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She can live without us, we cannot.
Responsible Manufacturing and Sustainability – ITC’s Paper & BoardsSustainability ITC s Paper & Boards
Business
S.N.Venkataraman ITC LTD PSPD
AgendaIndustry ScanSustainability Challenges.
Fiber sourceEnergyEnergyWaterSolid waste managementCleaner Technologies
ITC Approach to challenges
Global Paper IndustryTotal market of 400 million tons per annum CAGR of 4.5%
Higher growth in emerging g g g gmarkets, particularly Asia
Expected to grow at 4% pa in the next three years (RISI)next three years (RISI)
33
29
710
21
Container BD Tissue NP P & W Pkg Bd
Indian Paper Industry Total Market ~ 10.2 Million Tons Per Annum Growing at ~ 7% p.a. Value added segment growing at ~ 15% p.a.
19% 3%
26%19%
14%7%
31%
Kraft Pkg Bd Others P & W NP Spl
M th & F t b t PMyths & Facts about Paper Making Paper cuts trees Paper comes from responsibly
managed plantationsmanaged plantations
Paper is bad for the environment
Comes from a natural and renewable crop – forest
Paper consumes a lot of
products help store 540 Mn Tons of CO2 every year 13 KWH of electricity is used to make 10 kg of paper ourenergy to make 10 kg of paper - our per capita consumption = powering a computer continuously for 4 days
Paper has a high carbon footprint
Carbon footprint is reducing year on year due to increasing plantations ( sequester carbon) and use of biomass & renewable energy
Major Challenges for j gSustainable Manufacture
Fiber SourceWaterEnergySolid Waste ManagementSolid Waste ManagementClean Technologies
Fiber Source
Sourcing of Wood; Global practiceForests are owned by people, fi G tfirms or Govt.Forests owned by companies –captive forestGovt. forest leased to companies – concession forestsGovt. forest managed by govt. – open market sale, auction 64% of the forest is managed64% of the forest is managed
Source: All about paper; Green Rating project - CSE
Classification of Indian paper mills according to fiber so rce for paper
Indian Paper Industry - Fiber
according to fiber source for paper & Paperboard mfg.
65% of the paper produced in India65% of the paper produced in India is from non-wood sources.
www. ipma.co.in
S i f W d Ch llSourcing of Wood ChallengesIndian Industry needs about 8 million MT of wood/year.Demand by 2012-13 is estimated to be 9 million ton/YearTo generate 9 million ton/year requires 2.5 million Ha of land to maintain ecological balance.No government policy in place for future wood supplyNo private forest for sustainable wood supplyN ll ti f t l d f P I d t t d lNo allocation of waste land for Paper Industry to develop sustainable wood source.
www. ipma.co.in
Wood supply is from
Sourcing of Wood Challenges
Farm forestry from small and marginal farmersSocial forestry, andy,Government supplies
Waste paper mills do not have downstream integration or partnership for fiberintegration or partnership for fiber.
Waste paper is mainly imported
Carbon Credits – Not viable, for issues like
Sourcing of Wood: Other Challenges
land ownershipMonitoringUNFCCC protocol criteria needsUNFCCC protocol criteria needs
(a) Land should not be under forest from1989 onwards for reforestation projectsL d h ld t b d f t f 1950 d f(b) Land should not be under forest from 1950 onwards for afforestation projects (farm forestry with farmers)
1 million ton/year of waste i d hi h
Sourcing of Waste Paper Challenges
paper is recovered which works out to be 20%. Potential for recovering 4
illi t / I I dimillion ton/year. In India, no institutional set up for recycling of waste paper.60% of the waste paper required is imported.Cost of imported waste paper is high due to non availability.
