y. Gao, K. Li

Effet du prétraitement chimique sur les propriétés de la pâte chimico-thermomécanique (PCTM) de trembleAbstract: In this study, the effect of sulfite and sodium hydroxide pretreatment on aspen CTMP fiber properties was examined in comparison with the impregnation with water only, aiming to understand how the impregnation chemicals affect fibre morphol-ogy and fibre surface chemistry and how these properties relate to fiber separation, refining, and pulp properties. Impregnation of wood chips with sulfite resulted in more long fibers, less fines and shives, and a higher brightness compared with impregnation of wood chips with water only. It is observed that sulphonated pulps have more middle lamella coated fibers after the first-stage

refining and more f lake-like fines than the pulp produced from water impregnation. This is mainly attributed to the difference in fiber separation. The pulp produced from water impregnation has a lower light scattering coefficient than the sulphonated pulp although the former has more fines.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.

Measuring Uniformity in Kraft Digesters Using Flow-Following SensorsBy E. Albadvi, T. C. M. Graham, E. Liu, M. Alaqqad, C. P. J. Bennington, R. J. Kerekes, M. Martinez, S. Mirabbasi

Détermination de l’uniformité du fonctionnement des lessiveurs kraft à l’aide de capteurs miniatures injectables dans la suspensionAbstract: Variability studies in kraft pulp digesters have been the subject of intense interest for many years. This paper reviews the various past approaches to measure this variability and then introduces a new method of its measurement: the SmartChip. This device measures and records the temperature directly within the digester as it f lows with the wood chips during the kraft cook. Multiple SmartChips deployed in a single cook will then provide insight on the temperature variability and heat transfer mechanisms occurring within the digester. Moreover, by taking pulp samples in the vicinity of the SmartChip sensors, correla-

tions between nonuniformity and temperature gradients can be established. The SmartChips have been tested in two laboratory batch digesters and as expected, little variability was observed in these small scale devices. These findings suggest that the Smart-Chip works well under the harsh conditions of the kraft cook and further work is warranted to develop the instrument for its use at the industrial scale.Paper presented at the 2010 PacWest Conference in Sun Peaks, B.C., June 9-12, 2010.Full manuscript available at www.paptac.ca.







PAPTAC ABSTRACTS


On-Line Measurement of Air Content in Pulp and Papermaking Systems. Part II: Applications to Defoamer Addition and to the Correction of a Consistency TransmitterBy G. Dorris, S. Gendron, N. Pagé, T. Murray, Y. Ben, H. Peters

Mesure en ligne de la teneur en air des systèmes de fabrication de pâtes et papiers. Partie II : utilisation lors de l’ajout d’anti-mousse et pour la correction d’un convertisseur de concentration Abstract: We have previously described the use of a pressure-based, on-line air content probe in various commercial f lotation cells used for the removal of ink and other hydrophobic con-taminants from recycled pulps. In this second report, other uses of the air content probe are described. For example, the probe was installed in the foam tank of a recycling mill to correct the signal of a microwave consistency transmitter. Without this correction, predicted consistencies of f lotation rejects were highly erroneous. We also describe how the air content measurement was successfully

used to automatically control defoamer addition in the foam tank of f lotation rejects. Finally, on-line measurement of air content in the vat of two kraft brownstock washers is shown to provide use-ful information on the effect of air on pulp drainage and washer effectiveness.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.

Automation of a Microcontaminants Deposition Tester Relating the Rate of Deposition to the Pressure Drop Across a CollectorBy G. Dorris and C. Castro

Automatisation d’un appareil d’essai de dépôts de contaminants indiquant la vitesse de dépôt lors de la chute de pression dans un collecteurAbstract: The importance of organic microcontaminants (i.e. pitch and microstickies) as contributors to deposition problems in paper machines is recognized but there is no consensus in the industry on a microcontaminants definition and on monitoring method. Rather than measuring the quantity of pitch/microstick-ies in pulp or whitewater samples, we previously described a means of monitoring their deposition rate in forming fabrics because this is one of the most common deposit locations in paper mills using recycled pulps. In this report, we describe the automation of this dynamic deposition test, whose key feature is the continuous mea-surement of pressure across a fabric rather than the measurement of deposited material. The sigmoid shape of the deposition curve is

explained by a change in f low regime as the pores of the fabric are progressively plugged. Capture of the P100 whitewater elements in the fabric is caused by a combination of overlapping phenomena such as surface pore deposition, pore bridging by fibrillar elements, and filtration of f lowing elements when the pores start to be con-stricted. To obtain a measurable rate of deposition, the presence of lypophilic extractives is required both on the surface of the fines and also in the water phase, as colloidal particles.Paper presented at 94th PAPTAC Annual Meeting in Montreal, February 5-7, 2008Full manuscript available at www.paptac.ca.


For up-to-date industry news visit







D.M. MARTINEZPulp and Paper Centre, University of British Columbia, Vancouver, B.C.

R. BEATSONDepartment of Chemical Science, British Columbia Institute of Technology, Burnaby, B.C.

T. KANGAbitibiBowater, Liverpool, N.S.Formerly Pulp and Paper Centre, University of British Columbia, Vancouver, B.C.

J.A. OLSONPulp and Paper Centre, University of British Columbia, Vancouver, B.C.

G. SOONGPulp and Paper Centre, Uni-versity of British Columbia, Vancouver, B.C.

X.F. CHANGDepartment of Chemical Science, British Columbia Institute of Technology, Burnaby, B.C.


ENERGYSAVINGS T82

Low Consistency Refining of Oxalic Acid Pretreated Wood ShavingsBy T. Kang, G. Soong, X.F. Chang, R. Beatson, J.A. Olson, and D.M. Martinez

Enzymes including cellulases, xylanase, pectinase, manganese peroxidise and proteinase have been used to pretreat wood chips prior to refining and decreased the refining energy [1, 15-19]. Oxalic acid is secreted by wood-decaying fungi [20], and has been shown to break down hemicellulose, resulting in a reduction in refining energy [21-22].

Although wood chips are the main feed mate-rial in HC thermomechanical pulp (TMP) refin-

echanical pulping of wood chips offers major advantages such as lower capital cost, higher yield and bet-ter paper properties, including light scattering coefficient, smoothness

and bulk. However, the high energy consumption and rising electrical energy costs associated with the process hinder its full utilization. This cur-rent situation has created a large demand for the development of more energy-efficient mechanical pulping processes and alternative raw materials for mechanical pulping.

Traditionally, the high consistency (HC), energy-intensive chip refiner has been used as a primary and/or secondary refiner, while the low consistency (LC) refiner is either not used or used as a third stage refiner or as a post refiner or, rarely, as a reject refiner. However, the LC refiner is gain-ing more attention because it consumes less energy than the high consistency refiner to achieve the same quality change in pulp [1-3]. Recent work has shown that energy reduction of up to 30% can be achieved by replacing the HC refiner with a LC refiner in the secondary refiner position [4-7].

Another way to reduce energy consumption is to modify the properties of the raw material. There have been many attempts using mechani-cal, chemical and biological pre-treatments on wood chips prior to refining. Compression of wood chips prior to refining was shown to improve chemical and enzyme penetration into wood chips and to reduce the energy consumption in refin-ing [8-10]. Chemical pretreatment such as alka-line peroxide pretreatment (APMP) [11-14] can reduce the refining energy by softening the lignin.

M

Abstract: The objective of this study was to evaluate the potential use of wood shavings as a raw material for the low consistency (LC) refining at the primary refining stage to significantly reduce electrical energy consumption. It was possible to produce wood shavings with longer fibre length than wood chips. Oxalic acid, followed by alkaline peroxide, was applied to both wood shavings and wood chips before LC refining. LC refined wood shavings were found to be a low energy raw material. The refining energy was reduced by about 33% using wood shavings compared to wood chips at a given freeness, and oxalic acid pretreatment of wood shavings further reduced the refining energy by approximately 57%. Tensile strength and brightness of LC refined wood shavings was found to be higher than high-consistency refined wood chips. Oxalic acid pretreatment further improved the tensile strength of LC refined wood shavings, but not the brightness. This study demonstrates the potential to develop a novel mechanical pulping process that produces high tensile, high brightness pulp with half the electrical energy consumption.

p 25-29 Kang tech paper.indd 25 03/12/10 1:54 PM


ENERGY SAVINGST83

of oxalic acid. After oxalic acid treatment, both chips and shavings were washed, chelated with DTPA (60 min at 60°C), washed and steamed. Subsequently, the samples were impregnated with 6% sodium hydroxide (NaOH), 4% hydrogen perox-ide (H2O2), 0.05% magnesium sulphate (MgSO4), 1% sodium silicate (Na2SiO3) and 0.5% DTPA for 60 min at 70°C at a consistency of 20%. The initial pH of the bleaching liquor was raised using NaOH to the range of 12-13 before the bleach-ing bag was sealed. The pretreated wood shavings and wood chips were then directly fed through a refiner. Figure 1 shows the experimental design for chemical pretreat-ment of wood chips and wood shavings.

RefiningA Sprout-Waldron 305 mm atmospher-ic single disc refiner (Koppers Co. Inc., Muncy, USA) equipped with D2A507 Ni Hard plates was used for all refining runs. Wood chips and wood shavings were separately refined at 18-21% consistency (referred to as HC refining), and the shav-ings were also refined at 4-6% consistency (referred to as LC refining). After refining, the pulp discharged from the refiner was neutralized with sulphuric acid (H2SO4).

obtained from Quesnel River Pulp, British Columbia, Canada, and were used for pro-ducing both wood chips and wood shav-ings. Wood shavings were produced using a metal lathe (Nardini-MS 1440E, Brazil) at a speed of 160 rpm as described earlier [24]. The thickness and width of wood shavings were about 3 mm and 20 mm respectively. Wood chips were produced using a chipper at the British Columbia Institute of Technology, Burnaby, Canada.

Chemical pretreatmentBoth wood chips and shavings were sepa-rately impregnated with 0.5% diethylene-triaminepentaacetic acid (DTPA) for 60 min at 60°C at a consistency of 10%. After washing, they were atmospherically steamed for 20 min, and then impregnated with either 0.04M or 0.08M oxalic acid/Na-oxalate solution buffered at pH 2.5 for 120 min at 90°C at a consistency of 10%. The control experiment used water instead

ing process, wood shavings can be mixed with chips or used solely for the same process [23-24]. When 100% wood shav-ings are used for TMP refining, the refin-ing energy can be reduced up to 25%, but fibre shortening is increased [24]. Industry planer wood shavings was investigated as a new energy-saving raw material for LC refining, but limited tensile strength devel-opment and fibre shortening was a major problem [24]. The shorter fibre length of the industry planer shavings can be over-come by tailor-made wood shavings [25].

This study examines the use of cus-tom made long-fibred wood shavings and oxalic acid pre-treatment to extract hemi-cellulose as a feed material to LC refining as a means of creating a novel, ultra low energy mechanical pulp.

