Lightweight, high-opacity paper : process costs and energy use reduction

Abstract

Fiber loading is an environmentally friendly, energy efficient, and economical method for depositing precipitated calcium carbonate (PCC) partly within pulp fibers. Fiber loading can easily be done within the existing pulp processing system. This paper is a review of the process development from bench-scale to industrial-scale demonstrations, with additional experimental results showing the benefit of high consistency and high pH used in fiber-loading processing. Initially increasing the filler level without decreasing paper strength was the objective. Subsequently, substituting low cost PCC for higher cost fiber was evaluated. Finally, a fiber- loading method was developed that processes fiber at high consistency and pH, resulting in a high ash pulp without reducing freeness. A principal advantage of fiber loading is in applications for lightweight, high opacity, mechanical pulp containing printing grade papers. An example of this use of fiber loading is in adding 4% PCC and reducing grammage by 4 g/m2 processing of 600 metric fans per day of newsprint. This example gave an estimated return on investment from 26.7% to 39.0%, depending on raw material costs for the PCC.

Citation

Klungness, John H.; Pianta, Fabienne.; Stroika, Mathew L.; Sykes, Marguerite.; Tan, Freya.; AbuBakr, Said. 1999. Lightweight, high-opacity paper : process costs and energy use reduction. Fundamental advances and innovations in the pulp and paper industry. New York : American Institute of Chemical Engineers, 1999. AIChE symposium series ; no. 322.:p. 99-102.