Pulp and Paper Industry: Chemicals

Pulp and Paper Industry

Chemicals

Pratima Bajpai

Pulp and Paper, Consultants Patiala, Punjab, India

Table of Contents

Cover image

Title page

Copyright

List of Tables

Preface

Abbreviations

Chapter 1. Introduction

1.1. General Aspects

1.2. Historical Perspectives

1.3. Pulp and Paper Chemicals Market Overview

Chapter 2. Paper and Paperboard Industry

2.1. General Background

2.2. Pulp and Paper Manufacture

Chapter 3. Pulp and Paper Chemicals

3.1. Pulping Chemicals

3.2. Bleaching Chemicals

3.3. Starch

3.4. Aluminum Compounds

3.5. Pigments As Fillers

3.6. Coating Pigments

3.7. Process Chemicals

3.8. Functional Chemicals

3.9. Chemicals Used in Paper Recycling

3.10. Chemical Additives for Tissue and Towels

Chapter 4. Enzymes

4.1. Xylanase

4.2. Cellulase

4.3. Pectinase

4.4. Lipase

4.5. Esterase

4.6. Catalase

4.7. Amylase

4.8. Laccase and Peroxidase

Chapter 5. Major Pulp and Paper Chemical/Enzyme Suppliers

5.1. Chemical Suppliers

5.2. Enzyme Suppliers

Chapter 6. Future Trends

Index

Copyright

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List of Tables

Table 1.1 Raw material consumption of paper and board in relation to world paper production 1

Table 1.2 Types and attributes of functional chemicals in the paper making process 4

Table 1.3 Most probable areas of wet-end chemistry emphasis for the next 5 years 6

Table 2.1 Global paper production by region 13

Table 2.2 Global paper production by grade 13

Table 2.3 Global pulp production by region 14

Table 2.4 Global pulp production by quality 14

Table 2.5 The world consumption of paper 14

Table 2.6 Per capita paper consumption 2012 15

Table 2.7 Major paper manufacturing processes 17

Table 3.1 Uses of caustic soda 28

Table 3.2 Typical physical properties of sodium sulfite 32

Table 3.3 Classification of bleaching chemicals 49

Table 3.4 Chemical and physical properties of chlorine dioxide 55

Table 3.5 Oxidation potentials of various oxidants 69

Table 3.6 Peracids for kraft pulp delignification/bleaching 69

Table 3.7 Raw material cost, $ per lb of equivalent H2SO5 70

Table 3.8 Application of starch in paper industry 84

Table 3.9 Methods used for modification of starch 85

Table 3.10 Benefits offered by the modified starches 88

Table 3.11 Reasons for using fillers 90

Table 3.12 Fillers and/or specialty pigments used in different types of paper grades 91

Table 3.13 Comparison of kaolin, PCC, and GCC in papermaking 93

Table 3.14 Advantages of using GCC compared with kaolin in alkaline papermaking 94

Table 3.15 Function of coating pigments 101

Table 3.16 Improvement of quality parameters of coated paper by changing specific pigment properties 102

Table 3.17 Properties of pigments used in coating paper 103

Table 3.18 Sources of detrimental substances 113

Table 3.19 Commonly used fixing agents 114

Table 3.20 Biocides used today in paper industry 117

Table 3.21 Biodispersants used in the paper industry 120

Table 3.22 Use of cleaning agents in different applications 127

Table 3.23 Commonly used cleaning agents 127

Table 3.24 Contaminants in dryer fabric 131

Table 3.25 Widely used coagulants for water treatment 132

Table 3.26 Effect of polyaluminum compound on rosin sizing 153

Table 3.27 Sizing features of paper with rosin size-polyamines 153

Table 3.28 Typical paper grades using AKD sizes 154

Table 3.29 Chemical and physical properties of alkyl/alkenyl ketene dimer 157

Table 3.30 Sizing against various fluids with ASA 162

Table 3.31 Split addition of PSA at the wet end and size press 170

Table 3.32 Use of PSA at the size press 170

Table 3.33 Starch used for surface sizing 175

Table 3.34 Regional shares of specialty papers 198

Table 3.35 Global market share of speciality papers 199

Table 3.36 Coating additives 213

Table 3.37 Properties of an ideal pigment 213

Table 3.38 Properties of an ideal binder 217

Table 3.39 Binders used in coating 217

Table 3.40 Binder system and their influence on coating properties 220

Table 3.41 Chemicals used for deinking 229

Table 3.42 Function of the common deinking chemicals 229

Table 3.43 Typical use levels of deinking chemicals found at recycled paper mills 230

