Effective Paper Machine Slime Control and No Vapor Phase ...€¦ · Vapor Phase CorrosionVapor Phase Corrosion • ClO 2 •Imppgroved small scale generation of ClO 2 • Improved

PaperCon 2011 Rethink Paper – Lean and GreenpEffective Paper Machine Slime Control and No Vapor Phase Corrosion

Jim AndersonJim AndersonGuilherme Fernando Cortinovi

Bruno Bolduc

PaperCon 2011 Page 2284

“Evolution” of Effective PM Slime ControlAlkaline Fine Paper (North America)Alkaline Fine Paper (North America)• The evolution of using oxidizing biocides • What are the current issues/problems?• What are the current issues/problems?• A “new” technology to address the current and

“old” issuesold issues

PaperCon 2011 2


“Evolution” of Effective PM Slime ControlAlkaline Fine Paper (North America)Alkaline Fine Paper (North America)

1985-2000

“Strong” Oxidizers

1995-2005

“Mild” Oxidizers

2000-Present


1980-1990

Non Oxidizing Oxidizers

w/ BiocideOxidizers w/ Biocide

Oxidizers w/o Biocide

Oxidizing Biocide(s)

a) Performance Issues:

a) Cost

Issues:• Cost• Performance

Issues:• Ox Control• Interactions


Issues:• Cost• Vapor phasea) Cost

b) Performance

Performance Interactions• Performance

Performance Vapor phasecorrosion

PaperCon 2011 3


“Evolution” of Effective PM Slime ControlAlkaline Fine Paper (North America)Alkaline Fine Paper (North America)

1985-2000

“Strong” Oxidizers

1995-2005


2000-Present


1980-1990

Non Oxidizing Oxidizers

w/ BiocideOxidizers w/ Biocide

Oxidizers w/o Biocide

Oxidizing Biocide(s)

Issues:

a) Ox Control

Issues:

a) Cost


Issues:• Ox Control• Interactions


Issues:• Cost• Vapor phasea) Ox Control

b) Interactions

c) Performance

a) Cost

b) Performance

Performance Interactions• Performance

Performance Vapor phasecorrosion

PaperCon 2011 4


Eka Purate® CIO2

• It is a blend of sodium chlorate (NaClO3) & peroxide (H2O2)• Patented ClO2 method 2

• Chemical generation reaction:(2NaClO3 + H2O2) + H2SO4 2ClO2 + O2 + Na2SO4 + 2H2O(2NaClO3 + H2O2) + H2SO4 2ClO2 + O2 + Na2SO4 + 2H2O

(Chlorate + peroxide) plus (acid) (chlorine dioxide)• Lowest cost for small scale generation of CIO• Lowest cost for small scale generation of CIO2

• State of the art control • Generation of chlorine dioxide (efficiency and simplicity)( y p y)• Application for disinfection & slime control

PaperCon 2011 5


CIO2 Generation

H2SO4 EPI PlatformChlorate/Peroxide

Blend

EPI Platform(Eka Process Information)

GeneratorFresh Water

Process Water flow

0.5-3.0 g/l

0.5-3.0 g/l

PaperCon 2011 6


CIO2 Generator

Generator

Chemical Pumps

PaperCon 2011 7


The Benefits of Using CIO2

• Widely used in Europe (Paper & Water) & North America (Water)

• Cost effective• Improved runnability

• Less web breaks • Better retention – filler, sizing agents

PaperCon 2011 8


The Benefits of Using CIO2

• Improved paper quality• Less holes and spotsp• Less biofilm in pipes and towers

• Increased ORP• Reduced Odors (No H2S smell)• Increased pH/less dissolved Ca++ level

L d d f d h• Lower demand for wet end starch• Reduced potential for vapor phase corrosion

PaperCon 2011 9


Corrosion with OxidizerHypo Chloramines and ClO2Hypo, Chloramines, and ClO2• Liquid phase

• SS is resistant• No issues reported

• SS pitting due to chlorides• Chloride levels are normally a problem• No issues reportedV h• Vapor phase• Corrosion in wet end mist area (cat walks, ceiling,

frame etc )frame, etc.)• Corrosion in dryer section (dryer can surface, dryer

section ventilation, dryer felt carrying rolls, etc.)

PaperCon 2011 10


Vapor Phase Corrosion TestingHypo Chloramines and ClO2Hypo, Chloramines, and ClO2• Lab studies to simulate WW evaporation and

condensation – measuring the condensed vapor components

• Lab studies to document the impact of the WW vapors have on corrosion couponshave on corrosion coupons

• Paper Machine testing for the components in the condensed vapor from the first section of drying

PaperCon 2011 11


Evaporation & Condensation Lab Apparatus

Cooling WaterCondenser

Condensed Vaporsfrom WW

WhiteWater

PaperCon 2011 12


Evaporation & Condensation Lab Apparatus

WW VaporCooling Water WW VaporWater

Heated WW200 mlCondensed

WW VaporsHeat

WW Vapors~40 mls __

Untreated, Hypo, Chloramines (MCA or BAC),& ClO2Hypo, BAC, MCA , & ClO2 @ varying ppms

