Fiber Processing & Paper Performance
FS-FPL-4710
More Information |
o |
|
|
o |
|
|
o |
|
|
o |
|
o |
|
|
o |
|
|
o |
|
|
o |
|
|
o |
|
|
o |
|
|
o |
|
|
o |
Laboratory Facility |
|
o |
Vacuum Compression Tester |
|
o |
Imaging Systems |
|
o |
Semiautomatic Handsheet |
|
o |
Mold Flotation Cell |
o |
|
JunYong Zhu, Ph.D.
Project Leader
Phone: (608) 231-9520
|
|
|
Fiber Loading for Lightweight High-Opacity Papers
Introduction
The shift to alkaline conditions in papermaking has been prompted
in part by the increased level of filler permitted in alkaline-sized papers. Because alkaline sizing enhances paper strength, a higher
level of filler can be incorporated into the sheet. Calcium carbonate, a filler that could not be used in acid sized papers, is popular
as a filler in alkaline-sized papers because of its high brightness level [1,2]. In general, fillers cost less than fiber, and have
the ability to improve the surface smoothness, optical and printing properties, and the formation of paper. However, as the level of filler
increases, the interfiber bonding decreases. If additional filler could be added inside pulp fibers, interfiber bonding might be maintained.
A method to incorporate fillers inside fibers has been the subject of
extensive research. Scallan and associates [3,4] reported the first studies as lumen loading. These experiments focused on the use of
titanium dioxide. An excess of titanium dioxide was mechanically mixed with a pulp slurry depositing titanium dioxide within the fiber lumen.
However, limitations of this method were the large excess of titanium dioxide required for lumen loading and the need of a separate process for
recycling the excess filler.
More recent studies on cell wall loading have been reported by Allan and associates [5]. Their approach was
to saturate pulp fibers with sodium carbonate and react the resulting pulp mixture with salt-containing calcium (e.g., calcium chloride). The
resulting pulp mixture could contain high levels of calcium carbonate within the fiber; however, additional processing was required to remove
the salt remaining in the mixture.
Fiber loading, which was developed at the Forest Products Laboratory (FPL), consists of at least two steps [6]. First,
calcium hydroxide is mixed into a pulp fibers slurry. Then, the pulp and calcium hydroxide mixture is reacted using a high consistency
pressurized reactor (refiner or disk disperser) under carbon dioxide pressure to precipitate calcium carbonate. Calcium carbonate is deposited
within, on the surface of, and outside the pulp fibers, and is termed fiber loaded precipitated calcium carbonate (FLPCC). As a result of
fiber loading, fiber bonding is increased as shown by increased handsheet strengths.
Fiber-loaded pulps are stronger than similar direct-loaded pulps at the same precipitated
calcium carbonate (PCC) levels as a result of three independent mechanisms: (a) deposit of FLPCC within the fiber wall and lumen
[6], (b) gentle refining of fiber at high pH [7], and (c) gentle refining of fiber at high consistency [7,8]. The low energy
(approximately 6.84 x 104 kJ/metric ton) needed for the reaction process during fiber loading causes only small drops in pulp Canadian
standard freeness (CSF) (30 to 40 ml) [7,9]. Measurement of fiber length, kink, curl, and fines (fibers <0.2 mm) content after fiber
loading revealed no change in fiber characteristics [10]. By enhancing fiber bonding without any significant loss in freeness, fiber loading
is thus a viable method to produce lightweight high-opacity paper.
The morphology and particle size of the FLPCC particle is critical. Calcium carbonate is known to exist in three
distinct crystal structures. The structure most important to papermakers is calcite, which itself has over 300 reported forms [11]. The
properties of these crystals, such as shape, surface area, and size distribution, determine the fiber/filler interactions and ultimately
influence the strength, optical, and printing properties of the final paper product. The fiber loading process environment has a profound
impact on properties of the FLPCC crystals.
As grammages are reduced, the printing inks tend to penetrate through the paper (strike-through) and can be a limiting
factor in grammage reduction. At reduced grammages, filler properties profoundly effect strike-through. How FLPCC particles effect
strike-through is unknown and difficult to predict. Newsprint and white-top liner grades need to reduce grammage, improve printability, or
both in order to remain viable [12].
Top of Page Initial Experiments
Initially, fiber-loading experiments at the FPL were directed at minimizing a critical problem of recycling-hornification.
If fillers could be precipitated within fiber voids, collapse of these voids during subsequent drying might be reduced. Although the impact of
fiber loading on hornification remains unclear, other economic and environmental benefits were apparent.