Table 3.44 Some of the surfactants used in deinking 237

Table 3.45 Positive and negative aspects of non-ionic surfactants in the process 237

Table 3.46 Use of chemical additives for stickies control 242

Table 3.47 Functional additives used in the manufacture of tissue paper 247

Table 3.48 Processing aids used in the manufacture of tissue paper 248

Table 4.1 Enzymes used in pulp and paper industry 276

Table 5.1 Leading pulp and paper chemicals companies 297

Table 5.2 Leading suppliers of process and functional wet-end chemicals 298

Table 5.3 Kemira pulp and paper chemicals turnover 298

Preface

Pulp and paper manufacturing is one of the largest global industries with very high capital investments. The process of making paper, paperboard, and tissues today is highly cost-sensitive. The necessity for increasing productivity and quality, combined with environmental regulatory pressures, has resulted in an increased demand for pulp and paper chemical additives. The market for pulp and paper chemicals is projected to reach 65 million tons by the year 2017, driven by growing demand from developing markets, particularly Asia, and the rising use of specialty chemicals. The Asia Pacific continues to remain the largest regional market, followed by the United States. The Asia Pacific and Latin America compose the most promising markets in terms of sales value as well as volume. Urged by high growth rates in China, India, and the Asian countries, the Asia Pacific has emerged as a region with high potential in the pulp and paper chemicals market. This prediction is based on the growth of coating binders and other coating additives (lubricants, thickeners) because of predicted increase of coated grades production. Predicted increase in internal and surface sizing applications reflected expected need for improved printability and runnability of uncoated, wood-free grades. Strength additives growth will result from the need to assist the trends of basis weight reduction and filler level increase. A strong movement of chemical additives into paper and paperboard grades that traditionally did not use chemical additives to any great extent has been seen in recent years. The past several years showed an increase in activity in the use of enzymes in pulp and papermaking. This book features in-depth and thorough coverage of chemical additives in the pulp and paper industry. This book also discusses the use of enzymes (green chemicals) that can improve operations in pulp and paper, and describes many key and niche players such as Kemira, Akzo Nobel NV, Eka Chemicals AB, Ashland, Inc., BASF, Buckman Laboratories International, Inc., Clariant, Nalco Chemicals, Novozymes, Enzymatic Deinking Technologies, Genencor, AB Enzymes, DSM (Netherlands), Diversa (USA), Kao (Japan), and Tritex, among others, and what the future holds.

Abbreviations

AOX

   Adsorbable organic halide

AQ

   Anthraquinone

AHQ

   Anthrahydroquinone

BOD

   Biological oxygen demand

BPGW

   Bleached peroxide pressurized groundwood

BTMP

   Bleached thermomechanical pulp

CFA

   Cationic fatty acid

CBH

   Cellobiohydrolase

COD

   Chemical oxygen demand

CSBS

   Coated solid bleached sulfate

CFS

   Coated wood-free sheet

CMC

   Critical micelle concentration

DETA

   Diethylenetriamine

DTPA

   Diethylenetriaminepentaacetic acid

ERIC

   Effective residual ink concentration

ECF

   Elemental chlorine free

EDT

   Enzymatic deinking technologies

EG

   Ethylene glycol

EDTA

   Ethylenediaminetetraacetic acid

EDDS

   Ethylenediamine disuccinic acid

FAS

   Formamidine sulfinic acid

Tg

   Glass transition point

GLDA

   Glutamic acid diacetic acid

GPAM

   Glyoxalated polyacrylamide

HLB

   Hydrophile-lipophile balance

HEEDTA

   Hydroxyethylethylenediaminetriacetic acid

IDS

   Iminodisuccinate

LWC

   Light weight coated

MOW

   Mixed office waste

MIP

   Modified inorganic particle

MEE

   Multiple effect evaporator

NDLKC

   New double lined kraft cuttings

NTA

   Nitrilotriacetic acid

OCC

   Old corrugated container

OMG

   Old magazine grades

ONP

   Old news print

PAE

   Poly (amido-amine)-epichlorohydrin

PS

   Polysulfide

PEIS

   Polyethyleneimines

PVA

   Polyvinyl alcohol

PVAMS

   Polyvinylamines

RDA

   Retention and drainage aid

SC

   Supercalendered

TAD

   Through-air drying

TOC

   Total organic carbon

TCF

   Totally chlorine free

TRI

   Toxics release inventory

WRV

   Water retention value

WSPE

   Wet strength performance efficiency

Chapter 1

Introduction

Abstract

Pulp and paper continue to be the largest industry in demand for chemical additives. Even with the increasing reliance on electronic media curtailing paper use, specialty chemical consumption is still huge, leading to a very large opportunity for specialty chemical additives that impart strength/performance enhancements at a lower or equivalent cost of existing products. The global market for pulp and paper chemicals is projected to rise to $20  billion by the end of 2015. In North America, the demand for pulp and paper chemicals is expected to increase to $4.8  billion in 2015. General aspects of pulp and paper chemicals, historical perspectives, and an overview of the pulp and paper chemicals market are presented.

Keywords

Chemical additives; Market overview; Productivity; Pulp and paper chemicals; Quality; Specialty chemicals

1.1. General Aspects

The paper industry has undergone significant changes because of mergers, acquisitions, and restructurings in order to survive the competitive nature of the business. The process for making paper is very capital- and resource-intensive (Bajpai, 2010). Modifications to the process regarding chemical additives or processing conditions can be met with resistance. At the same time, the market is in need of innovation and creative solutions to improve profitability and performance.

Pulp and paper manufacturing is one of the largest global industries with very high capital investments in mills producing paper on machines 10  m wide at speeds in excess of 2000  m per minute. The process of making paper, paperboard, and tissues today is highly cost-sensitive. The necessity for increasing productivity and quality, combined with environmental regulatory pressures, has resulted in an increased demand for pulp and paper chemical additives. On a global scale, paper consists of approximately 98% natural material. As shown in Table 1.1 (Zellcheming, 2006, 2008), 89% consists of chemical and mechanical pulps and paper for recycling. About 8% are added fillers and coating pigments, mainly in the form of China clay and calcium carbonate. The remaining 3% include chemical additives. Slightly more than half of this is starch, which is also derived from renewable raw materials and one tenth of it from aluminum compounds, for example the traditional chemical papermakers’ alum (aluminum sulfate). Only 1.1% of the raw materials used for paper and board production is synthetic chemical additives (speciality chemicals). These values are calculated on the basis of the dry content of the product in relation to the current world paper production.

Table 1.1

Raw material consumption of paper and board in relation to world paper production

Based on Zellcheming (2008).

Pulp and paper chemicals, the fine chemicals applied in the pulp and paper industry, have high social and economic benefits. High-end pulp and paper chemicals can provide paper with special characteristics such as wet strength, smoothness, printability, and softness, and make it waterproof. Although some can help make thinner, whiter, and stronger paper with low-quality fibers, others can increase manufacturers’ profits by optimizing the production process and improving the operation speed. Pulp and paper chemicals’ increasing applications are augmenting the revenue of the global pulp and paper chemicals market. The pulp and paper chemicals market has grown steadily over the past few years, one of the reasons being governmental recognition. Wastewater discharge from the pulp and paper industry accounts for one sixth of the total industry effluents, whereas organic pollutants account for one fourth of the same, making it the third most polluting industry. However, the increasingly stringent rules and regulations are compelling paper manufacturers to adopt cleaner production methods (Bajpai, 2010). Several manufacturers are working toward identifying biological substitutes for their current use of pulp and paper chemicals (Paice & Zhang, 2005). One of the effects of environmental consciousness has been the inclusion of drainage and retention aids, strength additives, and other pulp and paper chemicals. These help reduce the total volume of chemicals required for the papermaking process, by offering improved and more effective products with specific functions, many of which work synergistically with one other. Market participants also receive a huge boost with paper manufacturers considering waste paper deinking and pulping a big help in easing the high pressure on the environment. The increasing popularity of recycled fibers has created a significant market for corresponding chemical types such as deinking and strength agents, bleaching chemicals, and rosin sizes (Bajpai, 2013).

Paper additives can be used to create a specific grade of paper or paperboard product and they can be used in different steps of the production process. Chemical additives can help reduce the consumption of water and energy as well as raw material (Dulany et al., 2000). When the additives are used in the pulp slurry, the addition is called internal or wet-end addition, whereas when they are applied onto the paper sheet the addition is called surface or dry-end addition (Dulany et al., 2000).

