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CLEANER PRODUCTION IN AUSTRIA CLEANER PRODUCTION IN AUSTRIA PRACTICAL EXAMPLE: PULP & PAPER INDUSTRY PRACTICAL EXAMPLE: PULP & PAPER INDUSTRY Karl E. Lorber Institute for Sustainable Waste Management and Technology (IAE) University of Leoben – Austria A-8700 Leoben Tel. +43 (0) 3842 402-5101 Web: www.unileoben.ac.at/iae Peter-Tunner-Strasse 15 Fax +43 (0) 3842 402-5102 E-Mail: [email protected] PDF created with pdfFactory Pro trial version www.pdffactory.com

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CLEANER PRODUCTION IN AUSTRIACLEANER PRODUCTION IN AUSTRIAPRACTICAL EXAMPLE: PULP & PAPER INDUSTRYPRACTICAL EXAMPLE: PULP & PAPER INDUSTRY

Karl E. LorberInstitute for Sustainable Waste Management and Technology (IAE)

University of Leoben – Austria

A-8700 LeobenTel. +43 (0) 3842 402-5101

Web: www.unileoben.ac.at/iae

Peter-Tunner-Strasse 15Fax +43 (0) 3842 402-5102E-Mail: [email protected]

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1. INTRODUCTION

2. INTEGRATED POLLUTION PREVENTION & CONTROL (IPPC)

3. PRACTICAL EXAMPLE: PULP & PAPER INDUSTRY

3.1 Statistical Data

3.2 Processes & Technologies

3.3 The KRAFT (Sulphate) Pulping Process3.3.1 Unit operations of a KRAFT Pulp Mill3.3.2 Chemicals and Energy Recovery System3.3.3 Input-Output Mass Balance3.3.4 Bleaching of Pulp3.3.5 Process Related Emissions & Wastes3.3.6 Waste Management3.3.7 Best Available Technologies for Reducing Environmental Impacts

4. CONCLUSIONS

CLEANER PRODUCTION IN AUSTRIACLEANER PRODUCTION IN AUSTRIAPRACTICAL EXAMPLE: PULP & PAPER INDUSTRYPRACTICAL EXAMPLE: PULP & PAPER INDUSTRY

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MINIMISATION of adverse ENVIRONMENTALIMPACTS by REDUCTION of:

• EMISSION into AIR

• EMISSION into WATER

• GENERATION of WASTE• CONSUMPTION of ENERGY & RAW MATERIALS

by ZERO–WASTE TECHNOLOGY

Practical Approach: LOW WASTE TECHNOLOGY

BEST AVAILABLE TECHNIQUE (BAT)

Also: Part of ENVIRONMENTAL MANAGEMENT of ISO 14001 CERTIFICATION

1. 1. IntroductionIntroduction

„„Cleaner ProductionCleaner Production““

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1. 1. IntroductionIntroduction

Follows Hierarchy:• PREVENTION• RECYCLING & RECOVERY• TREATMENT• SAVE DISPOSAL

In EUROPEAN UNION (EU):COUNCIL DIRECTIVE (CD), 96/61/EC of 24. September 1996

concerning “Integrated Pollution Prevention & Control (IPPC)

STRATEGY of BATSTRATEGY of BAT

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• Achieve integrated prevention & control of pollution arising from(industrial production) activities.

• Lay down measures for prevention or reduction of emissions inthe air, water and land (including waste) to achieve a high levelof protection for the environment as a whole.

• Whereas different approaches to controlling emissionsseparately may result in shifting of pollution between the variousenvironmental media (air, water, soil).

• IPPC–Directive is concerned with installation whose potentialfor pollution, and therefore trans-boundary pollution, issignificant (List contains: major production industry but alsowaste management facilities like incinerators & landfills).

2. INTEGRATED POLLUTION PREVENTION &2. INTEGRATED POLLUTION PREVENTION &CONTROL (IPPC)CONTROL (IPPC)

OBJECTIVE & SCOPE of IPPC:OBJECTIVE & SCOPE of IPPC:

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• Emission limit values or standard parameters and technicalmeasures to achieve them are based on the Best AvailableTechniques (BAT), without prescribing the use of specific techniqueor technology.

• “Best available techniques” or “BEST AVAILABLETECHNOLOGIES” means the most effective and advanced stage ofmeasures & techniques to prevent or reduce emissions and thenegative impact on the environment as a whole at reasonable costs.

• CD 96/61/EC contains list of industrial activities and list of major (air& water) pollutants concerned.

IPPC–Council Directive (CD) 96/61/ECIPPC–Council Directive (CD) 96/61/EC

2. INTEGRATED POLLUTION PREVENTION &2. INTEGRATED POLLUTION PREVENTION &CONTROL (IPPC)CONTROL (IPPC)

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For selecting the Best Available Techniques (BAT), the principles ofprecaution & prevention have to be considered:

• Use of low–waste technology• Use of less hazardous substances• Encouraging recovery & recycling of wastes generated in the process

(when appropriate).• Considering R & D, technological progress and scientific knowledge• Economical use & consumption of raw materials (including water)

and energy efficiency.

IPPC–Council Directive (CD) 96/61/ECIPPC–Council Directive (CD) 96/61/EC

2. INTEGRATED POLLUTION PREVENTION &2. INTEGRATED POLLUTION PREVENTION &CONTROL (IPPC)CONTROL (IPPC)

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3. PRACTICAL EXAMPLE: PULP & PAPER3. PRACTICAL EXAMPLE: PULP & PAPERINDUSTRYINDUSTRY

3.1. Statistical3.1. Statistical DataData ( (yearyear 2002) 2002)

Data on Production & Consumption of Pulp and Paper.

Production [in 103 t] Consumption [in 103 t] per capitaconsumption [kg/a]

CountriesPaper Pulp &

Mechanical PulpPaper Pulp &

Mechanical PulpPaper

Austria 4,419 1,755 1,974 2,106 246Germany 18,526 2,148 18,984 5,898 228Finland 12,776 11,730 1,728 9,849 333Sweden 10,724 11,354 2,382 8,385 268Spain 5,365 1,719 6,949 1,701 173Argentina 1,209 849 1,383 666 37Brazil 7,774 8,127 6,879 5,047 39Total World 330,704 182,000 330,761 182,649 54

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Statistical Data (year 2002)Statistical Data (year 2002)

Raw Material Consumption Structure inRaw Material Consumption Structure inPaper & Board Manufacturing (2000).Paper & Board Manufacturing (2000).

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Statistical Data (year 2002)Statistical Data (year 2002)

Pulp & Paper Industry in AustriaPulp & Paper Industry in Austria

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3.2 Processes & Technologies3.2 Processes & Technologies

The following processes are applied for pulping:

• KRAFT (Sulphate) Pulping Process• Sulphite Pulping Process• Mechanical Pulping• Chemi–Mechanical Pulping• Recovered Paper Processing• Novel Technologies (e.g., Organosolv pulping)

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3.3 The KRAFT (Sulphate) Pulping Process3.3 The KRAFT (Sulphate) Pulping Process

SULPHATE or KRAFT process:SULPHATE or KRAFT process: most applied (ca. 80 % of world pulpproduction) chemical pulping process.

Chemical Pulping:Chemical Pulping: fibres are liberated from the wood matrix as thelignin is removed by dissolving in the cooking chemical solution(KRAFT process: White Liquor with NaOH and Na2S) at hightemperature. Lignin and part of the hemicellulose (ca. 50 % of chips –input) is dissolved in the cooking, resulting in the Black Liquor.

• Advantages: – superior pulp strength properties – applicable to all wood species

• Disadvantages: – inherent potential problem of malodorous compounds.

– formation of chromophores is causing dark color of unbleached pulp.

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3.3.1 Unit operations of a KRAFT Pulp Mill3.3.1 Unit operations of a KRAFT Pulp Mill

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3.3.2 Chemicals and Energy Recovery System3.3.2 Chemicals and Energy Recovery System

Recovery Boiler: Recovery Boiler: NaNa22SOSO44 + 2 C + 2 C →→ Na Na22S + 2 COS + 2 CO22

2 2 NaOH NaOH + CO+ CO22 →→ Na Na22COCO33 + H + H22OOCausticizerCausticizer:: NaNa22COCO33 + + CaO CaO + H+ H22OO→→ 2 2 NaOH NaOH + CaCO+ CaCO33

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3.3.3 Input–Output Mass Balance3.3.3 Input–Output Mass Balance

Mass Flow of aKRAFT pulp mill.

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3.3.4 Bleaching of Pulp3.3.4 Bleaching of Pulp

•• Elemental Chlorine Free (ECF) BleachingElemental Chlorine Free (ECF) BleachingBleaching sequence without the use of chlorine gas (Cl2). Mainbleaching agent is ClO2, bleach plant consists of a sequenceof separate bleaching stages with different chemicals added.

•• Totally Chlorine Free (TCF) BleachingTotally Chlorine Free (TCF) BleachingHydrogen peroxide (H2O2), ozone (O3) or / and peracetic acid(PA) are most commonly used chemicals, aft removal of Mn2+

in the chelating stage. No chlorine containing chemicals areused at all. Practically no PCDD/PCDF, Chlorophenols, AOX.

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•• BAT levels for emission to airBAT levels for emission to air

3.3.5 Process–related emissions & wastes3.3.5 Process–related emissions & wastes

•• BAT levels for emission to waterBAT levels for emission to water(after biological treatment with best available technique)(after biological treatment with best available technique)

Parameters Units Bleached KraftCOD kg/ADt 30 2 – 45BOD kg/ADt 13 2 – 19TSS kg/ADt 2 – 4AOX kg/ADt (-) – 0.4Total P kg/ADt 0.04 – 0.06 4

Total N kg/ADt 0.3 – 0.4Process wastewater amount m3/ADt 30 – 50

ADtADt: tonne of final product (100 % DS): tonne of final product (100 % DS)

2) lower values achievable for hard wood pulping4) for pulp wood eucalyptus, the range is 0.037 – 0.23 kg P/ADt

Dustkg/Adt

SO2 (as S)kg/Adt

NOx (NO+NO2 asNO2) in kg/Adt

TRS (as S)kg/Adt

Bleached and unbleached kraft pulp 0.2 – 0.5 0.2 – 0.4 1.0 – 1.5 0.1 – 0.2

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•• BAT Generation of solid wastesBAT Generation of solid wastes

Process–related emissions & wastesProcess–related emissions & wastes

Examples Type of wasteAmount

[kg DS/Adt]Total

[kg DS/Adt]– Ashes 2.0 15– Dregs 10.0– Bark, wood waste etc. 3.4

Bleached Kraft marketpulp mill

– Rejects 0.3– Lime mud 9.7 45– Green liquor dregs 8.1– Bio- & primary sludge 8.7– Reject (woodhandling) 2.1– Wood ashes 3.9

Bleached Kraft marketpulp mill

– Other 10.5

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3.3.6 Waste Management3.3.6 Waste Management

Decission making tree for waste management

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Waste ManagementWaste Management

Material recycling options of Pulp & Paper mill residuesand factors governing options choice.

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3.3.7 Best Available Techniques (BAT) for3.3.7 Best Available Techniques (BAT) forReducing Environmental ImpactsReducing Environmental Impacts

•• BAT–Measures for reducing of emissions to airBAT–Measures for reducing of emissions to air

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Best Available Techniques (BAT) for ReducingBest Available Techniques (BAT) for ReducingEnvironmental ImpactsEnvironmental Impacts

•• BAT–Measures for reducing of emissions to waterBAT–Measures for reducing of emissions to water

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3.3.7 Best Available Techniques (BAT) for3.3.7 Best Available Techniques (BAT) forReducing Environmental ImpactsReducing Environmental Impacts

•• BAT–Measures for reducing solid wastesBAT–Measures for reducing solid wastes

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4 CONCLUSIONS4 CONCLUSIONS

•• In the European Union (EU), the subject of CleanerIn the European Union (EU), the subject of CleanerProduction is dealed with the COUNCIL DIRECTIVEProduction is dealed with the COUNCIL DIRECTIVE96/61/EC of 24. September 1996, concerning “Integrated96/61/EC of 24. September 1996, concerning “IntegratedPollution Prevention & Control (IPPC).Pollution Prevention & Control (IPPC).

•• Best Available Techniques (BAT) are recommended toBest Available Techniques (BAT) are recommended toreduce the adverse environmental impacts of majorreduce the adverse environmental impacts of majorindustrial sectors.industrial sectors.

•• As a practical example, IPPC–measures in the KRAFTAs a practical example, IPPC–measures in the KRAFT(sulphate) pulp & paper industry are reported in this(sulphate) pulp & paper industry are reported in thispaper.paper.

•• For Reference Documents on Best Available TechniquesFor Reference Documents on Best Available Techniquesin different industrial sectors see:in different industrial sectors see:

http://eippcb.jrc.es/pages/FActivities.htm

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