In our initial study [13], we investigated whether complete conversion of the reactants had occurred (using x-ray
diffraction), where calcium carbonate was deposited (scanning electron microscopy (SEM) analysis), and how the properties of handsheets prepared
from fiber-loaded pulps compared to those made from direct-loaded pulps (conventional method of adding filler in the doler tank or papermachine
chest).
The SEM revealed the presence of calcium carbonate crystals on both external surfaces and within the cell lumen; x-ray
microprobe analysis identified the presence of calcium within the cell wall. Calcium carbonate was readily detected and identified with SEM
and x-ray micro-analytical methods. X-ray diffraction measurements were made to confirm to the presence of crystalline calcium carbonate
precipitate after the reaction in a pressurized refiner. For comparison, two diffraction traces were presented. A trace from a fiber-loaded
handsheet prepared from unbleached softwood fiber (loaded with calcium hydroxide and treated with CO2 in the refiner). A similar trace was
obtained from a commercial PCC suspension, deposited and dried on a filter paper. Comparison of the x-ray diffraction traces indicated that
the patterns were identical, and the crystals can be indexed as the rhombohedral form of calcium carbonate.
Initial fiber loading experiments indicated that rhombohedral calcite crystals in the 1 to 3 um range were achievable.
Cross-sections of fiber-loaded softwood pulp and handsheet fibers examined by SEM showed that calcium carbonate was precipitated in discrete
angular particles, i.e., crystals. Crystalline aggregates could be seen in the lumen and on the fiber surfaces (Figures 1,2). The distinctive
spectrum of calcium was found by x-ray microanalysis on the surface, in the lumen, and in the wall [13]. This information indicates that a
portion of the calcium ions diffuse into the fiber wall and subsequently react with carbon dioxide depositing calcium carbonate. Figure 3
confirms the presence of calcium carbonate on both the internal and external surfaces of pulp and handsheet fibers.
Investigations of fiber loading on never-dried, bleached hardwood pulp are summarized in Figures 4-7. These figures
compare strength, optical properties, and density to paper ash levels on handsheets made from direct and fiber-loaded pulps. In each case,
a dotted line indicated interpolated values for direct-loaded handsheets, at Canadian standard freeness (CSF) values comparable to
fiber-loaded pulps at the same ash level.
For strength properties, the curve for fiber-loaded handsheets gives higher strength values at the same ash levels as
the direct-loaded handsheets at the same CSF values. This is partly due to the difference in consistency at which the refining takes place.
The direct-loaded pulps were disk refined at low consistency, while the fiber-loaded pulp was pressurized refined at high consistency. In
general, high-consistency refining is known to have beneficial effects on strength properties [14]. However, we compared our fiber loading
method with direct loading at low consistency because that is the consistency conventionally used for commercial production.
Figure 4 illustrates that at any given burst index, fiber-loaded handsheets contain 3.5% to 4.0% more
calcium carbonate than do handsheets made from direct-loaded pulp. For example, the carbonate content of a handsheet can be increased from
7.5% to about 11.5% with the same burst index. Fiber loading exhibits even greater advantage over direct-loading when comparing tear indices
of handsheets prepared from the two processes. To achieve comparable tear strength as the 7.5% carbonate handsheet, 15.5% carbonate can be
incorporated by fiber-loading method, an increase of 8 percentage points (Figure 5).
Scattering coefficient of the two loading methods are shown Figure 6. This figure shows that scattering coefficient
values for 7.5% ash on direct-loaded handsheets compare with 11.5% ash content on the fiber-loaded handsheets. Fiber loading gave
comparable scattering coefficient properties at 4% higher carbonate content.
At equal ash content levels, fiber-loaded handsheets exhibit poorer optical properties in comparison to direct-loaded
sheets. This is understandable because the papermaker calcium carbonate was specifically designed in terms of crystal morphology and particle
size to achieve maximum scattering power. In addition, filler in close contact with cell wall material (e.g., inside cell lumen) may
inherently scatter less, because the difference in refractive index between filler and fiber material is smaller than that between filler
and air.
Top of Page
(click
above for larger image)
Figure 3. Handsheet density of fiber-loaded pulp is
compared to direct-loaded handsheet density in Figure 7. Fiber-loaded handsheets
are shown to be 60kg/m3 more dense than the 7.5% ash direct-loaded handsheets.
(click
above for larger image)
Figure 4. Comparison between direct and fiber loading on BL. HW 430 or 330 CSF.
