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contents
AUGUST 2014 - VOLUME 56 NUMBER 8
THE PULP ISSUE

Cover: Setting Cloquets new neutralization liquor mixing accumulator in place: Photo courtesy of Sappi.
DISSOLVING PULP
10

OPINION
ON TIME, ON BUDGET, CLOQUET CONVERTS TO

DISSOLVING PULP
3 FROM THE EDITORS

Goodbye email hello typewriter
40 RISI VIEWPOINT
Newsprint conversions to packaging
gaining momentum
THE PPI INTERVIEW

17
THE CHANGING FOREST PRODUCTS INDUSTRY
MAINTENANCE
19
DEPARTMENTS
BACK TO BASICS
BLEACHING
25
38 SHOWCASE
BURGO ARDENNES STABILIZES BLEACHING PROCESS
28
THRIVE THROUGH INNOVATION
32
PUSHING THE BARRIERS
RECOVERY BOILER PROCESSES

NEW OPPORTUNITIES FOR AUTOMATION
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Editorial
Executive Editor...............................................................................Graeme Rodden
Editor................................................................................................... Mark Rushton
News
Editorial Director, North American News..................................................Will Mies
News Editors...........................................Nick Chang, Chris Cook, Marina Faleiros,

39 CLASSIFIED
39 ADVERTISERS INDEX
COATING
34
WHATS NEW
Anne Grimbert, James McLaren, Eva Nyman,
IN THE NEXT ISSUE . . .

The Top 100
North American CEO of the Year
Tissue
Sales and Marketing

Sales Director, Marketing Services..........................................................Remy Poos
Account Executive.......................................................................Monica Zaskiewicz
Management
Chief Executive Officer...................................................................Charles Rutstein
Chief Operating Officer .........................................................................Iain Murray
For Display advertising, please contact
International - Remy Poos - Sales Director, Marketing Services
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by RISI, Inc.

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Pulp & Paper International (PPI) A u g u s t 2 0 1 4
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from the editors
FROM THE EDITORS

Goodbye email hello typewriter?
By MARK RUSHTON, Editor
I am sure all of us who use email a lot have done it that

hugely embarrassing blunder that makes us wince every time
we think about it. My admission is I once sent an email telling
a particularly gruff and hairy Finnish paper machine engineer
that I loved him obviously the email was meant for someone
else my wife in fact!
But email and electronic communication is getting some
really bad press at the moment for other reasons, particularly in
the German parliament. Politicians in the country are reported
to be seriously considering going back to the typewriter and
recording sensitive documents individually on paper due to the
US surveillance scandal. Allegedly an employee of BND, Germanys intelligence agency, passed confidential documents to
the US secret service all of which has led to the departure of of a
CIA station officer and a bit of embarrassment all around. It is
of course a lot easier to pass documents along electronically.
The head of the enquiry into the affair was quoted as saying that they were considering ditching email completely and
going back to typewriters and not electronic ones either. It
seems to be a new trend, Russias federal guard service, which
is tasked with protecting the countrys highest ranking officials,
has put in an order for 20 Triumph Adler typewriters which
create unique handwriting that allows the source of any document to be traced, according to the Guardian newspaper.
Other beneficiaries of the new awareness of security
in Germany are restaurants and coffee shops as the paper
reports that people in the parliament are trying to stay away
from technology wherever they can, and they talk less on the
phone and prefer to meet in person. More coffees are being
drunk, and lunches eaten together. Even the walk in the park is
increasingly enjoying a revival.
Nothing beats a letter
Other good news for the graphics paper industry comes in the
shape of the good old fashioned letter which has set Twitter
alight around the world. A head teacher at a primary school
in Lancashire in the UK sent individual letters to pupils after
their exam results telling them that the school was very proud
of their efforts and that exams and test can take away the fact
that each of you are special and unique. The letter has gone viral
around the world, and the extent it trended on Twitter will almost
certainly result in more of the same in education circles. Nothing
really beats a good old-fashioned personal letter.
These stories seem like good news for the printings & writings
industry, but perhaps dont order that 1 million tonne/yr new
machine just yet.
Fantastic response to the PPI Awards
This editorial comes to you this month from a hotel in Tampere,
Finland, where coincidently my room overlooks Mets Boards
Tako mill, right in the middle of the city. It is amazing actually,
because I can see a tiny little bit of steam coming out of some
vents at the top of the mill, but can hear hardly as sound, just a low
rumble from the PMs. Which reminds me that as I write this piece
this month, our highly esteemed judges for the PPI Awards are all
vigorously pouring over the hundreds of entries that have come in
this year.
We have been truly delighted with the response we have had
and the awards, now in their sixth year, have truly come of age. I
remember when we first launched it was like pulling teeth trying to
get companies to enter, now all we need is a reminder and a bit of
ushering.
The most popular categories, and the area where the judges
are undoubtedly going to have their work cut out are, Business
Strategy, Environmental Strategy, Sustainable Packaging and Speciality Papers. Both the quality and the quantity in those categories
this year was very impressive.
It does seem as if producers all around the world are embracing the PPI Awards, for those of you who have entered, it will be
really great to see you and your colleagues in Boston in October to
celebrate.
Good luck to all our contestants for the PPI Awards 2014!
To read more industry opinions or give your own opinion, please

visit our RISI Blog and Forums online at www.risi.com
c
.mia
www
.info
International Exhibition
of Paper Industry
At MIAC 2014 you will find machinery, plants and
equipment for the production and for the converting
of paper and paperboard. In Europe, Lucca is the
number one spot for tissue production and Italy is
also one of the leader countries in the corrugated
cardboard sector. The Visitors of MIAC 2014 will
be able to meet, during the 3 days of Exhibition, the
leader suppliers of the Paper Industry sector which
will present the latest developments in machines,
systems and avant-garde solutions.
15 16 17
OCTOBER 2014
LUCCA - ITALY
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w h a t s n e w
WHATS NEW
N e w s s h o r t s f r o m t h e p u l p a n d pa p e r w o r l d
UPM to become exclusive distributor of Domtars

Stora Enso ends negotiations with Val- BioChoice lignin in Europe
UPM and Domtar have entered into an agreement for UPM to
paco regarding sale of Corbehem mill
become the exclusive distributor of Domtars BioChoiceTM lignin
in France
in Europe. BioChoiceTM is produced at Domtars biorefinery in
Stora Enso has decided not to prolong the exclusive negotiations it
Plymouth, NC.
was holding with the French trader Valpaco regarding the sale of its
BioChoiceTM lignin is a by-product of the kraft pulping process.
330,000-tonne/yr Corbehem lightweight coated (LWC) paper mill, loIt is a 100% bio-based sustainable alternative to replace fossil
cated in northern France. The firms management informed employees
based products. BioChoiceTM lignin holds the USDA Certified
of the decision on July 11, citing profound differences between the
Biobased product label.
parties. An employee at the mill said workers now feared this might
We at UPM are truly excited about this agreement, not only
be the end of the factory, the fate of which has been hanging in the
because we get a great product in our offering, but also bebalance since Stora Enso first announced that it was considering a
cause together with Domtar we can develop the market and
sale of the facility in October 2012.
offer our customers sustainable, value added products for a
growing variety of end uses, said Juuso Konttinen,
Vice President Biochemicals from UPM.
C ORPORATE STRATE G Y
Versatile use of renewable wood
Norways Borregaard joins BioTOP TEN HEADLINES
biomass combined with innovabased Industries Consortium
ON THE RISI WEBSITE
Only two Norwegian companies,
tion and sustainability is the
LAST MONTH
Borregaard and Norske Skog, are
cornerstone of UPMs Biofore
members of the BIC (Bio-based
strategy.
1. Stora Enso to enter exclusive negotiations with
Industries Consortium), an
C ORPORATE STRATE G Y
10
Valpaco regarding sale of Corbehem
industrial consortium that

EU and industry
2. International Paper sets date in June for spin off of xped
is the counterpart to the
partners launch new
European Union in the
European Joint Un3. RISI VIEWPOINT: BSK expansion projects: Too much, too late?
BBI (bio-based industries
dertaking on bio4. Sappi sells Nijmegen CWF mill to affiliate of American Industrial Acquisition
research programme).
based industries
5. RISI VIEWPOINT: Facing reality in the coated mechanical paper market
The purpose of the BIC
EU and industry leaders
is to create bioeconomy
have launched a new
6. RISI VIEWPOINT: How bad was Chinas paper and board demand in 2013?
companies, i.e. companies
European Joint Undertak7. Fatal accident at UPMs Kaukas pulp and paper mill in Finland
with a greener footprint.
ing on Bio-based Industries
8. RockTenn to invest $60 million on newly-acquired Simpson mill in
The funding for the compa(BBI). The aim is to trigger
Tacoma over three years
nies projects is earmarked
investments and create a
9. Sun Paper plans 300,00-tonne/ye uncoated P&W paper machine in China
for measures to make both
competitive market for bioproducts and production more
based products and materials
10. Chinas Shandong Tranlin Paper to invest $2 billion in
environmentally friendly. Borregaard
sourced
locally and Made in
straw-based pulp and paper mill
has been a member since the inception
Europe, tackling some of Europes
For more daily news headlines,
of the Consortium.
biggest societal challenges.
visit www.risi.com
Euro
3.7
billion ($5 billion) will be injected into
Not all companies are involved in this partnership.
the European economy between 2014 and 2024: Euro
It is generally the leading companies involved in the
processing of wood and other biomass that have joined, said Borregaards 975 million ($1.32 billion) from the European Commission and Euro 2.7
billion ($3.6 billion) from the Bio-based Industries Consortium (BIC) - to
Technology Director, Business Development, Gudbrand Rdsrud.
develop an emerging bioeconomy sector. Through financing of research
Companies can apply for funding for any project that meet the requireand innovation projects, the BBI will create new and novel partnerships
ments as stated in the advertisements. A company can provide financacross sectors, such as agriculture, agro-food, technology providers,
ing or other resources itself, and then the EU will also cover a portion of
forestry/pulp and paper, chemicals and energy.
the costs. Anyone can apply for funding for the various projects; this is
The aim of the BBI is to use Europes untapped biomass and wastes
not dependent on membership.
w h a t s n e w
WHATS NEW
as feedstock to make fossil-free and greener everyday products. At the
heart of it are advanced biorefineries and innovative technologies that
will convert renewable resources into sustainable bio-based chemicals,
materials and fuels.
Organised in five value chains - that range from primary production to
consumer markets - the BBI will help fill the innovation gap between
technology development and commercialisation, sustainably realising
the potential of bio-based industries in Europe.
P R O J E C T S & O P E R AT I O N S
Arauco to convert BSK/BHK Valdivia
mill to dissolving pulp
Chilean group Arauco has plans to convert its 550,000-tonne/yr Valdivia
bleached and hardwood kraft pulp mill to dissolving pulp (DP) by 2017.
The project is estimated to cost $180 million (Euro 133 million) and
would allow the company to produce both paper grade and dissolving pulp at the same mill, according to market conditions, said the
companys marketing & sales director, Ricardo Strauszer.
The first step for the change was taken this week, when Arauco filled
with Chiles environmental authorities the request for industrial modifications. We expect that the permission will be granted by the end of
the year and then we can move on with the equipment purchase, so the
conversion is expected to be completed in the first quarter of 2017,
the executive stated.
After the revamp, the mill will have capacity to produce about 500,000
tonnes/yr of viscose DP. Within the mill learning curve, Arauco also
expects to produce high quality DP for the specialty markets.
Chinas Zhuji Paper considers intalling new tissue

