ONR Convention - 2018 @ Kirtland Lake - Saturday

Day 2 of the ONRHT&S convention had us reviewing the morning lineup and trying to determine which trains and locations we could photograph.  Our first train of the day was the southbound train from Englehart to North Bay.  ONR SD75I #2105 was leading a newly repainted SD40-2 #1734.  While some of the group decided to shoot this train at Englehart, Bram Bailey, Mike Robin and I opted to head south to Earlton, where we had previously seen some piles of hay bales.

Southbound train passing by Mini Farm Rd crossing at Earlton. Photo by Ken Stroebel

We chased this train southward, however, he got ahead of us and we watched him beat us to the Hwy 11 crossing at New Liskeard and broke off the chase.

Pacing shot through the farmers fields around Earlton. Photo by Ken Stroebel

We found the ditcher still working at New Liskeard after a brief lunch break at Gillies, however, the sun was mostly behind the clouds and the ditcher would soon be headed back north.

Work train at the New Liskeard station siding. Photo by Ken Stroebel

So it was back to Englehart as we tried to remain one step ahead of the northbound work train.

Work train approximately 1/2 mile east of the Englehart River bridge. Photo by Courtland Saunders

Northbound Work 1733 is captured crossing the Englehart River. Photo by Mike Robin.

ONR 1733 and 1735 at Englehart. Photo by Terry Shwetz.

Catching the work train was our last bit of railfanning for the day, as attendees had an appointment to tour the Museum of Northern History in Kirkland Lake. Located in the former chateau home of successful mine owner Sir Harry Oakes, this museum focuses on Northeastern Ontario including the Kirkland Lake area.  The site’s collection dates from 1907 to the present and includes many objects related to the home as well as mining industry and documents from the area.

Chateau of Sir Harry Oakes

Various mineral and rock specimens; note large scale on top of cabinet

Our evening presentations included a review of mining and smelting operations for Kidd Creek, Rouyn-Noranda, and Sudbury, as well as an overall review and discussion of the geology of the area and how the various ore deposits came to be.  Bill Woods then taught us how to make conifer trees using wire, hemp sisal, spray paint and ground foam.

ONR Convention - 2018 @ Kirtland Lake - Friday

This years convention was held in Kirkland Lake, with accommodations provided by the Super 8 motel.  Our thanks to Peter Ross for doing all of the planning and up front work to secure locations. Special thanks to Gerald Harper for helping to arrange our Friday morning trip to the Glencore Horne copper smelter located in Rouyn-Noranda, Quebec.  The following set of blog entries recounts my impressions as well as the fun we had once again getting together to share our interest in the Ontario Northland railway.  I will try to post some thoughts and photos to summarize the daily activities. 

We begin our day after a great meal on Thursday evening at Vienna's Bar & Grill. Somewhere in the night the weather changed to rain and cooler temperatures.  A quick breakfast and we were off to Rouyn-Noranda and the Glencore Horne copper smelter.  According to our two tour guides, Glencore is one of the world's largest copper and precious metal producers, as well as North America’s biggest recycler of electronic components. 

Aerial view of smelting operations (Photo courtesy Horne website)

Copper casting (Photo courtesy Horne website)

Our tour started with an overview of the company and operations which take place at this site, as well a history and discussion of the geology of the area and previous copper deposits.  After suiting up in coveralls, safety glasses, steel toed shoes, dust respirator, gloves and ear protection, we got the chance to see the molten copper coming out of the furnace as well as seeing the copper cast.

Hey we look like miners....Check out all of that PPE on ONRHT&S members as we get ready to enter the smelter bldg

Boxcar spotted outside of smelter. Note reporting marks

Sulfuric acid plant

Switching gondolas

Our trip back included a stop at Cheminis, MP 32 of the where members of the ONRH&TS got a chance to photograph train 211 as it passed through on its way to Noranda.  

Cheminis MP 32. Photo by Mike Robin

Passing MP32 sign. Photo by Ken Stroebel

After returning to the Super 8, Bram Bailey gave an outstanding presentation of his new book, Trackside around Ontario’s Cottage Country, which will be available on January 5, 2019.  This book will showcase various ONR, CP, ACR and CN trains around the cottage country of northern/southern Ontario. Looks like another solid read from Bram and shouldn't be missed.

New Power for the Paper Mill

The long anticipated SW1200RS from Rapido has arrived and I immediately had to try it out at the paper mill.  All I can say is what a beautiful piece of model railroading engineering and manufacturing.  I purchased the unit with DCC sound, as the price difference isn't enough to go for a non-DCC unit, and DCC version includes sound.  For anyone who has followed the development of a suitable Canadian version of the SW1200, designated by the trailing letters RS, there has been on-going controversy for some time as both Rapido and True Line Trains announced intentions to build this model.  It was actually an interesting story as it developed, as Rapido announced their intentions and showed production samples, while TLT announced their version and showed a photo of an OMI model as their unit.  In any event, Rapido delivered the goods and TLT (as of a May 2017 web site posting) has not.  Knowing the quality of work that goes into a Rapido model, I spent my modeling $$$ and ordered CN 1341, with the idea that this would become my main power for switching at the paper mill, similar to use of the SW1200RS units at paper mills in Marathon and Iroquois Falls, Ontario. 

A little history for the SW1200RS, which comes from the Rapido website.  General Motors Diesel (GMD) delivered the first example of what would come to be known as the SW1200RS model to Canadian National in September 1955. As its dieselization progressed, CNR needed a compact, lightweight locomotive to replace steam power on branch lines and other over-the-road assignments (freight and passenger) not requiring a full-fledged mainline road switcher. General Motors’ 1,200-hp SW1200 switcher model, in production since January 1954, combined the right size and muscle, but needed modifications for use out on the road.

First impressions out of the box...Rapido just continues to produce detailed, quality products which get better each model produced.  Starting off it is very well packaged and the model rides snugly in its plastic cocoon.  A detailed instruction manual (more on that to come) is included and one of the first things you see after opening the box.  Sound is very good and matches what I have seen with my RDC unit.  Engine noises are very throaty and nice chugging sound on acceleration.  Lots and lots of detail included on the model.  My only initial complaint after running it for about 30 minutes is a slight jerky movement at very slow speeds although it's getting better with more running.  My other concern is that the motor seems to have a slight whiny sound when the sound is off and you can hear the engine running alone.  Hopefully both of these problems will continue to work themselves out of the unit.  

The instruction manual is a typical Rapido manual.  Too much frivolity and joking for my tastes.  I understand that maybe a couple of humorous lines of text breaks up the monotony of a technical manual but let's focus on tech issues and specifics to the loco rather than more attempts at humor.  For example I searched and could not find if there is anyway to turn off the side lights on the trucks but I did find the oblique reference to Quantum Physics while dancing the Watusi.  Nice to know but my question remains unanswered.  Maybe a little more thought given to some tech drawings such as showing the 21 pin socket and less jokes.

I am quite please with the unit after running it on the layout.  Now comes the hard part, how much weathering should be done to give it that proper industrial locomotive feel versus how it currently looks.  I choose to loosely model the 1341 using the 1305, which was used at the Abitibi-Consolidated mill in Iroquois Falls, Ontario.  Abitibi acquired the 1305 in January 1994 (ex CN 1305) and a photo taken in 2003 clearly shows that the CN noodle is long faded away and the CN red is heavily faded.  Sounds like a topic for another posting if I decide to weather the unit to this condition.  The last photograph I have of these unit was after it was repainted into the green/black scheme and was serving the Resolute Forest Products (last reported as DESX 1305) in Thorald. 

Modeling a Paper MIll - Part 3 Rail Services

The Spruce Creek facility receives most of its bulk raw materials via rail.  I have purposely chosen not to include truck operations in my modeling, as I lacked the space to include a large enough loading area for trucks and opted to set my warehouse building at the end of the module, so that I might have more storage track space. 

Rail traffic for the four mills consists primarily of boxcars, chemical slurry tank cars, and chemical tank cars.  When I began to design my mill, one of the first items I noted that the prototype had was a number of storage tracks that were present, either within or outside the mill itself.  The second item was that, with the exception of the Temiscaming mill, each mill had its own or several switcher engines.

Switching Power

One the most interesting aspects of the mill I find is the power used to move the various boxcars and tankcars and the number of movements needed to keep the operations running smoothly.  I chose to replicate my mills power based on the various types of equipment that have been used at my four prototype mills.  The following is a rough list of engines that have been known to operate at the different mills in the area and is simply used to illustrate the variety of power over the years.  

