G S. surfactant. Bubbles. surfactant. Ink Fibers and fines

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1 REDUCING FIBER LOSS IN LABORATORY- AND MILL-SCALE FLOTATION DEINKING USING SURFACTANT SPRAY TECHNOLOGY G. DiLozier 1, Y. Zhao 1, Y. Deng 1, J.Y. Zhu 2, D. White 3 and M. Prein 4 by Presented by Richard A. Venditti Wood and Paper Science -- NCSU 1: School of Chemical & Biomolecular Eng, Georgia Institute of Technology 2. Institute of Paper Science and Technology, Georgia Institute of Technology 3. USDA Forest Products Laboratory 4. Abitibi Consolidated Snowflake Division

2 G S Bubbles surfactant L surfactant Ink Fibers and fines

3 Colloidal processes in deinking: 1,2,3, Detachment (chemical mechanical) 2. Floculation 3. Flotation 4. Redeposition

4 Balance of Forces flocculate free ink particles have them adsorbed onto rising bubbles prevent ink re-deposition onto the fiber prevent adhesion of fibers on froth. V R (repulsive energies): V R(bf) > V R(if) >> V R(ib) > V R(ii) surfactant Bubbles (b) surfactant V R(ii) V R(ib) V R(bf) Ink (i) V R(if) Fibers and fines (f)

5 Presentation Outline Background and Objectives Laboratory Results Snowflake Mill Trial Results Conclusions

6 Objective Reduce the fiber loss, chemical and water consumption in flotn Reduce fiber contamination ti Increase ink and sticky removal efficiency i Improve the process control in flotation ti deinking operation

7 Concept Development Laboratory and Pilot Results

8 Problems Related to Surfactant Use in Flotation Deinking Surfactant adsorption: Reduces ink hydrophobicity (ink removal) Reduces liquid surface tension Reduces fiber-fiber bonding Surfactant carryover: Creates foaming problem on paper machine Environmental effects Strength loss in paper Difficult to control the froth Surfactant cost

9 BASIC CONCEPT OF THE PROPOSED TECHNOLOGY Conventional Surfactant Spray Pulp Out Pulp In Froth Surfactant In Air In Pulp In Air In

10 Conventional Flotation Deinking Surfactant mixed into pulp feed Nonselective flotation

11 Surfactant Spray Flotation Deinking Surfactant Layer Surfactant Layer

12 Advantages of Surfactant Spray High ink removal efficiency Reduced adsorption of frother agent on ink particles Reduce fiber loss Foam layer is generated after bubbles reach the top of flotation cell: reduce the possibility of fiber entrainment Less fiber contamination Reduce direct contacts t between fibers and frother agent Less Surfactant carryover Effectively control the froth Reduce surfactant cost Reduce water loss and water contamination

13 Conventional Flotation Process: Multiple stages Cell 1 Cell 2 Cell 3 Cell 4 Cell 5 Too much foam and high fiber loss Too little foam and poor ink removal

14 Deinking performance measured from paper mill A (7 stages) BRIGHTNESS ERIC MIX B1 B2 B3 B4 B5 B6 B MIX B1 B2 B3 B4 B5 B6 B7 DIRT COUNT Results indicated that the last 4 cells 200 did not remove inks MIX B1 B2 B3 B4 B5 B6 B7

15 Spray technology can separately control foams in each cell Cell 1 Cell 2 Cell 3 Cell 4 Cell 5

16 Laboratory Study Old Newsprint in Voith E-18 Cell 18 liter Old Newsprint Mixed With Old Magazine in Voith E-250 Cell IPST Pilot Scale Facility 250 liter

17 Lab Bench Scale: E-18 CELL Pulping Conditions 8% consistency, T = 50 o C, ph = 10 with NaOH Brightness after pulping = 35.2 Deinking Chemicals Vinings A (low foaming deinking agent) (Low HLB) Material: Atlanta Journal- Constitution TX 100 frother (tert- octylphenylpolyoxyethyleneet her) either sprayed at 100 mg/l or added to pulp TX-15: low LHB nonionic surfactant TDA (anionic polydimethylsiloxane based defoamers) Experimental Conditions Suspension consistency 0.8%, T = 43 o C Air flow 20 SCFH Overflow foam removal

18 Lab Pilot Scale: E-250 CELL Materials: ONP/OMG =70:30 Pulping Conditions: 8% consistency, T = 50 o C, ph = 10 with NaOH Brightness after pulping = 41.5 (on average) Deinking Chemicals: Vinings A and/or fatty acid as collector + calcium chloride (200 mg/l) TX 100 either sprayed at 100 mg/l or added to pulp) Experimental Conditions Suspension consistency 0.8%, T = 43 o C Air flow 60 SCFM Overflow foam removal

19 Conventional Deinking with Vinings A FO STRUCTURE Collector + TX-100 Surfactant Spray

20 HIGHLIGHTS of E-18 Voith Cell Brightn ness gain/f Fiber loss Conventional Water spray Surfactant spray TX15+Surfactant spray Ch i l L di Vi i A 50 d TX 15 1 /L Chemical Loading: Vinings A = 50 and TX-15 = 1 mg/l Spray Loading 5.6%, mg/l