(click above for larger image)
Figure 5. Comparison between direct and fiber loading on BL. HW 430 or 330 CSF.
Top
of Page
(click above for larger image)
Figure 6. Comparison between direct and fiber loading on BL. HW 430 or 330 CSF.
(click above for larger image)
Figure 7. Comparison between direct and fiber loading on BL. HW 430 or 330 CSF.
Top
of Page In a subsequent study [10] we investigated the impact
of high consistency and high pH processing on fiber properties and evaluated
the parameters that influence the dimensional stability of handsheets made
with pulp obtained from recycled fiber. The effects of high consistency hot
dispersion followed by conventional high consistency fiber loading were compared
with a control employing low consistency fiberization and minimal mechanical
processing. Three differently processed samples of this pulp were compared.
Although fiber loading increased individual fiber curl slightly more than
that of the other two processing methods, most curl indices obtained were
within the range considered to be relatively straight. We found a direct correlation
between the coefficients of hygroexpansion and the curl indices of pulps reprocessed
by the high consistency methods. Fiber loaded handsheets displayed slightly
higher hygroexpansion than did direct-loaded sheets at comparable ash levels.
Fiber length, kink, curl, and fines (fibers <0.2 mm) content after fiber
loading revealed essentially no change in fiber characteristics. The improved
water retention values obtained with recycled fiber-loaded pulp is consistent
with improved water removal of fiber loaded pulp which was indicated both
by increased freeness after loading and higher solids after pressing when
compared with conventionally filled handsheets. Improved water removal could
translate to faster drying, energy savings, or both on the papermachine.
Industrial Evaluations
There have been two published evaluations of fiber loading. The first evaluation [15] involved fiber loading virgin never
-dried birch hardwood bleached kraft pulp. An atmospheric high consistency refiner was used as a mixer for adding calcium hydroxide to high
consistency pulp, followed by high consistency pressurized refining under carbon dioxide pressure for the reaction stage. The fiber-loaded
pulp was then processed on a pilot scale paper machine. The paper machine trials revealed some technical obstacles. Changes in color and
brightness, cross machine web shrinkage, and apparent density increases were observed and became the focus of the follow-up laboratory
evaluations following the trials. The problems were duplicated in the laboratory, and methods for preventing or over-coming the
obstacles were developed.
Brightness and yellowing that occurred in the pilot papermachine trials were traced to residual lignin in the totally
chlorine free (TCF) bleached pulp. We demonstrated that including a low level of hydrogen peroxide prevented brightness loss and yellowing
of the fiber-loaded pulp. Web shrinkage was tracked to greatly improved water removal for fiber loaded pulps compared to the conventional.
Web shrinkage occurred before the paper machine cross machine direction restraint rolls. This was due to improved water removal. Filler
retention was shown not to be a problem with fiber loaded pulps. Apparent density was increased by about 10% for fiber loaded pulps.
Laboratory hand sheet experiments demonstrated several methods for bulking the sheet, e.g., increased use of thermomechanical
(TMP) pulp and decreased wet pressing.
The second published industrial evaluation of fiber-loading involved deinked mixed office waste (MOW)[9]. A disk
disperser was used to convert calcium hydroxide to calcium carbonate on the deinked pulp. Conventional deinking mill conditions
were simulated, including typical pulping chemistry, deinking process sequence, and process water clarification and recirculation.
Industrial-scale fiber loading was technically successful; calcium carbonate was completely converted to calcium carbonate and deposited on
the external and internal surfaces of pulp fibers. However, we found that calcium hydroxide had to be thoroughly mixed with fiber prior to
reaction with carbon dioxide to insure the uniform loading and complete conversion to carbonate. The fiber loading processes used in the
trials needed to be modified to obtain optimum conversion to calcium carbonate. Separate operations for mixing calcium hydroxide into the
pulp and chemical reaction with carbon dioxide were needed.
