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This Environmental Report is printed on Amber Graphic 110 G/M2 paper from Arctic Paper Kostrzyn S.A.
Introduction
Arctic Paper Kostrzyn S.A. (APK S.A.) is the largest producer of offset paper in Poland and the second largest producer of graphic paper. Since 1993, the company has belonged to the Swedish paper industry group Arctic Paper.
The products of the Kostrzyn’s mill are paper grades of Amber brand. These are the supe-rior quality, uncoated woodfree papers, manufactured in the modern, safe and environment friendly conditions.
Arctic Paper Kostrzyn S.A. has been certified to quality management systems ISO 9001 and work safety systems PN/N 18001 and OHAS 18001. The Company has implemented the environmental management system ISO 14001 and publishes generally available EMAS report about its impacts on the environment.
APK S.A. in numbers – 2010
• Production came to 274 311 tons of paper • Turnover amounted to PLN 801 million • Arctic Paper gives employment for 423 people
Foreword
I have a pleasure of handing over to you the EMAS Report, summarizing environmental actions taken by Arctic Paper Kostrzyn S.A. in 2010.
Year 2010 was for the Kostrzyn mill a consecutive year when actions were taken to mitigate a production process impact on the environment. Starting up and next development of high-efficiency combined heat and power plant in previous years do not exempt us from responsibility to reduce continuously our production processes impact on the environment. In consideration of this, appropriate actions were taken to use power resources more effec-tively yet. Application of additional heat recovery from flue gases has increased the process effectiveness. These actions brought the effect in form of additional thermal energy that was used in processes performed by Arctic Paper Kostrzyn S.A.
Arctic Paper Kostrzyn SA continuously takes actions that reduce an impact of its activity on the environment. It involves both investments in the production process and use of ecologi-cal raw materials. One of those actions is reduction of oil consumption on paper machines. The mill possesses FSC and PEFC certificates for Amber grades produced. Continuous development is depicted in our mission and our objective is development with reduction of paper production process impact on the natural environment.
In this report, you will find a description of our environmental policy implementation; I encourage you to read the report.
Kostrzyn nad Odrą, 25 May 2011
Henryk Derejczyk
President of the Management Board Content INTRODUCTION 2 FOREWORD 2 ENVIRONMENTAL MANAGEMENT 3 ENVIRONMENTAL POLICY 3 OPERATIONS DESCRIPTION 4 ENVIRONMENTAL ASPECTS 7 MILL’s ACTIVITY RELATED PERMITS 8 ENVIRONMENTAL IMPACT 9 ACCOMPLISHMENT OF ENVIRONMENTAL GOALS IN 2010 14 ENVIRONMENTAL GOALS FOR 2011 AND ACTION PLAN 15 GLOSSARY 19
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Environmental
management
At Arctic Paper Kostrzyn, we perceive our environmental mana-gement system as a part of the Company’s general manage-ment system, covering quality, natural environmanage-ment and labour environment.
Environmental management system means that work in favour of the environment is arranged in systematic way and the Com-pany undertakes actions oriented towards continuous improve-ment in respect of affecting the environimprove-ment.
Environmental management system is based on carried out ecological assessment and requirements imposed by EMAS and ISO 14001. We have adopted a policy that describes how we see our impact on the environment and our pro-environ-ment activity. The Company provided training for our staff in pro-environment activity, described how responsibility had been assigned, pro-environment activity procedures had been developed, goals and tasks had been set jointly with action plans. Results of our actions are systematically followed up and assessed.
EMAS /ISO 14001
EMAS is the abbreviation for Eco Management and Audit Scheme. Companies and organisations can join the EMAS project voluntarily. The aim of the project is encouraging com-panies and organisations to develop continuously their activity in favour of the environment in a systematized way, reaching far beyond regulatory requirements. To register to EMAS, the company or organisation has to:
make an initial review,
• adopt an environmental policy,
• establish environmental goals and action plans, • implement an environmental management system, • carry out an environmental management system audit, • develop and publish an environmental statement which
is checked by an impartial environmental verifier.
