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Kemira's international customer magazine for the pulp and paper industry.

Solutions
Kemira

2
09

• Focusing on water
and energy efficiency

• Kemira's flagship
retention technology

New bio- Modern Karton's Biocides


degradable brand-new board in action at
chelating agent machine Äänekoski
11 18 26
Editorial

Contents
Water
efficiency
photo kreetta järvenpää

efficiency is becoming an ­increasing key


Water and energy issue in all areas of industry. Limited sup-
plies of clean water, ever-stricter official permit levels, and the need
to cut costs all mean that more water needs to be recycled. Based on
the extensive know-how we have in water treatment chemistry, we 18 22 26
want to do everything we can to help our customers face these types
of challenges.
The importance of optimizing water and energy usage is growing,
and the need to recycle water and treat the raw water used in proc- 04 Short Cuts 22 R&D
esses is growing with it. Wastewater treatment costs are rising as well. Ten years ago we were talking about water Kemira's new, special dry strength additive is
Water and energy efficiency is an environmental issue, but it is also recycling, and we still are today. Marcelo one of the latest innovations to emerge from
very much an economic one, as making better use of these resources Costa from São Paolo gives us his take on the company's R&D pipeline, says Bernd
can bring major cost savings to a production plant. R&D in South America in the Q&A column. Hauschel.
Water chemistry is an increasingly important factor as recycling
08 On Topic 24 At Your Service
levels increase, as Kaj Jansson of Kemira’s R&D explains in this issue of There are still a lot of opportunities left for Kemira’s new line of high-temperature,
Solutions. The more closed a process is, the better its water chemistry reducing the energy intensity of the pulp and water-based defoamers provide
management needs to be. Recycling water within a production plant paper industry, says Research Professor Kari effective foam and entrained air control at
increases its temperature and the level of contaminants it contains and Edelmann. higher temperatures.
can lead to corrosion problems and elevated microbial growth.
The amount of water used by paper machines has dropped signifi- 11 To the Point 26 Partnership
Kemira’s patented biodegradable chelating M-real’s Äänekoski board mill in Finland
cantly over the last decade, and in the future we are likely to see even
agent, Fennobio S, has been registered under has been involved in testing and developing
more water being recycled. Modern Karton, based in ­Turkey and the ­European REACH regulation. Kemira’s new slime control concept from the
featured in this issue, is a good example of a producer that has been start.
12 Analysis
able to increase its water recycling thanks to ­efficient wastewater
treatment. “Water and When closing water cycles, it is always 28 At Your Service
By focusing on water and energy efficiency, and on how
­improvements can be made, we want to highlight some of the
energy efficiency important to evaluate physical, chemical, and
biological factors, according to Kaj Jansson.
Kemira's flagship retention technology is
now in use at multiple mills around the
­expertise that Kemira has to offer in this area – expertise that could is an environmental 18 Modern Karton
world producing both printing paper and
packaging board.
help you too.
issue, but also very Turkey's leading board producer is thoroughly
committed to quality.
Kaisa Sipilä
Editor-in-chief much an economic
one.”
Kemira Solutions is published in Finnish and English two times a year.
PUBLISHER Kemira Oyj, P.O. Box 330, 00101 Helsinki, Finland, tel. +358 (0) 10 8611, Try some recycling
fax +358 (0) 10 862 1694, www.kemira.com. technology for yourself!
EDITORIAL BOARD Kemira: Kaisa Sipilä (Editor-in-Chief), Ari Pirneskoski, Nichlas Kavander, There’s a lot of fun things you can do with
Jean-Francois Caisso, Susan Flesher, Darren Swales, Tuomo Keskinen, Jan-Luiken Hemmes, water, and it’s easy to recycle at home as well.
Mats Rönnbäck, Clayton Campbell, Susanna Ruotsalainen, Johan Grön, Johanna Juuti, Kirsti Check out the back cover to see how you can get
Kalaniemi. Lehdentekijät: Jussi-Pekka Aukia (producer), Jenni Sepponen (subeditor), Mervi
water to move along a piece of thread from one
Ahlroth (photo editor), Miikka Tikka (AD). PRODUCED BY Alma Media Lehdentekijät Oy, P.O. Box 502,
container to another, just by capillary action.
00101 Helsinki, tel. +358 (0) 10 665 102, fax +358 (0) 10 665 2533, www.lehdentekijat.fi.
REPRODUCTION Aste Helsinki PRINTED BY Punamusta Oy, 2009. Paper Lessebo design smooth
white 115 g. Produced using Kemira products. ADDRESS REGISTER Kemira's customer register.

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ISSN 1456–5064

2 Kemira Solutions 2 | 2009 3


Short Cuts text Jussi-Pekka Aukia photos gettyimages, jussi-pekka aukia

Q& A
text Jenni Sepponen photo miika kainu

Focusing on water Marcelo Costa


and energy efficiency Kemira at Expo 2010
South American Research
and Development Center
in Shanghai
news Optimizing water and energy usage is becoming increasingly important for the Manager, São Paulo
pulp and paper industry. As a leader in water chemistry, Kemira is ideally placed to help Kemira will take part in the Shanghai
its customers optimize their processes, water quality, and water consumption (WQQM). World’s Fair in 2010 as one of the part- What are your main goals regarding the South
Kemira will continue to focus on further developing its unique capabilities in this area ners in Finpro’s Finland at Expo 2010 American marketplace?
and its presence in regions where the pulp and paper industry is growing the most: APAC project. The event – which will focus on “Our main goals initially will be to initiate a tech-
countries, South America, and Eastern Central Europe. the theme of Better Cities, Better Life nical customer service (TCS) for Kemira’s customer
“We’re committed to improving our long-term profitability and strengthening our – will run from the beginning of May industries in South America, with a focus on water-
competitive position through a regional approach based on understanding the needs of to the end of October and is expected intensive processes. This will mean developing our
to attract over 70 million visitors. Pho-
different regions and offering a product portfolio designed for these needs. We want to capabilities for carrying out product development
tographs from a competition organized
understand our customers needs even better and adapt our operations rapidly to meet and R&D activities for specific regional needs to
by Kemira and Finland at Expo 2010 in
them, and seize new opportunities that emerge in a marketplace where things are chang- fall 2009 will be featured at the event open up new markets and new customers, and
ing all the time,” says Petri Helsky, President of Kemira’s Paper segment. to give visitors a view of life in Finland building a strong network with local customers
and the importance of clean water in and research institutes.”
today’s world.
Are you going to develop some new research
­areas? When will the Center start operations?
Record production in Russia See you there!
“We expect eco-friendly processes to grow rapidly
in the region, and the R&D Center will cooperate
case One of the largest paper machines in Rus- with universities and institutions in this area. We
Kemira is set to showcase its capa-
sia was recently modernized, but following the hope to start up the center during Q4/2010. We
bilities at a number of trade fairs next
start-up it was found that extractives from the spring. We will take part in Tissue World see future R&D looking at areas like biorefineries
birch pulp used at the site was having a negative Americas in Miami between March linked to the sugar cane industry and pulp mills,
impact on runnability. Following the introduc- 24 and 26 and in Asian Paper 2010 in and membranes and desalination technologies
tion of Kemira’s pitch control solution, which Bangkok between April 21 and 23; and for the partial closure of industrial water cycles,
includes Fennodispo 320 and Fennofix 41 we will be back in the US, at Papercon ­drinking water supply, and deep water drilling.”
chemicals, the problem has disappeared and the ’10 in Atlanta, between May 2 and 5.
machine has been breaking all its previous speed What is your own professional background?
and output records. “I have over 12 years of experience in the pulp
“This is a great example of what Kemira’s local and paper industry. I transferred to Kemira from a
organization in Russia and our experts in Finland
Clean technology Suzano Pulp and Paper mill, where I was process
can achieve by working together to solve a customer’s
from Finland manager and responsible for process optimization.
problem,” says Customer Service Engineer Konstantin Kemira recently joined the Clean-
Before Suzano, I worked for several years at mills
Khudozhilov. tech Finland program to promote its operated by Veracel and Cenibra Pulp. I earned my
water-related customer solutions. The Ph.D. in 2001 and completed an MBA in 2003.”
program brings together top Finnish