Top of Page
Rationale
Deinking Sludge Reduction
Because the PCC in printing papers generates tons of deinking sludge which become a disposal problem,
we explored the impact fiber-loading could have on the calcium carbonate portion of sludge production during recycling of recovered
paper [16]. Once calcium carbonate is precipitated in the fiber interior and on the fiber surfaces, much of the carbonate remains with the
fiber when recycled. We compared the retention of FLPCC with the conventional papermaking process that adds PCC to recycled pulp. Hot
dispersion, frequently one of the last steps in recycling pulp, breaks down and distributes residual contaminants. Hot dispersion followed
by direct loading of PCC (we designated these two steps as direct loading for this study) is a common final step in deinking wastepaper
derived pulps. Both direct loading and fiber loading process high consistency pulp using a high consistency refiner. The fiber-loading
process operates at ambient temperature; the direct-loading process dispersion operates at elevated temperatures. However, our preliminary
experiments suggest that the fiber-loading process results in at least as good dispersion as the direct loading process [17]. So, fiber
loading could possibly replace direct loading using the same high consistency refiners already in place in some papermills. In this study,
a common never-dried pulp filled by both processes was recycled several times to evaluate relative impact on whitewater and, ultimately,
sludge production. The direct-loading and fiber-loading processes were compared with a control pulp to which calcium carbonate was added,
directly followed by drying and recycled by fiberizing without additional mechanical treatment.
The following results were obtained from the retention study: Handsheet physical and optical properties of recycled
fiber-loaded pulps were maintained without need for additional refining or carbonate addition. Measuring recycled handsheet ash levels for
fiber-loaded pulps required only about 50% of the calcium carbonate addition as that for direct-loaded pulps. Recycled fiber-loaded
pulps tended to have shorter fiber length than the direct loaded pulps, indicating perhaps natural fines retention for fiber loading.
Process water analysis showed about 50% less total suspended solids and 50% less calcium ion concentration than did the direct-loaded pulps,
indicating about 50% less calcium carbonate in the fiber-loaded process water. Cellulose fines and COD analysis showed somewhat less
cellulose fines in the fiber loading process water than for the direct-loaded pulps. Fiber-loading shows potential to reduce calcium carbonate filler
content of deinking sludge by up to 50%.
Top of Page
Economics and Energy
According to a recent feature article on paper industry needs, "research
on breakthrough technology that significantly increases the capital effectiveness of paper machines and papermaking should rank among the
highest pulp and paper industry research priorities"[18]. We believe that fiber loading can be a key factor in producing lightweight
high-opacity newsprint at an attractive return on investment (ROI).
Newspaper publishers are well aware of the economic benefits of lightweight newsprint: As stated in a recent newsletter, "Over the past
decade newspapers on the West Coast have shifted to lighter grammage newsprint as producers have pushed to save on fiber costs…Today,
West Coast publishers and producers are looking at reducing grammages further to 43 g/m2 newsprint, in line with a trend catching
on in Europe and Asia" [18].
We investigated the ROI for fiber loading for a hypothetical newsprint mill [19]. The investment analysis covered savings
resulting from reduced fiber needs, substitution of low-cost FLPCC for higher cost fiber, and reduced drying costs, as well as a premium for
lightweight paper. We balanced these savings with the added capital costs for new equipment, energy needed to operate the new process,
additional personnel, depreciation, maintenance, and bleaching chemical costs.
The assumptions and estimated costs associated with a hypothetical newsprint mill producing 600 metric tons of
newsprint/day, operating 350 days/year are shown in Table I. The mill is assumed to use a mix of 80% softwood thermomechanical pulp (TMP) and
20% deinked pulp (DIP). The fiber-loading process consists of four major operations: fiber fractionation, dewatering of long fiber fraction,
mixing of bleach chemicals and calcium hydroxide into pulp, and reacting of pulp with carbon dioxide in high-consistency pressurized reactor
(refiner).
We assumed that the 600 daily metric tons are fractionated into equal amounts (300 tons) of long and short fibers.
Only the 300 tons/day of long fiber are processed through the fiber-loading equipment. The additional cost for purchasing and installing the
equipment is estimated at $4.396 million. An additional 25% of installed cost for engineering and soft expenses comes to $1.934 million, for
a total capital cost of $6.333 million. Depreciation of total installed cost was calculated on a 10-year straight-line basis as $439,650/year.
The cost of additional personnel was estimated at $50,000/year. Energy for operating the fiber loading equipment was estimated at 2.4 x 1010
kJ/year. We also included a $65,946/year maintenance fund of 1.5% of the installed cost.
Savings which would result from reduction in grammage and increased FLPCC content were calculated assuming the cost of
FLPCC at both $75 and $150/metric ton. The cost of FLPCC varies depending on the availability of carbon dioxide and calcium hydroxide at the
mill site. We did not attempt to estimate the impact of the many factors involved in the FLPCC raw material costs, and merely used a cost at
both the high and low ends. The estimated savings per year for reduced grammage and increased FLPCC content included the additional cost of
hydrogen peroxide bleaching chemicals. Additional bleaching chemicals are needed to prevent alkaline darkening when alkaline calcium
hydroxide is added to lignin-containing mechanical pulps. We assumed a cost of $0.66/kg for hydrogen peroxide, $0.37/kg for magnesium sulfate,
and $0.22/kg for sodium silicate.