ISO 14001 is the International Standard that describes what should be included in an environmental management system to guarantee well arranged work in favour of the environment. As the minimum, it is expected that national regulatory requ-irements are met. One important rule supporting ISO 14001 is continuous improvement of environmental effects resulting from carried out actions and the fact that this improvement rate is decided by a given company itself.
Environmental
policy
„Being solicitous for natural environment, we always choose long-lasting solutions.”
The goal of Arctic Paper Kostrzyn is mitigation of adverse impact of the mill processes on the environment.
Means to achieve goals:
1. increasing personnel awareness concerning protection of the natural environment,
2. increasing a share of raw materials originating from ratio-nally managed forest crops,
3. optimization of water consumption,
4. reduction of energy consumption per production unit, 5. reduction of noise emission to the environment, 6. Preventing pollution and utilization of all solid wastes
produced.
Arctic Paper Kostrzyn meets legal standards and honestly informs about its activity impact on the environment.
The environmental policy of Arctic Paper Kostrzyn is known to every employee and is available to all interested.
Michał Jarczyński
President of the Management Board Kostrzyn nad Odrą, 19 October 2009
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Business description
Production processArctic Paper Kostrzyn is the producer of uncoated woodfree graphic paper. The process flow scheme below shows opera-tions beginning from pulp preparation to the finished product.
1. The basic raw material for paper production is pulp. Both types of pulp, softwood pulp (from coniferous wood) and hardwood pulp (from deciduous wood), are used in the production process.
2. Pulp is subjected to a pulping process with addition of circulation water (being returned from paper machines). Separate lines are provided for pulping SW and HW pulps.
3. Pulp suspension is pumped to refiners and refined there according to a recipe.
4. Main chemical additives: calcium carbonate, starch, size and process aids are mixed with pulp.
5. Paper stock is poured out from a machine headbox onto a wire table.
6. In a wire section, initial formation of paper web and par-tial dewatering occur.
7. A press section is responsible for removal of a next part of water in press nips.
8. Then a paper web is transferred to a drying section where further dewatering takes place.
9. The next step is paper surface processing through appli-cation of starch film in a size press,
10. after which a paper web is after-dried.
11. Now only calendering needs to be done and
12. winding on reels.
13. Reels are cut into smaller rolls, according to Customer’s requirements.
14. Paper in rolls is also cut into sheets, according to Custo-mer’s requirements.
15. After packing and loading on trucks, a finished product is shipped to Customers.
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Energy production
1. The basic fuel for energy production is natural gas from local resources. The back-up fuel is light heating oil.
2. Gas parameters are continuously monitored before bur-ning.
3. Generated heat is used for production of process steam necessary to dry a paper web.
4. Electric energy is generated by means of gas turbines and as the result of steam pressure reduction in two steam turbines.
5. Pollutants emission to the atmosphere is monitored in a half-year scheme.
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Waste water treatment
1. The first stage of treatment consists in mechanical eli-mination of contaminants from waste water, which are generated in a paper production process (mostly pulp fibres and filler particles). This treatment takes place in two basins called sedimentation tanks, where contami-nants are settling under gravity on a bottom and are removed, whereas pre-treated waste water passes fur-ther to be treated in next stages.
2. The second stage of waste water treatment occurs in two oxygen bioreactors. These are tanks where air is supplied. The “bio” prefix means that contaminants dis-solved in waste water are subjected to degradation by micro-organisms.
3. At the third stage, treated effluents are separated in the sedimentation tank from products of bacteria activity and then are led to a flotation chamber, where after-treat-ment by means of air and chemicals takes place. Clean effluents are discharged to the Warta River.
4. Separated deposit from a mechanical and biological treatment plant is transferred, after being mixed and dewatered, to recycling (composting or production of construction material).
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Environmental aspects – components of Arctic Paper Kostrzyn activity, products and/or services – influencing the environ-ment, have been identified, based on a map of processes performed in the mill. For every unit process input data have been collected and output data defined, with a special atten-tion paid to:
• emissions to the air, • discharge to waters, • waste handling, • soil contamination, • use of natural resources,
• other local environment and community related issues. An aspect is considered to be significant, when at least one condition is fulfilled:
• a scale of effects is large,
• it can be difficult to eliminate consequences,
• there can be a risk of exceeding limit values / emission standards.
