SITUATION

A producer of recycled linerboard

needed to reduce slip and improve size response on their 2-ply fourdrinier machine. The mill, currently using AKD, wanted to investigate the benefits of an ASA sizing program based on proven conversions at other mill locations.

PROGRAM

The mill currently used an AKD program fed to the stuffbox. Faced with customer complaints of slip and poor size response, coupled with the mounting costs of increased AKD usage, the mill was required to take corrective action. The Nalco NALSIZE ASA program was selected in response to the mill’s issues.

Neutral linerboard mill improves slide angle and eliminates slip with a Nalco NALSIZE™ Tiger program

CH-377

CASE STUDY – PAPER

The program consisted of 2.5 –3.0 lb/ton (1.0-1.3 kg/ton) of NALSIZE Tiger 63007 emulsified with at an ASA ratio of 0.8:1. The emulsion was fed to the discharge side of the fan pump.

RESULTS

The Nalco ASA program allowed the mill to resolve slip and slide angle issues, reducing customer complaints. Slide angle improved by 15-20% with the NALSIZE Tiger program. Improved size response allowed the mill to obtain on-machine sizing, thus reducing the practice of overdosing AKD in order to attain on-machine size response. The overdosing of AKD was the primary contributor to the increase in board slip.

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Mill Overview

Grades: 23 – 26 lb medium, 26 – 59 lb linerboard

Machine: 2 ply fourdrinier

Furnish: 100% OCC base and top ply

pH: 6.9-7.6

Sizing Program: NALSIZE 7542 2.5-3.0 lb/t discharge of fan pumpNALSIZE Tiger 63007 ASA ratio 0.8:1

In addition, with the conversion to a Nalco ASA program, sizing costs were reduced 20-30% over AKD. Where doses of 4-7 lb/ton of AKD were needed to obtain the target Cobb of 30-35, only 2.5-3.0 lb/ton of NALSIZE were required. The mill also gained the flexibility to use the new NALSIZE Tiger 63007 with the Nalco ASA program.

CONCLUSIONS

A Nalco ASA program, consisting of NALSIZE 7542 and NALSIZE Tiger 63007, helped a mill to eliminate slip issues with no effect on machine runnability. In addition, the program resulted in a 20-30% reduction in sizing costs.

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Before NALSIZE After NALSIZE

COBB Test Low 30’s Low 30’s

Slide Angle 20-22 25-29

Sizing Dosage 4.0-7.0 lb/ton 2.5-3.0 lb/ton

On-machine Sizing No – Needs cure time Yes – Immediate

Slip Issues Yes None

Chemical Cost $/T 7.00-9.00 4.00-5.00

The following table summarizes the benefits of the Nalco NALSIZE program: