Tag: paper mill

Using Energy More Efficiently

  • The Sappi paper mill in Cloquet Minnesota produces most of the electricity it needs, using steam that also powers the industrial process. Sappi can even sell power when demand is high. Electric co-generation is enjoying a come-back. (Photo by Stephanie Hemphill)

More and mores states are establishing a “renewable energy standard”
for their electric utilities. So far, wind power is producing the bulk
of renewable energy. But there are other sources. Some are brand new.
Others have been around for a long time. Stephanie Hemphill reports:

Transcript

More and mores states are establishing a “renewable energy standard”
for their electric utilities. So far, wind power is producing the bulk
of renewable energy. But there are other sources. Some are brand new.
Others have been around for a long time. Stephanie Hemphill reports:


The first thing to know about electricity is that making it can be
incredibly inefficient.


In a conventional power plant, burning fuel turns water into steam.
The steam drives a turbine, which spins the generator. Only about a
third of the energy in the original fuel is converted to electricity.
Two thirds goes up the smokestack in the form of heat.


“Every time you convert energy from one form to another, you lose
something. That’s just the way it is, ’cause nothing’s perfect.”


Dwight Anderson works for Minnesota Power. He’s lived with that
inefficiency for his whole working life. Now, he’s trying to wring
more electric power out of every bit of fuel.


He’s high on something called co-generation. The basic idea is to
harness the heat or steam that normally goes up the smokestack.
There’s a good example of co-generation at the Sappi paper mill in
Cloquet, in northern Minnesota. Like many paper mills, Sappi makes
most of the electricity it needs.


Engineering Manager Rick Morgan points to a mountain of wood chips:


“We have about 20,000 tons of biomass stored.”


That’ll last less than a month. The plant uses 53,000 watts, enough to
power a small city.


Inside the sprawling buildings, there are several electric generators.
One of them is fueled by a recovery boiler, which burns the byproducts
of the paper-making process, to run steam through a turbine.


“…The actual turbine is manufactured in Czechoslovakia and the generator’s
made in Vestros, Sweden.”


Higher pressure steam spins the turbine to produce electricity. The
waste steam from the same boiler goes to the pulp dryer, the paper
machines, and other parts of the process.


Back in his office, Rick Morgan says energy is the fourth largest
expense for paper mills:


“If you can’t control energy costs in this business, you can’t be in
business.”


The main product here is paper, but sometimes Sappi sells electricity
too. That happened during a recent cold snap:


“The electric demand increases and the costs go higher and higher, to
the point that it’s financially feasible for us to generate power for
Minnesota Power.”


Opportunities to produce electricity turn up in some surprising places.
Like along natural gas pipelines. The pressure has to be boosted
periodically as the gas travels through the pipe. Compressors fueled
by the natural gas do that work, and normally they vent off waste heat.


But now in South Dakota, the waste heat is fueling small power plants.
They look like the barns and silos of a farm. The generator itself is
about the size of a truck.


Basin Electric Power Coop spokesman Daryl Hill says the plants are
owned and operated by an Israeli company, and the co-op buys the power:


“We get basically 22 megawatts of baseload for little investment.”


Other countries are leading in these approaches because their fuel
prices have been so high. As prices go up in the U.S., power producers
are finding ways to use more efficient technologies, and they’re
returning to old-fashioned ideas like combined heat and power. This is
a form of co-generation that was once common across the country.


A central electric plant uses its waste steam to heat buildings. Of
course, most people don’t want to live next to a coal-fired power
plant. But Neal Elliott, with the American Council for an Energy-
Efficient Economy, says with combined heat and power, cleaner fuels,
like natural gas, can become competitive:


“Use natural gas, but use it much more efficiently. And instead of
throwing more than half of the fuel value away, let’s do it with co-
gen.”


Elliott says combined heat and power and other forms of co-generation
could provide 20% of America’s electricity needs, and save on heating
fuel at the same time. And he says recovered energy generation like
along the natural gas pipelines could provide another 20%.


For the Environment Report, I’m Stephanie Hemphill.

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Banking on Birch Bark

  • David Peterson is president of NaturNorth Technologies. The business is a spinoff from the University of Minnesota-Duluth's Natural Resources Research Institute. It has a patent on a process to extract large quantities of pure betulin, a component of birch bark. (Photo by Stephanie Hemphill)

A start-up company is banking on birch bark. The papery bark can be used for more than baskets and canoes. It’s used in skin creams, and scientists are studying it for use in treating skin rashes and even cancer. But Native American healers have been using birch bark for years, and some of them are worried about the supply. The Great Lakes Radio Consortium’s Stephanie Hemphill reports:

Transcript

A start-up company is banking on birch bark. The papery bark can be used for more than baskets and canoes. It’s used in skin creams, and scientists are studying it for use in treating skin rashes and even cancer. But Native American healers have been using birch bark for years, and some of them are worried about the supply. The Great Lakes Radio Consortium’s Stephanie Hemphill reports:


Have you ever noticed – walking in the woods – those cylinders of bright white bark, lying on the forest floor? Those are the remains of a birch tree. The inside of the tree rots away quickly, but the bark lasts much longer.