21 HIGHLIGHTS of E-250 CELL Brightne ess Gain (ISO) 18 Fiber loss Brightness gain 16 Water loss 14 E-250 Cell, ONP:OMG=0.7: Collector = 30 mg/l TX-100=450 mg, 1.8 mg/l loading Fatty acid soap conventional Vinings A conventional TDA-32-surfactant spray

22 Surfactant Spray Results from both E-18 and E250 cells Bright tness Gai in xe 2 1xe 3 y= *ln(x), R 2 =0.92 Collector, Spray TX-100, E250 Cell Collector, Spray Water, E18 Cell Collector, Spray Water, E18 Cell Conventional, E250 Cell Vinings A Fatty Acid 2 Conventional, E18 Cell y= *ln(x), R 2 =0.96 No Chemical Vinings A Fatty Acid Fiber Loss (%)

23 Surfactant Spray vs. Conventional Flotation for Flexographic Ink Removal Brightn ness Gai in 70 Flexo: 30 OMG Fiber Loss (%) spray (flexo) convention al (flexo) spray (flexo)

24 SUMMARY Both E-18 cell (standard lab test) and E-250 cell (pilot-scale) results indicated that surfactant spray technology has significant advantages in reducing fiber loss without compromising brightness gain For a give brightness gain of 8 points 50% reduction in fiber loss for ONP/OMG furnished in E-250 Cell comparing to the conventional flotation process

25 Mill Trial 93%ONP and 7% OMG Two flotation lines in this mill. The capacity of the cell for the trial: 550t/d.

26 Surfactant Spray Trial TX-100 Mill Water GSC Feed TDA-32 GSC

27 Surfactant Spray Trial 14 nozzles delivering 3.5 gpm at 20 psi (49 total gpm)

28 Fiber Accept Consistency (Mill Data) Accept consistency (%) % /23/03 12:00 6/28/03 12:00 7/3/03 12:00 7/8/03 12:00 7/13/03 12:00 7/18/03 12:00 7/23/03 12:00 7/28/03 12:00 8/2/03 12:00 8/7/03 12:00 8/12/03 12:00 8/17/03 12:00

29 Total Reject Consistency (Mill Data) Reject consistency (%) total % SST total /18/03 12:00 6/28/03 12:00 7/8/03 12:00 7/18/03 12:00 7/28/03 12:00 8/7/03 12:00 8/17/03 12:00

30 Brightness (Mill Data) Brightness ISO / 18/ 03 6/ 28/ 03 7/ 8/ 03 12:00 7/ 18/ 03 7/ 28/ 03 8/ 7/ 03 12:00 8/ 17/ 03 12:00 12:00 12:00 12:00 12:00 feed accept SST feed SST accept Results are the average of 3 measurements taken from each side of two separate 3 g pulp pads prepared from each pulp

31 Fiber Consistency in Reject (Mill Data) Fiber Yield Loss Normal SST % /24/0 3 7:00 6/29/0 3 7:00 7/4/03 7:00 7/9/03 7:00 7/14/0 3 7:00 7/19/0 3 7:00 7/24/0 3 7:00 7/29/0 3 7:00 8/3/03 7:00 8/8/03 7:00 8/13/0 3 7:00 8/18/0 3 7:00 Average fiber loss for conventional from 6/24/03 to 8/10/03 is 8.33% If eliminate 3 data that are high than 15%, the average of fiber loss for conventional is 5.99 SST trial result is (4 hours average) is 3.58%

32 Fiber Consistency in Reject (Mill Data) Fiber Yield Loss vs. Brightness Gain Brigh htness Gain (points) Fiber Yield Loss (%) Normal SST Average for Conventional Brightness 4.0 Yield loss: 8.33 Average for SSD Brightness 3.6 Yield loss: 3.58

33 Fiber loss (Mill Data) Fiber Yield Loss (%) Conventional SST

34 Conclusions Surfactant spray technique can be applied to almost all paper grades to improve the total performance of flotation deinking Significant ifi cost savings Save $10/mt fiber cost (~$1million/yr for a 300mt/day recycling machine) Save $3/mt chemical cost Reduce surfactant usage and carryover Reduce water treatment costs Technique is ready to transfer to the industry

35 Thank You Questions

36 Pre-trial results from 93%ONP and 7% OMG mill samples (E-18 Lab Cell) FIBER LOSS vs. BRIGHTNESS GAIN 15 Conventio nal D50-SST4 Gain 14 D100 ISO Brightness Yield Loss (%) D100- SST4 D100- SST8 D150 D200 D200- SST4 D200- SST8 D50 defoamer at 50 ppm STX4 = TX100 (at 100 ppm spray) sprayed at 4 ppm overall loading

37 Background Surfactant spray technology was invented by Drs. Y. Deng and J.Y. Zhu at IPST under the sponsorship of IPST member companies in 1997 The technology was awarded a US patent in 1998 The most recent project effort was sponsored by DOE with IPST member companies provided cost share, and Abitibi b Consolidate provided d mill support for initial mill trial

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