Delivering Sustainable Growth

Nalco Company Operations
Asia Pacific HQ
Europe HQ
Latin America HQ
North America HQ
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3D TRASAR, 4D Air, CMV, Coating Space, Core Shell, DC-PRO, DIAMOND, DuraSoft, eROI, EXTRA WHITE, FillerTEK,
HYBRID, METRIX, NALSIZE, NAL-TEX, NCAT, NEWCD, OptiLux, OxiPRO, PARETO, PenSurf, POSITEK, SAFESCAN,
SCALE-GUARD, SuperWash, TRASAR, TULIP, VELOX, NALCO and the logo are trademarks of Nalco Company
Ecolab is a trademark of Ecolab USA Inc.
All other trademarks are the property of their respective owners
©2012 Ecolab USA Inc. All Rights Reserved
B-1121
– Delivering Sustainable Growth
to the pulp and paper industry
– Delivering Sustainable Growth
CMV™ process
to the pulp and paper industry
We adopt a grade-based approach to understand and address
the unique needs of each industry segment: graphics, board
and packaging, tissue, and fiber.
We partner with pulp and paper producers
worldwide to deliver economic and environmental
value through our reliable, cost-effective and
safe solutions. Our ultimate goal is to deliver a
Through the CMV process, our local account team works
directly with you to discover your prioritized needs. We audit
your systems and work together to develop a service and
improvement plan to deliver maximum performance from
your existing applications. We leverage industry leading
people, processes and technologies in a manner that is
tailored to your operations and key business drivers to
achieve measured results.
measurable return on investment.
Key Business
Drivers
System
Assurance
ECONOMIC
Continuous
Improvement
Value
Communications
SUSTAINABILITY
SUSTAINABILITY
ENVIRONMENTAL
SOCIAL
Customer
Feedback
Economic
Environmental
Social
Safety culture
✔
✔
✔
Reliable operations
✔
✔
✔
Raw material savings
✔
✔
✔
Water & energy savings
✔
✔
✔
Machine efficiency
✔
✔
✔
Grade development
✔
Innovation
Essential expertise
for the pulp and
paper industry
Nalco is an Ecolab company. Ecolab Inc. is on the
forefront of water, hygiene
and energy technologies
and services, providing
and protecting clean water,
safe food, abundant energy
and healthy environments
globally. Ecolab delivers
comprehensive programs
and services to the food,
energy, healthcare,
industrial and hospitality
markets in more than 160 countries.
With an 80-year track
record, Nalco is the world’s
leading process and
water treatment solutions
provider. Nalco’s focus on
innovation consistently
brings new technology
to the pulp and paper
industry, securing dozens
of new patents each
year. Supported by a
comprehensive network
of supply chain facilities in
each country and regional
research centers, our global
presence enables us to
offer a consistently high
level of service to local,
regional and multinational
customers.
Addressing your key business drivers
Safety culture
Reliable operations
Machine efficiency
◆ Safety training
◆ Operator training
Microbiological control
OxiPRO®
◆ Zero preventable accidents
◆ Best practice audits
Pitch & stickies
DC-PRO
◆ On-site assessments
◆ Responsible care
Cleaning solutions
NAL-TEX
◆ Product stewardship
◆ Monitoring and control systems
◆ Recovery boiler leak indication (RBLI)
◆ CMV process
◆ 3D TRASAR® for boilers
◆ Reliable feed systems
Wet-end management
POSITEK 3G
Core Shell®
HYBRID
PARETO
4D Air™
Machine speed
VELOX
POSITEK 3G
4D Air
Yankee coating
Coating Space™
TULIP™
NEWCD™
Bleaching efficiency
SCALE-GUARD®
Washing efficiency
SuperWash™
◆ SAFESCAN program
®
◆ Strong safety champions network
◆ Boilout safety procedures
◆ Legionella control
Raw material savings
Water & energy savings
Grade development
Filler loading
FillerTEK®
Additive dilution
PARETO™
Bulk & stiffness
OptiLux
Low cost furnish
METRIX®
DC-PRO™
POSITEK® 3G
OptiLux®
HYBRID™
Water recycle & reuse
3D TRASAR for
process water
PARETO
Dry strength
METRIX
Brightness
EXTRA WHITE
Cooling water cycle
3D TRASAR
METRIX
3D TRASAR
Coating Space
NCAT™
Lightweighting
Heat exchange capacity
Tissue softness
Fiber quality
PenSurf™
Membranes
3D TRASAR
Steam demand
VELOX®
NAL-TEX®
POSITEK 3G
HYBRID
FillerTEK
Higher recycled fiber content DC-PRO
METRIX
HP Indigo qualified
DIAMOND™
Chemical savings
Retention aids & additives
PARETO
POSITEK 3G
Core Shell
HYBRID
Dry strength aids
METRIX
Sizing
NALSIZE®
OBA
EXTRA WHITE®
Washing aids
SuperWash
Yankee coating
Coating Space
TULIP
DuraSoft™
Felt life
NAL-TEX
Engineered Filler
cost of operation.