Source: All about paper; Green Rating project - CSE
Water
Paper Industry - Mass BalanceAverage Indian Mill
INPUT: 124 TONS Conversion Efficiency=0.80%
Wood / Fiber Losses: 7 TONS
y
Wood / Fiber1.9 MT
Water120 MT
Gaseous Emissions
OUTPUT: 1 TON
Vapor Loss
Losses: 7 TONS
120 MT
Fuel1.6 MT
Paper
PAPER MAKING PROCESS
Chemical0.50 MT
Waste
Waste: 116TONS
Waste Water Solid Waste
High Consumption is due to:
Water Management Challenges
Bleaching & paper making process together consume 71% of total water consumption.Sp. water consumption of an Indian mill is 120m3/MT p pagainst the global best of 40m3/MT
Energy
Energy Management European Paper mill Indian Paper mill
# Swedish pulp and paper Industry meets 83% of it’s energy demand through waste biomass. In India, higher dependence on fossil fuel increases GHG emissions and higher waste generation. # Avg. Energy consumption for an Indian Mill is 50GJ/BDMT, twice the European bestSource: All about Paper, Centre for Science and Environment, Green Rating Project
ITC Approach
ITC Li it dITC LimitedThe only company in the world of its size to be
Carbon positive ( last 5 years ) Water positive ( last 8 years ) Waste Recycling Positive ( last 3 years )Waste Recycling Positive ( last 3 years )
Fiber Sourcing – ITC Approach
Sourcing of Wood: ITC Approach99.42% of Bhadrachalam mill’s total wood requirement in 2009-10 came from plantations under agro-forestry initiatives. Company has enabled a cumulative plantation coverage of 1,07,000 hectares as on 30th Sept 2010.Provided 48 million persondays of employment to tribals and marginal farmers
Sourcing of Wood: ITC ApproachDuring 2009-10, 2,082 hectares were brought under Social Forestry plantations, expanding the cumulative total to 16,442 hectares. The Social Forestry project to date has created sustainable livelihood opportunities for 19,376 poor h h ld h h dhouseholds who have earned an average of Rs31,000 per farmer This has led to a potential earning of 57,799 CER annually for 30 years under CDM–EB of the UNFCCC
In India more than 800 million people liveunder $ 2 a day according to World Bankdata. – ITC Sustainability Report 2009Source : ITC Sustainability Report 2010
Sourcing of Wood Fiber –ITC A hITC Approach
90127
1,00,000100000
120000Area planted (Hectares) from 1992 to 2009
65037
80152
90127
60000
80000
19579
29241
4089140000
60000
16 55 216 455 1245 2004 3207 4561 6139 858612773
19579
0
20000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
As on date we have covered more than 1,15,000 hectares under plantations
Sourcing of Wood Fiber –ITC A hGFTN is a WWF initiative to eliminate illegal logging and i th t f l bl d th t d
ITC Approach
improve the management of valuable and threatened forests, while encouraging sustainable forest management practices and minimizing the forest footprint of industries trading in or procuring forest goodstrading in or procuring forest goods.ITC’s Paperboards and Specialty Papers business, a pioneer in ECF technology, and the only producer of ozone-bl h d l i I di i b f WWF GFTNbleached pulp in India is now a member of WWF GFTN (World Wildlife Fund – Global Forest & Trade Network), since July 1, 2009.
Monitoring Sustainability of FiberThe ITC Plantations are
d i tmapped using remote sensing technique through National Remote Sensing Agency (NRSA)Agency (NRSA). The GIS data base is maintained for plantations to provide vital information onprovide vital information on periodic wood generation.
Source: ITC Sustainability Report 2008
Carbon Sequestration by ITC
CO2 Sequestration U it 03 04 04 05 05 06 06 07 07 08 08 0 09 10
qFigures
Unit 03‐04 04‐05 05‐06 06‐07 07‐08 08‐0 09‐10
CO2 released (Manufacturing &
Freight)Kilo Tonne 1013 1058 1202 1143 1352 1572 1709
Freight)
CO2 Sequestration Kilo Tonne 311 906 1244 2025 2638 3695 4785
% 31 86 104 177 195 235 280
Source: ITC Sustainability Report 2010
Sourcing of Waste Paper - ITC ApproachOver 60% of all recycled fiber used in India is importedITC has initiated Wealth Out of Waste (WOW) campaign to recover the waste paper from households and corporate.Partnered with:
Local Governmental Authorities (Municipal Corporation)CorporateNGOs and Rag pickersNGOs and Rag pickers
In the process of developing a Supply chain to collect waste from households, segregation at source and transportation to the mill is arranged.the mill is arranged.
