PAPER TECHNOLOGY INTERNATIONAL VOLUME 59, …5 OMYAAT A GLANCE 8,000 employees in 175 plants in over 50 countries Turnover of CHF 3.5 billion Most plants are ISO 9001/ ISO 14001certified

PAPERTECHNOLOGY INTERNATIONAL

PAPERTHE JOURNAL OF THE BIOFOREST PRODUCTS SECTOR

VOLUME 59, NUMBER 3AUTUMN 2018

FEATURING: AXCHEM; HEIMBACH; JRS GROUP; PROCSIM; SCHÄFERROLLS

NANO TECHNOLOGY: NANO- & MICRO-CELLULOSE STRENGTH AIDS; SCALE FORMATION & CONTROL

IMPROVING EFFICIENCY: CONTROL TECHNOLOGIES; FORMING FABRICS; ROLL COVERS

COLUMNS: CPI; LETTER FROM INDIA; NEWS & VIEWS; PEOPLE; STANDARDS UPDATE

Use of Calcium Carbonate for Improved Efficiency in the Production of Container Board Grades

Mark Smith (Omya AG)

PAPERmatters 2018!

Mark Smith Omya

After graduating from Exeter and Bristol Universities Mark has spent over 30 years in the

Paper Industry providing Technical Support to optimise paper machine operations. 10 years

in the North American Industry and over 20 years with Omya based in the UK.

The author may be contacted via the PITA Office

Telephone: 0300 3020 150 or E-mail: [email protected]

The

Presentations

Mark Smith 26/09/2018

PAPERmatters! 2018 Conference 1

omya.com

Use of Calcium Carbonate for Improved Efficiency in the Production of Container Board GradesEdgar Habich, Beat Kuebler and Mark Smith, Omya AG

Agenda

28 June 2017

This document contains proprietary information which shall not be used and disclosed without Omya explicit written authorization

2

• Omya at a glance

• Containerboard – situation today

• Adding GCC in RCF – the concept

• Case Study: Results & experiences

• Summary



Omya is a leading

global producer of

calcium carbonate and

a worldwide distributor

of specialty chemicals.Omya at a glance

Key figures

28 June 2017


4

OMYA AT A GLANCE

Leading global producer of industrial minerals derived from Calcium Carbonate and Dolomite

Worldwide distributor of specialty chemicals

Corporate head office in Oftringen, Switzerland

Ownership of mineral deposits for the next 100 years of business

Privately-owned Swiss based Corporation



Key figures

28 June 2017


5

OMYA AT A GLANCE

8,000 employees in 175 plants in over 50 countries

Turnover of CHF 3.5 billion

Most plants are ISO 9001 / ISO 14001 certified

Pioneer in ISO 14001 for quarries

In business for 130 years

Our Markets

28 June 2017


6

OMYA AT A GLANCE

ConstructionPrinting & Writing Technical Polymer Applications

Agriculture & Forestry Water & EnergyConsumer GoodsPackaging



A growing market with

additional capacities is

facing rising of costs

for OCC and challen-

ges in availability.Containerboard – situation today

Manufacturers

28 June 2017


8

CONTAINERBOARD – SITUATION TODAY

The decline for graphical papers in mature markets has consequences for the packaging paper market

Graphical paper mills include packaging paper into portfolio

Conversion of graphical paper machines to packaging mills

New assets already installed or will be installed in near future

Reduction of high quality fiber based material = prices increases

Board & Packaging Industry

Over-capacity

Raw material shortness

Pressure on Paper

prices

Margins



Procurement Market

28 June 2017


9


Expansion is driven by containerboard production in China and other Asia

Converting of graphical paper mills will continue

Recycling fiber based packaging materials will increase market share

China & other Asia will be one reason for availability problems and price increases for RCF

Price development of european OCC grades + China

28 June 2017


10


Source: RISI

Volatile OCC prices with trend upwards



Improve output,

maintain mechanical

paper properties and

manage costs.Improve efficiency by adding GCC – the concept

Requirements for Testliner & Medium Grades

28 June 2017


12

IMPROVE EFFICIENCY BY ADDING GCC – THE CONCEPT

The challenge

What added value CaCO3 could provide to increase production output, without any negative impact on costs and paper specs?

The objectives

Increase machine capacity orreduce specific steam demand

Maintain physical paper properties

No change in optical paper prop.

No problems with converting and finishing assets (creasing, die cutting, folding, gluing, boxing)

The Idea

Adding cost competitive fresh filler with amounts of 3 to 6% into testliner / medium grades.



