Perspectives on the Pulp and Paper Industry pdf

Perspectives on the Pulp and Paper Industry QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture Douglas C Pryke, P.Eng Executive Director, AET Alliance for Environmental Technology QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture A Responsible Care® Supporting Association Outline North America Pulp & Paper Industry Printing & Writing Paper Market Manufacturing Fundamentals Environmental Protection Measures of Progress Summary Source: Canfor Ltd N American Pulp & Paper Industry Bleached pulp production is ~ 35 million tons Printing and Writing Grades Uncoated Free Sheet Coated Free Sheet Uncoated Groundwood Coated Groundwood Printing and Writing Grades ~ 25 million tons 50% UFS 25% CFS N American Pulp & Paper Industry US P&P industry 6% of GDP comparable to automotive and plastics industries $200 Billion Annual Sales Million employees $54 Billion payroll US Paper Mill Closures Source: AF&PA International Capacity Change 1998-2008 Significant growth in emerging economies Ave Annual Change,% North America declining on average 1% per year Manufacturing Fundamentals Basic overview Bleached kraft pulp manufacturing Pulping Bleaching Waste treatment Environmental Protection QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture Manufacturing Overview The Paper Mill Flowsheet Logs Sawmill Residue Pulping Chemicals Recovery Debarking Chipping Pulping Washing Waste Treatment Screening Chemicals Bleaching Cleaning Paper Machine or Pulp Dryer Pulp and Paper Mill Eco-industrial Park EcoWaste Treatment Fresh Water Wood Fiber Pulping Causticizing Chemical Recovery Boiler (Black Liquor) Bleaching Power Generation Power Boilers Papermaking Land Application Paper Consumers Power Grid Mine Reclamation Sludge Stabilization Building Products Coal Eco-industrial Park Photo Courtesy of: Celso Foelkel, Celsius Degree Minimum Impact Manufacturing A Minimum Impact Mill: Minimizes the number of trees used to make a piece of paper Maximizes energy production Minimizes water consumption, solid waste, and air emissions Make high quality paper that is easily recyclable Treats and disposes of waste optimally Creates sustainable value to society 10 Eco-System Recovery ECF and the elimination of dioxin are key contributors to the sustainable recovery of affected eco-systems Since 1990 U.S authorities have lifted 27 fish consumption advisories downstream of pulp and paper mills The U.S EPA predicts all remaining advisories will be lifted following full implementation of ECF bleaching 30 25 20 Waterbodies with Dioxin Advisory Advisories Lifted 15 10 Projected '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 Similar results have occurred in fresh water and marine environments in Canada 28 World Bleached Chemical Production Graphic shows growth of ECF bleaching technology since 1990 ECF represents more than 89% of world Bleached Chemical Pulp Production TCF is less than 5% and declining Millions of Tonnes 90 80 ECF TCF 70 Other 60 50 40 30 TCF represents ~ 5% of market and is forecast to decline 20 10 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 29 Eco-System Protection: Waste Treatment Urea From Pulp Mill Primary Clarifier Aeration Basin Phosphoric Acid Secondary Clarifier River Mix Tank Sludge Removal To Power Boiler Source: N McCubbin Consultants, Inc 30 Biological Treatment Mills typically have primary and secondary treatment Primary for removal of solid material Secondary to minimize oxygen consuming compounds 31 Measures of Progress Specific Water Consumption Emission to Aquatic Enviroments Emissions to Atmosphere GHG Emissions Comparison of million tonne per year from yesterday to today 32 Minimize Water Consumption Modern debarking system; m3/ADt Evaporator condensate recovery and reuse for within mill washing; 90 Counter current washing with high efficiency washers; 60 Filtrate reuse within the bleach plant; and 80 70 Median State of the Art 50 40 30 20 10 Surface condenser water reuse using cooling towers 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 33 Minimize Air Emissions Low odor design recovery boiler 5.0 SO2, kg/ADt Median 4.5 State-of-the-Art 4.0 Condensate stripping and combustion of odorous gases 3.5 3.0 2.5 2.0 1.5 1.0 Low and high concentration non-condensable gas collection and combustion 0.5 0.0 0.6 Elimination of dissolving tank vent 1994 2004 2006 TRS kg/ADt Median State-of-the-Art 0.5 0.4 Electrostatic precipitators on recovery boiler and lime kiln 0.3 0.2 0.1 0.0 1994 2004 2006 34 Ecosystem Protection 2.0 COD, kg/ADt BOD kg/ADt 30 Median 1.8 Median 1.6 State-of-the-Art 25 State-of-the-Art 1.4 20 1.2 1.0 15 0.8 10 0.6 0.4 0.2 0.0 1994 2004 2006 1994 2004 2006 35 GHG Emissions US Pulp and Paper Mills; Data from AF&PA 36 Industry Progress: 3000 t/d Bleached Pulp Production 300 Total Mill Effluent Volume, '000 m3/day 35 250 30 200 BOD, t/day 25 20 150 15 100 10 50 30 1975 1995 2006 Suspended Solids, t/day 40 25 1975 1995 2006 SO2, t/day 35 30 20 25 15 20 10 15 10 5 1975 1995 2006 1975 1995 2006 37 Summary The industry’s environmental progress over the last 30 years, while maintaining economic viability, bodes well for the next 30 years, and provides confidence that the Minimum-Impact Mill of the next generation will be realized “It is an industry we are so proud of we encourage our grandchildren to join” 38 Photo Courtesy of: Canfor Ltd 39 Photo Courtesy of: Celso Foelkel, Celsius Degree 40 Thanks 41 What is AOX? AOX means “Adsorbable Organic Halogen (X)” AOX is the result of a test to determine the amount of chlorine attached to organic substances AOX is not a “thing”, it is simply a number AOX does not determine the compounds present; whether the compounds are persistent; whether the compounds are bioaccumulative; the toxicity and biological properties of the compounds; or the degree of chlorination Due to these limitations, AOX does not provide environmentally relevant information There is no relationship between AOX test results and the presence of dioxin 42 ... pollution or end-of-pipe treatment Pollution prevention means stopping pollution before it starts! In the late 80s the international pulp and paper industry voluntarily implemented a pollution prevention... reduces the amount of any hazardous substance, pollutant, or contaminant entering any waste stream or otherwise released into the environment; and reduces the hazards to public health and the environment... (PCDD) and 75 possible Polychlorinated Dibenzofurans (PCDF) PCDD Of those, only 17 are considered to express “dioxin-like” toxicity The compounds with the Cl in the 2, 3, 7, and positions on the