Filler Engineering for Energy Savings and Improved Paper Properties

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1 Filler Engineering for Energy Savings and Improved Paper Properties TAPPI Con 09 June, 2009 Delong Song, Chunxu Dong, Art Ragauskas and Yulin Deng* IPST at Georgia Tech Georgia institute of Technology

2 Advantages of Using Filler in Paper Increase filler content in paper will improve paper optical properties (brightness, opacity, printing quality) Increase filler content in paper will reduce the papermaking cost pulp price: $ /ton filler cost (clay or PCC): $ /ton Increase water drainage rate Increase solid content of paper web Substitution of fiber will reduce the carbon footprint

3 Problems of Using Filler in Paper Reduces the paper strength Reduce the bulk Some effects on the wet-end end operation retention sizing reversion (PCC filler) water clarification two sideness dense paper Linting and dusting

4 Filler Engineering: Past Researches New generation filers High aspect ratio fillers (PCC, Clay) Low cost fillers (Gypsum fillers) High quality fillers (TiO 2, nanofillers) Nanosilicate filers Filer modification and novel treatment techniques Wood fines-filler filler composites Pretreatment of fillers (preflocculation( preflocculation) Polymer coating

5 Our Approach: Filler Treatment Using Starch f i b e r In traditional papermaking Filler Starch Our approach Coated Filler f i b e r Starch adsorbed on filler Starch coated on filler aggregate

6 Filler Modification with Polymer Coating Spray drying method Wet slurry method Polymer precipitation method The best method depends on your paper grade, location (transportation cost), and fillers (PCC, Clay)

7 Spray Drying Method Filler + starch + water Filler Cook Filler + dissolved starch + water Spray Dry Starch-coated filler Coated Filler Starch used is raw starch, which is ~$0.3/Lb, comparing with cationic starch of ~$1.3/lb Both potato and corn starch can be used 2.5% starch based on clay is enough

8 Modifying the Spraying Dry Method by Adding Crosslinker One of our engineered fillers: raw starch (corn starch) coated clay: Spray dried method

9 Starch Coated Clay for Linerboard Application Why do we add filler in linerboard? Energy saving Machine running ability improvement Printing quality Raw material cost reduction Problems Strength reduction Filler retention

10 Spray Dried Starch-Coated Clay Handsheet Results Modified Clay IMERYS (Atlanta, GA) Modified clay coated with precooked 2.5% corn starch via spray drying of 40% clay slurry Control: conventional clay with 3 lb/ton cationic starch Furnish SW kraft pulp, kappa 105, Inland Pulp was beaten to C.S.F. 350 ml Handsheets TAPPI method, 180 g/m 2, CPAM retention aid. Tensile Index (Nm/g) RIng Crush Index (Nm/g) Tensile Index vs. Filler Content Orig. Clay 2.5Corn Filler Content (%) Ring Crush Index vs. Filler Content at Different CPAM Levels Orig. Clay (0-2 ppm CPAM ) Spray-Dried M od. Clay, 2.5 Corn (0-2 ppm CPAM) Filler Content (%)

11 Handsheet Properties Using different Starches (Lab Results) 65 Tensile Index (G eom etric M ean) vs. C lay C ontent 14 R ing C rush Index (G M ) vs. C lay C ontent G M T e n s ile In d e x (N m /g ) % 5% 10% 15% 20% 25% Filler Content in Sheet (% ) U nfille d L ine r C o ntro l (W itho ut S tarc h) U n m o d. C la y C o n tro l w ith C a tio n ic S ta rc h M odified C lay (Unm odified S tarch) Modified Clay (Low Visc. Starch) M o d ifie d C lay (P ro p rie tary P o lym e r) G M Ring Crush Index (Nm /g) % 5% 10% 15% 20% 25% Unfilled Liner C ontrol (W ithout S tarch) Modified Clay (Unm odified Starch) Modified Clay (Proprietary Polym er) F ille r C o n te n t in S h e e t (% ) Unm od. C lay C ontrol with C ati Modified Clay (Low Visc. Starc

12 Herty Trial GM Ring Crush Index vs. Clay Content 3.5 GM Ring Crush index (Nm/g) Clay Content in Sheet (%) Original Clay Modified Clay Stiffness (mnm), GM Modified clay Original clay Clay content (%) Stiffness reduced only slightly at 10% modified clay content. Over 10% increase in tensile and ring crush with modified vs conventional clay

13 Herty Pilot Trial Effect of Clay on Sheet Dewatering Dryness out of Press Bulk (cm 3 /g) Modified clay Original clay Clay content (%) Solid Content (%) Dryness off Couch Sheet Ash Content (%) Clay, Couch C Mod. Clay, Couch C Clay, Press C Mod. Clay, Press C Bulk maintained at 10% modified clay content