pH ORP Total Cl2 ClO2 ConductivityWW X X X X XWW after test X X X X X

PaperCon 2011 13

Condensed WW Vapors X X X X X


Lab Study – Condensed Vapors

450

ORP Trend – Condensed Vapors – Mill A

mv

400

450

OR

P -m

350HypoAmBr - BACVa

pors

250

300 AmBr BACClO2

dens

ed

2000.0 1.0 2.0 3.0 4.0 5.0

D f O idi

Con

d

PaperCon 2011 14

Dosage of Oxidizer - ppm



0 5

Total Cl2 – Condensed Vapors – Mill A

ppm

0.4

0.5

tal C

l 2 -

0.3HypoAmBr - BACpo

rs T

o

0.1

0.2 AmBr BACClO2

nsed

Va

00.0 1.0 2.0 3.0 4.0 5.0

D f O idi

Con

den

PaperCon 2011 15




400

ORP Trend – Condensed Vapors – Mill B

mv

350

400

OR

P -m

300 HypoAmBr - BACVa

pors

200

250 ClO2AmSO4-MCA

dens

ed

1500.0 1.0 2.0 3.0 4.0 5.0

D f O idi

Con

d

PaperCon 2011 16




6

Total Cl2 – Condensed Vapors – Mill B

ppm

5

6

tal C

l 2 -

3

4HypoAmBr - BACpo

rs T

o

1

2ClO2AmSO4-MCA

nsed

Va

00.0 1.0 2.0 3.0 4.0 5.0

D f O idi

Con

den

PaperCon 2011 17



Mill Study – Condensed Vapors

Dryer Section Ice Chest

Hose to collect vaporsfrom above the paper web

Vacuum Pump

PaperCon 2011 18

from above the paper web


Mill Study– Condensed Vapors

Mill Data – Total Chlorine in VaporsAlkaline Fine Paper

2.25

2 00

2.50

AC

H D

PD

Alkaline Fine Paper

1.50

1.251.50

2.00

(ppm

) HA

Headbox

C d d

0.56

0.89

0.22

0.85

0.50

1.00

Chl

orin

e Condensed Vapors

0.02 0.03 0.000.00

AmSO4(MCA)

AmBr(BAC)

ClO2PM1

ClO2PM2

ClO2PM4

Tota

l

PaperCon 2011 19


Mill Study– Condensed VaporsIncreased ClO2Increased ClO2

Mill Data – Total Chlorine in VaporsAlkaline Fine Paper

0.80 0.71

AC

H D

PD

Alkaline Fine Paper

0 40

0.600.41

(ppm

) HA

Headbox

Condensed

0.20

0.400.22

0.00 0.00 0.00Chl

orin

e ( Condensed

Vapors

0.00ClO2

NormalDose

ClO22X Normal

Dose

ClO24X Normal

Dose

Tota

l C

PaperCon 2011 20

Dose Dose Dose


Mill Study– Condensed VaporsVarying Operations and BAC DoseVarying Operations and BAC Dose

Mill Data – Total Chlorine in VaporsAlkaline Fine Paper - 1st Dryer Section

1 401.60

1.60

1.301.20

AC

H D

PD

Alkaline Fine Paper - 1st Dryer Section

0 801.001.201.40

0.61 0 55(ppm

) HA

Headbox

Condensed

0 200.400.600.80

0.40

0.55 0.49

0 03Chl

orin

e ( Condensed

Vapors

0.000.20

July 1normal

operation

July 22normal

operation

Aug 16baled pulp

Sept 9BAC stopped

for 6 hrs

0.03

Tota

l C

PaperCon 2011 21

operation operation for 6 hrs


Vapor Phase Testing – Coupons

2 Coupons suspended in the Heated Vaporsp(30 hrs)

To refill with HB stockHB stock

MaxMin

PaperCon 2011 22



ClO2Front & Back

AmSO4Front & Back

AmBrFront & Back

PaperCon 2011 23

Front & Back Front & Back Front & Back



Corrosion Rate ResultMild Steel Coupons Suspended in Vapors 30 hrs

52.050

60

py)

Mild Steel Coupons Suspended in Vapors 30 hrs

23 4 25.7

34.4 33.3

41.3

30

40

n R

ate

(mp

23.4 25.7

10

20

Cor

rosi

on

0

10

ClO2 ClO2 MCA MCA BAC BAC

C

PaperCon 2011 24



Corrosion Rate ResultMild Steel Coupons Suspended in Vapors 30 hrs

27 6

34.535

40

py)

Mild Steel Coupons Suspended in Vapors 30 hrs

15 3 16 118.8

16 4

24.6 23.227.6

20

25

30

n R

ate

(mp

15.3 16.1 16.4

5

10

15

Cor

rosi

on

0

5

Blank Blank ClO2 ClO2 MCA MCA BAC BAC

C

PaperCon 2011 25


Summary – Condensed Vapor Studies

• Lab Studies – Heating WW and Condensing Vapors• AmBr (BAC) – always detected Total Cl2 in condensed

vapors, varying amount & increased with BAC dose• AmSO4 (MAC) – always detected Total Cl2 in condensed

vapors, varying amount & increased with MCA dosevapors, varying amount & increased with MCA dose• ClO2 – zero to trace amounts of Total Cl2 in

vapors, increased to trace amounts with increased dose of ClOClO2

• Mill Condensed Vapor Studies – agreed with Lab Studies• Corrosion Coupons in the Vapor Phase – the trend agreed

with condensed vapor studies• All agreed with what we see in the “real world

PaperCon 2011 26


Effective Paper Machine Slime Control and No Vapor Phase CorrosionVapor Phase Corrosion • ClO2

• Improved small scale generation of ClO2p g 2

• Improved control with PLC• A “new” technology to address

• The current issues (vapor phase corrosion) and • “Old” issues (control and application)

PaperCon 2011 27


Documents

Effective Paper Machine Slime Control and No Vapor Phase ...€¦ · Vapor Phase CorrosionVapor Phase Corrosion • ClO 2 •Imppgroved small scale generation of ClO 2 • Improved