“The birch tree has some incredible defense mechanisms that protect the tree from weather, from rain, from sun, keep the moisture in, keep moisture out.”


David Peterson knows birch trees pretty well. He was a top manager at the Potlatch Paper Mill near Duluth, Minnesota. The plant processes thousands of trees every day, and burns the bark to make steam.


“I always was interested in trying to come with a way of using some of these low value waste streams generated from pulp paper mills and other places, it seemed like such a horrible waste, to take these really interesting compounds and put them in a boiler for boiler fuel.”


Peterson’s new company, NaturNorth Technologies, plans to make something worth a lot more than boiler fuel. The company has patented a process to extract large quantities of a chemical, betulin, that gives birch bark its anti-bacterial and anti-fungal qualities.


Mill workers remove bark from a tree that’s harvested for lumber or paper-making. It’s shredded into pellets, and put through a chemical process that extracts the betulin. It ends up looking something like salt.


“Here’s a sample of betulin, and you can see how bright and white it is. It’s got a chalky feel when you touch it.”


Apparently, what birch bark does for the birch tree, it can also do for human skin – protect it from the assaults of the physical world. Betulin is already used in some creams and cosmetics, but NaturNorth plans to be the first company in the world to market it on a large scale.


The idea of selling lots of betulin from birch bark makes Skip Sandman nervous. He’s a Native American traditional healer for the Mille Lacs Band of Ojibwe. He uses birch bark for medicine. He says it’s a pain-killer and blood-thinner and can be used for intestinal disorders.


“Fortunately, when people use it for medicines and stuff, one small tree does go a long way. But you might have to travel 15, 20 miles to find the right type of tree.”


Sandman says the bigger trees – ten to twelve inches in diameter – have a bigger supply of the properties he uses in medicine. And lately he’s had to go farther to find those big trees. He says that’s because timber companies have cut down so many of the big trees and now they’re working on smaller and smaller trees.


“But you see the logging trucks go by, and they’re just whacking down everything. Well they think it’s only a tree. But when the trees are gone, then what do we do?”


Sandman says in the Ojibwe creation story, each plant and animal promised to help people in some way, and birch trees offered their healing qualities. He says it’s important to use them respectfully, and not for profit, but only to help people. He says he approaches the tree with an offering of tobacco.


“I will put tobacco down and ask and talk to that tree, because it is alive.”


The folks at NaturNorth are hoping to make money from birch trees, but they’re also excited about helping people. David Peterson says he gets letters from people who want some betulin to treat a skin condition.


“When you get those letters, you can’t help but to feel that somebody out there that’s gonna benefit eventually from these compounds, I think it’s quite sobering and humbling.”


NaturNorth has started marketing betulin to cosmetics companies, and scientists are studying betulinic acid for its disease-fighting potential. Peterson says it’ll be several years before NaturNorth generates a profit.


For the GLRC, I’m Stephanie Hemphill.

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Long Road to River Recovery

  • Aerial view of industry along the Fox River. Photo by Great Lakes United.

One of the rivers that flows into Lake Michigan is polluted so badly that it’s being treated much like a Super Fund site…an environmental disaster. It’ll be decades before it’s cleaned up, and some environmentalists think it might never be cleaned up properly. The Great Lakes Radio Consortium’s Lester Graham reports:

Transcript

One of the rivers that flows into the Great Lakes (Lake Michigan) is
polluted so badly that it’s being treated much like a Super Fund site –an
environmental disaster. It’ll be decades before it’s cleaned up. And some
environmentalists think it might never be cleaned up properly. The Great
Lakes Radio Consortium’s Lester Graham reports:


(Sound of fish splash)


It’s late at night. The moon’s out. And the fish are flopping on the Fox
River. In downtown Green Bay, Wisconsin, Robert Hageman and a few of his
friends have been fishing. A couple of the guys are bragging about the big
fish they caught. But they’re not taking any home with them tonight.