14 Summary of Starch Coated Clay in Linerboard Application (Spray Dry Method) Raw Starch can be easily coated on clay surface 2.5% starch (based on filler) is enough to achieve highest strength benefit Adding starch coated filler to linerboard can reduce papermaking cost Up to 8% of starch coated filler do not reduce the strength properties Adding filler can significantly improve the drainage rate, solid content and drying rate Several mill trials using starch coated filler have been done

15 Wet methods Starch-clay Composite by Fatty Acid Complexation Starch Clay Fatty acid Cooking NaOH (ph 11~12) Neutralization HCl (below ph 4) Unmodified corn starch and palmitic acid (or stearic acid sodium salt) The mechanism of starch-filler composite is due to the formation of starch-fatty acid complex which is water insoluble at low ph

16 Starch-Clay Composite Aggregates Formation Clay slurry (2-25%) Cooked raw starch Fatty acid Low ph < 4 Starch-clay composite suspension

17 Solubility: temperature and ph effects Solubility Swelling Power Solubility Swelling Power % 20 % Temperature, C ph

18 Application of the technique Can be used for modifying both clay and PCC. For PCC, calcium ions can precipitate the starch and no acid is need to bring the ph down Can be applied to different paper grades

19 Copy paper Physical properties Tensile Index, Nm/g starch(palmitic 10%) clay 1:1 starch(palmitic 30%) clay 1:1 clay 10 conventional method 0% 10% 20% Clay dosage, % ZDT, KPa starch(palmitic 10%) clay 1:1 starch(palmitic 30%) clay 1:1 clay conventional method 0% 10% 20% Clay dosage, % ~120% increase comparing to clay-fiber only ~ 60% increase comparing to cationic starch (conventional method) method

20 Copy paper Physical properties (cont.) Burst Index, kpa m2/g starch(palmitic 10%) clay 1:1 starch(palmitic 30%) clay 1:1 clay Folding Index, times m2/g starch(palmitic 10%) clay 1:1 starch(palmitic 30%) clay 1:1 clay 0.0 0% 10% 20% 30% Composite dosage, % 0 0% 10% 20% 30% Composite dosage, %

21 Copy paper Optical properties Tensile Index, Nm/g starch(palmitic 30%) clay 1:1 starch(palmitic 10%) clay 1:1 clay Tensile Index, Nm/g starch(palmitic 30%) clay 1:1 starch(palmitic 10%) clay 1:1 clay Opacity. % Brightness

22 Copy paper Distribution and Bonding (SEM) fatty acid 10% fatty acid 30% fatty acid fatty acid 10% 30%

23 Additional advantage (sizing) Pamitic 10% to starch Palmitic 30% to starch 10% Wettability (R) % 10% 20% 30% 40% Compostite Dosage, % 30% Rate of change of wettability (R) = Change of contact angle / change of time 5s 60s

24 Energy saving and machine runnability improvement by adding fillers Drainage test The pulp with various amounts of clay-starch composites was diluted to 1L of 0.5 wt% respectively. Percol-175 was added at 0.1wt% based on solid weight for clay retention. Drainage time was measured by a Dynamic drainage analyzer (DDA).

25 Stirrer (800rpm) DDA drainage unit Vacuum vessel (0.2 bar) Drainage is measured as the time from the start of run until air start being sucked though the sheet.

26 Effect of filler content on the drainage rate time of drainage/s filler content Clay filler; C-PAM retention aid at 2lb/ton; linerboard Drainage rate was increased (or drainage time decreased) >20% by adding 20% fillers

27 Water removal tests (press and drying sections) Unbleached kraft pulp (60% hardwood and 40% softwood) was refined in a Valley beater to a freeness of 400 CSF. Starch modified clay (spray-dry method) was provided by Imerys as the filler. Percol-175 (high molecular weight, low charge density polyacrylamide retention aid) was obtained from Ciba specialty Chemicals. The filler content was determined by ashing the paper in a muffler oven according to the standard TAPPI method T211. After a slightly wet pressing (50psi,5min, no heating), handsheets with a target basis weight of 200g/m 2 were prepared and ready for pressing and drying test

28 Wet pressing test The testing system used was the MTS Testing Machine controlled by a MTS Micro Console. Handsheets were cut to a suitable size for the MTS press. The weights of the samples before and after press (600psi) were both measured immediately. MTS Micro Console.

29 Drying test After wet pressing test, the sheets were dried at 105 C by a Mettler Toledo LJ16 moisture analyzer. The percent of solids content was measured every 30 seconds, and the lost water weight was obtained. Mettler Toledo LJ16 moisture analyzer

30 Effect of filler addition on the solid content after press Solid Content after Pressing (%) Test Filler Content (%) Solid content after pressing (%) Test-2 0% 5% 10% 15% 20% 25% 30% filler content, % Test-1 and Test-2 were two independent tests with the same pressure Solid content increased from 30% to 36% under 600 psi pressing Solid content increased 6 absolute points by adding 23% filler.