Premium for reduced grammage paper $2.24/metric ton/g grammage
Top of Page
Table I. Assumptions and estimated costs of fiber-loading newsprint |
Production (600 metric tons/day newsprint) |
Cost |
Process equipment and costs
Fiber fractionation, two stage pressure screening dewatering, two belt
presses
Chemical addition and pressurized reactor |
$256,000
$700,000
$998,000 |
Total equipment costs |
$1.954 million |
Installation (total % 1.25) |
$2.442 million |
Total installed costs (TIC) |
$4.396 million |
Engineering, etc. TIC % 0.44 |
$1.934 million |
Total capital costs |
$6.333 million |
Maintenance (1.5% installed cost) |
$65,946/year |
Depreciation |
$439,650/year |
Additional personnel |
$50,000/year |
Electric power |
$0.04/kW |
Energy for operating equipment |
2.4 x 1010 kJ/year |
Energy for drying paper |
1.98 x 106 kJ/metric ton (dry basis) |
Cost of natural gas |
$2.82/m3 |
Value of fiber |
$242/metric ton at mill |
Bleaching chemicals (based on fiber) 1% hydrogen peroxide
3% sodium silicate
0.05% magnesium sulfate |
$0.66/kg
$0.37/kg
$0.22/kg |
Top of Page
Savings resulting from reduced drying were also
estimated. For the reduced grammage, values were obtained by multiplying a
ratio of the grammage at the lower level
to grammage at the original level (assumed to be 49 g/m2) by energy
needed for drying paper (Table I) [20]. The energy was then converted to a
dollar value
by using the heating value and cost of natural gas. The beneficial effect
of FLPCC in increasing solids content prior to drying has been determined
experimentally
and published [17,21]. We multiplied the drying energy needed for drying
pulp by a factor proportional to the fiber fraction of the total solids. As
noted in Table I, fiber in the mill was valued at $242/metric ton [20].
Manufacturers of lightweight newsprint have claimed a premium in the
tonnage price. Price differentials
of $45 to $65/metric ton have been reported for reducing grammage
from 48.8 to 43.9 g/m2 [22]. Another source reports that 45 g/m2 newsprint
costs
6% more per
metric ton than its 48.8-g/m2 counterpart, but yields an additional
8% of printable surface [12]. However, the newsprint grades with reduced
grammage probably do
not have increased strength and opacity coupled with high Canadian
standard freeness, which are possible with fiber-loaded newsprint. Rather,
the premium
for lightweight
newsprint is probably for the additional cost of bleached softwood
kraft pulp required for reducing grammage. Our calculations for savings include
only 20%
of the reported average lightweight premium. That is, we added a premium
of $2.24/metric ton for each gram reduced. This is a conservative estimate
and tends to underestimate
the value of fiber loading to the paper manufacturer. Also, we did
not
include a value for reduced shipping charges, which could be a considerable
added value
for overseas shipments.
Our ROI calculations were based on total savings
divided by total capital costs. Savings included reduced drying, filler
for fiber substitution,
and premium for
reduced grammage. From these savings we subtracted costs for additional
personnel, running the process, depreciation, and maintenance.
Figures
8 and 9 show estimated yearly cost savings for reduced fiber and increased
FLPCC use. We obtained savings for both the reduced
grammage and increased FLPCC
content, but the reduced grammage had the greatest impact on savings.
As shown in Figure 8, only the additional 8% FLPCC approached
a positive value, assuming
that FLPCC costs $75/metric ton and grammage is not reduced. If
FLPCC is assumed to cost $150/metric ton, fiber reduction of about
2 g/m2
is needed to obtain
savings (Figure 9).
Savings resulting from reduced drying are listed in
Table II. We report the savings as kilojoules per year and the corresponding
dollar value.
This is based on our
assumption that substituting FLPCC for fiber will result in
proportionately
higher solids that enter the dryer section of the paper machine.
The savings range from
$73,540/year for 2 g/m2 fiber reduction and 4% increase in FLPCC
to $178,923/year for 6 g/m2 fiber reduction and 8% increase
in FLPCC.
