EXHIBIT 1029
`
`EXHIBIT 1029
`
`

`
`w w w . r i s i . c o m - A p r i l 2 0 1 0
`
`Longview:
`Looking up to a brighter future
`
`P&P Int'l - PPI April 2010 - Cover - 7.75x10.5.indd 1
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`4/2/2010 11:29:37 AM
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`

`
`By MICHAEL ANCONA and KATHERINE BROADUS
`Mills have been able to increase filler content in graphic papers with
`Nalco’s new filler technology
`
`SAVE FIBER
` AND MAINTAIN PROPERTIES
`
`R aw material cost-reduction is a key business
`
`driver in today’s market. Paper producers
`are under constant pressure to improve the
`overall cost efficiency of their operations in the face
`of unforeseen economic challenges, shifting market
`demands, and escalating costs. Typically, fiber can
`account for half of the expense in paper production.
`Over the years, there has been a continual effort to
`replace fiber with less costly fillers, such as calcium
`carbonate, since purchased virgin fiber can cost as
`much as seven times more than filler. Market pulp
`prices have also started to rise; the current cost for
`kraft pulp is approximately $750/ton. In contrast,
`the cost of calcium carbonate has remained steady
`over the past 10 years. Additionally, increased filler
`content in the sheet can provide other benefits, such
`as energy savings in the dryer section, and improved
`opacity, brightness, and smoothness of the sheet.
`While increased filler content has long been
`sought after by the paper industry, technical limita-
`tions have precluded the practice. The critical
`
`Fig. 1 - DIFFERENTIATING ASPECTS OF FILLERTEK,
`NALCO’S FILLER PREFLOCCULATION TECHNOLOGY
`
`Pulp & Paper International (PPI) A p r i l 2 0 1 0
`
`limiting factors include the loss in sheet strength
`and physical durability with respect to dusting at el-
`evated ash levels. Filler disrupts the fiber-fiber bond-
`ing network of the sheet by reducing the number of
`fibers. The small filler particles also prevent effective
`contact of the fibrils.
`For every 1% increase in ash content, the tensile
`strength of the sheet is reduced by 1-2%. Unfor-
`tunately, dry-strength agents do not perform well
`in the presence of filler. The loss in strength is also
`detrimental to paper machine operation, as well as
`subsequent printing operations. Low internal bond
`strength can cause problems such as delamination
`in the printing press, especially for high basis
`weight grades.
`Another challenge in increasing the ash content is
`that fillers are harder to retain in the system. This of-
`ten leads to elevated retention aid dosages and poor
`formation of the sheet. Operational instabilities due
`to dusting or center roll picking are other potentially
`negative consequences of incorporating higher ash
`levels in graphic papers.
`
`N E W F I L L E R T R E AT M E N T
`
`Nalco has developed its patent-pending FillerTEK
`technology to address the concerns of paper produc-
`ers. This technology delivers an increase in filler
`content up to five units, while preserving the critical
`strength and optical attributes of the final sheet. The
`technology is based on increasing the particle size of
`the filler through a unique method of preflocculation.
`The net outcome is reduced interference of the filler
`with fiber-fiber bonding. The concept behind the
`technology was designed to circumvent some of the
`limitations of previous approaches of filler prefloccu-
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`4/7/2010 8:15:57 AM
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`

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`chemicals
`
`lation. The differentiating aspects of this technology
`are summarized in Fig. 1.
`The method involves a chemical treatment of a
`filler slurry to produce filler flocs with a well-defined
`particle size distribution. The controlled floc size
`eliminates detrimental effects on sheet strength and
`formation. The treatment also was especially de-
`signed to produce flocs that exhibit improved shear
`stability in paper machines. These attributes of the
`technology are achieved by a combination of chemi-
`cal and mechanical approaches.
`The third differentiating aspect of FillerTEK tech-
`nology is return on investment (ROI). The program
`is economical, even for paper producers targeting a
`relatively low increase in sheet ash of 3-5%.
`FillerTEK technology is a fit for customers using
`precipitated or ground calcium carbonate (PCC or
`GCC), or a blend of the two carbonates as their filler
`source. The technology has been demonstrated with
`a variety of furnish types, and the program is best
`suited for the uncoated or coated freesheet market.
`The chemical treatment is carried out on-site with a
`
`Fig. 2 - IMPACT OF FILLERTEK TECHNOLOGY ON INTERNAL BOND STRENGTH
`OF HANDSHEETS AS MEASURED BY Z-DIRECTIONAL TENSILE (ZDT).
`THE FILLERTEK TECHNOLOGY LINE WAS EXTRAPOLATED. THE BLACK LINES
`INDICATE THAT THE FILLER LEVEL CAN BE INCREASED BY 8.5 UNITS
`AT EQUAL ZDT STRENGTH WITH THE FILLER TREATMENT
`
`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.
`
`L A B T E S T I N G
`
`The FillerTEK technology concept of increased ash
`content without a loss in sheet properties was initially
`demonstrated in laboratory handsheet experiments.
`For this purpose, a furnish was prepared with 63%
`hardwood kraft pulp, 27% softwood kraft pulp and
`10% percent broke, along with starch at 9 kg/ton, of
`which 5 kg/ton was added with ASA (dosed at 2.5 kg/
`ton), POSITEK 3G 8692 microparticle at 2 kg/ton, and
`Core Shell® 61067 cationic flocculant at 0.9 kg/ton.
`Additionally, four filler levels were investigated: un-
`treated PCC at 20% and 28%, and FillerTEK technol-
`ogy treated PCC at the same levels. Eight handsheets
`were prepared for each condition.
`The results for internal bond strength are plotted
`in Fig. 2. At 18% ash content, FillerTEK technology
`results in a 10% gain in z-directional tensile (ZDT),
`which allows for an increase in filler content of 8.5
`units without a loss in internal bond strength. Again
`at 18% ash, the tensile index strength improves by
`7% with FillerTEK technology, such that the ash
`content can be increased by three units at equal
`tensile strength.
`The opacity data is illustrated in Fig. 3, and
`indicates a loss in opacity for the treated PCC
`sheets. This loss of 0.2 units can be recovered by
`a 1% increase in filler content. Similar trends are
`also observed for sheet brightness. Overall, the Fil-
`lerTEK technology program results in a smoother
`and slightly less porous sheet compared with the
`untreated PCC samples.
`The ability to provide strength improvements
`without insurmountable optical penalties is also a
`challenge of increased filler content. The use of a
`larger-sized filler particle can provide strength, but the
`opacity loss is so severe that it often cannot be recov-
`ered even with a 10-point increase in ash content. This
`point was demonstrated in handsheet experiments
`with two samples of PCC whose median sizes were
`3.6 and 4.5 microns, as measured by light scattering
`using a Malvern Mastersizer. The ability to deliver
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`A p r i l 2 0 1 0 Pulp & Paper International (PPI)
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`P&P Int'l - PPI April 2010 - p39 to 45.indd 40
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`4/7/2010 8:15:58 AM
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`chemicals
`
`18% filler content using a blend of PCC and GCC as
`the filler source. This is a non-integrated mill faced
`with increasing pulp prices. Previous attempts to
`increase the ash level were unsuccessful due to limi-
`tations in sheet strength as well as operational issues
`on the machine, such as dusting, deposits and poor
`retention. The technology was implemented across
`all grades and has been utilized continuously for over
`a one-year period. As a result, the mill has achieved
`a 5% increase in the ash content of its sheet while
`maintaining runnability.
`Nalco installed equipment at the mill to treat the
`filler slurry. The resulting filler was then stored in a
`run tank and used as needed. The FillerTEK technol-
`ogy equipment has been successfully operated in a
`continuous mode with little maintenance.
`A snapshot of the technology’s performance is
`summarized by the sheet properties shown in Table
`1. These results represent the average of 10 sheets
`randomly selected from a set of 10,000 sheets produced
`with and without FillerTEK technology. The overall
`ash level has been increased from 17.7% to 22.2%, or
`
`Fig. 3 - IMPACT OF FILLERTEK TECHNOLOGY ON THE OPACITY OF HANDSHEETS.
`THE BLACK LINES INDICATE THAT THE OPACITY LOSS DUE TO THE FILLER
`TREATMENT CAN BE RECOVERED AFTER A ONE-POINT INCREASE IN ASH CONTENT
`
`higher ash content at equal strength and opacity is a
`fundamental aspect of FillerTEK technology.
`
`VA L I D AT I O N O N G A P - F O R M E R
`P I L O T M A C H I N E
`
`FillerTEK technology has also been demonstrated on
`the EuroFEX gap former pilot machine at Innventia in
`Stockholm, Sweden. The high-speed and high-shear
`environment of this pilot machine was considered to
`be a rigorous test for the filler flocs. Precipitated calci-
`um carbonate was treated with the FillerTEK technol-
`ogy program and compared with the untreated filler.
`Filler levels of 20% and 30% were evaluated in a fine
`paper furnish comprised of 85% eucalyptus and 15%
`pine. An 80-g/m2 sheet was produced at a speed of
`1,000 m/min, and the following additives were used:
`cationic starch at 7.5 kg/ton, OBA at 4.5 kg/ton, and
`POSITEK 3G 8694 microparticle at 5 kg/ton.
