Metafore Presentation.ppt [Read-Only]

The Minimum-Impact Mill:
“State-of-the-Art” Manufacturing
Alliance for
Environmental Technology
Douglas C. Pryke, P.Eng.
Executive Director, AET
Q u i c k T i m e ™
a n d
a
T I F F
( U n c o m p r e s s e d )
A Responsible Care®
Supporting Association
d e c o m p r e s s o r
a r e
n e e d e d
t o
s e e
t h i s
p i c t u r e .
Outline
Background
AET Minimum-Impact Mill
Workshop, 1996
What is a Minimum-Impact
Mill?
State-of-the-Art
Manufacturing
Measures of Progress
The Future
Source: Canfor Ltd.
Summary
AET Mission: www.aet.org
To communicate, foster, and promote the
environmental, economic, scientific, and technical
benefits resulting from the responsible production and
safe use of sodium chlorate and chlorine dioxide in
bleached pulp manufacturing.
Key Activities
Ecological Risk Assessment of the Use of Chlorine Dioxide
Documenting Environmental Progress of Pulp and Paper
Industry
Minimum Impact Mill
Submissions to Regulatory Authorities
Tracking Growth of ECF
Active in Environmentally Preferable Paper Issue
Minimum-Impact Mills:
Issues and Challenges An AET Scientific Workshop
In September 1996, AET convened a scientific workshop
attended by 70 representatives of the international pulp and
paper industry, chemical industry, academia, government
research, and consulting communities.
Purpose was to discuss and debate a number of questions at
play in the industrial and NGO community
Concepts espoused at the time emphasized elimination of
bleaching effluent:
Minimum-Impact Manufacturing, Minimum-Impact Mill, Bleach
Filtrate Recovery®, Closed Loop Bleaching, Eco-Balanced Pulp Mill,
Progressive Systems Closure, Closed Cycle Mill, Ecocylic Pulp Mill
Assertions Debated
Elimination of bleaching effluent is the “right thing to
do” to improve the environmental performance of
bleached kraft pulp mills with secondary effluent
treatment
Elemental Chlorine-Free (ECF) and Totally ChlorineFree (TCF) bases processes are compatible with the
minimum impact mill
Consensus Reached
“Based on current scientific evidence, the best
approach to eliminating environmental responses is to
focus on eliminating losses from spent pulping liquor
and those containing wood extractives, and improving
unbleached pulp washing to minimize carryover to
bleaching, rather than eliminating bleaching effluent”
“Eliminating bleaching effluent might be considered
where
Fresh water resources are scarce;
The receiving water or ecosystem is particularly sensitive; or
Low flow receiving waters are unable to assimilate the
organic carbon load”
Consensus Reached
“Both ECF and TCF are compatible with minimum
impact mills and require:
System closure;
Potassium control;
Chloride control; and
Must meet yield, quality, and energy targets”
“No bleached kraft pulp mills have successfully
demonstrated, complete bleach plant effluent
elimination”
“There are no zero effluent bleached kraft mill bleach
plants”
Consensus Reached:
The Minimum-Impact Mill
Source: Veracel Celulose
“A completely ecocyclic system for high quality pulp and paper
production which efficiently utilizes the energy potential of the biomass”
“An ecologically sound industry, producing recyclable products from
renewable resources”
“An industry we are so proud of we encourage our grandchildren to join”
The 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
Source: Celcius Degree
State-of-the-Art Mills
Source: Celcius Degree
Mills and fiberlines that encompass “State-of-the-Art” technology
and management practices that have recently started up are:
Stendal, Germany
Aracruz, Line C, Brazil
Bowater, Catawba SC, USA
Aracuco Celulosa, Validivia Chile
Veracel Celulose, Bahia, Brazil
State-of-the-Art Mfg. Example:
Veracel Celulose S.A., Brazil
Source: Veracel Celulose
Veracel Celulose
Veracel Celulose
Mill is located in state of Bahia in
Brazil
Ownership is 50% Aracruz
Celulose and 50% StoraEnso
Production is 900,000 t/y
bleached eucalyptus market pulp
for printing and writing grades
Investment for the mill $US 860
million
Started up May 2005
Forest Management
Total area for management is
173,000 ha of which:
74,440 ha is planted eucalyptus
85,122 ha is protected Atlantic
rainforest
Certified to Brazilian CERFLOR
standards
Seeking FSC Certification
Mosaic concept planting
Debarking in the forest
Preservation and restoration of
Atlantic Rainforest
Collaborating with Conservation
International
Source: Veracel Celulose
From Seedling to Forest
From Seedling to Forest
From Seedling to Forest
From Seedling to Forest
From Seedling to Forest
The 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
The Paper Mill Flowsheet
Logs
Sawmill Residue
Pulping Chemicals
Recovery
Debarking
Chipping
Digesting
Washing
Screening
Chemicals
Bleaching
Cleaning
Paper Machine or Pulp Dryer
Maximizing Yield
Barking in the forest to
provide nutrients - minerals,
carbon, and soil protection
Efficient wood chipping to
minimize fines and oversize
Modern digester system
Selective to lignin, preserve
cellulose
Cooking to a relatively high
lignin content (kappa no.)
Efficient knot removal and
screening system
Re-cook knots and screen
rejects - no waste
Source: Veracel Celulose
Maximizing Yield
Selective two-stage
oxygen delignification
Excellent lignin removal
with cellulose
preservation
Elemental Chlorine-Free
(ECF) bleaching
sequence
Excellent lignin removal
with cellulose
preservation
Minimum damage to
cellulose fibres
High pulp strength
High brightness
Source: Veracel Celulose
Maximize Energy Production
Burning of over/under sized chips
and log area bark waste in
fluidized bed power boiler
Efficient recovery, evaporation,
and combustion of black liquor in
recovery boiler
Recovery boiler provides 90% of
energy production; and
Mill steam requirements
120
Minimize within mill power
consumption with power saving
technologies such as variable
frequency drives etc.
Megawatts
100
80
60
40
70% of power generated is
consumed and 30% is renewable
“green” power exported to grid
20
0
Produced
Consumed
Exported
Minimize Water Consumption
Dry debarking system;
Evaporator condensate
recovery and reuse for
within mill washing;
m3/ADt
90
Median
80
State-of-the-Art
70
Veracel
60
Counter current washing
with high efficiency
washers;
*
50
40
30
Filtrate reuse within the
bleach plant; and
20
10
0
Surface condenser water
reuse using cooling
towers
1994
2004
2006
* Predicted
Minimize Solid Waste
De-barking in forest;
Re-cooking knots and
pulp screening rejects;
Primary sludge fiber
enters the local recycled
fibre market, e.g., egg
cartons
kg/ADt
35
30
25
20
15
Secondary treatment
spent biomass, boiler
ash, and yard wood
waste composted and
sold to local farmers
10
5
0
Generated
75% of solid waste
generated leaves site as
a product
Sold
Landfilled
Minimize Air Emissions
SO2, kg/ADt
Low odor design recovery
boiler
5.0
Condensate stripping and
combustion of odorous
gases
3.0
Median
State-of-the-Art
4.0
Veracel
2.0
1.0
Low and high concentration
non-condensable gas
collection and combustion
0.0
1994
0.60
2004
2006
TRS, kg/ADt
Median
State-of-the-Art
0.50
Elimination of dissolving
tank vent
Veracel
0.40
0.30
Electrostatic precipitators on
recovery boiler and lime kiln
Filter bags for fluidized bed
power boiler
0.20
0.10
0.00
1994
2004
2006
High Quality Pulp for Paper
Selective two-stage oxygen
delignification
Excellent lignin removal with
cellulose preservation
Elemental Chlorine-Free (ECF)
bleaching sequence
Using chlorine dioxide, oxygen and
peroxide
Excellent lignin removal with
cellulose fibre quality preservation
High pulp strength
Excellent run-ability on paper
machines
High recycle-ability
High brightness 90% ISO
Low brightness reversion
Source: Veracel Celulose
High Quality Pulp for Paper
Graphic shows growth
of ECF bleaching
technology since 1990
Millions of Tonnes
100
90
80
In 2005 more than 70
million tonnes ECF
represented 84% of
world bleached chemical
pulp production
(excluding China and
India)
TCF represents ~ 5% of
market and is forecast to
decline
Forcast Growth
ECF
TCF
Other
70
60
50
40
30
20
10
0
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Source: AET
Eco-System Protection
Utilization of ECF bleaching
technology
16
14
Elimination of polychlorinated
phenols to non-detectable levels
Compliance with the Stockholm
Convention on Persistent
Organic Pollutants (POPs
Treaty) Draft Guidelines for
Bleached Chemical Pulp
Production
12
10
Dioxin, ppq
Elimination of 2378-TCDD and
2378-TCDF to non-detectable
levels
8
6
4
2
Not Detected
0
10
20
30
40
50
60
70
80
90 100
Chlorine Dioxide Substitution, %
Eco-System Protection:
Waste Treatment
Urea
From
Pulp Mill
Primary
Clarifier
Mix
Tank
Sludge
Removal
Aeration
Basin
Phosphoric
Acid
Secondary
Clarifier
River
To Power
Boiler
Source: N. McCubbin Consultants, Inc.
Waste Treatment
Source: Canfor Ltd.
Primary clarification to remove
suspended material
Secondary biological treatment
to minimize oxygen demand
when waste water sent to
receiving environment
95% BOD removal
70% COD removal
Effluent introduced into
receiving environment via
submerged diffusers
Aquatic environmental
assessment program
implemented
Source: Celcius Degree
Ecosystem Protection
3.0
BOD, kg/ADt
40.0
COD, kg/ADt
Median
Median
State-of-the-Art
State-of-the-Art
2.5
Veracel
Veracel
30.0
2.0
20.0
1.5
1.0
10.0
0.5
0.0
1994
2004
2006
0.0
1994
2004
2006
Sustainable Value to Society
Total investment for new
State-of-the-Art mill such as
Veracel
$US 1.2 billion
$US 860 million for mill
$US 360 million for
infrastructure
Local residents trained for
highly skilled employment in
the mill operation
3900 permanent employees
in forestry, mill and corporate
offices
Foreign exchange credits
Source: Veracel Celulose
Sustainable Value to Society
$US 12 million is being
invested in local social
projects
Projects to improve
sanitation, health, education
and security in local region
Safety
3%
Others
18%
Environmental
sanitation
37%
Health
23%
Education and
culture
19%
Partnerships with local
industries:
Apiculture
Furniture manufacturing
Indigenous Seedling
Program
Source: Veracel Celulose
The Minimum-Impact Mill
How far have we traveled along the road to the
Minimum-Impact Mill
Example that follows shows the changes over the last
30 years for a annual production of ~ 1 million tonnes
per year (3000 t/d)
Water Use
Organic Discharge
Suspended solids in waste water
SO2
Elimination of POPs and Ecosystem Recovery
Industry Progress:
3000 t/d Bleached Pulp Production
BOD, t/day
Volume, '000 m3/day
35
300
30
250
25
200
20
150
15
100
10
50
5
0
0
1975
30
1995
1975
2006
Suspended Solids, t/day
1995
2006
SO2, t/day
40
25
35
30
20
25
15
20
10
15
10
5
5
0
1975
1995
2006
0
1975
1995
2006
Industry Progress
Canadian Bleached Chemical Pulp
and Paper Mills: Elimination of
Dioxin
300
Lifting of Fish Consumption Dioxin Advisories
Downstream of U.S. Pulp and Paper Mills
30
250
25
200
20
150
15
100
10
Waterbodies with Dioxin
Advisory
Advisories Lifted
Projected
5
50
0
0
'90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07
1988
1990
1992
1994
1996
Dioxin TEQ- grams per year
1999
Source: AET
The Future
The Future
Bio-refinery Concepts
Chemical feed stocks for pharmaceuticals
Lignin for fossil fuel replacement
Energy self-sufficiency
Green power exports
Designed cellulose products
Continued Progress in Environmental Protection
Advanced treatment processes
Elimination of biological responses in ecosystem
Further minimization of water consumption
Summary
Minimum Impact Manufacturing has and will continue to be the
vision of the pulp and paper industry
Today’s State-of-the-Art mills compared to 1975:
Use less wood to make a piece of paper;
Are energy self sufficient and export green power to the grid;
Use 70% less water, discharge less solid waste, and emit 96% less
SO2 and 90% less odorous compounds;
Protect the ecosystem with advanced wastewater treatment
n Discharging 95% less Biochemical Oxygen Demand (BOD)
n Discharging 90% less Suspended Solids
n Discharging no Persistent Organic Pollutants
Creates high quality recycleable products while providing
sustainable value to society
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”
Acknowledgement
The member companies of AET:
ERCO Worldwide
Eka Kemicals
Kemira Chemicals
Canexus Chemicals
Tronox Inc.
Chemtrade Logistics
Aracruz Celulose and StoraEnso and most of all
The team at Veracel for their willingness to share their
commitment to sustainablility with me and the
privilege to present it.