f' Materials Needs and Opportunities in the Pulp and Paper Industry Advanced Industrial Materials (AIM) Program August 1995 Office of Industrial Technologies U.S. Department of Energy This report has been reproduced directly from the best available copy. Available to DOE and DOE contractors from the Office of Scientific and Techni- cal Information, P.O. Box 62, Oak Ridge, TN 37831; prices available from (615) 576-8401,FTS 626-8401. Available to the public from the National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Rd., Springfield, VA 22161. I I This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, corn- pleteness. or usefulness of any information, apparatus, product, or process dis- closed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily consti- tute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. ORNLm-12865 MATERIALS NEEDS AND OPPORTUNITES IN THE PULP AND PAPER INDUSTRY Date Published: August 1995 NOTICE This document contains information of a preliminary nature. It is subject to revision or correction and therefore does not represent a final report. Prepared for the U.S. Department of Energy Office of Industrial Technologies Advanced Industrial Materials (AIM)Program ED2204000 P. Angelini, Compiler Prepared by the OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee 378316065 managed by MARTIN MARIETTA ENERGY SYSTEMS,INC. for the U.S. DEPARTMENT OF ENERGY under contract DE-AC05-840R21400 r: TABLE OF CONTENTS PREFACE (C. A. Sorrel and S. E Sobczynski) ........................... 1 1. WOOD PREPARATION ...................................... 3 3 1.1 WOOD YARD OPERATIONS ............................. 12 DEBARKING ........................................... 3 13 CHIPPING ............................................. 4 1.4 MATERIALSREQUIREMENTS ............................ 4 2. PULPPREPARATION ........................................ 4 2.1 MECHANICALPULPING.. ............................... 5 2.1.1 Groundwood ....................................... 5 21.2 Mechanical Refining ................................. 5 2.2 CHEMICALPULSING ................................... 7 22.1 Digester.. ......................................... 9 2.2.2 Recovery Boiler ..................................... 9 223 Chemical Recovery System.. ........................... 11 2.24 Newprocesses ...................................... 11 2.3 RECYCLED PAPER SYSTEh4S ............................ 13 24 MATERIALS REQUIREMENTS ............................ 13 3. BLEACHING ............................................... 14 3.1 CURRENT BLEACHING METHODS ........................ 15 3.2 NEWPROCESSES ....................................... 15 33 MATERIALSREQUIREMENTS ............................ 16 4. PAPERMAKING .............................................. 16 4.1 STOCK PIPING AND HEADBOX. .......................... 17 / iii 4.2 INTERMEDIATE STRUCTURESDRYERS ................... 18 4.3 PAPER FINISHJNG AND HANDLING ...................... 19 4.4 NEW PROCESSEs/GENERAL ISSUES ...................... 19 45 MATERIALSREQUIREMENTS ............................ 20 5. OTHERTECHNOLOGIES ..................................... 20 20 5.1 MOTORS/GENERATORS/IUR.BINES....................... 5.2 SENSORS AND CONTROLS ............................... 21 22 5.3 MATERIALSREQUIREMENIS ............................ 6. ENVIRONMENTAL ASPECTS/WASTE HANDLING AND . MINIMIZATION ........................................... 22 6.1 MATERIALSREQUIREMENIS ............................ 23 7. WEAR ...................................................... '23 8. CORROSION ............................................... 26 9. STRUCI'URAL AND OTHER ASPECTS . ....................... 29 10. ACKNOWLEDGMENTS ...................................... 31 11. APPENDIX ................................................. 32 iv ADVANCED INDUSIRIAL MATERIAIS (AIM) PROGRAM (C. k Sorrell) The Department of Energy's (DOE) Office of Industrial Technologies (OW)supports research and development (R&D) in industry, the DOE national laboratories, and in universities to develop energy efficient, environmentally-acceptable industrial technologies. The Office of Industrial Technologies is working with Seven energy-intensive industries to develop R&D roadmaps that will facilitate cooperativegovernment-industry efforts to achieve energy-efficient, environmentally-acceptable, sustainable industries of the future. The forest products industry is one of the industries with which OIT is working to develop an R&D roadmap. The Advanced Industrial Materials (AIM) Program of the Office of Industrial Technologies sponsors long-term, directed research on materials that will enable industry to develop and utilize more energy-efficient, sustainable processes and technologies. The purpose of the study described in this report was to identify the material R&D needs and opportunities for the pulp and paper mill of the future. PUIS AND PAPER MII;L OF THE FUTURE (S. E Sobczynski) During the past 12 years, DOE has, together with industry support, provided funding for the development of technologies that could have a significant impact on the energy efficiency, productivity, and environmental compliance of paper and paperboard manufacture. The paper industry has played an important role in the guidance of this R&D program. An exciting new task is beiig undertaken to develop a more comprehensive and formalized strategic plan for DOE'S paper program. This new plan, entitled Pulu and Pauer Mill of the Future, will address the paper mill of the future. The program will impact all National Energy Strategy (NES) goals. These include: 1. EconomicGrowth - enhance U.S. position in global markets - maintain U.S. competitiveness 2. EnergySecwity - encourage the use of renewable energy resources - promote energy self-sufficiency 3. Environmental Improvement - promote environmentally acceptable.processes - maximize the utilization of resources The program is also consistent with the mission of DOE, Energy Efficiency and Renewable Energy, and Office of Industrial Technologies (OIT). The mission of OIT is to facilitate research, development, and demonstration of energy-efficient, waste-reducing industrial technologies which are ultimately factors of successfulglobal productivity and competitiveness. 2 The program plan will be responsive to industry needs. The capital intensiveness of processes will be reduced. One goal is to have the enhand technologies be more cost effective and less capital intensive. The objective will be to improve productivity and to reduce energy consumption. The environmental impact of current and future processing methods will also be mlnlml;red.. The goal is to develop improved processing methods which will reduce effluents, air emission, and/or solid waste. The program will be structured to maximize the impact by leveraging industrial and federal budgets. In general, the industry is evolutionary, not revolutionary, and has low R&D budgets which are generally -1% of sales. DOE will leverage its funding with that from industrial and other federal programs and will seek joint ventures with sustained efforts to introduce pew technologies. Critical technologies will be evaluated that will address the near-, mid-, and long-term needs of the paper industry and those that would best benefit from federal sponsorship. The technology needs that are identified'should span the spectrum from fundamental, or basic research knowledge, to applied R&D activities encompassing pilot plants or commercial demonstrations. The program plan will have a time-phased approach (1) in the near term (to year 2000), where appropriate, demonstrate particularly attractive technologies that are currently available but underutilized; (2) in the mid term (to year ZOlO), refine existing laboratory-scale concepts and develop these technologies with pilot-scale demonstrations; and (3) for the long term (to year 2020), develop completely improved new processes and materials and focus on areas with very substantial energy savings potential. The major focus of the program will be on four general process areas. These include (1) chemical pulping and recovery, (2) mechanical pulping, (3) papermaking, and (4) advanced processes and systems that reduce environmental impact. THE MISSION STATEMENT FOR THE DOE PULP AND PAPER MULOFTBEFUTURE The mission of the DOE program is to enable the paper industry to increase production, reduce energy consumption, reduce operating costs, and meet environmental goals by 2020. The program will identify and then fund R&D to develop, improve, and demonstrate retrofit and advanced technoIogies and, if the demonstrated economics and market needs then warrant, to facilitate the commercial utilization of these advances in the pulp, paper,'and paperboard industry in the United States. The U.S. paper industry, universities, and national laboratories who conduct paper R&D have collectively and convincingly shown that there