`The dose of NALCO® 74508 cationic flocculant
`was varied to maintain a constant white water con-
`sistency of 2.3 g/L for all trial conditions. The sheets
`were not surface sized and were dried off-line with a
`multi-cylinder open dryer. Samples produced on the
`pilot machine indicated that the filler content could
`be increased by five points at equal tensile strength,
`internal bond strength, brightness, opacity, and
`formation of the sheet.
`One disadvantage of higher filler content is a loss
`in sheet bulk. The magnitude of loss depends on the
`filler type and furnish composition. Preflocculation of
`the filler can also produce an additional loss in bulk
`depending on filler type. If this is a critical parameter
`for a particular grade, the papermaker may be able to
`employ one of the following strategies to recover the
`bulk loss at the higher ash levels.
`One option is to take advantage of the improved
`sheet smoothness and reduce the calendering load.
`The use of a mechanical fiber source such as
`BCTMP is another approach to increase bulk.
`
`C A S E S T U D Y
`
`FillerTEK technology has been utilized by a mill pro-
`ducing 400 tons/day of copy paper and offset grades
`in the basis weight range of 75-105 g/m2. The majority
`of the mill’s production is 75-g/m2 copy paper with
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`Pulp & Paper International (PPI) A p r i l 2 0 1 0
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`P&P Int'l - PPI April 2010 - p39 to 45.indd 41
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`4/7/2010 8:15:58 AM
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`chemicals
`
`4.5 units. In this comparison, the basis weight for the
`treated sheets was less than the untreated, i.e., 74.9 vs.
`76.3 g/m2, respectively. At the 22.2% ash level, the tech-
`nology delivered equal internal bond strength, tensile
`index, bulk, opacity, brightness, porosity, and sizing
`response. The treated filler produced a smoother sheet,
`and a slight loss in stiffness or bending resistance.
`The mill also incorporated BCTMP into its
`
`Fig. 4 - Z-DIRECTIONAL ASH DISTRIBUTION FOR COMMERCIAL SHEETS
`PRODUCED WITH AND WITHOUT FILLERTEK TREATMENT FROM THE
`CASE STUDY. A SIMILAR PROFILE IS MAINTAINED AT THE HIGHER ASH LEVEL
`
`furnish for cost savings and bulk advantage at the
`higher ash level. The ASA sizing dosage has remained
`steady even as filler use has increased. Additionally,
`the sheets described in Table 1 were subjected to a
`converting study to monitor dust formation. It was
`found that the FillerTEK technology sheets, at 4.5%
`higher filler content, generated 47% less dust than the
`sheets containing untreated filler. Figure 4 illustrates
`that the z-directional ash distribution in the sheet is
`similar at the elevated filler level.
`
`P R I N T T R I A L O F C O M M E R C I A L
`S H E E T S
`
`Enhanced propensity for linting or dusting in the
`printing press is a substantial concern for paper
`producers interested in higher filler content. In
`an effort to address this concern, a print trial was
`conducted at Rochester Institute of Technology (RIT)
`Print Industry Center on 75 g/m2 text grade sheets
`produced commercially with the FillerTEK technol-
`ogy program. Sheets containing 25% untreated PCC
`were compared with sheets containing treated PCC at
`25% and 29% levels.
`A Goss Sunday 2000 four-color, heat-set offset
`press was used to make 28,000 impressions.
`FillerTEK technology was found to have no negative
`
`››› continued on page 45
`
`Table 1 - COMMERCIAL CASE STUDY SUMMARY OF SHEETS PRODUCED USING A BLEND OF PCC/GCC WITH AND WITHOUT THE FILLERTEK
`TECHNOLOGY. RESULTS REPRESENT THE AVERAGE OF 10 SAMPLES RANDOMLY SELECTED FROM 10,000 SHEETS
`
`Sheet property
`
`Sheet ash, %
`Basis weight (g/m2)
`Bulk (cm3/g)
`Internal bond (ZDT)
`Tensile index (Nm/g)
`Bending resistance (mN)
`Porosity (ml/min)
`PPS Roughness (um)
`Sizing, HST (sec)
`Opacity at 75 g/m2, %
`Brightness, %
`
`Untreated filler
`Value
`Std. Dev.
`17.7
`0.50
`76.33
`1.17
`1.38
`0.02
`571.7
`18.0
`54.32
`2.97
`103.5
`9.3
`1157
`87
`6.43
`0.32
`69.15
`25.3
`94.43
`0.76
`91.20
`0.08
`
`FillerTEK treatment
`Value
`Std. Dev.