Paper mills account for a large share of almost all pulp and paper chemicals. In particular, paper mills consume the vast majority of fillers and coating pigments and specialty additives in the overall pulp and paper industry (Auhorn, 2006). Printing and writing papers will continue to account for the majority of the chemicals used in paper mill operations and will record more rapid growth than other paper grades (Freedonia, 2011). This is due to the increasing use of specialty chemicals and higher loadings of fillers and opacifiers to create smoother, brighter printing grade papers. Although coated papers will continue to account for most of the demand, uncoated printing papers are also increasing their share of chemicals consumed as papermakers look to produce higher quality uncoated grades. Tissue paper will record above-average gains, supported by production growth of these paper grades, which include paper towels, facial tissues, napkins, and toilet paper. The production of newsprint consumes smaller amounts of chemicals because the demand for higher gloss and opacity is not as great in these lower price uncoated grades.

The market for pulp and paper chemicals is projected to reach 65  million tons by the year 2017, driven by growing demand from developing markets, particularly Asia, and the rising use of specialty chemicals (www.companiesandmarkets.com). The Asia Pacific area continues to remain the largest regional market, followed by the United States. The Asia Pacific and Latin America comprise the most promising markets in terms of sales value as well as volume. Urged by high growth rates in China, India, and the Asian countries, Asia Pacific has emerged as a region with high potential in the pulp and paper chemicals market. This prediction is based on the growth of coating binders and other coating additives such as lubricants and thickeners because of a predicted increase of coated grades production. Predicted increase in internal and surface sizing applications reflected expected need for improved printability and runnability of uncoated, wood-free grades. Strength additives growth will be results from need to assist the trends of basis weight reduction and filler level increase. Recent years have seen a strong movement of chemical additives into paper and paperboard grades that traditionally did not use chemical additives to any great extent. Examples include newsprint, which now uses fillers, sizing agents, retention aids, and linerboard, which now uses more fillers and retention aids. The greatly increased use of recycled fibers in some of these grades has also led to the application of greater amounts of dry-strength agents. The past several years showed an increase in activity in the use of enzymes in pulp and papermaking. Enzymes are extremely attractive green chemicals that can improve operations in pulp and paper. Examples of such applications are use of enzymes in bleaching; increase of freeness; improved beatability and strength properties of fibers; deinking of recycled fiber; cationic demand reduction by the application of pectinases, control of pitch, slime and stickies; and modification of starches for surface sizing and coating.

Chemical additives used in papermaking can be divided into three groups—general (commodity) and two classes of specialty chemicals—process and functional (Auhorn, 1999, 2006; Rice, 2001). Process chemicals are used to optimize the production process by increasing machine speed, runnability, providing deposit control, and reducing steam consumption. These chemicals include retention and drainage aids, defoamers/deaerators, fixative agents, biocides/slimicides and pitch-control agents, and pulp and fiber treatment chemicals such as deinking, bleaching, and pulping chemicals. Functional chemicals are used to impart various properties to the finished paper, ranging from improved strength and optical properties to enhanced printability. These include dry- and wet-strength resins, sizing agents, coating binders, and specialties as well as dyes, pigments, and fluorescent whitening agents (Alén, 2007; Persson, 2004; Rice, 2001; Hipolit, 1992; Biermann, 1996; Auhorn, 1999, 2006; Gullichsen & Fogelholm, 2000; Sundholm, 1999; Göttsching & Pakarinnen, 1999; Casey, 1981; Triantou, 2009). The functional chemicals can be added both at the wet-end and the dry-end processes of the paper production (Roberts, 1996; Dulany et al., 2000). Table 1.2 gives an overview of the types and attributes of functional chemicals in the papermaking process. Sizing chemicals are used to create liquid resistance hydrophobicity in the paper. A distinction should be made here between internal sizing and surface sizing. Internal sizing refers to liquid penetration inside the paper, whereas surface sizing refers to liquid penetration through the surface of the sheet (Roberts, 1996). In simple terms, a liquid can penetrate a sheet of paper in two ways: by the fibers or by the space between the fibers (i.e., the pores of the paper) (Roberts, 1996). With internal sizing, fibers are modified to develop a hydrophobic character toward water (i.e., develop water resistance). With surface sizing, the paper is layered with a coating material in order for the paper to develop additional water resistance externally (Hubbe, 2005). Dry-strength additives are used to increase the tensile and other strength properties of the sheet. The use of these additives is essential especially when weaker fiber raw material is used, for example, recycled paper and paperboard. Even though refining of fibers can increase the sheet strength, it also increases the sheet density, which leads to the reduction of properties such as opacity and porosity. On the other hand, the addition of dry-strength chemicals does not alter the sheet density nearly at all (Roberts, 1996; Dulany et al., 2000). Moreover, dry-strength additives are added as surface treatment when surface strength is more important than increased internal strength (Dulany et al., 2000). Wet-strength additives are used for a paper to preserve part of its tensile strength while being wet because wet paper and paperboard loses around 90–97% of their initial tensile strength (Roberts, 1996). Wet-strength additives are usually applied only at the wet-end because they are efficiently absorbed at that stage (Dulany et al., 2000). Fillers and pigments are similar materials, but are used at different steps of the production process. Fillers are used at the wet end of the paper formation process and serve as to fill the sheet increasing its opacity (by increase of light scattering within the sheet). Pigments, on the other hand, are used at the dry end of the process with the main function of smoothing the paper surface and increasing paper printability and receptivity to ink (Roberts, 1996; Dulany et al., 2000). Fillers can consume sizing chemicals, thus making the increase in sizing chemicals used in the process necessary (Dulany et al., 2000).

