Domtar, in collaboration with Omya, has inaugurated a new precipitated calcium carbonate (PCC) plant at its Nekoosa, Wisconsin site. The project aims to ensure a reliable supply of this essential input for paper production, providing environmental, operational and economic benefits. The plant went into operation in September 2024.
LOGISTICAL CHALLENGE DRIVES INNOVATIVE SOLUTION
The closure of a regional PCC mill in 2020 significantly impacted Domtar’s supply chain, raising costs and compromising operational efficiency. Before the interruption, supply took place at approximately 16 kilometers. After the closure, PCC began to be transported from a facility located 200 kilometers away, resulting in high logistics costs, increased carbon emissions and production delays.
Faced with this situation, Domtar and Omya began studies to make it feasible to build a new PCC plant inside the Nekoosa factory. The analysis conducted by Omya and AFRY confirmed the feasibility of the project, considering the availability of raw materials, logistics infrastructure and storage capacity.
INVESTMENT IN INFRASTRUCTURE AND OPERATIONAL GAINS
Construction of the new plant, with capacity to produce 27,500 dry tons of PCC per year, was completed in July 2024. The project involved significant investment in engineering, licensing, infrastructure and CO2 supply. Omya has taken over ownership and operation of the plant, guaranteeing supply both to Domtar’s Nekoosa and Rothschild plants and to external customers.
ENVIRONMENTAL, OPERATIONAL AND ECONOMIC BENEFITS
The new PCC plant brings significant improvements:
- Environmental: reduction of 15,000 short tons of carbon emissions per year, reduction of 1,180,000 miles traveled in transport and reuse of CO2 from the Nekoosa recovery boiler.
- Operational efficiency: optimization of PCC use, greater flexibility in the scheduling of paper machines and elimination of waste.
- Competitiveness: reduced costs and guaranteed reliable supply, strengthening Domtar’s position in the market.
By executing this high-ROI, three-year project with a strategic partner, Nekoosa now has an unlimited supply of PCC on-site that allows for flexibility in our papermaking schedules and effective grade development,” says Jason McCauley, Nekoosa mill general manager.
The initiative reinforces Domtar and Omya’s commitment to sustainable and innovative solutions for the paper industry.