PMs with a combined capacity of 30,000 tonnes/yr
Shaoguan Nanxiong Zhuji Paper is mulling over building two tissue PMs
with a combined capacity of around 30,000 tonnes/yr at a mill in Nanx-
calendar
good month for . . . bad month for . . .
SEPTEMBER
17-19: TAPPI Bioenergy &
Bioproducts Conference -
Santa Maria
Brazilian paper producer Santa Maria Cia de Papel
e Celulose has finalized its 64,260-tonne/yr PM 2
revamp project, according to Voith Paper. PM 2 is
installed at Santa Marias 99,960-tonne/yr paper
mill located at the city of Guarapuava, Paran state,
southern Brazil.
Hotel Murano, Tacoma, WA,

www.tappi.org/events
OCTOBER
7-9: ABTCP 47th Pulp & Paper
International Congress &
Exhibition Transamerica Expo Center, Sao Paulo,
Brazil,
www.abtcp2014.org.br
8: PPI Awards -
Seaport Hotel, Boston, MA

events@risi.com
Chinas Shandong Dongshun starts up three tissue

PMs, six more coming
Shandong Dongshun Group has started up three new tissue
PMs in China, adding a combined capacity of 48,000 tonnes/yr.
All three units, provided by Kawanoe Zoki, are identical. Each
has a trim width of 2.76 m and a design speed of 1,000 m/min,
and can produce tissue at a rate of 16,000 tonnes/yr.
Two are located at the firms flagship mill in Taian city, Shandong province. The other is at a site in Zhaodong city, Heilongjiang province. Shandong Dongshun will bring six more tissue
PMs online at the Taian site by 2015. Four will be co-supplied by
the Japanese supplier and by Valmet.
Each unit, with a capacity of 25,000 tonnes/yr, will have a trim
width of 2.85 m and a design speed of 1,300 m/min. The first
two PMs will be delivered to the site this month and in September. Their startups are scheduled for the end of this year. The
other two units will be fired up in the second half of 2015.
Meanwhile, Shandong Dongshun is diversifying into the hand
towel segment. It has signed up Kawanoe Zoki to supply two
PMs to produce the grade. Each PM will be 2.85 m wide and
have a design speed of 450 m/min. The output of the PMs will
be in the basis weight range of 32-50 g/m.
Tetra Pak
Tetra Pak has announced the completion of a Euro
65 million upgrade for its packaging material plant
in Ponta Grossa, Brazil. The project increases the
capacity of the plant by 70% to 13 billion packs and
brings the Brazilian total to 22 billion, meeting both
domestic and export demands in the region.
Australian Paper
Australian Paper, a Nippon Paper Industries subsidiary, has recently seen a machine at one of its mills
hit by fire. The blaze started and was extinguished
on July 1 at the firms Maryvale mill in the state of
Victoria, which can produce around 280,000 tonnes/
yr of uncoated fine paper and 370,000 tonnes/yr of
various packaging grades.
Cascades
Cascades has announced that it will cease its kraft
paper manufacturing activities in the East Angus, QC,
plant because of unfavorable market conditions. Close
to 175 employees will be affected by the closure,
which will come into effect by October 3. The decision
means Cascades is leaving the kraft paper sector.
August 2014
Pulp & Paper International (PPI)
w h a t s n e w
WHATS NEW
iong city, Guangdong province, China. The firm and its parent company
Guangdong Shaoneng Group would fund the project, which would cost
RMB 178.9 million ($29 million).
The firm currently has a capacity of 65,000 tonnes/yr of bamboo pulp
and 35,000 tonne/yr of uncoated printing and writing paper at the
same site.
Zhuji Paper has been losing money over the past years amid the weak
pulp and paper market in China. To increase profitability, the firm plans
to diversify into the tissue sector, using its in-house bamboo pulp
capacity as furnish. A specific timeline for the project is unknown so far.
IP to start Euro 20 million upgrade investment in
green production process at its Saillat mill in France
International Paper announced earlier this year an investment
of approximately Euro 20 million ($27 million) into its Saillat
mill, located in the French Limousin region, to further reduce
the facilities water emissions and offer customers an even
more environmentally friendly product portfolio. The implementation of the project will commence in the summer of 2014 and
is expected to be completed in 2015.
At its core, the investment involves advanced technology to
extract an improved quality of fiber from wood by using a
smoother process. The new process leaves fibers more intact
resulting in even higher quality paper, and at the same time further reduces water emissions by another 30% from the already
very good levels the Saillat mill is achieving today.
The investment will allow International Paper to offer an even
greater choice of top notch products to customers. It follows
other investments into the companys service capabilities and
modernization of its paper machines at the Saillat facility in
recent years.
The project is supported by local and national French and
European agencies, notably the European Union (through the
Limousin Region) and the Loire- Brittany Water Agency.
The company is partnering with Voith Paper for equipment supply, and
Robins & Morton for engineering services. The press section replacement is scheduled for completion in July 2015, with an estimated
downtime of 24 days.
LATEST RISI PULP PRICE INDICES

RISI European Pulp
PricePulp
Index
European
Price Index
180
January 2000 = 100

US$
160
140
120
100
80
60
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
RISI North American Pulp Price Index
North American Pulp Price Index

180
185
January 2000 = 100
165
January
2000
=
100
150
170
135
120
105
155
90
75
140
60
125 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14
US$
2014 RISI, Inc.
Euro
110
95
80
65
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
RISI Asian Pulp Price Index
Asian Pulp Price Index
185
240
Green Bay Packaging invests $30 million in new

press section replacement for PM 1 at its Arkansas
kraft division
Green Bay Packaging Inc. (GBP) announced that it is moving forward
with a press section replacement for PM 1 at its Arkansas Kraft Division
in Morrilton Arkansas. in Morrilton, AK. The $30 million (Euro 22.1 million) project will include a new large nip press in the first press position,
followed by a new shoe press in the second press position. In addition,
the project will include significant infrastructure upgrades to the press
section framework and structural supports. These PM1 upgrades will
increase production by over 13% and significantly improve efficiency
when running lightweight liner-board and medium.
Euro
January2000
2003 = 100
January
= 100
170
225
155
140
210
125
110
180
95
80
165
65
195
150 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14
135
120
105
90
03
04
05
06
07
08
09
10
11
12
13
14
2008 RISI,most
Inc.
theindustrys
Get an objective view of pulp and paper markets with

trusted
250 prices and market reports. Learn more at www.risi.com/ppmp
230
210
190
170
150
130
January 2003 = 100
w h a t s n e w
WHATS NEW
The mont h in pict u res
The Wirral Grammar School for Girls has
won the Confederation of Paper Industries
PaperWorks Design and Technology competition for corrugated cardboard packaging
with an ingenious concept for cupcakes.
The judges decided that WGSGs imaginative design of outer corrugated packaging
which opens to reveal a smaller box inside
hiding the item stood out as best in the
competition.
ENVIRONMENT
with 43% believing that it is just getting started, and
Quote
39% believing it is the new norm.
SCA survey shows Canadian conof the month
sumers seeking green products
and services
APRIL affirms full compliance
The aim was to draw [De Guwith its sustainable forest
Canadians are increasingly looking
chts] attention to the violation by the
management policies in
for green products and services, and
Russian Federation of its WTO commitments.
response to Greenpeace
many are even willing to pay more
The import tariff increase that has been applied
accusations
for them, but they may be selecon coated paper and paperboard aims to protect
Asia Pacific Resources Internative on which they choose based
the interests of a few manufacturers established in
tional Limited (APRIL) affirmed
on the strength of environmental
Russia is in breach of the WTO Accession Protocol
that it is in full compliance with
claims. The findings, that suggest an
signed by Russia ahead of its accession in
its
sustainable forest manageimportant shift to mainstream green
August 2012,
ment
policies and that attacks
purchasing practices, are a result of
CEPIs trade & competitiveness director Bernard
on
its
credibility
by Greenpeace
an inaugural survey on green purchasLombard, telling RISI abut his meeting with EU
are
off-base.
ing behaviours and attitudes in Canada
Trade Commissioner Karel De Gucht to discuss
Were sticking to all the policies
commissioned by SCA, the maker of the
measures that the EU can take to protect
we
announced in January this year. Our
Tork brand of away-from-home hygiene
the interests of the European paSustainable
Forest Management Policy
products. As an international leader in creatper industry on the Russian
(SFMP)
is
being
vigorously
implemented and
ing an ethical and sustainable marketplace, SCA
market.
overseen by an independent, multi-party Stakeworked with Leger in Canada to capture in-the-moment
holder Advisory Committee. We are working towards a oneconsumer insights that reflect market trends.
to-one
commitment for conservation, meaning one hectare of
However, most of those purchasers look for third-party certification
conservation for every hectare of plantation area, said Michael
(33%) or conduct their own research (24%) to verify claims. This fact
Zampa, APRIL Director of Corporate Communications.
combined with the knowledge that their prime purchase driver is the
We have been identifying and protecting areas of high consercare of the environment itself (48%) rather than other motivations
vation value (HCV) in our land concessions since 2005. Overall,
means organizations should showcase their environmental commitment
we only use about 50% of our concessions for plantation
beyond their direct business offer.
establishment, with most of the balance being conservation or
Whether they are early adopters or just picking up on the trend, Canafor community use, he said.
dians on the whole are strong believers in green products and services,
August 2014
THIRD ANNUAL
CHINA INTERNATIONAL RECYCLED FIBER

CONFERENCE
September 23-24, 2014 Shanghai, China www.rcpconference.com
Register Now!
For program updates, sponsorship information or registration
details please visit the event website or contact us directly.
Email: conferences@risi.com Tel: + 866.271.8525, + 32.2.536.0748 www.rcpconference.com
mill
profile
Lifting the new ozone generator into place
Setting the new neutralization liquor mixing accumulator into place
ON TIME, ON BUDGET,
CLOQUET CONVERTS TO
SPECIALISED CELLULOSE
By GRAEME RODDEN, Executive Editor
The Minnesota mill is Sappis first North American facility to produce dissolving pulp
s the worlds foremost producer

of Specialised Cellulose (dissolving
pulp), it should come as no surprise
that Sappi decided to convert its kraft pulp
mill at Cloquet, MN, to produce dissolving
pulp. Announced in November 2011, the
$170-million Athena project kicked off in
10
June 2012 and the mill has been making

Specialised Cellulose since early June 2013.
Mike Schultz, managing director at Cloquet, says the company was looking ahead
when it made its decision. As we looked
across our pulp and paper businesses, we
saw the greatest opportunity for future
growth and returns by growing Sappis position as the worlds largest producer of dissolving pulp (1.3 million tonnes/yr). From a
capital and economy-of-scale perspective,
Cloquets pulp mill was ideally suited for the
conversion to dissolving pulp. We are well
positioned in the business with our low-cost
August 2014
profile
production capabilities.
Prior to the conversion, Cloquet was an
integrated mill as the kraft pulp mill fed two
paper machines, PM 4 and PM 12, producing about 350,000 tonnes/yr of coated
wood-free grades, and provided significant
pulp production for external sales. (see
sidebar.) Pulp capacity has dropped from
500,000 tonnes/yr to 330,000 tonnes, a
reflection of the higher purity requirements
of dissolving pulp.
The pulp mill uses a 100% hardwood
furnish, a mix of aspen and maple. The
Cloquet mill is triple certified in accordance
with the leading sustainable forestry chain
of custody certification bodies: FSC, SFI and
PEFC and the mill is proud to be associated
with these organizations and their efforts
to drive sustainable business practices. The
mill draws wood from Wisconsin and Michigan as well as Minnesota.
F I R S T S U P E R B AT C H
In 1996, Cloquet installed the first Sunds
Defibrator (now Valmet) SuperBatch pulping system. A second phase was installed in
1999. The washing process is press based.
The SuperBatch system paved the way
for Cloquets conversion. The mill had a
lower cost because of its starting base with
SuperBatch. Therefore, Cloquet was already
one of the most modern pulp mills in North
America before its conversion.
Other factors working in its favor were a
world-class environmental performance, a
good workforce and excess utilities capacity
steam, electrical, water and effluent.
Sappi fast tracked this project and
Schultz says it was treated as 11 separate

projects under one umbrella. Every aspect
of the mill was touched.
Beyond the work on the paper machines, there were main design objectives.
Schultz explains, First, we designed the
equipment and construction to meet the
permit limits of our recovery boiler in order
to fast track the project.
Second, we had a strong focus on
ensuring that our product quality would be
consistent and compatible with other Sappi
dissolving pulp mills in South Africa, Saiccor
and Ngodwana.
Then, equipment was designed to
achieve production costs in the lowest
quartile ensuring a higher return on the investment. Finally, Schultz adds, We wanted
to have the flexibility to produce either
Specialised Cellulose or NBHK depending
on market conditions.
The following lists the steps Sappi did to
meet its goals:
The drum de-barker was replaced with
an Acrowood rotary de-barker.
Liebherr supplied a new woodroom
infeed crane.
Because our existing digesters are
modern displacement batch digesters,
our focus was to make necessary piping
and tank farm changes to accommodate the pre-hydrolysis step, Schultz
explains. We also added two additional
digesters (10 in all) to allow production
at a pace to match the recovery boiler
permit limit. This was the largest and
most complex project within the overall
conversion. The digesters were built
mill
Inside of a new digester during its construction
on site and the eight original units were

changed so that all match exactly, e.g.,
same nozzle arrangement.
Cloquet worked with Lenzing Technik
and converted to its Continuous Batch
Cooking (CBC) process from the SuperBatch process. Lenzing calls this process
VISCBC. The VIS stands for viscose
which, Schultz says, is essentially the
addition of a pre-hydrolysis step to the
CBC process. The CBC process has
cooking liquor circulate between the
digester and the tank farm providing for
a more uniform cook. CBC is Lenzings
licensed technology. As well as being a
producer in its own right, the Austrian
producer has an engineering arm, Lenzing Technik, with whom Sappi worked.
Following the fiber path, in addition to
an existing two-stage oxygen delignification, Cloquet added an ozone generator
and ozone bleaching stage in front of
the W-D-Eop-D bleach plant. Wedeco
supplied the ozone generation equipment while Andritz provided the ozone
bleaching stage. The W is a pre-wash
Work done on the paper machines

The $170 million includes $19 million that Sappi spent to prepare the
machines for their new furnish. Instead of a mixture of dry and slurry
pulp, the two machines, PM 4 and PM 12, are now fed with 100%
purchased hardwood pulp.
A new building to handle the incoming pulp was added. New refining
technology was installed on both machines and each received a new
wet end to ensure the change in fiber would not materialize as a
quality shift for the mills paper customers.
The machines produce high end coated paper (magazines, direct

mail). Both machines can coat both sides. An off machine coater was
installed in 1989. The off machine coater can also coat both sides,
Schultz adds, so we can double coat both sides of the sheet.
The finishing end of the paper mill has two winders and three
sheeters. Paper production rates and quality have been maintained
with the change in fiber.
11
mill
profile
Pipe laid out before

installation
stage to bring the pulp up to its needed

consistency.
Ahead of the pulp dryer, the mill added
a Noss six-stage cleaning system to
replace the screening system. Schultz
adds, We also made certain modifications to the pulp dryer and bale line to
increase capacity and to accommodate
the different characteristics of the
dissolving pulp as well as packaging
requirements.
GE supplied a very large demineralized water system (3,000 gal/min).
Schultz explains that this was a necessity
in order to achieve the required quality
characteristics.
To maximize capacity of the recovery
boiler, more surface area was added to
the evaporator train and modifications
were made to some of the evaporator
bodies to improve throughput. We
also added quaternary air and made
liquor firing modifications to increase
production through the recovery boiler,
Schultz says. On the recaust side, we
added an additional green liquor cassette (three in total) and an additional
disc in our white liquor pressure disk
12
filter (10 in all). This work was done by

Valmet (then Metso).
On the control side, Cloquet converted
to a Honeywell distributed control
system (DCS) across its fiber processing
areas while remaining with its Fisher
system for liquor processing.
SAICCOR QUALITY USED AS A
MODEL
As mentioned, Sappis Saiccor mill has
been used as a benchmark. As Schultz says,
Given that one of our primary objectives
was to be compatible to the attributes of
our Saiccor mill, we relied heavily on the
experience and the technical expertise
that we have developed over the years in
South Africa. Through our quality and sales
objectives, we have truly made this a global
business for Sappi.
Although Saiccor was used as a model
for quality, Cloquet did not need to send
any of its personnel there for training.
Schultz explains, Saiccor is a sulfite-based
operation while Cloquet is pre-hydrolysis
kraft-based (PHK, the pre-hydrolysis step
removes hemicellulose). We utilized Sappis
Technology Center and Specialised Cel-
lulose Center of Excellence, as well as Lenzing Technik to help make the translation
between the two processes and deliver the
quality objectives.
Also, at the same time we were making
the conversion at Cloquet, we were also
converting our Ngodwana (South Africa)
mill: 210,000 tonnes/yr Specialised Cellulose. As a result, resources were involved in
each of the mills capital projects.
Nonetheless, training was extensive,
but given that most of the project was
modifications/additions to well-understood
processes, and given that the mill had an
operation that needed to keep running right
until the final conversion steps, traditional
classroom training was minimized.
We involved the operators in all
project HAZOP reviews, DCS development
work including simulator times and some
classroom training, Schultz adds. The best
preparation was the hands-on problem
solving that took place on a day-to-day basis
to ensure the project was executed successfully.
The mill has three power boilers, two
of which are fired with wood waste while
the other uses natural gas. It also has three
August 2014
profile
mill
Raising the log conveyor to its new elevation
turbine generators that can produce 89 MW

of power and three hydro-generators by the
adjacent St. Louis River that can produce an
additional 6.54 MW. The mill only generates
what it needs and does not sell any surplus
electricity.
Its effluent treatment system includes
two primary clarifiers; effluent undergoes primary treatment in Cloquet then
discharges to a publicly owned treatment
works (WLSSD - Western Lake Superior
Sanitary District). The mill is in the Lake
Superior watershed from which it draws
most of its influent water, but can also draw
from the St. Louis River as back-up. In the
late 1980s there was a large campaign to
protect the Great Lakes from increasing
pollution levels resulting in the construction
of the WLSSD.
The government wanted a large, stateof-the-art treatment plant but to make it viable, it had to draw from a large area to have
enough effluent. The mill is now the largest
single source of the WLSSD. The treatment
facility is in Duluth, MN, about 35 km east.
Schultz believes the mill has one of the
lowest published greenhouse gas (GHG)
emissions figures of any of its competi-
tors globally. In 2013, it emitted about 0.35

tonnes of carbon dioxide per tonne of
product produced (including emissions
associated with purchased power).
About 95% of its steam is generated
from renewable sources. And, Schultz notes,
that 95% is across the mills entire energy
picture. Cloquet did a Pinch study after the
conversion to dissolving pulp to bring the
level back up to 95%. All of the electricity the
mill generates is Green-e certified.
Cloquet has also done extensive work
to increase the life of its landfill. At one
point in 2004, it was down to seven years.
Through the mills efforts, landfill life expectancy is back up to 32 years.
G R E AT S TA R T U P
The job at hand now is bringing the mill to
capacity with a consistent quality. Sappis
extensive expertise and planning have
helped speed that goal along. We essentially started up on NBHK in early May 2013
after taking four weeks down to make the
final conversion steps, Schultz explains.
We then started producing Specialised
Cellulose at the beginning of June. We hit
first quality right from Day One and we have
Mother
Nature did
not comply
In Schultzs words, the project began with
a flood and ended with a blizzard. Days
after the official groundbreaking, the
region was hit with massive rainfall that
flooded the St. Louis River causing some
damage at the mill and forcing it to shut
down.
Then, the winter of 2012-2013 was one
of the worst on record for Minnesota with
temperatures frequently dropping to -30C
and snowfall up to mid-May. During the
final tie-ins in April 2013, the mill suffered
through the highest monthly snowfall on
record in April.
Despite the worst that Mother Nature
could throw at Cloquet, the project came
in on time and on budget.
Ed. Note: Even the day I visited in late April
2014, I had to drive two hours through a
snowstorm to reach Cloquet.
13
mill
profile
Some history
The Cloquet mill is more than 115
years old, being opened in 1898 as a
groundwood pulp and newsprint mill.
Going through various owners, the mill
ended up in Potlatchs hands in 1964. PM
12 was added in 1989 (the 12th paper
machine in the company). Installed in
1941, PM 4 was rebuilt in 1983 and 1994
by Potlatch.
In 2002, Sappi purchased the mill.
Rebuilds of PM 12 followed in 2004 and
2013, and a rebuild of PM4 occurred in
2012. The wood room was rebuilt in 2006
to help increase wood yield. A finishing
room modernization was done in 2011
when the company brought some of the
assets of its shuttered Muskegon, MI, mill
to Cloquet.
New demineralizer building
far exceeded all of our quality objectives and quickly

reached 90% of our production goals. Heading into
2014, we were able to close that last 10% gap and are
exceeding our availability objectives.
The ability to still produce NBHK is an important
consideration as Schultz has noted. The mill did have
a 10-day campaign of NBHK in January. We had
room in our schedule and we wanted to prove our
capability to swing to NBHK and back. Our ability to
make that swing also exceeded our expectations.
Paper grade pulp capacity is still 500,000 tonnes/yr.
The flexibility built into the conversion project also
allows a further conversion to produce acetate-grade
pulp in the future. Another possibility for the mill is
the active bio-sector. The mills pre-hydrolysis stream
is very sugar-rich so rather than burning it, there is
potential for value-added products.
Current production is supplying the rayon (clothing) and non-wovens (wipes) markets. Most production is transported to a North American port shipping
to overseas markets.
Cellulose fiber accounts for just 4% of the global
textile fiber market so there is room to grow. Polyester
has 48% of the market and cotton has 33%. But, for
the latter, Schultz says it is basically at capacity because of the demand for food crops from arable land.
14
In February 2013 the Chinese Ministry of Commerce (MOFCOM) announced it would conduct an
anti-dumping investigation of dissolving pulp from
the U.S., Canada and Brazil imported into China
during 2012.In April, MOFCOM released its final duty
determination and imposed final antidumping duties
on dissolving pulp exported to China from the U.S.,
Canada, Brazil. Sappi does not anticipate that the
duties announced will impact its business or ability to
service its customers due to the nature of its current
sales plans.
It is also important to note that while all of the
major producers of dissolving pulp in Brazil, Canada
and the U.S. were initially named in the request for
an anti-dumping investigation, Sappi was not named
because the Cloquet pulp mill did not produce dissolving pulp during the period of investigation. PPI
To read more articles on Pulping, visit our Pulping

