Flow Doctor FY09
Q3 Consultant Level
Training Class
Pulp and Paper
Industry Training
Learning Objectives
- After this session you should…
 Understand the basic processes of a pulp and
paper, and gain confidence when visiting our
customers
 Be able to identify application opportunities for
our products and value proposition
Be ready to capture incremental business in
FY09 and FY10!!!
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 2
Operational Challenges for Mills Today
- Survey of 17 Pulp & Paper CEO’s

Forest, paper and packaging
CEO Perspectives Survey by
Price Waterhouse Coopers :
– Operating with High Energy
Costs
– Improving Mill Performance
and Productivity
– Spending Capital Strategically
– Are Assets Performing at
Acceptable Levels
– Environmental Sustainability
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 3
Table of Contents




History of Paper Making
Industry Challenges
Papermaking Overview
Pulp Mill Process Applications
– Emerson Solutions

Liquor Recovery Process Applications
– Emerson Solutions

Bleaching Process Applications
– Emerson Solutions

Paper Mill Process Applications
– Emerson Solutions


Energy Solutions
Glossary of Terms
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 4
History of Papermaking






Egyptians first (B.C.) wrote on
papyrus – where “paper” gets it’s
name
Persians wrote on parchment made
from skins of goats, sheep & calves
Chinese were first to make paper
2000 years ago
1799 French first patented design for
continuous paper machine; first built
in England in 1803
1807 Fourdrinier brothers acquired all
patent rights; all paper machines had
Fourdrinier wire on wet end until late
1980’s; “twin wire” emerged
First simple paper machines had
headbox, wire, felt to nip press, drying
in sheeted form
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 5
Papyrus Plant
Papyrus from Egypt
Old Paper Machine
Papermaking Overview


Paper is made from fiber; wood is most
commonly used
Hardwoods and softwoods have different
characteristics and are both required to
make most grades of paper
– Rag used for American money
– High softwood count in toilet paper

Bamboo and Eucalyptus used as a
hardwood fiber due to similar
characteristics
– Both have fast growth in Brazil and Asia
– Hardwoods take 40+ years in northern climates
– Softwoods are fast growth; 8 years
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 6
Pulp and Paper Mill Overview
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 7
Measuring Productivity
Millwide KPI
Cost/Ton
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 8
Pulp Mill Overview
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 9
Pulping Overview
Yield
Quality
GWD
TMP
Chemi- Chemi- Semi- Hi-Yield Chemical
TMP Chem. Chemical
PGW
RMP Mech.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 10
Chemical Pulping : Batch Digesters
KPI’s
• Optimize yield
• Hit Kappa target consistently
• Optimize production
• Good energy management
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 11
Rosemount Magmeter handles Tough
Service on White Liquor Charge
Large Pulp and
Paper Mill

– Customer installed redundant Rosemount
mag meters
– Flow rates monitored and alarm on
deviation > 3%
Global Company

Application: White
liquor charge to
digesters
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 12
SOLUTION
RESULT
– Immediate improvement in reading
accuracy and consistency
– Within one week deviation alarm identified
problem due to scaling
– Cooking problem avoided
Chemical Pulping : Batch Digesters
Temperature
H-Factor
Cooking
Heating
t0
t1
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 13
Blowing
Time
t2
t3
Chemical Pulping : Continuous Digesters
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 14
Chemical Pulping : Continuous Digesters
KPI’s
• Optimize yield
• Hit Kappa target consistently
• Optimize production
• Good energy management
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 15
Chemical Pulping : Continuous Digesters
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 16
Chemical Pulping : Continuous Digesters
Impregnation
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 17
Chemical Pulping : Continuous Digesters
Impregnation
Heating
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Cooking
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 18
Chemical Pulping : Continuous Digesters
Key:
Orange: pulp
Green: black liquor
Yellow: white liquor
Magenta: steam
Washing
Chip chute
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 19
Cooling
Flash
Tank
Flash
Tank
Choosing and Implementing the
Right Meter for the Application

Extending life in tough
applications
– Abrasion resistance
– Chemical resistance


Installation practices that
increase survivability
Pick the right meter for the
measurement
– Technology
– Materials
– Configurations
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 20
Tough Service Applications That
Typically Have Poor Performance
Black liquor
recirc flow
Lime slurry
White liquor
feed
Sludge flows
Black liquor feed to
recovery boiler
Bleach Chemicals
(O2, ClO2, etc.)
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 21
Rosemount Magmeters Can Handle Your
Tough Service Applications
• Lining Selection and design is most
critical to minimizing wear and
maintenance costs
• Teflon Materials are the most commonly
used for a blend of harsh chemicals and
high temperature
•Not all Teflon liners are the same
•Engineered liners can extend life in
harsh applications
• High temperature design can reduce
permeation and improve reliability
• Select materials to match application
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 22
Black & White Liquor are the Most
Aggressive Applications for Liners

Combination of high temperature and harsh
chemicals can increase permeation of
Teflon liners
– Permeation shows up as “blisters” or
“bubbles” and can cause premature failure
and reduced up-time
– Permeation rates are driven by temperature
gradients
Teflon General Blistering From a High
Temperature Black Liquor Application
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 23
Engineered Teflon Liners Extend Liner Life

Sintered PTFE Teflon Liner Sleeves
– Sintering under high pressure adds strength
and resistance to permeation
– Thicker liner increases resistance to
permeation proportionally to the square of liner
thickness.

Virgin Transfer Molded PFA
– No recycled PFA improves liner integrity
– Stainless Liner Retaining Mesh with more spot
welds for better retention
– Flange Retaining Groove
Rosemount has the thickest
Teflon liners in the industry
Number of Stainless Mesh Welds are
Critical to Proper Liner Retention
Flange Grooves ensure
retention at flange face
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 24
Best Practices for Increasing Reliability
in High Temperature Applications

High Quality Teflon Liners
– Increases resistance to permeation

High Temperature (TA) Option
– Channels permeated fluids away from active components

Insulation of the pipe reduces temperature gradients that increase
permeation rates
Insulated by Coil Housing
- Reduced permeation
Uninsulated area
-Greater permeation
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 25
Proper Selection and Capabilities
Extends Meter Life

Liner Selection
– Engineered liners matched to
slurry or liquor
– Lining Protectors to reduce
abrasive wear – blow line and
lime slurry

Electrode Selection
– Chemical compatibility
– Material hardness
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 26
Material
Brinell Hardness
Tungsten Carbide
Exceeds Scale
Titanium Grade 2
200
Nickel Alloy 276
194
316 Stainless Steel
146
Platinum Iridium
(90/10%)
130
Nickel
90
Tantalum
45
Increased Meter Life in Black Liquor
Application

