PULP AND PAPER INDUSTRIES

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PULP AND PAPER INDUSTRIES

• Group 4
• Cynthia Alcántara
• Lucía Escorial
• Sara Gómez
• Michael Moreau
• Marta Pérez

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General Information
Introduction

• Main consumer of natural resources
• Wood (as raw material)
• Fossil, fuel, electricity (as energy)
• Water
• Wood contains
• 50 water
• 45 cellulose
• 25 hemicelluloses
• 25 lignin
• 5 other organic a inorganic materials

Classification
Process
Consumption
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BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Classification of pulp and paper mills
Introducción
Introduction
Classification

• Kraft pulping process
• Sodium sulphate
• Sulphite pulping process
• Magnesium sulphite pulping
• Mechanical and chemi-mechanical
• mechanical energy applied to the wood matrix
• Recycled fibre processing (recovered fibre)
• Non integratepaper mills
• paper manufacturing independently from pulp
  manufacturing.

Process
Consumption
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BAT
Emerging
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TECNOLOGÍA del MEDIO AMBIENTE
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Non integratepaper mills
Introducción
Introduction

• Paper and board manufacturing is described
  independent from pulp manufacturing.
• Most paper mills in Europe are non-integrated
  mills.
• All types of paper and board-making processes
  have the following basic units
• Stock preparation
• Approach flow system
• Paper and board machine
• Calenders, coaters, a coating colour kitchen,
  winders, rewinders and a roll wrapping station.

Classification
Process
Consumption
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BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Applied Processes and Techniques
Introducción
Introduction

• Stock preparation
• Is conducted to convert raw stock into finished
  stock
• The pulp is prepared for the paper machine
• Including the blending of different pulps,
• dilution and the addition of chemicals
• Is based on the removal of impurities
• Paper machine
• The paper is formed
• Most of the properties of the paper are
  determined.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Applied Processes and Techniques
Introducción
Introduction

• Water circuits and fibre recovery
• 3 process water circuits in a paper mill
• primary circuit (short circulation)
• secondary circuit (long circulation)
• tertiary circuit (excees water from secondary)
• Broke system
• Return the paper fibre back to the process
• The amount of broke produced during papermaking
  is normally 5 - 20 of the machine capacity
• Wet broke normal operation
• Dry broke in finishing operations

Classification
Process
Consumption
Techniques
BAT
Emerging
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Applied Processes and Techniques
Introducción
Introduction

• Sizing (optional)
• agents are applied to the fibre matrix to
  increase the strength of the base paper
• and tomodify the surface properties with respect
  to liquid uptake during writing, printing or
  coating
• Coating (optional)
• application of a mixture of water, white
  pigments, binderto create specific surface
  qualities
• Dyeing (optional)
• For coloured papers

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Applied Processes and Techniques
Introducción
Introduction

• Addition of chemicals
• To achieve certain paper properties
• To improve operations in the production process
• Calendering (optional)
• The objective is to produce a smooth paper
  surface that meets the printing and writing
  requirements for the intended use.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Consumption and emission levels
Introducción
Introduction

• Consumption of major raw material
• Fibres, water and chemical additives
• Water use
• Cleaning water, solvent, cooling
• Use of additives
• Energy demand
• Wastewater emissions
• Rejects from stock cleaning
• Temporary and accidental discharges
• Cooling and sealing waters

Classification
Process
Consumption
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BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Consumption and emission levels
Introducción
Introduction

• Solid waste generation wastewater
• Rejects from stock preparation
• Sludge from water treatment
• Atmospheric emissions
• Air emissions from paper machines
• Air emission from energy generation
• Odour from vapours and from wastewater
  treatment
• Noise from paper machines (local)

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Techniques to consider in the determination of BAT
Introducción
Introduction

• Techniques currently commercially available for
  prevention or reduction of
• emissions/waste
• reducing consumption of energy
• reducing consumption of raw materials
• 1) Internal treatment of white water by use of
  membrane filtration and recycling of treated
  process water
• Micro-filtration
• Ultra-filtration
• Nano-filtration (NF)
• Reverse osmosis (RO)

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
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Techniques to consider in the determination of BAT
Introducción
Introduction

• 2) Water management and minimising the use of
  water for different paper grades
• Efficient separation of cooling waters from
  process water.
• The shower water system is usually the biggest
  consumer of fresh water most of the fresh water
  must be replaced by clarified white water.
• Recycling part of the vacuum pump sealing water.
• Design and maintenance of piping and storage
  chests.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Techniques to consider in the determination of BAT
Introducción
Introduction
Classification

• 3) Reduction of fibre and filler losses
• Tuning of the pulp refining and screening just
  ahead of the feed to the paper machine to
  maintain proper balance of different types of
  fibres in pulp.
• Efficient control of paper machine headbox
• Sufficient use of paper chemicals to reach
  improved fibre retention in order to get a good
  paper web formation.

Process
Consumption
Techniques
BAT
Emerging
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Techniques to consider in the determination of BAT

Introducción
Introduction
Classification

• 4) Recovery and recycling of coating
  colour-containing effluent
• The pigments are expensive, so the recovery of a
  part of the coating colour for reapplication and
  minimisation is cost-effective
• One method is ultra-filtration water and
  chemicals are separated from each other by using
  a semi-permeable membrane.

Process
Consumption
Techniques
BAT
Emerging
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Techniques to consider in the determination of BAT

Introducción
Introduction
Classification

• 5) Energy savings through energy efficient
  technologies
• There are opportunities for energy saving in many
  stages of the process.
• Example Energy savings through heat recovery
  systems
• The purpose to lower the mill' s consumption of
  primary energy by using waste energy from the
  process

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
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Techniques to consider in the determination of BAT

Introducción
Introduction
Classification

• 6) Measures for noise reduction
• For internal noise sources
• Installations of a new closed hood with higher
  sound insulation
• For external noise control
• Installation of absorptive silencers
• Installation of pipe resonators to reduce noise
  levels from exhaust air fans and vacuum pumps,
• Silencers and sound insulation hoods for the fans
  on the building roof.

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Techniques to consider in the determination of BAT

Introducción
Introduction
Classification

• 7) Others techniques are
• Control of potential disadvantage of closing up
  the water systems
• Separate Pre-treatment of Coating Wastewaters
• Measures to reduce the frequency and effects of
  accidental discharges
• Measurement and automation
• Installation of an equalisation basin and
  primary treatment of wastewater
• Secondary or Biological Treatment - Aerobic
  Methods
• Chemical precipitation of wastewater from paper
  mills
• Substitution of potentially harmful substances
  by use of less harmful alternatives
• Pre-treatment of sludge (de-watering) before
  final disposal or incineration
• Options for waste treatment.
• Installation of low NOx technology in auxiliary
  boilers (oil, gas, coal)
• Use of combined heat and power generation
• Optimisation of de-watering in the press section
  of the paper machine

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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BAT Best Available Techniques

Introducción
Introduction
Classification

• General measures
• Training, education and motivation of staff and
  operators.
• Process control optimisation.
• Sufficient maintenance has to be ensured.
• Environmental management system which clearly
  defines the responsibilities for environmentally
  relevant aspects.

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
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BAT Best Available Techniques

Introducción
Introduction
Classification

• Measures for reducing emissions to water
• Minimising water usage for different paper grades
  by increased recycling of process waters.
• Control of potential disadvantages of closing up
  the water systems.
• Construction of a balanced white water, filtrate
  and broke storage system and use of
  constructions, design and machinery with reduced
  water consumption when practicable.
• Measures to reduce frequency and effects of
  accidental discharge.

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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BAT Best Available Techniques

Introducción
Introduction
Classification

• Measures for reducing emissions to water
• Collection and reuse of clean cooling and sealing
  waters or separate discharge.
• Separate pre-treatment of coating wastewaters.
• Substitution of potentially harmful substances by
  use of less harmful alternatives.
• Effluent treatment of wastewater by installation
  of an equalisation basin and primary treatment.
• Secondary or biological treatment of wastewater

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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BAT Best Available Techniques

Introducción
Introduction
Classification

• Measures for reducing emissions to air
• Installation of low NOx technology in auxiliary
  boilers.
• Reducing SO2 emissions from steam boilers by
  using low sulphur oil and coal or controlling S
  emissions.
• Use of combined heat and power generation.
• Using renewable sources like wood or wood waste
  to reduce the emissions of fossil CO2 (only
  applicable if papermaking is integrated with
  virgin pulp production).

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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BAT Best Available Techniques

Introducción
Introduction
Classification

• Noise attenuation
• BAT is the reduction of noise levels audible in
  the vicinity of paper mills.
• The measures applied will depend to a large
  extent on the specific noise problem of a mill
  and the targets set.
• Usually they will be much stricter when the mill
  is located adjacent to a residential area.

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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BAT Best Available Techniques

Introducción
Introduction
Classification

• Chemical usage
• Ensure the availability of a database for all
  used chemicals and additives .
• Application of the principle of substitution
  less hazardous products are used when available.
• Measures to avoid accidental discharges to soil
  and water from handling and storage of chemicals.
  
• Design and operation of facilities in such a way
  that dangerous substances cannot escape.

Process
Consumption
Techniques
BAT
Emerging
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Emerging Techniques

Introducción
Introduction
Classification

• Some promising techniques are addressed that
  can not (yet) be considered BAT due to the stage
  of development of these techniques.
• The paper mill of the future can be probably
  described by the following characteristics
• Decrease in paper mill water consumption and
  specific emissions by means of increasing water
  re-use, closed water loops and internal water
  treatment
• Increase in electricity consumption (specific to
  production)
• Decrease in paper mill noise level

Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Emerging Techniques

Introducción
Introduction

• Minimum effluent paper mills - optimised design
  of water loops and advanced wastewater treatment
  technologies.
• Impulse technology for dewatering of paper.
• Condebelt process.
• Internal heat pumps.
• Total site integration tools.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Emerging Techniques

Introducción
Introduction

• Minimum effluent paper mills - optimised design
  of water loops
• To apply a combination of membrane filtration,
  ozonation and evaparation
• Can reduce fresh water consumption
• Are only applied in pilot-scale.
• Full scale expierences are limited to a few
  examples in the world
• There are still operation problems and
  relatively high costs

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Emerging Techniques

Introducción
Introduction

• Impulse technology for dewatering of paper
• Dryness levels of 55-65 before the drying
  section (15-25 more than ordinary press
  section)
• Decrease the heat consumption
• The development work is still at an early stage.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
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Emerging Techniques

Introducción
Introduction

• Condebelt process
• The Condebelt drying process is a new way to
  dry paper and board.
• The paper web coming from the press section is
  dried between two steel belts instead of
  traditional steam cylinders.
• In 1999 there was two Condebelt drying
  processes in commercial operation
• More square meters from the same amount of
  fibres can be manufactured without loosing
  product quality
• Higher potential for energy recovery

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Emerging Techniques

Introducción
Introduction

• Internal heat pumps
• Are used for pumping heat from one medium (air)
  to another (for example water)
• Investment costs are quite high

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Emerging Techniques

Introducción
Introduction

• Total site integration tools
• Try to combine the whole energy, water, fibre,
  chemicals, system to create a good integration of
  the mill
• Lower emissions to air and water and at the same
  time to reduce the formation of solid waste and
  energy
• The total site integration tool software is not
  a big investment.

Classification
Process
Consumption
Techniques
BAT
Emerging
Departamento de INGENIERÍA QUÍMICA y
TECNOLOGÍA del MEDIO AMBIENTE
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Thank you for your attention!