Technology Channel at www.risi.com/
technologychannels/pulping
August 2014
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the ppi
interview
By Davic Price
FFIF CEO sees light at the end of tunnel for the Finnish
forest products industry
The changing
forest products industry
During a recent Finnish Forest Industries Federation
(FFIF) breakfast event held in London, David Price, who has
many years experience covering the forest products industry, spoke with FFIF CEO Timo Jaatinen.
1. The global forest products market has changed. Has

the FFIF changed in response to it?
One of the FFIFs areas of activity alongside the pulp
and paper industry and the woodworking industry is new
business. We have several working groups and issue groups
that are active in lobbying for new forest-based businesses.
To mention some examples: nano-/microcellulose, biofuels
and biochemicals.
The FFIF is also active in standardisation work for both
existing and new products. In the standardisation of new
products, our aim is in most cases to create basic rules for
business that allow companies to compete with their own
solutions.
2. How has your membership changed in the last 20

years? Who has left, who has joined?
Industry consolidation has led to mergers and acquisitions also between the FFIFs members and this development has slightly reduced the number of members over the
past decades.
Apart from the consolidation development, the number
of FFIF member companies has remained quite stable. Every
year some companies leave and others join the federation.
3. How has the FFIF managed the huge job losses in the
industry?
Our industry is undergoing a global transformation. The
growth in demand for printing and writing paper has slowed
down due to the expansion of digital media. Investments in
Finland dropped after the start of the European economic
crisis, and mill closures were unfortunately unavoidable.
On the other hand, companies have outsourced operations
like maintenance, cleaning and logistics as well as

security.
Now theres light at the end of the tunnel:
major new investment decisions have been made
recently. These new investments provide
more jobs mainly in the value chain,
for example, in wood harvesting and
transport.
Still, the forest sector continues
to be a notable employer: it employs
nearly 50,000 Finns directly. The Finnish forest industry creates well-being
in over 50 localities in Finland: 49
paper, pulp and paperboard mills and
over 200 sawmills and wood products
companies manufacture products for
export and for the domestic market.
4. A significant part of Finnish

industry is now outside Finland. Arethere
consequences?
Products are manufactured where it
is cost-effective to do so, mainly close to
the markets. Finnish mills compete over
production and investments with mills in
other countries. From that point of view, it is
important to maintain cost competitiveness.
Efforts to this end have been made in Finland
and companies will continue to, for example,
reduce bottlenecks in production and make
operations more efficient.
It is also important that the Finnish labour
markets become more flexible, that industrys
access to raw materials is guaranteed and that
political decision makers refrain from increasing taxes and fees that weaken the cost competitiveness of industry.
17
the ppi
interview
5 . What is the significance of Russia to

the Finnish forest industry?
Russian markets are important to Finnish
companies, especially now that the main markets in Europe have shown weak development
due to the economic crisis. Timber imports are
also important to Finnish mills. There is, for
example, a shortage of birch in Finland and
the supply is supplemented with imports from
Russia.
Russia hopes for investments, as the
country has substantial forest resources. So
far, except for some sawmill and plywood mill
investments, Finnish companies have been
rather restrained in terms of investing in Russia because the operating environment has
not been attractive. Russia should improve its
forest economy, its harvesting operations, infrastructure and energy sector. The instability
of political decision making and bureaucracy
also increase investment risks in Russia. Forest
industry investments are made for decades

at a time and conditions must be stable and
predictable.
6. What R & D does the federation support?
The FFIFs R&D&I (research, development and innovation) lobbying objective is
to create an environment where our member
companies can find partners in areas such
as research (universities, research institutes),
public funding (technology and innovation
agencies) and, of course, other companies that
have joint interests.
The FFIF does not, however, participate in
consortia-building or co-ordination of R&D&I
work. The FFIFs role is purely in lobbying
towards the public authorities both in Finland
and in the EU.
We maintain close ties with all R&D&I
stakeholders: politicians, ministries civil
servants, funding agencies, universities and

research institutes as well as the two publicprivate-partnerships that have been created
in the forest industry sector: the Finnish Bioeconomy Cluster [FIBIC] and Finnish Wood
Research.
7. How productive are your links with

other European federations?
In Europe we are actively working
through our sector confederations: CEPI for
paper industry and CEI-Bois for the woodworking industry. We also maintain close
connections to other trade associations in
member states. It is essential to build a common voice for the entire forest-based industry
in Europe and we support that work. PPI
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Products Co.
maintenance
By TERRY WHALEN
Managing outside resources properly will

provide more than just monetary benefits
BACK TO BASICS
or decades the pulp and paper industry has

contracted outside resources to design, build,
and maintain manufacturing facilities. When
it comes to maintenance and reliability of manufacturing assets, it is almost inconceivable that the
industry could continue its business without access
to these important resources. In short, contracted
services are critical to short and long term infrastructure integrity and profitability. That being said, we
must ask ourselves: How well do pulp and paper mills
manage these important relationships and capture
their essential contributions for strategic gain? Are
the contracted resources true partnerships? Are they
strong, reliable, and cost effective?
Consulting in the North American pulp and
paper industry since early 1975, I have seen many
approaches to managing outside resources, working with single-mill companies as well as those who
count their mills in the dozens. Across the industry,
managing contractors has always come down to

four objectives: maintenance of infrastructure, improved manufacturing productivity and quality, and
increased profitability. How mills attempt to realize
those strategic goals varies widely across the industry.
The simple fact is outside contractors are only as
effective as a mills purpose for hiring them and its
strategy for managing the projected work.
AV O I D C O M P L A C E N C Y
A mill manager in the southeastern US shared
the following thoughts on contractor management.
When the mill makes a request for bids, the low
bidder typically gets the work. The majority of the
bids are lump sum because they are the easiest to
manage. The contractor selected is often a known
quantitysomebody we have contracted with for
years and who is familiar with the mill. The mill
rarely reviews costs or performance against plan after
19
maintenance
Work Order
Job
Description
Area
Asset
Planner
Misc
Date
B070049
Replace #1 Kamyr Floor Valve or Valves - (V64A, 64B, 65A or 65B) - Valve(s) TBD
Digester - 221
Vessel - 012010
G Lopez
Staging Required
Location
At low pressure feeder floor outside of control room on the southeast side.
Job Steps
Verify Lockout - complex (listed as #1 Kamyr R&M).

SAFETY: Hang personal lock(s)
10" 300# GLOBE VALVE REMOVAL
Prep Job site with rigging tools - (2) 20Ft Wire Cable Slings (Minimum 1/2" DIA),
(2) 1 Ton Chain Falls with 20Ft chain and 1 Cable Come-along. See attached
image for rigging points.
PREP WORK: Carpenters to erect staging below the floor for access to the
valve(s) - this needs to be scheduled at least one day prior to start of valve
removal.
SAFETY: Proper PPE for Black Liquor break-in must be worn when
breaking flanges for valve removal. Remember to always treat flanges as
being under pressure when loosening bolts.
SAFETY: Reference the Line Breaking Documentation for details regarding
line breaking procedure(s).
Crew
Job
Hours
Man
Hours
PF
0.80
1.60
CA
4.00
8.00
PF
PF
PF
0.50
0.10
0.10
1.00
0.10
0.20
PF
3.00
6.00
PF
0.50
1.00
PF/YC
0.80
2.40
6.00
12.70
PF
PF
0.10
0.10
0.20
0.20
Remove the Handwheel(s) from the valve(s), rig and remove the 50" X 50" floor
plate and set aside away from work area. See attached image for details.
SAFETY: Use Yellow Caution Tape and barricade the area.
Rig Valves for removal - make sure to properly distribute the load.
With one pipefitter on the staging below the floor and other pipefitter above,
safely unbolt the valve flanges and lift valve. SAFETY: The pipefitter above the
valve must be in control of the 1 Ton Chain Fall and all must pay attention to load
shifting.
SAFETY: when working from staging use good body mechanics when
bending, reaching etc.,
When valve is lifted, place the valve on 4 wheel carry cart and transport to the
North side of #1 Kamyr low pressure feeder for yard crew to lower to ground
level.
Contact Yard Crew and notify them to mobilize the Mini-Grove (with Jib attached)
to lower old valve and to lift new valve. Place new valve on 4 wheel carry cart
and transport to work area.
Total Hours:
Fig. 1 - Kamyr job plan
20
August 2014
maintenance
the work is completed, being satisfied simply that

the work is done. This approach to managing outside
resources has led to a certain complacency and absence of effective oversight of the contractors activities. Contractors receive little follow up, are viewed as
a simpler way to get work done, and are almost never
interviewed to review performance or learn evolving
best practices.
To modernize their aged practices and expand limiting views of outside resources, pulp and
paper mills require strategic management plans
that include long-term outage objectives, financial
management guidelines, and contractor relationship
development. This article is a blueprint to develop
and implement such a plan, but first, here is an example illustrating the effect of unmanaged contractor
resources.
In 2005 during a maintenance improvement project at a west coast mill, we were asked to reduce the
cost of maintenance and increase the reliability of the
mill assets. To begin, a planning strategy was created;
improved scheduling processes implemented; foremen were coached on the job; and improved interand intradepartmental cooperation established (Pulp
& Paper, Nov. 2007; Maintenance renaissance: Bringing reliability to production). The project proceeded
as planned and projected results began to materialize
with one exception, costs were not falling as quickly
as predicted. Further investigation uncovered a surge
in expenditures on outside maintenance resources.
The number was large, and growing out of control.
The cause? Improved processes, particularly planning and scheduling, allowed for more work to be
completed, which led to the hiring of more contractors to fill the increased capacity to do maintenance.
A strategic planning initiative was implemented,
including financial checks and balances, to manage
the situation and significantly reduced the contractor
expenditures by creating efficiencies.
The first step we took was to stop the free
spending. The second step was to determine how
to regain control of the outside resources employed
by the mill. Both steps were taken with a sense of
urgency and determination. Costs were quickly
brought under control and significantly reduced.
Our approach to assisting clients with performance
issues changed; the impact of contractor management strategies became a more important element
in our improvement process design strategy. This was
especially true with regard to the annual outages that
#1 Kiln
1. Install new roller unit
a) Remove existing thrust roller unit.
b) Install new roller unit.
This task will consist of 4 men for 4 12 hour shifts.
192 Man Hours
NTE $20,000.00
2. Install new gear cover and labyrinth seals.
a) Remove existing gear cover.
b) Remove existing uphill and downhill seal plates.
c) Grind shell as required.
d) Layout and install seal plates.
e) Install gear cover.
f) Minor modifications to cover supports are
included, if necessary.
216 Man Hours
NTE $25,000.00
3. Install new feed end seal, plates and riding band.
a) Gouge loose existing riding band.
b) Grind shell.
c) Install new riding band.
d) Install new seal plates.
108 Man Hours
NTE $25,000.00
4. Install new oil wiper @ gear cover.
This task will consist of 2 men for 12 hours.
24 Man Hours
NTE $25,000.00
5. Remove end caps from all trunion rollers.
a) Check bearings.
b) Check thrust buttons.
c) Clean and check oiling system.
240 Man Hours
NTE $25,000.00
21
maintenance
almost every one of our clients performed in their

