EXHIBIT 1027
`
`EXHIBIT 1027
`
`

`
`New Technology for Increased Filler Use and Fiber Savings in Graphic Grades
`
`Weiguo Cheng, Katherine Broadus, Michael Ancona
`
`Nalco Company, Naperville, lllinois USA
`
`ABSTRACT
`
`Virgin fiber is an expensive raw material in the paper making process. There are continual efforts to replace it with
`less costly materials, such as calcium carbonate. While increased filler usage has long been sought after by the
`paper industry, technical limitations have precluded the practice. A novel solution to this problem will be presented.
`The approach involves the preparation of filler designed to be incorporated at higher levels in papermaking
`operations without compromising the performance of the final product.
`In particular, the critical dry strength and
`optical properties of the sheet are preserved at the higher filler level. Results from commercial applications of this
`technology in the uncoated and coated wood-free grades will be presented.
`
`INTRODUCTION
`
`It has long been a goal of the paper industry to increase the filler content of graphic papers. The cost of filler is
`approximately four to seven times less than the price of market kraft pulp. A 1% increase in filler content is
`estimated to save $6/ton raw material cost, assuming the price of market kraft pulp and filler is $700 and $100,
`respectively. Sheets with higher filler content are easier to dry, resulting in reduced steam consumption. Increasing
`filler content also has the potential to improve sheet optical properties, surface smoothness and printability.
`
`Significant challenges exist for utilizing more filler in terms of both end product quality and machine runnability.
`The largest technical challenge is the loss in strength as filler disrupts the fiber-fiber bonding network of the sheet
`by reducing the number of fibers and preventing effective contact of the fibrils. The increased total surface area of
`the papermaking stock due to higher filler levels reduces the efficiency of conventional dry-strength agents. Loss in
`strength is detrimental in printing operations; for example, low internal strength can cause sheet delamination and
`low surface strength results in picking, linting and dusting. Another issue with higher ash content is that fillers are
`harder to retain. This often leads to elevated retention aid use, poor sheet formation and increased difficulty of
`maintaining an even distribution of fillers across the z~direction ofthe sheet. Operational instabilities due to dusting
`or center roll picking are other potentially negative consequences of higher ash levels.
`
`FILLER TREATMENT TECHNOLOGY
`
`Various approaches to circumvent the challenges with higher filler usage have been pursued over the years. One
`approach is to preflocculate fillers prior to their addition to the wet end approach system. Preflocculation means the
`modification of filler particles into agglomerates through proper chemical treatment. Preflocculation effectively
`increases the size of the filler, and reduces the filler surface area. Therefore, disruption of fiber-fiber bonding from
`fillers becomes less. The high fluid shear rates present in modern high-speed papermaking demand stable and shear
`resistant filler flocs. Furthermore, the size distribution and surface properties of filler flocs must be controlled in
`order to meet the following requirements:
`allow high and uniform filler retention, minimize reduction in sheet
`strength with increased ash content, minimize the loss of light scattering efficiency from the filler particles, and
`minimize negative impacts on sheet uniformity and printability. Patent—pending FillerTEK technology from Nalco
`utilizes a combined chemical and mechanical approach to deliver these attributes.
`
`FillerTEl< technology is a fit for customers utilizing precipitated or ground calcium carbonate (PCC or GCC), or a
`blend of PCC and GCC as their filler source. The chemical treatment is carried out on-site with a mill’s existing
`filler slurry. This can be accomplished in-line or the treated filler slurry can be stored in a run tank; no residence or
`aging time is required before use. The program is economical, even for paper producers targeting the relatively low
`increase in sheet ash of3 to 5 percentage points.
`
`This paper presents two case studies of commercial applications offiller preflocculation technology. The first is for
`an uncoated woodfree sheet, and the second is for a coated woodfree sheet.
`
`PaperCon 2011 Page 616
`
`

`
`IQ
`
`COMMERCIAL APPLICATION IN UNCOATED WOODFREE SHEET
`
`The FillerTEK program has been run in one North American fine paper machine for about two years and has helped
`the mill increase sheet ash from 18% to 23%. The mill produces 400 tons/day of copy paper and offset grades in the
`basis weight range of 75 «~ 105 g/ml. The majority of the mill’s production is 75 gsm copy paper using a blend of
`FCC and GCC as the filler source. Previous attempts to increase the ash level were unsuccessful due to limitations in
`sheet strength, as well as machine operational issues like dusting, deposits and poor retention. FillerTEK technology
`was implemented across all grades and has been utilized continuously for over a two year period. As a result, the
`mill has achieved a 5 percentage point
`increase in the ash content of their sheet while maintaining machine
`runnability.
`
`Sheets made before and after implementation of the FillerTEK program were collected and analyzed in the lab.
`Results represent the average of 10 samples randomly selected from 10,000 sheets. The major sheet properties were
`listed in Table 1. The results showed that filler preflocculation enabled the filler content of the sheet to be increased
`by 4.5% without the loss of internal strength, tensile strength, optical properties, and bulk. Bulk was maintained
`because the mill incorporated BCTMP into the furnish mixture. Sheets with preflocculated filler at higher ash were
`significantly smoother. This smoothness gain can be transferred into bulk improvement by reducing calendering
`load.
`
`It was found that
`The sheets described in Table 1 were subjected to a converting study to monitor dust formation.
`sheets produced using FillerTEK technology at 4.5 percent higher filler content generated 47% less dust than the
`sheets containing untreated filler.
`
`Z-directional ash distribution in the sheet was also measured using a tape—peeling method. As shown in Figure 1, the
`distribution ofpreflocculated filler at the elevated content is similar to that of untreated filler.
`
`COMMERCIAL APPLICATION IN COATED WOODFREE SHEET
`
`The FillerTE1( program was successfully implemented on a world class machine in Asia producing coated woodfree
`paper and has been utilized across all grades for about one year. The preflocculation technology enabled the mill to
`increase the base sheet ash level about 3 to 5 percentage points. The critical sheet properties, including internal
`bond strength, tensile strength, stiffness, optical properties, porosity and roughness, were maintained. Table 2
`compares the properties of sheets with 17% untreated filler and 22% treated filler. The data was obtained from one
`ofthe FillerTEK trials on this paper machine.
`
`Because of elevated filler content in the sheet, steam consumption in the dryer section was reduced by over 20%
`since the implementation ofthis technology, as shown in Figure 2
`
`CONCLUSIONS
`
`FillerTEK technology delivers cost-efficiency to paper producers by allowing them to utilize less expensive raw
`materials without compromising product quality. This patent-pending technology is based on a unique filler
`preflocculation approach that produces flocs with a narrow particle size distribution and high shear stability. The
`technology has been demonstrated on both uncoated and coated woodfree commercial paper machines.
`
`Fi1lerTEK and Nalco are trademarks ofNalco Company.
`© Copyright Nalco Company 201 1.
`
`PaperCon 2011 Page 617
`
`