Table 1.2

Types and attributes of functional chemicals in the paper making process

Based on Roberts (1996); Dulany et al. (2000); Hubbe (2005).

The boundary between process and functional chemicals is not very definite because process chemicals may either significantly influence performance of functional chemicals and/or affect sheet properties directly. Retention aids, for example, significantly affect the expected performance of added fillers and sizing and strength additives, but also have a direct impact on sheet properties by influencing formation and porosity. About 90% of all chemical additives belong to functional additives—coating binders, sizing, bleaching chemicals, strength additives. The remaining 10% are process chemicals with retention aids—including fixatives, coagulants, flocculants, and microparticles—representing the biggest and most important part.

There are many drivers contributing to the growth of the global specialty pulp and paper chemicals market; one of the most important being the introduction of innovative products by vendors. For instance, several vendors in the market have introduced eco-friendly chemicals for the bleaching process. Further, one of the major challenges is the stringent laws and regulations governing the market that require vendors to comply with elaborate procedures before gaining approval for a new chemical or ingredient. Such regulations are particularly stringent in developed countries in North America and Europe. Specialty pulp and paper chemicals are used by the pulp and paper industry for the production of specialty paper, which is a niche segment of the global paper market. Specialty paper is used to provide customized and high-value solutions for writing, printing, packaging, and labeling.

A significant increase of chemical usage is predicted. This prediction is based on the growth of coating binders and other coating additives because of predicted increase of coated grades production (educa.univpm.it/inglese/paperche.html). Predicted increase in internal and surface sizing applications reflect an expected need for improved printability and runnability of uncoated, wood-free grades. Strength additives growth will result from the need to assist the trends of basis weight reduction and filler level increase (Pruszynski, 2003). Table 1.3 shows the most probable areas of wet-end chemistry emphasis for the next 5  years (BTG UPTIMES, 2007).

Several processes and functional chemical additives are based on synthetic polymer compounds and are not readily biodegradable; others are classified as hazardous to the environment or to watercourses. This may apply for some fixing and retention aids, wet- or dry-strength agents, polymer-based size, or coating binders. The majority of these chemical additives, which are introduced to the pulp before the sheet formation, remain almost entirely in the paper because of their cationic charge or by fixation with cationic polymers. Thus, the concern with regard to protection of water bodies is reduced. Sizing agents and coatings are applied directly on the surface of the finished paper web either by means of an aqueous solution of size (size press) or in a closed circuit in the case of coating colors. Only during changes of paper grades or recipes are the rest of these chemical concentrates discharged via the wastewater treatment plant. Chemical additives contribute to the effluent load or may have a potential to accumulate in the environment and organisms. If the additives are used as directed, they should not cause significant negative impacts on the efficiency of the wastewater treatment plant. Sudden changes in loads because of system cleaning or batch-wise additive adjustments to fulfill product requirements might have a negative impact on the performance of the wastewater treatment plant. In this case, the biomass may require a certain period for adapting to the additives appearing in the effluents. During this limited period, the efficiency of the treatment plant may be reduced and the settling of the sludge may possibly be deteriorated (increased sludge volume index). Therefore, additives should be handled carefully, cautiously, and as directed.

Table 1.3

Most probable areas of wet-end chemistry emphasis for the next 5  years

Processing aids to control stickies and deposits while meeting increasingly stringent government environmental regulations

New wet-end chemistry measurement and control systems

Chemical additives that function efficiently in highly contaminated papermaking systems

More efficient dry-strength agents that can be retained at high levels without adversely affecting the papermaking system

Experimentation with new combinations of chemical additive addition points and retention times to achieve more effective use of chemicals

Based on BTG UPTIMES (2007).