manufacturing facilities. The benefits we sought to
provide were:
Reduced/eliminated causes of equipment
failures
Reduced maintenance costs
Reduced product loss or production downtime
due to equipment failure, repair or deterioration
Ensure equipment operates to design specifications
Maximize the life of equipment
Improve equipment reliability.
In many mills the same approach to contractor
management and spending numbers can be found.
However, unmanaged contractor activities impact
reliability and expense. When the numbers in the
example where examined, corporate leadership and
mill personnel were embarrassed and angry. They
questioned how it could be? Why didnt we see this?
And how did it could get so out of control?
K N O W T H E R E S U LT S Y O U W A N T
The biggest factor affecting the success of an outside contractor is the planning and preparation made
by the mill prior to engaging the resource. The mill
must be able to describe the results it is seeking from
the contractor. The description must be as precise as
possible, the more precise the greater opportunity for
success. In those unusual situations where the mill
does not possess the skills to develop the scope and
content of the work, help can often be found elsewhere in the corporation or from trusted resources
outside the company.
Failure to thoroughly understand what you are
requesting of the contractor makes it impossible to
negotiate a fair and reasonable cost for the work and
develop the performance parameters that will be
used to measure contractor performance.
A detailed work identification and planning process also allows mills to move from lump sum and
not to exceed contracts to more precise and manageable time and material contracts. It strengthens the
negotiating position of your purchasing personnel
and allows for the contractor to bill only for the work
and materials you are requesting them to provide. For
example, a contractor may insist that a particular job
22
would require 200 man hours and that is what they are
going to invoice you for. However, if the purchasing
person has a detailed step plan developed by one of
your maintenance planners or engineers stating the
work should require only 120 man hours, a discussion
must ensue. The discussion is not about who is right or
wrong. Rather it promotes opportunities for learning,
enables mill personnel and contractors to focus on
results rather than activities, allows for a clearer understanding of the work to be performed by the contractor, and strengthens the mill-contractor partnership.
To illustrate what we mean by step plan, see Fig. 1.
Another real example for your consideration:
Major mechanical work was required on two lime
kilns during an eight-day annual outage at a South
Carolina mill. The contractor bid the job with a lump
sum proposal of $1 million and was awarded the
contract. Upon review of the bid with maintenance
and purchasing personnel, it was concluded that
the work would be more efficiently done on a time
and materials contract. The final cost of the work
was roughly half of the initial bid, a cost reduction of
approximately $500,000. The effort required to secure
this reduction was surprisingly little. It did however
require the mill to modify its approach to this long
time contractor and ask different questions than they
had asked in the past. The highlighted copy on page 2
illustrates a wide variance in the man hours required
to perform the five jobs listed, but only a small variance in the fees being charged. In fact, four of the jobs
have identical quotes.
In another situation at an Arkansas mill, a package of larger jobs was placed for bids, the winning bid
was a $906,000 lump sum proposal. The planner who
was to oversee the work felt uncomfortable with some
of the details of the proposal. In partnership primarily
with maintenance foremen and craftsmen, it was
determined that there was far too many man hours
in the proposal for the scope of work. A new time and
material contract was developed and the reduction in
this example was approximately $400,000.
The opportunities are not always hidden in the
$1,000,000 proposals; they appear in every size of
contractor proposal presented. With an outage approaching an Arkansas mill was planning some metal
work around one of the paper machine. It wanted to
replace three 25-ft steel beams, and because of the
corrosive environment the beams were to be placed
August 2014
maintenance
Start
3/17/14
Start 3/17/14
Monday
3/17/2014
7am 7pm
Tuesday
Wednesday Thursday
3/18/2014 3/19/2014 3/20/2014
7am 7pm 7am 7pm 7am 7pm
Friday
3/21/2014
7am 7pm
Saturday
3/22/2014
7am 7pm
Sunday
3/23/2014
7am 7pm
Monday
3/24/2014
7am 7pm
Tuesday
Wednesday Thursday
3/25/2014 3/26/2014 3/27/2014
7am 7pm 7am 7pm 7am 7pm
Friday
3/28/2014
7am 7pm
Cool Down
Cool Down
Pull Hood
Pull Hood
Out
/ Drive Work
Clean Out Clean
/ Drive
Work
DEMO
DEMO
Brick Work
Brick Work
Chain Work
Chain Work
Remove Deck / Pull Hood
Remove Deck / Pull Hood
Burner Management
Burner Management Checkout
Checkout
Light Off
Light Off
Fig. 2 Emlex schedule
Direct Labor: $
Per Diem and Travel: $
Material: $
Total Cost: $
Total 12 hr Shifts: $
Labor Rates
47,281.00
12,834.00
96,323.00
156,438.00
-
Linear Ft
13.5 ft. Diameter Kiln Brick Repair
# of Sections
30
Total
BL total MH
Mech B
Total Hour/Craft
Step Plan
Hours
Super
WF
Mech
SD
TK
Watch
MH
Set up platform (include scaffold stairs)

Install lights
Inspection scope verification
Set brock machine and saw (electrician)
Tear out brick
Remove brock machine
Clean out brick
Sand blast set up
Sand blast shell
Clean out debris
Inspection plant
Layout square lines (masonite board)
Set up brick rollers
Stock brick
Start laying brick (bed out) no more rolling of kiln
Set up bricking rig and platform
Start laying brick overhead
Clean out kiln
Mop kiln
Remove platforms and pipe
Heat up
Clean up
Shift
GF
BL
Mech B
LBR
CW
HW/BW/FW
Material List
Quantity
Total Hrs
Unit
cost/unit
overage
# Pallets
ea
CW
Watch
Total
Total Duration
Average Manpower/Craft
Kruzite 70 108-126 RKB

Refratherm 150
Sairset Mortar
LBR
Total Cost $
Total Sum
Total
Lbs
ea
ea
ea
Total
Fig. 3 Kiln work step job plan
23
maintenance
in, mill personnel determined they should be coated

for protection. The mill has a national account with
the contractor, who theoretically is providing the
best value, the bid for the job was $10,000. The mill
purchased the steel and coating materials and had it
delivered to a location less than a mile from the front
gate of the mill where the work would be completed.
It seems like a fairly simple job, until you look a
little closer at the numbers. This contractors stated
rate for a painter who can also do surface prep if
necessary is $19.95/hour. Deducting 30% for equipment rental, the contract contained $7,000 for the
actual labor. That equates to roughly 30 12-hour shifts
to prep and coat three 25-ft beams, or 120 man hours
for each beam. Because it lacked a robust contract
review process, the mill grossly overpaid to have three
beams coated.
Although most mills possess similar policies and
procedures, very few apply them uniformly across
manufacturing systems. As a result they lose opportunities to reduce contractor costs. Everyone knows
it; few talk about it. Everyone can recall instances of
receiving contractor invoices, scratching their heads
and wondering: Why did that cost so much?
Contractors are, in general, businessmen and
women who want to provide good services at a
reasonable price; they want to deliver good value,
and develop productive relationships with their mill
customers. They cannot do that in a vacuum. Mill
leadership must participate in robust interactions
with contractors that promote diligent and precise
examinations of every significant job that mills expect
contractors to tackle. Without the mills active participation, we will continue to scratch our heads and
wonder why contractor job costs are so high. This is
true in day to day work with contracted resources and
especially critical in major outage and capital project
efforts.
Developing an effective planning process will
transform how a mill approaches its engagement and
24
management of outside resources. A transformation

from outdated approaches will save mills money,
improve infrastructure maintenance, and improve
productivity and reliability.
This blueprint is more than doable. It is not a
matter of awaiting new technology or changed labor
union rules; it is a matter of the will of management
to apply the process and expect improved results.
It is time for the pulp and paper industry to
strategically develop transformational processes
and cultures that better utilize and manage outside
resources with an eye toward improved maintenance
reliability and planning, and a more productive and
profitable future.
PLAN VS PLAN
The planning process is a fundamental ingredient in the successful contract management formula.
However, as we all have observed, there are numerous
opinions about what a good plan actually contains.
Two examples illustrate the point. The first is taken
from a recent North Carolina mill annual outage. The
contractor submitted a plan for the $500,000 plus
kiln work with the document, Fig. 2. You can draw
your own conclusions as to the acceptability of the
submitted plan.
The second example represents what I believe to
be a more precise instrument that breaks down the
work into more manageable and measurable activities. It identifies who is doing what, when, and for
how much money. Safety is better served, productivity is easier to promote and measure, and the quality
of work is simpler to assess, Fig. 3
Terry Whalen is the founder and president of Team
Development Group (TDG, Florida, twhalen@teamdevelopmentmn.com PPI
To read more articles on Mill Maintenance &
Upgrades, visit our Mill Maintenance & Upgrades
technologychannels/millmaintenance
August 2014
bleaching
By MARK WILLIAMSON
Optimization solution smooths out bleach plant operation,

saves bleaching chemicals, improves brightness stability
BURGO ARDENNES
STABILIZES BLEACHING PROCESS
Burgo Ardennes
bleach plant
aced with a difficult to control process

and high bleaching chemical consumption
Burgos Ardennes mill in Belgium needed to
update its measurements and controls to achieve
better process stability, consistent quality and lower
costs. And that has been accomplished through
Metsos expert Bleaching Optimization services. The
mill lists its capacity as 360,000 tonnes/yr, but that
has recently been increased to 400,000 tonnes/yr, all
of which is for short fiber papermaking applications,
either used in the integrated coated paper mill or sold
to external customers. The final brightness targets
range between 88 and 90.
The wood species used at the Ardennes mill
are poplar, beech, birch and oak and this mixture
presents a challenge for bleach plant operations. The
bleaching of mixed hardwood pulps is a very difficult
task as the differing delignification and brightening
characteristics of various wood species are added
complications to the naturally complex chemical
reaction process. Effective control implementation
requires some in depth knowledge of the process and
how to deal with disturbances. Bleaching process
stability and efficiency is influenced by many process
variables that can affect the reaction rate, chemical
consumption and final pulp brightness endpoint.
Therefore, the measurements and the controls have
to be in top notch working order and tuned to perfection to get process stability and the target quality with
minimum chemical dosage.
The improvements at the Ardennes mill have
been achieved by a successful measurement and
control implementation using new Metso analyzers
and Bleaching Optimization services that have demonstrated a substantial saving in bleaching chemicals
with a more stable process. Most importantly, the
stability has been maintained after the project was
completed in the summer of 2013 by a continuing
Performance Service Agreement (PSA). After the initial commissioning, the controls have been adapted
25
bleaching
to significantly higher production rates later in the

