Best Available Techniques (BAT) Reference Document for the Production of Pulp, Paper and Board. Industrial Emissions Directive 2010/75/EU (Integrated Pollution Prevention and Control)

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Best Available Techniques (BAT)

Reference Document for the

Production of Pulp, Paper and Board

Industrial Emissions Directive

2010/75/EU

(Integrated Pollution

Prevention and Control)

Michael Suhr, Gabriele Klein, Ioanna Kourti, Miguel Rodrigo Gonzalo, Germán Giner Santonja, Serge Roudier, Luis Delgado Sancho

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Joint Research Centre

Institute for Prospective Technological Studies Contact information

European IPPC Bureau

Address: Joint Research Centre, Edificio Expo c/ Inca Garcilaso 3, E-41092 Seville, Spain E-mail: JRC-IPTS-EIPPCB@ec.europa.eu Tel.: +34 95 4488 284 Fax: +34 95 4488 426 http://eippcb.jrc.ec.europa.eu https://ec.europa.eu/jrc/en/institutes/ipts Legal Notice

Under the Commission Decision of 12 December 2011 on the Re-use of Commission Documents (2011/833/EU), the present BREF document is subject to free re-use, except for parts covered by any third-party rights which may be present in the document (such as images, tables, data, written material, or similar, the rights to which need to be acquired separately from their respective rights-holders for further use). The European Commission is not liable for any consequence stemming from the re-use of this publication. Any re-use is subject to the acknowledgement of the source and non-distortion of the original meaning or message

All images © European Union 2015, except: Cover pictures credits, from the top-left to the bottom-right: 1. © Fotolia.com – lnzyx; 2. © Fotolia.com –Moreno Soppelsa; 3. © Fotolia.com –EyeMark; 4. © Fotolia.com –itrija; 5. © Fotolia.com –Moreno Soppelsa; 6. © Fotolia.com –miket; 7. © Fotolia.com –hxdyl.

JRC95678 EUR 27235 EN

ISBN 978-92-79-48167-3 (PDF) ISSN 1831-9424 (online) doi:10.2791/370629

Luxembourg: Publications Office of the European Union, 2015 © European Union, 2015

Reproduction is authorised provided the source is acknowledged. Abstract

The BAT reference document entitled ‘Production of Pulp, Paper and Board' forms part of a series presenting the results of an exchange of information between EU Member States, the industries concerned, non-governmental organisations promoting environmental protection, and the Commission, to draw up, review and, where necessary, update BAT reference documents as required by Article 13(1) of the Directive 2010/75/EU on industrial emissions. This document is published by the European Commission pursuant to Article 13(6) of the Directive. This BREF for the production of pulp, paper and board covers the activities specified in Sections 6.1(a) and 6.1(b) of Annex I to Directive 2010/75/EU, i.e. the integrated and non-integrated production in industrial installations of:

(a) pulp from timber or other fibrous materials;

(b) paper or cardboard with a production capacity exceeding 20 tonnes per day. In particular, this document covers the following processes and activities:

- chemical pulping:

(a) kraft (sulphate) pulping process (b) sulphite pulping process

- mechanical and chemimechanical pulping

- processing paper for recycling with and without deinking

- papermaking and related processes

- all recovery boilers and lime kilns operated in pulp and paper mills.

Important issues for the implementation of Directive 2010/75/EU in the pulp, paper and board industry are the emissions to air of nitrogen oxides, sulphur oxides, dust, total reduced sulphur and ammonia; emissions to water of organic carbon, suspended solids, nitrogen, phosphorus and adsorbable organically bound halogens. The BREF contains nine chapters. Chapters 1 and 2 provide general information on the pulp, paper and board industry and on the common industrial processes and techniques used within the whole sector. Chapters 3, 4, 5, 6 and 7 correspond to the following specific sectors: kraft (sulphate) pulping process, sulphite pulping process, mechanical and chemimechanical pulping, processing of paper for recycling with and without deinking, and papermaking and related processes. For each sector, these five chapters provide information and data concerning the applied processes and techniques; the environmental performance of installations in terms of current emissions, consumption of raw materials, water and energy, and generation of waste; the techniques to prevent or reduce the environmental impact of installations; and the emerging techniques. In Chapter 8 the

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Best Available Techniques (BAT)

Reference Document for the

Production of Pulp, Paper and Board

Industrial Emissions Directive 2010/75/EU Integrated Pollution Prevention and control

Authors:

Michael Suhr Gabriele Klein Ioanna Kourti

Miguel Rodrigo Gonzalo Germán Giner Santonja Serge Roudier

Luis Delgado Sancho

2015

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Acknowledgements

This report was produced by the European Integrated Pollution Prevention and Control Bureau (EIPPCB) at the European Commission's Joint Research Centre – Institute for Prospective Technological Studies (IPTS) under the supervision of SergeRoudier (Head of the EIPPCB) and Luis Delgado Sancho (Head of the Sustainable Production and Consumption Unit). The authors of this BREF were Mr Michael Suhr, Ms Gabriele Klein, Ms Ioanna Kourti, Mr Miguel Rodrigo Gonzalo and Mr Germán Giner Santonja. Mr Michael Parth participated in the reactivation of the Technical Working Group and started the review of the BREF.

This report was drawn up in the framework of the implementation of the Industrial Emissions Directive (2010/75/EU) and is the result of the exchange of information provided for in Article 13 of the Directive.

Major contributors of information were:

 among industry, the Confederation of European Paper Industries (CEPI);  among environmental NGOs, the European Environmental Bureau (EEB);

 among EU Member States, Austria, Denmark, Finland, France, Germany, Italy, the Netherlands, Poland, Portugal, Spain, Sweden, and the United Kingdom;

 among non-EU EEA Member States, Norway.

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This document is one from the series of foreseen documents listed below (at the time of writing not all of the documents have been drafted):

Best Available Techniques Reference Document Code

Ceramic Manufacturing Industry CER

Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical

Sector CWW

Emissions from Storage EFS

Energy Efficiency ENE

Ferrous Metals Processing Industry FMP

Food, Drink and Milk Industries FDM

Industrial Cooling Systems ICS

Intensive Rearing of Poultry and Pigs IRPP

Iron and Steel Production IS

Large Combustion Plants LCP

Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers Industries LVIC-AAF

Large Volume Inorganic Chemicals – Solids and Others industry LVIC-S

Large Volume Organic Chemical Industry LVOC

Management of Tailings and Waste-rock in Mining Activities MTWR

Manufacture of Glass GLS

Manufacture of Organic Fine Chemicals OFC

Non-ferrous Metals Industries NFM

Production of Cement, Lime and Magnesium Oxide CLM

Production of Chlor-alkali CAK

Production of Polymers POL

Production of Pulp, Paper and Board PP

Production of Speciality Inorganic Chemicals SIC

Refining of Mineral Oil and Gas REF

Slaughterhouses and Animals By-products Industries SA

Smitheries and Foundries Industry SF

Surface Treatment of Metals and Plastics STM

Surface Treatment Using Organic Solvents STS

Tanning of Hides and Skins TAN

Textiles Industry TXT

Waste Incineration WI

Waste Treatments Industries WT

Wood and Wood Products Preservation with Chemicals WPC

Wood-based Panels Production WBP

Reference Document

Economics and Cross-media Effects ECM

General Principles of Monitoring MON

Electronic versions of draft and finalised documents are publicly available and can be downloaded from http://eippcb.jrc.ec.europa.eu/.

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PREFACE

1. Status of this document

Unless otherwise stated, references to ‘the Directive’ in this document refer to Directive 2010/75/EU of the European Parliament and the Council on industrial emissions (integrated pollution prevention and control) (Recast).

The original best available techniques (BAT) reference document (BREF) on Production of Pulp, Paper and Board was adopted by the European Commission in 2001. This document is the result of a review of that BREF. The review commenced in April 2006.

This BAT reference document for the Production of Pulp, Paper and Board forms part of a series presenting the results of an exchange of information between EU Member States, the industries concerned, non-governmental organisations promoting environmental protection and the Commission, to draw up, review, and where necessary, update BAT reference documents as required by Article 13(1) of the Directive. This document is published by the European Commission pursuant to Article 13(6) of the Directive.

