paper making
TRANSCRIPT
EUROPEAN COMMISSIONDIRECTORATE-GENERAL JRC JOINT RESEARCH CENTRE Institute for Prospective Technological Studies Sustainability Production and Consumption Unit European IPPC Bureau
Integrated Pollution Prevention and Control Draft Reference Document on Best Available Techniques in the
W O
R
Edificio EXPO, c/Inca Garcilaso 3, E-41092 Seville - Spain Tel. (direct line) +34 95448-8284, (switchboard) +34 95448-8318. Fax: +34 95448-8426. Internet: http://eippcb.jrc.ec.europa.eu. E-mail: [email protected]
KI
N
G
D
R
AF
Pulp and Paper IndustryDraft April 2010
T
IN
PR O
G R
ES S
This document is one from the series of documents listed below: Reference Document on Best Available Techniques . . .Large Combustion Plants Mineral Oil and Gas Refineries Production of Iron and Steel Ferrous Metals Processing Industry Non Ferrous Metals Industries Smitheries and Foundries Industry Surface Treatment of Metals and Plastics Cement, Lime and Magnesium Oxide Manufacturing Industries Glass Manufacturing Industry Ceramic Manufacturing Industry Large Volume Organic Chemical Industry Manufacture of Organic Fine Chemicals Production of Polymers Chlor-Alkali Manufacturing Industry
CodeLCP REF I&S FMP NFM SF
PR O
Large Volume Inorganic Chemicals Ammonia, Acids and Fertilisers Industries Large Volume Inorganic Chemicals Solids and Others industry Production of Speciality Inorganic Chemicals
IN
Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical Sector Waste Treatments Industries Waste Incineration
T
AF
Management of Tailings and Waste-Rock in Mining Activities Pulp and Paper Industry Textiles Industry
R
D
N
Tanning of Hides and Skins
G
Food, Drink and Milk Industries Intensive Rearing of Poultry and Pigs
KI
Slaughterhouses and Animals By-products Industries
R
W O
Surface Treatment Using Organic Solvents Industrial Cooling Systems Emissions from Storage Energy Efficiency
Reference Document . . . General Principles of Monitoring Economics and Cross-Media Effects MON ECM
Electronic versions of draft and finalised documents are publicly available and can be downloaded from http://eippcb.jrc.ec.europa.eu/.
G RSIC WT WI PP SA ICS
ES SSTM CLM GLS CER LVOC OFC POL CAK LVIC-AAF LVIC-S CWW MTWR TXT TAN FDM IRPP STS EFS ENE
Executive Summary
EXECUTIVE SUMMARY[EIPPCB will completely rewrite this section for the final document.]
W O
R
i
KI
N
G
D
R
AF
T
INApril 2010 MS/EIPPCB/PP_Draft_1
PR O
G R
ES S
W O KI N G D R AF T IN PR O
R
G R
ES S
Preface
PREFACE[EIPPCB will update this section for the second draft.] 1. Status of this document Unless otherwise stated, references to the Directive in this document refer to the Directive 2008/1/EC of the European Parliament and the Council concerning integrated pollution prevention and control (IPPC). As the IPPC Directive applies without prejudice to Community provisions on health and safety at the workplace, so does this document. This document is a working draft of the European IPPC Bureau. It is not an official publication of the European Communities and does not necessarily reflect the position of the European Commission.
2.
Relevant legal obligations of the IPPC Directive and the definition of BAT
W O
The term best available techniques is defined in Article 2(12) of the Directive as the most effective and advanced stage in the development of activities and their methods of operation which indicate the practical suitability of particular techniques for providing in principle the basis for emission limit values designed to prevent and, where that is not practicable, generally to reduce emissions and the impact on the environment as a whole. Article 2(12) goes on to clarify further this definition as follows: techniques shall include both the technology used and the way in which the installation is designed, built, maintained, operated and decommissioned; available techniques means those developed on a scale which allows implementation in the relevant industrial sector, under economically and technically viable conditions, taking into consideration the costs and advantages, whether or not the techniques are used or produced inside the Member State in question, as long as they are reasonably accessible to the operator; best means those most effective in achieving a high general level of protection of the environment as a whole.
R
MS/EIPPCB/PP_Draft_1
KI
N
More specifically, the Directive provides for a permitting system for certain categories of installations requiring both operators and regulators to take an integrated, overall view of the potential of the installation to consume and pollute. The overall aim of such an integrated approach must be to improve the design, construction, management and control as well as decommissioning of industrial processes so as to ensure a high level of protection for the environment as a whole. Central to this approach is the general principle given in Article 3 of the Directive which states that operators should take all appropriate preventative measures against pollution, in particular through the application of the best available techniques enabling them to improve their environmental performance.
G
D
R
AF
T
The purpose of the IPPC Directive is to achieve integrated pollution prevention and control arising from the activities listed in its Annex I, leading to a high level of protection of the environment as a whole. The legal basis of the Directive relates to environmental protection. Its implementation should also take account of other European Community objectives such as the competitiveness of the industry of the Community thereby contributing to sustainable development.
IN
April 2010
PR O
In order to help the reader understand the legal context in which this document has been drafted, some of the most relevant provisions of the IPPC Directive including the definition of the term best available techniques are described. This description is given for information only. It has no legal value and does not in any way alter or prejudice the actual provisions of the IPPC Directive.
G R
ES S
iii
Preface
Furthermore, Annex IV to the Directive contains a list of considerations to be taken into account generally or in specific cases when determining best available techniques ... bearing in mind the likely costs and benefits of a measure and the principles of precaution and prevention. These considerations include the information published by the Commission pursuant to Article 17(2) of the Directive. Competent authorities responsible for issuing permits are required to take account of the general principles set out in Article 3 of the Directive when determining the conditions of the permit. These conditions must include emission limit values, supplemented or replaced where appropriate by equivalent parameters or technical measures. According to Article 9(4) of the IPPC Directive, these emission limit values, equivalent parameters and technical measures must, without prejudice to compliance with environmental quality standards, be based on the best available techniques, without prescribing the use of any technique or specific technology, but taking into account the technical characteristics of the installation concerned, its geographical location and the local environmental conditions. In all circumstances, the conditions of the permit must include provisions on the minimisation of long-distance or transboundary pollution and must ensure a high level of protection for the environment as a whole.
3.
Objective of this document
The aim of this series of documents, which will be continually reviewed and updated, is to accurately reflect the exchange of information which has taken place as required by Article 17(2) of the Directive and to provide reference information for the permitting authority to take into account when determining permit conditions. By providing relevant information concerning best available techniques, these documents should act as valuable tools to drive environmental performance. 4. Information sources
W O
This document represents a summary of information collected from a number of sources, in particular, through the expertise of the groups established to assist the Commission in its work under Article 17(2) of the Directive, and verified by the Commission services. The work of the contributors and the expert groups is gratefully acknowledged. 5.iv
How to understand and use this documentApril 2010 MS/EIPPCB/PP_Draft_1
R
KI
The Commission established an information exchange forum (IEF) to assist the work under Article 17(2) of the Directive and a number of technical working groups have been established under the umbrella of the IEF. Both IEF and the technical working groups include representation from Member States and industry as required in Article 17(2) of the Directive.
N
G
D
should help to redress the technological imbalances in the Community should promote the worldwide dissemination of limit values and techniques used in the Community and should help the Member States in the efficient implementation of this Directive.
R
AF
The purpose of the information exchange is given in recital 27 of the Directive, which states that the development and exchange of information at Community level about best available techniques:
T
IN
Article 17(2) of the Directive requires the Commission to organise an exchange of information between Member States and the industries concerned on best available techniques, associated monitoring and developments in them, and to publish the results of the exchange.
PR O
Member States have the obligation, according to Article 11 of the Directive, to ensure that competent authorities follow or are informed of developments in the best available techniques.
G R
ES S
Preface
The information provided in this document is intended to be used as an input to the determination of BAT in specific cases. When determining BAT and setting BAT-based permit conditions, account should always be taken of the overall goal to achieve a high level of protection for the environment as a whole. The rest of this section describes the type of information that is provided in each chapter of the document. Chapters 1 and 2 and the first sections of Chapters 3 to 7 provide general information on the pulp and paper industry and on the industrial processes used within this sector. Data and information concerning current emission and consumption levels are then presented in the second sections of Chapters 3 to 7 reflecting the situation in existing installations in operation at the time of writing. The third sections of Chapters 3 to 7 describe in more detail the emission reduction and other techniques that are considered to be most relevant for determining BAT and BAT-based permit conditions. This information includes the consumption and emission levels considered achievable by using the technique, some idea of the costs and the cross-media issues associated with the technique. It also includes the extent to which the technique is applicable to the range of installations requiring IPPC permits, for example new, existing, changed, large or small installations. Techniques that are generally seen as obsolete are not included. A conclusion section on best available techniques in each of the Chapters 3 to 7 presents the techniques and the emission and consumption levels that are considered to be compatible with BAT in the sector. The purpose is thus to provide general indications regarding the emission and consumption levels that can be considered as an appropriate reference point to assist in the determination of BAT-based permit conditions or for the establishment of general binding rules under Article 9(8) of the Directive. It should be stressed, however, that this document does not propose emission limit values. The determination of appropriate permit conditions will involve taking account of local, site-specific factors such as the technical characteristics of the installation concerned, its geographical location and the local environmental conditions. In the case of existing installations, the economic and technical viability of upgrading them also needs to be taken into account. Even the single objective of ensuring a high level of protection for the environment as a whole will often involve making trade off judgements between different types of environmental impact, and these judgements will often be influenced by local considerations. Although an attempt is made to address some of these issues, it is not possible for them to be considered fully in this document. The techniques and levels presented in the conclusion section on Best Available Techniques in each of the Chapters 3 to 7 will therefore not necessarily be appropriate for all installations. On the other hand, the obligation to ensure a high level of environmental protection including the minimisation of long-distance or transboundary pollution implies that permit conditions cannot be set on the basis of purely local considerations. It is therefore of the utmost importance that the information contained in this document be fully taken into account by permitting authorities. All comments and suggestions should be made to the European IPPC Bureau at the Institute for Prospective Technological Studies at the following address: European Commission Institute for Prospective Technological Studies Edificio Expo c/ Inca Garcilaso, 3 E-41092 Seville, Spain Telephone: +34 95 4488 284 Fax: +34 95 4488 426MS/EIPPCB/PP_Draft_1 April 2010 v
W O
R
KI
N
G
D
R
AF
T
IN
PR O
G R
ES S
Preface
e-mail: [email protected] Internet: http://eippcb.jrc.ec.europa.eu 6. Dynamic nature of BAT and review of BAT reference documents (BREFs)
BAT is a dynamic concept because new techniques may emerge, technologies are still developing, or new environmental processes are being successfully introduced in the industry. Since the elements of BAT change over time and industry develops, BREFs have to be reviewed and updated as appropriate. The original BREF on the Paper and Pulp Industry was adopted by the European Commission in [Author: insert the year the BREF was adopted]. This document is the result of the review of the Paper and Pulp Industry BREF.
W O
vi
R
KI
N
G
D
R
AF
April 2010
T
INMS/EIPPCB/PP_Draft_1
PR O
G R
ES S
Best Available Techniques Reference Document on Pulp and Paper IndustryEXECUTIVE SUMMARY.........................................................................................................................I PREFACE................................................................................................................................................ III SCOPE ................................................................................................................................................. XXV 1 GENERAL INFORMATION ........................................................................................................... 1 1.1 Paper consumption in Europe .................................................................................................... 1 1.2 Overview of pulp and paper manufacturing............................................................................... 4 1.3 The European pulp industry ....................................................................................................... 7 1.4 The European paper industry ................................................................................................... 12 1.5 Types of pulp and paper mills in Europe.................................................................................. 17 1.5.1 Classification of paper mills from a commercial point of view ..................................... 17 1.5.2 Classification of pulp and paper mills from an environmental point of view ................ 18 1.6 Economics and employment in the EU paper industry ............................................................ 21 1.7 Main environmental issues of the production of pulp and paper.............................................. 25 1.8 Major commitments and activities of the European Paper industry related to the environment .................................................................................................................................................. 32 GENERAL PROCESSES AND TECHNIQUES .......................................................................... 33 2.1 Best available techniques approach for pulp and paper mills................................................... 34 2.2 BAT for integrated and multi-product pulp and paper mills .................................................... 35 2.2.1 Definition of non-integrated, integrated and multi-product mills .................................. 35 2.2.2 Approach to establish and to verify BAT for integrated mills ....................................... 36 2.2.3 Proposed method for assessing BAT-AELs for specific waste water discharges .......... 37 2.3 Receipt, storage and handling of fibrous materials and chemicals........................................... 40 2.3.1 Wood handling............................................................................................................... 40 2.3.1.1 Wood yard operations ............................................................................................ 40 2.3.1.2 Debarking............................................................................................................... 41 2.3.2 Sorting, handling and storage and of recovered paper ................................................... 42 2.3.3 Storage and handling of chemicals and chemical additives ........................................... 44 2.3.3.1 Use of basic chemicals and chemical additives...................................................... 44 2.3.3.2 EU regulations on the storage, handling and use of chemicals .............................. 48 2.3.3.3 Storage, handling and transportation of chemicals................................................. 49 2.4 Water supply for processes and cooling................................................................................... 50 2.4.1 Raw water treatment ...................................................................................................... 50 2.4.1.1 Process water treatment.......................................................................................... 50 2.4.1.2 Boiler feedwater treatment ..................................................................................... 50 2.4.2 Cooling systems and use of cooling water ..................................................................... 51 2.4.2.1 Types of cooling systems in pulp and paper mills ................................................. 51 2.4.2.2 Cooling water and the BAT-AELs for specific process effluents .......................... 53 2.5 Energy consumption in pulp and paper mills ........................................................................... 55 2.5.1 Aspects needing consideration when reading reported energy consumption data ......... 55 2.5.2 Typical total process energy consumption of pulp and paper mills ............................... 58 2.5.3 Relevance of process units for total process energy consumption ................................. 60 2.5.4 Energy consumption for supporting activities................................................................ 61 2.6 Steam and power generation in pulp and paper mills............................................................... 63 2.6.1 Applied combustion processes and techniques .............................................................. 63 2.6.1.1 Main fuels utilised and pretreatment ...................................................................... 64 2.6.1.2 Energy recovery ..................................................................................................... 66 2.6.1.3 Fluidised bed boilers .............................................................................................. 69 2.6.2 Current consumption and emissions levels .................................................................... 71 2.6.2.1 Emissions to air ...................................................................................................... 71 2.6.2.2 Waste from combustion plants (ash, slag).............................................................. 77 2.7 Effluent treatment..................................................................................................................... 78 2.8 Management of production residues and solid waste............................................................... 80 2.8.1 Types of generated process-specific residues/waste ...................................................... 80 2.9 General techniques to consider in the determination of BAT common to all mills ................. 82 2.9.1 Environmental management tools.................................................................................. 82
2
W O
R
MS/EIPPCB/PP_Draft_1
KI
N
G
D
R
AF
T
IN
April 2010
PR O
G R
ES S
vii
3
THE KRAFT (SULPHATE) PULPING PROCESS ...................................................................181 3.1 Applied Processes and Techniques.........................................................................................181 3.1.1 Reception and storage of wood.....................................................................................182 3.1.2 Debarking .....................................................................................................................183 3.1.3 Wood chipping and screening ......................................................................................183 3.1.4 Cooking and delignification .........................................................................................183 3.1.5 Washing and screening.................................................................................................185 3.1.6 Oxygen delignification .................................................................................................186 3.1.7 Bleaching......................................................................................................................187 3.1.8 Bleached stock screening..............................................................................................190 3.1.9 Drying...........................................................................................................................190 3.1.10 By-products of kraft pulping ........................................................................................190 3.1.11 Chemical and energy recovery system .........................................................................190 3.1.12 Preparation of bleaching chemicals on site...................................................................192 3.1.12.1 Chlorine dioxide ...................................................................................................192 3.1.12.2 Ozone....................................................................................................................196 3.1.12.3 Other bleaching chemicals....................................................................................196 April 2010 MS/EIPPCB/PP_Draft_1
W O
viii
R
KI
Training and commitment of staff ..................................................................................89 Techniques to reduce emissions from handling and storage of raw materials................91 Reduce environmental impacts from wood handling .............................................91 Dry debarking .........................................................................................................92 Recovered paper storage.........................................................................................94 Safe storage and handling of basic chemicals and chemical additives ...................94 Environmental assessment system for chemicals ...................................................95 Substitution of potentially harmful substances for less harmful alternatives..........96 Systematic approach towards water management ..........................................................99 Model-based evaluation of optimisation measures for water circuits...........................102 Energy efficiency analysis, energy management and energy audits.............................105 Reduction of energy consumption applicable to all/most grades..................................108 Reduction of thermal energy use ..........................................................................109 Reduction of electrical energy use........................................................................113 Reduction of air emission of multifuel, biomass and auxiliary boilers.........................115 Reduction of dust (particulate matter) emissions..................................................116 Reduction of NOX emissions ................................................................................118 Reduction of SO2 and other gaseous pollutants ....................................................125 Monitoring of emissions in pulp and paper mills .........................................................129 Complete data production and reporting of emissions in pulp and paper mills ....129 Relevant emission sources, capture of total emissions and operational conditions considered.............................................................................................................130 2.9.10 Emission data production in pulp and paper mills........................................................131 2.9.10.1 Waste water discharges.........................................................................................131 2.9.10.2 Emissions to air ....................................................................................................137 2.9.11 Reporting emission data ...............................................................................................147 2.9.11.1 Variation of emissions during different reference periods....................................148 2.9.11.2 Reasons for variations of emissions and counteractions.......................................150 2.9.12 Prevention, minimisation, recycling and treatment of process residues minimising solid waste to landfill....................................................................................................151 2.9.13 Reduction of emissions from the use of chelating agents in the peroxide stages of the bleach plant...................................................................................................................155 2.9.14 Ensuring smooth running and minimising accidental releases .....................................160 2.9.15 Control of biological waste water treatment plants nutrient supply and the retention of nitrogen, phosphorus and total suspended solids..........................................................162 2.9.16 Prevention of pollution risks from decommissioning ...................................................166 2.9.17 Reduction of noise ........................................................................................................170 2.9.18 Reduction of odour .......................................................................................................173 2.10 General Best Available techniques .........................................................................................177 2.11 Emerging techniques ..............................................................................................................178 2.11.1 General trends in the pulp and paper sector..................................................................178 2.11.1.1 Bio ........................................................................................................................178 2.11.1.2 Integrated ..............................................................................................................178 2.11.1.3 Simplified .............................................................................................................178 2.11.1.4 Diversity techniques .............................................................................................179
N
G
D
R
AF
T
IN
PR O
G R
2.9.2 2.9.3 2.9.3.1 2.9.3.2 2.9.3.3 2.9.3.4 2.9.3.5 2.9.3.6 2.9.4 2.9.5 2.9.6 2.9.7 2.9.7.1 2.9.7.2 2.9.8 2.9.8.1 2.9.8.2 2.9.8.3 2.9.9 2.9.9.1 2.9.9.2
ES S
3.2 Present consumption/emission level for integrated and non-integrated mills ........................ 197 3.2.1 Overview of input/output of the production of kraft pulp ............................................ 197 3.2.2 Consumption and emission levels arising from process units...................................... 198 3.2.2.1 Wood consumption .............................................................................................. 198 3.2.2.2 Water consumption and waste from different process steps ................................ 198 3.2.2.3 Emissions to the atmosphere ................................................................................ 206 3.2.2.4 Solid waste generation ......................................................................................... 221 3.2.2.5 Consumption of chemicals ................................................................................... 223 3.2.2.6 Use of energy ....................................................................................................... 225 3.2.2.7 Noise (local)......................................................................................................... 230 3.2.2.8 Emission to soil and groundwater ........................................................................ 230 3.3 Techniques to consider in the determination of BAT............................................................. 232 3.3.1 The relevance of the wood species when determining BAT for kraft pulp mills......... 236 3.3.2 Dry debarking .............................................................................................................. 236 3.3.3 Extended modified cooking (batch or continuous) to a low kappa value..................... 236 3.3.4 Closed screening .......................................................................................................... 239 3.3.5 Oxygen delignification................................................................................................. 240 3.3.6 ECF bleaching.............................................................................................................. 242 3.3.7 TCF bleaching technique ............................................................................................. 245 3.3.8 Partial closure of the bleach plant ................................................................................ 248 3.3.9 Collection of most spillages ......................................................................................... 250 3.3.10 Efficient washing and process control ......................................................................... 252 3.3.11 Stripping of the most concentrated contaminated condensates and the reuse of most condensates in the process ........................................................................................... 253 3.3.12 Use of correctly dimensioned buffer tanks for the storage of concentrated or hot liquids from the process ........................................................................................................... 256 3.3.13 Aerobic biological treatment and total emissions to water .......................................... 257 3.3.14 Tertiary treatment of waste water with chemical precipitation .................................... 265 3.3.15 Efficient system for collection and treatment of strong and weak malodorous gases with high availability ........................................................................................................... 266 3.3.15.1 Incineration of the collected strong and/or weak gases in the recovery boiler..... 272 3.3.15.2 Incineration of collected odorous gases (strong and weak gases) in the lime kiln274 3.3.15.3 Incineration of odorous gases (strong and weak gases) by use of a separate furnace equipped with scrubbers for SO2 removal............................................................ 275 3.3.16 Reduction of sulphur emissions (SO2 and TRS) from the recovery boiler................... 276 3.3.16.1 Increasing the dry solids content of black liquor.................................................. 276 3.3.16.2 Installation of scrubbers on the recovery boiler ................................................... 279 3.3.17 Control of NOx emissions on recovery boilers ............................................................ 281 3.3.17.1 Minimising emissions from the recovery boiler by controlling the firing conditions (low NOx and CO emissions) ............................................................................... 281 3.3.17.2 Over fire air technique (additional air feeding level) on recovery boilers............ 285 3.3.17.3 Total NOx emissions from the processes.............................................................. 288 3.3.17.4 Secondary measures for NOx reduction ............................................................... 291 3.3.18 Reduction of dust emission from the recovery boiler .................................................. 293 3.3.18.1 Electrostatic precipitators..................................................................................... 293 3.3.18.2 Electrostatic precipitators followed by scrubbers................................................. 297 3.3.19 Reduction of sulphur emissions (SO2 and TRS) from the lime kiln ............................ 299 3.3.19.1 Selection of fuels.................................................................................................. 299 3.3.19.2 Installation of improved washing of lime mud in recausticising.......................... 299 3.3.20 Reduction of NOx, CO and TOC emission from the lime kiln..................................... 300 3.3.20.1 Selection of fuels, process optimisation and lime kiln control............................. 300 3.3.20.2 Installation of low-NOx burners in the lime kiln ................................................. 301 3.3.21 Reduction of dust emissions from the lime kiln........................................................... 302 3.3.21.1 Electrostatic precipitators..................................................................................... 302 3.3.21.2 Electrostatic precipitators followed by scrubbers................................................. 304 3.3.22 Substitution of fossil fuels for bark gasifier ................................................................. 305 3.3.23 Reduction of dust emissions from the bark boiler........................................................ 305 3.3.24 SNCR on bark boilers .................................................................................................. 305 3.3.25 Integrated waste management concept......................................................................... 305 3.3.26 Measures for increased energy efficiency .................................................................... 306 3.3.27 Techniques for noise reduction .................................................................................... 307 3.4 Best Available Techniques..................................................................................................... 308 3.5 Emerging techniques .............................................................................................................. 308
W O
R
MS/EIPPCB/PP_Draft_1
KI
N
G
D
R
AF
T
IN
April 2010
PR O
G R
ES S
ix
3.5.1 3.5.2 3.5.3 3.5.4 4
Gasification of black liquor ..........................................................................................308 Use of SNCR on the recovery boiler ............................................................................311 Removal of chelating agents by modest alkaline biological treatment or by use of kidneys..........................................................................................................................313 Increased system closure combined with the use of kidneys........................................315
THE SULPHITE PULPING PROCESS ......................................................................................319 4.1 Applied processes and techniques ..........................................................................................322 4.1.1 Fibre line operations .....................................................................................................323 4.1.1.1 Wood handling .....................................................................................................324 4.1.1.2 Cooking and delignification of unbleached pulp ..................................................324 4.1.1.3 Screening and washing of unbleached pulp..........................................................325 4.1.1.4 Oxygen delignification and bleaching ..................................................................326 4.1.1.5 Fine screening and drying.....................................................................................328 4.1.2 Chemicals and Energy Recovery System .....................................................................328 4.1.3 By-products of sulphite pulping ...................................................................................330 4.1.4 Use of spent sulphite liquor in mills using the 'biorefinery concept' ............................331 4.1.5 Preparation and handling of sulphur dioxide and bleaching chemicals ........................332 4.1.6 The major groups of sulphite pulp mills in Europe ......................................................334 4.1.6.1 Acid bisulphite pulping for papermaking .............................................................334 4.1.6.2 Magnefite process.................................................................................................334 4.1.6.3 Dissolving sulphite pulp for the textile industry...................................................335 4.1.6.4 Speciality pulp for chemical applications .............................................................335 4.1.6.5 Neutral sulphite semi chemical pulp (NSSC) .......................................................338 4.2 Present consumption/emission levels .....................................................................................340 4.2.1 Overview of input/output..............................................................................................340 4.2.2 Consumption and emission levels arising from process units ......................................342 4.2.2.1 Wood consumption...............................................................................................342 4.2.2.2 Consumption of chemicals....................................................................................343 4.2.2.3 Energy consumption and carbon dioxide emissions .............................................343 4.2.2.4 Water use and emissions.......................................................................................347 4.2.2.5 Emissions to the atmosphere.................................................................................352 4.2.2.6 Solid waste generation ..........................................................................................357 4.2.2.7 Noise.....................................................................................................................359 4.3 Techniques to consider in the determination of BAT .............................................................360 4.3.1 Dry debarking...............................................................................................................365 4.3.2 Extended cooking to a low kappa.................................................................................365 4.3.3 Oxygen delignification .................................................................................................366 4.3.4 Closed screening...........................................................................................................368 4.3.5 Efficient washing and process control ..........................................................................368 4.3.6 Collection of most spillages .........................................................................................369 4.3.7 Totally chlorine free (TCF) bleaching ..........................................................................369 4.3.8 Partial closure of the bleach plant and increased evaporation ......................................372 4.3.9 Closed-loop bleaching in a sodium based sulphite mill using ultrafiltration, flotation and separation......................................................................................................................373 4.3.10 Reduction of emissions from the use of chelating agents in the peroxide stages of the bleach plant...................................................................................................................375 4.3.11 Neutralising of weak liquor before/inside the evaporation plant ..................................375 4.3.12 Pretreatment of waste water from the oxygen stages of the bleach plant in an ultrafiltration plant followed by aerobic treatment of the total effluent........................376 4.3.13 Evaporation of effluents from the alkaline extraction stage and incineration of the concentrates in a sodium liquor boiler..........................................................................379 4.3.14 Use of emergency and buffer tanks for concentrated liquids........................................382 4.3.15 Anaerobic pretreatment of the condensate and the highly COD-loaded effluent from the bleach plant followed by aerobic treatment of the total effluent ..................................382 4.3.16 Aerobic biological waste water treatment ....................................................................384 4.3.17 Tertiary treatment of waste water with chemical precipitation.....................................400 4.3.18 Optimising the Recovery Boiler by controlling the firing conditions...........................400 4.3.19 SNCR (ammonia or urea injection) on the recovery boiler ..........................................403 4.3.20 Installation of an ESP and multistage scrubbers on the recovery boiler recovery of chemicals and abatement of dust and SO2 emissions ...................................................407 4.3.21 Collection of odorous gases and diffuse process SO2 emissions and combustion in the recovery boiler or washing in scrubbers .......................................................................415
W O
x
R
KI
N
G
D
R
AF
April 2010
T
IN
PR O
MS/EIPPCB/PP_Draft_1
G R
ES S
Measures to prevent uncontrolled operational conditions and to reduce the consequences of accidents............................................................................................ 417 4.3.23 Reduction of energy consumption (energy efficiency) ................................................ 418 4.3.24 Techniques for noise reduction .................................................................................... 420 4.4 Best Available Techniques..................................................................................................... 421 4.5 Emerging Techniques............................................................................................................. 422 5 MECHANICAL PULPING AND CHEMI-MECHANICAL PULPING.................................. 423 5.1 Applied processes and techniques.......................................................................................... 425 5.1.1 Wood handling............................................................................................................. 425 5.1.2 Groundwood pulping ................................................................................................... 425 5.1.2.1 Grinding ............................................................................................................... 425 5.1.3 Refiner mechanical pulps............................................................................................. 426 5.1.4 Thermomechanical pulping (TMP).............................................................................. 427 5.1.5 Chemi-mechanical pulping .......................................................................................... 428 5.1.6 Screening and cleaning ................................................................................................ 430 5.1.7 Bleaching of mechanical pulps .................................................................................... 431 5.2 Present consumption/emission levels ..................................................................................... 433 5.2.1 Overview of input/output ............................................................................................. 433 5.2.2 Consumption and emission levels arising from process units...................................... 435 5.2.2.1 Wood consumption .............................................................................................. 436 5.2.2.2 Water use.............................................................................................................. 436 5.2.2.3 Waste water emissions ......................................................................................... 437 5.2.2.4 Emissions to the atmosphere ................................................................................ 439 5.2.2.5 Solid waste generation ......................................................................................... 440 5.2.2.6 Consumption of chemicals ................................................................................... 441 5.2.2.7 Energy use............................................................................................................ 442 5.2.2.8 Noise .................................................................................................................... 445 5.3 Techniques to consider in the determination of BAT............................................................. 446 5.3.1 Emission control from the wood yard .......................................................................... 448 5.3.2 Dry debarking .............................................................................................................. 448 5.3.3 Minimisation of fibre losses when removing impurities from the mechanical pulping process ......................................................................................................................... 449 5.3.4 Minimisation of the disposal of rejects to landfill by efficient dewatering and incineration with energy recovery................................................................................ 450 5.3.5 Efficient washing and process control ......................................................................... 451 5.3.6 Water recirculation in pulp and paper mill................................................................... 452 5.3.7 CTMP mill effluent treatmentclosing up the water circuits by use of evaporation and burning the concentrates .............................................................................................. 455 5.3.8 Application of cogeneration of heat and power (CHP) ................................................ 459 5.3.9 Heat recovery from TMP refiners ................................................................................ 459 5.3.10 Abatement of VOC emissions from steam releases ..................................................... 462 5.3.11 Emission optimised incineration of solid waste and energy recovery.......................... 462 5.3.12 Use of sufficiently large buffer tanks for storage of concentrated or hot liquids from the process ......................................................................................................................... 464 5.3.13 Secondary or biological waste water treatment............................................................ 465 5.3.14 Tertiary waste water treatment..................................................................................... 468 5.4 Best Available Techniques..................................................................................................... 469 5.5 Emerging techniques .............................................................................................................. 470 5.5.1 Use of new evaporation techniques as 'kidney' for the internal cleaning of process water ..................................................................................................................................... 470 5.5.2 New energy efficient TMP processes........................................................................... 471 RECOVERED PAPER PROCESSING....................................................................................... 473 6.1 Applied processes and techniques.......................................................................................... 474 6.1.1 Examples of recovered paper processing systems ....................................................... 478 6.1.1.1 Packaging paper and boards................................................................................. 478 6.1.1.2 Newsprint and simple writing and printing paper ................................................ 479 6.1.1.3 LWC/SC paper ..................................................................................................... 481 6.1.1.4 Tissue paper and market deinked pulp ................................................................. 482 6.2 Present consumption/emission levels of RCF-based paper mills ........................................... 484 6.2.1 Overview of input/output ............................................................................................. 484 6.2.2 Consumption and emission levels arising from process units...................................... 491 6.2.2.1 Recovered paper consumption ............................................................................. 492 April 2010 xi
4.3.22
W O
R
6
MS/EIPPCB/PP_Draft_1
KI
N
G
D
R
AF
T
IN
PR O
G R
ES S
W O
xii
R
KI
N
G
D
R
7
PAPERMAKING AND RELATED PROCESSES .....................................................................571 7.1 Applied processes and techniques ..........................................................................................572 7.1.1 Stock preparation..........................................................................................................572 7.1.2 Paper machine ..............................................................................................................572 7.1.3 Water circuits and fibre recovery .................................................................................575 7.1.4 Broke system ................................................................................................................577 7.1.5 Sizing (optional) ...........................................................................................................578 7.1.6 Coating (optional).........................................................................................................579 7.1.7 Dyeing of paper (optional) ...........................................................................................580 7.1.8 Addition of chemicals...................................................................................................581 7.1.9 Calendering (optional) ..................................................................................................581 7.1.10 Reeling/cutting/dispatch ...............................................................................................582 7.1.11 Examples of non-integrated paper mills in Europe.......................................................582 7.1.11.1 Uncoated wood-free printing and writing papers .................................................583 7.1.11.2 Coated wood-free printing and writing paper .......................................................583 7.1.11.3 Tissue paper..........................................................................................................584 7.1.11.4 Speciality paper ....................................................................................................584 7.2 Present consumption and emission levels of paper mills........................................................586 7.2.1 Overview of input/output..............................................................................................586 7.2.2 Consumption and emission levels ................................................................................589 7.2.2.1 Consumption of major raw material .....................................................................590 7.2.2.2 Water use ..............................................................................................................590 7.2.2.3 Use of additives ....................................................................................................593 7.2.2.4 Energy demand .....................................................................................................595 7.2.2.5 Waste water emissions..........................................................................................600 7.2.2.6 Solid waste generation ..........................................................................................603 7.2.2.7 Atmospheric emissions .........................................................................................605 7.2.2.8 Noise from paper machines (local) .......................................................................607 April 2010 MS/EIPPCB/PP_Draft_1