EXPERIMENTALRaw materialLodgepole pine (Pinus contorta) logs were

(Na2SiO3) and 0.5% DTPA for 60 min at 70ºC at a consistency of 20%. The initial pH of the bleaching liquor was raised using NaOH to the range of 12-13 before the bleaching bag was sealed. The pretreated wood shavings and wood chips were then directly fed through a refiner. Fig.1 shows the experimental design for chemical pretreatment of wood chips and wood shavings.

Alkaline peroxide

(NaOH, H2O2,

MgSO4, Na2SiO3

& DTPA): 60 min/70°C

pH:12-13

AtmosphericRefining

Oxalic acid120 min/90°C 0.08M, pH:2.5

Wood chips

Wood Shavings

Water120 min/90°C

Water120 min/90°C


Chelation

Washing

Steaming

Wood chips18-21% consistency

(HCR)

Wood shavings4-6% consistency

(LCR)

Washing

Chelation

Washing

SteamingOxalic acid120 min/90°C 0.08M, pH:2.5

Figure 1. Experimental design for chemical pretreatment of wood chips and wood shavings. Refining A Sprout-Waldron 305 mm atmospheric single disc refiner (Koppers Co. Inc., Muncy, USA) equipped with D2A507 Ni Hard plates was used for all refining runs. Wood chips and wood shavings were separately refined at 18-21% consistency (referred to as HC refining), and the shavings were also refined at 4-6% consistency (referred to as LC refining). After refining, the pulp discharged from the refiner was neutralized with sulphuric acid (H2SO4). Measurements The pulps were hot disintegrated (TAPPI T262) and screened (TAPPI T275) on a Somerville screen (0.15 mm slots) before pulp testing. All pulp and paper samples were tested according to TAPPI standards (CSF: TAPPI T227, fibre length by Bauer-McNett classifier: TAPPI T233, bulk: TAPPI T411, tensile strength: TAPPI T494, ISO brightness: TAPPI T525). Fibre length was measured using the fibre quality analyzer (FQA, OpTest Equipment, Hawkesbury, Canada) according to TAPPI standard method T271. To measure fibre length of wood chip or shavings, chopped wood chips or shavings were boiled with 5 ml of deionized water, 5 ml of 30% H2O2 and 5 ml of glacial acetic acid for about 90 min. The pulp was washed with tap water and then the fines removed using a 200 mesh screen in a Britt Jar according to TAPPI T261. The fibres are then ready for FQA analysis. RESULTS AND DISCUSSION In the previous study (25), the initial fibre length of industry planer wood shavings was much shorter than that from wood chips. This problem can be solved using a specially designed knife in the shaving process (24, 26). The energy consumption for producing wood shavings was found to be as low as 5 kWh/t while that for wood chips is in the range between 15‐25 kWh/t (26). Fig. 2 shows wood shavings and wood chips used in the study. The fibre length of wood shavings was 2.51 mm while that of wood chips was 2.21 mm.

Figure 2. Photos of wood shavings (top) and wood chips (bottom). Although the longer initial fibre length is shown for wood shavings, fibre length of wood shavings decreases more than wood chips as a function of refining. This is shown in Fig.3. Oxalic acid pretreatment further decreases the fibre length.

0

0.5

1

1.5

2

2.5

3

0 1000 2000 3000 4000

Net refining energy, kWh/t

Fibr

e le

ngth

, mm

ChipsChips/0.08M OAShavingsShavings/0.04M OAShavings/0.08M OA

Figure 3. Fibre length as a function of refining energy.

Fig. 4 shows the decrease in freeness with refining for both wood chips and wood shavings. For the control without oxalic acid pretreament, more refining energy is required for wood chips to reach the similar freeness level. For instance, 3171 kWh/t of refining energy for wood chips is required to reach 100 ml CSF, while only 2112 kWh/t of refining energy for

Fig. 1. Experimental design for chemical pretreatment of wood chips and wood shavings.


Alkaline peroxide

(NaOH, H2O2,

MgSO4, Na2SiO3


pH:12-13

AtmosphericRefining


Wood chips

Wood Shavings

Water120 min/90°C

Water120 min/90°C


Chelation

Washing

Steaming


(HCR)


(LCR)

Washing

Chelation

Washing




0

0.5

1

1.5

2

2.5

3

0 1000 2000 3000 4000


Fibr

e le

ngth

, mm




Fig. 3. Fibre length as a function of refining energy.


Alkaline peroxide

(NaOH, H2O2,

MgSO4, Na2SiO3


pH:12-13

AtmosphericRefining


Wood chips

Wood Shavings

Water120 min/90°C

Water120 min/90°C


Chelation

Washing

Steaming


(HCR)


(LCR)

Washing

Chelation

Washing




0

0.5

1

1.5

2

2.5

3

0 1000 2000 3000 4000


Fibr

e le

ngth

, mm




Fig. 2. Photos of wood shavings (top) and wood chips (bottom).



PEERREVIEWED T84

RESULTSANDDISCUSSIONIn the previous study [25], the initial fibre length of industry planer wood shavings was much shorter than that from wood chips. This problem can be solved using a specially designed knife in the shaving process [24, 26]. The energy consumption for producing wood shavings was found to be as low as 5 kWh/t while that for wood chips is in the range between 15-25 kWh/t [26]. Fig. 2 shows wood shavings and wood chips used in the study. The fibre

(FQA, OpTest Equipment, Hawkesbury, Canada) according to TAPPI standard method T271. To measure fibre length of wood chip or shavings, chopped wood chips or shavings were boiled with 5 ml of deionized water, 5 ml of 30% H2O2 and 5 ml of glacial acetic acid for about 90 min. The pulp was washed with tap water and then the fines removed using a 200 mesh screen in a Britt Jar according to TAPPI T261. The fibres are then ready for FQA analysis.

MeasurementsThe pulps were hot disintegrated (TAP-PI T262) and screened (TAPPI T275) on a Somerville screen (0.15 mm slots) before pulp testing. All pulp and paper samples were tested according to TAP-PI standards (CSF: TAPPI T227, fibre length by Bauer-McNett classifier: TAP-PI T233, bulk: TAPPI T411, tensile strength: TAPPI T494, ISO brightness: TAPPI T525). Fibre length was mea-sured using the fibre quality analyzer

Raw Oxalicacid Refining Refining CSF Bulk BauerMcNettfractionsmaterial Pretreatment Consistency energy R48 R200 P200 (%) (kWh/t) (ml) (cm3/g) (%) (%) (%)

Wood – 21 1646 268 2.4 58.8 18.8 22.5chips 2242 159 2.2 57.9 18.5 23.7 2759 122 2.1 51.8 19.5 28.7 3171 100 2.0 50.3 20.1 29.7Wood 0.08 M 18 1522 271 2.7 59.9 17.6 22.5chips pH 2.5 1994 169 2.4 57.8 20.7 21.5 2221 68 2.0 53.1 18.6 28.3 2683 67 2.0 51.8 19.6 28.6Wood – 6 593 644 3.7 76.4 12.5 11.2shavings 1134 412 3.0 64.9 17.4 17.8 1533 166 2.3 60.2 20.0 19.8 2112 67 2.0 52.2 23.6 24.2Wood 0.04 M 5 545 482 3.1 68.2 17.6 14.2shavings pH 2.5 1017 357 2.7 62.7 18.6 18.7 1375 101 2.1 54.8 24.5 20.7 1628 71 2.0 52.1 26.3 21.7Wood 0.08 M 5 906 563 3.2 74.1 13.9 12.0shavings pH 2.5 1546 138 2.2 55.6 24.4 20.0 1877 74 2.1 48.2 29.0 22.9 2155 51 2.0 43.2 33.0 23.7

TABLE I. Pulp properties.

wood shavings is required for 67 ml CSF. This equates to about 33% reduction in refining energy. For oxalic acid pretreated wood chips and wood shavings, there is a further reduction in refining energy, except for treatment with 0.08M oxalic acid used in wood shavings. When comparing the control for wood chip at 100 ml CSF (3171 kWh/t) to wood shavings pretreated with 0.04 M oxalic acid at 101 ml CSF (1375 kWh/t), about 57% energy reduction can be achieved. The concentration of oxalic acid should be optimized to obtain the maximum freeness drop at a given refining energy.

0

100

200

300

400

500

600

700

0 1000 2000 3000 4000


CSF

, ml

Chips/ControlChips/0.08M OAShavings/ControlShavings/0.04M OAShavings/0.08M OA

Figure 4. Freeness as a function of refining energy. As refining continues for both wood shavings and wood chips, the bulk was reduced down to 2.0 cm3/g as shown in Table I. Lower refining energy is required for wood shavings than wood chips to reach the same bulk (2.0 cm3/g). In other words, a sheet made from wood shavings gives denser sheet structure than that from wood chips at a given refining energy. Thinner wood shavings allowed for better penetration of chemicals during the pretreatment stage than the thicker wood chips, which resulted in more flexible fibres for wood shavings at lower refining energy. The energy required both for wood shavings and wood chips at the same bulk can be reduced further by oxalic acid pretreatment, except for 0.08 M oxalic acid pretreatment used in wood shavings. For the control at about 2100-2200 kWh/t, slightly higher amount of long fraction (R48) is shown for wood chips relative to shavings, but their middle fraction (P48/R200) is slightly lower and the amount of fines fraction is similar. Oxalic pretreament (0.08M for both chips and shavings) decreases further the amount of the long fractions (R48).

TABLE I. PULP PROPERTIES.

Raw Oxalic acid Refining Refining

material Pretreatment Consistency energy R48 R200 P200(%) (kWh/t) (ml) (cm3/g) (%) (%) (%)

Wood - 21 1646 268 2.4 58.8 18.8 22.5chips 2242 159 2.2 57.9 18.5 23.7

2759 122 2.1 51.8 19.5 28.73171 100 2.0 50.3 20.1 29.7

Wood 0.08 M 18 1522 271 2.7 59.9 17.6 22.5chips pH 2.5 1994 169 2.4 57.8 20.7 21.5

2221 68 2.0 53.1 18.6 28.32683 67 2.0 51.8 19.6 28.6

Wood - 6 593 644 3.7 76.4 12.5 11.2shavings 1134 412 3.0 64.9 17.4 17.8

1533 166 2.3 60.2 20.0 19.82112 67 2.0 52.2 23.6 24.2

Wood 0.04 M 5 545 482 3.1 68.2 17.6 14.2shavings pH 2.5 1017 357 2.7 62.7 18.6 18.7

1375 101 2.1 54.8 24.5 20.71628 71 2.0 52.1 26.3 21.7


1877 74 2.1 48.2 29.0 22.92155 51 2.0 43.2 33.0 23.7

CSF Bulk Bauer McNett fractions

Fig. 5 shows the tensile strength development with refining. For the control, tensile strength of wood shavings is higher than wood chips at a given refining energy. Oxalic acid pretreatment (0.04M) further increases the tensile strength of both wood shavings and wood chips at a given refining energy. Although average fibre length was less for wood shavings with refining as shown in Fig.3, paper strength seems to be improved by better penetration of chemicals during the pretreatment stage. Tensile stiffness shows a similar trend as shown in Fig. 6. In the previous study using industry wood shavings and wood chips (25), the maximum obtainable tensile strength for LC refined shavings was lower than that of HC refined wood chips. This was a major limitation of using industry shavings in LC refining, but this can be improved both by utilizing custom generated wood shavings, oxalic acid and alkaline peroxide pretreatment.

10

20

30

40

50

60

70

0 1000 2000 3000 4000

Ten

sile

inde

x, N

m/g



Figure 5. Tensile strength as a function of refining energy. Error bars represent the 95% confidence interval.

Fig. 4. Freeness as a function of refining energy.

wood shavings is required for 67 ml CSF. This equates to about 33% reduction in refining energy. For oxalic acid pretreated wood chips and wood shavings, there is a further reduction in refining energy, except for treatment with 0.08M oxalic acid used in wood shavings. When comparing the control for wood chip at 100 ml CSF (3171 kWh/t) to wood shavings pretreated with 0.04 M oxalic acid at 101 ml CSF (1375 kWh/t), about 57% energy reduction can be achieved. The concentration of oxalic acid should be optimized to obtain the maximum freeness drop at a given refining energy.

0

100

200

300

400

500

600

700

0 1000 2000 3000 4000


CSF

, ml


Figure 4. Freeness as a function of refining energy. As refining continues for both wood shavings and wood chips, the bulk was reduced down to 2.0 cm3/g as shown in Table I. Lower refining energy is required for wood shavings than wood chips to reach the same bulk (2.0 cm3/g). In other words, a sheet made from wood shavings gives denser sheet structure than that from wood chips at a given refining energy. Thinner wood shavings allowed for better penetration of chemicals during the pretreatment stage than the thicker wood chips, which resulted in more flexible fibres for wood shavings at lower refining energy. The energy required both for wood shavings and wood chips at the same bulk can be reduced further by oxalic acid pretreatment, except for 0.08 M oxalic acid pretreatment used in wood shavings. For the control at about 2100-2200 kWh/t, slightly higher amount of long fraction (R48) is shown for wood chips relative to shavings, but their middle fraction (P48/R200) is slightly lower and the amount of fines fraction is similar. Oxalic pretreament (0.08M for both chips and shavings) decreases further the amount of the long fractions (R48).

TABLE I. PULP PROPERTIES.

Raw Oxalic acid Refining Refining

material Pretreatment Consistency energy R48 R200 P200(%) (kWh/t) (ml) (cm3/g) (%) (%) (%)

Wood - 21 1646 268 2.4 58.8 18.8 22.5chips 2242 159 2.2 57.9 18.5 23.7

2759 122 2.1 51.8 19.5 28.73171 100 2.0 50.3 20.1 29.7

Wood 0.08 M 18 1522 271 2.7 59.9 17.6 22.5chips pH 2.5 1994 169 2.4 57.8 20.7 21.5

2221 68 2.0 53.1 18.6 28.32683 67 2.0 51.8 19.6 28.6

Wood - 6 593 644 3.7 76.4 12.5 11.2shavings 1134 412 3.0 64.9 17.4 17.8

1533 166 2.3 60.2 20.0 19.82112 67 2.0 52.2 23.6 24.2


1375 101 2.1 54.8 24.5 20.71628 71 2.0 52.1 26.3 21.7


1877 74 2.1 48.2 29.0 22.92155 51 2.0 43.2 33.0 23.7

CSF Bulk Bauer McNett fractions

Fig. 5 shows the tensile strength development with refining. For the control, tensile strength of wood shavings is higher than wood chips at a given refining energy. Oxalic acid pretreatment (0.04M) further increases the tensile strength of both wood shavings and wood chips at a given refining energy. Although average fibre length was less for wood shavings with refining as shown in Fig.3, paper strength seems to be improved by better penetration of chemicals during the pretreatment stage. Tensile stiffness shows a similar trend as shown in Fig. 6. In the previous study using industry wood shavings and wood chips (25), the maximum obtainable tensile strength for LC refined shavings was lower than that of HC refined wood chips. This was a major limitation of using industry shavings in LC refining, but this can be improved both by utilizing custom generated wood shavings, oxalic acid and alkaline peroxide pretreatment.

10

20

30

40

50

60

70

0 1000 2000 3000 4000

Ten

sile

inde

x, N

m/g



Figure 5. Tensile strength as a function of refining energy. Error bars represent the 95% confidence interval.

Fig. 5. Tensile strength as a function of refining energy. Error bars represent the 95% confidence interval.



ENERGY SAVINGST85

and wood chips [25], the maximum obtain-able tensile strength for LC refined shavings was lower than that of HC refined wood chips. This was a major limitation of using industry shavings in LC refining, but this can be improved both by utilizing custom gener-ated wood shavings, oxalic acid and alkaline peroxide pretreatment.

Figure 7 shows the changes in ISO brightness of sheets as a function of refin-ing. For the control, brightness of the thinner wood shavings is much higher than wood chips. Alkaline peroxide penetrates into thinner wood shavings better than thicker wood chips. The same trend was observed in the previous study although the brightness is relatively lower in this study [25]. The alkaline peroxide bleaching in the previous study was done at about pH 11, and the present study was done at the pH 12-13. This may be the reason for the lower brightness in this study [27]. Oxalic acid pretreatment reduces brightness slightly for wood shavings, but it increases brightness for wood chips. For wood shavings, the highest brightness can be achieved even without oxalic acid pretreatment.

CONCLUSIONSThis study demonstrates the potential to develop a novel mechanical pulping process that produces high tensile, high brightness pulp with half the electrical energy.

Both wood chips and wood shavings produced in the laboratory were used as a feeding material in HC and LC refining processes, respectively. Fibre length of wood

reach the same bulk (2.0 cm3/g). In other words, a sheet made from wood shavings gives denser sheet structure than that from wood chips at a given refining energy. Thinner wood shavings allowed for bet-ter penetration of chemicals during the pretreatment stage than the thicker wood chips, which resulted in more flexible fibres for wood shavings at lower refin-ing energy. The energy required both for wood shavings and wood chips at the same bulk can be reduced further by oxalic acid pretreatment, except for 0.08 M oxalic acid pretreatment used in wood shavings.

For the control at about 2100-2200 kWh/t, slightly higher amount of long fraction (R48) is shown for wood chips relative to shavings, but their middle frac-tion (P48/R200) is slightly lower and the amount of fines fraction is similar. Oxalic pretreament (0.08M for both chips and shavings) decreases further the amount of the long fractions (R48).

Figure 5 shows the tensile strength devel-opment with refining. For the control, tensile strength of wood shavings is higher than wood chips at a given refining energy. Oxalic acid pretreatment (0.04M) further increases the tensile strength of both wood shavings and wood chips at a given refining energy. Although average fibre length was less for wood shavings with refining as shown in Fig. 3, paper strength seems to be improved by better penetration of chemicals during the pretreatment stage. Tensile stiffness shows a similar trend as shown in Fig. 6. In the previous study using industry wood shavings

length of wood shavings was 2.51 mm while that of wood chips was 2.21 mm.

Although the longer initial fibre length is shown for wood shavings, fibre length of wood shavings decreases more than wood chips as a function of refining. This is shown in Fig. 3. Oxalic acid pretreatment further decreases the fibre length.

Figure 4 shows the decrease in freeness with refining for both wood chips and wood shavings. For the control without oxalic acid pretreament, more refining energy is required for wood chips to reach the similar freeness level. For instance, 3171 kWh/t of refining energy for wood chips is required to reach 100 ml CSF, while only 2112 kWh/t of refining energy for wood shavings is required for 67 ml CSF. This equates to about 33% reduction in refining energy. For oxalic acid pretreat-ed wood chips and wood shavings, there is a further reduction in refining energy, except for treatment with 0.08M oxalic acid used in wood shavings. When com-paring the control for wood chip at 100 ml CSF (3171 kWh/t) to wood shavings pretreated with 0.04 M oxalic acid at 101 ml CSF (1375 kWh/t), about 57% energy reduction can be achieved. The concentra-tion of oxalic acid should be optimized to obtain the maximum freeness drop at a given refining energy.

As refining continues for both wood shavings and wood chips, the bulk was reduced down to 2.0 cm3/g as shown in Table I. Lower refining energy is required for wood shavings than wood chips to

0

2

4

6

8

0 1000 2000 3000 4000

Ten

sile

stif

fnes

s ind

ex, M

Nm

/kg


Chips/Control

Chips/0.08M OA

Shavings/Control

Shavings/0.04M OA

Shavings/0.08M OA

Figure 6. Tensile stiffness index as a function of refining energy. Fig. 7 shows the changes in ISO brightness of sheets as a function of refining. For the control, brightness of thinner thickness of wood shavings is much higher than wood chips. Alkaline peroxide penetrates into thinner wood shavings better than thicker wood chips. The same trend was observed in the previous study although the brightness is relatively lower in this study (25). The alkaline peroxide bleaching in the previous study was done at about pH 11, and the present study was done at the pH 12-13. This may be the reason for the lower brightness in this study (27). Oxalic acid pretreatment reduces brightness slightly for wood shavings, but it increases brightness for wood chips. For wood shavings, the highest brightness can be achieved even without oxalic acid pretreatment.

20

30

40

50

60

0 1000 2000 3000 4000


ISO

Bri

ghtn

ess,

%


Figure 7. ISO brightness as a function of refining energy.

CONCLUSIONS This study demonstrates the potential to develop a novel mechanical pulping process that produces high tensile, high brightness pulp with half the electrical energy. Both wood chips and wood shavings produced in the laboratory were used as a feeding material in HC and LC refining processes, respectively. Fibre length of wood shavings was longer than that of wood chips. As refining proceeded, fibre length of LC refined wood shavings was reduced more than that of HC refined wood chips. Oxalic acid pretreatment further reduced the fibre length of LC refined wood shavings. A great advantage of using wood shavings was found in reducing refining energy over wood chips. LC refined wood shavings reduced the refining energy about 33% compared to HC refined wood chips at a given freeness. Oxalic acid followed by alkaline peroxide pretreatment of wood shavings further reduced refining energy by approximately 57%. Tensile strength of LC refined wood shavings was much higher than HC refined wood chips at a given refining energy. Maximum obtainable tensile strength of LC refined wood shaving was also higher than HC refined wood chips. 0.04M oxalic acid pretreatment increased further the tensile strength of wood shavings with refining, while 0.08M oxalic acid did not seem to change their tensile strength. Brightness of LC refined wood shavings was found to be higher than HC refined wood shavings. Oxalic acid pretreatment improved the brightness of HC refined wood chips, but it decreased the brightness of LC refined wood shavings slightly. This study indicates that a longer fibre length of wood shavings can be produced using a specially designed knife in a metal lathe. These shavings can be used as a feed material for LC refining as a primary stage refiner in mechanical pulping. Since LC refining consumes much less energy than HC refining, wood shavings has a great potential to be a low energy raw material in mechanical pulping. Pre-deformed structure caused by the shavings process and the thinner thickness has a great advantage over thicker wood chips. This makes it easier to separate fibres from wood shavings during refining process, and for water or chemicals to penetrate into the thinner pre-deformed structure of wood shavings during the pretreatment stage. As a consequence, refining of wood shavings would result in more flexible fibres using lower energy refining energy. ACKNOWLEDGEMENTS This work was funded by the Natural Sciences and Engineering Research Council of Canada through the Collaborative Research and Development program and through the support of our partners BC Hydro, Paprican, Catalyst Papers, Howe Sound Pulp and Paper, West Fraser Quesnel River Pulp, Canfor, Andritz, Arkema, Honeywell, WestCan Engineering, Advanced Fiber Technologies, Ontario Power Authority and CEATI international.