Omyaboard reduces

furnish costs and

provides quality

consistency.Case Studies: Results & Experiences

Case Study 1 – Mill Data

28 June 2017


14

RESULTS & EXPERIENCES

PM 2 at Model AG, Weinfelden, Switzerland

Dual ply fourdrinier machine and speed up to 850 m/min

Size-press – top side application

Retention aid Cationic polyacrylamide

Trial set-up

Paper grade Testliner III; Basis weight 130-170 g/m2

Speed 500-840 m/min

Dosage of Omyaboard in top ply 5% and bottom ply 2-5%

Trial duration 48 hours



Case Study 1 Trial Results (Avg. over trial duration)

28 June 2017


15


Results out of mill trial Model, Weinfelden, Switzerland

Minimum req.

V 1.1 V 1.2Minimum

req.V 2.1 V 2.2

Total FillerAmount

% 18 22 24 15 18 20

Grammage g/m² 100% 100% 101% 100% 100% 99%

Production t/h 100% 100% 100% 100% 102% 104%

Speed Pope m/min 100% 100% 100% 100% 103% 106%

Steam Pressure bar 100% 98% 94% 100% 100% 100%

Short Compr. Test CD

kNm 100% 114% 113% 100% 104% 109%

Ring Crush Test kNm 100% 105% 101% 100% 105% 116%

Burst Strength kPa 100% 108% 106% 100% 106% 106%

Case Study 1 – Conductivity and German Hardness

28 June 2017


16


Reduction of Conductivity Reduction of German Hardness



Summary Case Study 1

28 June 2017


17


It is possible to add 3 - 6% fresh filler with positive impact optional on production output or steam pressure

Mechanical paper- properties remains on save level within given specification

High Filler (CaCO3) retention in both plies

Case Study 2 - Two ply machine 400 m/min 170 g/m²

February 19, 2018


18

OMYA CUSTOMERS

Omyaboard successfully added to bottom ply for over 10 hours

Up to 5% Omyaboard added.

This reduced steam demand by 1% for every 1% of filler added

No issues with wet end chemistry, runnability on paper machine or winders

Expected effect on board properties

All board produced was within specification



This document contains proprietary information which shall not beused and disclosed without Omya explicit written authorization.

October 24, 201819

Case Study 3 – CaCO3 Filler in Testliner / Machine Data

Paper grade

Furnish

Secondary filler

Machine speed

Basis weight

Production rate

Testliner – Fluting / with MSP

100% RCF (OCC)

12 – 18 %

900 – 1200 m/min

90 – 130 g/m2

40 – 60 t/h


October 24, 201820

Case Study 3 – CaCO3 Filler in Testliner / Machine Data

Top ply

Retention agent (PAM+)

Bentonite

Dye

FPR

FPAR

Bottom ply


Bentonite

FPR

FPAR

Steam consumption

100 – 250 g/t

1000 – 2000 g/t

none (brown dye)

60 – 80 %

35 – 55 %

100 – 250 g/t

1000 – 2000 g/t

60 – 70 %

30 – 50 %

1.0 – 1.3 t/t

Primary CaCO3 filler added to the bottom ply – not quenching the expensive dye!




October 24, 201821

Case Study 3 – CaCO3 Filler in Testliner / Mill Trial Wet End

pH

Conductivity

Anionic charge SCD

Turbidity

Water hardness

Alkalinity

FPR

FPAR


Bentonite

unchanged – normal variations OCC related

decreased – OCC variations related

unchanged

unchanged

decreased – OCC variations related

slightly decreased – OCC variations related

unchanged

unchanged

unchanged

unchanged


October 24, 201822

Case Study 3 – CaCO3 Filler in Testliner / Mill Trial Results

Primary filler addition

Total filler

SCT cd

CMT

Internal bond

Burst strength

Breaking length md

Breaking length cd

Air permeability

Production capacity

Steam consumption

4 %

22 % (secondary 18 %)

unchanged

unchanged

increased (+8 %)

unchanged

unchanged

unchanged

decreased (-10 % = positive!)

unchanged

decreased (-4 %)




October 24, 201823

Wet End Summary / Impact on the Quality and Productivity

Slightly decreased

SCT

CMT

Burst

Breaking length MD

Air permeability

Decreased (size press application)

Increased

Ply bond strength

Productivity

Unchanged

and Energy

Reduction of specific steam demand

+1 % CaCO3

+1 %Production

output

-1 %Steam con-

sumption

or

Omyaboard reduces

furnish costs and

provides quality

consistency.Laboratory StudiesWhy no loss in strength?Why no increasing in scaling?