Analyzing biomass cleantech companies and experts in a


new type of network and will provide
What is it like living in São Paulo? What about
your personal life?
concrete marketing and communica- “São Paulo is a very cosmopolitan city and a great
NEWS Kemira’s portable LumiKem technology monitors the health of the biomass in a tions support for profiling Kemira as a place to live. As traffic congestion is a big problem,
wastewater treatment plant by measuring levels of adenosine triphosphate (ATP), which leading cleantech company in the field it’s very important to live near where you work, so
of water quantity and quality manage-
acts as a direct and interference-free indicator of total living biomass. once we’ve decided where the lab will be we’ll be
ment.
LumiKem brings a new generation of process efficiency to biological treatment opera- moving close by. I enjoy swimming, fishing, and
The cleantech concept covers all
tions, according to Edouard Papin, Senior Application Specialist, W ­ ater Quality Manage- products, services, processes, and tech- spending time with my family on the weekend. I
ment. LumiKem PORTAL software can monitor treatment processes in their entirety, nologies that prevent or reduce man’s like travelling and meeting people from around "I've come to like the
from early toxicity detection to energy cost optimization. harmful impact on the environment the world, and I've enjoyed my stay In Finland Finnish sauna and
“It’s a user-friendly program that can make quick correlations between process data – and is designed to promote better very much.” I would like to try
snowboarding during
and help optimize wastewater treatment operations at a customer’s facility. It can assist quality, efficiency, progress, effective-
my two-month stay
in minimizing nutrients, energy costs, and incoming toxic shocks to a process, as well as ness, and profitability. in Finland.”
optimizing the living biomass inventory.”

4 Kemira Solutions 2 | 2009 5


Short Cuts

New JV in China gets off to a good start


10 text Jussi-Pekka Aukia
photo katri tamminen
News Kemira and the Chinese company, Tiancheng Ltd., set up a joint venture in January Successful start-up
Years 2009 to produce AKD wax and AKD size for the paper and board industry. Kemira has a for the microbiology
Ago 51% holding in the company – known as Kemira-Tiancheng Chemicals (Yanzhou) Co.,
Ltd – and Tiancheng 49%. Operations have got off to a good start and demand for product
has developed well.
lab in Leverkusen
The new laboratory began opera-
tions as planned in May, managed
by Professor Dr. Olof Norrlöw and his

Look at the R&D Center in Atlanta colleagues. Based at the R&D Center
in Leverkusen, Germany, the new

big picture up and running facility is part of moves to concen-


trate Kemira’s R&D functions into
five centers operating as a global,
research The opening of the latest addition to company-wide network. The labora-
Kemira’s R&D capabilities was celebrated in Sep- tory handles a very wide range of
The 2/1999 issue of Kemira Solutions fea- tember. Located in the centre of Atlanta in the different types of samples and works
tured an article on a biocide project at UPM- Technology Enterprise Park alongside the Georgia particularly closely with the labora-
Kymmene’s Jämsänkoski mill in Finland. The Tech campus, the Atlanta R&D Center has global tory in Espoo, Fnland to compare
mill’s Process Manager, Matti Taimisto, told responsibility for oil, mining, tissue, recycled fiber, analysis data and develop strategies.
readers about his water usage philosophy in defoamers, and polymer research and will be a key In addition, the lab routines focus
on technical customer service for the
a sidebar to the main article. Reducing water part of Kemira’s global R&D network. The Center
microbial process control at Kemira's
consumption was already an important target consolidates the expertise of four separate North
production site in Leverkusen. The
in the industry. American research locations under one roof and is target of the new lab is to develop
“Even though water volumes, as such, are intended to promote new levels of synergy between and offer tailor-made solutions for
not a problem in Finland, attempts are being academic research and commercially focused technology microbial process control to custom-
made here to cut water consumption as well, and product development. ers of different production segments
for environmental and image reasons. When based on the right product combina-
reducing water consumption, care needs to be tions and engineering know-how.
taken that solids emissions are reduced as well.
Water quality can be a problem. Lower demand Q3 | 2008

decreased revenue
“Reducing total water consumption, and the
use of cooling water in particular, is an impor- ABTCP fair 2009
Q3 | 2009
tant objective − and can be achieved by things
Kemira took part in the 42nd ABTCP
such as circulating process water through Numbers Revenue at Kemira’s Paper segment de-
fair organized in Saõ Paulo by the
­cooling systems. creased by 14% in the third quarter of 2009, to €230.2 Brazilian Pulp and Paper Technical
“New technologies can help cut water con- million (2008: 267.7 million), as a result of a significant 267.7 230.2 Association (ABTCP) in conjunction
sumption, but energy consumption shouldn’t slowdown in demand from the segment’s custom- million million with the Finnish Paper Engineers'
be forgotten either. Great technical solutions ers. Consumption of newsprint, magazine paper, and € € Association. The four-day event, the
can easily increase power consumption, so you printed advertising material was lower in traditional largest of its kind in Latin America,
always need to look at the big picture when core markets in Europe and North America in particu- attracted 163 exhibitors and 8,200
planning water use. In addition to optimizing lar. Management estimates that demand has fallen by visitors.
energy and water flows, attention must be paid 10–25%, depending on paper grade. “ABTCP 2009 was a very good
place to consolidate our relationship
to wet-end chemistry as well. The main goal is The segment recorded an operating profit, exclud-
with our customers,” according to
to improve the operating efficiency of paper ing non-recurring items, of €14.8 million (2008: 11.7
Luiz Leonardo, Paper Sales Senior
machines, in terms of their runnability and million), equivalent to a net operating profit percent- Manager – South America. “More
efficiency. When managing the totality of a age of 6.4% compared to 4.4% last year. Lower fixed than 300 visitors visited our stand,
process, everything affects everything else.” and variable costs compensated for the decline in sales Net Net from plant operators to senior execu-
operating operating
volumes. Paper segment revenue for the first three profit tives, which helped make the event
profit
quarters of the year, at €676.8 million, was 11% down 6.4% a great success for us.”
on 2008 (756.5 million). 4.4%

6 Kemira Solutions 2 | 2009 7


On Topic text Jussi-Pekka Aukia photos MIKKO VÄHÄNIITTY

“Recycling
water and air
saves energy.”

Getting more out of your


energy inputs
Although the pulp and paper industry has already implemented
all the easy ways to save energy, there are still a number of
opportunities out there for making more savings.

energy it uses is a Energy-saving strategies


Reducing how much critical issue for Greenhouse gas emissions can be reduced
the pulp and paper industry. by making use of new sources of bioenergy,
“Energy costs are rising all the time and the such as harvesting residues and internal waste
price the industry pays for its energy is fluctuat- streams, and by improving process efficiency.
ing to an increasing extent. New power lines The latter will not be easy, however, according
and energy market consolidation are pushing up to Edelmann, as modern processes are already
the cost of electricity in areas where prices have quite efficient. Virtually all the ‘easy’ solutions
typically been low, such as Northern Europe,” have already been implemented in Finland, for
says Research Professor Kari Edelmann of VTT example.
Technical Research Centre of Finland. Making additional savings will become
“Alongside this trend, we’re seeing a parallel ­increasingly expensive.
drop in profitability in the industry’s mature “At some point, we’ll need to start looking at
markets in Europe and North America, despite completely new approaches, and this will call
the cuts in overcapacity that have been made for a radical rethink of processes, machine de-
recently.” sign, chemistry, and the way machines are run.
Rising energy and raw material costs are eating The challenges here include the operation of Kari Edelmann
away at the industry’s ever-smaller margins and the wet end at significantly higher consistency is a research professor at VTT Technical Research
undermining its potential to invest in the future. and ­temperature or how to operate the process Center of Finland, and r­ esponsible for coordinat-
“And we shouldn’t forget that energy is still with smaller amount of water. There will also ing VTT’s strategic research on energy usage in
cheap in many places compared to what it’s need to be adjustments in process and additive papermaking processes. He has over 30 years of
likely to cost in the future. As a result, cutting chemistry.” experience in R&D in the forest products industry.
energy consumption and greenhouse gas emis- Automatic control and measurement systems
sions is critical.” and new types of ‘proactive’ systems can help in

8 Kemira Solutions 2 | 2009 9


text timo hämäläinen photo gettyimages To the Point

enhancing process energy efficiency. Other potential savings


"In terms of overall
energy efficiency,
“Another approach could be to simplify VTT has looked at many other approaches

An eco-friendly alternative
the best solutions things, by minimizing intermediate stor- to saving energy as well, including such
are those that do age, for example. Eliminating these buff- things as wood fractionation and more
not generate waste ers would improve the control you have energy-efficient mechanical pulping.
heat that is difficult
or impossible to over a process. At the same time, though, “Using process water for cooling would
recover", says Kari it presents some major new challenges to bring some real savings, for example. Kemira’s patented biodegradable chelating agent is the
Edelmann. system capabilities.” ­Preheating raw water in different parts of
Systematically monitoring energy us- a process by making use of heat that would company’s first product to be registered as a new substance
age is critically important to improving otherwise be lost makes it possible to get
energy-related performance. something out of even low-temperature under the European REACH chemical regulation system.
“Process operators today don’t really un- water.”
derstand the impact the choices they make Installing a wet end hood would enable
have on a line’s energy efficiency or why moist air to be recycled there. Excess mois- chelating agent, based on the ­ ennobio S, based on the AES molecule. Mill-
F
some mills achieve better performance ture could be removed by scrubbing units
Fennobio S AES molecule, has recently scale tests showed that Fennobio products were
and how. Better monitoring would teach if necessary. been officially registered as a new substance with capable of solving the key problems associated
operators to improve the energy efficiency “Turbo fans could be used instead of the REACH regulatory system, introduced by the with traditional EDTA and DTPA chelating
of the way they run their machines.” annular water pumps in vacuum drainage EU to reduce chemicals-related risks and provide agents.
systems in environments with a higher better protection for human health and the
Reducing heat loss process temperature and could raise the environment. Multiple benefits
Everything that is put into a process will temperature of exhaust air to a level where The registration process involving the Euro- While EDTA and DTPA are very efficient in
come out of it at some point. The majority it could be used for heat recovery purposes. pean Chemicals Agency (ECHA), which is based binding metals, they decompose slowly and find
of the energy lost by a modern paper mill is Doing this, though, would call for solving in Helsinki, was a long and involved one. Part their way into rivers and lakes via water treat-
channeled through cooling and exhaust air a number of questions, particularly things of the reason for this was that Kemira did not ment plants. They are suspected of releasing
or effluent as it passes through treatment like how to avoid or manage airborne dirt.” want to register AES as a formulate but as a pure harmful heavy metals, such as cadmium, mer­cury,
plants on its way to local waterways. The Raising the moisture content of air substance. and lead, from bottom sediment. As a result, the
temperatures involved here are relatively ­inside dryer hoods can reduce steam usage, environmental authorities have imposed increas-
low, as all the hotter streams have already although condensation risks are involved Eliminating unwanted metals ingly tough restrictions for their use.
been addressed. here. Chelating agents are used to remove metal ions Biodegradable Fennobio products do not have
VTT’s extensive modeling work on the “There’s some potential for savings in that undermine bleaching performance from this problem. They also contain only about a
energy and raw material streams typical of the design and dimensioning of pumps and pulp. Kemira began studying and developing third of the nitrogen that EDTA and DTPA do.
today’s mills has shown that around 80% of other equipment. It also makes sense to biodegradable chelating agents in the mid-1990s This means that they also reduce the nitrogen
the material input of a modern integrated look at whether we can find passive alter- with the aim of producing a more eco-friendly al- content of the mill effluent.
site takes the form of air, which is pumped natives to the components that ­currently ternative to existing products for removing trace When using EDTA and DTPA, it is generally
back into the surrounding atmosphere at consume a lot of the energy used by today’s copper, iron, and manganese from mills’ pulp recommended that a separate chelating stage
some point. fast paper machines.” • streams. This work generated some completely should be used to remove iron and manganese
“Around 75% of the energy used by a new molecules and a number of patent applica- from pulp. This is because the metal complexes
modern mill is expelled from the process tions. Among them were two molecule patents of EDTA and DTPA act as catalysts for decom-
via its cooling air. Technologies that are where the AES (Aspartic Acid Etoxy Succinate) posing bleaching chemicals such as hydrogen
capable of reducing this or that can recover Summary area was included. peroxide.
the heat it contains as efficiently as pos- Developing products based on one’s own pat- Thanks to their completely different chemical
sible will be in great demand in the future.” There are still a lot of opportunities left for ented molecules is pretty rare in industry. Glo- composition, Fennobio S products can be dosed
Heat pumps are one of the technolo- reducing the energy intensity of the pulp bally, only some 20-30 molecule patents appear a directly into a mill’s bleaching process, avoid-
gies that can address this; the use of heat and paper industry: year. Companies generally patent formulations ing the need for a separate chelating stage. This
- Improving the efficiency of unit operations
exchangers will also grow. Employing these produced by blending existing raw materials to makes it easier to simplify the pulping process
- Developing new types of processes
units in hot, corrosive areas full of process - Improving heat recovery techniques create a unique combination that can be used in and introduce closed water cycles. Some trials
contaminants will require the use of new - More advanced control, measurement, a customer’s process. have also shown that the use of Fennobio im-
materials and efficient deposit manage- and monitoring systems. Kemira was given special dispensation under proves the bleaching performance compared to
ment, however. previous chemical regulations to develop EDTA and DTPA. •

10 Kemira Solutions 2 | 2009 11


Analysis text timo hämäläinen photos gettyimages and kemira

Saving Saves
WaterEnergy Too “In principle, it would be
Pulp and paper mills have improved their water and best if we could close the
energy usage significantly by recycling their white water, process completely.”
but recycling has its limits. The less water a process uses,
the more well-managed its chemistry needs to be.

of clean water, substances in its water will be, and the


Limited sources environmental greater the amount of compounds that will
concerns, and ever-rising energy prices precipitate out.
are continuing to encourage the forest Water temperature will also tend to rise,
products industry to improve the efficiency corrosion problems will increase, and the
of its energy and water usage. The more size of microbial populations will grow as
­efficient a mill is in these areas, the bigger well, thanks to the warmer conditions.
the cost savings it can achieve.
Cutting back on water and energy usage Managing the water cycle
in mill processes goes hand in hand, as a In principle, the best thing would be to
large proportion of the energy a site uses close processes completely in terms of
is transferred to its water in the form of their water cycle, according to Kaj Jansson, to look at the areas where fresh water is it has passed through their wastewater
heat. The more a mill recycles its water, Vice President of Common Chemistry at essential and where suitable recycled water treatment plants. Typical volumes vary
the greater the amount of energy absorbed Kemira Research and Development. So far, can be sourced from. The right filtrates for between 10% and 20%. The reason for this
by the water can be recovered. Any water however, only a few mills producing some the right parts of a process need to be iden- is that they rely on biological treatment to
piped off-site represents a massive loss of unbleached board grades have been able to tified and whether they can be used as such remove the organic matter that builds up
energy. do this. All the others producing both pulp or whether they may need to be treated, in water flows to ensure that this does not
Recycling water is particularly important and paper recycle water in varying degrees. chemically for example or not. promote the growth of microbial colonies,
in areas where clean water is in short sup- “All mills have the potential to improve “Clean water is normally essential in the cause production problems, and undermine
ply, such as Central and Southern Europe, their water and energy balance, whether final stages of a process to ensure the qual- product quality,” says Jansson.
and even more so in Asia. Mills further we’re talking about sites producing ity of the end-product. ‘Dirtier’ water can “Some mills producing unbleached board
north do not face the same problem, but chemical or mechanical pulp or ones using be used in the early process stages, though.” recycle all their waste water after biological
they too are keen to increase the amount of recycled fiber or deinking waste paper. A general rule is that it is most cost- treatment. They often use anaerobic treat-
water they recycle and reuse. The challenges involved are big, though, as effective and efficient to remove pollutants ment to reduce the organic load from the
Recycling water brings with it a number processes need to be closed in a well-man- where they are generated. But not always. water, and because it produces methane,
of problems, however. The more closed a aged and cost-effective way. “European mills using recycled fiber and which can be used as energy. The prob-
process cycle is in terms of water usage, When a mill begins investigating how it those producing board, as well as deinking lem here, however, can be that the entire
the higher the concentrations of various can recycle more of its water, it first needs units, often recycle their water only after system can become very anaerobic, which

12 Kemira Solutions 2 | 2009 13


Analysis

usually results in an increase in corrosion A similar approach is used when look- the same time, we also look at whether the Jansson also believes that evaporation
problems and a drop-off in the dewatering ing for chemical techniques to prevent water would need to be treated in some technology has more to offer. The draw-
performance of board machines caused by problems developing on the biological side, way,” says Jansson. backs here are its high energy requirement
anaerobes.” such as build-ups on machine and pipe “We also carry out lab tests to check how and problems keeping equipment clean
surfaces. Chemicals can be used to improve much different filtrates would need to with certain types of water. Evapora-
You’ve got to know your chemistry the efficiency of a biological treatment be treated to bring the concentrations of tion plants are simple and hard-wearing,
Kemira has been involved in numerous plant by eliminating the substances that problem substances they contain down to however, and can handle large amounts of
development projects aimed at closing mill impact its operation, such as reduced sulfur the required level. The results of these tests water easily. The sludge they produce can
water cycles, often in partnership with an compounds and extractives. are fed into the simulation model, which be burned directly as fuel as well.
equipment manufacturer. You need to know your white water can then tell us whether we will achieve “In the future, we’ll also see solutions in
“It’s good to have a manufacturer on chemistry in detail to avoid selecting chem- the targeted reduction in water and energy which water that’s passed through biologi-
board from the start, as this enables us to icals that will only make problems worse. usage with the parameters we’ve selected.” cal treatment is then sent through local
develop a maximally stable, reliable, and “Chlorine-based products can easily lead marshland for further polishing. I wouldn’t
cost-efficient system from the very start.” to increased corrosion, as their concen- Making the most be surprised to see green methods like this
Jansson emphasizes that when closing trations in process water will rise, while of energy recovery increasing over the next couple of decades.”
water cycles it is always important to sulfates can cause odor issues in anaerobic Although the forest products industry has Enhancing the efficiency of energy recov-
evaluate physical, chemical, and biological treatment units if water is recycled too been able to improve the efficiency of its ery is also important. One option is to send
factors. much. Some substances can easily cause processes significantly over the years, there treated waste water to other facilities, such
“You need to identify the substances deposit problems when they react with are still a lot of opportunities left in this as market gardens and fish farms, which can
that have a tendency to cause deposits and each other, while others can encourage the area. recover the heat it contains.
in doing so upset a process. These sub- growth of microbial populations.” In Finland, the amount of water used per “Heat can also be recovered using heat
stances – typically extractives and calcium When looking at a major project, tonne of output has been roughly cut in pumps or heat exchangers. The right chemi-
carbonate – need to be removed from the Kemira’s specialists always evaluate the half since 1992, and the amount of ­water cals can help keep their surfaces clean to
filtrate using chemicals. The process can be entire process before doing anything. used by paper machines has fallen by a maximize their overall efficiency.” •
enhanced using flotation, evaporation, and “We can use a mill simulation model to third in the last 10 years.
filtering. These ‘kidneys’, as they’re known, see which parts of a process it would be Producers of chemical pulp typically use
can be installed at suitable locations best to take water from for recycling and around 35 cubic meters of water per tonne
Summary
around a mill.” where it would be best to return it to. At of pulp at the moment, while mechanical
pulp mills use less than 20, deinking units Industry is recycling an increasingly large pro-
less than 10, and board mills less than five. portion of its process water today. This is not
Jansson expects these figures to move without its problems, however. As processes
down further in the future, thanks to become more closed in terms of their water
things like new film technologies capable cycle, concentrations of contaminants tend
of removing the harmful components that to rise, as do water temperatures.
Kaj Jansson build up in recycled water. Many sites have the potential to further
“We’ll also probably see more biologi- improve their water and energy performance,
M.Sc. (Eng), has been responsible for numerous water
and that includes mills producing chemical
research-related projects at Kemira since the mid-1990s. cal treatment being used in the recycling
and mechanical pulp, those using recycled
He is currently Vice President of Common Chemistry at chain. The popularity of anaerobic treat-
fiber, and deinking units. The challenges are
Kemira Research and Development. ment is set to increase, because of the significant, however, as water cycles need
methane benefit. Some mills are already to be closed in a controlled way that is also
generating 5–10% or more of the energy cost-effective.
they need from this methane.”

14 Kemira Solutions 2 | 2009 15


Theme Spread text jussi-pekka aukia photo M.L.Carstens (ca 1900), the collection of the national board of antiquities

The Ankkapurha rapids in the


River Kymijoki around 1900.

The amount of raw water


used by the pulp and paper industry today has dropped to a fraction of what it
was 50 or 60 years ago. As much as 60 to 70 tonnes of water were needed to
produce a tonne of paper in the 1950s, for example, while the best technology
today can produce a tonne of paper with only 6-8 tonnes of water, and as little
as 2 tonnes of water are needed in the case of fine paper.
“The first flocculent-based clarification basins were introduced in the 1960s.
They were followed by systems designed to separate cooling and white water
from each other in the 1970s, when biocides were introduced. The 1970s–
1980s also saw the launch of biological wastewater treatment, the recycling of
filtrates, material recovery, and the use of fixatives to bind problem substances
into the paper web,” explains Research Professor Kari Edelmann.
“A little later, we saw the introduction of washing presses in paper mills,
and the reuse of cooling water. The counter-current principle was introduced for
managing white water streams soon after. And by the 1990s systems were be-
ing introduced that were capable of managing process fluctuations, as well as
internal treatment systems within mill processes. The new millennium has seen
engineers begin developing balanced water networks based on sophisticated
control and expert systems.”