The following have been considered as the most significant environmental aspects:
• Water consumption • Discharge of mill effluents • Waste water sludge
• Possibility of chemicals and oils leakage • Emission of carbon dioxide
• Noise emission.
• Possibility of gas explosion • Fire
Environmental Aspects
Mill’s activity related permits
Emission Permitted Current value Water consumption 30 000 m3/24 h 8 923 m3/24 h
Waste water volume 13 000 m3/24 h 7 394 m3/24 h
COD 250 mg/l 43,8 mg/l BOD5 30 mg/l 4,8 mg/l SS 50 mg/l 9,9 mg/l N total 30 mg/l 6,1 mg/l P total 3 mg/l 0,3 mg/l Effluents temperature 35 °C 28-35 °C Dust 15,3 t/year * 1 t/year SO2 74,1 t/year * 10,3 t/year NO2 410,3 t/year * 124,1 t/year CO2 208 448 t/year 143 660 t/year Sludge 2 500 t/year 1 724 t/year
We are meeting all other legal requirements applicable to operations of Arctic Paper Kostrzyn S.A. * amendment of decision of the head of the Lubuskie Voivodeship, DW.II.781-24/09 of 16.09.2009
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Summary of Environmental Data for 2010
Consumption of natural raw materials, energy, chemicals and emission of contaminants to the air, water and ground, per ton of paper (figures in brackets are 2009 values).
Raw materials Water 11.87 m3 (11.35) Pulp 737.27 kg (736.98) Filler 322.92 kg (326.19) Starch 53.81 kg (54.18) Size 1.40 kg (1.27) Other additives 16.70 kg (15.35) Energy Electricity 588,04 kWh (601,6) Heat 8,07 GJ (8,28)
Natural gas 444,4 m3 (418,4) Emission to water
SS 0.10 kg (0.06) CODCr 0.43 kg (0.36) BOD5 0.05 kg (0.04) Nitrogen total (N) 0.06 kg (0.06) Phosphorus total (P) 0.003 kg (0.002) Sewage 9.8 m3 (9.1) Emission to air
Sulfur dioxide (SO2) 0.04 kg (0.02)
Nitrogen dioxide (NO2) 0.45 kg (0.51)
*Carbon dioxide (CO2) 524 kg (487)
Noise 44.9 dB(A) at night (44.9)
Waste
Hazardous 0.03 kg (0.09) Non-hazardous 10.90 kg (11.75) including sediments 6.28 kg (6.82)
Biodiversity
Installations of Arctic Paper Kostrzyn S.A. cover 1.088.316 m2, including 194.642 m2 planted with trees.
Products
Paper 274311 t (268928) Energy Electricity 219420.3 MWh (178336.4)
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Environmental Impact
Net paper production
tonnes/year Consumption of natural raw materials
Main raw materials for production of paper are: SW pulp = softwood pulp and HW pulp = hardwood pulp, bleached in TCF and ECF processes (when producing TCF pulp it is not allowed to use neither chlorine nor chlorine dioxide in a pulp mill’s bleaching process; during production of ECF pulp it is not allowed to use chlorine a pulp mill’s bleaching process, but use of chlorine dioxide is acceptable), filler (calcium carbonate), starch for surface sizing as well as other process aids.
Water consumption
Water is the necessary raw material in paper production pro-cess. Arctic Paper Kostrzyn carefully treats water before using it in a process so as not to disturb product quality, and before returning it to the Warta River, water is thoroughly treated as well. Within the space of last years we were closing water cir-cuits on regular base. Effectiveness of those actions is visible when comparing specific consumption of fresh water. Presently, we have achieved the level of about 11.87 m3/t of paper. The natural consequence of closing water circuits is an increase of contaminants concentration in waste water, which we have evi-dently noticed. Reduction of specific water consumption invo-lves the increased use of chemical process aids and that is why we decided to cease closing the other water circuits.