`
`DJ
`
`Table 1. Summary of sheet properties produced during the commercial production of uncoated woodfree paper
`using a blend of FCC and GCC with and without FillerTEK technology. Results represent the average of 10
`samples randomly selected from 10,000 sheets.
`
`sheet property
`
`Untreated Filler
`Value
`Std. Dev.
`
`Pretreated Filler
`Value
`Std. Dev.
`
`Impact Of Filler
`Treatment
`
`Sheet ash 1%)
`
`Basis Weight (gsm)
`
`Bulk (cm3/g)
`
`rl_n_ternal bond (ZDT, l<Pa)
`
`Tensile index (Nm/g)
`
`17.7
`
`76.33
`
`1.38
`
`571.7
`
`54.32
`
`Bending resistance (mN)
`
`4
`
`103.5
`
`Porosity (ml/min)
`
`PPS Roughness (pm)
`Sizing, HST (sec)
`
`1157
`
`6.43
`69.15
`
`0.50
`
`1.17
`
`0.02
`
`18.0
`
`2.97
`
`9.3
`
`87
`
`0.32
`25.3
`
`22.2
`
`74.87
`
`1.38
`
`574.0
`
`52.73
`
`91.1
`
`1 198
`
`_ 6.01
`61.43
`
`T
`
`7
`
`0.50
`
`0.92
`
`0.01
`
`10.6
`
`2.73
`
`8.6
`
`66
`
`0.11
`25.4
`
`+4.5 pt ash increase
`
`Lower
`
`E ual
`
`Ejual
`
`Egual, within std dev
`
`Reduced
`
`____J
`
`Equal, within std dev
`
`j
`
`Smoother sheet
`Egual, within std dev
`
`Qpacity at 75 gsm (%)
`Brightness (%)
`
`¥
`
`94.43
`91.20
`
`0.76
`0.08
`
`94.63
`91.09
`
`0.52
`0.20
`
`Equal
`Egual
`
`Table 2. Summary of sheet properties from Fi1lerTEK technology trial in a world class reference machine in Asia
`producing coated woodfree paper.
`
`Untreated Filler
`
`Pretreated Filler
`---—-—————~——
`
`Ave. Std. Dev. Std. Dev. Ave.
`
`
`
`
`
`Sh
`
`tP
`
`t
`rope”
`
`ee
`
`Ash Content (%)
`
`Basis Weigl1t(gsm)
`
`Internal Strength (l<g.cm)
`Caliper (,um)
`Bulk (cm3/g)
`Formation
`
`4
`
`Porosity (ml/min)
`
`Opacity (%, ISO)
`
`(ml/min)
`
`Tensile Strgngth
`(kg1~/ 15mm)
`,
`Stiffness (mN~m)
`
`
`
`loo
`MD
`CD
`
`17.1
`
`__,.__
`
`105.7
`
`1.03
`140.6
`1.33
`39.3
`
`621
`
`96.5
`
`186
`
`3.3
`1.3
`0.41
`
`0.2
`
`0.6
`
`0.02
`0.8
`0.01
`3.4
`
`46
`
`0.1
`
`11
`
`0.1
`0.1
`0.02
`
`22.0
`
`104.8
`
`1.04
`137.0
`1.31
`32.7
`
`648
`
`97.0
`
`179
`
`3.3
`1.3
`0.39
`
`L
`
`1
`
`0.2
`
`0.4
`
`0.02
`0.4
`0.01
`1.5
`
`17
`
`0.1
`
`12
`
`0.1
`0.1
`0.04
`
`Papercon 2011 Page 618
`
`

`
`
`ii
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`
` O
`
`10
`
`20
`
`30
`
`40
`
`50
`
`60
`
`70
`
`80
`
`90 100
`
`Relative Basis Weight, %
`
`Figure 1. Z-directional ash distribution for commercial sheets produced with and without filler treatment. A similar
`profile is maintained at the higher ash level.
`
`Papercon 2011 Page 619
`
`

`
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`
`Papercon 2011 Page 620
`
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