Identifying a New Source of Wood Pulp for Manufacture of Nitrocellulose
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1 BAE SYSTEMS, INC. Identifying a New Source of Wood Pulp for Manufacture of Nitrocellulose NDIA IMEM Conference, San Diego, CA October 8, 2013 Kelly Moran BAE Systems Radford Army Ammunition Plant BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 1
2 Background Opportunity: Most propellants for the U.S. DoD rely on high quality cellulose as a critical raw material for the production of nitrocellulose. Single Point Failure: Current single qualified Canadian sulfite wood pulp source has potential for supply interruption. Strategic sourcing requires new qualified wood pulp suppliers. Project Goal: To investigate the use of Kraft cellulose for the production of military grade NC and propellants in order to reduce risk associated with single point failure and provide opportunities to source cellulose from domestic sources. Outline for Discussion: RFAAP cellulose supply history and global pulp supply Difference between sulfite and sulfate wood pulp RFAAP wood pulp sources - criteria for wood pulp and available suppliers Risk assessments for new wood pulps Current NC Production Process Modernization Effort BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 2
3 RFAAP Cellulose Supply History Limited supply changes over past 60 years Buckeye Foley * L-P Ketchikan * Tembec Pulp Western Pulp Neucel Rayonier southern wood pulp Cotton linters baled and sheeted 1950s 1960s 1970s 1980s 1990s * Intermittent suppliers BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 3
4 Recent RFAAP Wood Pulp Suppliers Company Mill location Wood pulp Recent RFAAP supply history Neucel (previously known as Western Pulp) Port Alice, British Columbia Western hemlock several owners over the past 10 years mill stoppages put RFAAP NC at risk (10/22/2004) Feb 2010 Chinese firm bought 20% of mill, the remaining 80% in Feb 2011, stopped pulp sales to RFAAP Tembec Temiscaming, Quebec Eastern spruce unable to fill all RFAAP wood pulp orders short-term in past 3 years - Sept 2010 mill operating problems - Jan 2011 digester tank failure BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 4
5 Global Pulp Supply Global pulp (Million Tons) Specialty wood pulp Global Nitrocellulose RFAAP NC (100%) 4.0 (1.3%) 0.14 (0.046%) (0.002%) Source: Buckeye Feb 2013 BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 5
6 Evolution: From Tree to Molecule Source: SAPPI 2012 BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 6
7 Pulping Process Removes Lignin: Acidic (Sulfite) or Caustic (Sulfate) Source: SAPPI 2012 BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 7
8 Cellulose Markers for Successful NC Production Cellulose Key Parameters Chemical Purity Alpha Cellulose Contaminants (Lignin, Hemicellulose, Iron, Silica, etc.,) Acid Wettability in Fibers (Mass Transfer) Physical Characteristics Fiber Length/Wall Thickness Sheet Bulk Density/Basis Weight Sheet Thickness Mullen/Tear Strength Sheet Shear Properties Cuttability & Dusting NC Key Requirements Chemical Reaction & Predictability % Nitrogen Solubility (AI, EAI) Viscosity Stability Physical Characteristics Particle Size Morphology Fiber Aggregates/Bundles Fines Particle Size Distribution Solvent Wettability/Dough Rheology BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 8
9 US Mills - RFAAP Alternative Sulfate Pulps Southern pine Buckeye Foley, Florida Has dissolving pulp that meets military specification Rayonier Jesup, Georgia Has dissolving pulp that meets military specification Weyerhaeuser Port Wentworth, Georgia Lower alpha content RockTenn Panama City, Florida Lower alpha content Northern Pine SAPPI Cloquet, Minnesota BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 9
10 Risk Assessment for New Sources of Cellulose Fiber wettability with acid and washing/centrifuging Fiber density as cut fiber in reactor Residuals from higher hemicellulose/lignin levels and effect on stability/poaching Overall yield based on variations in alpha content Viscosity control Nitration set points, ratio of nitric, sulfuric and water Fiber handling in cutting and air-veying Dough rheology and solubility BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 10
11 Nitrocellulose Manufacturing Acid Boiling Nitrocellulose is the energetic binder for all RFAAP propellants BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 11
12 Modernized NC Facility Coming to RFAAP Project Description: Design, Procurement and Construction of a New NC Facility 20M lb/yr NC with a surge capacity of 28M lb/yr Performance / Benefits: Two nitration trains capable of producing Grades A, B, & C IAW MIL-DTL-244B Increased operational efficiencies, reduced emissions, reduced energy consumption Projected Commissioning: 4 th Quarter 2016 BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 12
13 Questions?? Thanks For Your Attention! Kelly Moran R&D Manager, Radford Army Ammunition Plant BAE Systems OSI 2013 "Non Export Controlled Information - Releasable to Non-US Persons S2DSEA " 13
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