Our innovations, your solutions
FillerTEK technology combines
several aspects of wet-end
chemistry to achieve higher filler
content while maintaining
runnability and paper quality.
Increased filler content replaces
high cost fibers, reducing total
◆ Reducing fiber cost by 3-10%
◆ Maintaining paper strength at higher filler loading
◆ Reducing energy cost for drying and refining
Engineered Quality
Speed Up Performance
POSITEK 3G microparticle
technology is Nalco’s latest
retention and drainage program
for fine paper and board grades.
It improves paper machine drainage
in a controllable manner, increasing
ash and fines retention without
sacrificing formation and other physical and
printing properties.
OxiPRO microbial control technology
is Nalco’s latest innovation in
monitoring and controlling microbial
deposits. It combines Nalco’s
proprietary and proactive
monitoring tools, individually
tailored chemistry strategies and
local application expertise to improve machine
efficiency and reduce total cost of operation.
◆ Improving drainage and productivity
◆ Enhancing sheet quality
◆ Maximizing machine efficiency
◆ Real-time monitoring of biocide program
◆ Improving machine efficiency and sheet attributes
◆ Reducing fiber and energy cost
Strong Performance
Clean Running
Bulk & Opacity
HYBRID technology enables
papermakers to attain important
on-machine-efficiency (OME) and
sheet quality gains in formation,
porosity and smoothness. Designed
for performance, this new
technology provides controllable
drainage in high-speed machines, and improves ash/
fines retention to complement existing programs
without hurting formation.
DC-PRO contaminant control
technology enables papermakers to
optimize chemical usage, ensure
pitch and stickies control and
improve operating efficiency.
Providing enhanced productscreening, this innovative chemistry
helps effectively control organic contaminants in
papermaking systems to reduce total cost of
operation.
◆ Maximizing retention and drainage performance
◆ Reducing total cost of operation and environmental
impact
◆ Enabling contaminant control for recycled furnish
◆ Optimizing chemical performance
Leading Speed
VELOX dewatering aid technology
is formulated to improve water
removal in the forming and press
sections. This unique cross-linked
chemistry improves productivity
through increased machine speed
and runnability, whilst also reducing
variable cost and energy consumption.
◆ Increasing machine speed by 5-10%
◆ Reducing energy consumption
Clean & Clear
NAL-TEX advanced cleaning
technology promotes the effective
and efficient removal of contaminants.
Based on the application of Nalco’s
mechanical, operational and
chemical (MOC) principle, this
technology improves machine
efficiency and delivers cost savings.
◆ Maximizing fabric performance
◆ Improving machine efficiency
Waterproofing
Free Flow
Stress Management
NALSIZE sizing technology delivers
stable, controllable, on-machine
sizing. This unique technology
reduces chemical requirements,
optimizes surface sizing, and
reduces size press breaks. When
combined with Nalco’s METRIX
application, it also presents an opportunity to bypass
the size press on some machines.
SCALE-GUARD program helps
control scale in the pulping process.
It combines Nalco’s unique
chemistries, monitoring tools and
expertise to eliminate scale
concerns. Inner surfaces are kept
clean to allow optimum process flow
and heat transfer, reducing energy consumption.
3D TRASAR technology is Nalco’s
integrated approach to water
treatment, delivering optimized,
cost efficient and sustainable
solutions to provide peace of mind.
Combining Nalco’s unique chemistry
with real-time monitoring tools
enables a quick response to cooling water, boiler and
reverse osmosis (RO) system problems, helping reduce
total cost of operation.
◆ Cost effective sizing
◆ Improving machine efficiency
Softer & Stronger
Essentially White
TULIP technology is Nalco’s
latest solution for tissue grades.
Formulated with unique chemistries,
and service and monitoring tools,
this technology has been designed
to meet specific requirements,
delivering softer tissue and energy
savings at a competitive cost.
EXTRA WHITE brightness
technology reduces optical
brightener usage and enables
papermakers to achieve brightness
targets not previously possible or
economically feasible. The patented
technology is added to size press
formulations to activate OBA and prevent thermal
darkening and greening effects.
◆ High brightness grade development
◆ Reducing OBA impact on production cost
◆ Reducing energy consumption
◆ Improving production rates
Washed Clean
SuperWash technology is a
complete package combining wash
aid chemistries, mixing technology,
monitoring and process expertise
to enhance pulp mill performance.
This unique combination increases
washing efficiency, resulting in
higher production rates.
◆ Reducing soda loss
◆ Saving energy in evaporation
Improved Yield
OptiLux bulk and opacity
technology structures the sheet
so that it has more air to fiber
interface. This unique chemistry
increases bulk and opacity,
allowing for a reduction in
basis weight.
◆ Increasing bulk and stiffness by 4-8%
◆ Improving opacity by 1-3 points
Simply Brilliant
DIAMOND printability technology is
added to the size press formulation
to deliver on-machine digital grade
paper at optimal cost. This
technology produces paper that
exceeds quality standards set by
HP Indigo.
◆ Digital paper grade development
◆ Energy savings with on-machine application
Inner Strength
METRIX strength technology
combines Nalco’s unique chemistry
with process knowledge to improve
productivity and product quality by
enhancing press dewatering and
sheet strength in board and
packaging grades.
PenSurf digester additive
technology, aligned with our
operational expertise, increases
pulp yield and quality, through
increasing liquor penetration into
the chips resulting in a more
uniform cooking process. This
improves fiber quality, minimizing white liquor usage
and bleaching costs.
◆ Meeting strength targets
◆ Using lower quality recycled fiber
◆ Increasing pulp yield
◆ Improving operational efficiency
4D Air
Less Is More
4D Air technology is designed to
minimize the detrimental effects of
entrained air and surface foam in
the carton and container board
market. Combining specially
formulated chemistries with the
PARETO delivery system, entrained
air on-line monitoring and application knowledge, this
technology delivers improved drainage and machine
efficiency, and enhanced sheet quality while reducing
total cost of operation.
◆ Improving wet-end stability
◆ Increasing productivity and sheet quality
◆ Saving water and energy
◆ Providing asset protection and plant reliability
PARETO mixing technology
is a new proprietary feeding
solution that increases process
stability and saves fresh
water and energy, by optimum
mixing of chemicals into
the process.
◆ Increasing process stability
◆ Maximizing chemical efficiency
Quality Water
Water and waste water
innovation applies Nalco’s
comprehensive mechanical,
operational and chemical (MOC)
approach to optimize plant
operation. This completely
integrated approach improves
performance and increases output.
◆ Reducing environmental risk
◆ Saving water and energy, and reducing
maintenance cost
Reuse & Recycle
3D TRASAR for process water is a
new proprietary monitoring and
control solution for dissolved air
flotation systems. This solution
consistently produces high quality
effluent that can be reused in the
process application rather than
discharged to the waste water treatment (WWT) plant.
◆ Saving water and energy
◆ Reducing environmental impact
Safe & Sure
Recovery boiler leak indication
(RBLI) technology* combines mass
balance and TRASAR® monitoring,
with independent system processes
to provide reliable, safe operations.