16 Kemira Solutions 2 | 2009 17


Case text JUSSI-PEKKA AUKIA photos Arif Mustafa Zade

Committed to

Quality
Turkey’s largest packaging board producer
is committed to quality, in its products, its
technology, and its choice of partners.

packaging board plant is located in Çorlu,


Modern Karton’s
roughly 100 kilometers from Istanbul. Part of
the Eren Holding Group, the plant is Turkey’s largest and most modern
papermaking facility and also a significant player on the European
market.
Mill Production Manager Sirzat Açikgöz explains that the growth in
the plant’s capacity in recent years has been driven by the rapid expan-
sion of demand in the marketplace.
“We started up our first board machine, PM1 in 1981 and this was
joined by a similar-sized unit, PM2, 10 years later. Both are 100,000
t/a units. With the coming of the new millennium, we invested in a
new 200,000 t/a machine, PM3, and last year we started up our biggest
machine yet, PM4, with 400,000 t/a of capacity.”
Modern Karton produces over half of Turkey’s 1.4 million t/a
­requirement for unbleached packaging board.
The Çorlu mill occupies a 530,000 m² site, of which 130,000 m² are
under cover. The location is excellent, as the majority of the mill’s test
liner, corrugating medium, and white top liner goes mainly to custom-
ers in the Marmara region, which also supplies the bulk of the mill’s
recycled input.

Being large is not all plain sailing


Çorlu’s PM4 is Turkey’s largest paper machine, and its PM3 the country’s
second-largest. PM4 virtually doubled the mill’s capacity at a single stroke,
and its speed has been steadily increased, and it is now running at some
85% of its baseplate capacity. Capacity levels have been partly affected by
“We want to achieve the best European
the ongoing global economic crisis.
standards when it comes to both efficiency
Modern Karton has always believed in making use of the best avail- and quality, and we believe we will. Our
able technology and PM4 is no exception, but its size has called for approach is to concentrate on problems
a number of changes in mill operations to make the best use of its and bottlenecks one at a time, resolve
them, and then move on,” says Mill
capabilities. Production Manager Sirzat Açikgöz (on the
“We understood early on that standard solutions were not going to left). Mill Maintenance Manager Bülent
be sufficient to boost capacity and develop the quality of our output Binat (on the right) stresses the importance
of efficient maintenance as part of good mill
with this new fast and efficient machine,” says Açikgöz.
management.

18 Kemira Solutions 2 | 2009 19


Case
Sirzat Açikgöz, in the middle,
with the proud team running PM4.

Getting the most out


of PM4 is a key issue for us.
“So we set about looking for partners in chemicals. That’s why it’s very useful to be
paper machine clothing, felts, and chemi- able to sit down together and go through
cals that could offer us a high standard of test results with Kemira and identify pos-
product support and expertise, and would sible problems and decide how we should
be able to tailor their products to our proceed.
needs where needed.” PM3 was the first machine at Çorlu to
One of the partners Modern Karton switch to using Kemira’s retention system,
selected was Kemira, which is responsible but PM4 followed soon after. Handling
for retention and dewatering, the key the switch-over in this order made the
­aspects of wet-end chemistry, for both testing process a lot cheaper and safer, says
PM3 and PM4. Açikgöz.
“Getting the most out of PM4 is a key “Larger-capacity machines mean faster Summary
issue for us. We’re keen to keep on im- and faster running speeds. Retention and
proving its productivity, runnability, and drainability quickly become key factors. • Modern Karton produces over half of Turkey’s requirement for unbleached packaging board.
• Kemira is responsible for the retention and dewatering chemistry of both PM3 and PM4, which
the quality of its end-product by working The strength and homogeneity of our
are Turkey's two largest paper machines.
together with our partners. Kemira has a products are already very good, and we
wide range of products that enable us to want to see our efficiency and quality rank
adapt to even small changes in running among the best in Europe.”
conditions, such as the charge level of our
process.” Recycling saves resources “Alongside the PM4 project, we also impact runnability. The effluent running together as smoothly as possible.”
Açikgöz has been very satisfied with Turkey follows the EU lead in envi- invested in an advanced wastewater treat- from PM4 to the treatment plant has a Problems in any part of the integrated
Kemira as a partner in this respect. ronmental legislation, which means ment facility. We recycle the water treated COD content of 5,000 – 10,000 mg/l. process at Çurlu, from raw material
“Kemira provides us with regular that o
­ perating permit limits are getting here in our process. In the case of PM4, “You can begin to experience runnabil- sourcing to sales, are likely to become
technical support, and their local support tougher all the time, and this is one of over 60% of the water treated is returned ity problems if white water COD content expensive. At the same time, the inte-
personnel can call on Kemira’s exten- the reasons why a producer like Modern to the machine, which means that we only exceeds 7,000 mg/l, and by 10,000 mg/l grated nature of the mill’s operations is
sive international expert network when Karton is keen to invest in the latest pro- use less than four tonnes of water for you can encounter serious problems on one of Modern Karton’s strengths. Some
needed. Kemira regularly takes samples duction technology that offers the best in every tonne of board we produce,” says the production line. COD is one of our of the board it produces is converted into
from our process to analyze and passes on resource usage. Açikgöz. most important parameters for making the corrugated board-based packaging in an
all the data to us as well. This has seen Modern Karton become “The treatment plant is the first in Tur- most of our potential to treat and recycle adjacent plant, for example.
“We’re papermakers, so we only know a pioneer in the environmental field in key to use anaerobic digestion to process water.” “Modern Ambalaj, one of our Group
the main parameters when it comes to Turkey. sludge. The biogas produced is used as companies, buys around a quarter of our
fuel in our natural gas-fired power plant Efficient and integrated output,” explains Açikgöz. “The remain-
to generate electricity and steam. We use The most important reason for ensuring ing three-quarters goes to other Turkish
specialty Kemira chemicals to dewater the that the mill has a modern production producers, and some volumes even go for
plant’s sludge.” infrastructure, according to Açikgöz, is to export.”
Working together helps improve The mill uses groundwater for its water keep everything running smoothly. Açikgöz says that end-product quality is
raw material quality needs. Quality water is a limited natural “Runnability is the main parameter often a more important factor than price
The average per capita consumption of paper in Turkey is very low. In the country’s large cities, resource, as it is in many other countries, when it comes to getting the most out in Turkey, as it is elsewhere. The extended
however, such as Istanbul, which has a population of 14 million, consumption runs at European and the Turkish government is monitor- of the efficiency offered by PM4, which width of PM4 makes it possible to supply
The extended width of PM4
levels. Modern Karton depends on a partner supplier to source its recycled raw material. makes it possible to supply even ing and restricting usage to an increasing means that effective maintenance man- even large roll sizes both flexibly and cost-
“The recycled paper we get from Turkey is of a better quality than the material we can buy large roll sizes both flexibly and extent. agement is very important,” continues effectively. Many customers have various
from the European spot market, which we do buy sometimes. One of the reasons for this is the cost-effectively. “Our permit sets a maximum of 870 mg/l Mill Maintenance Manager Bülent Binat. other special requirements as well. Which
good partnership relationship we have with our local supplier and the fact that their personnel is COD for the effluent leaving the mill, but “That’s why we’ve introduced a proac- is why Modern Karton focuses on quality
well-trained,” according to Çorlu’s Mill Production Manager Sirzat Açikgöz. thanks to the new treatment plant the ef- tive system at the mill, and why mainte- as one of its main selling points.
“In the future, the government wants to regulate paper collection more closely to ensure that fluent leaving PM4 has a COD content of nance issues are discussed with operations “We tried producing poorer-quality
the original source of the material can be tracked easily and help prevent chemical residues
only around 200 mg/l now.” people at our weekly meetings. This product for the low-price category, but
from ending up in the wrong products, for example. But it won’t bring any improvements for us,
Reducing water usage brings its own helps ensure that we have a good produc- had problems, as we ended up with run-
as we already operate to these higher standards.”
limitations, however, as too high a COD tion program for the week ahead and nability issues, so that wasn’t for us,”
content in white water will eventually that maintenance and operations work laughs Açikgöz. •

20 Kemira Solutions 2 | 2009 21


R&D text Jussi-Pekka Aukia photo miika kainu

Synthetic dry strength chemicals

have been available since the 1970s, and there are


currently a handful of options for enhancing the
strength of various paper grades and reducing raw

Increased dry strength with material costs.