The reported rate of return on capital investment includes
the cost of bleaching chemicals at both 1% and 0.5% hydrogen peroxide
levels
(Tables III and IV). The
amount of bleaching chemicals to be added to the fiber loading
process depends on many factors [8]. For example, the pulp
for fiber loading
may have been highly
bleached and only sufficient chemicals to prevent alkaline
darkening are required to obtain relatively low brightness newsprint.
Another possibility is that value-added
newsprint grades may require especially high brightness and
so a high level of hydrogen peroxide is needed to obtain the
additional
brightness.
Therefore, we
calculated ROIs at both the 1% and 0.5% hydrogen peroxide
levels. For both levels, we obtained positive ROIs for all levels of
grammage reduction and FLPCC increase.
Top of Page
Figure 9. Annual savings from reducing fiber and increasing FLPCC assuming FLPCC costs $150/ton.
Top
of Page
Assuming that a reduction of 4 g/m2 and an additional
6% of FLPCC are reasonable goals for fiber-loaded newsprint, high ROIs can
be reached. Assuming that FLPCC is available at $150/metric ton, the ROI is
estimated to be 59.7%; at $75/metric ton FLPCC, the ROI is estimated to be
73.4%. If only 0.5% hydrogen peroxide is used with typical stabilizing chemicals,
the corresponding ROIs are further improved. At $150/metric ton FLPCC, fiber
reduction of 4 g/m2, and FLPCC increase of 6%, the ROI is 81.9% and 96.5%
at $75/metric ton FLPCC. These ROIs are significantly higher than the typically
reported ROIs of 5% to 10% for papermaking capital investments [18].
Top of Page
Our engineering analysis for estimating cost reduction
is based on producing lightweight high-opacity newsprint by fiber loading.
Similar applications
of fiber loading are possible for mottled and white-top linerboard and printing & writing
grades. We have not included the engineering analysis of how the faster
paper machine speeds used to produce lightweight high-opacity paper increase
the
rate of production. Nor have we included the benefits of reduced greenhouse
gas emissions [23], reduced process water solids that result from improved
FLPCC retention [16], and pacification of pitch and stickies [17], all of
which accompany fiber loading. Nor have we investigated the effect of improved
printing surface that is potentially possible with partially filled fibers
and increased levels of FLPCC achieved with fiber loading. All of these
advantages of fiber loading have an associated economic value that can be
estimated and
all are potential topics for future engineering analyses. Greenhouse Gas
Emission Reduction
In order to estimate the potential reduction
in greenhouse gas emissions from all U.S. newsprint mills converting over
to production of lightweight high-opacity
newsprint, we determined first the greenhouse gas emission reductions for
a single hypothetical newsprint mill. The analysis consisted of calculating
the
reduction of CO2, N2O, and CH4 emissions for various levels of grammage reduction
and increased FLPCC levels possible with fiber loading. The calculations
covered the savings in drying both from reduced fiber needs and for increased
FLPCC
levels, and reduced energy needed for processing pulp. This was balanced
by the increased energy needs for operating the fiber loading processing equipment.
The same process assumptions and estimated energy uses, which effect the
associated greenhouse gas emissions, were again made for a hypothetical newsprint
mill
producing 600 metric tons of newsprint per day as was used for the economic
and energy evaluations [19].
Drying energy savings for reduced grammage
were obtained by multiplying the a ratio of grammage at the lower level
to grammage at the original level
(assumed to be 49 g/m2) by the energy needed for drying paper (1.98 x106
kJ/metric ton)[20]. The energy source for drying was assumed to be natural
gas. The reduction of greenhouse gases due to a reduction in natural gas
use were calculated on the basis of: 50.7 metric tons of CO2 /109 kJ, 3.5x10-3
metric tons of N2O /106 kJ, and 1.29x10-3 metric tons of CH4 /106 kJ of
natural gas [24].
The beneficial effect of FLPCC in increasing solids content prior
to drying has been determined experimentally and published [17,21]. Thus,
we multiplied
the drying energy needed for drying pulp by a factor proportional to the
fiber fraction of the solids.
The energy needed for processing the pulps
was estimated at 1.8x106 kJ/metric ton for DIP and 10.1x106 kJ/metric ton
for TMP [20]. Energy for processing
pulps was assumed to be electricity from bituminous coal. The reduction
of greenhouse gases from a reduction in the use of coal were calculated on
a
basis of 88.4 metric tons of CO2 /109 kJ, 3.0x10-3 metric tons N2O /109
kJ, and 2.0x10-3 metric tons CH4 /109 kJ of coal [24]. The reduction of greenhouse
gases due to a reduction in coal use were calculated by the percent energy
saved times the energy needed for processing pulps times the appropriate
greenhouse gas factor for the energy saved.