Noise
There are two essential noise sources in the mill: • operation of fans in the paper mill building,
• occasional steam bleeding in the power plant or in the paper production department.
We are obliged by requirements of the integrated permit to take measurements once every two years. Presently, the noise level is 44.9 dB in the night (acceptable standard is 45 dB).
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kg/tonne Emission of dust
(kg/ton paper) Heath (GJ/ton paper)
GJ/tonne Power engineering and energy production
In response to increasing demand for energy and having envi-ronmental aspects in mind, the company launched at the end of 90s the project for new Power Plant, based on the use of natural gas. Since 1 January 2006, more stringent standards have been valid for emissions to the atmosphere, which APK would not be able to meet when combusting coal in worn out, coal-fired boiler house. That is why the adaptation program, consisting in erection of the gas based, combined heat and power plant, was launched to avoid closing down the mill. The new plant was commissioned on 02.03.2007. Modern techno-logy and changed type of fuel are a direct reason for reduced emissions to the air. In 2009 a further expansion of the combi-ned heat and power plant facilities occurred.
Emission to the air
Emission to the air refers mainly to dust, NO2, SO2 and CO2.
Dust
Dust generation is inextricably linked with all production pro-cesses and combustion propro-cesses. Particularly big quantities of dust are produced when combusting solid fuels. Dust harm-fulness rate depends mostly on its concentration in the atmo-sphere and its chemical composition. Dust emission has decre-ased dramatically since the moment the gas-firing was started.
NO2 = Nitrogen oxide
This gas is generated during combustion. Nitrogen oxides can form nitrogen acid in wet air, which in turn falls in form of “acid rain”. This nitrogen-containing rain produces also a fertilizing effect (eutrophication).
Electricity (kWh/ton paper)
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Sulphure dioxide (SO2) to the air (kg/ton paper)
kg/tonne
kg/tonne Nitrogenoxides (NOx) to the air
(kg/ton paper)
Carbon oxide (CO) to the air (kg/ton paper)
kg/tonne SO2 = Sulphur dioxide
This gas is generated during combustion of fuels containing sulphur and, as a by-product, during production of pulp. After a contact with moisture, SO2 forms a sulphuric acid that contri-butes to “acid rains” and soil acidification.
CO2 = Carbon dioxide
In a paper production context, carbon dioxide is generated during combustion of fossil fuels in production of pulp and paper.
Increased volume of carbon dioxide and other „green house” gases in the atmosphere gradually reduces heat radiation from the surface of our planet. Carbon dioxide is produced in a natural way through bio-degradation of organic substances. The “green house” effect is produced mostly by combustion of fuels.
Waste water discharge
Before being directed to the Warta River, waste water is subjected to two-stage treatment. In 2008, the waste water treatment plant was significantly expanded. It was equipped with a buffer tank and a 2nd stage of biological treatment. The purpose of the buffer tank is to average waste water qualities and the 2nd stage of biological treatment intensifies a treat-ment process and prolongs the time of retention from 2 to 14 hours. Main contaminants of waste water from Arctic Paper Kostrzyn are some organic compounds as well as nitrogen and phosphorus. Nitrogen and phosphorus are biogenic elements for many plant species. When introduced to a river, they con-tribute to exuberant growth of plankton, which is an undesired effect.
Organic compounds, subjecting to chemical transformations, consume part of oxygen contained in water. Oxygen is neces-sary for existence of many aquatic plants and animals.
Water flow to recipient (m3/ton paper)
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COD to recipient (kg/ton paper)
kg/tonne
Suspended solids (SS) to recipient (kg/ton paper)
kg/tonne
Phosphorus to recipient (kg/ton paper)
kg/tonne
Sluges to landfill or reuse
kg/tonne Nitrogen to recipient (kg/ton paper) kg/tonne COD to recipient (kg/ton paper) kg/tonne
Wastes disposed on dumping ground
We do our best to segregate wastes. The main produced wastes are packing material wastes. For a paper mill having an own waste water treatment plant a typical waste is also a slud-ge which is entirely transferred to contractors for recycling. At present it is used to produce compost.