later part of 2013. Remote diagnostic reporting has
pointed out some process improvements that were
implemented with positive results. The improvements in chemical utilization are continuing.
TA I L O R M A D E C O N T R O L S
Eric Bazzoni, fiber line production manager, sums
up the mills objectives and the results achieved:
Before the new controls it was difficult to achieve
higher brightness targets for some customers. We
were having problems with process stability and high
chemical consumption. Our goal with the new measurements and controls was to stabilize the process
and reduce costs. Now, we have a big advantage as we
can achieve the right brightness even at the higher
production rates. Before, it was difficult to achieve
stability from shift to shift as operators would manually change parameters. Now, the control system
adjusts by itself and the parameters are the same. We
do not have any off-specification pulp.
He points out that chemical consumption is kept
to a minimum since the chemical residual of chlorine
dioxide after the bleaching towers is at a very low
level. He says there are no problems with off-gassing
that might cause health, safety and environmental
problems.
Pierre Carnevali, mill projects manager, adds
his thoughts on the controls implementation, I am
impressed that the Metso engineers have adapted the
controls to our own process. For us, it is a tailor made
control for our own mill.
PROJECT SCOPE DEFINED BY AUDIT
The project scope was defined by a Metso measurement and controls audit requested by the mill. The
process study defined the measurement and control
requirements and the agreed control guarantees for
final brightness stability and reduction in chlorine
dioxide consumption. The study concluded that
many of the process measurements were obsolete
and needed replacement with modern versions. The
Metso engineers also recommended some changes
in the measurement scheme that would improve
process controllability. Franois Zune, Burgo process
engineer, says the most significant recommendation
was to change the pulp Kappa sampling point from
after the B0 (or D0) stage chemical mixer to before the
mixer. This would provide a more responsive feedforward control.
The new measurements included a Metso Kappa
26
Franois Zune, project

engineer (left) and
Pierre Carnevali, mill
projects manager
Q for online Kappa measurement at five sampling

locations, three new Metso Cormec5 inline brightness measurements and three new pH measurement
points that include a Metso Filtrate sampler. The
new filtrate sampler provides a clean sample to the
pH probe and thus avoids fouling and measurement
instabilities that are common to the previous inline
measurements. Metso engineers implemented the
Bleaching Optimization using advanced process
control (APC) tools in order to optimize the stability
and costs of the bleaching operation. The process
measurement points are shown in Fig.1
The control strategy automatically manages delignification (as measured by Kappa) and brightness
to achieve the final brightness target in a cost-effective way. This is done by avoiding over consumption
of bleaching chemical. In dioxide stages, adding more
chemical past a certain optimum point no longer
produces a corresponding brightness response. In
many cases the chemical dosage is kept above this
optimum limit to ensure that the brightness target
will be achieved. This is typically what operators do in
a manually controlled operation as Burgo had. When
the standard deviation of brightness is reduced due
to more effective process control, this safety margin
can be cut. This results in significant chemical savings.
August 2014
bleaching
Burgo Ardennes Fiber line
ClO2
H2SO4
O3
Filtrate B0
H2O2
NaOH
H2SO4
O2
ClO2
ClO2
HD 4000
WP6
Oxytrac
WP8
HD
B0
Cormec5
D1
Filtrate
pH
C%
Kappa
EOP
pH
Kappa
C%
D2
Filtrate
pH
pH
Temp Cormec 5 C%
Kappa +
Brightness
Filtrate
pH
pH
Kappa+
Brightness
Cormec 5
C%
Brightness
Controls linked to mill DCS

Operator Interface
Metso
Fig. 1 - Bleaching process measurement points
The control guarantees were tested in the summer of 2013 and the results were better than the guarantees. Brightness variability was reduced by 47.9%
and chlorine dioxide consumption was reduced by
8.7%. The project was accepted.
O P T I M I Z AT I O N C O N T I N U E S
But this was not the end of the task to maintain and
improve the controls. The mill planned to increase
production from 1,015 tonnes/day to 1,100 tonnes/
day. This would affect the residence time in the
bleaching towers hence change the dynamics of
the bleaching chemical reaction. With a shorter
residence time the consumption of chemical went
up as expected. Metso retuned the controls for the
shorter residence time and different control dynamThe KappaQ Analyzer
takes online samples
of pulp from five
points in the process
ics .The controls were retuned to give the original

and expected process stability. This was done under
a continuing PSA that includes an annual site visit for
control issues. To keep the important measurements
in good working order a Preventive Maintenance
Agreement contract for Kappa Q and other fiber line
measurement includes several visits per year.
The PSA includes remote system and process monitoring though a link to Metso and 24/7
telephone help services. The service monitors the
bleaching process performance stage by stage and issues daily and monthly control performance reports.
Bazzoni finds this a useful tool as it gives a concise
report on key control objectives and uncovers any
problems. Carnevali adds: The reports tell us if we
are in a good control range or not and if we are consuming the right amount of chemicals.
Even after a short time this service proved its
worth by detecting a problem, notes Zune. He says
that a process temperature regulation problem was
detected by the remote link to Metso. Temperature
has a significant impact on reaction rate so this
problem had to be fixed to improve stability. This was
done and the bleaching is more stable, reports Zune.
The optimization process continues. Metso has
recommended that B1 stage pH could be reduced to
save bleaching chemical further. The preliminary results look promising. FRP piping has been installed to
avoid corrosion at the lower pH levels. Control tuning
was ongoing at the end of March, 2014.
Zune says that the mill people have learned a
lot about bleaching control from Metso. The remote
and telephone help services help to detect and correct problems quickly. It has opened our eyes, he
concludes.
The mill will continue to improve mill operations
with the installation later this year of Metsos Causticizing Optimization along with a Metso Recovery Analyzer that will measure key chemical concentrations
in the process. The goals are to stabilize and increase
causticizing efficiency, stabilize residual carbonate
levels and to reduce fresh lime consumption.
Mark Williamson is a journalist/engineer based in
Thornhill, ON, Canada PPI
To read more articles on Automation & IT,
visit our Automation & IT Technology Channel at
www.risi.com/technologychannels/
automation
27
coating
THRIVE THROUGH
Higher quality, high-speed printing presses, improved environmental performance are but some of the demands
suppliers such as Cargill must meet to help customers.
28
August 2014
coating
INNOVATION
From research to the market, Cargill knows a
company needs to understand customer demands
By ANDREAS BECKER
aper coating technology has seen a fast development during the last 50 years. Machines
got faster and wider, more efficient by utilizing
different application concepts also in combinations.
Coating color formulations were adapted to meet
the increasing demands of production with regard to
rheology, binding and quality of the coated papers.
Starches as well as starch preparation have seen
similar developments to enable higher coating solids
at high speeds with high amount of starch based
binders possible to get optimal cost performance,
runnability and quality.
Cargill set up its Application and Development
Center (A&DC) in Krefeld, Germany, in the mid1960s being a partner to the paper coating industry
enabling the development of starch based binders
alongside and in close cooperation to the most actual
technologies. In the early 1990s, Cargill was the first
to develop a product for filmpress high solids coating
with smooth rod premetering.
During the last couple of years the paper industry
in Europe has seen a variety of challenges and
changes. Starting with a higher degree of consolidation coupled with overcapacity in the graphic sector
as a result of new media and IT the industry nowadays is focusing on cost optimization at a maintained
quality.
To face the market challenges Cargill is trying to
help its customers thrive by proposing innovative
solutions and optimizing their recipes to meet their
needs. Its understanding of coating technology is
the basis for its success as a leading manufacturer of
coating starches.
The Application & Development Center is further
backed up by satellite operations in Vilvoorde (BelPulp & Paper International (PPI) A u g u s t 2 0 1 4
gium) and is bridging the gap between research and

the market.
HELPING CUSTOMERS THRIVE
T H R O U G H I N N O VAT I O N
Partnership between producers and suppliers
is an essential component of product innovation.
Exchanging ideas and experiences with people from
production and R&D is critical as understanding
customers needs is one of the most relevant ways to
develop the optimum solution.
Paper coating requires the fine tuning of multiple
parameters to optimize runnability and performance, e.g., coating color rheology, water retention,
coater adjustment. It is about taking a holistic view,
rather than looking at the effect of starch in isolation. Advanced instrumentation techniques allow an
understanding of the rheological behavior of starch,
its interactions with other coating color components
and interactions between the coating colors and the
base paper. Mastering this complexity allows Cargill
to fine tune its products to provide solutions for the
different coating processes under most diverse conditions. By using those tools, it continuously works to
improve the performance of its coating starches.
G R O W I N G T H E C O AT I N G S TA R C H E S
OFFER
In the early 1990s Cargill introduced the
C*Film series. Their excellent rheology meets the
requirements of runnability and performance in
a demanding application. And, to futher extend
the amounts of starches that can be used in coating formulations and thus their performance, the
C*iFilm range has been developed which extends
29
coating
the working range up to 25% higher compared with

C*Film.
Cargill specialists know there is a consensus in
coating applications that maximizing coating color
solids has positive effects on coated paper quality
and energy efficiency. Therefore, Cargill developed
the C*iCoat series, specially designed for high solids
coating. With high powder solids and thus enabling
higher coating solids right from the start, this concept
captured the imagination of coating technologists.
Since sustainability and biodegradability are major concerns for customers too, the challenge today is
no longer just to provide optimal goods and services,
but to do so in a sustainable way, reducing the impact
on the environment. Made from renewable natural
resources C*Film, C*iCoat and C*iFilm are cost effective solutions allowing to replace petroleum synthetic
binders. Added to this, Cargills product ranges are
100 % biodegradable, chlorine free and support
greener papermaking processes.
T H I N K I N G T H E F U T U R E O F C O AT I N G
A N D . . . W E T- E N D S TA R C H E S
Cargill is not just looking for a simple replacement of latex or other synthetic binders but also
to improve the overall value proposition for its
customers. Todays markets require cost effectiveness with an expected ongoing pressure on graphic
papers, but also higher demands for printed packaging materials. The aspects of sustainability and
biodegradability alongside quality and cost will
be an integral part of Cargills continuous effort to
meet its customers needs and for the company to
develop innovative products and solutions to meet
the future challenges of coated paper and board.
In the wet-end application, novel starches are
available enabling high levels of wet-end starch
addition, allowing customers to meet the expected
future challenges for paper strength. Packaging papers in particular may face issues of availability, cost
and quality of fibers. By combining solid technical
knowledge with deep industry insights, Cargill has
developed and officially launched its new C*iBond
wet-end solution during the latest PulPaper exhibition in Helsinki.
In this increasingly competitive paper market,
manufacturers need to constantly improve their
products performance. At the same time, the guaranteed availability of potato starch is coming under
pressure, which means its availability for industrial
applications is likely to become scarce.
30
Obtained from renewable resources which secures durable availability, the C*iBond wet-end starch
developed by Cargill achieves a better or at least
similar performance than any other raw materials.
This solution increases paper machine runnability and decreases the risk of paper web breaks. It
ensures quality performance over time and plays a
key role in the total retention and dewatering.
ACHIEVING HIGHER EFFICIENCY IN
W E T- E N D P R O C E S S
Having a higher starch paste viscosity which leads
to a high level of ash retention, Cargills solution proposes high bonding with pronounced dry strength
properties and offers paper makers additional cost
saving through fiber replacement.
For dewatering behavior C*iBond delivers
significant benefits. Its dewatering time at 1% addition is close to that of a cationic potato starch at
0.6% addition. This means higher machine speed
can be targeted, which in turn leads to further cost
optimization. In addition C*iBonds low impact on
furnish charge neutralization enables either high
addition levels if strength increase is desired, or allows fiber replacement with cheaper alternatives to
reduce costs.
Cargills patented solution has been designed to
match modified potato starch performance while
remaining a long-term and cost effective alternative. Compared with a potato starch with the same
cationic degree of substitution, Cargills C*iBond
customers identified a lower starch consumption,
better ash retention as well as first pass retention
combined with similar paper strength.
C*iBond wet-end starch is part of Cargills comprehensive package of services and tools to help its
paper making customers businesses thrive.
Andreas Becker is Global Technical Manager Paper,
Cargill PPI
To read more articles on Chemicals, visit our Chemicals

technologychannels/chemicals
August 2014
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coatings
Pushing the barriers

By Sally Cousins
Peace of mind for the consumer is all important

to counter mineral oil migration
ew barrier coatings and

grades for paper-based packaging
are part of the push forward to
protect against mineral oil migrations into
food.
The risks of possible health damaging mineral oil residues migrating from recycled board
and paper to food hit global headlines two
years ago causing a high profile media storm.
As cardboard packaging is often
produced from recycled waste paper, such
as newspapers, these can have residues of
printing ink that are not approved for food
contact, and cannot be completely removed
in the recycling process. Scientific tests at the
time showed that mineral oil hydrocarbons
were found in Advent calendar chocolates.
In the controversy that ensued, the German government recommended functional
barriers for mineral oils to prevent contact
between mineral oil residues and the food,
and legislation is currently underway to
formalize the situation.
With impending legislative change on
the horizon coating suppliers are upping
their game and paper and board producers
are developing new grades with increased
barrier qualities.
BASF has made considerable headway in
developing solutions to combat the risks of
migration. BASF has developed various barrier solutions that are applied to the internal
surface of the cardboard box. According to
the company, these extremely thin coatings are made from polymers or sometimes
termed macromolecules made up of many
repeating smaller molecules. Barrier coatings
that are only 10-15 micrometers thick by
comparison a hair is 120 micrometers thick
already protect food from the contaminants
for up to three years. Products like noodles
that remain for an average of 15 to 24 months
in the packages, are reliably protected.
32
The prevention is better than cure theory

is working for Sun Chemical
Heiko Diehl, the BASF manager responsible for the paper chemicals division, explains:
The most important requirement for the
barriers is that the breakthrough time which
is the period until a barrier can become
permeable and allow health hazardous substances to penetrate into the food is longer
that the shelf-life of the packaged product.
Our barrier coatings can be imagined as
being like a close meshwork that allows only
certain molecules to pass through, continues
Diehl.
According to BASF, only very small molecules like water vapor can pass. Larger molecules like mineral oil residues cannot cross. In
addition, the polar nature of the BASF barriers
hinders the migration of the molecules.
BASF said that developing the barrier
effect for large molecules was not the only
challenge when designing the various coating solutions. The coating has to be flexible
enough to stop fractures when the cardboard
is folded and has to be capable of being easily
removed in the recycling process.
The company works closely with one of
Europes leading manufacturers of folding
cartons and boxes, Van Genechten in Kempten in Germany. The company processes
about 200,000 tonnes/yr of cardboard. Michael Avemarg, innovation manager for materials says: We anticipate that strict limits will
be imposed and have already modified our
production lines. To develop optimal coating
solutions for our manufacturing process,
we are already cooperating with BASF and
testing products in our plants. For the jointly
developed WLC Food Safe coating based on
BASFs plastic Ultramid, the company won
the German Packaging Prize last year.
Sappi Fine Paper Europe is also addressing concerns about migration.
Developed in partnership with BASF and
Eurofins the company has launched Algro
Guard M and Leine Guard M barrier paper
grades. The grades were developed to allow
brand owners to use their current recycled fiber
based folding boxes, shelf ready packages and
transport boxes. The food inside is protected by
inner bags, pouches and sachets manufactured
from the Sappi mineral oil barrier papers.
The integrated solution of mineral oil
barrier functionality combined with excellent
heat sealing properties minimize converting
process steps and considerably reduce costs
in the supply chain, comments Ren Khler,
product group manager Flexpack Sappi Fine
Paper Europe.
Mayr-Melnhof Kartons product contribution to the mineral oil migration issue
is the result of a two-year comprehensive
test project with leading multinational food
producers. The end result is its cartonboard
product Foodboard, which has a distinctive functional barrier on the food contact
side of the board.
Careful consideration has also been given
to how the board performs once it is on the
converting line. The company states that two
million boxes produced so far is evidence of
August 2014
coatings
high converting standards and fast packing

line performance. Foodboard is also in full
compliance with the provisions of the currently
discussed and pending mineral oil regulation.
Significant investment has gone into the
production of Foodboard and the Austrian
parent mill of Mayr-Melnhof Karton in Frohnleiten will be supplying the product by the end
of this year.
Direct migration isnt the only concern
regarding mineral oil. Not wanting to leave any
stone unturned Mets Board has looked into
the subject of indirect migration conducting a study based on the presumption that
mineral oils migrate from recycled fiber based
transport packaging, through the food package
and into the food itself.
The companys folding boxboards are
manufactured from fresh forest fibers, which
have been approved for direct food contact. The
indirect migration study was carried out where
mineral oil content, both in dry food and in
packaging materials, was measured after one,
two, five, seven and 11 months storage time.
Fresh forest fiber based folding boxboard
cartons were packed in high density polyethylene recycled fibers. All dry food samples
were received direct from the customers mill,
and stored in their original packaging. They
were then compared to an unpacked sample
of the same food, which had been wrapped
in aluminum to protect it from any external
contamination.
According to Pirita Suortamo, senior
R&D engineer at Mets Board R&D Centre
there was no increase in harmful mineral oil
content either in the food or in the cartons.
This was also proven by analyzing the same
type of product purchased from a local supermarket that had gone through the whole
transportation chain.
Suortamo is, however still concerned over
direct migration. To avoid this risk only fresh
fiber based board is recommended. It is also
important to pay attention to other packaging components and to make use of the best
possible design to avoid migration, she adds.
Prevention is better
than cure
The prevention is better than cure theory is
BASF has developed various barrier solutions to answer the problem of migration
working well for Sun Chemical. Its launch of

its fourth edition low migration guide entitled:
Designing Packaging with Certainty A Best
Practice Guide has proved to be an extremely
useful tool for converters with around 5,000
copies being shipped to date.
The guide is laid out in a logical sequence
to help readers understand how to design,
produce and store packaging safely with respect
to migration of unwanted contaminants, and
provide practical ways to minimize the risks.
The company aims to address the most important questions from the viewpoint of inks and
coating manufacturers.
Support is key according to Jonathan Sexton, European product manager energy curing.
He says: Our guide can be a great support to
the packaging development workflow in the
production of safe packaging for food and sensitive applications such as tobacco and pharmaceuticals. We are a very supportive partner for
brand owners on this issue.
Printing ink manufacturer Domino is
tackling the subject from a much earlier stage
by ensuring that ink used on the packaging
contains no mineral oils in the first place. It
has developed MOF 950BK, which contains no
harmful substances, is fully sustainable and
based on organic raw materials.
Andrew Gunton, product manager fluids
at Domino comments: We have taken a proac-
tive stance by developing an environmentally

friendly mineral oil-free ink for our C6000 outer
case coding solution. This gives brand owners
and manufacturers complete peace of mind
that their food products will remain free from
mineral oil contamination.
Giving customers peace of mind before
any legislation comes into play is key. Smurfit
Kappas new solution Catcher Board MB12 uses
a method that creates a blocking mechanism
across the surface area of the packaging including at the cut edges of the board. Made using
natural ingredients, the new board will be introduced as white lined chipboard and solid board.
A Smurfit Kappa spokesperson says: In addition to blocking mineral oil migration across
the whole surface area of the packaging, the
product feels and reacts just like normal board
during the manufacturing process. This means
our customers wont have to change any of their
packaging processes.
If European legislation is introduced we
believe we will be in a position to offer an innovative product to our customers that will meet
new regulatory requirements. PPI
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technologychannels/chemicals
33
recovery
NEW OPPORTUNITIES
FOR AUTOMATION
Efficient chemical recovery
processes are vital to the economic
success of pulp mills
By THANH TRUNG
he chemical recovery process continues to be a critical

component of pulp mills, infusing chemical, steam, and
power back into the system. The economic viability of mills
rests in large part from efficient and optimized chemical recovery operations.
At the heart of the process is the recovery boiler and the dissolving tank.
Aside from consumed air control and
density control of the raw green liquor
At the smelt dissolving tank, molten
(RGL), little has been done to further
smelt from the recovery boiler is mixed
advance automation and control of the
with weak wash such that the density of the
recovery boiler and dissolving tank. The
resultant RGL is within a desirable limit. The
common practice in a recovery boiler is
green liquor (GL) is then clarified and slaked
to manipulate the percent solids of black
with lime to form white liquor (WL) through
liquor (BL), firing temperature, airflow, and
the causticizing process. Common practice at
gun pressure. However, changes in the BL
the dissolver is to control density using either
chemistry are often unknown. As such,
hand tests, such as Baum, or the use of bubble pipes, refractometers or nuclear density
swings in strong BL chemistry result in
meters in conjunction with manual titrations
problematic fluctuations in boiler perforfor total titratable alkali (TTA). Downstream,
mance and smelt compositions.
clarified GL control is accomplished by trim

control using nuclear density while at the
recausticizing unit operation, manual titrations paired with differential temperature and
conductivity have been applied to slaker and
causticizing efficiency (CE) control.
The use of these traditional techniques
(density, temperature, conductivity) all lack
chemical specificity and are often prone to
drift due to scaling. Process supervisor control using these traditional techniques have
failed and stifled advancement in develop-
Above: Fig. 1 - Fourier-transform near infrared

analyzer: Platform technology providing
whole mill measurements of liquor chemistry
The FT-NIR analyzer station is installed above

the causticizing tanks. See also Fig 2
34
August 2014
recovery
Fig. 2 - FT-NIR liquor

analyzer sampling station
showing sampling tree
and transmission cell
ing supervisory control of the chemical

recovery operations. With rising energy,
chemical, raw material, and labor costs,
there is renewed emphasis on optimizing
the chemical recovery operation.
New technology brings
opportunities for
a u t o m at i o n
Fourier-transform near infrared spectroscopy (FT-NIR) has been fully developed by
FPInnovations and its Alliance Partners as

proven process analyzers for online measurements of various streams in the chemical
recovery processes, including: dissolving
tank GL, clarified GL, causticizer WL samples
from the first causticizer (1C) and fourth
causticizer (4C), final WL for complete compositions including reduction efficiency (RE).
For weak black liquor measurements provide
residual effective alkali (REA), lignin, organics, inorganics, and total solids content.
FT-NIR is based on the principle of

vibrational spectroscopy. Infrared light
illuminates a sample and the resulting
absorbance spectrum with its characteristic feature bands can provide quantitative
determination of the liquor compositions
including: effective alkali (EA), active alkali
(AA), TTA, sulfide, carbonate, sulfate, lignin,
organic solids, inorganic solids, etcetera. As
an optical method of measurement, analysis
time is in the order of minutes and does not
Fig. 3 - Smelt dissolving tank TTA control strategy.
35
recovery
Fig. 4 - Comparison between traditional density control and TTA control using FT-NIR
require reagents or reaction vessels. Water is