Fig. 6. Tensile stiffness index as a function of refining energy.

0

2

4

6

8

0 1000 2000 3000 4000

Ten

sile

stif

fnes

s ind

ex, M

Nm

/kg


Chips/Control

Chips/0.08M OA

Shavings/Control

Shavings/0.04M OA

Shavings/0.08M OA

Figure 6. Tensile stiffness index as a function of refining energy. Fig. 7 shows the changes in ISO brightness of sheets as a function of refining. For the control, brightness of thinner thickness of wood shavings is much higher than wood chips. Alkaline peroxide penetrates into thinner wood shavings better than thicker wood chips. The same trend was observed in the previous study although the brightness is relatively lower in this study (25). The alkaline peroxide bleaching in the previous study was done at about pH 11, and the present study was done at the pH 12-13. This may be the reason for the lower brightness in this study (27). Oxalic acid pretreatment reduces brightness slightly for wood shavings, but it increases brightness for wood chips. For wood shavings, the highest brightness can be achieved even without oxalic acid pretreatment.

20

30

40

50

60

0 1000 2000 3000 4000


ISO

Bri

ghtn

ess,

%


Figure 7. ISO brightness as a function of refining energy.

CONCLUSIONS This study demonstrates the potential to develop a novel mechanical pulping process that produces high tensile, high brightness pulp with half the electrical energy. Both wood chips and wood shavings produced in the laboratory were used as a feeding material in HC and LC refining processes, respectively. Fibre length of wood shavings was longer than that of wood chips. As refining proceeded, fibre length of LC refined wood shavings was reduced more than that of HC refined wood chips. Oxalic acid pretreatment further reduced the fibre length of LC refined wood shavings. A great advantage of using wood shavings was found in reducing refining energy over wood chips. LC refined wood shavings reduced the refining energy about 33% compared to HC refined wood chips at a given freeness. Oxalic acid followed by alkaline peroxide pretreatment of wood shavings further reduced refining energy by approximately 57%. Tensile strength of LC refined wood shavings was much higher than HC refined wood chips at a given refining energy. Maximum obtainable tensile strength of LC refined wood shaving was also higher than HC refined wood chips. 0.04M oxalic acid pretreatment increased further the tensile strength of wood shavings with refining, while 0.08M oxalic acid did not seem to change their tensile strength. Brightness of LC refined wood shavings was found to be higher than HC refined wood shavings. Oxalic acid pretreatment improved the brightness of HC refined wood chips, but it decreased the brightness of LC refined wood shavings slightly. This study indicates that a longer fibre length of wood shavings can be produced using a specially designed knife in a metal lathe. These shavings can be used as a feed material for LC refining as a primary stage refiner in mechanical pulping. Since LC refining consumes much less energy than HC refining, wood shavings has a great potential to be a low energy raw material in mechanical pulping. Pre-deformed structure caused by the shavings process and the thinner thickness has a great advantage over thicker wood chips. This makes it easier to separate fibres from wood shavings during refining process, and for water or chemicals to penetrate into the thinner pre-deformed structure of wood shavings during the pretreatment stage. As a consequence, refining of wood shavings would result in more flexible fibres using lower energy refining energy. ACKNOWLEDGEMENTS This work was funded by the Natural Sciences and Engineering Research Council of Canada through the Collaborative Research and Development program and through the support of our partners BC Hydro, Paprican, Catalyst Papers, Howe Sound Pulp and Paper, West Fraser Quesnel River Pulp, Canfor, Andritz, Arkema, Honeywell, WestCan Engineering, Advanced Fiber Technologies, Ontario Power Authority and CEATI international. Fig. 7. ISO brightness as a function of refining energy.



PEERREVIEWED T86

12. YUAN, Z., HEITNER, C., MCGARRY, P., Evalu-ation of the APMP process for mature and juvenile lob-lolly pine, Tappi J. 5(7):24-32 (2006).13. BIAN, Y., NI, Y., YUAN, Z., HEITNER, C., BEAULIEU, S., Improving TMP rejects refining through alkaline peroxide pretreatment for value-added mechanical papers, Tappi J. 6(3):24-32 (2007).14. ZANUTTINI, M., MARZOCCHI, V. Alkaline che-mi-mechanical pulp from poplar. Relationship between chemical state, swelling and papermaking properties, Holzforschung. 57(5):489-459 (2003).15. MAIJALA, P., KLEEN, M., WESTIN, C., POP-PIUS-LEVLIN, K., HERRANEN, K., LEHTO, J.H., REPONEN, P., MÄENTAUSTA, O., METTÄLÄ, A., HATAKKA, A. Biomechanical pulping of softwood with enzymes and white-rot fungus Physisporinus rivulosus, Enzyme & Microbial Tech. 43(2):169-177 (2008).16. PETIT-CONIL, M., HODDENBAGH, J.M.A., MEYER, V., TOLAN, J. Can enzymes really be used to reduce chip refining energies? A study of xylanase pre-treatment of hardwood chips, Proc. Intl. Mech. Pulp. Conf., p. 71-77 (2005).17. MANSFIELD, S.D., WONG, K.K.Y., RICHARD-SON, J.D. Improvements in mechanical pulp processing with proteinase treatments, Appita J. 52(6):436-440 (1999).18. PENG, P., FERRITSIUS, R., ANGSAS, U., Meth-od of producing mechnical pulp and the mechani-cal pulp thus produced, US Patent, Publication No. US2005/0241785 A1 (2005).19. PERE, J., ELLMÉN, J., VIIKARI, L. Process for preparing mechanical pulp, US Patent, Publication No. US2007/0151683 A1 (2007).20. GREEN, F., LARSEN, M.J., WINANDY, J.E., HIGHLEY, T.L. Role of oxalic acid in incipient brown-rot decay, Material & Organism. 26(3):191-213 (1991).21. KENEALY, W., HORN, E., HOUTMAN, C. Vapor-phase diethyl oxalate pretreatment of wood chips: Part 1. Energy savings and improved pulps, Holzforsc-hung. 61(3):223-229 (2007).22. MEYER-PINSON, V., RUEL, K., GAUDARD, F., VALTAT, G., PETIT-CONIL, M., KUREK, B. Oxalic acid: a microbial metabolite of interest for the pulping industry, C.R.Biologies. 327(9-10):917-925 (2004).23. LEASK, R.A. A potential use of a wider range of raw material in thermomechanical pulping, Tappi J. 60(12):82-87 (1977).24. VIFORR, S., SALMÉN, L. From wood shavings to mechanical pulp- a new raw material?, Nord. Pulp Paper Res. J. 20(4):418-422 (2005). 25. KANG, T., SOONG, G., OLSON, J.A., MARTI-NEZ, D.M. Low consistency refining of wood shavings, Proc. Intl. Mech. Pulp. Conf., p. 317-321 (2009).26. HEDBLOM-HUE, S., MALM, Å, SALMÉN, L. Shear cut chips for mechanical pulping with lower energy demand, Proc. Intl. Mech. Pulp. Conf., p. 143-148 (2001).27. MOLDENIUS, S., The effects of peroxide bleaching on the strength and surface properties of mechanical pulp-ing, J. Pulp Pap. Sci. 10(6):172-177 (1984).

and Development program and through the support of our partners BC Hydro, Paprican, Catalyst Papers, Howe Sound Pulp and Paper, West Fraser Quesnel River Pulp, Canfor, Andritz, Arkema, Honeywell, WestCan Engineering, Advanced Fiber Technologies, Ontario Power Authority and CEATI international.

LITERATURE1. MUSSELMAN, R., LETARTE, D., SIMARD, R., LACHANCE, C. Third stage low consistency refining of TMP for newprint/directory grades, Proc. Appita Conf., p.363-368 (1996). 2. MUENSTER, H., FERRITSIUS, O., LECOURT, M., PETIT-CONIL, M. Energy savings in TMP by high temperature LC/MC refining, Proc. Intl. Mech. Pulp. Conf., p.213-223 (2005).3. SABOURIN, M., Minimizing TMP energy consump-tion using a combination of chip pre-treatment, RTS and multiple stage low consistency refining, Proc. Intl. Mech. Pulp. Conf., CD-ROM (2007).4. HAMMAR, L-Å., HTUN, M., SVENSSON, B. A two-stage refining process to save energy for mechanical pulps, Proc. Intl. Mech. Pulp. Conf., p. 257-262 (1997).5. XU, E.C., KOEFLER, H., ANTENSTEINER, P. Some latest developments in alkali peroxide mechanical pulping, Part 2: Low consistency secondary refining, Pulp Paper Can. 104(10):47-51 (2003).6. ERIKSEN, O., HAMMAR, L-Å. Refining mecha-nisms and development of TMP properties in a low-consistency refiner, Proc. Intl. Mech. Pulp. Conf., p. 62-75 (2007).7. HAMMAR, L-Å., SALMÉN, L., SANDBERG, C., SUNDSTRÖM, L. The effect of process conditions on pulp quality development at low consistency refining of mechanical pulp – TMP, Proc. Intl. Mech. Pulp. Conf., p.182-185 (2009).8. FRAZIER, W.C., WILLIAMS, G.J. Reduction of specific energy in mechanical pulping by axial precompres-sion of wood, Pulp Paper Can. 83(6):87-92 (1982).9. GORSKI, D., ENGSTRAND, P., HILL, J., JOHANSSON, L. Review: Reduction of energy con-sumption in refining through mechanical pretreatment of wood chips, Proc. Intl. Mech. Pulp. Conf., p. 17-21 (2009).10. HART, P.W., WAITE, D.M., THIBAULT, L., TOMASHEK, J., ROUSSEAU, M-E., HILL, C., SABOURIN, M.J. Selective enzyme impregnation of chips to reduce specific refining energy in alkaline perox-ide mechanical pulping, Holzforschung. 63(4):418-423 (2009).11. BOHN, W., SFERRAZZA, M. Alkaline peroxide mechanical pulping, a revolution in mechanical pulping, Proc. Intl. Mech. Pulp. Conf., p. 184-200 (1989).

shavings was longer than that of wood chips. As refining proceeded, fibre length of LC refined wood shavings was reduced more than that of HC refined wood chips. Oxalic acid pretreatment further reduced the fibre length of LC refined wood shav-ings. A great advantage of using wood shavings was found in reducing refining energy over wood chips. LC refined wood shavings reduced the refining energy about 33% compared to HC refined wood chips at a given freeness. Oxalic acid followed by alkaline peroxide pretreatment of wood shavings further reduced refining energy by approximately 57%.

Tensile strength of LC refined wood shavings was much higher than HC refined wood chips at a given refining energy. Maximum obtainable tensile strength of LC refined wood shaving was also higher than HC refined wood chips. 0.04M oxalic acid pretreatment increased further the tensile strength of wood shavings with refining, while 0.08M oxalic acid did not seem to change their tensile strength.