As set out in Article 13(5) of the Directive, the Commission Implementing Decision 2014/687/EU on the BAT conclusions contained in Chapter 8 was adopted on 26 September 2014 and published on 30 September 2014.1

2. Participants in the information exchange

As required in Article 13(3) of the Directive, the Commission has established a forum to promote the exchange of information, which is composed of representatives from Member States, the industries concerned and non-governmental organisations promoting environmental protection (Commission Decision of 16 May 2011 establishing a forum for the exchange of information pursuant to Article 13 of the Directive 2010/75/EU on industrial emissions (2011/C 146/03), OJ C 146, 17.05.2011, p. 3).

Forum members have nominated technical experts constituting the technical working group (TWG) that was the main source of information for drafting this document. The work of the TWG was led by the European IPPC Bureau (of the Commission's Joint Research Centre).

3. Structure and contents of this document

Chapter 1, the Sections 2.1 to 2.8 of Chapter 2 and the first sections of Chapters 3 to 7 provide general information on the production of pulp, paper and board and on the industrial processes used within this sector.

The second sections of Chapters 3 to 7 and Section 2.6.2 provide data and information concerning the environmental performance of installations within the sector, and in operation at the time of writing, in terms of current emissions, consumption and nature of raw materials, water consumption, use of energy and the generation of waste.

Section 2.9 and the third sections of Chapters 3 to 7 describe in more detail the techniques to prevent or, where this is not practicable, to reduce the environmental impact of installations in this sector that were considered in determining the BAT. This information includes, where relevant, the environmental performance levels (e.g. emission and consumption levels) that can be achieved by using the techniques, the associated monitoring and the costs and the cross-media issues associated with the techniques.

1_{OJ L 284, 30.9.2014, p. 76.}

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Chapter 8 presents the BAT conclusions as defined in Article 3(12) of the Directive.

The fourth sections of Chapters 3 to 7 present information on 'emerging techniques' as defined in Article 3(14) of the Directive.

Concluding remarks and recommendations for future work are presented in Chapter 9.

4. Information sources and the derivation of BAT

This document is based on information collected from a number of sources, in particular through the TWG that was established specifically for the exchange of information under Article 13 of the Directive. The information has been collated and assessed by the European IPPC Bureau (of the Commission's Joint Research Centre) who led the work on determining BAT, guided by the principles of technical expertise, transparency and neutrality. The work of the TWG and all other contributors is gratefully acknowledged.

The BAT conclusions have been established through an iterative process involving the following steps:

 identification of the key environmental issues for the sector (e.g. emissions to water, especially organic load, total suspended solids, etc.; emissions to air from recovery boilers, lime kilns or combustion plants for the production of steam and power; odour and noise nuisance);

 examination of the techniques most relevant to address these key issues;

 identification of the best environmental performance levels, on the basis of the available data in the European Union and worldwide;

 examination of the conditions under which these environmental performance levels were achieved, such as costs, cross-media effects, and the main driving forces involved in the implementation of the techniques;

 selection of the best available techniques (BAT), their associated emission levels (and other environmental performance levels) and the associated monitoring for this sector according to Article 3(10) of, and Annex III to, the Directive.

Expert judgement by the European IPPC Bureau and the TWG has played a key role in each of these steps and the way in which the information is presented here.

Where available, economic data have been given together with the descriptions of the techniques presented in Chapters 3, 4, 5, 6 and 7. These data give a rough indication of the magnitude of the costs and benefits. However, the actual costs and benefits of applying a technique may depend strongly on the specific situation of the installation concerned, which cannot be evaluated fully in this document. In the absence of data concerning costs, conclusions on the economic viability of techniques are drawn from observations on existing installations.

5. Review of BAT reference documents (BREFs)

BAT is a dynamic concept and so the review of BREFs is a continuing process. For example, new measures and techniques may emerge, science and technologies are continuously developing and new or emerging processes are being successfully introduced into the industries. In order to reflect such changes and their consequences for BAT, this document will be periodically reviewed and, if necessary, updated accordingly.