used to clean the cell and the sample lines.
Figure 1 illustrates the platform technology measurement capability. Figure 2
illustrates the implementation of an FT-NIR
analyzer at a mills recovery/recaust area
with the analyzer station installed above the
causticizing tanks.
a p p l icati o n s F O R r e c o v e r y
b o i l e r s m e lt d i s s o lv in g
tan k c o ntr o l
Control of the dissolving tank has traditionally been accomplished through continuous
measurements of the RGL density. While
density is correlated to TTA, it is more
advantageous to control TTA since it defines
the liquor strength. A higher and more
36
stable RGL TTA is desirable as it reduces

volumetric flow. This decrease in flow
increases residence time in the GL clarifiers
and allows for further trim control of the
CGL, improving the stability of the liquor
feeding into the slake. However, density
measurements drift from scaling and are
not sufficiently reliable.
Combining the measurement capability of the FT-NIR technology with the smelt
dissolving tank TTA supervisory control that
incorporates a soft-sensor, mills have access
to a continuous interpolation of TTA from
the relationship between density and TTA.
The drift in the density is corrected by the
measurements of TTA from the analyzer at a
frequency of every 5 to 10 minutes. The TTA
is used as input to a controller that compares
the value to the set point and cascades to a

flow controller, which in turn manipulates
the weak wash valve to achieve the desired
dissolver TTA, Fig. 3.
The FT-NIR analyzer provides complete
liquor compositions, including reduction
efficiency (RE), making it possible to calculate
the saturation limit of the liquor. Moreover,
constraints can be put in place to avoid
pirssonite deposition due to liquor properties excursions. Using this control strategy,
TTA variability can be significantly reduced,
by as much as 70%, Fig. 4. By stabilizing the
dissolver TTA, a higher TTA can be targeted
to take further advantage of higher strength
liquor, leading to debottlenecking of recovery
and recausticizing processes at a mill.
With the ability to measure sulfate,
August 2014
recovery
Fig. 5 - Contour plot relating primary air flow with black liquor solids content to green liquor reduction efficiency. Red indicates
higher RE
RE can be calculated, providing valuable

information on the reduction process in the
boiler. Mill process data has shown that RE
correlates extremely well with changes in
strong BL solids and primary airflow. A contour map was generated by monitoring the
RE of the dissolver GL during a period which
saw a rise in the strong BL solids content
from 69% to 78% and was accompanied by
changes in the primary flow. The contour
map shows the possible combinations of
solids content and primary air that would
result in the best RE, Fig. 5.
N e w t ec h n o l o g y b r i n g s
b enef i t s a n d c o s t s a v i n g s
The progress of FT-NIR technology for true
liquor composition measurements have led
to new advancements in control strategies

that take advantage of the multitude of liquor
chemical compositions supplied by the FTNIR analyzers. Advanced control strategies for
smelt dissolving tank TTA are now in practice
at many mills. Trim control of the clarified
green liquor as well as feed-forward slaker
control and final CE control have also been
applied at mills. The integration of process
measurements and advanced control strategies have resulted in significant reductions in
process variability, typically from 40% to 60%,
allowing for target shifts to higher TTAs and
higher CEs.
Mills have also reported sizeable reductions in purchased lime usage and all mills
have claimed reductions in pressure filter
maintenance, reduced plugging in evapora-
tors and in the recovery boiler. In one case, an

increase in WL strength and debottlenecking
recovery and recausticizing area substantially
increased digester production. All of this translates into an ROI ranging from $500,000 to $3
million. This is just the tip of the iceberg. With
a successful implementation of FT-NIR analyzers, pulp mills can realize further potential cost
savings in chemical recovery optimization.
Thanh Trung, FITNIR Analyzers Inc., Canada PPI
To read more articles on Pulping,

visit our Pulping Technology Channel at
www.risi.com/technologychannels/pulping
37
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38
A u g u s t 2 0 1 4 Pulp & Paper International (PPI)
classifieds
CLASSIFIEDS
CAN-AM MACHINERY, INC
W W W. C A N A M I N C. C O M
Lincoln Paper & Tissue
Interstate Paper
www.canaminc.com/lincoln
www.canaminc.com/interstate
119 Wire Width- 102 Trim

117 Wire Width- 99 Trim
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Fox River Paper Mill
Wet Lap Machine
Screens - Thickeners - Pulper
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94 Wire Width
350 TPD Complete
Domtar: Plymouth, NC
186 Shoe Press*
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249 Wire Width
New in 2008
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Visit the RISI Market Place online for more information on products and services at www.risi.com/marketplace
ADVERTISERS INDEX
page #
website
AdForum...................................................................................... 16.........................www.chinapaperexpo.cn
CRI................................................................................................. 2.........................www.cricatalyst.com
Deublin...................................................................................... IBC.........................www.deublin.com
HP ColorLok.............................................................................OBC.........................www.colorlok.com
MIAC.............................................................................................. 4.........................www.miac.info
PAP-FOR Russia........................................................................... 15.........................www.papfor.com
Penford........................................................................................ 18.........................www.penfordproducts.com
RISI China Intl Recycled Fiber Conference.................................. 9.........................www.rcpconference.com
RISI Markets & Prices Service..................................................... 31.........................www.risi.com/europe
Thiele......................................................................................... IFC.........................www.thielekaolin.com
39
RISI viewpoint
RISI VIEWPOINT
Newsprint conversions to packaging gaining momentum
By Derek Mahlburg, Senior Economist, North American Graphic Paper, dmahlburg@risi.com
Newsprint demand in North America and Western Europe
has been in a state of perpetual, and steep, decline for the
past decade, forcing producers to find new markets for their
products or make major capacity adjustments. One way in
which the industry has approached this problem has been
through an increased focus on offshore exports, but now that
newsprint demand is sinking even in emerging markets like
Asia and Latin America, producers will find it increasingly
difficult to place excess newsprint tonnage offshore. This has
forced producers to once again search for a new market for
their output, and conversion to packaging grades has become
an increasingly popular tactic, particularly in North America.
By the end of 2014, the North American newsprint industry will have converted a total of 925,000 tonnes of newsprint
capacity to a variety of packaging grades, mostly recycled,
since 2011, with 468,000 tonnes of these conversions occurring
in 2014 alone. Newsprint producers have experimented with
packaging grades for some time, including AbitibiBowaters
(now Resolute Forest Products) abandoned 2010 attempt to
convert its Coosa Pines mill to packaging grades.
SP Fiber led the way
However, the trend did not truly take off until companies
gained experience with this conversion and packaging producers began to take an interest in moving out of the stagnant
newsprint market altogether. SP Fiber Technologies led the way
by converting a machine at its mill in Dublin, GA, in 2011, and
the company reduced its newsprint capacity by an additional
325,000 tonnes in 2013-2014. Atlantic Packaging converted the
idle newsprint machine at its Whitby, ON, mill in the second
quarter of 2013, and it will be joined by PCA/Boises conversion
of the remaining active newsprint machine at the DeRidder,
LA, mill later this year. Finally, Kruger is reportedly studying a
possible conversion of a 214,000-tonne/yr machine at its TroisRivires, QC, mill, demonstrating the North American newsprint industrys continued enthusiasm for alternative grades.
This trend has spread to Europe, although last years wave
of nearly 1.0 million tonnes of newsprint capacity reductions has made the immediate need for supply adjustments
somewhat less urgent. Nonetheless, the European industry
will inevitably face oversupply in the future, and producers
will make every attempt to keep their equipment operating.
Already, SCAs Ortviken, Sweden, mill is scheduled to complete
40
its shift of 160,000 tonnes of newsprint

production into packaging grades in 2014,
which will be followed in 2016 by a restart
of PM 2 at Parencos Renkum, Netherlands,
mill, where newsprint production was
shelved in 2010.
Will Kondopoga convert?
There is also speculation regarding potential packaging conversion projects in Europe, most notably the 695,000 tonnes of
annual capacity at Kondopogas huge newsprint mill in Russia,
not to mention the exploration of packaging grades by printing & writing producers as a response to structural demand
declines. An uncoated woodfree machine at Stora Ensos
Varkaus, Finland, mill will undergo an extensive rebuild and
be converted to virgin lightweight packaging production by
the end of 2015, and the graphic paper industrys potential for
further packaging conversions will be the focus of a forthcoming RISI study.
Besides the better demand prospects offered by packaging
grades, another obvious reason for the outbreak of conversions
is changes in the price differential between newsprint and
recycled linerboard. European newsprint prices have lost some
ground but are still higher than recycled linerboard, a common
grade for newsprint machines to convert to, while recycled linerboard prices in the USA have now climbed 23% higher than
newsprint prices after trailing them by nearly 40% as recently
as 2005, and the lower cost of producing recycled linerboard
makes the impact on profitability even more dramatic, even
for newsprint machines that become relatively high cost
packaging producers. The popularity of newsprint conversions
could eventually cause the packaging market to deteriorate,
but the superior margins and longer-term demand prospects
are likely continue to draw newsprint producers in both North
America and Europe.
Derek Mahlburg is co-author of the Paper Trader, the North
American Graphic Paper 5-Year Forecast and the North American
Graphic Paper 15-Year Forecast. He works out of RISIs Charlottesville, VA, office.
To read more industry opinions or give your own opinion, please
visit our RISI Blog and Forums online at www.risi.com
A u g u s t 2 0 1 4 Pulp & Paper International (PPI)
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com | august 2014

If you had to choose a kaolin

Thiele Kaolin Company Sandersville, GA

Tailoring kaolin to your needs.

AUGUST 2014 - VOLUME 56 NUMBER 8

THE PULP ISSUE

ON TIME, ON BUDGET, CLOQUET CONVERTS TO

3 FROM THE EDITORS

THE PPI INTERVIEW

THE CHANGING FOREST PRODUCTS INDUSTRY

BURGO ARDENNES STABILIZES BLEACHING PROCESS

THRIVE THROUGH INNOVATION

PUSHING THE BARRIERS

RECOVERY BOILER PROCESSES

RISI Corporate Headquarters

Anne Grimbert, James McLaren, Eva Nyman,

IN THE NEXT ISSUE . . .

Sales and Marketing

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Fuel production is branching out

CRIs revolutionary IH2 technology is easily adaptable to a variety of common feedstock

from the editors

FROM THE EDITORS

I am sure all of us who use email a lot have done it that

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To read more industry opinions or give your own opinion, please

UPM to become exclusive distributor of Domtars

Valpaco regarding sale of Corbehem

industrial consortium that

Chinas Zhuji Paper considers intalling new tissue

good month for . . . bad month for . . .

Hotel Murano, Tacoma, WA,

Seaport Hotel, Boston, MA

Chinas Shandong Dongshun starts up three tissue

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Lifting the new ozone generator into place

Setting the new neutralization liquor mixing accumulator into place

s the worlds foremost producer

June 2012 and the mill has been making

Pulp & Paper International (PPI)

Schultz says it was treated as 11 separate

Inside of a new digester during its construction

on site and the eight original units were

Work done on the paper machines

Pulp & Paper International (PPI) A u g u s t 2 0 1 4

The machines produce high end coated paper (magazines, direct

Pipe laid out before

stage to bring the pulp up to its needed

filter (10 in all). This work was done by