31 Effect of filler addition on the solid content after press 3 3 water/dry weight after press filler content water weight /dry weight after press filler content, % Two figures were generated from two independent tests Relative water content (water/dry paper) after press decreased from 2.3 to 1.65 by adding 25% filler, witch corresponding to 26% reduction in the water content

32 Web solid content as a function of press cycles at 600psi 50 solid content, % % filler 6% filler 11% filler 18% filler 23% filler Solid content increased by 5 weight percents by adding 23% filler. For every 1% increase in exiting press solids, an approximate 4% increase in machine speed can be projected on a dryer-limited machine. 5% increase in solid content will result in 20% improvement in the machine speed press cycles

33 Solid content as a function of filler content solid content, % psi 610psi solid content, % filler content, % filler content, % Different pressure (single cycle) Different cycles at 600 psi

34 Effect of filler addition on the drying rate Drying time (8min) with 24% filler Drying time (10min) with 0% filler water removed/total water,% Test-1 24% 21% 16% 11% time,min 6% 0% water removed/total water (% ) Test time (min) 0% 4.98% 9.39% 16.41% 21.70% 25.90% Two figures were generated from two independent tests The water drying time decreased from 10 minutes to 8 minutes, which saving drying energy by 20%.

35 Mill Trials 5 mill trials have been done by Imerys at different mills (4 at Interstate Paper and 1 at Stora Enso). Linerboard and starch coated filler made by spray drying was used

36 Impact of Traditional Filler in Linerboard STFI (Nm/g) % loss from unfilled 9.5% loss from unfilled Control (0) % Filler in board Ring Crush (Nm/g) % loss from unfilled 14% loss from unfilled Control (0) % Filler in board Most suitable for mills making heavy weight linerboard with some strength to give. Probably not applicable across the grade range for any mill. Probably won t allow incremental production gains (machine speed gains not possible due to strength loss) - improved drying rates recouped as energy savings, or if machine can refine more will gain back some strength whilst reducing CSF

37 Commercial Trial History March 2007: 8 hour trial on 55lb (268 g/m2) High Performance Liner Speed kept constant 10% reduction in steam demand seen at 4% in base ply October 2007: 24 hour trial on same grade as previous In all trials: Machine speed gains of m/min were achieved Old Corrugated Containerboard (OCC/recycled) flow was interrupted, which - No paper was lost to breaks allowed an unexpected evaluation of OCC versus SEK SEK appeared - Strength to have levels more impact were on within machine specification speed at lower levels than OCC - Runnability was excellent March 2008: 72 hour trial encompassing a range of grades Addition rates up to 5.5% were run successfully Significant gains in productivity (up to 6%) were achieved relative to typical run rates (speed increases >30 m/min on some grades) **Interstate Paper was member of a state funded project, and is aware that this information has been shared with other paperboard producers. 37

38 Commercial Trial 3: Productivity Summary Grade 42# Mullen (205g/m 2 Standard) 69# Mullen (336g/m 2 Standard) 55# STFI (268g/m 2 High Performance) Average SEK addition 3.90% 4.50% 4.80% Target Speed (m/min) Trial Speed (m/min) Trial Speed Gain (m/min) Target Production Rate (stph) Trial Production Rate (stph) Trial Productivity Boost (%) 3.2% 3.3% 2.9% Max Speed (m/min) Max Speed Gain (m/min) Max Trial Production Rate (stph) Max Productivity Boost (%) 3.9% 5.3% 5.8%

39 Commercial Trial 3: Impact on Strength Target 35 Mullen Minimum Target STFI (lbf/in) Target Minimum Minimum SEK Flow (% of Primary Ply) 42# Mullen 69# Mullen SEK Flow (% of Primary Ply) No correlation between critical strength tests and SEK dosage rates.

40 Value Proposition for SEK in Linerboard 4-5% SEK in linerboard results in the following benefits: Fiber replacement or extender Can substitute or extend OCC and Virgin fiber No statistical impact on strength and slide angle Faster drainage and drying Reduced steam demand - 10% Potential for speed increase - ~ 100 fpm Production rate increase of up to 3tph on 55lb liner 40

41 Overall Conclusions Adding our starch coated clay to linerboards improve water drainage rate increase machine runnability increase solid content by 3-5 absolute point Saving drying energy by >10% Starch coated filler does not detrimentally impact linerboard sheet strength up to filler content of 8% The starch modified filler can also be used to improve newsprint properties The starch coated filler shows higher strength properties than adding filler and starch separately in wet end. Two modification methods (wet and spray drying) are developed Our techniques can be used for both PCC and clay Several mill trials have been done, and the longest trial was last three weeks. The trail was very success. Intellectual Property A patent of filler modification use starch and starch-fatty acid composite has been filed at US Patent Agent in September 2007 Publication number: US 2008/ A1

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