Brightness of LC refined wood shav-ings was found to be higher than HC refined wood shavings. Oxalic acid pre-treatment improved the brightness of HC refined wood chips, but it decreased the brightness of LC refined wood shavings slightly.

This study indicates that a longer fibre length of wood shavings can be produced using a specially designed knife in a metal lathe. These shavings can be used as a feed material for LC refining as a primary stage refiner in mechanical pulping. Since LC refining consumes much less energy than HC refining, wood shavings has a great potential to be a low energy raw material in mechanical pulping. Pre-deformed struc-ture caused by the shavings process and the thinner thickness has a great advantage over thicker wood chips. This makes it easier to separate fibres from wood shav-ings during refining process, and for water or chemicals to penetrate into the thinner pre-deformed structure of wood shavings during the pretreatment stage. As a con-sequence, refining of wood shavings would result in more flexible fibres using lower energy refining energy.

ACKNOWLEDGEMENTSThis work was funded by the Natural Sci-ences and Engineering Research Council of Canada through the Collaborative Research

Reference: Kang, T., Soong, G., Chang, X.F., Beatson, R., Olson, J.A., Martinez, D.M. Low Con-sistency Refining of Oxalic Acid Pretreated Wood Shavings, Pulp & Paper Canada 111(6):T82-T86 (Nov./Dec. 2010). Paper presented at PacWest Conference, 9-12 June 2010, Sun Peaks, B.C. Not to be reproduced without permission of PAPTAC. Manuscript received Jan. 1, 2010.

Résumé: La présente étude porte sur la possibilité d’utiliser des rognures de bois comme matière première pour le raffinage basse concentration (BC) à la première étape de raffinage, afin de réduire considérablement la consommation d’énergie électrique. Il a été possible de produire des rognures de bois dotées de fibres plus longues que les copeaux de bois. Nous avons appliqué de l’acide oxalique, puis du peroxyde alcalin, tant aux rognures qu’aux copeaux avant le raffinage basse concentration. Nous avons constaté que les rognures de bois après raffinage basse concentration étaient une matière première à faible consommation d’énergie. Comparative-ment à l’énergie consommée par les copeaux de bois, celle utilisée pour le raffinage a été réduite d’environ 33 % lorsque nous avons utilisé des rognures de bois à un indice d’égouttage donné, et le prétraitement des rognures avec de l’acide oxalique a encore réduit d’environ 57 % l’énergie de raffinage requise. La résistance à la traction et la blancheur de la pâte de rognures raffinées à basse concentration étaient plus élevées que celles de la pâte de copeaux de bois après raf-finage à haute concentration. Le prétraitement à l’acide oxalique a aussi amélioré davantage la résistance à la traction de la pâte de rognures de bois raffinées à basse concentration, mais non la blancheur. La présente étude démontre qu’il est possible de développer un nouveau procédé de mise en pâte mécanique qui produit des pâtes à forte résistance à la traction et à blancheur élevée, et qui exige la moitié moins d’énergie électrique.


J. BACKSTRÖM,Honeywell Process Solutions, North Vancouver, BC

R. MACHATTIE,Honeywell Process Solutions, North Vancouver, BC

S. CHU,Honeywell Process Solutions, North Vancouver, BC


TISSUET87

Multivariable Control and Energy Optimization of Tissue MachinesBy S. Chu, R. MacHattie and J. Backström

(located after TAD2) measuring TAD Moisture are the on-line measurements available. Before the optimization trials, the machine direction (MD) controls were multivariable but only Stock Flow and TAD2 exhaust temperature were used in cascade control. The setpoints for the rest of the manipu-lated variables (MVs) were fixed based on operator experience and previous operating conditions.

A new multivariable control strategy was devised to take advantage of the economic optimization layer in the multivariable MPC. The control strat-egy was based on customer requirements, a benefit analysis of MPC MD controls [3], and a case study that was published [2]. Several new MVs were add-ed to the control strategy with process upper and lower limits. The MVs added were TAD1 Supply Temperature (TAD1 Supply Temp), TAD1 dry end differential pressure (TAD1 DE DP), TAD1 gap pressure (TAD1 Gap Pres), TAD2 dry end differential pressure (TAD2 DE DP) and TAD2 gap pressure (TAD2 Gap Pres). Furthermore, Machine Speed and Tickler Refiner were added as disturbance variables (DVs) to the control strategy. These provide feedforward information to MVs such that disturbances will be minimized before their impact on the controlled variables (CVs) is measured. Figure 1 shows the relative locations of the MVs and CVs and Fig. 2 shows the control matrix. Bump tests were performed to determine the transfer functions between the MVs and CVs.

EXPRESS MOISTURE MEASUREMENT - TAD MEASUREMENTFor moisture, traditional tissue machine MD controls almost always include controlling the

raditional and through-air dried (TAD) tissue manufacturing expends more resources removing water than any other function. Knowing the water content throughout the process and the

efficiencies of the various water removal elements used, allows an advanced control system to control the process in the most economical manner.

The studied paper machine was equipped with an ExPress Moisture scanner measurement [1] before the Yankee dryer in addition to the mea-surements of a traditional reel scanner. With these measurements along with advanced multivariable control, the economic efficiencies of each drying element and the optimization layer, it was shown that the advanced control system distributed the drying load such that significant economic benefits were realized.

Several trials were run with different energy costs. It is given that energy costs change with time, so the cost of energy is updated in the advanced control system periodically, which can have a big impact on how the tissue machine is optimized. In all trials, the more expensive manipulated variables (MVs) were driven down to their lower operating cost limits and the cheaper MVs were driven to their higher operating cost limits. Significant energy cost savings were realized without sacrificing paper quality and machine runability.

MACHINE OVERVIEWThe paper machine studied uses two TADs and a Yankee dryer to dewater the tissue (Fig. 1). A tradi-tional reel scanner measuring Dry Weight and Reel Moisture along with an ExPress Moisture scanner

T

Abstract: The desire to increase profits by minimizing operating costs without sacrificing paper quality and runnability is a goal all papermakers strive for. Modern tissue machines are typically equipped with more than twenty low-level control loops and multiple sheet property measurements at various locations along the machine. It is a large and strongly coupled process that can be difficult for control engineers to optimize with-out advanced multivariable control techniques. This paper examines the process interactions and energy cost reductions using model predictive control (MPC) technology with an optimization layer that automatically drives the process towards the lowest cost while honoring hard process and quality constraints. The studied paper machine was equipped with a fast scanning moisture measurement before the Yankee dryer in addition to the measurements of a traditional reel scanner.

p 30-34 Chu tech paper.indd 30 03/12/10 1:58 PM


PEERREVIEWED T88

where are the linear objective coeffi-cients for the MVs representing the energy cost per engineering unit of the MVs.

Bump tests were performed to deter-mine the linear objective coefficients for each MV used in the Optimizer. Table I shows the linear objective coefficients for the MVs used in the Profit multivariable MPC with the optimization layer.

LINEAROBJECTIVECOEFFICIENTSThe linear objective coefficients are param-eters in the objective function of the opti-mization layer. The general form of the objective function is eq. 1:

Minimize J = ∑j

bj × MVj (1)

reel moisture only (i.e. the final product moisture). However, the final moisture is controlled by many elements far up the machine where the moisture levels are different, and there are drying elements between those locations and the reel that can further change the moisture [4]. The various drying elements that can manipu-late moisture also have varying efficiencies and costs. These costs change with time.

It has long been understood that better control will lead to better quality and cost performance and this can be achieved by measuring the moisture further up the machine, but this has not been practi-cal, until recently [5]. With the ExPress Moisture scanner located after TAD2, moisture can now be measured upstream of the reel and closer to the critical drying elements. Combining this new direct moisture measurement with the reel moisture measurement via the Profit multivariable MPC along with the eco-nomic efficiencies of these various dry-ing elements then makes it possible to truly optimize the energy consumption of the machine, since the control has direct feedback of process changes and true moisture levels going into various machine sections. As the cost of dif-ferent energy forms change, the Profit controller with the optimization layer will automatically adjust and attain the lowest possible operating cost while maintaining the product quality.

TADREGULATORYCONTROLLOOPSEach TAD has several regulatory control loops that can affect TAD Moisture and Reel Moisture. The regulatory control loops have different efficiencies and costs because of the various forms of energy that each consumes. The temperature control loops consume natural gas and the pressure control loops consume electricity.

By adding the temperature and pres-sure loops in the control strategy along with associating costs and defining upper and lower limits with each loop, the Profit multivariable MPC with the eco-nomic optimization layer can distribute the drying load in the TADs to mini-mize costs while not upsetting quality (i.e. maintaining TAD Moisture and Reel Moisture).

Table I shows the TAD loops that affect the TAD Moisture and Reel Moisture.

Figure 1: Paper Machine Overview with Profit Multivariable MPC

Stock Flow

TAD1 Supply Temp

TAD1 DE DP

TAD1 Gap Pres

TAD2 Exh Temp

TAD2 DE DP

TAD2 Gap Pres

Yankee Hood Temp

Yankee Supply

Fan Speed

Machine Speed

Stock Flow

TAD1 Gap

Pressure

Tickler Refiner

Dry Weight

Reel Moisture

TAD Moisture

TAD1 Exhaust Pressure

Figure 2: Profit Multivariable MPC Control Matrix

It has long been understood that better control will lead to better quality and cost performance and this can be achieved by measuring the moisture further up the machine, but this has not been practical, until recently [5]. With the ExPress Moisture scanner located after TAD2, moisture can now be measured upstream of the reel and closer to the critical drying elements. Combining this new direct moisture measurement with the reel moisture measurement via the Profit multivariable MPC along with the economic efficiencies of these various drying elements then makes it possible to truly optimize the energy consumption of the machine, since the control has direct feedback of process changes and true

EXPRESS MOISTURE MEASUREMENT – TAD MEASUREMENT For moisture, traditional tissue machine MD controls almost always include controlling the reel moisture only (i.e. the final product moisture). However, the final moisture is controlled by many elements far up the machine where the moisture levels are different, and there are drying elements between those locations and the reel that can further change the moisture [4]. The various drying elements that can manipulate moisture also have varying efficiencies and costs. These costs change with time.

2

FIG. 1. Paper machine overview with Profit multivariable MPC.

Figure 1: Paper Machine Overview with Profit Multivariable MPC

Stock Flow

TAD1 Supply Temp

TAD1 DE DP

TAD1 Gap Pres

TAD2 Exh Temp

TAD2 DE DP

TAD2 Gap Pres

Yankee Hood Temp

Yankee Supply

Fan Speed

Machine Speed

Stock Flow

TAD1 Gap

Pressure

Tickler Refiner

Dry Weight

Reel Moisture

TAD Moisture

TAD1 Exhaust Pressure

Figure 2: Profit Multivariable MPC Control Matrix

It has long been understood that better control will lead to better quality and cost performance and this can be achieved by measuring the moisture further up the machine, but this has not been practical, until recently [5]. With the ExPress Moisture scanner located after TAD2, moisture can now be measured upstream of the reel and closer to the critical drying elements. Combining this new direct moisture measurement with the reel moisture measurement via the Profit multivariable MPC along with the economic efficiencies of these various drying elements then makes it possible to truly optimize the energy consumption of the machine, since the control has direct feedback of process changes and true

EXPRESS MOISTURE MEASUREMENT – TAD MEASUREMENT For moisture, traditional tissue machine MD controls almost always include controlling the reel moisture only (i.e. the final product moisture). However, the final moisture is controlled by many elements far up the machine where the moisture levels are different, and there are drying elements between those locations and the reel that can further change the moisture [4]. The various drying elements that can manipulate moisture also have varying efficiencies and costs. These costs change with time.

2

FIG. 2. Profit multivariable MPC control matrix.

MV EnergyFuel Units LinearObjCoefCost/EngUnit

TAD1 Supply Temp Gas deg F 0.680TAD1 DE DP Electricity Inch H2O 47.267TAD1 Gap Pres Electricity Inch H2O -0.030TAD2 Exh Temp Gas Deg F 5.858TAD2 DE DP Electricity Inch H2O 40.249TAD2 Gap Pres Electricity Inch H2O -16.415

MV EnergyFuel Units LinearObjCoefCost/EngUnit

TAD1 Supply Temp Gas deg F 0.680TAD1 DE DP Electricity Inch H2O 47.267TAD1 Gap Pres Electricity Inch H2O -0.030TAD2 Exh Temp Gas Deg F 5.858TAD2 DE DP Electricity Inch H2O 40.249TAD2 Gap Pres Electricity Inch H2O -16.415

TABLE I. TAD Regulatory Loops with Linear Objective Coefficients



TISSUET89

�o�TAD2�Exh�Temp�(rank�1)�is�driven�to� its� lowest� cost� operating� limit� (175�deg�F).�See�Fig.�6.�o�TAD2�DE�DP�(rank�2)�is�driven�to�its�lowest�cost�operating�limit�(1.0�inch�H2O).�See�Fig.�6.�o� To� keep� the� TAD1� Moisture� the�same,� TAD1� Sup� Temp� (rank� 4),�TAD2�Gap�Pres� (rank�5)�and�TAD1�Gap� Pres� (rank� 6)� are� driven� to� their�maximum� operating� limits� (450� deg�F,�0.2�and�0.4�inch�H2O�respectively).�These�are�the�low�cost�MVs.�See�Figs.�5�and�6.�

The�trial�sequence�was�as�follows:-� Baseline� data� was� collected� between�8:30�-�9:30.

o� 100.0� relative� cost� units� of� energy.�See�Fig.�4.

-� Attempted� to� put� optimizer� on� con-trol�between�9:30� -�10:44.�Some�windup�errors�were� encountered�with� some�MVs�on� the� DCS� that� prevented� the� Profit�controller� from� optimizing.� This� caused�some�abnormal�behavior�and�hence�higher�energy�costs.-� 10:44� -� 12:30� -� all� windup� errors� were�cleared�and�optimizer�on

ECONOMIC OPTIMIZER - TRIAL 1A�trial�was�performed�with�the�economic�optimization�layer�turned�on�with�the�lin-ear� objective� coefficients� that� are� shown�in�Table�I.�To�rank�the�cost�of�each�MV,�the� linear� objective� coefficients� must� be�converted� to� a� relative� cost� in� common�units�of�Cost�/%�Moi.�This�can�be�accom-plished� by� taking� the� linear� objective�coefficients�and�dividing�by�their�respec-tive� process� gains.� Table� II� shows� each�MV� along� with� their� respective� linear�objective� coefficients,� process� gains� and�cost�rankings.

LinearObj Process Cost Coef Gain (Cost/% OptimizationMV EnergyUnit LowLimit HighLimit Cost/EngUnit (%Moi/EngUnit) Moi) Rank Behavior

TAD1 Supply Temp Deg F 300.0 450.0 0.68 -0.12 5.48 4 450 (max)TAD1 DE DP Inch H2O 1.0 3.9 47.30 -5.12 9.24 3 Controlling MoiTAD1 Gap Pres Inch H2O 0.4 1.5 -0.03 1.95 0.02 6 0.4 (max)TAD2 Exh Temp Deg F 175.0 250.0 5.86 -0.45 13.02 1 175 (min)TAD2 DE DP Inch H2O 1.0 3.5 40.26 -3.14 12.82 2 1 (min)TAD2 Gap Pres Inch H2O 0.2 1.5 -16.40 4.25 3.86 5 0.2 (max)

Table II. MV Cost Ranking - Trial 1.

Figure 3: TAD Natural Gas Costs and Electrical Costs- Trial 1

Figure 4. Total Costs – Trial 1

Figure 5: TAD1 Manipulated Variables – Trial 1


tem

Controlled Variables

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Figure 7: CVs undisturbed – Trial 1 ECONOMIC OPTIMIZER – TRIAL 2 Since the energy costs change with time, the cost of energy is updated in the control system periodically, which can have a big impact on how the machine is optimized. Trial 2 shows that even though different MVs were manipulated to minimize energy costs, all CVs remained undisturbed. Natural gas costs varied greatly in 2008. The peak of the natural gas cost was in the summer of 2008 and it was approximately double the cost in trial 1. Trial 2 was performed with the cost of natural gas at close to its peak. With the increased price of natural gas, the natural gas costs were higher than the electrical costs. This is reflected during this trial as natural gas usage decreased as electrical usage increased (Figure 8). Table 3 shows each MV along with their respective linear objective coefficients, process gains and cost rankings. As expected, TAD2 exhaust temperature and TAD1 supply temperature are ranked 1 and 2 respectively since both MVs consume natural gas. The trial sequence was as follows:

- Baseline data was collected between 3:00 – 3:24.

4

Fig. 3. TAD natural gas costs and electrical costs- Trial 1.





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Fig. 5. TAD1 manipulated variables - Trial 1.





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Fig. 4. Total costs - Trial 1.





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PEERREVIEWED T90

price of natural gas, the natural gas costs were higher than the electrical costs. This is reflected during this trial as natural gas usage decreased as electrical usage increased (Fig. 8). Table III shows each MV along with their respective linear objective coefficients, process gains and cost rankings. As expected, TAD2 exhaust temperature and TAD1 supply tempera-ture are ranked 1 and 2 respectively since both MVs consume natural gas.

The trial sequence was as follows:- Baseline data was collected between 3:00 - 3:24.

ECONOMICOPTIMIZER-TRIAL2Since the energy costs change with time, the cost of energy is updated in the control system periodically, which can have a big impact on how the machine is optimized. Trial 2 shows that even though different MVs were manipulated to minimize ener-gy costs, all CVs remained undisturbed.

Natural gas costs varied greatly in 2008. The peak of the natural gas cost was in the summer of 2008 and it was approximately double the cost in Trial 1. Trial 2 was performed with the cost of natural gas at close to its peak. With the increased

o TAD1 DE DP (rank 3) is within limits and controlling Reel Moisture and TAD Moisture. See Fig. 5.Throughout the trial (8:30 - 12:20) all

CVs (Reel Dry Weight, Reel Moisture and Express Moisture) were undisturbed, see Fig. 7.

98.8 relative cost units of energy is achieved while the Energy Optimizer is on, i.e. a 1.2% energy saving, see Fig. 4.

In this trial, the cost of natural gas is less than electricity. Natural gas usage increased and electricity usage decreased, see Fig. 3.

LinearObj Process Cost Coef Gain (Cost/% OptimizationMV EnergyUnit LowLimit HighLimit Cost/engunit (%Moi/engunit) Moi) Rank Behavior

TAD1 Supply Temp Deg F 300.0 450.0 1.41 -0.12 11.40 2 Controlling MoiTAD1 DE DP Inch H2O 1.0 3.7 55.64 -5.12 10.86 3 3.7 (max)TAD1 Gap Pres Inch H2O 0.4 1.5 -5.43 1.95 2.78 6 0.4 (max)TAD2 Exh Temp Deg F 175.0 250.0 10.40 -0.45 23.11 1 175 (min)TAD2 DE DP Inch H2O 1.0 2.9 28.01 -3.14 8.92 4 2.9 (max)TAD2 Gap Pres Inch H2O 0.2 1.5 -24.97 4.25 5.88 5 0.2 (max)

Table III. MV cost ranking - Trial 2.






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Fig. 7. CVs undisturbed - Trial 1.

o 100.0 relative cost units of energy. See Figure 9.

- The Optimizer was turned on at 3:25. Natural gas usage decreased and electrical usage increased. See Figure 8.

o Some sheet breaks and machine upsets were encountered during the trial between 3:35 – 4:25.

o Machine settles down to steady state conditions after 4:25.

o TAD2 Exh Temp (rank 1) is driven to its lowest cost operating limit (175 deg F). See Figure 11.

o To offset the low TAD2 Exh Temp (rank 1), TAD1 DE DP (rank 3), TAD2 DE DP (rank 4), TAD2 Gap Pres (rank 5), and TAD1 Gap Pres (rank 6) are driven to their maximum operating limits (3.7, 2.9, 0.2 and 0.4 inch H2O respectively) to help dry the sheet. These are the low cost MVs. See Figures 10 and 11.

o TAD1 Sup Temp (rank 2) is within its operating limits and therefore performing TAD Moisture and Reel Moisture control. See Figure 10.

Throughout the trial (3:00 – 5:00) all CVs (Reel Dry Weight, Reel Moisture and TAD Moisture) were undisturbed, see Figure 12. Total energy costs during steady state optimization (4:25 – 5:00) = 99.4 relative cost units of energy, see Figure 9. The energy cost reduction was 0.6%. Table 3: MV Cost Ranking – Trial 2

MV eng unit Low Limit High Limit

Linear Obj Coef

(Cost/eng unit)

ProcessGain

(%Moi/eng unit)

Cost(Cost/%

Moi) RankOptimization

BehaviorTAD1 Supply Temp deg F 300.0 450.0 1.41 -0.12 11.40 2 controlling MoiTAD1 DE DP inch H2O 1.0 3.7 55.64 -5.12 10.86 3 3.7 (max)TAD1 Gap Prs inch H2O 0.4 1.5 -5.43 1.95 2.78 6 0.4 (max)TAD2 Exh Temp deg F 175.0 250.0 10.40 -0.45 23.11 1TAD2 DE DP inch H2O 1.0 2.9 28.01 -3.14 8.92 4 2.9 (max)TAD2 Gap Prs inch H2O 0.2 1.5 -24.97 4.25 5.88 5 0.2 (max)

175 (min)

Figure 8: TAD Natural Gas Costs and Electrical Costs – Trial 2

Figure 9: Total Costs – Trial 2



5

Fig. 9. Total costs - Trial 2.










Linear Obj Coef

(Cost/eng unit)

ProcessGain

(%Moi/eng unit)

Cost(Cost/%



175 (min)





5

Fig. 8. TAD natural gas costs and electrical costs - Trial 2.










