An Overview of Process Engineering Work in the Pulp & Paper Industry

1. An Overview of Process Engineering Work in the Pulp & Paper Industry By Rich Bankhead

2. Manufacturing Locations that I worked Prince Albert NORPAC Rothschild Cedar River Plymouth Valliant

3. Cedar River Paper Mill • Cedar Rapids, Iowa • #1 PM Startup: March 17, 1995 • #2 PM Startup: April 1, 1996 • 2700 tpd production of Linerboard and Corrugating Medium • 100% Recycle Post-Consumer Waste • 225 Team Members • 4 Process Teams (32 People per team) • 50 Optimization Team Members • Support Staff

4. Process Flow Diagram #1 OCC #1 Stock Prep #1 Winder #1 PM OCC WT System Raw Materials Shipping #2 Winder #2 Stock Prep #2 PM #2 OCC Customer

5. Raw Materials

6. Screening and Cleaning

7. Process Control

8. Paper Machine Wet End

9. Paper Machine Press Section

10. Paper Machine Dry End

11. Paper Quality

12. Finished Rolls

13. Environmental Stewards Weyerhaeuser • Invested over $1.5 billion for environmental protection • Promised to reduce greenhouse gas emission by 40% • Reuse 90% of chemicals used in paper making process • 40% of wood fiber is from recycled wastepaper • Generate 2/3 of required energy from the manufacturing process itself Cedar River Paper • Recycled 2 billion pounds of OCC last year • Year-to-date recycled over 50% of our industrial waste • By 2008 CRP will have reduced greenhouse gas emissions by 60% • Practice minimum impact manufacturing

14. Process Engineer • What does a process engineer do? • Jack or Jill of all trades • safety • environmental • quality • technical support • budgeting • chemical handling • training • fire fighting: daily problem solving • process improvements projects • interface with suppliers • interface with customers • computer systems support

15. Skills needed to do job • Technical Skills • Engineering • Applied math (statistics!), physics, biology, chemistry • Accounting • Without understanding money it is hard to add value to a business • Computer Skills (Word, Excel, Power Point, Database) • Social Skills • Communication (Read, Write, Speak, Listen) • Initiative • Leadership (Everyone’s responsibility) • Respect, Trust and Integrity

16. Chemical Engineering Applications • Mass and Energy Balances on a Hood system • Flash Steam Flow in Condensate System • Jet Velocity Control out of the Headbox • Moisture Control with a spray shower • Surface and Colloid Science • Steam control in a dryer section • Functional chemistry of paper making

17. Process ownerships including Complete rounds Review process and equipment set points Track runability Monitor quality data Use process data to understand Water Usage Energy Usage Steam Usage Chemical Usage Tons Produced Downtime Effluent Production Emissions Work with vendors New/better equipment New/better chemicals Lead special teams Chemical Management Project teams Residual Management Safety Work with People Leadership Laboratory Technicians Maintenance Teams Process Teams Administration Accounting Contractors Vendors Daily Activities