1.2. Historical Perspectives

Specialty chemicals have been introduced to the paper industry in response to the industry’s quality and production requirements (Auhorn, 2006). A number of significant industrial trends within past 3  decades dictated an increased need for the application of specialty chemicals and set the direction of the research and development effort that led to the development of several new technologies. Some of the most important trends related to changes in composition of papermaking furnish resulting from economic, environmental, and quality pressures. Replacing fiber with inorganic fillers of various natures may be, in some cases, a result of any of the triggers mentioned previously—cost, environmental impact, and quality goals. Few of important industry trends that determined the increasing importance and complexity of chemical applications follow:

• Introduction or increased levels of recycled fiber

• Higher brightness targets

• Increased degree of closure of water systems

• Lower basis weight of produced paper

• Changes in printing technologies

• Increasing speed and shear of forming sections

Most of these trends have exponentially increased the challenge for suppliers of papermaking chemicals by combining increased performance expectations with creating a chemical environment that adversely effects fundamental mechanisms of chemical additive operations (Pruszynski, 2003). For instance, a reduction in the basis weight of paper often requires the addition of mineral filler to make up for loss of opacity. From a chemical supplier’s point of view, this means a requirement for higher retention at a lower mechanical retention contribution and a significant need for controlling the strength of the paper. In another case, the introduction of hydrogen peroxide–bleached and highly filled grades of paper created the requirement for high filler retention at a high concentration of harmful substances, which negatively impacts the performance of retention additives. Finally, increased speed of paper machines and higher shear stress in the forming sections have a negative effect on the level of retention and on the stability of colloidal dispersion of pitch and stickies materials, resulting in a new level of technical challenges for a retention and deposit control program. Several examples can be listed that show the fascinating and challenging relationships between various paper properties.

The late 1980s and 1990s brought another noteworthy challenge that chemical suppliers to the paper industry had to answer—alkaline conversion of wood-free sheet production, practically completed in 1990s, followed by neutral pH conversion of mechanical grades of paper that is still continuing. This change in pH of paper production was started for several quality and economic reasons, but it mainly cleared the way for using calcium carbonate fillers in a variety of forms, either through wet-end addition or coating formulations. This pH change also had other significant consequences because it corresponded to major changes in the chemistry of alum. Again, major chemical suppliers assisted papermakers with developing chemicals that could substitute for alum or even operate in the absence of alum. These developments related mainly to sizing technology and resulted in the introduction of reactive sizes that were based on the alkenyl succinic anhydride and alkyl ketene dimer chemistries (Bajpai, 2004). In addition, cationic dispersions of fortified rosin sizes were developed that could operate at pH levels higher than rosin soaps and did not depend on the aluminum ion precipitation on the wet end to operate. A large number of low-molecular-weight cationic polymers—coagulants or fixatives—were also developed for replacing alum in its pitch-control role.

Compared with the period of rigorous influx of radically new technologies required to match the changing requirements of paper industry, the past several years could be characterized as optimization of existing technologies. This appears to be a natural consequence of the technical and economical landscape of the industry. There are no major technology changes resembling the scale of alkaline conversions, water consumption reduction, filler introduction, and paper machine technology observed in 1990s. Furthermore, the economy of the pulp and paper industry is under significant pressures that require cost reduction measures. The optimization of existing technologies includes some new products, but it also includes cost reduction, increased attention to final sheet quality, stabilization of machine performance, and a better understanding of the influence of the chemical environment on the performance of additives. These activities result in a better understanding of fundamental, operational principles of chemical applications. They also build knowledge that will be used in the future should radical technological changes take place. The advances in alkaline papermaking have been fueled by developments in the calcium carbonate and synthetic sizing areas. The prime wet-end filler ingredient in alkaline systems, calcium carbonate, has undergone a virtual resurgence in processing technologies. Today, it is a highly cost-effective chemistry for improving printing quality of fine papers and also brightness, opacity, and bulk.

1.3. Pulp and Paper Chemicals Market Overview

Global market for pulp and paper chemicals was 51  million tons in 2010 and is expected to rise to 58  million tons by the end of 2015 (Howe et al., 2011). Japan and Europe are expected to be impacted similarly. The highest growth region will be in the developing nations in Asia Pacific, South American, and many United States–based chemical manufacturers will have a significant presence.