Water Management – ITC Approach
Water Management StandardsSpecific water consumption
Cubic meters per metric ton of paper production
ITC Bhadrachalam: Specific water consumption of mill for period April – Aug 2009
Source: National Productivity Council New DelhiSource: National Productivity Council, New DelhiFinal report on water conservation in pulp and paper sector.Table 14: Region/Country specific average water consumption in large scale wood based pulp and paper mills, (Page 48/115)h
Water Management at ITCWaste Water Discharge: Indian Standards
Standard Discharge (KL/MT)
CREP 100
Benchmark * 50
Best Achievable *
53
Relaxed Standard * 63
Bhadrachalam 53.9
Source: National Productivity Council, New DelhiFinal report on water conservation in pulp and paper sector.
Source: ITC Sustainability Report 2009y p
Quality of Waste Water:Ad b bl O i
Water Management at ITCAOX (K /T )Adsorbable Organic
Halides (AOX) have been reduced to a mere 0.0074 Kg/tonne of production
(Kg/Ton)
Bhadrachalam Mill 0.0074
Kg/tonne of production during 2008-09 against CREP guideline of 1.0 kg/ton by March 2009.
Indian Paper/Paperboards Mills*
0.46-0.8
European Paper Industries# 0.03kg/ton by March 2009.
World Bank Standard** 0.2
* Average as per Comprehensive Industry Document for Large Scale Paper Mills, study conducted by Central Pulp & Paper Research Institute, 2007
# Confederation of European Paper Industries- Sustainability Report 2007p p y p
** World Bank Guideline for New Paper MillsSource: ITC Sustainability Report 2009
33
Energy Management – ITC Approach
Energy Management at ITC
-Commissioning of Green Boiler will result in coal saving of 1,20,000MT/annum Post Green boiler,
2.5 Lac MT of biomass= 1.70Lac MT of coal equivalent of 4500kcal/kg GCV 1.70Lac MT of coal equivalent of 4500kcal/kg GCV = 2.9LacMT/Year of CO2 emission reduction
C ti t ITCCogeneration at ITC96% self sufficiency through cogenerationHigh pressure steam generation from recovery boilers for power generationAFBC boilers to fire low grade fuel at higher thermal g gefficiencyBack pressure and Extraction cum back pressure steam turbine combination to achieve higher efficiency. g yIsland mode operation to optimize generation frequency
Energy Management at ITC
(in GJ/BDMT)
Source: Indian: All About Paper, Green Rating Project, CSE – 2004, Page 191European Union (EU): European Commission, Reference document for Best Available Techniques in the Pulp & Paper Industry 2001 – Energy consumption for integratedTechniques in the Pulp & Paper Industry 2001 Energy consumption for integrated bleached Kraft mill, Page 89 ITC-BCM: Based on primary energy consumption for year 2008-09, International Paper: All About Paper, Green Rating Project, CSE – 2004, Page 192
C b C dit f ITCCarbon Credits for ITCRegistered 7 CDM projects with UNFCCC
6 projects from Energy Efficiency & Energy Conservation1 project from Social Forestryp j y
Potential to generate 18.5 Lac CERs over 10 year periodUNFCCC has issued 2.28 Lac CERs till date
Solid Waste – ITC Approach
Solid Waste Management
100% recycling of fly ash through brick manufacturing & cement manufacturing 100% recycling of lime sludge through supply to cement manufacturing
Solid Waste Management at ITCPlastic Waste:
Off site sorting of waste paper Recycling of plastics and metalsIn process equipments for separationIn process equipments for separation Development of entrepreneurship to recycle separated plastics
Clean Technologies at ITC
Clean Technologies
M/s Metso supplied high capacity chippers. Reduction in fines generation from 3.5%to less than 2%Reduction in chemical consumption for cooking due to uniform sized chips..
Clean TechnologiesOxygen Delignification
BLS recovered per ton of blown pulp increased from 1.7 to 2.1Increased biomass component in energy mixReduced water pollutionImprovement in pulp brightnessR d d bl hi h i lReduced bleaching chemicalsReduction of Kappa no. by 40%
Clean Technologies
M/s Metso supplied Fiberline First ECF Fiberline in IndiaFirst ECF Fiberline in IndiaFirst Lite ECF Fiberline with Ozone Bleaching
Clean TechnologiesOzone Bleaching: Colour effluent
46
Extending Sustainability through g y gour Products
FSC - Forest Stewardship Council headquartered in Bonn, G i i d d t t l t fGermany is an independent, non-governmental, not for profit organization established to promote responsible management of the world’s forests.