Linear Obj Coef

(Cost/eng unit)

ProcessGain

(%Moi/eng unit)

Cost(Cost/%



175 (min)





5




TISSUET91

LITERATURE1. F. HARAN, R. BESELT, R. MACHATTIE, Embedded High-speed Solid State Optic Sensor, Pulp & Paper Canada, 108:12, pp.57-60 (2007).2. J.U. BACKSTRÖM, P. BAKER, A Benefit Analysis of Model Predictive Machine Directional Control of Paper Machines, Proceedings from 2008 Control Sys-tems/Pan Pacific Conference, June 16-18, Vancouver, BC, Canada, pp. 197-202 (2008).3. S. CHU, Wet End Control Applications using a Mul-tivariable Model Predictive Control Strategy, Proceedings from PACWEST 2008, June 18-21, Jasper, AB, Canada, (2008).4. T. STEELE, R. MACHATTIE, A. PAAVOLA, B. VYSE, Tissue & Towel Quality Measurement & Control Advances, Presentation from Tissue World America 2008 Conference, March 11-14, Miami, FL (2008).5. P. BAKER, R. MACHATTIE, B. VYSE, Early Measurement and Control of Paper Machine Moisture, Proceedings from 2008 Control Systems/Pan Pacific Conference, June 16-18, Vancouver, BC, Canada, pp. 105-110 (2008).

the press and reel on tissue machines. This technology is well proven and reliable enough for continuous control, provid-ing positive results for producers globally. When combined with multivariable con-trol, it produces consistent drying along the length of the machine, increasing product quality and reducing manufactur-ing costs. With the addition of energy costs, the system is able to optimize the machine to stay within product quality requirements, while running at the lowest possible energy costs, balancing various energy forms and their associated costs as well as product quality. A 1.2% energy cost reduction was achieved with the energy optimization layer enabled.

o 100.0 relative cost units of energy. See Fig. 9.

- The Optimizer was turned on at 3:25. Natural gas usage decreased and electrical usage increased. See Fig. 8.

o Some sheet breaks and machine upsets were encountered during the trial between 3:35 - 4:25. o Machine settles down to steady state conditions after 4:25. o TAD2 Exh Temp (rank 1) is driven to its lowest cost operating limit (175 deg F). See Fig. 11. o To offset the low TAD2 Exh Temp (rank 1), TAD1 DE DP (rank 3), TAD2 DE DP (rank 4), TAD2 Gap Pres (rank 5), and TAD1 Gap Pres (rank 6) are driven to their maximum operating limits (3.7, 2.9, 0.2 and 0.4 inch H2O respectively) to help dry the sheet. These are the low cost MVs. See Figs. 10 and 11. o TAD1 Sup Temp (rank 2) is with-in its operating limits and therefore performing TAD Moisture and Reel Moisture control. See Fig. 10.Throughout the trial (3:00 - 5:00) all

CVs (Reel Dry Weight, Reel Moisture and TAD Moisture) were undisturbed, see Fig. 12.

Total energy costs during steady state optimization (4:25 - 5:00) = 99.4 relative cost units of energy, see Fig. 9. The energy cost reduction was 0.6%.

CONCLUSIONNew sensor technology now permits the placement of high precision moisture mea-surements at almost any location between










Linear Obj Coef

(Cost/eng unit)

ProcessGain

(%Moi/eng unit)

Cost(Cost/%



175 (min)





5


Figure 12: CVs undisturbed – Trial 2 CONCLUSION New sensor technology now permits the placement of high precision moisture measurements at almost any location between the press and reel on tissue machines. This technology is well proven and reliable enough for continuous control, providing positive results for producers globally. When combined with multivariable control, it produces consistent drying along the length of the machine, increasing product quality and reducing manufacturing costs. With the addition of energy costs, the system is able to optimize the machine to stay within product quality requirements, while running at the lowest possible energy costs, balancing various energy forms and their associated costs as well as product quality. A 1.2% energy cost reduction was achieved with the energy optimization layer enabled. REFERENCES [1] F. Haran, R. Beselt, R. MacHattie, “Embedded High-

speed Solid State Optic Sensor”, Pulp & Paper Canada, 108:12, pp.57-60 (2007).

[2] J. U. Backström, P. Baker, “A Benefit Analysis of Model Predictive Machine Directional Control of Paper Machines”, Proceedings from 2008 Control Systems/Pan Pacific Conference, June 16-18, Vancouver, BC, Canada, pp. 197-202 (2008).

[3] S. Chu, “Wet End Control Applications using a Multivariable Model Predictive Control Strategy”, Proceedings from PACWEST 2008, June 18-21, Jasper, AB, Canada, (2008).

[4] T. Steele, R. MacHattie, A. Paavola, B. Vyse, “Tissue & Towel Quality Measurement & Control Advances”, Presentation from Tissue World America 2008 Conference, March 11-14, Miami, FL (2008).

[5] P. Baker, R. MacHattie, B. Vyse, “Early Measurement and Control of Paper Machine Moisture”, Proceedings from 2008 Control Systems/Pan Pacific Conference, June 16-18, Vancouver, BC, Canada, pp. 105-110 (2008).

6

Fig. 12. CVs undisturbed - Trial 2.

Reference: CHU, S., MACHATTIE, R., BACKSTRÖM, J. Multivariable Control and Energy Optimization of Tissue Machines. Pulp & Paper Canada 111(6): T87-T91 (Nov/Dec 2010). Paper pre-sented at PacWest 2009, June 10-13, 2009 in Sun Peaks, B.C. and Control Systems 2010, Sept. 15-17, in Stockholm, Sweden. Not to be reproduced without permission of PAPTAC. Manuscript received January 01, 2009. Revised manuscript approved for publication by the Review Panel July 12, 2010.

Keywords: MULTIVARIABLE CONTROL; MODEL PREDICTIVE CONTROL (MPC) TECHNOLOGY; MACHINE DIRECTION (MD); CONTROL; ENERGY OPTIMIZATION; ECONOMIC OPTIMIZATION; TISSUE MACHINES; MAXIMIZING PROFIT; EXPRESS MOISTURE SENSOR; MOISTURE CONTROL; YANKEE DRYER CONTROL; THROUGH AIR DRYER (TAD) CONTROL.

Résumé: Les fabricants de papier visent tous à accroître leurs profits en réduisant les coûts d’exploitation, mais sans sacrifier la qualité du papier et l’aptitude au passage sur machine. Les machines à papier mince modernes sont en général dotées de plus de vingt boucles de régula-tion de faible niveau et de multiples éléments permettant de mesurer les propriétés de la feuille à divers endroits le long de la machine. C’est un vaste procédé compliqué en raison de son impor-tant couplage et les préposés aux services techniques le trouvent difficile à optimiser sans avoir recours à des techniques de régulation multivariables perfectionnées. La présente communication évalue les interactions du procédé et les réductions du coût de l’énergie possibles à l’aide d’un modèle prévisionnel de commande avec un module d’optimisation qui entraîne le processus automatiquement vers le coût le plus bas, tout en tenant compte de la nature du processus et des contraintes de qualité. La machine à papier à l’étude était dotée d’un appareil de mesure de la teneur en eau à balayage rapide installé avant la sécherie monocylindrique (Yankee), en plus des mesures prises à l’aide d’un scanner classique à l’enrouleuse.



TECHNOLOGYNEWS

J.D. Irving has completed an enterprise geographic information system (GIS) deployment that has centralized geographic information throughout the organization and extended its GIS to other business areas. The new GIS platform has also allowed JDI to centrally manage workflows for its forestry operations, resulting in more efficient processes.

“Centralizing our geographic information into one enterprise system has created significant efficiencies and allowed us to create standards for managing GIS data and workflows,” said Joe Pelham, GIS IS leader, IT division, JDI. “The system has helped to improve the quality of data and increased our capability for developing targeted applications to support the diverse needs of our various businesses.”

“JDI has a successful history of using GIS to manage forests sustainably,” said Alex Miller, president, ESRI Canada. JDI was the first forest products company in North America to use ESRI technology back in 1983, and has used GIS in its forestry operations to manage more than six million acres of land in New Brunswick, Nova Scotia and Maine. “While the use of GIS data and maps is inherent in forest management, users across their different lines of businesses can apply and benefit from advanced geographic analysis through their enterprise GIS. This allows them to gain unprecedented insight about their resources and workflows, enhance decision making, and strengthen JDI’s ability to meet its broad range of environmental and business objectives.”

The Irving project began in 2007 and involved migrating numerous GIS applications and hundreds of datasets managed across 10 regional offices into a single geodatabase. ESRI’s ArcGIS technology provided JDI with

New generation of polyurethane pressure roll covers for tissue machines

J.D. Irving implements enterprise GIS to enable more efficient workflows

ArcGIS Workflow Manager allows you to create, manage and execute workflows using simple visual tools.

The Rebel polyurethane roll cover technology from Xerium Technologies is uniquely engineered to maximize tissue machine performance.

Rebel’s stable dynamic properties, consistent pressure roll nip intensities, consistent cover hardness and superior tensile strength provide faster start-ups and increased drainage control. In addition, Rebel roll covers ensure minimal

process variability in summer to winter temperature changes and sustained superior nip conditions and tissue quality.

Rebel is available in a wide hardness range and in all venting combinations of suction, blind drilled and grooved. Excellent hardness stability assures a uniform Yankee/Pressure Roll nip for the life of the cover.XeriumTechnologies,www.xerium.co

comprehensive functionality for building the enterprise GIS. It allows hundreds of users throughout the organization to view, edit, and distribute geographic information on servers, desktops, mobile devices and over the Web. The technology seamlessly integrates with other business systems, providing JDI with the capability to leverage GIS applications and data in their business processes.

The company also implemented the Job Tracking for ArcGIS Server extension (JTX) to improve workflow management for processes including harvesting timber, planting trees, managing wildlife habitat, building roads, and managing land ownership. JTX automates and tracks each job in the GIS workflow including loading field data, editing the enterprise

geodatabase, and producing maps and reports.

The system passes the job from one user to the next, prompting for input and approvals until the entire workflow is completed. It improves user productivity by automating tasks and helps JDI to effectively manage a dispersed workforce by distributing work geographically. Staff and management can view every stage of the workflow by job type, number and priority, increasing accountability and enabling them to easily create and assign work to the appropriate resources. ESRICanada,www.esricanada.com.

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TECHNOLOGY NEWS


Consultants

Global Know-how and Local Service for the Forest Industry

Pöyry (Montreal) Inc. Pöyry Forest Industry Consulting Inc.Montreal, QC Tarrytown, NY Montreal, QC514 341 3221 914 332 4000 514 845 8715

Pöyry (Vancouver) Inc. Pöyry (Appleton) LLCVancouver, BC Appleton, WI604 689 0344 920 954 2000

Engineering balanced sustainability for a complex world.www.poyry.ca

CareersPulP & PaPer Jobs

Freeman Staffing, Inc.(800) 221-9629 or FAX (360) 653-8271

email: [email protected]

web site: www.freemanstaffing.com

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.

Engineering services for the pulp and paper industry

Telephone 416. 391.2322E-mail [email protected] site www.dickeng.com

Professional Connections

HR system provides self-service functionsHowe Sound Pulp & Paper Corp. has chosen an emPath® human resources and payroll system for its pulp and paper complex in Port Mellon, B.C. Distributed by Now Solutions, emPath is is a Web-based HRMS/payroll solution that leverages Microsoft®.NET technology.