The United States market for pulp and paper chemicals was estimated to be 12.7  million tons in 2010 and is expected to increase to close to 14  million tons by 2015 (GIA, 2011). Bleaching chemicals represent the largest volume with more than a 30% share, translating to 3.9  million tons. However, pigment coatings dominate on a value basis, with a share of 25% or $1.1  billion. Pigments and coatings chemicals are predominately (more than 90%) calcium carbonate and clays. Pigment coatings are used to compensate for lower basis weight paper in which cost savings comes at the expense of appearance such as opacity and print performance. The addition of highly pigmented coatings is a low-cost alternative that currently uses 25–30  million pounds of soy proteins every year (Howe et al., 2011). Fillers and coating pigments will continue to represent the largest pulp and paper chemical segment in terms of volume. In particular, fillers are widely used by papermakers to reduce the amount of fibers, thereby reducing costs because fibers are much more expensive than fillers. Growth will largely be centered in calcium carbonates, particularly the precipitated varieties, which are the major filler and coating chemicals in use. Clays will remain widely used, although growth will be below average as kaolins lose ground to both precipitated and ground calcium carbonate. Good opportunities exist for chemical suppliers that can develop new fillers, allowing higher loading levels without reducing paper strength and overall quality. Although the majority of paper chemicals are commodity in nature, about 48% are specialty chemicals, including some that are polymeric from both synthetic and natural sources. Bio-based additives and soy proteins are common in conventional paper and include starch, dextrin, carboxymethyl cellulose, and casein. Specialty additives are generally the most expensive chemicals; as such, this segment accounts for half the total chemical demand in the United States pulp and paper industry in sales value, but only one quarter of the total volume. Growth factors include the increasing demand for whiter, brighter, and glossier paper.

The use of recycled paper and continuing efforts to reuse process water will support demand for water treatment chemicals such as biocides, coagulants, and flocculants. Specialty products also help to improve the strength, water resistance, opacity, and other performance and aesthetic characteristics of paper and can be used to improve productivity allowing faster operating speeds on machinery, protect equipment and machinery, and reduce waste and emissions. It is not surprising to expect growing demand in additives that promote cost-effective, high-speed production of paper while providing the highest performance standards possible. This is obtained through the proper use of fillers/fibers and specialty chemicals to assist in processing or performance requirements, particularly as they relate to recycle processes. The following strategies have been adopted to meet profitability demands and, eventually, impact the growth of associated specialty additives in the pulp and paper market:

• Reduced virgin fiber content

• Reduced basis weight of paper

• Faster production speed

• Reduction in liquid effluent

Specialty pulp and paper chemicals are used in variety of functions such as deinking, bleaching, and coating during the manufacturing of specialty paper—a niche segment that accounted for less than 5% of overall paper production. However, the increasing demand for specialty papers in a wide range of industries for abrasive backings, paint masking, carpet flooring, medical packaging, and art media is expected to drive the demand for the market. In addition, a growing global population drives businesses, the consumer and industrial sectors, food, and graphics is expected to contribute to the growth of the market. Nevertheless, increasing environmental concerns regarding certain chemicals used in the manufacture of specialty papers is expected to hamper the growth of the specialty chemicals market.

The global specialty paper chemicals market accounts for approximately 50% of the total global paper chemicals market on a value basis. Specialty paper chemicals help reduce the consumption of water and energy and increase the use of wastepaper as well as save raw materials by decreasing the paper weight without sacrificing the functional or optical properties of the paper sheet. They also enabled the tremendous speed increase of paper machines. Often, they are formulations of several chemicals, but there are also many single-chemical products. Water treatment chemicals used in the paper industry are not included in the specialty paper chemicals category.

North America and Europe are the major regional markets for specialty pulp and chemicals in terms of consumption because of the huge demand from the specialty paper industry owing to different applications of the specialty papers in the region. In addition, the southern United States and Canada have major wood pulp manufacturing sites that use a great deal of specialty chemicals that augment its demand growth. Asia Pacific is expected to witness the swift demand growth of specialty chemicals because industrial development coupled with mounting retail market mainly in China, India, Indonesia, and Japan. In addition, expansion of pulp and paper industries in this region is expected to increase the demand for specialty pulp and paper chemicals.