Reductions in energy and greenhouse
gas emissions were balanced by the energy needed for operating the fiber
loading equipment. The energy for operating
the fiber loading equipment was estimated at 2.4x1010 kJ/year [19]. Figures
10-12 show the reduction of green house gas emissions due to the reduction
in grammage and increase in FLPCC possible for various scenarios. The greenhouse
gases reported are carbon dioxide, nitrous oxide, and methane. The greatest
greenhouse gas reduction is for CO2 (Figure 10). Increasing the FLPCC levels
with fiber loading is more effective for reducing CO2 emissions than reducing
grammage.
In Figure 11 we also see a similar pattern for N2O emissions
as for the previous CO2 pattern. The level of FLPCC has a greater effect
on N2O emissions
than
grammage reduction and results in about three orders of magnitude smaller
than for CO2 emissions. The emissions for methane type gases from reduction
in grammage and increases in FLPCC are an order of magnitude lower than
for the N2O type gases (Figure 12).
Using the above estimates for a single newsprint
mill, we estimated the potential reductions in greenhouse gas emissions
for the entire U.S. The U.S. production
of newsprint is about 6.5x106 metric tons per year [22]. Assuming that
a reasonable goal for lightweight high opacity newsprint by fiber loading
is
for a reduction in grammage of 4g/m2, and an increase of as by 6% FLPCC,
the following estimates can be made: 341,000 metric tons/year of CO2, 127.1
metric tons/year of N2O, and 8.7 metric tons /year of CH4 can be reduced
from present newsprint manufacture in the U.S.
The main use of energy in newsprint
manufacturing is in the drying process [20,25]. Even the small percentage
reduction (10-20% potential reduction
in drying energy needs)[19], possible by producing lightweight high-opacity
newsprint, still significantly reduces greenhouse gas emissions in terms
of absolute numbers.
Adopting fiber loading for domestic production
of lightweight high-opacity newsprint for current newsprint production has
the potential
for reducing
CO2 emissions by over 340,000 metric tons per year, as well as over 120
metric tons of N2O and 8 metric tons of CH4. Given the high reductions in
greenhouse
gases possible by lightweight high-opacity newsprint, the environmental
benefits for producing lightweight high-opacity mottled and white-top linerboard
and
printing & writing grades need to be assessed.
Top of Page
Figure 10. Annual reduction in CO2 emission from reducing grammage and increasing FLPCC.
Figure 12. Annual reduction in CH4 emissions from reducing grammage and increasing FLPCC.
Top of Page
REFERENCES
- Gill, R., and Scott,W., "The relative effects of different calcium
carbonate filler pigments on optical properties," Tappi Journal,
70(1): 93(1987).
- Downs, T., "A bright future for calcium carbonate," Pulp
and Paper, 64(4) 39(1990).
- Scallan, A.M., Middleton, S.R., "Lumen
loaded paper pulp," In:
Papermaking Raw Materials, Transactions of the symposium held at
Oxford, Sept. 1985, p.613.
- Green, H.V., Fox, T.J., and S Allan, A.M., "The
preparation of lumen loaded pulps," Pulp and Paper Canada,
83(7):T203 (1982).
- Allan, G.G., Negri, A.R., and Ritzenthaler,
P., "The
microporosity of pulp: the properties of paper made from fibers
internally filled with calcium
carbonate," Tappi Journal, 75(3):239(1992).
- Klungness, J.,
Caulfield, D., Sachs, I., Sykes, M., Tan, F., and Shilts, R. "Method
for fiber loading a chemical compound," U.S. Patent
5,223,090, RE35, 460 Feb. 25 (1997).
- Klungness, J.H., Stroika,
M.L., Sykes, M.S., Tan, F., and AbuBakr, S.M., "Development
of fiber loading from laboratory to industrial application," In:
1998 AIChE Symposium Series in cooperation with Tappi Pulping
Conference, Oct.25–29,
1998; Montreal, Canada. (1998).
- Sykes, M.S., Klungness, J.H., Tan,
F., and AbuBakr, S.M., "Value-added
mechanical pulps for lightweight high opacity paper," In
:1998 Tappi Pulping Conference Proceedings, Oct.25–29,
1998;Montreal, Canada. Atlanta, GA: TAPPI Press, 539(1998).