EmPath provides comprehensive administrative and workflow capabilities, as well as employee empowerment via employee and manager self-service.

“EmPath gives us the ability to access information and reports in a user-friendly, versatile single solution. As a result, we’ll be able to have optimal functionality in a cost-effective, scalable solution,” says Marc Turenne, systems superintendent for Howe Sound. Now Solutions, 905-671-9888, www.nowsolutions.com

AFT makes major contribution to UBC’s new LC refining research facilityA new low-consistency (LC) refiner system donated to the Pulp and Paper Centre at the University of British Columbia (UBC) was started up in August, marking another milestone in the University’s research program to enhance paper quality and reduce energy consumption.

Advanced Fiber Technologies (AFT) contributed the key process equipment to enable UBC to expand its capabilities in LC refining -- a technology that is now being exploited by the world’s leading papermakers to significantly improve the energy efficiency of mechanical pulp production, according to James Olson, a professor in the Mechanical Engineering Department at UBC and a member of the Advanced Papermaking Initiative.

“We are now starting up the most state-of-the-art, university-based LC refining facility in the world,” Olson says.

A member of the Aikawa Group, AFT designs and manufactures screening components and Finebar® refiner plates for the worldwide pulp and paper industry. To UBC, the company donated a 16-inch Aikawa AWW single-disc LC refiner plus Finebar refiner plates to process a full range of hardwood, softwood, and recycled fibers.

The Natural Sciences and Engineering Research Council of Canada (NSERC) provided funding to purchase ancillary equipment and West Fraser Mills in British Columbia donated a 150 HP motor to drive the refiner.

“AFT has consistently contributed to R&D to fully understand the science of screening,” says Dr. Robert Gooding, vice -president of technology at AFT. “This most recent contribution underscores our commitment to LC refining research.”

After a short “learning curve” to understand the complexities and nuances of the new facility, fundamental research and development will begin in earnest. The LC refining facility will allow UBC to test new ideas and concepts for pre-treatment, power reduction strategies, advanced controls, and the impact on paper surface qualities. “Of course, we will be eager to perform sponsored research for pulp product development to help the industry further improve its paper products,” Olson says.

Gooding adds that AFT will also utilize the facility for fundamental research on plate geometries and power-gap relationships, as well as supporting customer trials. Advanced Fiber Technologies, 819-562-4754, www.aikawagroup.com/html/aft.html

Pump shaft seal system saves water, maintenanceJames Walker has developed a reliable, cost effective alternative to mechanical seals and compression packing. The KlickFix® cartridge sealing system contains multiple in-built lips that can be sequentially deployed in order to provide extended sealing

life and predictable operational performance. Easy to fit, the cartridge has the potential to significantly outperform traditional mechanical seals and compression packings.

To date the longest KlickFix trial has been running at a mill in North America where the cartridge replaced a tungsten carbide faced mechanical seal on a 2.25” shaft Allis-Chalmers pump. The mechanical seal required clean water flush at a rate of 20 US gallons/hour and had an operational life of between nine and eleven months pumping a 3-5% process paper stock concentration.

Following the installation of a KlickFix cartridge, the flush rate was immediately reduced to less than 2 US gallons/hour – a 90% reduction in clean water consumption. The KlickFix cartridge has now been in continuous operation without leakage or adjustment for more than three and a half yearsJames Walker www.jameswalker.biz/klickfix




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PROFESSIONAL CONNECTIONS

pulpandpapercanada.com November/December 2010 PULP & PAPER CANADA 37

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Equipment/Materials

46 J u l y 2 0 1 0 Pulp & Paper International (PPI)

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-YANKEE DRYER, UNUSED, NEW IN 2001, 233.5" FACE, 215.73" DIAMETER, DESIGN SHEET WIDTH 208" -YANKEE DRYER, 230" FACE, 215.6" DIAMETER, DESIGN SHEET WIDTH 204", OPERATING PRESSURE 114 PSI, 500 PLI LOAD, SHELL THICKNESS 1.841", HEAD THICKNESS 2.17", DRY CREPE COATED, RIBBED BORE. HISTORY AND DRAWINGS AVAILABLE. LAST GRIND 2/13/2003 JAGENBERG WINDER -VARI-DUR WITH A&F UPGRADES IN 2001. MAX WEB WIDTH 118" AT UNWIND, 115" ATWINDUP. DRUM FACE 125". MAX SPEED 5000 FPM ON 50 LB/3000 SQ FT. BALANCE SPEED 5500 FPM. MAX WOUND ROLL DIAMETER 60". MIN SLIT WIDTH 20". REFINERS -DD 4334, 34/38" REFINER, 34" DISC, STAINLESS STEEL LINED WITH 575V SET UP MOTOR 2 - BELOIT JONES 30" DOUBLE DISC REFINER DD4330, WITH SET-UP MOTOR 2 -TWIN FLOW DISC REFINER, 20", R20 TF III EM HIGH CONSISTENCY PULPER-HIGH CONSISTENCY PULPER, 14%-16%, 18 CUBIC METER (626 CUBIC FEET), COMPLETE PAPER MACHINE-COMPLETE FOURDRINIER, 141" FINAL TRIM, SUBSTANTIALLY NEW IN 1987. FOR COMPLETE DESCRIPTION AND DETAILS PLEASE VISIT http://www.canaminc.com/jaypapermill/SCREW PRESS-ANDRITZ DUPPS DEWATERING SCREW PRESS, WITH GEARBOX, MOTOR, VARIABLE FREQUENCY DRIVE, CONTROL PANEL, Model: 4224C, S/N: C80-252086, EXCELLENT CONDITION BELT PRESS-WINKLEPRESS, 2.0 METER, WITH INLET GRAVITY DEWATERING TABLE, VERTICAL WEDGE SECTION AND MULTIPLE S-WRAP DEWATERING ROLLS. INCLUDING HYDRAULIC UNIT TROMMEL SCREEEN- TROMMEL SCREEN, STAINLESS STEEL DRUM, MILD STEEL FRAME. INCLUDES SANTASALO NASH VACUUM PUMPS-Models CL9001, C6001, CL6002, CL4001, CL4002, 904R1, 904P2, CL1001, CL2001 600 PLUS GOULDS PUMPS IN STOCK. Models 3405, 3175, 3196, JC, HS, MC pumps

For additional information contact Dan Nigrosh or Tom Shannon at Can-Am Machinery, Inc. Visit our website at www.canaminc.com to view all of our inventory.

P&P Int'l - PPI July 2010 - p46-47.indd 46 6/25/2010 10:37:04 AM


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TECHNOLOGY NEWS

What types of paper machine clothing can you repair? We repair all styles of single, double and triple layer synthetic forming fabrics (wet-end fabrics) for all types of paper products ranging from tissue to cartonboard. Why should companies consider fabric repair rather than purchasing a new fabric?Companies should consider fabric repair because of the potential cost savings involved, which can be significant, especially when the fabric is damaged relatively early in its life-cycle. How long does a repair take, generally? A fabric repair can take anywhere from one day to two weeks or more, depending on the complexity of the fabric’s construction, the size of the defect and the number of damaged yarns in the defective area. How does your method compare to other methods of fabric repairOther methods of fabric repair consist of the adhesive-backed iron-on patch and the do-it-yourself baseball stitch.

The do-it-yourself baseball stitch is an attempt to close the damaged area while providing some machine side support, but this type of repair is ugly and can leave defects in the web because of the degree to which the surface of the repair is out-of-plane with the rest of the fabric’s surface. These repair methods are performed on the papermachine, and are temporary stopgap measures at best.

Our handwoven fabric repairs are permanent. We reconstruct the damaged area by replacing the damaged yarns with yarns from a similarly woven fabric sample. These new yarns are individually woven into the damaged fabric in-plane with the top and bottom sides of the fabric. We use a sewing needle and microscope to manually reconstruct the original weave pattern and restore the fabric’s original drainage capabilities and dimensional support. What types of damage can you repair? We repair tears, holes, scratches and creases. There is no upper limit to the size of the repair. We can repair anything with enough time and money. The photos above show a relatively large double-and-a-half layer fabric repair. It took 12 days to complete.

Repair, not replaceQ&A about forming fabric repair with Dawn Cammack, FabFix

FOCUS: PAPER MACHINE CLOTHINGMetso fabrics contribute to world speed recordMetso’s fabrics contributed to a new world speed record for newsprint paper machines, 2,020 m/min, achieved with Rhein Papier PM 1 in Germany on September 9, 2010. During the 24-hour record run, the press felt in both the pick-up and 1st press was Metso’s Transmaster Open (TMO). According to Metso both positions are considered to be the most demanding fabric positions on the entire line. September also saw the machine’s best ever average monthly speed, 1,937 m/min.

Metso reports that the machine performed very well during the record run, with a high efficiency rate (97 %) and extremely good runnability. General manager of Rhein Papier, Juha Ebeling, commented: “This would never have been possible without the TMO duo, which worked like a dream on the first press. At best the dry content measured over 55%, when the speed exceeded 2,000 m/min. The edges of the web moved evenly through the press and dryer sections, and we succeeded in keeping the draw between the press and dryer section small. These factors determine the machine’s runnability, because if there are problems here, it will lead to breaks and a reduction in speed.” Metso, www.metso.com

Carbon nanotubes used in forming fabricStable, robust carbon nanotubes (CNT) have been used for the first time in the manufacture of a forming fabric and successfully put into operation in the Voith Paper pilot paper machine.

As an additive, carbon offers very good stability and can withstand high mechanical stresses. The machine clothing community has worked for some time on trying to integrate carbon nanotubes (CNT) into forming fabrics, to reduce strain and increase wear resistance.

The company is continuing to work on bringing carbon nanotubes for forming fabrics onto the market. Voith Paper, www.voithpaper.com

Hollow yarns improve dewatering for press fabricAstenJohnson’s FlexFlow™ press fabric may be the world’s most compressible seamed fabric, due to the company’s patented cross machine direction hollow monofilament yarns. Sheet smoothness is a benefit for the papermaker because of the planar surface of the base under

compression in the nip.FlexFlow offers better nip dewatering,

plus increased sheet solids and therefore reduced steam usage. The amount of vacuum required at uhle box is also lower. AstenJohnson, www.astenjohnson.com

Press fabric provides uniform pressure and dimensional stabilityImpact press fabric from Xerium features a unique combination of innovative raw materials, highly compressible base structure elements and exclusive needling technology. Hydrophilic base

yarns aligned perfectly parallel provide an ideal combination of pressure uniformity, mark-free surface, exceptional dimensional stability and immediate nip saturation.

This new base concept, along with the exclusive Huyperm and Huyperpunch-D needling technology, produces a premium press fabric family that provides immediate startup, active self-cleaning and optimum

steady-state performance.In addition, Impact press

fabrics contribute to lower energy consumption, and superior sheet quality and printability.Xerium Technologies,

www.xerium.com


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At Buckman, the most important commitment we can make is to a sustainable future. We know it isn’t

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