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Goal 1: Reduction of oil consumption on paper machines – continued goal of 2008 and 2009.
We achieved the targeted reduction of oil consumption on the paper machine No. 1 which confirms a high efficiency of leaka-ges elimination. The goal was not accomplished in case of the paper machine No. 2, but we will take actions to reach this goal through continued reduction of oil consumption on both paper machines.
Goal 2: Protection against possible spillage of chemicals during unloading operation.
Task: Modernization of unloading stations for cistern trucks with chemicals at the paper production department. A technical design has been prepared, the task is waiting to be released for execution.
Goal 3: Reduction of heat and electricity consumption on paper machines.
Power engineering audit was conducted in the mill owing to which locations and process were pointed out with a high potential for energy savings.
One of the first tasks executed within frames of reduction of energy consumption is installation of a flue gas heat recovery device Q-box in the power department. The concept of this device is relatively simple. Hot flue gas is directed first to a heat exchanger instead of a stack. In the heat exchanger, the gas returns its heat to a system and next passes to a stack, being cooled down to about 100 oC, and further to the atmo-sphere. The project performs very well and accurate estimation of savings will be possible at the end of 2011, due to different heat consumption in particular seasons of a year. Details will be presented in the report for 2011.
Achievement of environment targets in 2010
Paper Machine No. 1
kg of oil/month
Paper Machine No. 2
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Goal: Continued reduction of oil consumption on paper machines.
We set us a target of oil consumption reduction on both paper machines to the level below 823 kg per month.
Goal: Continued protection against possible spillage of chemicals during unloading operation.
Goal: Reduction of heat and electricity consumption.
Task: Modernization of the central heating system in produc-tion departments
Heat recovered on Q-box is perfectly suitable for mill heating. A comprehensive modernization of central heating system in two big departments: Pulping Department and Paper Produc-tion Department is planned for 2011. Accurate estimaProduc-tion of savings will be possible at the end of 2011
Goal: Reduction of noise emission level to 43 dB in the night.
Task: Marking out and attenuation of the biggest noise sources in the mill.
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Yearly update of reports is anticipated.
Next scheduled update will be published
in June 2012.
For any questions please contact:
Mariusz Bartosiak
Arctic Paper Kostrzyn S.A. Ul. Fabryczna 1
66-470 Kostrzyn nad Odrą
e-mail: [email protected]
TUV NORD Polska Sp. z o. o., ul Mickiewicza 29, 40 –085 Kato-wice, with the environmental verifier registration number EMAS PL-V-0001, accredited for NACE 17.12, declares to have veri-fied whether the whole organization as indicated in the envi-ronmental statement, with registration number PL 2.08-001-13, meets all the requirements of Regulation (EC) No 1221/2009 of the European Parliament and of the Council of 25 November 2009 on the voluntary participation by organisations in a Com-munity eco-management and audit scheme (EMAS).
Signing this declaration, I hereby declare that:
• the verification and validation have been carried out in full compliance with the requirements of Regulation (EC) No 1221/2009,
• the outcome of the verification and validation confirms that there is no evidence of non-compliance with appli-cable legal requirements related to the environment, • data and information of the environmental statement of
the organisation reflect a reliable, credible and correct image of all organisation’s activities, within the scope mentioned in the environmental statement.
This document is not equivalent to EMAS registration. EMAS can only be granted by a competent body under Regulation (EC) No 1221/2009. This document shall not be used as a stand-alone piece of public communication.
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Glossary
ACCREDITED COMPANYA company approved by an official authority to perform defined analy-ses and audits of industrial procesanaly-ses.
BIOLOGICAL TREATMENT
A method for waste water treatment by means of microorganisms used to degrade organic substances.
BOD5
Oxygen required by microorganisms to decompose easily degradable organic compounds during 5 days.
CARBON DIOXIDE
CO2. A naturally occurring gas produced by biological degradation as well as during fuels combustion process.