The next decision was how the mill would be switched. Paper mills receive a large number of cars on a daily basis when in operation, which can tie up the local switching crew for the better part of a day or more.   For a start-up operation, this would have strained the resources of the crew, so the decision was reached early on that KLR crews would go to the mill, drop any empties and pick-up the cars ready for transport from the yard, while a two-person yard crew would work at least one shift to move cars within the mill.

I decided to go with similar engines and power requirements as were typically seen at my four example mills.

	Engine #	Type	Notes
Iroquois Falls	1203	S4	Ret. from ONR 1973; sold to Abitibi Pulp & Paper
	1310	RS3	Sold from ONR in 1985 to Abitibi Pulp & Paper
Smooth Rock Falls	104	S4	Mattagami Rail; formerly Quebec Iron & Titanium
Kapuskasing	108	RS23
	109	RS23	Former Devco #201
	168	GP7	Mattagami Rail, ex ACR 168
Temiscaming			No known dedicated engines; services provided by CP and RaiLink via the branch line (Temiscaming Sub.) from Mattawa to Temiscaming, Quebec (approximately 41 miles).

Currently, the Spruce Creek mill is serviced by an S4 (former Boston & Maine ) and a Mattagami GP7 unit.  With the introduction of the SW1200RS by Rapido in 2017, a unit in CN's black and orange paint scheme may become the newest switcher.  Ideally, when funds allow and a model is available, power will be replaced by an Alco RS23.

Inside the Mill

Let me first start off by saying that I firm believer that modeling an industry should be realistic to the prototype but also fun to operate.  After all, who wants to operate on a layout or switch an industry if they’re not having fun.  So I subscribe to the thought following what the prototype has done is the simplest and most realistic way of achieving your goal. This may include modeling only some of the basic buildings one might find in a paper mill, as well as following the general track arrangements, or modeling each and every building if it is needed to support a variety of rolling stock which is received. 

The idea of keeping the track plan simple and close to the prototype became very apparent during a review of my first mill track plan.  My first design was based where I had cited various buildings and where they fit best, rather than based on any logical flow from a manufacturing standpoint.  That was a mistake, as the initial design created the situation where I would need to build a crossing within the facility just so that I could access both my chemical delivery track, as well as the warehouse tracks using different movements.  So it was back to the drawing board and a little more review of the aerial photos I had from several of the northern Ontario mills before planning the track work.    What really jumped out at me was that each of the mills had sufficient yards within or immediately outside of the mill, such that empties and filled cars were shuttled to and from the yard from the active loading or unloading areas.  When switching was completed, the plant switcher was generally returned to its engine house or bay.

Location	# Yard Tracks	Notes
Iroquois Falls	6+	Exterior to Plant; between Cambridge Ave and Ambridge Drive; use of a Wye
Smooth Rock Falls		Unknown within mill; Access via rail along 4th Street
Kapuskasing	5+	Yard tracks adjacent to ONR main; parallel to ONT-11
Temiscaming	6	Yard tracks well south of the mill; Small wye towards south end and near river

Car Loads

Let’s take a look at what the Spruce Creek plant produces, what the various raw materials that are needed, and how often rail cars enter the plant.  Similar to the Temiscaming mill, I modeled operations to include three main mills that manufacture different forest products, including specialty cellulose, high-yield-pulp and coated bleached board (containerboard) as well as a chemical products facility.   The chemical products division produces a variety of products made from spent sulphite liquor (primarily alcohol, resin or lignin based).  

It goes without saying that modeling four operating plants takes up a large amount of space, which typically is not available with a model railroad regardless of which scale you're modeling.  However, I have used photos from the Kapuskasing and Temiscaming mills as backdrop, which is how I incorporate each of the mills.    

The Spruce Creek Pulp and Paper Mill is located on two 2’ by 6’ modules in the center of the room.  Starting from the left side, my buildings include a power plant, the pulp mill, alcohol plant, acid building, kaolin building, specialty cellulose mill, board mill and the warehouse.

High Yield Pulp - the pulp mill is a manufacturing facility that converts wood chips or other plant fibre source into a thick fibre board which can be shipped to a paper mill for further processing. Pulp can be manufactured using mechanical, semi-chemical or fully chemical methods (kraft and sulfite processes). The finished product may be either bleached or non-bleached, depending on the customer requirements.  In our mill, kraft pulp is produced using softwood pulp, while the "B" mill can produce either softwood or hardwood pulp.  Similar to the Boardmill, final products are shipped via both rail and truck.  The Kraft mill also produces large amounts of lignin liquor, a byproduct of the digestion process. This material can be shipped out in tankers, dried, or fed to other bacterias to make yeast.  The Kraft mill also uses other chemicals such as sodium hydroxide (caustic soda) and sulfuric acid. Kaolin (slurry form) is brought in to make glossy paper. Kaolin is often supplemented by calcium carbonate (lime) slurry and titanium dioxide.