In printing and writing, dry strength chemicals
are mainly used to increase the filler content. In the

Fennobond 4000
packaging and board segment, they are used to give
more strength to products made of recycled and
other lesser quality fibers. They can also be used to
manufacture lighter weight products or make it pos-
sible to use lower quality and cheaper raw material.

Kemira’s new, special dry strength additive is more efficient and stable,
has a higher solids content, and works better in packaging than the
conventional alternatives. The product launch is expected next year.

Bernd Hauschel The second goal was that the product “Savings might come through increased
Team Leader says that the existing should be efficient in recycled furnishes, filler loading or the replacement of expen-
technologies do not work efficiently in where the existing chemistry is not effec- sive kraft pulp fibers. In packaging, they
board production and recycled furnishes. tive. Strength improvement in packaging might also be derived from surface starch
This was the need driving the develop- materials offers huge potential. replacement. This reduces the need for
ment of Kemira’s new strength additive, “It took eighteen months to two years energy in the post-drying section and also
­Fennobond 4000. to really develop the recipes, including the number of breaks. Using less wet-end
The project dates back to the beginning about nine months of intensive laboratory starch gives better drainage, and that ena-
of this decade. Hauschel led the devel- development work. Now we're looking bles faster-running paper machines.”
opment work in those days, as he does at the stability of the formulation and At the moment Fennobond 4000 is be-
today. improved versions of the product.” ing produced in Europe, which is the pilot
“We picked it up again in 2007 with market for the application’s development.
people from R&D and from the product A completely new technology Later, it may be transferred to North
line, and came to the conclusion that we The main innovation of the new technol- America and Asia.
should take a closer look at it. We did the ogy is the combination of two types of “We have not yet launched this of-
upscaling very quickly in two months, polymers. ficially within the company or on the
and it worked very well. Since then, we “The product is a chemical combination market. We're currently building up expe-
have been working on the product’s fur- of a natural polymer and a synthetic poly- rience from trials for further development
ther development,” says Hauschel. mer. It’s not just a question of mixing the of the appli­cation. The product launch is
The laboratory development work was two – the chemical process is such that we expected in 2010.”
done by Kemira's R&D in Leverkusen in benefit from both. The resulting product Bernd Hauschel is also a team leader
Germany and the upscaling in Vaasa in has a higher solids content, is more stable for wet end chemicals, which combine
Finland. and efficient, and works better in packag- not only strength and retention but also
ing.” drainage and sizing. He predicts that
Stable and effective Hauschel points out that the product is Fennobond will be an important part of
Two primary goals were set for the still in the development phase. Different Kemira’s wet end portfolio.
project: the first was to create a stable versions for board and paper could be “I think it’s very important that we
product with a high solids content. developed later, for example. ­develop a good product line for dry
“The competing products currently “The strength enhancement depends on strength enhancement. Filler loading and
available have a low solids content and the paper grade, furnish quality and the fiber substitution using lower quality
remain stable only for weeks. Fennobond particular property in question. Currently, fiber will be a general and ever-growing
4000, on the other hand, has a shelf life of it is between 5 and 50%. Clean systems trend in the industry.
up to six months and has a much higher and rather strong fibers benefit the most. “The paper industry is always looking
solids content than its competitors. Fen- It’s more difficult to add strength in dirty for ways of cutting its costs. Suppliers
nobond’s greater stability and higher systems with high conductivity.” can help them in this process. Strength
solids content make the distance to the The new technology also brings indirect enhancement has the potential to play an
customer a much less critical factor.” cost savings. important role here.” •

22 Kemira Solutions 1 | 2009 23


At Your Service text JUSSI-PEKKA AUKIA photo Gettyimages

Figure 1 Figure 2

Foam Height
Foam Height
70°C 60°C 50°C 70°C 60°C
50°C

40°C

40°C

Cleaner
systems
0 20 40 60 80 100 120 140 -10 10 30 50 70 90 110 130 150
Time (sec) Time (sec)

Figure 3 Figure 4

Oil Based Defoamer

Foam Height
Cleaner pulp and paper processes are now possible thanks

Foam Height
Traditional @ 70°C High Temp @ 70°C

to Kemira’s new high-temperature water-based defoamers. Kemira’s new product

0 20 40 60 80 100 120 0 20 40 60 80 100 120 140 160 180


Time (sec) Time (sec)
and paper industry has striven for years to This innovation also provides customers with an alternative
The pulp clean up its internal systems and effluent to using oil-based and water-extended defoamers in their
streams. Tighter municipal, regional, and national regula- processes at elevated temperatures.”
tions have forced the industry to adopt practices designed to
reduce the environmental impact of mill operations. An oil-free alternative Figure 1:
Kemira’s Research Scientist John Martin says that these The use of traditional oil-based defoamers has never been Performance of a traditional water-based defo-
amer at varying temperatures. Shorter run time
improvements have not come without their costs, however. problem-free. Oil and EBS are routinely found in pitch and higher foam height means lower performance, Comparing the technologies
“Closing process cycles, which has led to the increased use deposits, both in machinery and in paper, and residual longer run time and lower foam height means best
of recycled water, has left pulp and especially paper mills ­defoamer in pulp can lead to downstream quality issues. performance. Traditional water-based defoamers are typically formulated with fatty alcohols or waxes, or both,
to deal with a myriad of issues, such as higher operating “These typically come from over usage or poor product which have a relatively low melting point range (40 – 55 °C). The defoamer in Figure 1 is formu-
Figure 2:
temperatures and increased dirt and pitch.” placement in the system, or both. Because of these issues, lated with a fatty alcohol that has a melting point range of 50 – 57 °C, and demonstrates that
Performance of a Kemira high-temperature water-
water-based defoamers are the preferred product.” based defoamer at varying temperatures.
once the melting point of the wax is reached, the efficacy of the defoamer decreases dramati-
cally, resulting in lower initial knockdown and quicker foam recovery.
Defoamers that can take the heat The use of the appropriate product at the appropriate
Figure 3: Kemira’s new high-temperature defoamers provide better initial knockdown and better
Higher operating temperatures on paper machines are a place and time is crucial in preventing runnability and Traditional water-based product compared to one longevity at higher temperatures when compared to traditiownal water-based defoamers. Figure
growing trend in the industry, and can lead to foam and ­quality issues. of Kemira's new high-temperature water-based 2 demonstrates the efficacy of one of Kemira’s new high-temperature defoamers at various tem-
entrained air control issues when using traditional water- “By offering a line of water-based defoamers that provide ­products at 70 °C.
peratures. Note that while the knockdown and longevity is affected by the increase in tempera-
based defoamers. effective foam and entrained air control at higher tempera- ture, the performance drop observed between 40 °C and 70 ° C is relatively low when compared
Figure 4:
“Historically, water-based defoamers were the product of tures, and providing the application and operational knowl- Kemira’s new product compared to a paper machine to traditional water-based defoamers.
choice for paper machines that ran at temperatures below edge to use the products, we are providing a cleaner option defoamer containing oil, EBS, and silica. When tested head to head at equal solids dosage, the performance advantage of the new
50 °C. However, due to the melting point of the waxes to traditional chemistries,” says Kemira’s Defoamer Product Kemira defoamers at higher temperature becomes apparent. Figure 3 demonstrates the knock-
and fatty alcohols used in water-based defoamers, which Manager Ricky Dixon. down and longevity advantage of Kemira’s new water-based technology at 70 °C.
is around 40–50 °C, these products are not as effective at “By removing EBS and oil from the paper machine, the Kemira’s new line of high-temperature, water-based defoamers enables the customer to
higher operating temperatures.” remove EBS and oil from their system by eliminating the need to use these substances for
new Kemira defoamers are helping to provide higher-quality
foam and entrained air control. Figure 4 shows the performance one of Kemira’s new defoam-
To address this issue, Kemira has recently developed a new products, improved runnability, lower pitch deposits, lower
ers compared to a traditional oil-based paper machine defoamer containing silica and EBS. The
series of water-based defoamers to alleviate the problem. dirt counts, and lower volatile organic compounds, while results show an increase in longevity – control of foam build over time – with the use of the new
“The new technology offers effective foam and entrained maintaining foam and entrained air control at the higher derefoamer and over an oil-based defoamer containing EBS and silica at 60 °C.
air control at temperatures up to and even exceeding 70 °C. operational temperatures seen on today’s paper machines.” •