AF
6.2.2.2 Water use ..............................................................................................................492 6.2.2.3 Use of chemical additives .....................................................................................495 6.2.2.4 Energy demand .....................................................................................................496 6.2.2.5 Waste water emissions..........................................................................................500 6.2.2.6 Solid waste generation ..........................................................................................502 6.2.2.7 Emissions to the atmosphere.................................................................................506 6.2.2.8 Noise from paper machines ..................................................................................508 6.3 Techniques to consider in the determination of BAT .............................................................509 6.3.1 Separation of sealing and cooling water from contaminated process water and water reuse..............................................................................................................................513 6.3.2 Optimal water management, water loop separation and arrangement, countercurrent flows and internal water clarification ...........................................................................514 6.3.3 Closed water loops with in-line biological process water treatment.............................519 6.3.4 Removal of calcium from process waters.....................................................................522 6.3.5 Installation of an equalisation basin and primary treatment of waste water .................524 6.3.6 Anaerobic/aerobic biological waste water treatment ....................................................524 6.3.7 Aerobic biological treatment ........................................................................................532 6.3.8 Upgrading of stock preparation plants with decreased electricity consumption and emissions ......................................................................................................................535 6.3.9 Generation of clarified water from recovered paper processing with deinking ............540 6.3.10 Cogeneration of heat and power (CHP)........................................................................542 6.3.11 Effective reject and sludge handling and processing (dewatering) on-site...................545 6.3.12 Environmental sound residue utilisation and incineration............................................548 6.4 Best Available Techniques .....................................................................................................562 6.5 Emerging techniques ..............................................................................................................563 6.5.1 Advanced effluent treatment with a combined process of ozonation and fixed bed biofilm reactors.............................................................................................................563 6.5.2 Membrane bioreactor for end-of-pipe or (partly) in-line treatment ..............................565 6.5.3 Recovery of boiler ash and carbon dioxide gas to produce recycled mineral fillers for use in paper...................................................................................................................566 6.5.4 'Kidney' treatmenttechniques for further circuit water cleaning .................................567 6.5.5 The continuous batch fibre recovery system to processing recovered paper in a complete system...........................................................................................................................569 6.5.6 Super critical wet oxidation of deinking sludge to obtain filler material......................570
T
IN
PR O
G R
ES S
8
CONCLUDING REMARKS ........................................................................................................ 669
REFERENCES....................................................................................................................................... 671 GLOSSARY............................................................................................................................................ 685 9 ANNEXES ...................................................................................................................................... 693 9.1 Annex I: chemicals and additives in paper manufacturing..................................................... 693 9.2 Annex II: Determination of BAT-AELs for specific waste water discharges from 'multiproduct' mills.......................................................................................................................... 701 9.3 Annex III: Monitoring of Discharges and Emissions in European pulp and paper mills ....... 705 9.4 Annex IV: Examples for Variations of Emissions ................................................................. 713
W O
R
MS/EIPPCB/PP_Draft_1
KI
N
G
D
R
AF
T
IN
7.3 Techniques to consider in the determination of BAT............................................................. 609 7.3.1 Water management and minimising water usage for different paper grades ............... 612 7.3.2 Control of potential disadvantage of closing up the water systems ............................. 615 7.3.3 Internal treatment of white water by use of membrane filtration and recycling of treated process water................................................................................................................ 618 7.3.4 Reduction of fibre and filler losses .............................................................................. 622 7.3.5 Recovery and recycling of effluent containing coating colour..................................... 624 7.3.6 Separate Pretreatment of Coating Waste waters .......................................................... 627 7.3.7 Measures to reduce the frequency and effects of accidental discharges ...................... 628 7.3.8 Measurement and automation ...................................................................................... 630 7.3.9 Installation of an equalisation basin and primary treatment of waste water................. 632 7.3.10 Secondary or Biological Treatment - Aerobic Methods............................................... 633 7.3.11 Chemical precipitation of waste water from paper mills.............................................. 639 7.3.12 Pretreatment of sludge (dewatering) before final disposal or incineration................... 641 7.3.13 Options for waste treatment ......................................................................................... 643 7.3.14 Installation of low NOx technology in auxiliary boilers (oil, gas, coal) ...................... 647 7.3.15 Use of combined heat and power generation ............................................................... 649 7.3.16 Optimisation of dewatering in the press section of the paper machine (Wide nip press) ..................................................................................................................................... 649 7.3.17 Energy savings through energy efficient technologies................................................. 652 7.3.18 Measures for noise reduction ....................................................................................... 656 7.4 Best Available Techniques..................................................................................................... 661 7.5 Emerging Techniques............................................................................................................. 662 7.5.1 Minimum effluent paper mills - optimised design of water loops and advanced waste water treatment technologies........................................................................................ 662 7.5.2 Impulse technology for dewatering of Paper ............................................................... 664 7.5.3 Condebelt process ........................................................................................................ 665 7.5.4 Internal Heat Pumps..................................................................................................... 666 7.5.5 Total site integration tools............................................................................................ 667
April 2010
PR O
G R
ES S
xiii
List of figuresFigure 1.1: Figure 1.2: Figure 1.3: Figure 1.4: Figure 1.5: Figure 1.6: Figure 1.7: Figure 1.8: Figure 1.9: Figure 1.10: Figure 1.11: Figure 1.12: Figure 1.13: Figure 1.14: Figure 1.15: Figure 1.16: Figure 1.17: Figure 1.18: Figure 1.19: Figure 1.20: Figure 1.21: Figure 1.22: Figure 1.23: Figure 1.24: Figure 1.25: Figure 2.1: Figure 2.2: Figure 2.3: Figure 2.4: Figure 2.5: Figure 2.6: Figure 2.7: Figure 2.8: Figure 2.9: Figure 2.10: Figure 2.11: Figure 2.12: Figure 2.13: Figure 2.14: Figure 2.15: Figure 2.16: Figure 2.17: Figure 2.18: Figure 2.19: Figure 2.20: xiv Paper consumption by region in 2007 ....................................................................................3 The papermaking process.......................................................................................................5 Pulp production by region in 2006 .........................................................................................7 Total pulp production by grade in Europe in 2007 (95 % of production for CEPI-associated European countries)................................................................................................................8 Pulp production by grade in Europe (95 % of production for CEPI-associated European countries)................................................................................................................................8 Geographical and size distribution across Europe for pulp mills ...........................................9 Number of pulp mills by volume in Europe in 1997 and 2007 (CEPI-associated European countries)..............................................................................................................................10 Trade flows of pulp to and from CEPI-associated European countries in 2007 (all figures in 1000 tonnes) .........................................................................................................................10 Recovered paper use in EU-27 countries .............................................................................11 Trade flows of recovered paper to and from Europe in 2007 (in 1000 tonnes)....................11 Paper production by region in the global context in 2006....................................................12 An overview of the distribution of the paper manufacturing industry across Europe (2007) ..............................................................................................................................................13 Number of paper mills by volume in Europe in 2007 ..........................................................14 Number of paper mills by volume in CEPI-associated countries 1997 and 2007 ................15 Trade flows of paper to and from Europe (95 % of production for CEPI-associated