The Chemical plant consists of products which are made from the spent sulphite liquor generated within the facility.  The plant can be divided into an alcohol division, resin division and lignin division.  Most of this operation takes place within numerous tanks situated within three central buildings.  Due to their relative size, I chose to model only the fronts of the buildings and blended the building into the photo backdrop.

Refined from wood pulp, specialty cellulose is used in a range of applications across many industries – cosmetics, pharmaceuticals, personal care, food, coatings, electronics and energy.  Specialty cellulose is manufactured in both rolls and bales.  Similar to the chemical plant, this area was modeled using only the front of the building set against the photo backdrop.

The Boardmill Division produces high quality paper and manufactures newsprint for publishers of daily newspapers and commercial printers, as well as controlled bulk paper for mass-market paperback book publishers and commercial printers.  Coated bleach board is a product used for a broad range of commercial printing, publishing and packaging applications.  Newsprint production uses wood fibre obtained from four separate sources, including thermomechanical pulp (TMP), recycled pulp, groundwood pulp and kraft pulp. Kaolin is used to make glossy paper. While chlorine was used to bleach the paper, in recent years it has been replaced by sodium chlorate.

Rail Traffic

One of the other key aspects I looked at when designing my mill was how much traffic did a typical northern Ontario paper receive and could I support anything close to that. For example, both the Kapuskasing and Temiscaming mills generally receive rail traffic at least 5 days per week.  Aerial photographs are readily available for the Kapuskasing mill, and show that it has at least 5 storage tracks which appear to be able to easily hold forty (40) fifty-foot boxcars easily.  There are several additional tracks within the property which can also accommodate 15-20 cars easily per track.  If a typical train load is 20-30 tank cars and boxcars, I knew that there was no way to accommodate that much storage for my modelling. 

Another aspect that goes hand in hand with this was how much yard trackage would I be able to accommodate within two modules, given that this would become the easiest way to move traffic around with the yard switcher.  With the exception of the Temiscaming mill, each of the other mills discussed previously have been supported by a fairly large amount of trackage either on or just off the mill property.  It was very common to see numerous strings of boxcars just waiting to be pushed into the warehouse tracks, however, stored just along the property boundary.  Warehouse tracks were typically designed to support multiple boxcars, with the area under roof supporting at least 3 tracks and it was quite common to see 4-5 boxcars on each track.

The next step was to determine which types of rolling stock would be needed at the mill.  Paper mills take in and also ship out of lot of things, which may typically include: 

Rail Car	Inbound	Outbound
Boxcars	Scrap paper	Paper Rolls, Kraft or bleached paper	Various sized boxcars paper rolls and bundles bleached kraft bundles, scrap paper
Gondolas/Hi-cube Hoppers	Wood Chips
Bulk Head/Pulp Wood Flats	Pulp Wood Logs (cut to lengths of 4 to 6 feet long)
Tank Cars	Kaolin Chlorine  Limestone Slurry Caustic Soda Sodium Hydroxide Sodium Hydrosulfide Sulfuric Acid Lignin liquor	Tall Oil by-product Lignin Liquor Turpentine by -product	Chlorine (pulp bleaching); Clay slurries (note: Kaolin would be used for glossy papers)
Gondola		Scrap Iron
Bulkhead flat cars	10-foot pulpwood		Single-stacked cross-ways
Hopper	Coal, although most facilities burn some sort of wood waste
Covered Hoppers	Salt Cake, Calcium Carbonate, Lime, Sodium Chlorate, Corn Starch		Calcium carbonate – off loaded near the fourdrinier building for coatings; replaces kaolins

 Rail Spurs

 For my operations, I opted to go with the following arrangement:

• Warehouse (1 interior track within the Building; 2 interior tracks in adjacent Bldg.); each track to hold 2-3 boxcars
• Rotary chip dumper (1 track); able to store one hopper
• Chemical Plant (1 track – min. 5 loading/unloading spots)
• Engine House – (single track off of the outbound storage track)
• Yard Tracks (2 tracks, one for outbound cars and one for inbound; able to store 8 cars min.)

Engine house - Iroquois Falls, ONT