This technology protects assets
while saving time, energy and cost.
◆ Increasing plant safety and reliability
◆ Reducing energy consumption
*Currently available only in North America
METRIX technology helps deliver savings of US$2.5M and improve sustainability performance
Grade:
Recycled linerboard
Fourdrinier with top wire former; 3 nip
press – 1st double-felted straight-through,
2nd bottom-felted straight-through,
3rd double-felted sym belt shoe
Machine speed:
700 m/min (2,300 fpm)
Basis weight range:181-337 g/m2 (37-69 lb/1,000ft2) linerboard
Production:
846 ton/day
System pH:
5.8–6.1
Machine type:
Value delivered
Grade:
Linerboard and corrugated medium
Two-ply Fourdrinier (70:30);
press – 1st straight-through, 2nd LNP
Machine speed:
609-914 m/min (2,000-3,000 fpm)
Basis weight range:112-220 g/m2 (23-45 lb/1,000ft2)
Production:
72 ton/hr
System pH:
6.8
Furnish:
100% recycle
US$770,000/year
profit from increased
production
Machine type:
1.5% increased
production
ASSETS
US$9,200/year savings
> 302 m3/day savings
WATER
US$91,000/year savings
> 42 MM BTU/day savings
ENERGY
US$275,000/year savings
122,470 kg/year reduced
chemical consumption
Operating well within VOC
regulatory limits
> 3,493 kg/year volatile
organic compounds (VOC)
reduction
AIR
US$2.2M/year savings
in fiber
6% reduction in basis
weight (1.2 kg) with no
loss of strength
Equivalent to CO2
allowances of US$2M
within the EU Emissions
Trading Scheme
> 110,000 ton/year CO2
emission reduction
EARTH
RESOURCES
Grade:
Uncoated freesheet
Fourdrinier with top former
Machine speed:
400–600 m/min (1,319-1,969 fpm)
Basis weight range:130-250 g/m2 (27-51 lb/1,000ft2)
Production:
132,000 ton/year
System pH:
7.5
Furnish:
35% LBKP, 10% NBKP, 25% BCTMP,
5% uncoated broke, 25% coated broke
Filler:
PCC
Machine type:
Grade:
Linerboard testliner and fluting
Fourdrinier with head box dilution (Octopus)
Machine speed:
270-450 m/min (886-1,476 fpm)
Basis weight range:120-220 g/m2 (25-45 lb/1,000ft2) mainly
testliner (75%)
Production:
8-12 ton/hr
System pH:
6.4-6.6
Furnish: 100% recycled waste paper (OCC, mix waste)
Machine type:
3% profit from increased
production
5% machine runnability
increase
Minimized risk associated
with working operations
Avoided dust resulting
from powder polymer,
improving operating
conditions
SAFETY
Grade:
ASSETS
1.5-2.0% productivity
increase & 7-10%
increase in manufactured
area
> US$135,000/year
savings
> 29.4 billion BTU/year
savings
ENERGY
> US$1.1M/year savings
4,847 ton/year less fiber
usage due to basis weight
reduction
Grade:
ASSETS
Production:
> 487 kg/year volatile
organic compounds
(VOC) reduction
12,276 ton/year steam
savings from lower drying
energy requirement
Financial savings based
on CO2 trade market
4,800 ton CO2 emission
reduction due to steam
energy savings
US$200,000/year profit
improvement
0.25% improved annual
tonnage
US$91,000/year steam
savings
11.8 MM BTU/year energy
savings
US$15,000/year water
treatment/WWT savings
95,390 m3/year water
savings
ASSETS
ENERGY
US$5.25M annual profit
increase due to additional
production of 25 ton/day
based on US$595/ton
coated paper
8% machine productivity
increase at a constant
energy input
WATER
Grade:
Consumer paper towels; heavy-weight
dry crepe
Twin wire former
1,400 m/min (4,575 fpm)
Grade:
Machine type:
ASSETS
US$922,000/year paper
production increase
US$423,000/year biocide
cost reduction
2.6% OME increase
6,613 ton/year
production increase
US$2,576/year steam
savings
184 ton of steam not
used to reheat water
Increased safety
12 hour reduction in high
risk activity
Exact costs vary
for savings in water
consumption
2,800 m3/year savings
in reduced boilouts
US$325,000 fiber
savings
5.9% increase in short
reclaimed chip pulp
fiber use from replacing
premium long fiber in
consumer towel products
US$315,000 displaced
fiber consumption
savings
2.2 ton/day increase in
short fibrous material
retention in place of
normal product furnishes,
avoided material going
to landfill
US$78,000 chemical
savings
US$224/day savings in
reduced application rates
EARTH
RESOURCES
OxiPRO technology reduces downtime and improves machine efficiency by 2.6%
Uncoated freesheet
Twin-wire gap former
Machine speed:
1,230 m/min (4,035 fpm)
Basis weight range:66–100 g/m2 (14-21 lb/1,000ft2)
Production:
250,000 ton/year
Filler:
15–20%
US$142,000/year steam
savings
Nalco retention program helps reduce cost by US$655,000 per year
9.8% adhesive chemistry
savings
2.4% release chemistry
savings
ENERGY
EARTH
RESOURCES
Mill is operating within
VOC regulatory limits
Coated & uncoated freesheet
g/m2 (30-45 lb/1,000ft2)
87,500 ton/year
Basis weight range:146-220
Machine speed:
Operational return on
investment; US$750/
hour of production or
US$2.9M/year
6.3% LBKP reduction due
to replacing with BCTMP
(saved 63kg LBKP/ton
paper)
PARETO mixing technology helps save US$200,000 and over 95,000 m3 of water per year
Machine type:
High performance linerboard
Machine type:
Single-ply Fourdrinier;
press – 1st straight-through, 2nd LNP
Machine speed:
518-686 m/min (1,700– 2,250 fpm)
Basis weight range:170-205 g/m2 (35-42 lb/1,000ft2)
Production:
45 ton/hr
System pH:
5.2
Furnish:
65% OCC and 35% Kraft
US$3.65M/year LBKP
fiber savings
US$7.45M/year raw
material savings
ASSETS
METRIX technology reduces basis weight and increases production
Grade:
6,200 ton/year less
pulp used due to 4.7%
additional filler
AIR
VELOX technology increases productivity by up to 8%
Coated fine paper
Fourdrinier/ 3-nip/ shoe press
Machine speed:
230-570 m/min (755-1,870 fpm)
Basis weight range:100-300 g/m2 (21-62 lb/1,000ft2)
finished paper
Production:
60,224 ton/year
System pH:
Alkaline
Furnish:
50-70% Kraft, 0-15% CTMP
Filler:
GCC (12-17% ash in base sheet)
EARTH
RESOURCES
US$3.8M/year pulp
savings
ENERGY
Nalco RDF program helps achieve 5% runnability improvement
Machine type:
EARTH
RESOURCES
Equivalent to 25,000
kWh/year reduction in
natural gas consumption
ENERGY
AIR
PARETO, Core Shell and POSITEK 3G solutions increase production and wet-end stability to
deliver savings of more than 365 m3 of water per day
> US$600,000/year
average savings in energy
consumption
Wet-end optimization program helps recover US$7.5M in filler loading, fiber optimization,
and steam savings
US$136,000 chemical
savings
US$389/day savings due
to 38% reduction in
dissolved air flotation
(DAF) chemical application
US$102,000 savings in
productivity increase
8 hours/month production
increase due to fewer
machine cleanups
SAFETY
AIR
WATER
ASSETS
OxiPRO technology reduces downtime and improves profitability by US$800,000 per year
SuperWash technology lime mud dewatering aid program helps save US$900,000 per year
Grade:
Grade:
Process:
Machine speed:
Furnish:
Tissue
LDC
1,530 m/min (5,000 fpm)
Recycled
US$80,600/year savings
SAFETY
Zero employee exposure
to hazardous boilout
chemistries
US$286,700/year savings
158 ton/year production
increase due to microbiological boilout downtime
reducing by 1.2 hours/week
Eliminated all boilouts
and bleach containing
wash ups of stock