European countries)..............................................................................................................16 Capacities versus number of mills in Europe .......................................................................18 Classification of pulp and paper mills in Europe for this document including the relevant chapters for those mills ........................................................................................................20 Typical variation of prices for market pulp ..........................................................................22 Total employment evolution in Europe (CEPI-associated countries) 1991 2007..............23 Manufacturing cost structure for the European pulp and paper industry .............................23 Evolution of the environmental impacts of the European pulp and paper industry since 1990 2006...................................................................................................................................25 Aerial view of an integrate kraft pulp, mechanical pulp and paper site with a power plant and a waste water treatment plant ........................................................................................26 Raw materials consumption in papermaking in CEPI-associated countries 1991 2007....27 Non-fibrous material consumption in CEPI-associated countries 1991 2007 ...................27 Shares of energy carriers in primary energy consumption in Europe in 2006......................28 Overview over the different processes in a multi-product mill and where they are described ..............................................................................................................................................36 Chip pile with cement paving...............................................................................................41 Unloading and storage of loose recovered paper in an enclosed facility with a roof ...........43 Outdoor storage of recovered paper with cement paving.....................................................44 Recovered paper storage in bales under roof .......................................................................44 Raw material consumption of paper and board in 2005 (volume shares) ............................45 Market share of specialty chemicals (dry volume shares)....................................................45 Fate of chemical additives in the paper manufacturing process for biocides .......................46 Options for use and discharge of cooling water ...................................................................52 Types of water used in pulp and papermaking .....................................................................53 Schematic of energy balance with subsystems.....................................................................57 Water-steam cycle of an installation with pure steam generation ........................................67 Typical CHP production at a pulp/paper mill (S.Kankkonen, Pyry Finland Oy, 2010) .....68 Example of a CCGT unit as CHP producing unit at a mill with both a back pressure steam turbine and a saturated steam circuit (S.Kankkonen, Pyry Finland Oy, 2010)...................68 Common biological waste water treatment applications for different paper grades and organic loads ........................................................................................................................79 Continuous improvement in an EMS model ........................................................................82 Pragmatic approach for assessment of the amount of heavily biodegradable additives to be expected in effluents from paper mills after treatment.........................................................97 Schematic presentation of the fate of chemical additives in paper manufacturing including external treatment.................................................................................................................98 Steps towards lower water consumption and lower pollution load to the environment .....101 Approach of data analysis and simulation..........................................................................103
W O
R
KI
N
G
D
R
AF
April 2010
T
IN
PR O
MS/EIPPCB/PP_Draft_1
G R
ES S
Figure 2.21: Figure 2.22: Figure 2.23: Figure 2.24: Figure 2.25: Figure 2.26: Figure 2.27: Figure 2.28: Figure 2.29: Figure 2.30 Figure 3.1: Figure 3.2: Figure 3.3: Figure 3.4: Figure 3.5: Figure 3.6: Figure 3.7: Figure 3.8: Figure 3.9: Figure 3.10: Figure 3.11: Figure 3.12: Figure 3.13: Figure 3.14: Figure 3.15: Figure 3.16: Figure 3.17: Figure 3.18: Figure 3.19: Figure 3.20: Figure 3.21:
W O
R
Figure 3.22: Figure 3.23: Figure 3.24: Figure 3.25: Figure 3.26: Figure 3.27: Figure 3.28: Figure 3.29: Figure 3.30: Figure 3.31:
Systematic evaluation and improvement of the energy use in paper mills ........................ 106 Management method for continuous monitoring and optimisation of energy use ............. 107 Schematic of a thermo compressor .................................................................................... 110 Daily average emission data of the bubbling fluidised bed boiler equipped with SNCR from the Smurfit Kappa Pite kraft pulp mill ............................................................................. 124 Flow diagram of the circulating fluidised bed boiler of UPM Kymmene Austria............. 128 Different forms of BAT for data production and the reporting of emission data .............. 130 Example for the conversion of the concentration of a water pollutant of concern (mg/l) into daily emission loads and specific emission loads and flows.............................................. 136 Example for the conversion of the concentration of an air pollutant of concern (mg/Nm3) into the specific emission factor (e.g. kg dust/ADt). ......................................................... 144 COD and BOD emission data after biological treatment expressed as daily, monthly or yearly means ...................................................................................................................... 148 :Emissions levels according to how mill is operated ......................................................... 160 Overview of the processes of a kraft pulp mill .................................................................. 182 Continuous digester ........................................................................................................... 185 Recovery circuit of chemicals for a kraft mill ................................................................... 191 Mass stream overview of a kraft pulp mill ........................................................................ 197 Emissions to water from a kraft pulp mill ......................................................................... 199 Emissions to the atmosphere from kraft pulp mills ........................................................... 206 Some conceptual chemical reactions in a recovery boiler ................................................. 209 Simplified nitrogen reaction paths from black liquor (N releases in % are indicative as there is certain uncertainty about mass flows); figure amended by EIPPCB.............................. 211 Example of the particle size distribution of dust from recovery boilers measured upstream of the electrostatic precipitators ......................................................................................... 213 Kappa trends in Finnish kraft pulp mills............................................................................ 237 Single-stage oxygen delignification................................................................................... 240 Two-stage oxygen delignification...................................................................................... 240 COD concentrations of the effluents of a bleached kraft pulp mill after biological treatment for different reference periods ........................................................................................... 260 COD load of the effluents of a bleached kraft pulp mill after biological treatment for different reference periods ................................................................................................. 261 TSS, BOD5, Ninorganic concentrations of kraft pulp mill effluents after biological treatment for different reference periods ........................................................................................... 262 COD load of effluents for an unbleached kraft pulp mill after biological treatment for different reference periods (Smurfit Kappa kraftliner Pite mill, SE) ............................... 263 Treatment and collection systems of high concentrate malodorous gases (Botnia Rauma mill) ................................................................................................................................... 267 Treatment and collection systems of high concentrate malodorous gases (Botnia Joutseno mill) ................................................................................................................................... 268 Treatment and collection of dilute odorous gases, in the fiberline (Botnia Rauma mill) .. 268 Collection and treatment of light odorous gases of the evaporation area and the tall oil cookery (Botnia Rauma mill) ............................................................................................ 269 Collection and treatment of light concentrate odorous gases of the caustisation area (Botnia Rauma mill) ....................................................................................................................... 270 Air emissions from a TRS burner equipped with a scrubber ............................................. 276 Continuously measured daily average data of SO2 emissions of a kraft pulp recovery boiler ........................................................................................................................................... 278 Flue-gas scrubber for recovery boilers .............................................................................. 279 Continuously measured daily average data of SO2 emissions of a kraft pulp recovery boiler equipped with an ESP and scrubber .................................................................................. 280 Complete view of a boiler and schematic view of the lower and middle part of the furnace of a recovery boiler of a kraft pulp mill (Source: Keijo Salmenoja, Botnia) ..................... 282 Daily average NOx and CO values over a full year from a kraft pulp recovery boiler...... 284 Schematic view of the arrangement of the four air levels in a recovery boiler (Source: Keijo Salmenoja, Botnia) ............................................................................................................ 285 Continuously measured daily average data of NOx and CO emissions of a kraft pulp recovery boiler ................................................................................................................... 287 Continuously measured daily average data of NOx and CO emissions of the recovery boiler of the Sdra Vr kraft pulp mill, Sweden ........................................................................ 287 Continuously measured daily average data of dust emissions downstream of the ESPs of a kraft pulp recovery boiler .................................................................................................. 294
MS/EIPPCB/PP_Draft_1
KI
N
G
D
R
AF
T
IN
April 2010
PR O
G R
ES S
xv
Figure 3.32: Continuously measured daily average data of dust emissions downstream of the ESPs of a kraft pulp recovery boiler (Pls AG, AT, 2010) ................................................................298 Figure 3.33: Continuously measured daily average data of dust emissions downstream of the ESPs of a lime kiln of a kraft mill ......................................................................................................303 Figure 3.34: Daily average data over a full year of dust emissions from a lime kiln equipped with an ESP and a wet scrubber (CO emissions are also included) ................................................304 Figure 3.35: The Chemrec process with a gasifier and a quench dissolver for green liquor production and with a weak liquor gas scrubber for hydrogen sulphide absorption ...................................309 Figure 3.36: Integrated gasification with a combined cycle (IGCC) ......................................................310 Figure 3.37: Combined cycle for power production by means of a gas turbine and a steam turbine with a condensing tail ...................................................................................................................310 Figure 3.38: Recovery of chelating agents in bleach plant filtrates by use of a kidney..........................314 Figure 3.39: Kidneys under development in an EU project on separation methods for closed loop technology in bleached kraft pulp production ....................................................................316 Figure 4.1: Areal view of an integrated sulphite pulp mill producing coated fine paper including the power plant (centre) and the waste water treatment plant (background, right) ..................322 Figure 4.2: Main processes for the manufacturing of magnesium sulphite pulp showing the fibre line operations and the chemical and energy recovery..............................................................323 Figure 4.3: Typical fibre line of a sulphite pulp mill manufacturing pulp for papermaking ................324 Figure 4.4: Example of a wash filter and a wash press in brown stock washing ..................................326 Figure 4.5: Pressure screens for final screening ...................................................................................328 Figure 4.6: Recovery cycles of chemicals and energy for a magnesium-based sulphite mill (modified by EIPPCB)........................................................................................................................329 Figure 4.7: Scheme of the manufacturing of fodder yeast and separation of lignosulphonates from the spent sulphite liquor ...........................................................................................................330 Figure 4.8: Basic principle of the flow of pulp and spent liquor in mills applying the 'biorefinery concept'...............................................................................................................................331 Figure 4.9: Preparation of chlorine dioxide by the 'Kesting method'....................................................333 Figure 4.10: Process flow of a sulphite mill producing speciality pulp and various products based on the conversion of the spent sulphite liquor...............................................................................337 Figure 4.11: Production scheme of a neutral sulphite semi chemical mill (220000 t/yr) with chemical and energy recovery units ..................................................................................................339 Figure 4.12: Mass stream overview of the input and output of a sulphite pulp mill...............................340 Figure 4.13: Major sources of emissions to water from sulphite pulping...............................................348 Figure 4.14: Example for the collection of sulphur dioxide-containing and odorous gases and their treatment.............................................................................................................................352 Figure 4.15: Example for SO2 emissions from recovery boilers for 'normal operation' and 'acid of operation mode' ..................................................................................................................354 Figure 4.16: Example of a fibre line with O2 delignification including the COD and DCM extract values before and after O2 delignification (Biocel Paskov, CZ)....................................................367 Figure 4.17: Closed-loop prebleaching with MgO as a base ..................................................................372 Figure 4.18: Ultrafiltration system in a dissolving pulp mill, Domsj Fabriker AB, SE........................374 Figure 4.19: Flow sheet of the use of the ultrafiltration plant.................................................................377 Figure 4.20: Simplified scheme of the evaporation and incineration of the EOP effluents....................380 Figure 4.21: Example of organic loads and removal efficiencies of anaerobic and aerobic waste water treatment in a German mill of Sappi Fine Paper Europe....................................................383 Figure 4.22: Process diagram of the effluent treatment plant for an integrated pulp and paper mill manufacturing magnesium bisulphite pulp ........................................................................386 Figure 4.23: Process diagram of the effluent treatment plant for a pulp mill manufacturing magnesium bisulphite market pulp ........................................................................................................390 Figure 4.24: Process diagram of waste water treatment of an integrated mill producing NSSC-pulp and SC fluting ...........................................................................................................................393 Figure 4.25: Process diagram of the effluent treatment plant (aerated lagoon) for a pulp mill manufacturing ammonium bisulphite specialty pulp..........................................................397 Figure 4.26: Schematic view of a recovery boiler of a sulphite pulp mill (M-real Hallein, 1985) .........401 Figure 4.27: Schematic view of the ammonia injection into the recovery boiler ...................................403 Figure 4.28: NOx emission from the recovery boiler as determined by the automatic emission monitoring system. Daily mean values during 2008 ..........................................................405 Figure 4.29: Simplified flow chart of a flue-gas desulphurisation plant (ESP + multistage scrubbers) and its integration in cooking chemical preparation .................................................................408 Figure 4.30: SO2 circuit in a sulphite mill and major source for diffuse SO2 emissions that are collected and burned in the recovery boiler.......................................................................................416 Figure 5.1: Main steps in mechanical pulping ......................................................................................423 xvi
W O
R
KI
N
G
D
R
AF
April 2010
T
IN
PR O
MS/EIPPCB/PP_Draft_1
G R
ES S
Figure 5.2: Figure 5.3: Figure 5.4: Figure 5.5: Figure 5.6: Figure 5.7: Figure 5.8: Figure 5.9: Figure 5.10: Figure 5.11: Figure 5.12: Figure 6.1: Figure 6.2: Figure 6.3: Figure 6.4: Figure 6.5: Figure 6.6: Figure 6.7: Figure 6.8: Figure 6.9: Figure 6.10: Figure 6.11: Figure 6.12: Figure 6.13: Figure 6.14: Figure 6.15: Figure 6.16: Figure 6.17: Figure 6.18: Figure 6.19: Figure 6.20: Figure 6.21: Figure 6.22: Figure 6.23: Figure 6.24: Figure 6.25: Figure 6.26: Figure 7.1: Figure 7.2: Figure 7.3: Figure 7.4: Figure 7.5: Figure 7.6: Figure 7.7: Figure 7.8: Figure 7.9: Figure 7.10: Figure 7.11:
Flow scheme for a pressure groundwood process mill ...................................................... 425 Schematic of the TMP process and emissions ................................................................... 427 Schematic of the CTMP process........................................................................................ 429 Mass stream overview of an integrated mechanical pulp and paper mill .......................... 433 Emissions to water from a CTMP mill .............................................................................. 437 Emissions to the atmosphere from CTMP mills ................................................................ 440 Main water sources and sinks in an integrated mechanical pulp and paper mill ............... 454 Water recycle system of the Meadow Lake BCTMP mill ................................................. 457 Zero liquid effluent process concept Meadow Lake BCTMP mill .................................... 457 Energy and mass flows as well as energy flows bound to mass flows in a SD or CD refiner ........................................................................................................................................... 460 Energy and mass flows as well as energy flows bound to mass flows in a Twin or DD refiner ................................................................................................................................ 460 Flowsheet of an example stock preparation plant for processing recovered paper for casemaking material (two-ply Testliner) .................................................................................. 476 Example of an overall plant concept for Testliner (two-loop system) ............................... 479 Example for an overall plant concept for (improved) newsprint ....................................... 480 Example for an overall plant concept for a recovered paper preparation plant for tissue paper .................................................................................................................................. 483 Mass stream overview of an integrated recovered paper processing mill.......................... 484 Range of yearly average consumption and emission levels for the manufacturing of tissue ........................................................................................................................................... 491 Basic flow chart of the recovered paper processing paper and board production.............. 493 Example of water circuits for an integrated RCF mill for corrugated medium without deinking ............................................................................................................................. 494 Example of an optimised stock-water system for the integrated production of deinked pulp ........................................................................................................................................... 494 Specific energy consumption for recovered paper processing of a newsprint mill............ 499 Scheme of water loops in paper mills ................................................................................ 515 Layout of water loops in a paper mill with separation of wa