LG: “Had any luck?” RH: “Yeah, I caught 23 fish.”
LG: “And wwhat did you do with them? RH: “Let ’em right back.” LG: “why?” RH: “Because it’s dirty. Fox River’s dirty.”
LG: “What have you heard about the Fox River?” RH: “The fish ain’t good for you. They can’t hurt you, but they ain’t good for you.
(friends in background say “PCBs, man.”) “yeah.”
LG: “What do you know about PCBs?
RH: “I don’t know nothing about it. That’s why I ain’t eatin’ them.” (all laugh)


Hageman and his friends are right when they say there are PCBs in the Fox
River. But apparently they haven’t heard that eating fish from the river
probably can hurt you in the long run. There are 60-thousand pounds of
PCBs, or poly chlorinated byphenyls, in the 39 mile run of the Fox
River. Of that, 50-thousand pounds – that’s 25 tons – is in the sediment of
the last seven mile stretch just before the river flows into Green Bay and
on into the rest of Lake Michigan. It’s that final stretch where Hageman
and his friends have been fishing.


The Environmental Protection Agency says seven paper mills along the Fox
River are the likely polluters. The EPA says PCBs were produced as a
by-product of the paper manufacturing process, and from the 1950s to the 1970s
they were dumped into the river. Now, the agency intends to make those
mills pay for cleaning up the contaminants.


Dennis Hultgren works for Appleton Papers, and is a spokesperson for a group
that represents the seven companies. Hultgren says the paper mills want to
clean up the pollution. But they don’t want to pay more than they have to.


“What we want to do is make sure that the money that we do spend
is spent wisely and it does the most environmental good for the region. And
so, we have one chance to do it right and we want to do it right the first
time.”


The paper mills have been working closely with government agencies to try to
determine where the PCBs are concentrated and how best to clean up the
pollution. Some of the companies have spent millions of dollars on tests in
the river. Just recently, Hultgren’s firm offered 40-million dollars… ten-million dollars a year for four years… for data collection and preliminary clean-up tests. The government agencies praised the decision and some environmental groups voiced their approval. But a local grassroots group, the Clean Water Action Council of Northeast Wisconsin, does not approve. Rebecca Katers is with the council and says it’s a delay tactic by the paper mill companies.


“It makes the company look generous. But, in fact, they should be doing this anyway. They should have done this ten years ago.”


Giving the money now, Katers says, only manages to delay legal action
against the company for four more years. Besides, she says, while
40-million dollars might seem like a lot of money, the estimated clean-up
could cost as much as 30 times that amount.


The Clean Water Action Council says this money and the government’s
willingness to accept it are representative of the cozy relationship the
companies seem to have with regulators. But Katers says the state and
federal agencies are forgetting about the people who live here. She
bristles when she hears the government agencies talk about how close they
are to the paper mills.


“They talked at the announcement about ongoing discussions they
have on a daily basis with the paper industries on this issue. But, they
haven’t met once face-to-face with the public. They haven’t held a public
discussion or debate on this issue.”


And it appears there won’t be many opportunities in the future. Although
the Fox River is not a Superfund site, the EPA is generally following the
process used for Superfund sites. The EPA says that means the public can
submit comments in writing. But there won’t be a lot of public discussion
until the EPA actually has a proposed plan. Katers thinks the people
should have a voice a lot earlier in the process.


But, the paper mills’ representative, Dennis Hultgren says it’s better to
let the experts work first.


“It’s complicated. For the normal citizen, it’s going to be very difficult to comment on it because they’re going to be looking at the technical merits
of their comments. And a general citizen, not having been involved, it’s going to be very difficult to have germane comments.”


The companies say they’ve been studying and testing and they’ve found
disturbing the sediment by trying to remove it proves that the PCBs should
be left in the sediment, allowed to slowly break down… a process called
natural recovery. And where there’s risk that sediment laden PCBs might
be disturbed by the river’s currents, engineered caps could be put in place.


The Clean Water Action Council says the paper mills tests were designed to
end up with that conclusion because that would be the cheaper way to deal
with the PCBs. The council wants the PCBs removed from the river and
disposed of safely… a much more expensive job.


The acting regional administrator for the USEPA, David Ullrich, says
there’ll likely be some combination of natural recovery, capping, and
removal. But, Ullrich says none of that will happen anytime soon. It’s a
big job, and it looks as though it will take up to ten years to deal with
the PCBs. And Ullrich says that’s just the beginning.


“The actual recovery of the resource, getting fish contaminant
levels down to acceptable levels and getting the PCB loadings to Green Bay
and out to Lake Michigan down, could take a longer period of time than that,
perhaps up to twenty years.”


And over that 20 year period, experts say that contamination will
naturally spread farther and farther into Green Bay and Lake Michigan.


For the Great Lakes Radio Consortium, this is Lester Graham.

LONG ROAD TO RIVER RECOVERY (Short Version)

The Environmental Protection Agency says it could be a decade before a river that feeds Green Bay and Lake Michigan will have tons of PCBs cleaned up. And a lot longer before the river recovers from the effects of the pollution. The Great Lakes Radio Consortium’s Lester Graham reports: