Environmental standards in the Pulp and Paper Sector
Transcript of Environmental standards in the Pulp and Paper Sector
Environmental standards in the Pulp and Paper Sector
Almut Reichart German Federal Environment Agency
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Outline
Overview over the pulp and paper industry in Europe
Status of the BREF Pulp & Paper Industry
Structure of the BREF
Examples for Best Available Techniques for Recovered Paper Processing, Papermaking and related Processes
Concluding remarks
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Overview over the European Pulp and Paper sectorShare of world Paper & Board production - development 2000-2010 (Cepi 2012, RISI)
Worldwide paper production: 370 mio. tEurope: 104,8 mio. tGermany: 22 mio. t
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Overview over the European Pulp and Paper sector
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Environmental issues of the sector in Europe Increase of production by 50% electricity consumption, primary
energy consumption have increased
The water consumption and some emissions like and NOxand CO2 emissions stay around the same high level
other emissions are decreasing significantly like COD, SO2, BOD, AOX
Substantially environmental improvements in the production have lead to a partially decoupling of environmental impacts from the production
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Best Available Techniques (BAT) Reference Document for the Production of Pulp, Paper and Board
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Status and scope of the BREF Pulp and Paper
The BREF Pulp and Paper Industry is the major outcome of the European information exchange on BAT for the sector
The BREF provides a lot of information on available techniques.
Information source for permitting authorities, public, and operators
First Edition BREF Pulp and Paper was published in 2001
First Revision of the document will be published in 2014
• Final draft from July 2013• Technical discussion is finalized• Political adoption in 1st. Quart. 2014
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Scope and status of the BREF Pulp and Paper industry
Related activities:• Power and steam
generation
• Raw water treatment
• Waste water treatment
• Waste handling and on-site treatment
• Storage and handling of chemicals
Download of the BREF: http://eippcb.jrc.ec.europa.eu/reference/BREF/PP_BREF_FD_07_2013.pdf
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
The structure of the BREF
Best available techniques (BAT) conclusions (chapter 8)
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Examples for BAT in recycled fibre paper mills
1. Water use and waste water management2. Fibre recovery from paper machine effluents3. End of pipe - waste water treatment4. Waste management, incineration of residues5. Energy efficiency
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
1. Water and waste water management
BAT 5: In order to reduce fresh water use and generation of waste water, BAT is to close the water system to the degree technically feasible in line with the pulp and paper grade manufactured by using a combination of the techniques….
• Monitoring an optimisation of water use• Evaluation of recirculation options • Balancing the degree of closure of water circuits and potential draw
backs • Separation from less contaminated waters and reuse, e.g. sealing
water from pumps, cooling water• In line treatment of process water to improve water quality to allow
recirculation
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
BAT 5: associated environmental performance levels for the waste water flow at the point of discharge
subsector BAT –AEPL in m³/ Air dried ton
Recycled fibre (RCF) paper mills without deinking
1.5 ‐ 10
RCF paper mills with deinking
8 ‐ 15
RCF‐ based tissue mills with deinking
10 ‐ 25
non‐integrated paper mills
3.5 ‐ 20
Techniques to reduce fresh water consumption:a. Separation of the water systemsb. Countercurrent flow of process water and
water recirculationc. Partial recycling of treated waste water after
biological treatmentd. Clarification of white watere. Continuous control of process water qualityf. Prevention of biofilms by using methods that
minimise emissions of biocidesg. Removal of calcium by a controlled
precipitation of calcium carbonate
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Separation of water loops and counter current flow Countercurrent flow: White water goes into
the opposite direction than the product flow In many paper mills fresh water is only used
for dilution of chemicals and at the paper machine for clean spray pipes and edge sprays
Short circulation on the paper machine Long circulation to the stock preparation Separation is done by thickeners (e.g.
filtration, wire and presses) Save-alls are filtration (e.g. microfiltration),
flotation (dissolved air flotation) or sedimentation units to clean the water from fibers etc.
Advantages: less water consumption, (RCF without deinking 2-6
m³/t, RCF with deinking below 10 m³/t) Lower volumes for effluent treatment, decreased fibre an filler losses, elevated process temperature reduced energy
demand
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: In-line biological process water treatment for closed water loop
1 mill Germany Production of 400.000 t/a case material and testliner, 2 paper machines, zero effluent
Partial stream of process water is cooled preacified anaerobic reactors (UASB) (optional decarbonisation stage) aerobic treatment sedimentation sand filter COD concentration in the water circuit 7 000 – 8 000 mg/l
Benefits: less excess sludge, energy for aeration can be saved, Biogas from anaerobic treatment can be used for steam production on site
Risks: uncontrolled precipitation of calcium, optimisation of water-fibre system is complex and needs years
Costs: capital and operational costs total EUR 1.8/ton paper and 0.7/m³ process water
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
2. Efficient fibre and filler recovery (BREF sec.7.3.4)
1. Screening in stock preparation and recycling to pulping unit2. Short water circulation in paper machine, reuse of untreated water
containing not-retained fibres3. Wet end save alls (drum or disc filter, flotation, microfiltration,
sedimentation) collection of fibres in a chest recycling to paper machine or next lower quality unit
4. Wet and dry end broke handling recycling5. Further integrated measures:
1. Tuning of refining and screening (heavy refining increases amount of short fibres)2. Control of even paper web across the machine width3. Efficient use of chemical additives for better retention of fibres4. Suitable size of white water and broke storage (run of 2-3 hours production) equals
out sudden peak fibre discharges5. Collection and recycling of broke after the coating unit
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: efficient fibre and filler recovery
Achievable min. solid losses: 10 – 20 kg/t produced paper
(i.e. 1 – 2% loss)
Benefits: return of raw material to the
process, less waste to dispose, improved runability of paper
machine, lower solid content in the
excess water for treatment
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Cleaning and recycling of white water -Dissolved Air filtration (DAF)
Cleaning of white water for recycling
Anionic trash and fines are agglomerated into physically treatable flocs
The suspended solids are attached to air bubbles to the surface of a basin scraped off dewatered incineration
Clarified water is taken from the bottom recirculated to a suitable place in the water cycle
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Diskfilter
DENSIDISC ® is a product by O.M.C. Collareda Srl - Div. Aqua Engineering.
Stainless steel gravity filter, filtering by metal wire
Application Solids separation from liquids Fibres separation from fillers and
fines Sludge and supension thickening Effluent filtration Pulp thickening in stock preparation
Rotation of disks provides friction for cleaning action and preventing the wire clogging
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example Microfiltration unit (ALGAS)
Corrugated surface increasing filtration area
Inside to outside filtration, slowly turning drum (stainless steel), small motor, no vacuum
Cleaned by full width showers
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: other Membrane filtration
Efficient removal of suspended solids from white water is a prerequisite for further recirculationof treated water to production and a preliminary measure for closing up water circuits.
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
3 . Emissions to water – waste water treatment
BAT 13-16 and BAT 43 – 49 are relevant BAT is to substitute chemical additives with high nutrient contents
(nitrogen, phosphorus) Pretreatment of effluents containing coating colors Optimised fibre, filler and pigment recovery In order to reduce emissions of pollutants into receiving waters, BAT is
to use: 1. primary (physico- chemical) treatment and2. secondary (biological) treatment
When further removal of organic substances, nitrogen or phosphorus is needed, BAT is to use tertiary treatment (e.g. filtration, flocculation/precipitation or advanced oxidation processes)
Proper design and operation and control of WWTP is BAT
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
BAT AELs for RCF mills - emissions to water
Parameter RCF with deinking in kg/t as yearly average
RCF without deinking in kg/t as yearly average
Chemical oxygen demand (COD)
0.4 ‐ 1.4 0.9 – 3.0(4.0 for tissue)
Total suspend solids (TSS) 0.02 – 0.2 0.08 – 0.3(up to 0.4 for tissue)
Total nitrogen 0.008 – 0.09 0.01 – 0.1(up to 0.15 for tissue)
Total phosphorus 0.001 – 0.005 0.002 – 0.01 (up to 0.015 for tissue)
Adsorbable organically bound halogens (AOX)
0.05 for wet strength paper 0.05 for wet strength paper
For mills with closed water circuits, there are no emissions of COD.The BOD concentration in the treated effluents is expected to be low (around 25 mg/l as 24‐hour composite sample)
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
modified by A. Reichart original source: Efinger D., Der R2S-Reaktor – Funktion und erste Erfahrungen; IN: PTS-Seminar „Betrieb biologischer Abwasserreinigungsanlagen – Anaerobtechnologieund Betrieb von Anaerobanlagen“, 13. – 14.10.2008, PTS München, PTS-Manuskript AR 819, G. Weinberger, H.-J. Öller (Hrsg.)
COD[mg/l]
10 20
15.000
4.000
2.000
DIP, white, newsprint, SC
brownpaper
TissueDIP, Mixed, without DIP Speciality p.,
primary fibre
Ca2+
[mg/l]
1.200
600
300
53specific water consumption in l/kg
Choice of biological waste water treatment technique depends on the kind of paper produced
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Anaerobic biological waste water (pre)-treatment
When concentrations are high > 1.000 mg/l COD, and SO4 is low (<1000 mg/l) anaerobic treatment works economically
Typical reactors: • Upflow anaerobic sludge blanket (UASB)• Extended granular sludge blanket (EGSB), e.g. internal current (IC) or BIOBED
reactor Advantages: reduction of organic pollution load compared to only
aerobic treatment, less excess sludge (minus 70 %) and less energy consumption, biogas production (400 – 600 m³/t COD removed)
Draw backs: sulphate reduction to sulfite is a potential inhibitor of methanogenesis, reduction of biogas production
Effluent of an anaerobic reactor never has sufficient quality for direct discharge aerobic treatment has to follow (activated sludge reactor)
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Chlorine free bleaching chemicals for recycling fibres processing mills
reduction of AOX was achieved by a combination of several measures
the use of molecular chlorine has been completely replaced by chlorine dioxide and the use of chlorine-free bleaching chemicals such as molecular oxygen, hydrogen peroxide, ozone or peracetic acid.
RCF – Bleaching: Reductive bleaching: Na2S2O4 sodiumdithionite, pH < 6Oxidative beaching: H2O2 hydrogenperoxide, pH > 8 Complexing agents stabilise H2O2
AOX emissions are below 10 g/t product
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
4. Waste management, treatment of residues
“Waste material is simply raw material in the wrong place”BAT 12 is to implement a waste assessment and management so
as to facilitate 1. waste reuse, 2. waste recycling, or 3. other recovery, including a combination of the following techniques:
a. Separate collection of different fractionsb. Merging suitable fractions for better utilisationc. Pretreatment before reuse or recycling ( e.g. dewatering, shredding,
biological stabilisation)d. Recovery or recycling on site (e.g. fibre or coating recovery)e. Energy recovery on- or offsite from wastes with high organic contentf. External material utilisationg. Pretreatment of waste before disposal
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Waste management, treatment of residues
Council Directive 99/31/EC dumping of waste with organic content > 5% is not allowed
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: incineration of residues with high calorific value
Incineration combined with power and steam generation is environmental and economically attractive
Pretreatment of rejects is necessary: dewatering (50% SC), crushing, screening
RCF mills with deinking have high amounts of deinking sludge, and process water treatment sludge up to 40% residue related to input material
Sludge contains: short fibres, fillers, coatings, ink particlesDifferent types of incineration possible e.g.:
• Separate mill reject incineration plant• Co-incineration in on-site coal fired power plants• Co-Incineration off-site in the cement or brick industry
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Incineration of residues - pretreatment of rejects
grate firing5 -25 MW heat capacity
fluidised bed firing25 MW heat capacity
Mixed systems are also possible
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
2012
Magnetseparator
Screwpress
Disc filter
Screwpress
Shred-ding
Screen
MagnetSeparator (NE)
Silo fibersludge
Silo Coarserejects
Gravity table
SPP Screens & cleaner rejects
Surplus aerationbiosludge
Mill´s U-drain
Pre Shredding
SPP Pulperrejects
PulperRagger
SPP= Stock Preparation Plant
Example SIPAPER Rejekthandling - source: Siemens AG 2012 Dr. H Schwarz
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Reject Split feeded to Reject Power at Saica UK
Coarse Rejects(mainly Plastics):50% of total rejectsLHV: ca.13000kJ/kgSC: 55% - 60%Mech. Dewatering via Screw presses andmech. preparation
Biosludge:20% of sludgeamountLHV: < 300kJ/kgSC: 50 - 55%Mech. Dewatering w/ fiber sludge
Fiber rejects :80% of sludgeamountLHV: ca. 5000kJ/kgSC: 50 - 55%
Capacity of solid reject fuel: ca. 80.000 t/aBased on 2010 planning data
Biogas of AnaerobicEffluent treatment:Ca. 5MWth max. , Ca.65% Methane, 30% CO2, biologicaldesulfurisation
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: SIPAPER Reject Power Technology
TechnologyReject Power Firering source : Siemens AG Dr. H Schwarz 2012
EconomiserBoiler
Cyklon
Grate
Spin wheel
Bag filter
Fuel-dosing
2 sec. Residence Time Pilot unit
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example incineration of rejects - flue gas treatment
Flue gas needs treatment: Flue gas recirculation
SNCR (urea injection) NaHCO3, coal and zeolite
are added as adsorbensfor acid gas, dioxins, furans
bag filter continuous monitoring of
dust, SO2, NOx, TOC, HCl
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Advantages of reject incineration
No landfillUtilisation of high heating value of residues 22- 24 MJ/kgAsh can by used in road constructionSteam generationLow emissionssavings of 1.3 EURO /aInvestment cost: 6 mio. EURO + 0.6 mio. EURO/a operation
(for treatment plant treating 15.000 t/a) Refer also to BREF section 6.3.14
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
5. Energy consumption and efficiency
BAT 6 Implementation of an energy management system e.g. ISO 50001• Incineration of residues with high calorific value• Use as far as possible the cogeneration of heat and power (CHP) • Use of excess heat for the drying of biomass, sludge, process water, buildings• Use thermo compressors• Insulation of steam and condensate fittings
BAT 46: • high consistency pulping for disintegrating RCF into separate fibres• efficient coarse and fine screening smaller equipment with lower energy consumption• Extracting impurities as early as possible
BAT 53: • best practice refining with heat recovery,• Optimised vacuum system for dewatering in the press section• Condensate recovery and efficient exhaust air heat recovery system,• Optimised pumping design, • Steam box heating of the paper web• Use of high efficiency motors• Preheating shower water with a heat exchanger• Use waste heat for sludge drying• Heat recovery from axial blowers, Yankee hood, infrared exhaust air (if used)
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Energy consumption assessment and optimisation
1. Assessment of the initial situation
2. method for locating, quantify of potentials and optimizing
3. Monitoring and sustainable safeguarding of achieved savings
MeasuresMeasures
RealisationRealisation
Data
acquisition
Tools
Potential assesmentPotential
assesmentConsumption valuesConsumption values
Purpose / functionPurpose / function
Process flowsProcess flows
Technical equipmentTechnical equipment
Waste heatWaste heat
Heat sinksHeat sinks
Distribution networkDistribution network
Process managementProcess management
Functional assessmentFunctional assessment
Pinch analysisPinch analysis
BenchmarkingBenchmarking
EfficienciesEfficiencies
Heat networkHeat network
Compressed airCompressed air
Refrigerating plantsRefrigerating plants
Dewatering performanceDewatering performance
Drives for pumpsDrives for pumps
RefiningRefining
Vacuum systemVacuum system
Steam & condensatesystem
Steam & condensatesystem
Hood ventilationHood ventilation
Hall ventilationHall ventilation
Power plantPower plant
Focal
analysis
points
EconomicassessmentEconomic
assessment
Action planAction plan
Assessment &
optimisation
MeasuresMeasures
RealisationRealisation
Data
acquisition
Tools
Potential assesmentPotential
assesmentConsumption valuesConsumption values
Purpose / functionPurpose / function
Process flowsProcess flows
Technical equipmentTechnical equipment
Waste heatWaste heat
Heat sinksHeat sinks
Distribution networkDistribution network
Process managementProcess management
Functional assessmentFunctional assessment
Pinch analysisPinch analysis
BenchmarkingBenchmarking
EfficienciesEfficiencies
Heat networkHeat network
Compressed airCompressed air
Refrigerating plantsRefrigerating plants
Dewatering performanceDewatering performance
Drives for pumpsDrives for pumps
RefiningRefining
Vacuum systemVacuum system
Steam & condensatesystem
Steam & condensatesystem
Hood ventilationHood ventilation
Hall ventilationHall ventilation
Power plantPower plant
Focal
analysis
points
EconomicassessmentEconomic
assessment
Action planAction plan
Assessment &
optimisation
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Energy consumption and efficiency
Type of RCF paper mill Energy consumption level for process heat in kWh/t
Energy consumption level for electricity in kWh/t
RCF without deinking ( packagingpaper, e.g. testliner and /or corrugated medium)
1100 ‐ 1500 350 ‐ 450
RCF without deinking (cardboard or folding boxboard(1) coated and uncoated)
1200 ‐ 1600 400 ‐ 500
RCF with deinking (graphic paper, e.g. newsprint (1)
1 000 – 1800 900 ‐ 1300
RCF with deinking (folding boxboard) (1)
1 000 – 1100 450 ‐ 550
(1) Figures refer to mills that do not produce mechanical pulp on‐site
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Energy saving screening techniques
Energy saving screens: Hole screens with multi stage
fine screening with higher consistency from 1.5 to 2.5 %lower water content to press section less energy demand for drying
Higher separation efficiencies lower rotations speed needed less electrical power demand
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Example: Use of steam boxUsed to heat up paper web for
improved drainage properties of the web for higher dewatering capacities of the following press
The alternative would be to increase the white water temperature by direct steam heating
Advantage: only a small amount of water has to be heated not the whole white water circuit
Savings 4 % reduction of specific energy consumption
Investment 600.000 EUROPayback 2.6 a
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Thank you for your attention!
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Useful links
BREF for the Production of Pulp, Paper and Cardboard: http://eippcb.jrc.ec.europa.eu/reference/pp.html
Cleaner production Germany:http://www.cleaner-production.de/en.html
Blue Angel for paper products: http://www.blauer-engel.de/en/products_brands/search_products/produkttyp.php?id=434http://www.blauer-engel.de/en/products_brands/search_products/produkttyp.php?id=459
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Papermaschine
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
AOX content in wet strength agents based on Epichlrohydrinefrom research projects – PTS
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“BAT in textile and pulp and paper sector” – 18th – 29th November 2013 A. Reichart, Umweltbundesamt
Deinking