EXHIBIT 1028
`
`EXHIBIT 1028
`
`

`
`FillerTEK® Technology Helps Achieve Fiber
`Reduction of 840 Ton Kraft/yr and Energy
`Conservation of 5,600 Tons Steam/yr
`
`Essential Expertise
`for Water, Energy and Air
`
`Mill Overview
`
`Paper Grade:
`Specialty papers
`Machine Type:
`Fourdrinier with top former, on-line blade coater,
`off-line supercalender
`
`System pH:
`7.2 – 7.3
`Production:
`55,000 ton/yr.
`Speed:
`750 – 800 m/min
`Basis Weight:
`50- 110 gm/m2
`Furnish:
`Bleached SWK & HWK, Broke (30-40%)
`Filler:
`PCC Based targeting 12 percent sheet ash
`on average
`
`Retention System: Core Shell® 74553 & UltraPOSITEK® 8694
`
`Background
`FillerTEK technology allows paper-
`makers to increase the sheet ash
`content up to five points without
`compromising quality of their prod-
`uct and operations. Controlled size
`distribution and excellent stability of
`
`filler flocs provides strength, while
`other sheet and printing properties
`are well maintained. At the same
`time, the drying energy is substan-
`tially reduced. Increased content of
`engineered filler substitutes expen-
`sive fiber furnish at a fraction of the
`
`EnviRonmEntal REsults
`
`eROI
`
`Economic REsults
`
`A reduction of 840 ton kraft/
`year of virgin kraft pulp /year
`through addition of filler
`
`10 percent less drying energy
`required Steam savings of
`5,600 tons/year.
`
`Steam savings of 11,200 MM
`BTU/yr.
`Steam energy savings
`equivalent to 2,200 tons CO2
`
`raw
`materials
`
`Virgin Kraft Fiber savings
`equivalent to 540,000
`€/year
`
`Reduction of Steam us-
`age equates to savings of
`140,000 €/year
`
`Financial savings based on
`CO2 trade market
`
`Case Study CH-1172
`
`

`
`FillerTEK Technology Raises Sheet Filler
`Content, Maintains Sheet Properties for
`CFS Operation, Achieving $14 MM/year
`Annual Raw Material Savings
`
`Essential Expertise
`for Water, Energy and Air
`
`Background
`FillerTEK technology effectively
`delivers cost efficiency to paper
`producers by allowing them to
`utilize less expensive raw materials.
`This patent-pending technology is
`based on preflocculation of filler in a
`controlled manner to produce flocs
`with a defined size distribution and
`improved shear stability. The net
`result is that the treated filler can be
`incorporated at higher levels in the
`sheet without a loss of strength or
`optical properties. This technology
`was demonstrated on a world class
`coated, woodfree machine in Asia,
`enabling the mill to increase the
`base sheet ash level three to five
`percent, resulting in a total of over
`
`a combined $16 MM savings in raw
`material and energy cost.
`
`Business Situation
`The world class paper machine at
`this mill was producing coated, base
`paper at 60-120 gsm basis weight
`that contained approximately 17
`percent sheet ash, using a mixture
`of PCC and GCC filler. At this mill,
`the key business driver for the use
`of FillerTEK technology was overall
`raw material cost savings. The mill
`had been purchasing market pulp
`at a cost of about $650/ton, using
`both GCC and PCC filler on-site,
`with the cost of filler being less than
`$100/ton. Therefore, a one percent
`
`EnviRonmEntal REsults
`
`eROI
`
`Economic REsults
`
`Average of 4 percent filler
`increase, reducing fiber use
`by 20,800 tpy
`
`raw
`materials
`
`Equivalent to $14 million in
`annual cost savings
`
`Reduced dryer steam
`consumption by 455,000 MM
`BTU per year
`
`Reduced refining energy by 8.6
`MM kWh per year
`Steam energy savings
`equivalent to 89,350 tons of
`CO2
`
`Refining energy savings
`equivalent to 5,800 tons of
`CO2
`
`$1.7 million in annual
`steam cost savings
`
`$0.6 million in annual
`refining energy savings
`
`Financial savings based on
`CO2 trade market
`
`Case Study CH-1110
`
`

`
`filler content increase meant more
`than $5.50/ton in raw material cost
`savings to the mill. In the past, mill
`personnel had made many attempts
`to raise the filler content. With
`increased filler content, sheet
`quality, especially strength
`properties, suffered, and the
`overall machine runnability also
`decreased.
`
` Program Design
`
`After a careful review of this mill, it
`was determined that FillerTEK
`technology would be an ideal fit
`to help this facility meet its over-
`all goals and business objectives
`through a program combining
`chemicals and equipment. As
`illustrated in Figure 1, Nalco
`provided the facility with a filler
`preflocculation skid. The skid
`effectively mixed two Nalco filler
`preflocculation agents with filler
`slurry and then produced stable
`filler flocs in a defined particle size
`distribution. The preflocculated filler
`flocs were then sent to the filler daily
`tank before feeding to the paper
`machine.
`
`Figure 1 – Nalco filler preflocculation skid that effectively mixes two Nalco
`filler preflocculation agents with filler slurry and produces stable filler flocs
`with a defined particle size distribution.
`
`Program Results
`The implementation of FillerTEK
`technology helped this mill increase
`its base sheet ash level from 17
`to 22 percent. The critical sheet
`properties, including internal bond
`strength, tensile strength, stiffness,
`optical properties, porosity and
`roughness were all maintained after
`the five percent ash increase, as
`illustrated in Table 1. Trial samples
`also passed the mill’s print test
`evaluations.
`
`The mill started to utilize FillerTEK
`technology across all grades in
`2010. Since then, it has been re-
`ported that filler content of all grades
`increased three to five percent,
`while keeping good machine
`runnability. Due to filler content
`increases, steam consumption
`was also reduced significantly.
`The average steam consump-
`tion per ton of base paper in every
`month is illustrated in Figure 2.
`The average steam consumption
`was 1.6 tons per ton of base paper
`before the full implementation of
`FillerTEK technology, and this was
`reduced to about 1.25 tons with
`FillerTEK technology. This meant
`that 0.35 ton steam was saved per
`ton of base paper with FillerTEK
`technology.
`
`

`
`Table 1 – Summary of sheet properties from FillerTEK technology trial with
`coated grade on the world class reference machine in Asia.
`
`Sheet Property
`
`Ash Content (%)
`Basis Weight(gsm)
`Internal Strength (kg.cm)
`Caliper (µm)
`Bulk (cm3/g)
`Formation
`Porosity (ml/min)
`Opacity (%, ISO)
`Roughness
`(ml/min)
`Tensile Strength
`(kgf/15mm)
`
`BWS
`TWS
`MD
`CD
`MD
`CD
`
`Stiffness (mN.m)
`
`
`
`Untreated Filler
`Ave.
`Std. Dev.
`17.1
`0.2
`105.7
`0.6
`1.03
`0.02
`140.6
`0.8
`1.33
`0.01
`39.3
`3.4
`621
`46
`96.5
`0.1
`141.0
`6.8
`186
`11
`10.8
`0.3
`3.3
`0.1
`1.3
`0.1
`0.41
`0.02
`
`FillerTEK Treatment
`Ave.
`Std. Dev.
`22.0
`0.2
`104.8
`0.4
`1.04
`0.02
`137.0
`0.4
`1.31
`0.01
`32.7
`1.5
`648
`17
`97.0
`0.1
`131.0
`9.2
`179
`12
`10.7
`0.1
`3.3
`0.1
`1.3
`0.1
`0.39
`0.04
`
`Figure 2 – Average steam consumption per ton of base paper; FillerTEK technology
`was started to be fully implemented across all grades since May, 2010.
`
`Conclusion
`With an average of 4 percent filler
`content increase in the base sheet,
`the mill was able to realize $22/ton
`savings in raw material cost, or over
`$14.0 MM of cost savings annually.
`Additionally, the mill benefitted from
`energy savings due to the reduc-
`tion of steam consumed in the dryer
`section. On average, 0.35 tons of
`steam were saved for every ton
`base paper produced, or 455,000
`MM BTU annual energy savings.
`Since less fiber was being used, the
`energy to refine the fiber was also
`reduced. With a 4 percent filler con-
`tent increase from 17 percent to
`21 percent, or fiber content reduc-
`tion from 83 to 79 percent, it is
`estimated that about 5 percent of
`refining energy will be saved, or
`8.6 MM kwh in annual electricity
`savings. The annual cost savings
`was estimated to be $1.7 MM due
`to steam consumption reduction,
`and $0.6 MM due to refining energy
`saving. Overall, FillerTEK
`technology helped the mill to
`realize over $16.0 MM total cost
`savings. The chemical cost to the
`mill is about $3.5 MM, resulting in a
`ROI of over 450 percent.
`
`As a result of this successful
`technology program integration,
`this mill was able to successfully
`meet their goals and improve their
`overall operating efficiency,
`
`

`
`
`
`
`
`Nalco reports Environmental Return on Investment (eROI) values to customers to account for contributions in delivering both
`environmental performance and financial payback.
`
`NALCO COMPANY Locations
`North America: Headquarters – 1601 West Diehl Road • Naperville, Illinois 60563 • USA
`
` Energy Services Division – 7705 Highway 90-A • Sugar Land, Texas 77487 • USA
`Europe: A-One Business Center • Z.A. La Pièce 1 • Route de l’Etraz • 1180-Rolle • Switzerland
`Asia Pacific: 2 International Business Park • #02-20 The Strategy Tower 2 • Singapore 609930
`Latin America: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • São Paulo • SP • Brazil
`www.nalco.com
`
`FillerTEK, eROI, NALCO, the logo and tagline are Trademarks of Nalco Company
`©2011 Nalco Company All Rights Reserved 5-11
`
`

`
`cost, saves drying energy costs and
`effectively increases a mill’s profit-
`ability. The treatment of fresh filler
`is done directly in the process with
`no holding time required before use
`and with minimal adjustments to
`typical wet-end and papermaking
`processes.
`
`Business Situation
`A European Specialty Free Sheet
`producer needed to improve its
`cost position to remain a viable
`entity in their market space. The
`paper machine at this facility used
`market pulp as a main component
`of papermaking furnish. Recent
`years’ increase in pulp prices from
`€350/ton to approximately €600/ton
`dramatically reduced the mill’s fi-
`nancial performance. The customer
`believed that increased filler loading
`would help return their mill to a more
`profitable position with the substitu-
`tion of high-cost fiber with five times
`lower filler cost. A recommendation
`by Nalco to implement FillerTEK
`technology was made to help this
`customer’s mill achieve their goals.
`
`Analysis of Business
`Situation
`Key Drivers
`• Reduce Total Cost of Operations
`(TCO) – Fiber Substitution
`
`Challenge/Opportunity
`•
`Increase Filler Loading and Main-
`tain Runability
`
`• Maintain Sheet Quality with In-
`creased Filler/Fiber Substitution
`
`Figure 1 – Nalco filler preflocculation skid that effectively mixes two
`filler preflocculation agents with filler slurry and produces stable filler
`flocs with a defined particle size distribution.
`
` Program Design
`
`Based on the current machine fur-
`nish and ash levels, Nalco recom-
`mended to run a FillerTEK technol-
`ogy trial to help increase base sheet
`ash by five points. The mill’s current
`filler addition strategy was to add all
`fresh filler in the suction side of the
`thick stock pump. Nalco proposed
`installing its preflocculation equip-
`ment into the process to treat the
`filler and then add the treated filler
`to the thin stock before the head-
`box fan pump. During the machine
`trials, the amount of broke was kept
`constant; the sheet ash content
`originating from broke was approxi-
`mately 50 percent of the total ash.
`The higher sheet ash target was
`then obtained by adding fresh filler
`to achieve the increased levels.
`
`The preflocculation equipment was
`installed in the vicinity of the mill’s
`filler supply tank with minimum
`installation work. After the treatment,
`the preflocculated filler was trans-
`ferred into the run tank and from
`there dosed into the process by
`using a low shear feed pump. Good
`floc size and proper shear stability
`were also maintained from the treat-
`ment up to the dosing point.
`
`Controlled floc size and shear stabil-
`ity are typically monitored using
`particle size measurement instru-
`ments to ensure proper treatment
`is occurring while running FillerTEK
`technology. Properly treated filler
`will usually increase in size, as indi-
`cated in Figures 2 and 3.
`
`

`
`Figure 2 – Untreated filler.
`
`Figure 3 – Treated filler.
`
`Program Results
`The implementation of FillerTEK
`technology helped this mill increase
`its base sheet ash level on average
`from 15 to 19 percent. The critical
`sheet properties, including internal
`bond strength, tensile strength,
`stiffness, optical properties, poros-
`ity and roughness were all main-
`
`tained after the ash increase. Trial
`samples also passed the mill’s print
`test evaluations. Table 1 illustrates a
`summary of the results from 80 gsm
`grade used in offset printing.
`
`With an average of four points ash
`increase in paper, direct savings in
`fiber replacement are estimated to
`
`Table 1 – Summary of sheet quality parameters for FillerTEK
`technology application.
`
`The newly-formed, shear stable floc
`maintains sheet strength without
`compromising the formation and
`optical properties at increase ash
`loading.
`
`Key Performance Indicators
`(KPIs)
`This customer agreed to run several
`trials of the FillerTEK technology
`program. Prior to chemical evalua-
`tion, Nalco worked with the mill to
`establish KPI’s for the trial, which
`included:
`
`•
`
`Increase sheet ash by four to five
`percent.
`
`• Maintain sheet quality, strength,
`and optical properties
`
`• Maintain production quality
`
`• Maintain printability on offset and
`rotogravure grades
`
`

`
`Conclusion
`This producer of specialty
`free sheet products needed to
`improve its cost effectiveness
`through increased filler loading.
`The machine had been running
`at 15 percent sheet ash and was
`producing 150 tpd. The mill ran
`several successful filler loading
`increase trials over a two month
`period utilizing FillerTEK tech-
`nology. With the help of Nalco,
`the customer now has the ability
`to increase sheet ash 5 points
`without negative impacts to sheet
`quality or machine runability.
`Implementation of FillerTEK
`technology also met the Key
`Performance Indicators and
`provided for achievement of the
`primary drivers for this machine.
`
`Figure 4 – Steam consumption used in web drying during the FillerTEK
`Technology production trial reduced by 10 percent.
`
`in 50 percent of the production and
`Talc for the rest of production. With
`the implementation of FillerTEK
`technology, it was possible to
`replace the talc with PCC, enabling
`smaller cost reductions and a
`simplified additive process across
`paper grades.
`
`be €12/ton of paper, resulting
`in more than €540,000 direct
`annual savings for this paper
`producer from fiber savings.
`The steam consumption for
`drying the paper dropped by
`approximately 10 percent, as
`illustrated in Figure 4. This
`benefit can be used either
`to boost the production or
`create extra savings at current
`production levels estimated at
`€140,000/yr. In addition to those
`savings, the mill utilized PCC
`
`Nalco reports Environmental Return on Investment (eROI) values to customers to account for contributions in delivering both
`environmental performance and financial payback.
`
`NALCO COMPANY Locations
`North America: Headquarters – 1601 West Diehl Road • Naperville, Illinois 60563 • USA
`
` Energy Services Division – 7705 Highway 90-A • Sugar Land, Texas 77487 • USA
`Europe: A-One Business Center • Z.A. La Pièce 1 • Route de l’Etraz • 1180-Rolle • Switzerland
`Asia Pacific: 2 International Business Park • #02-20 The Strategy Tower 2 • Singapore 609930
`Latin America: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • São Paulo • SP • Brazil
`www.nalco.com
`
`FillerTEK, eROI, NALCO, the logo and tagline are Trademarks of Nalco Company
`©2011 Nalco Company All Rights Reserved 7-11