SOY CHEMICALS FOR PAPER PROCESSING - Soy New Uses

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of low cost paper coatings and increased use of non virgin recycled/recovered fibers inthe pulp.• Even with the downturn in market pulp, the specialty pulp (dissolving and fluff used innonwoven for personal care products) has continued to rise.Environmental FactorsPulp and paper mills have become highly regulated because of the high use of naturalresources. The demand for cleaner, more efficient processes has brought about the followinginitiatives:• The less harsh alkaline or neutral papermaking process has been adopted in the majorityof United States paper mills over the last few decades. Different families of chemicaladditives were developed to perform at a higher pH range of 4.5 - 8.5.• Wood resources for fibers have become costly and scarce. Cellulosic alternatives areconstantly being evaluated. One significant trend is to reduce virgin fiber content byreplacing it with inorganic fillers and recycled fibers. Recycled fibers are shorter andinherently produce weaker base sheets which results in a greater need for strength andperformance additives. This has, in turn, driven the need for efficient and robustbinders for diverse fillers in both the base sheet and specialty coatings.• Water resources are at a premium. Paper mills are one of the highest water consumingindustries of today, prompting legislation and regulation of effluents and energyconstraints. For every one pound of wood pulp used to make a paper product, morethan 99 pounds of water are required. During the production process, this water mustbe removed mechanically or by evaporation over heated rolls. Significantimprovements in water consumption have occurred by the adoption of closed loopwater recycle processes. Water consumption in closed loop systems is five cubic metersper short ton of paper compared to 125 cubic meters per short ton without waterrecycling. Effluent system recycling has greatly increased the demand for a wide varietyof processing aids and deposition control.<strong>PAPER</strong> MANUFACTUREThe pulp and paper industry is one of the largest industries in the nation. The majority ofmanufacturing facilities in the paper industry are very integrated. Most paper mills begin withwood chipping at the front end, followed by pulping, bleaching, papermaking and recycling ofpost consumer products.5
Wood logs are delivered to the mill where they are chipped and sent to pulping. The pulpingprocess is used to break apart cellulose fibers by mechanical and/or chemical digestion toseparate the fibers and optimize the resulting paper strength. If white pulp is desired,bleaching occurs at this stage. The resulting furnish is a highly diluted slurry of pulp, fillers andadditives that are pumped into a pressurized headbox and extruded through a slit onto amoving screen. Water is continually removed by gravity or vacuum assist before moving to thewet-press section where the sheet is fed between felted nip rolls to remove remaining water.Further drying is accomplished by passing the supported sheet over metal cylinders heated bysteam to dry the paper mat. If necessary, a calendering process is used to smooth the surfaceof the mat. The attributes of the sheet can be further modified by the application of coatings(either during the papermaking process or secondary operations) or adding multi-plyconstruction. If the paper is to be coated, in line, it generally occurs at this point before thesheet is wound on a take-off reel. The furnish mixing to the wet-press section is designated the“wet-end” of the process and the remaining stages as the “dry-end”. Paperboard (papergreater than 0.3 mm thick) and tissue can be run on the same equipment with modifications.The paper industry has undergone significant changes due to mergers, acquisitions andrestructurings in order to survive the competitive nature of the business. The process formaking paper is very capital and resource intensive. Modifications to the process regardingchemical additives or processing conditions can be met with resistance. At the same time, themarket is in need of innovation and creative solutions to improve profitability and performance.According to RISI, top United States manufacturers for each market are:• Wood Pulp - Weyerhaeuser Company, Domtar and International Paper• Paper - International Paper, Domtar and Abitibi Bowater Inc.• Paperboard - International Paper and Rock-Tenn Company(acquired Smurfit Stone in 2011)• Tissues - Koch (GP), Kimberly-Clark and Procter and GambleDOMESTIC <strong>PAPER</strong> MARKETSThe selection of chemical additives is dependent on the application and function of theresulting paper or paperboard. One of the classifications of paper grades is shown in Figure 1.The full conventional designations can be found in Appendix I.6
Page 4 and 5: FIGURES1. Classification of Paper G
Page 6 and 7: EXECUTIVE SUMMARYThis report has be
Page 8: soy derivatives in heated, aqueous
Page 13 and 14: In paperboard applications, special
Page 15 and 16: FIGURE 3GLOBAL PAPER AND PAPERBOARD
Page 17 and 18: FIGURE 5COST SAVING STRATEGIESCOST
Page 19 and 20: Wood Chips and PulpingThe process o
Page 21 and 22: Fluff pulps primary come from softw
Page 23 and 24: PAPER CHEMICALSChemical additives c
Page 25 and 26: aluminum compounds, such as aluminu
Page 27 and 28: RECYCLINGThe growth of paper recycl
Page 29 and 30: Recycle processes generally include
Page 31 and 32: FIGURE 14POTENTIAL CONTAMINANT SOUR
Page 33 and 34: FIGURE 15MARKET DEMAND FOR PULPING
Page 35 and 36: strength additive, Lionsurf ® , Hy
Page 37 and 38: The amphoteric nature of protein co
Page 39 and 40: Agenda 2020 created in 1994 as a pa
Page 41 and 42: 1. Entrance into the market in esta
Page 43 and 44: APPENDIX IRef: Handbook for Pulp &
Page 45: REFERENCESGIA - Global Industry Ana

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