October 24, 201825

0.00

0.20

0.40

0.60

0.80

1.00

1.20

0.1 1 10

pore

vol

ume

[dV

/d(lo

gd)]

/ c

m3g-

1

diameter [d] / µm

0% primary filler

4 % primary filler

Sample Total specific intrudedvolume / cm3g-1

0 % primary filler 0.701


Hg-Porosimetry – Similar pore volume available for starch absorption


October 24, 201826

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

0.20

0.1 1 10

pore

vol

ume

[dV

/d(lo

gd)]

/ c

m3g-

1

diameter [d] / µm

0% primary filler

4 % primary filler

Sample Total specific intrudedvolume / cm3g-1



Hg-Porosimetry – More rapid starch absorption due to increase in sub micron pores




October 24, 201827 w/o filler 4 % filler

Relative starch distribution %

Improved starch distribution in Z-Direction


October 24, 201828

Scaling - Calcium Carbonate - solubility

5.0 9.0

0

400

800

1600

2000 ppm Ca++

g C

aCO

3/l

0

1

2

4

5

6.0

12003

7.0 8.0

Acid papermaking

Near neutral to slightly alkaline papermaking

pH-value

Solubility of CaCO3 vs. pH

Very important to know where the pH is and the Ca++ ions content in a corrugated board application!




October 24, 201829

Scaling - pH increase with primary CaCO3 filler addition

The addition of a primary GCC would not affect the system:

Ca++ level is too high to get dissolved CaCO3 with pH of 6.5 – 7.0 (German water hardness > 130° = saturated!).

The scaling issue would stay on a similar level, it will scale anyway, since it does it now, too.

Only the pH of the system would slightly increase with the dosage of a primary filler CaCO3 depending on the filler quantity applied.

50 t/h production PM 1 - ratio top/bottom 40/60 – 30 t/h bottom layer – s.c. HB bottom layer 1.2 % = 2500 m3/h HB stock with Ø HB pH 6.75

Dosage of primary CaCO3 filler slurry (s.c. 78 %) with pH 9.5 = 1 t/h dry (2 % based on the total production of 50 t/h) roughly 0.652 m3 slurry added to the HB stock composition 2500 m3 /h = 2500.652 m3/h.

Calculated on this base the pH increase in the HB bottom ply would increase from 6.75 to 6.752477 only!


October 24, 201830

Scaling - CaCO3 Application Lab Study – Conditions

In order to get a better feeling about the potential risk of pH increase a small lab study was carried out with HB stock.

RCF based fibers (headbox – corrugated board machine)

Primary filler addition

0 / 50 % (to the head box stock s.c. ~ 1 %)

Filler applied

Omyacarb MF-ME 78 %

6.5 ml (1% - 1000 ml)

Steering device

350 rpm 10 minutes




October 24, 201831

6.0

6.2

6.4

6.6

6.8

7.0

0 50

Scaling lab Study - pH

% primary filler applied


October 24, 201832

50

70

90

110

130

150

0 50

Scaling lab study - German Hardness

dH°

% primary filler applied




October 24, 201833

Scaling - Summary Lab Study

Only a slight increase of pH measured – 6.57 to 6.76 pH with 50 % filler addition

Unchanged German water hardness

Conclusion: based on this lab study, the real pH increase with a filler addition of 2

% would be 0.0076 pH in the HB.

Pigment Requirements

28 June 2017


34


Tailor made Pigment

Costs

AbrasionProductivity



1% Omyaboard

= 1% output increase

OR

= 1% reduction of

spec. steam demand.Summary

The Omyaboard – Benefits

28 June 2017


36

MPROVE EFFICIENCY BY ADDING GCC – THE CONCEPT

Adding Omyaboard at reasonable level and:

Keep similar mechanical and physical properties of testliner and medium grades

Improve machine output or energy savings caused by lower steam demand

Achieve comparable surface starch pick in the size-press

Level out variations in secondary ash content coming from RCF

Reduces furnish costs and provides quality consistency

1% Filler ≈ 1% speed increase OR 1% Filler ≈ 1% specific steam reduction

Documents

PAPER TECHNOLOGY INTERNATIONAL VOLUME 59, …5 OMYAAT A GLANCE 8,000 employees in 175 plants in over 50 countries Turnover of CHF 3.5 billion Most plants are ISO 9001/ ISO 14001certified