B th Bh d h l d K i it FSC C tifi d dBoth Bhadrachalam and Kovai units are FSC Certified and Tribeni and Bollaram will be certified within this year
FSC - Forest Management Certification is on and is expectedt b l t d thito be completed this year
Displaying our sustainability commitmentwww.itcgreenpapers.com
The website is a platform to discuss and understand sustainability and environmental topics relevant to the pulp, paper and packaging industry. The website also showcases our green operations and products. provides information to people looking for environmentally responsible paper and paperboards. www.itcgreenpapers.com will serve as an interactive tool, and will gradually expand to include Newsletters and Discussion Forumsgradually expand to include Newsletters and Discussion Forums.
WWF – Check Your Paper• Check Your Paper (CYP) is a user friendly tool designed by WWF to
facilitate transparency on environmental performance in the paper industry by helping the buyer in estimating the environmental footprint of the papers / paperboards they buy.
• ITC PSPD’s Unit Kovai has rated 2 of its products Coated Board Grey Back and Coated Board White Back on the website.
• The ratings can be viewed at http://checkyourpaper.panda.org/
Displaying our sustainability commitment
S stainable prod cts Biobarrier BoardsSustainable products - Biobarrier Boards
Introduction of Biopolymer Coated Papers for food and beverages especially paper cups Biopolymer coatingbeverages - especially paper cups. Biopolymer coating makes the cups biodegradable in a composting environment Poly Lactic Acid – Biodegradable biopolymer, Made from renewable sources (maize, wheat)( , )Properties are comparable to LDPEClassified as GRAS (Generally recognized As Safe) by FDA, US
Replacing 10 Million poly coated paper cups every month with PLA coated paper cups would lead to an overall Carbon Dioxide (CO2) reduction of approximately 220 Tons per year. This in turn translates to the followingEli i i h l l b f i ( l CO i iEliminating the total annual carbon footprint (annual CO2 emissions equivalents) from driving 40 passenger vehicles each year (million Kms in one year)
Our PLA based products under the umbrella brand of OmegaOur PLA based products under the umbrella brand of Omega provides a sustainable alternative to barrier coating.
www.natur-tec.com
Life Cycle Analysis – a tool to d istudy impacts
LCA studies for various products have been conducted in Europe for nearly 10 years and covers various impacts that a product has on the environment – land, water, air, plant, animal and human health.Usually commences with defining the scope of the study and the boundaries which can vary from Cradle to Gate , Cradle to Grave y ,and Cradle to CradleThe measure covers all raw material inputs , inward freight , processes , outputs, outward freight and further usage and disposaldisposalOnce these parameters are measured , weightages based on their impacts are given by a base inventory data which is then fed into a calculation mechanism to arrive at a single number –normally given as CO2 equivalentnormally given as CO2 equivalent.ITC has the ability to conduct LCA studies backed by software acquired from PE International. We have planned to use the tool to assess Paperkraft Copier and l f d t O l i LCA halso one more of our product . Our learning curve on LCA has
just now begun
Working together : between IndustriesArrive at norms for green products - especially paper paper cups and other related stationery other thanpaper, paper cups and other related stationery other than packaging Explore areas where recyclable waste can be responsibly disposed - for example our WOW programresponsibly disposed for example our WOW program Evolve green manufacturing technologies knowledge exchange programs in common areas of operations like -power, waste, effluents etc Nominate, procure and use higher rated products in rating systems like Greenco rating systemStart adopting LCA methodology in determining impacts p g gy g pof the products in the supply chain
Working together : Industry & Government Stipulate green credentials at the material level without any ambiguity encourage adoption of the Greenco ratingany ambiguity – encourage adoption of the Greenco rating and other recognised labelsEncourage products with the least impact on resources and that are sustainable and provide necessary incentivesand that are sustainable and provide necessary incentives
SummaryWaste Lands for Plantations
Industry / State PartnershipNational Recycle Drive
Public / Private partnershipPublic / Private partnershipEnergy and Water conservation Zero solid waste dumpingCleaner Technologies
54
$$$Money does grow on trees$$$with a bit of effortwith a bit of effort
Thank YouThank You