approach and wet-end of
the paper machine
US$819/day savings due
to 6.6% fewer machine
breaks and downtime
from microbiological
contamination
US$48,500/year savings
US$139/day productivity
savings from 1.9 ton/week
reduction in converted
waste
US$474,000/year savings
US$1,354/day savings
from 100% elimination
of boilouts – saving
2.42 m3 chorine based
bleach
EARTH
RESOURCES
US$73,900/year savings
Market pulp
Equipment:
2–5 stage bleach plant – D(EOP)DED
& D(EOP)DPD
Lime kiln:
Single kiln with two drum filters
Production:
7,000 ton/day
Kiln production: 710 ton/day (259,200 ton/year) CaO
Digester:
Continuous digester
Species:
Brazilian Eucalyptus hardwood
Eliminated hypobromous
microbiological control
program
US$900,000/year energy
savings
2,064,000 m3/year
reduction in natural
gas usage
US$24,000/year
chemical savings
45,600 kg/year less
chemical usage
US$58,500/year carbon
emissions savings (based
on US$28/ton
1,906,000 kg/year less
CO2 emissions discharged
to the atmosphere from
the kiln
ENERGY
EARTH
RESOURCES
AIR
Nalco digester additive technology helps save US$1M in chemical and energy savings
Grade:
Equipment:
Production:
Digester:
Species:
Coated & uncoated freesheet
3 stage bleach plant – D1,EOP,D2
1,050 ton/day
Kamyr digester
Bleached soft and hardwood
US$1M/year chemical
savings based on
US$9.50/ton pulp
1,677,550 kg reduction in
chemical usage
US$1M/year energy
savings
> 5M kWh/year savings
EARTH
RESOURCES
ENERGY
TULIP adhesive technology improves productivity and cost savings
Grade:
Machine type:
Machine speed:
Production:
System pH:
Furnish:
Tissue
Crescent former
1,830 m/min (6,000 fpm)
90 ton/day
Neutral
Recycled fiber
US$177,000/year Yankee
coating savings
EARTH
RESOURCES
44 ton/year adhesive
chemistry savings
73 ton/year release
chemistry savings
US$36,500 savings from
reduction in natural gas
9,100 MM BTU/year
reduction in dryer energy
load due to redesigned
spray boom
US$1,100/year water
savings
3,710 m /year fresh water
savings due to redesigned
spray boom
ENERGY
3D TRASAR technology for membranes saves water and reduces TCO in waste water recycle
RO system
US$43,013/year water
savings
268,836 m3/year
reduction in fresh water
intake
US$77,000/year chemical
savings
20 to 40 day extension
in cleaning cycle
WATER
3
Antiscalant dosage
optimized through
automation
EARTH
RESOURCES
WATER
US$288,000 membrane
savings
Membrane life extended
ASSETS
3D TRASAR technology for boilers improves runnability and efficiency
Grade:
Tissue
Machine type: Metso Advantage DCT 200TS
Machine speed: 1,998 m/min (6,560 fpm)
Basis weight range: 14.5-18 g/m2 (3-4 lb/1,000ft2)
Production: 207 ton/day
Creeping ratio range: 13–20%
Yankee diameter: 5,500 mm (18 ft)
US$1.56M/year profit
improvement
6.9% production increase
through reduced Yankee
soda straw mechanical
cleaning
US$62,846/year
savings from reduction
in natural gas
14,787 MM BTU/year
savings due to boiler
cycles increasing from
16 to 50
US$1,925/year water
savings at $0.29/m3
19 m3/day or 6,650 m3/year
savings – based on 350
operating days/year
ASSETS
ENERGY
WATER
3D TRASAR technology improves cooling system operation and sustainability performance
> US$16,250/year fresh
water savings
WATER
> US$16,580/year WWT
savings
US$32,785 reduced TCO
Water use reduction
equivalent to annual
needs of > 320 people
> 19,150 m3/year less
demand for fresh water
due to improved water
efficiency and increased
cycles of concentration
> 19,150 m3/year reduction
in waste water volume
protected surface water
resource quality