Major North American
Pulp Mill
CHALLENGE
– Mill increases Black Liquor
temperature in digester to increase
efficiency
– Higher temperatures increased rate of
permeation through liner
– Liner failure significantly reduced flow
meter life
North America

SOLUTION
– Rosemount PFA lined flow tubes

Application: Black
liquor flow
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 27
RESULT
– Significant increase in meter life
– Reduced downtime and maintenance
costs
Molded PFA Liners Resist Permeation at
Elevated Temperatures
Major North American
Pulp Mill
North America
Application: Black
liquor flow
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 28
“Attached is a picture taken of the inside of the
meter we installed several months ago. If you
recall, this is the PFA lined meter and it's in the
hottest location we have. I am pleased to report
that it looks absolutely unblemished! Not a
single blister, bump, or indication of liner fatigue.
I think we might have hit on something big here
for these extremely hot liquor applications... I've
got a feeling we are going to be aggressively
pursuing PFA liners for the digester area.”
Major North American Pulp Mill
*Excerpt from
customer letter to
Rosemount sales
person.
Rosemount Magmeter on Critical
White Liquor Charge

Large Pulp and
Paper Mill
Global Company
Application: White
liquor charge to
digesters
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 29
CHALLENGE
– White liquor charge to digester critical
to achieve proper alkali-to-wood ratio
– Another manufacturer’s meter was
reading low, and caused digester to
undercook
– Undercooking plugged blow line
during blow down; plugged blow line
caused shutdown
– Result was 5 lost days of production
or 6500 tons; over $1.3 million lost in
revenue
Emerson Magmeter handles Tough
Service on Blow Line Application

Large Pulp and
Paper Mill
CHALLENGE
– Continuous digester blow line
magmeters failed every 6-9 months –
resulting in digester shutdown
– high caustic, high temperature,
abrasive material (knots), and
occasional vacuum
Southeastern USA

SOLUTION
– Rosemount PFA lined magnetic flow
meter was chosen due to liner reliability
and stability of measurement output

Application: Digester
blow line flow
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 30
RESULT
– Rosemount magmeter with PFA liner In
operation for over 2 years with no
incidents
Brown Stock Washing
KPI’s
• High washing efficiency
• High pulp purity (alkali carryover)
• High black liquor solids
• Good energy management
Washer #1
Washer #2
Washer #3
H.D.
Storage
Seal
Tank #1
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 31
Seal
Tank #2
Seal
Tank #3
Chemical Pulp Bleaching
KPI’s
• Brightness/ Kappa# (on- target)
• Optimize yield
• Optimize throughput
• Minimize chemical usage
• Good energy management
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 32
Chemical Pulp Bleaching
KPI’s
• Brightness/ Kappa# (on- target)
• Optimize yield
• Optimize throughput
• Minimize chemical usage
• Good energy management
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 33
Chemical Pulp Bleaching
KPI’s
• Brightness/ Kappa# (on- target)
• Optimize yield
• Optimize throughput
• Minimize chemical usage
• Good energy management
Bleaching Conditions
Cl2 or
Caustic as %
of Dry Pulp
Stage
pH
Temp (oC)
Time
Pulp
Consistency
Caustic
Extraction
10.5
final
60o - 82o
(140o 180oF)
1/
12-15%
0.5-5.0%
Hypochlorite
11.011.5
27o - 60o
(80o 140oF)
1-2 hrs 1st
stage; 3-4 hrs
2nd stage
3-14%
1.5-3.0%
Chlorine
Dioxide
5.0 7.0
60o - 82o
(140o 180oF)
3 - 5 hrs
11-12%
0.5-1.5%
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 34
2
- 2 hrs
Abitibi Increases Throughput and Efficiency
With 16% Stock Flow Measurement

Fort Frances, Ontario
Application: 16%
stock flow for high
consistency bleaching
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 35
CHALLENGE
– Mill moved from “medium consistency”
bleaching (15%) to “high consistency”
bleaching (35%)
• Increases production rate
• Higher bleaching efficiency
– Dilution after bleach tower is 2-stage:
• from 35% to 16%
• from 16% to 4%
– Stable, accurate flow measurement of
both 16% and 4% stocks is critical for:
• Dilution control
• Bleaching chemical ratio control
• Efficiency improvement
Abitibi Increases Throughput and Efficiency
With 16% Stock Flow Measurement

Fort Frances, Ontario
Application: 16%
stock flow for high
consistency bleaching
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 36
SOLUTION
– Rosemount High Signal Magmeter
– Achieved ±1% accuracy on 16%
consistency stock
– over a 5:1 flow turndown
– Clean signal, minimal damping
– Tight flow rate control for
• Dilution Rate (16% and 4% stages)
• Chemical Addition
Abitibi Increases Throughput and Efficiency
With 16% Stock Flow Measurement

RESULTS
– Greater bleaching efficiency at higher
consistency achieved
Fort Frances, Ontario
Application: 16%
stock flow for high
consistency bleaching
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 37
– Reduced chemical consumption by 68% for revenue improvement of
$100K+/yr
– Increased production rate = $500K+/yr
• same equipment, more tons/hr
• operating at 150% of design
flowrate
• high grade paper = higher
profitability
3RD Party Process Noise
Testing at Andritz
Run 8: 4-20 mA Output Stability - 8% Pulp Stock Consistency
1100.000
1080.000
Flow Rate [m3/h]
1060.000
1040.000
1020.000
Krohne Flow [m3/h]
1000.000
Emerson Flow [m3/h]
980.000
960.000
940.000

920.000
Independent test of output
stability at multiple stock
consistencies
900.000
1
101
201
301
401
501
601
701
801
901
Sample Number [10/sec]
Run 2: 4-20 mA Output Stability - 10% Pulp Consistency
1100.000
1080.000

Rosemount (blue) more
stable across range of
stock consistency
1060.000
Flow Rate [m3/h]
– 8%, 10% and 12% stock
1040.000
1020.000
Krohne Flow [m3/h]
1000.000
Emerson Flow [m3/h]
980.000
960.000
940.000
920.000
900.000
1
101
201
301
401
501
601
701
801
901
Sample Number [10/sec]

Rosemount reacted faster
to changes in flow
Run 3: 4-20 mA Output Stability - 12% Pulp Stock Consistency
1100.000
1080.000
Flow Rate [m3/h]
1060.000
1040.000
1020.000
Krohne Flow [m3/h]
1000.000
Emerson Flow [m3/h]
980.000
960.000
940.000
920.000
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 38
900.000
1
101
201
301
401
501
601
Sample Number [10/sec]
701
801
901
3RD Party Process
Noise Testing at Andritz
4-20 mA Output Stability - 8% Pulp Consistency
1-Sigma Stability [% of rate]
15.00%

Independent test of output
stability across flow range
6.00%
3.00%
2.07
2.77
3.86
3.90
4.01
5.52
5.54
5.95
Velocity [m/s]
4-20 mA Output Stability - 10% Pulp Consistency
15.00%
1-Sigma Stability [% of rate]
Rosemount (blue) more
stable across range of
flow rates
Emerson 1-σ Stability
[% of rate]
Krohne 1-σ Stability
[% of rate]
9.00%
0.00%
0.46
– 8%, 10% and 12% stock

12.00%
12.00%
Emerson 1-σ Stability
[% of rate]
Krohne 1-σ Stability
[% of rate]
9.00%
6.00%
3.00%
0.00%
2.03
2.47
2.68
3.68
4.09
4.47
5.19
5.28
6.38
Velocity [m/s]
4-20 mA Output Stability - 12% Pulp Consistency
1-Sigma Stability [% of rate]
15.00%
12.00%
6.00%
3.00%
0.00%
2.18
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 39
Emerson 1-σ Stability
[% of rate]
Krohne 1-σ Stability
[% of rate]
9.00%
2.19
3.71
Velocity [m/s]
5.16
Paper Slurry Testing at PAPRICAN Confirms
Rosemount High Signal is Best for Stock Flow
Shows how much damping is required to match Stability of
Rosemount High Signal with 1.0 second of damping
Rosemount 8707/8712H (RMT) versus ABB FSM4000 (ABB) - 6.5% Pulp Stock
Consistency
Rosemount 8707/8712H (RMT) versus ABB FSM4000 with 40 seconds of damping (ABB) 6.5% Pulp Stock Consistency
1200
2000
1800
1000
1600
RMT Freq
RMT Freq
1400
800
ABB Freq
ABB Freq
RMT Mean
RMT Mean
RMT Low 2-Sigma
1000
RMT High 2-Sigma
Counts
Counts
1200
RMT Low 2-Sigma
600
RMT High 2-Sigma
ABB Mean
ABB Mean
800
ABB Low 2-Sigma
600
ABB Low 2-Sigma
400
ABB High 2-Sigma
ABB High 2-Sigma
400
200
200
0
200
210
220
230
240
250
260
270
280
Flow Rate (USGPM)
290
300
0
200
210
220
230
240
250
260
270
280
290
Flow Rate (USGPM)
RMT High Signal = 1.0 Sec
RMT High Signal = 1.0 Sec
Manufacturer A = 1.0 Sec
Manufacturer A = 40.0 Sec
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 40
300
Mechanical Pulp Bleaching
Goals
Brightness/ Kappa# (on- target)
Optimize yield
Optimize throughput
Minimize chemical usage
Good energy management
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 41
Liquor Recovery
CO2
Fresh
Water
Lime Pellets
CaO
Make-up Lime
Pre-wash
filter
Lime Kiln
Slaking
White Liquor
NaOH
Na2S
Slaked Lime
Ca(OH)2
Lime Mud
Ca(CO)3
Causticizers
Green Liquor
Evaporation/
Concentration
Na2CO3
Na2S
Energy
W.L.
Clarifier
Recovery Boiler
Smelt Tank
Labor
Soap Skimming
(softwood)
Black Liquor
Na2CO3
Na2S
Organics
Make-up
Chemicals
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 42
Make-up Sodium
Compounds
(“Saltcake”)
Liquor Recovery : Evaporation
KPI’s
• Maximize throughput
• Maximize solids
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 43
Liquor Recovery : Recovery Boiler
KPI’s
• Optimize throughput
• Mill Safety
• Meet emissions regulations
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 44
Liquor Recovery : Causticizing
KPI’s
• Causticizing efficiency
• Throughput
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 45
Liquor Recovery : Lime Kiln
KPI’s
• Throughput
• Energy use (BTU’s/ton)
CaCO3
CO2
CaO
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 46
Emerson Magmeter Handles
Tough Service on Lime Slurry

Pulp and Paper Mill
CHALLENGE
– Frequent process upsets due to
flow signal instability.
– Frequent tuning required to
compensate for instable flow signal
Wisconsin, USA
• Loop often could not be controlled in
automatic, reducing efficiency
– Abrasion and chemical corrosion
led to frequent downtime for
cleaning or to replace failed flow
tubes
Application: Lime mud
flow to precoat filter of
lime kiln
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 47

SOLUTION
– Rosemount magnetic flowmeter
with process noise mitigation
capabilities
High Signal Magmeter Solves
Tough Lime Slurry Problem
Pulp and Paper Mill
Wisconsin, USA

RESULT
– Rosemount magnetic flow meter
provided greater signal to noise ratio
and more stable output from the meter.
– Automatic control restored
• Increased efficiency
– Increased throughput in the lime kiln
– Maintenance due to repair and
replacement was significantly reduced
Application: Lime mud
flow to precoat filter of
lime kiln
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 48
Liquor Recovery : Lime Kiln
KPI’s
• Throughput
• Energy use (BTU’s/ton)
CaCO3
CO2
CaO
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 49
Actual Lime Kiln Installation
Proprietary
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 50
Paper Mill Overview
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 51
Stock Preparation : Stock Blending
KPI’s
• Blend ratio
• Grade change time
• Specific energy
• Freeness
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 52
Where is Noise Affecting Your
Magmeter Performance ?
Broke
Medium consistency
stock flows
Low consistency
stock flows
High consistency
stock flows
Basis Weight
loop
Recycle fiber
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 55
Where is Noise Affecting Your
Magmeter Performance ?
Stock
Consistency
Chemical
addition
5 Hz
37.5 Hz
37.5 HZ w/DSP
0 – 6%
4 – 10%
6 – 10+%
Add 1% point for chemical addition
Broke
Fiber Length
Short fiber
(tissue): subtract
1%
Medium fiber
(newsprint): no
change
Velocity
(normal flow)
Less than 3 ft/s:
subtract 1%
Between 3 and 10
ft/s: no change
Viscosity
Non-sticky: no change
No change when low solids
Solids content
Basis Weight
content
loop
Recycle fiber
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 56
Long fiber
(container board):
add 1%
Medium consistency
stock flows
Low consistency
Exceeds
10 ft/s:
stock
flows
add 1%
Sticky: add 1%
Add 1% when large solids
(knots, staples, etc.) areHigh consistency
stock flows
present
Stock Preparation : Stock Blending
KPI’s
• Blend ratio
• Grade change time
• Specific energy
• Freeness
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 57
Flowmeter Solutions for Noisy Additive
Flows
DTPA
Titanium
Dioxide (TiO2)
Sodium
hydrosulfate
Alum
Chelating Agents
Defoamers
Sodium aluminate
Coater Kitchen
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 58
Starch
Paper Machine Wet End
KPI’s
• Machine Breaks
• Cost/ton
• Throughput
• Retention efficiency
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 59
Paper Machine Basis Weight
Application Challenge
CT
4
From Machine
Chest
LV 3
FT4
Basis
Weight
Valve
CD Profiling
Computer
FV 4
Fan Pump
White Water
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 60
Screens/
Cleaners
HeadBox
Paper Machine Basis Weight
Application Challenge
CT
4
From Machine
Chest
Speed of response and signal
to noise are critical in this
flow measurement
LV 3
Grade
Selection
RSP
PV
gpm
FT4
Basis
Weight
Valve
Thick Stock
Flow
Basis
Weight
PV
%open
BW
FV 4
Screens/
Cleaners
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 61
RSP
gpm
HeadBox
CD Profiling
Computer
Norske Skog Restores Basis Weight Control
with High Process Noise Diagnostics
500% reduction in
flow variability
Bruck a.d. Mur, Austria
Application: Basis
Weight control
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 62
Legend
RED = Signal from other manufacturer meter (4 seconds damping)
GREEN = Signal from Rosemount meter (2 seconds damping)
Norske Skog can not control
Basis Weight –With ABB Mag
Bruck a.d. Mur, Austria
Values, of 7th Dec.
2006
Application: Basis
Weight control
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 63
Legend
Light blue = control signal for basis weight pump
Dark red = processed control signal (other manufacturer’s
damped signal + control system damping)
Norske Skog Restores Basis Weight Control
with High Process Noise Diagnostics
“Several hours after
commissioning the magnetic
flowmeter, we had full
confidence in the signal,
allowing us to have automatic
basis weight control.”
Christian Trieb, Line
Responsible PM4 -E Automation - IT
500% reduction in flow
variability
Legend
LIGHT BLUE = control signal for Basis Weight pump
Dark RED = processed control signal
GREEN = unfiltered signal from Rosemount meter
DARK BLUE = Basis weight value
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 64
Values, as of 2nd
Feb. 2007, same
scale and time
Norske Skog Restores Basis Weight Control
with High Process Noise Diagnostics
Results:


Bruck a.d. Mur, Austria



Application: Basis
Weight control
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 65
Automatic control restored
Flow measurement variability reduced by
500%
Reduced fiber and additive usage
Reduced cull
1.5% throughput improved on paper machine
“The successful installation of the Rosemount magnetic
flowmeter increased the throughput of the paper machine
and was one of the reasons that we could increase paper
production by 1.5%”
Christian Trieb, Line Responsible PM4 -E - Automation - IT
Basis Weight Noise Problem at Large
Fine Paper Mill In Southeast USA

Large Fine
Paper Mill
Southeastern USA
Application: Wet end
basis weight flow
measurement,
4.5% pulp stock
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 66
CHALLENGE
– Too much Basis Weight variability
– Noisy, thick stock difficult for existing
meters to measure
– Excessive damping required to
provide stable flow signal, but slow
response resulted in erratic control
and even higher variability
– High variability forced mill to run at
higher weight target to meet basis
weight requirements
Basis Weight Noise Problem at Large
Fine Paper Mill In Southeast USA

Large Fine
Paper Mill
Southeastern USA
SOLUTION
– Mill tested two meters to determine
which provided the most stable and
responsive flow signal
– Rosemount magmeter was 4x more
stable than the other manufacturer’s
magmeter
Figure 1 - Stability
Application: Wet end
basis weight flow
measurement,
4.5% pulp stock
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 67
Basis Weight Noise Problem at Large
Fine Paper Mill In Southeast USA

Large Fine
Paper Mill
Southeastern USA
SOLUTION
– Rosemount High Signal magmeter
was 3x faster in response than the
other manufacturer’s magmeter
– Rosemount chosen and system was
able to return to automatic control
Figure 2 – Response Time
Application: Wet end
basis weight flow
measurement,
4.5% pulp stock
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 68
Basis Weight Noise Problem at Large
Fine Paper Mill In Southeast USA

Large Fine
Paper Mill
Southeastern USA
Application: Wet end
basis weight flow
measurement,
4.5% pulp stock
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 69
RESULTS
– 5% reduction in process variability
– Basis weight target shift of .04 lbs
– Fiber and additive cost reduction of
over $162K per year
– Improved paper quality
California PaperBoard Reduces Basis
Weight Variability with Rosemount Mag

– Signal spikes in flow measurement
forced the control system to forfeit
command of the basis weight valve
on fourdrinier
– Signal spikes cost ½ hour of
production with each episode
– Productivity loss of $90K - $180K per
year in lost production and wasted
raw materials Too much Basis Weight
variability
California Paperboard
Santa Clara, California

Application: 3- 4%
stock for basis weight
control
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 70
CHALLENGE
SOLUTION
– Rosemount magmeter with advanced
digital signal processing filtered out
spikes; automatic control was never
suspended
California PaperBoard Reduces Basis
Weight Variability with Rosemount Mag

California Paperboard
Santa Clara, California
Application: 3- 4%
stock for basis weight
control
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 71
RESULTS
– Basis weight variation reduced from
+/-4 lbs to +/- 1lb; a 75% reduction in
variability
– Cull was reduced and customer
satisfaction improved
Once the Rosemount magmeter was installed, signal
spikes were no longer a problem and the process
could be controlled automatically.
Steve Blankenship, Plant Manager
Paper Machine Wet End
KPI’s
• Breaks
• Cost/ton
• Throughput
• Retention efficiency
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 72
Boise Cascade Improves Quality With Better
Screen Rejects Flow Measurement

– Erratic pressure screen reject flows
caused variability in paper quality
– Analog damping of existing flowmeter
minimized to help control variability
– Existing flowmeter unable to provide
stable output with minimal damping
– Rosemount mag tested against
another manufacturer's dualfrequency flow meter
De Ridder, Louisiana

Application:
Pressure screen
rejects flow
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 73
CHALLENGE
SOLUTION
– Only Rosemount magnetic flowmeter
was able to stabilize the flow signal
with minimal damping
Boise Cascade Improves Quality With Better
Screen Rejects Flow Measurement

De Ridder, Louisiana
Application:
Pressure screen
rejects flow
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 74
RESULTS
– 85% reduction in variability of the
pressure screen reject flow signal
– Improvement in paper quality
– Rosemount Mags are now the
standard on this application
Paper Machine Dry End
KPI’s
• Uptime / machine breaks
• Paper machine efficiency
• Throughput
• Quality
• Cost/ton
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 75
Reducer Vortex Technology Improves
Supercalendaring

CHALLENGE
– Paper producer requires wide range of
steam flow rates to supercalendar to
produce a wide range of low to high gloss
papers to serve its’ customers
– Current technology could not accurately
measure the wide range of flows, impacting
contol
Midwest Paper Mill
USA

SOLUTION
– Rosemount Vortex provide excellent
rangeability with reducer option to measure
much lower steam flow rates
Application: Steam
to Supercalendar
profiler
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 77

RESULT
– The fixed accuracy of the Rosemount 8800
vortex flowmeter over the entire flow range
allowed for tight control during both high
and low quality paper production
How can you reduce energy costs ?
 Understand and manage
your steam production,
demand, and usage
 Understand and manage
fresh water use and
compressed air leaks
Energy Cost
(Natural Gas US)
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 78
How can you reduce energy costs ?
 Understand and manage
your steam production,
demand, and usage
 Understand and manage
fresh water use and
compressed air leaks
 Compensated Vortex and
DP flow technologies
provide high accuracy,
multiple outputs
 Volumetric flow
 Mass flow
 Energy flow (BTU)
 Temperature
 Line Pressure
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 79
Energy Cost
(Natural Gas US)
Identifying Steam Energy Reduction
Opportunities with MultiVariable™ Vortex

Midwest Paper Mill
USA
CHALLENGE
– Mill challenged to reduce energy
costs; implements energy
management program
– Accurate steam use for each area
required for billing and management
– Existing mechanical meters
unreliable and expensive
• Unreliable measurements
• Require frequent maintenance
Application: “House
Heat” custody transfer 
• Steam use totals collected manually
SOLUTION
– Rosemount 8800 MultiVariable
vortex flowmeter replaces old
flowmeter
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 80
MultiVariable™ Vortex Technology Improves
Custody Transfer of Saturated Steam
Midwest Paper Mill
USA

RESULT
– Customer improves steam measurement
accuracy with mass flow measurement
• Old meter flow measurement off by 2-4%
due to steam density changes
– More accurate billing; better P/L
management
• 2-4% reduction in error of custody transfer
of steam
• Reduction of tax burden
Application: “House
Heat” custody transfer
– Eliminated 14 trips per year to read meter,
leading to $5000 per year in reduced
maintenance costs
“We eliminated about 14 operator and maintenance trips annually,
and the operators can see the totalized steam flow through the
operator screen at a glance.
Process Control Supervisor, Midwest Paper Mill
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 81
How can you reduce energy costs ?
 Understand and manage
your steam production,
demand, and usage
 Understand and manage
fresh water use and
compressed air leaks
 Compensated vortex and
DP flow technologies
provide high accuracy
 Wireless DP flow
provides cost effective
monitoring and
accounting of steam,
water and compressed air
Energy Cost
(Natural Gas US)
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 82
Conclusion of Pulp & Paper Industry
Training
- Our Call to Action
A. Reinforce Knowledge Learned Today
– Use Pulp & Paper training materials and tools
B. Identify & List Down Pulp & Paper Customers
– Work with your business leader on account coverage plan
C. Schedule 1 Customer Visit Every 2 Weeks
– Gain industry exposure to supplement your knowledge
– Listen to customer pain points and experiences
D. Understand The Customer Needs and Identify Opportunities
Using Our Value Proposition Capabilities
E. Get business on the first 3 months
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 83
Pulp and Paper Terminology
BARK HOG—a machine for breaking up bark into small pieces suitable for delivery to the fuel spouts of a bark-burning boiler; typically, a hammermill.
BARKING DRUM—a large drum (typically 10-15 ft in diameter by 45-80 ft long) mounted to rotate on a horizontal axis; designed to receive pulpwood
logs at one end and tumble them until the bark is removed by abrasion, discharging them at the other end; also called a de-barker or barker.
BLEACH PLANT—a facility designed to receive pulp from the pulp mill and whiten it to the desired degree for its intended purpose; typically consists of
towers, washers, chemical preparation units, pumps, tanks, piping, etc. all designed, to form a workable system for bleaching pulp; will utilize such
chemicals as chlorine, chlorine dioxide, sodium hydroxide, sodium hypochlorite, oxygen, etc.; usually consists of several bleaching stages, each one
followed by a washing operation to remove color and spent chemicals from the previous stage.
BLOW TANK—a vessel used to receive pulp discharged from a digester and to reduce the pressure level to atmospheric; the blow tank may have
provisions to allow the incoming pulp to be fragmented into fibers and to collect the steam as an energy-conservation measure.
BLOWDOWN DRUM—a cylindrical tank that receives blowdown liquid discharged from a boiler; most boilers have a blowdown system that removes
solids that settle at the bottom of the lower drum; this system may discharge continuously or intermittently.
BOILER—a large installation designed to produce steam; typically consists of a furnace, steam generator, and wide range of auxiliaries installed in a
large building; three general types are found in the paper mill: (1) a bark boiler utilizes bark as its fuel; (2) a power boiler will burn oil, coal, or natural gas
as fuel, sometimes in combination with each other or with bark, and (3) a recovery boiler burns the spent black liquor as fuel, recovering the
noncombustible chemicals for processing and reuse; the steam generator consists of two horizontally mounted drums and a set of tubes running
vertically between them; the unit is filled with water to approximately the middle of the upper drum, and hot gases are passed between and around the
tubes, thus heating the water and forming steam, which is collected above the water level in the upper drum; as steam is used, it is replaced with feedwater, which is introduced into the lower drum; auxiliaries are provided to treat the feedwater, provide an adequate air supply for combustion, cleanse the
exhaust gases as required, and to operate and control the entire system.
BREAK—an interruption in the production of paper on the paper machine; the sheet has broken and is being dumped into the pits below the machine to
be repulped and reused in the process; to restore operation, a narrow strip or "tail" is cut and threaded through the rope run to the dry end, and gradually
widened to full sheet width.
BREAST ROLL—the roll that supports the headbox end of the four-drinier wire; driven by friction with the wire.
BRIGHTNESS—a measure of the percent of light reflected from a sheet of paper or pulp; commonly called GE brightness based on the use of scales
and instruments marketed by GE; typical values range from 70 for newsprint to 90 for high quality book and printing papers; brightness measurements
are made by comparison with standard specimens.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 84
Pulp and Paper Terminology
BROKE—pulp that has been through the paper machine (or part-way through) and for some reason was not finished and shipped; typically consists of
material released from a break on the machine, trim from normal operations, unsalable quality paper, etc.; normally, this paper is repulped and returned
to the process as broke.
BROWNSTOCK—the unbleached pulp as it passes through the pulp mill.
CALENDER—a set of rolls located at the dry end of the paper machine and designed to smooth the sheet; commonly arranged in a vertical stack with
two to ten rolls forming many nips through which the sheet passes; the bottom roll, called the king roll or the roll above it (the queen roll) is driven and the
rest of the rolls are turned' by friction with the paper and each other; this provides some slippage that tends to smooth the sheet and make it glossy.
CAUSTICIZER—a tank designed to provide reaction time and intimate contact between the chemicals used to form white liquor; the basic reaction in the
causticizer is the interaction of calcium hydroxide and sodium carbonate to form sodium hydroxide and calcium carbonate; usually, several causticizer
tanks are connected in a series and the reacting chemicals pass through each tank in sequence, providing time to complete the chemical reaction.
CHEST—an agitated vessel designed to hold pulp at various degrees of consistency and stages of processing; may be rectangular or cylindrical, and
may have an open or closed top; usually constructed of tile or concrete; may have interior liner for corrosion protection; chests are usually located
between processing stages as temporary stora-ge to smooth out the flow of pulp through the mill; commonly used "to hold broke, blend stocks into a
furnish, supply stock to a paper machine, store bleached pulp, etc.; vessels designed for storing white-water are more commonly called tanks and do not
have agitators,
CHIPPER—a machine designed to reduce logs into chips; consists of a rotating disc or drum with knives set into it and a means of feeding logs to the
rotating knives; cuts logs into match book size chips; usually a large machine mounted in a permanent location and fed continuously by a conveyor;
smaller units, usually the drum-type, can be mounted on vehicles and used to chip brush, log ends, and trimmings, either in the forest or in urban areas
for trash removal; small units (sometimes of the hammermill type) are commonly used in the woodyard as "re-chippers" to process oversize rejects from
the main stream.
CLARIFIER—a large tank, usually circular and of concrete construction, designed to allow settlement of solid materials suspended in water; can be
rectangular in some cases; typically fitted with a rotating rake that scrapes the settled materials on the bottom to a central point for removal as a solid
waste; may include pumps, tanks, piping, and instrumentation for introduction of chemicals to aid settlement of solids; used to clarify raw water for use in
a mill, also to clarify waste-water discharged from process operations.
CLEANER—a cone-shaped device designed to remove dirt and other undesirable material from stock; commonly operates on the centrifugal force
principle in which the heavier particles are driven to the walls and fall out the bottom while the lighter materials pass out through the top; can be used in
applications where the impurities are either heavier or lighter than the stock; typical installations will have a set of vertical cleaners connected in parallel
for high capacity stock cleaning.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 85
Pulp and Paper Terminology
COATER—a machine designed to apply a coating to the sheet of paper; can be installed on the paper machine and apply the coating as the paper is
being manufactured or can be a separate machine with a system for unwinding the roll, passing the sheet through the coating substance, drying the
sheet, and then rewinding it into a roll; coatings can be applied by spraying or forming a "puddle" through which a loop of paper passes, receiving the
coating on both sides.
CONSISTENCY—the amount of fiber in a given amount of stock; commonly expressed as a percentage based upon weight; typical formula: R = weight
of fiber x 100 where the weight of stock ' weight of the fiber may be either its oven dry weight (no moisture) or its air dry weight (approximately 10 percent
moisture); the basis for the consistency measurement must be specified and all calculations and instrument calibration must be in conformance with the
specifications.
CONVERTING—transforming the basic roll of paper into a salable consumer product; includes cutting,- printing, coating, shaping, folding, forming into a
desired product, and packaging for distribution to consumers; converting is usually done at a different location from the paper mill; some paper companies
have found it convenient to build converting plants near their paper mills to reduce the transportation costs for basic roll stock.
COOLING TOWER—a structure designed for air cooling of hot liquid; as used in the pulp and paper industry it is a vertical tower/ usually square in cross
section, with wooden slats on all four sides, and designed for spraying hot water at the top, allowing the descending water to exchange heat with a rising
column of cooler air.
CORRUGATING MEDIUM—a type of paper commonly manufactured especially for use as the corrugated center section of box-board or container board;
frequently manufactured by the NSSC process and called "nine-point" from its nominal thickness of 0.009 inch; manufactured in rolls like other ( papers
and bant into characteristic curved shape in a converting plant, where the two outer layers are glued to the middle of the upper drum, and hot gases are
passed between and around the tubes, thus heating the water and forming steam, which is collected above the water level in the upper drum; as steam is
used, it is replaced with feed-water, which is introduced into the lower drum; auxiliaries are provided to treat the feedwater, provide an adequate air
supply for combustion, cleanse the exhaust gases as required, and to operate and control the entire system.
COUCH PIT—an open chest located beneath4the couch' roll; designed to receive the entire flow of stock from the wire in case of a break in the wet sheet
between the fourdrinier and the press section.
COUCH ROLL—the roll that supports the end of the fourdrinier opposite the headbox; usually a suction roll; on earlier vintage machines, the couch roll
was the main drive roll for the fourdrinier and also the place where the wet web was separated from the wire for transfer to the press section; this term is
derived from the word couch (pronounced cooch) meaning to separate the sheet of paper from the forming screen; in more recent vintage machines, the
wire is driven by an additional roll, the wire turning roll, which is placed below and beyond the couch roll, and the couch roll turns by friction with the wire;
with this arrangement, a pick-up roll transfers the wet sheet to the press section.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 86
Pulp and Paper Terminology
DEAERATOR—a tank used to remove entrained air from a process fluid; two basic applications in the pulp-paper industry (1) in the stock preparation
area, the deaerator removes air entrained in the stock before it is delivered to the fourdrinier, (2) a tank used in the boiler feedwater system to deaerate
the feed-water; acts as a direct contact heat exchanger using steam to heat the feedwater and strip out dissolved gases such as oxygen and carbon
dioxide, which are vented from the tank.
DECKER—a machine designed to thicken pulp by forcing water to pass through a screen; typically, it consists of a rotating, horizontally mounted drum
with the screen as its cylindrical surface and a vat to hold the incoming thin stock; as the drum rotates, the pulp clings to the screen and the water is
drawn through the screen by a vacuum suction system within the drum; the water thus removed falls down through barometric legs and is collected in
tanks; the decker will have provisions to remove the thick stock from the screen and discharge it into a suitable vessel; many variations are used for
different applications and called by various names, such as thickener, save-all, drum filter, or pulp washer; when used as a washer, the machine is fitted
with showers that spray water over the pulp on the drum, thus cleansing it of impurities; the operating principle is similar to that of the cylinder-type paper
machine formerly in general use, but now usually replaced by the fourdrinier machine.
DIGESTER—a digester is a vessel in which wood chips or other raw materials are cooked to produce pulp; most modern digesters have a continuous
feed and continuous discharge of pulp; a typical modern continuous digester is a pressure vessel approximately 200 feet tall and 15 feet in diameter,
complete with provisions to supply wood chips, cooking liquor, and steam continuously, and to maintain ^proper operating conditions (temperature,
pressure, and cooking time); older digesters (still in widespread use) operate on a batch basis, usually have several digesters in a set with staggered
operating cycles to provide a reasonably steady flow of pulp.
EVAPORATOR—in general, a device designed to thicken a fluid by causing water to evaporate; in the paper industry, the kraft process uses a multipleeffect evaporator to concentrate weak black liquor (about 15-20 percent solids) from the cooking process to strong black liquor (50 percent solids); usually
has five or six large vessels called bodies or effects, each operating at a successively higher temperature and pressure in the liquor flow direction; steam
heats the highest temperature body and flows through each successive body in the opposite direction to the liquor flow.
FAN PUMP—a large, high capacity pump designed to supply stock to a paper machine; typical capacity is 50,000 gpm at 0.5 percent consistency;
commonly called "primary" when used to supply the base sheet of a two-ply sheet and "secondary" for the top liner.
FELT—an endless belt of woven cloth material that contacts the sheet as it passes through the paper machine; felts serve as guides, cushions, and
drying media for the wet sheet; the various felts used in the paper machine are commonly called machine clothing; generally used in the press and dryer
sections of the machine; woolen or synthetic material is commonly used in the press section, while cotton or synthetics are used in the dryer section.
FOURDRINIER—specifically, the wet end of a paper machine that uses a moving endless belt of wire mesh to form the sheet; more generally, applied to
the entire paper machine that incorporates the fourdrinier wire belt for sheet formation; named for the promoters who sponsored the development of the
endless belt paper machine; most paper mills now use this type of machine; the older type, called the cylinder machine (see • DECKER), has been
replaced
the fourdrinier
[File by
Name
or Event] machine in many applications; in the fourdrinier machine, the speed of the wire is varied with the speed of the stock spouting
fromEmerson
the head Confidential
box slice to achieve the desired type of sheet formation.
27-Jun-01, Slide 87
Pulp and Paper Terminology
GRINDERS—large machines designed to produce groundwood; typically consist of rotating wheels with stones attached or imbedded in them; driven by
large electric motors rated in thousands of horsepower; operate by having logs pressed against the stones such that the wood is abraded into fiber.
HEADBOX—a box-shaped vessel mounted above and ahead of the fourdrinier and' containing the slice that delivers stock to the fourdrinier wire; extends
over the full width of the wire; designed to control the flow of stock at a uniform rate across the fourdrinier; may have internal rolls, baffles, and other
devices designed to prevent flocculation and to smooth out the flow of stock in the machine direction; may have pressure controlled by an air pad or other
means.
KNOTTER—a device designed for removing knots from pulp; typically, a perforated plate or screen placed in a stock line sized to pass stock but to retain
large pieces such as knots.
MECHANICAL PULP-a type of pulp produced by mechanically separating the fibers in the wood, as opposed to the use of chemicals to perform the fiber
separation as in chemical pulps (sulfate, sulfite, soda, etc.). The mechanical separation can take place using the following processes:
1. Stone groundwood (SWG). Barked logs are forced lengthwise against a rotating horizontal artificial stone. Power applied per stone can vary between
2,000-10,000 horsepower ,
2. Therm-mechanical (TMP). Chips from barked logs are refined in pressurized revolving disc refiners. Refiner horsepower can vary between 1,000
horsepower to 14,000 horsepower,
3. Chemical thermo-mechanical (CTMP). Same as TMP except that the chips are given a mild chemical pre-treatment ahead of the refiners.
4. Refiner mechanical (RMP). Same as TMP except that the refining is done under atmospheric pressure.
NEWSPRINT-the type of paper used for printing newspapers; commonly made from a blend of mechanical pulp and bleached chemical pulp.
NIP-the line of contact between two rolls'that apply pressure to a sheet passing between them; also the line between two wires used to form a wet sheet;
nip pressure is measured in pounds per linear inch along the nip line; typical values run from 100 to 1200 Ib/in, usually increasing in the machine direc
tion (for example, 1st press--250; 2nd press--350; 3rd press-- 800). - o>
NSSC PROCESS-the neutral sulfite semi-chemical process for making pulp; uses a bisulfite as the principal cooking chemical; can be sodium, calcium,
magnesium, or ammonium bisulfite in pH range of 6 to 9; the carbonate and possibly the hydroxide of the same radical may be present in the cooking
liquor; commonly used for producing "nine-point" for use as corrugating medium.
OPACITY-the property of a paper that prevents printing from showing through on the other side; the opposite of transparency.
OVEN DRY — containing no moisture; 100 percent fiber; achieved by exposing pulp or paper samples to elevated temperatures (approximately 215°F) in
a dry atmosphere; frequently called "bonedry"; oven' dry is term preferred by TAPPI.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 88
Pulp and Paper Terminology
PICK-UP ROLL—the roll that separates the wet sheet from the fourdrinier; located between the couch roll and the wire turning roll on the sheet side of the
wire; has internal suction and is covered by a continuous felt that provides a convenient and reliable method of transferring the wet sheet to the
PRESS—a set of two or more rolls designed to squeeze water out of the wet sheet; may have perforations and internal vacuum to withdraw water by
suction; some presses are designed for smoothing of the sheet or application of surface treatments; may be driven by an electric motor or differential
drive, or may be turned by friction; the line of contact between rolls is called a "nip"; many special names are used for presses, such as suction press,
pick-up press, size press, smoothing press, multi-nip press, etc.
PRESS SECTION— usually used on high-speed machines (1500-3500 ft/min) and on lightweight papers ranging from tissue to newsprint to coated book
and graphic papers. .
PULP — slurry of wood fibers (cellulosic material) suspended in water; this term is usually applied to the pulp in the pulp mill area — digesters, washing,
screening, and bleach plant; when it passes into the paper mill area (stock preparation and paper machine) , it is generally called stock or stuff.
PULPER—a large tank, usually rectangular and of tile construction, designed to re-pulp paper or dry pulp; fitted with one or more agitators to reduce the
incoming material to pulp with a consistency suitable for pumping and return to the process; most mills will have pulpers in the basement at the dry end
and under the presses or at other strategic locations for recovering broke; also made in cylindrical and tub-shape and used to re-pulp bales of pulp (offmachine service).
REFINER—a machine consisting of large discs, some stationary, some rotating, between which the pulp passes for frictional treatment to break up fiber
bundles and release individual fibers; refining is .also performed by jordans (primarily in older mills).
REJECTS — pulp or stock that is not acceptable for use in the machine furnish; commonly rejected at the screens or cleaners and returned for further
processing.
ROLL—a term with two general types of meaning in the pulp-paper industry: (1) a roll of paper manufactured by the paper machine and wound up on the
reel; typical rolls of liner-board can be-more than 25 feet wide and 9 feet in diameter, and weigh in excess of 10 tons; (2) a metallic cylinder mounted
horizontally and used to smooth, press, dry, or • otherwise process the wet (or semi-wet) sheet of paper being manufactured; most rolls have a fixed
diameter across their entire length, however some rolls (called "controlled crown") are designed to be expanded or contracted in diameter to accomodate
deflection at the center and achieve constant pressure across the nip; dryer rolls are heated by -steam, and contact with the sheet causes evaporation of
moisture from the paper.
ROPE—an endless band of rope that runs alongside the sheet through the press section and drier section of the paper machine; used to thread a new
sheet through the machine.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 89
Pulp and Paper Terminology
SALTCAKE — impure sodium sulfate (Na2SO4) ; also called Glauber's salt; used in sulfate process as make-up for lost chemicals; normally delivered to
the process in a saltcake tank just prior to injection of the black liquor into the recovery furnace .
SCREEN—in general, a wire mesh or plate with holes sized to pass desirable particles and retain undesirable particles; frequently takes the form of a
basket placed in a vessel and located in a stock line; usually made for removal and cleaning when clogged.
SLICE — a horizontal slot in the headbox through which the stock is sprayed out onto the fourdrinier; normally about three or four inches wide and
running the full length of the fourdrinier; adjustable in width to provide desired sheet formation.
SMELT — a molten liquid that emanates from the bottom of the recovery furnace; consists primarily of sodium sulfate, sodium sulfide, and sodium
carbonate; forms green liquor when dumped into the smelt tank.
STOCK — pulp after it has entered the stock preparation area, where it is processed for delivery to the paper machine; also called stuff by many
papermakers.
STUFF BOX — a box-shaped vessel that supplies stock to a succeeding stage at a constant pressure; elevated to achieve the correct pressure at the
delivery point; commonly used to supply the suction of a fan pump. ^
SULFATE PROCESS — the pulp-making process that uses sodium hydr- oxide and sodium sulfide as the principal cooking chemicals; also called the
"kraft" process because of the strong pulp it produces (kraft = strong in German) ; uses white liquor for cooking and produces black liquor as the spent
chemical solution; includes kraft recovery cycle with a recovery boiler and reconstitution of the whdte liquor through the causticizing process; generally
operates in pH range of 13-14 with about 12 percent active chemicals in solution.
SULFITE PROCESS — the pulp-making process that uses a sulfite V chemical for the cooking liquor, typically hydrogen sulfite Ap or calcium,
magnesium, sodium, or ammonium sulfite or bi-\ sulfite, frequently in combination with the hydroxide, carbonate, or sulfide of the same radical; may be
acid (pH 1-4); neutral (pH 6-9); or alkaline (pH 10+); approximately 20 percent of U.S. mills use this process (1970 survey) . Except for special products,
the use of this process is decreasing due to environmental problems and limited tech-nology on liquor recovery systems.
TALL OIL—a combination of many organic compounds such as fats, fatty acids, rosin, and rosin acids, all derived from the hydrolysis of wood in the kraft
process; many paper mills have tall oil plants for processing the soap from the evaporator into tall oil for sale to chemical plants for further separation into
products used in paints, inks, soap, detergents, plastics, adhesives, and many other applications.
TRIM—the width of the finished sheet of paper; also applied to a narrow strip that is cut off of each side during the manufacturing process.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 90
Pulp and Paper Terminology
TURBINE — a prime mover, generally driven by steam and designed to drive a rotating machine such as an electrical generator, fan, or pump; consists
of a case and set of rotating plates with blades designed for the service.
WASHER — a machine or vessel designed to wash pulp; usually, a machine like a DECKER, but fitted with showers for cleansing pulp on the cylinder; in
recent times, a different type called a diffusion washer has been introduced; it diffuses water through the pulp to remove impurities.
WEB—the sheet of paper being formed on a paper machine.
WHITE LIQUOR—the cooking liquor used in the sulfate process; consists primarily of sodium hydroxide and sodium sulfide dissolved in water; formed
from green liquor and lime when recovered (or purchased fresh).
WHITEWATER—water with a relatively small amount of fiber, usually too dilute to have a measured consistency (often expressed in pounds per 1,000
gallons rather than percent); commonly used in both pulp mill and paper mill areas.
WIRE — an endless belt of wire mesh upon which the sheet of paper is formed; originally made of metal; typically phosphor bronze, but more recently of
plastic; consists of the warp (lengthwise strands) and the shute (crosswise strands) ; the number of strands per inch (called mesh) varies widely, but falls
in the range of 40-80 for most linerboard, newsprint, tissue, and book papers . '
WIRE PIT — an open vessel under the fourdrinier; designed to collect water that drains through 'the wire.
WIRE RETURN ROLLS — rolls located below the wire and arranged to guide the wire from the couch end back to the headbox end; some wire return
rolls may be motor-drive (frequently, the first such roll) .
WIRE TURNING ROLL — the main wire drive roll on most modern fourdrinier paper machines; located below and forward of the couch roll; this is the roll
that is farthest from the breast roll.
YANKEE DRYER — also called "Yankee" or "Yankee machine"; a large steam-heated drum, some 15 to 20 feet in diameter and up to 20 feet wide; used
to dry a wet sheet of paper – tissue grade.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 91
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 92
Tough Service Applications in P&P That
Typically Have Poor Performance
Black liquor
recirc flow
Lime slurry
White liquor
feed
Sludge flows
Black liquor feed to
recovery boiler
Bleach Chemicals
(O2, ClO2, etc.)
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 93