Several issues affect the global specialty paper chemicals industry. These are: closed-loop water systems that reduce effluent discharge and create new chemical demands; consolidation that causes mill closures and fewer, larger customers; partnering of paper companies with a few select suppliers, generally decreasing the number of distributors; and higher collection and use of recovered fiber from postindustrial and postconsumer waste in place of virgin pulp. However, China competes for imports of recovered paper, especially from the United States, because it requires a source of pulp for its rapidly growing, but pulp-deficient paper industry. The key drivers for research and development activities, capital investment, growth in consumption, and selection of specialty paper chemicals are quality requirements for new and existing products, costs, productivity, and environmental issues in the papermaking process. The increasing substitution of virgin wood pulp by recycled fibers will increase the use of deinking chemicals and specialty chemicals such as defoamers, chelates, and thickeners. Fillers and coating pigments are increasingly used as less expensive replacements for pulp.

The main objectives for paper producers are to achieve or improve profitability, meet customer needs, and embrace technological change, particularly to meet regulations but also to meet the first two objectives. The changing requirements of paper producers and the highly competitive marketplace create a very selective environment for improved, new, and different specialty paper chemicals.

Chemical and mechanical pulps together account for approximately 50% of total raw material consumption, whereas recycled paper accounts for a share of about 32%. Commodity-type chemicals such as chlorine and oxygen, hydrogen peroxide, sodium salts and sulfuric acid (used mainly in pulp production), and fillers and pigments (mostly China clay and calcium carbonate) represent about 15% of total raw material consumption. For achieving environmental and regulatory compliance objectives and to reduce cost, the use of virgin fibers—especially chemical pulps and alum—is expected to decrease. On the other hand, recycled paper fibers, fillers and pigments, and specialty paper chemicals will extend their share in the raw material mix of the paper and board industry (Bajpai, 2013).

On a global basis, specialty paper chemicals consumption is forecast to grow very slowly, at about 1% annually, over the next 5  years. Growth patterns appear to be very different regionally (www.ihs.com). China’s consumption of specialty paper chemicals shows its excessively high production of lower grades of paper and paperboard, which require less specialty paper chemicals. Nevertheless, growth in consumption of paper chemicals in China is the highest in the world, with 6%–6.5% per year as new paper production capacity is added and higher grades of paper are produced.

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Chapter 2

Paper and Paperboard Industry

Abstract

The pulp and paper industry is one of the largest industries in the world, with very high capital investments. The world's total paper production amounted to 403  million tons in 2013. The majority of manufacturing facilities in the paper industry are integrated. Most paper mills begin with wood chipping at the front end, followed by pulping, bleaching, papermaking, and recycling of post consumer products. The paper and paperboard industry in the global market and general aspects of pulp and papermaking processes are presented.

Keywords

Bleaching; Papermaking; Pulp and paper industry; Pulping; Recycling

2.1. General Background

The pulp and paper industry is one of the largest industries in the world, with very high capital investments. Growth is fastest in Asia. This is mostly because of China’s rapidly expanding industry. Asia already accounts for well over a third of global paper and paperboard production. The world’s total paper production amounted to 403  million tons in 2013 (399  million tons in 2012) (www.forestindustries.se/Documentation/International). Asia, which accounts for 45% (179  million tons) of paper production, is by far the largest paper producer. Europe (107  million tons) and North America (85  million tons) are also significant producers (Table 2.1). Paper and paperboard consumption continues to grow in Asia, especially in China. It has been estimated that global paper consumption in 2025 will amount to 500  million tons. This means growth of about 1.6% a year. Global consumption of paper has increased by almost half since 1980. Europe and North America account for almost a third of consumption, whereas Asia’s share of global consumption is already 44%. Demand in Eastern Europe is also growing faster than in traditional markets. Belgium is the biggest paper consumer in the world. Table 2.2 shows global paper production by grade (printing and writing paper 30%; corrugated material 37%; paper board packaging 13%; newsprint 5%; others 7%). In 2012, 39.9  million tons of graphic papers were produced in Western Europe. More than 70% of printing paper is consumed in Western Europe and North America. In Western Europe in 2012, packaging paper production amounted to 41  million tons. Tables 2.3 and 2.4 show global pulp production by region and by quality. The total pulp production was 181  million tons in 2012 (chemical pulp 72%; mechanical pulp 20%; others 20%). The world consumption of paper is shown in Table 2.5 and per capita consumption is shown in Table 2.6. Per capita paper and paperboard consumption varies a great deal by country and region. The United States and Canada have historically been large consumers of the world’s paper. North Americans consume more than 17% of the world’s paper despite having only 5% of the population. The global average is about 57  kg of paper per person, with the extremes being the United States’ 300  kilos and Africa’s about