- Heise, O., Fineran,W.,
Klungness, J., Tan,T., Sykes, M., AbuBakr,
S., and Eisenwasser, J., In :1996 Tappi Pulping Conference
Proceedings, Oct.27–31,
1996;Nashville, TN. Atlanta, GA: TAPPI Press, 895(1996).
- Sykes,
M., Klungness, J., Tan, F., AbuBakr, S., Rantanen, W., and Aziz,
S., Progress in Paper Recycling, "Effects of
processing and recycling on properties of fiber-loaded handsheets," 6(4):37(1997).
- Fairchild,
G.H., and Clark, E.B., "PCC morphology and particle size
effects in alkaline paper,""In: 50th Appita Annual
General Conf., 1996 Proceedings, Vol 2,427(1996).
- Anonymous, Pulp & Paper
Week, "Publishers begin to test ‘super
lightweight’ newsprint; other stick with standard 48.8
g/m2. 20(41):5(1998).
- Klungness, J., Caulfield, D., Sachs, I., et
al., Tappi 1994 Recycling Symposium proceedings, "Fiber loading
Progress Report,"Tappi Press,
Atlanta, 1994, 283.
- Pulp and Paper Manufacture, Vol. 2,"Mechanical
Pulping"(Leask,
R.A., and Kocurek, M.S., eds.), Joint Textbook Committee of
the Pulp and Paper Industry, TAPPI, Atlanta and CPPA, Montreal,
1987,
p. 215.
- Klungness, J., Sykes, M., Tan, F., AbuBakr,
S., and Eisenwasser, J., In: Tappi 1995 Papermakers Conference Proceedings, "Effect
of FL on paper properties,",Tappi Press, Atlanta, 1995,
p. 553.
- Klungness, J.H., Sykes, M.S., Tan, F., Aziz,
S., "Retention
of calcium carbonate during recycling: direct loading versus fiber
loading," In:
Tappi Environmental Conference Proceedings, May 7–10,
1995, Atlanta, Atlanta, GA:TAPPI Press, 445(1995).
- Sykes, M., Klungness,
J., Tan, F., and AbuBakr, S., "Environmentally
sound alternatives for upgrading mixed office waste," In:
Tappi Environmental Conference Proceedings, May 5–7, 1997,
Minneapolis, MN, Atlanta, GA:TAPPI Press, 497(1997).
- Orloff,
D.I., Paper Age, "Improving capital effectiveness: a business
case for breakthrough paper machine and papermaking research," 114(9):29
(1998).
- Klungness, J.H., Stroika, M.L., Sykes, M.S.,
AbuBakr, S.M., Witek, W., and Heise, O.U., "Engineering analysis of
lightweight high-opacity newsprint production by fiber loading," In:
1999 Tappi Joint Conferences, Mar. 1-4, 1999; Atlanta, GA, (1999).
- Pesonen,
K.V., "Recycled vs. virgin-energy and manufacturing cost
differentials: four hypothetical case studies," In: Focus ’95,
Landmark Paper Recycling Symposium, Mar. 19–21, 1991,
Atlanta, GA. Atlanta, GA: TAPPI Press, 251(1991).
- Allan, G.G., Carroll, J., P., Devekula, M.,
L., P., Gaw, K., Joseph, A., A., and Pichitlamken, J., Tappi Journal, "The
effect of filler location on the drainage, pressing, and drying
of pulp and paper," 80(8):175(1997).
- Kincaid, J., Managing
Editor, "Newsprint," In: 1998 North
American Factbook, 1997, Miller Freeman, Inc., San Francisco,
CA. 159 (1998).
- Klungness, J.H., Stroika, M.L., AbuBakr, S.M., "Reduction
of greenhouse gases by fiber-loaded lightweight, high-opacity
newsprint production," In:
1999 Tappi Joint Conferences, Mar. 1-4, 1999; Atlanta, GA, (1999).
- Anonymous, "National industrial competitiveness through energy, environment,
and economics," U.S. Department of Energy, No. DE-PS44-97R490004,
Atlanta Regional Support Office, 730 Peachtree Street, NE; Suite
876, Atlanta, GA,
Sept. 11, 1996.
- Klungness, J.H., Sykes, M.S., Tan, F., and
AbuBakr, S., "Fiber loading-theory
and application," In: Proceedings of 4th International Refining
Conference, Mar. 18–20, 1997, Fiuggi, Italy. Pira International,
paper 6, (1997).
For more information contact the author Mr.
John Klungness.
Top of Page
|