`22.2
`0.50
`74.87
`0.92
`1.38
`0.01
`574.0
`10.6
`52.73
`2.73
`91.1
`8.6
`1198
`66
`6.01
`0.11
`61.43
`25.4
`94.63
`0.52
`91.09
`0.20
`
`Impact of FillerTEK
`technology
`+4.5 pt ash increase
`Lower
`Equal
`Equal
`Equal, within std dev
`Reduced
`Equal, within std dev
`Smoother sheet
`Equal, within std dev
`Equal
`Equal
`
`A p r i l 2 0 1 0 Pulp & Paper International (PPI)
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`P&P Int'l - PPI April 2010 - p39 to 45.indd 42
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`4/7/2010 8:15:59 AM
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`

`
`chemicals
`
`effect on pressroom runnability, and the operators
`noticed no distinction between the treated samples at
`25% and 29% ash levels. Tape pulls from the printing
`blanket were analyzed to determine the linting pro-
`pensity of the sheets. Specifically, calcium levels on
`the tapes were measured by energy dispersive x-ray
`spectroscopy. These tests indicated that the extent of
`linting was reduced on the top side of the sheet and
`was equal on the bottom side for the FillerTEK tech-
`nology sheet at 29% ash compared with the untreated
`sheet at 25% ash.
`
`C O N C L U S I O N S
`
`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. The technology
`has been demonstrated on the EuroFEX gap-former
`pilot machine and successfully implemented by a
`UCFS mill for more than a one-year period. PPI
`
`Michael Ancona is program manager, graphic grades,
`and Katherine Broadus is senior research chemist,
`Nalco Company
`
`FillerTEK technology effectively delivers cost-
`efficiency to paper producers by allowing them to
`utilize less expensive raw materials. This patent-
`
`To read more articles on Chemicals, visit our Chemicals
`Technology Channel at www.risi.com/
`technologychannels/chemicals
`
`R e p r i n t e d w i t h p e r m i s s i o n f r o m P u l p & P a p e r I n t e r n a t i o n a l © A p r i l 2 0 1 0
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`4/7/2010 8:15:59 AM
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`
`Essential Expertise for
`Pulp and Paper
`
`Only 25% of
`papermaking
`costs are
`beyond your
`control.
`
`Let’s work
`on the rest.
`
`In a world where producers face uncontrollable factors every day,
`cost control becomes a primary focus. Working with the right solutions
`provider, papermakers can reduce major cost categories and also
`positively impact the environment.
`In one year, Nalco helped mills:
` • Control Chemical Costs: A North American Graphics Mill realized
`
`
`a 40% reduction in OBA while achieving brightness levels by utilizing
`
` EXTRA WHITE Technology for Brightness.
`
` • Control Production Costs: An Asia Pacific Graphics Mill realized a
`
` 3% increase in production due to extended boilout periods by utilizing
`
` OxiPRO Technology for Deposit Control.
`
` • Control Energy Costs: A European Board & Packaging Mill realized
`
`
`a 40% reduction in steam by utilizing METRIX® Technology for
`
`
` Productivity and Strength.
`
` • Control Water Costs: An Asia Pacific Graphics Mill saved 16.8 MM
`
`
`gallons of water by utilizing PARETO Technology for Wet-End Optimization.
`
` • Control Maintenance Costs: A North American paper mill avoided
`
` $430,000 per day in lost production through 3D TRASAR® Technology for
`
` Boilers by minimizing outages related to preboiler corrosion failures.
`
`
`
`
`
`
`
`With intense focus on cost optimization, our technologies can help you
`reduce variable cost and increase your machine efficiency while reducing
`the use of raw materials, water, energy and commodity chemicals.
`
`For more information about how Nalco can help you,
`visit: http://www.nalco.com/paper.
`
`Essential Expertise
`for Water, Energy and Air
`
`SM
`
`©2010 Nalco Company
`1.630.305.1000
`www.nalco.com
`Nalco, the logo, the tagline, 3D TRASAR, METRIX,
`EXTRA WHITE, PARETO and OxiPRO are
`trademarks of Nalco Company
`
`

`
`1 6 0 1 W e s t D i e h l R o a d • N a p e r v i l l e , I L 6 0 5 6 3 - 1 1 9 8
`R e p r i n t R - 9 8 0
`F i l l e r T E K , P o s i t e k 3 G a n d C o r e S h e l l a r e t r a d e m a r k s o f N a l c o C o m p a n y.
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`P&P Int'l - PPI April 2010 - p39 to 45.indd 46
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`4/8/2010 8:42:07 AM