PULP
Collective definition for CELLULOSE PULP being used for paper pro-duction. Pulp can be produced by chemical processes (e.g. SULPHATE PULP, SULPHITE PULP) or by mechanical processes (e.g. MECHANI-CAL PULP, THERMOMECHANIMECHANI-CAL PULP). Pulp can be bleached by different processes: free of elementary chlorine, ECF, or totally free of chlorine, TCF.
COD
The amount of oxygen required for a specific chemical decomposition of organic compounds present in water.
dB(A)
Decibel A, a method for assessing sound intensity which takes into account the human sensitivity to the different frequencies of sound EMAS
Eco Management Audit Scheme. A scheme based on EU regulation involving an audited and publicly available yearly environmental report. EUTROPHICATION
PHOSPHOR, P, and NITROGEN, N, are components of the nutritive salts, which foster the growth of plankton in waters. Too high amount of nutritive salts can cause a rapid growth consuming all oxygen available. FINE PAPER
A general term for graphic paper, writing- and printing paper as well as for some technical and special papers. Fine paper can be COATED with layers consisting mostly of chalk, kaolin, starch and synthetic latex, or UNCOATED.
HAZARDOUS WASTE
Compounds, which are particularly hazardous to the environment such as certain chemicals, oils, used batteries and electronic materials. ISO 14001
The International Standard for environmental management systems. A certificate is issued once the requirements of the standard are fulfilled. LIMIT VALUE
A specific value, defined and assigned by the pollution-control authority, which is not allowed to be exceeded
NITROGEN DIOXIDE, NO2
A gas formed from nitrogen during combustion. Contributes to eutro-phication.
RECIPIENT
Environmental media such as rivers, seas, lakes, or atmosphere that receive emissions and discharges
OXYGEN DEMANDING MATERIAL
Substances in waste water discharged to a recipient which act as a fer-tilizer and reduce oxygen available for living organisms. Measured as COD and BOD
SUSPENDED SOLIDS, SS
Particles and fibres in waste water, visible with a human eye, causing water opacity. Suspended solids prevent sunlight access to water which reduces growth of aquatic plants.
SULPHUR DIOXIDE, SO2
A gas formed during combustion of sulphur-containing fuels and cau-sing acid rains.
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Arctic Paper Papierhandels GmbH, Austria Arctic Paper Benelux N.V., Belgium Arctic Paper Danmark A/S, Denmark Arctic Paper France SAS, France
Arctic Paper AB Representative Office, Ukraine Arctic Paper Deutschland GmbH, Germany Arctic Paper Ireland Ltd., Ireland
Arctic Paper Italia Srl, Italy Arctic Paper Baltic States, Latvia Arctic Paper Norge AS, Norway Arctic Paper Polska Sp.z o.o., Poland Arctic Paper Espana S.L., Spain Arctic Paper Sverige AB, Sweden Arctic Paper Schweiz AG, Switzerland Arctic Paper UK Ltd., United Kingdom
Arctic Paper Munkedals AB Arctic Paper Kostrzyn S.A.
Arctic Paper Mochenwangen GmbH Arctic Paper Grycksbo AB
Arctic Paper in Europe
Sales offices
Arctic Paper S.A. is second largest manufacturer of book paper, and a leading manufacturer of graphic fine paper in Europe. The Group produces several types of uncoated wood and wood-less paper for printing houses and publishers of books, magazines and advertising materials. The product portfolio comprises the following brands: Amber, Arctic, G-Print, Munk-en, Pamo and L-Print.
The group has four paper mills: Kostrzyn nad Odrą (Poland), Munkedal and Grycksbo (Sweden) and Mochenwagen (Ger-many) with total combined capacity of 800 thousand tones of paper a year.
Distribution companies and sales offices responsible for distri-bution and marketing of the Group’s products are an important part of the Group. Currently there are 15 distribution compa-nies and sales offices of the Group in Europe, enabling access to all European markets, with which the Group holds 1/5 of the European market of book paper.
The Group in brief
Paper mills
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Product control after cutting paper into sheets
Roll handling in finished products warehouse