24 Kemira Solutions 2 | 2009 25


Partnership text jussi-pekka aukia photos hanne nykänen

Kalle Viljanen Mikko Hietanen Petri Vakkilainen Joni Välimäki


Development Engineer, Operation Manager, Mill Manager, Area Manager,
Äänekoski board mill, Äänekoski board mill, Äänekoski board mill, Kemira
M-Real M-Real M-Real

Water is the
Best Biocide
M-real’s Äänekoski board mill in Finland has been involved in
testing and developing Kemira’s new slime control concept
from the start. The concept has been commercialized – and
successfully – as Fennoclean L.
Kalle Viljanen where runnability is a major priority.
Development Engineer remembers “Increasing the number of washing units was
the ‘father’ of biofilm research at Kemira, Marko an excellent fit with the new biocide philosophy
Kolari, visiting the mill to take samples back when focused on combating biofilm formation. Together,
he was working on his Ph.D. thesis. Kolari’s find- these two changes were what it took to put an end
ings made their way into a product in 2005, when to the conventional boardmaker’s ‘wisdom’ that
Fennosurf 300 was selected for short circulations. washing cycles have always been run every two
“It was around this time that we started ­taking weeks and always will be.”
a harder look at how clean things were in our Combating microbe colonization using biocides
machine, drawing people’s attention to the need is always a question of getting the balance between
to keep splash areas clean, and started carrying the problems caused by the microbes and those
out more systematic washing routines. We also caused by the residues from the active ingredients
switched to washing surfaces with hotter water. in the biocides right, continues Vakkilainen.
All in all, we learnt that even the best biocide “Water is the best biocide, if only you can spray
cannot keep a mill clean on its own, you also need it where the microbial colonies are growing. That’s
­thorough and regular washing routines as well.” the reason why we’ve installed new spray nozzles
Operations Manager Mikko Hietanen stresses throughout the process and why we’ve also been
that there is a limit to how much you can increase one of the pioneers of continuous ‘kidney’ technol-
your usage of biocides in any case, because of the ogy. When you can stop surfaces getting contamin-
costs involved and the residues that build up in ated in the first place, your biocide system will
end-products. keep them clean between your maintenance
“Following the introduction of Fennosurf 300 outages.”
and thanks to various other measures, we’ve been Increasing the amount of run-time washing does
able to extend our wash interval from a couple of not increase a machine’s overall water usage per
weeks to four to five weeks today.” tonne of output either.
KALLE VILJANEN:
Mill Manager Petri Vakkilainen brought the “Extending our washing intervals has improved “We have been moving towards a greener
concept of using run-time washing units and our productivity significantly,” says Mikko approach to combating microbial coloni-
large quantities of washing water to the board ­Hietanen. “We’re now able to coordinate our zation for some time. And it’s a move that
has saved us money as well.”
machine from paper production, where odor ­washing outages with our normal maintenance
and taste issues are not generally a big issue, but ­outages, rather than the other way around.”

26 Kemira Solutions 2 | 2009 27


Partnership

MIKKO HIETANEN:
“It took us some time to sell all the additional
capacity of the modernized machine, and this
gave us the time we needed to put all our
productivity-related matters in order. When
the machine was running at full output, no
one really had a problem about extending
our washing intervals.”

JONI VÄLIMÄKI:
“The work we’ve done
here has opened up
Petri Vakkilainen: opportunities for
“Our cooperation with Kemira has gone so well, in fact, Fennoclean applications
that although their people have been making regular on other M-real machi-
visits to the mill for a long time now, I’ve never had nes, and this has been
much cause to note down their names or keep their to both our advantages,
cell phone numbers handy.” I believe.”

A pioneer always takes a risk bial levels, but we emphasized that what tion with it can be allowed to cause those free and offer consistent quality, and they It has made it easier to plan maintenance one problem, you’ve got more time to deal
Kemira’s Joni Välimäki admits that shift- was most important was to keep surfaces kinds of problems.” can optimize their own processes as part outages and things like switching felts with the other ones.”
ing from simply eliminating microbes clean. The tough demands associated with of this. They make things easier for us, and wires more efficiently. Petri Vakkilainen says that the pressure
where and when you can to a new anti- “And it proved the right way to go, as these types of board products also impact and that’s something we want to pass on “When we no longer have to ‘budget’ to succeed has been pretty heavy, as M-real
slime philosophy based on dealing with it has improved our efficiency and the the mill’s chemical supplier. to our customers.” for emergency shutdowns and things are has invested a lot of money in the mill.
the select few bacteria that actually cause ­quality of our end-product. “What it means for Kemira is that we To ensure process continuity and better planned overall, our maintenance “Perhaps that’s also one reason why
biofilm to form in the first place was All our products today, whatever have a much smaller palette to work with eliminate unexpected problems develop- people have more time to concentrate on we’ve been a little more receptive to
something of a risk for the company. they’re intended for, are now suitable for in microbial control here than we do in ing, Kemira carries out checks on agreed what they’re doing. We can now plan our new solutions and technologies than the
“We couldn’t be completely sure in packing foods containing fats,” confirms other areas of paper and board produc- parts of Äänekoski’s process at regular fall outages well in advance. Everyone average. In a situation like this, it’s very
advance that the scientific data would Vakkilainen. tion,” says Välimäki. intervals to see that everything is working realizes the benefit of not having to shut important for a supplier to understand
actually translate into results in mill “Chocolate products are a real yardstick as it should. down the machine because of microbial where things stand and where they can
conditions.” here in terms of quality, as even the small- An ongoing partnership Kalle Viljanen describes this monitoring issues.” help, and not just try and get us to buy
Kalle Viljanen says that the choice to est taste issue with packaging can result The partnership between Kemira and the process as a joint one. “We both share common goals: to more of what they’re selling. Kemira
go with the new concept was taken with in major financial repercussions for our mill has every potential to be an ongoing “In addition to normal customer service extend our wash intervals, improve how understood where we wanted to go and
everybody’s eyes open and jointly. customers. Our approach is that nothing one, believes Petri Vakkilainen. routines, we also hold more extensive we monitor the state of our surfaces, and what was important for us and leveraged
“We decided to go out on a limb and we do on our board machine or with the “Kemira is helping us supply our cus- follow-up meetings every couple of ensure that our process stays aerobic,” all their expertise to help us get there.”
put the theories that had been developed chemicals and systems we use in conjunc- tomers with products that are problem- months even when there aren’t any prob- says Viljanen. Joni Välimäki believes that the partner-
in the lab at the University of Helsinki to lems. We’re all committed to continually ship between the two companies has been
work for us at the mill. The proposal to optimizing the process and our costs and Real progress very successful from Kemira’s standpoint.
do this came from Kemira, and by being Everything began around the beginning of the new millennium... getting everything running even better Following its last modernization, the "We’ve moved forward together very
part of the trial we were able to be in on than it is today.” output of the board machine at Äänekoski systematically. Recently we’ve started
...with a development project aimed at enhancing the quality of the mill’s coated folding
something that no one else knew any- “As part of this, we also do more with has increased from 160,000 t/a to 210,000 focusing on logistics, procedures, environ-
boxboard by improving its brightness and weight. The success of the project has reinforced the
thing about. We were very up front with mill’s reputation for high-quality, food-grade folding boxboard among customers in the tobacco, our analyses than we used to,” continues t/a, although average grammages have mental issues, and occupational safety."
Kemira, as they were with us. alcohol, pharmaceutical, and chocolate industries. Välimäki. “We pay a lot of attention to dropped. “The world’s changing and new things
“The efficacy of anti-slime measures Production machinery and the mill’s overall process have been upgraded on a phased basis. making sure we measure the right things “We haven’t needed any major invest- are coming up all the time,” says Petri
had previously been measured simply The board machine, with the exception of its wet end, was modernized in 2002, and its raw in terms of process and end-product per- ments to achieve this, we’ve just consist- ­Vakkilainen. “But when you come down
by measuring the numbers of colonies ­material input switched to BCTMP. The process was switched from an acid one to a neutral one formance.” ently focused on developing our opera- to it, it’s not really about the technical
of bacteria swimming in white water,” some time before to improve quality and runnability. Mikko Hietanen has been very satisfied tions,” says Mikko Hietanen. side of things. When a supplier under-
he continues. “We took the bold step of Kemira had supplied Äänekoski with biocides for many years prior to the start of the project, with the improved reliability and predict- “Efficient slime control has been one stands what’s important for a customer
and once it was under way cooperation between the two companies took on a new dimension. of the factors that’s made this possible,
turning this at least partly on its head. ability of operations that has resulted from like us, then we understand what’s impor-
We didn’t say no to monitoring micro- the mill and Kemira working together. among other things. When you eliminate tant for them as well." •

28 Kemira Solutions 2 | 2009 29


At Your Service text and photo JUSSI-PEKKA AUKIA 3d-illustration METSO

Adding strength and


saving energy
Kemira’s Kemform retention system was originally
developed for use in fine paper production. It also
has a lot to offer for board producers.

retention system is an all-in-one “Fennosil polymers also contain hydrophobic end groups
The Kemform solution for enhancing dewatering ef- that bind to hydrophobic substances in process water, such
ficiency, cutting energy costs, and optimizing the furnish mix. as pitch, stickies, and fine particles coated in pitch. In the
Product Line Manager Kimmo Strengell says that demand application, this results in less foaming in the process."
for Kemform technology, which was patented three years
ago, has grown strongly, and it is now in use at multiple mills Greater product strength ample. Floc size remains small when using can achieve as high a dry solids content The Kemform retention system gives the web
around the world producing both printing paper and packag- Kemform was initially developed for use in machines produc- Kemform, and this makes it possible to as possible from the suction roll stage good wet press strength, which is valuable in
delivering an optimum level of board perfor-
ing board. ing fine paper, and its first trial runs were done on these. maintain or improve formation even when onwards. Kemform typically increases dry
mance. A modern press section designed for
In fact, Kemform has become the undisputed flagship of Following its commercialization, it was tested on some cus- operating at a higher consistency in the HB solids by 1%, from 17% to 18% for example. board machines, a Metso ValPress, can be seen
Kemira’s retention product offering. tomers’ packaging board machines. The good results achieved than normally. This translates into better This reduces the amount of water trans- here.
“Thanks to Kemform, mills can achieve up to a 10–15% sav- with these encouraged Kemira to continue development work energy efficiency and strength.” ferred to the press and ensures that the
ings in energy usage as a result of improved dewatering. Stud- to extend Kemform’s scope to board production. Using Kemform also makes it possible to press will operate more smoothly.
ies have also confirmed that filler content can be increased by The key benefits Kemform offers in board production are reduce draw when the paper web travels “If a wet press is operating near the
2% in fine paper products,” says Strengell. reduced energy usage, as a result of improved dewatering, through the dryer process. The reeler at the upper limit of its hydraulic capacity, this
“Kemform works equally well with both new and old and an increased level of dry content in the web after the wet end of the dryer runs faster than the wire represents a clear production bottleneck
machines. In the case of new machines, the benefits tend to press section and further downstream. by a factor of few per cent and reducing and Kemform offers the perfect solution.
be seen in better overall productivity, while lower energy “A high level of dry solids after the wet press improves this difference, by 50% for example, will Let’s not forget that the wet press is a key
usage will be the biggest benefit in older setups with limited board strength, and makes it possible to keep the elastic improve the strength properties of board component of many paper machines when
dewatering capacity.” modulus as high as possible,” explains Strengell. significantly. it comes to the strength of the products
A Kemform system is typically made up of two or three “Elastic modulus is an important metaparameter for board “Thanks to Kemform, the dry solids they produce.
components: inorganic microparticles, either bentonite or col- manufacturers, as it tells you a lot more about a product’s of the web leaving the wet press will be “If there’s too much water in the nip,
loidal silica, and micropolymers, which are normally anionic stiffness and other strength-related characteristics than peo- higher and the web itself will be stronger. it will be squeezed out along the length
in fine paper applications and cationic in packaging ones. The ple generally realize.” This makes it possible to keep tension of the web (x-y direction), reducing the
third component is Fennopol retention polymer. Kemform helps keep elastic modulus as high as the strength between the wire and the wet press and elastic modulus of the board. Ideally, it
Strengell says that applications based on colloidal silica potential inherent in the fiber being used will allow, in fact. the wet press and the first drying section as should travel along the z-direction in the
seem to be growing in all segments, particularly in the fine Each fiber has strength potential as it is. A sheet matrix is small as possible. wet press. Efficient wet pressing is the
paper area. formed from the fiber raw material. The final elastic modulus “The smaller the total draw, the smaller cornerstone of good operations and good
“Our ‘three-dimensional’ Fennosil micropolymer, dosed in of the matrix is dependent on formation, wet pressing, draws, the loss of elastic modulus will be,” says end-product quality when producing board.
weak solution, plays a central part in Kemform solutions, as and drying. Strengell. Kemform offers an excellent solution Kemform has become the undisputed flagship
it results in significantly better dewatering performance than “Board mills typically run headbox consistency very low. In terms of dewatering efficiency when here."board. Kemform offers an excellent of Kemira’s retention product offering,” says
conventional ‘two-dimensional’ polymers,” he explains. Typically half of that used when running fine paper for ex- producing board, it is important that a mill solution here.” • Kimmo Strengell.

30 Kemira Solutions 2 | 2009 31


photo GETTYIMAGES illustration TUULI RANTA

Let’s do it!

Try some recycling


technology for yourself
If you want to see how water will absorb itself into a piece of thread and
start moving around, put a couple of containers of water on a table and
dye the water different colors using food color. Then place a piece of cotton
thread between the containers as shown in the illustration, ensuring that
the thread is slightly submerged below the surface of the water. It will only
take a minute or two before you will see the water getting on the move!