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6. Contact information

All comments and suggestions should be made to the European IPPC Bureau at the Institute for Prospective Technological Studies at the following address:

European Commission

Institute for Prospective Technological Studies European IPPC Bureau

Edificio Expo c/ Inca Garcilaso, 3 E-41092 Seville, Spain Telephone: +34 95 4488 284 Fax: +34 95 4488 426

E-mail: JRC-IPTS-EIPPCB@ec.europa.eu Internet: http://eippcb.jrc.ec.europa.eu

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Best Available Techniques Reference Document for the

Production of Pulp, Paper and Board

PREFACE ... I

SCOPE ... XXXI

1 GENERAL INFORMATION ... 1

1.1 PAPER CONSUMPTION IN EUROPE ... 1

1.2 OVERVIEW OF PULP, PAPER AND BOARD MANUFACTURING ... 4

1.3 THE EUROPEAN PULP INDUSTRY ... 7

1.4 THE EUROPEAN PAPER INDUSTRY ... 13

1.5 CLASSIFICATION OF PULP AND PAPER MILLS FOR THE PURPOSE OF THIS DOCUMENT 18 1.6 ECONOMICS AND EMPLOYMENT IN THE EU PULP AND PAPER INDUSTRY ... 20

1.7 MAIN ENVIRONMENTAL ISSUES OF THE PRODUCTION OF PULP AND PAPER ... 24

2 COMMON PROCESSES AND TECHNIQUES FOR THE WHOLE PULP

AND PAPER SECTOR ... 33

2.1 INTEGRATED AND/OR MULTIPRODUCT PULP AND PAPER MILLS ... 34

2.1.1 Definition of non-integrated, integrated and multiproduct mills ... 34

2.1.2 Proposed approach to estimate emissions for integrated chemical pulp mills and/or multiproduct mills ... 36

2.1.3 Proposed method for assessing emissions for specific waste water discharges 37 2.2 MONITORING ... 39

2.2.1 General aspects of emission monitoring in pulp and paper mills ... 39

2.2.1.1 Emission sources covered ... 40

2.2.1.2 Operating conditions covered ... 40

2.2.1.3 Data processing ... 41

2.2.1.4 Presentation of emission data ... 42

2.2.2 Emission data production in pulp and paper mills ... 42

2.2.2.1 Monitoring of waste water discharges ... 42

2.2.2.1.1 The sampling points ... 43

2.2.2.1.2 Sampling methods and periods and frequency of analysis ... 43

2.2.2.1.3 Major parameters and analytical methods ... 46

2.2.2.1.4 Interrelationship between measured concentrations and calculated emission loads ... 47

2.2.2.1.5 Special issue that influences the comparability of emission data ... 50

2.2.2.2 Monitoring of emissions to air ... 50

2.2.2.2.1 The sampling points ... 50

2.2.2.2.2 Sampling and continuous/discontinuous measurement methods ... 51

2.2.2.2.3 Major parameters and analytical methods ... 56

2.2.2.2.4 Reference conditions ... 58

2.2.2.2.5 Interrelationship between concentration and specific emission loads ... 59

2.2.2.2.6 Measurement of diffuse emissions in kraft pulp mills ... 60

2.2.2.3 Monitoring of solid waste ... 62

2.3 RECEIPT, STORAGE AND HANDLING OF FIBROUS MATERIALS AND CHEMICALS ... 63

2.3.1 Wood handling ... 63

2.3.1.1 Wood yard operations ... 63

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2.3.2 Storage and handling of chemicals and chemical additives ... 65

2.3.2.1 Use of basic chemicals and chemical additives ... 65

2.3.2.2 EU regulations on the storage, handling and use of chemicals ... 69

2.3.2.3 Storage, handling and transportation of chemicals ... 71

2.4 WATER SUPPLY FOR PROCESSES AND COOLING ... 72

2.4.1 Raw water treatment ... 72

2.4.1.1 Process water treatment ... 72

2.4.1.2 Boiler feedwater treatment... 72

2.4.2 Cooling systems and use of cooling water ... 73

2.4.2.1 Types of cooling systems in pulp and paper mills ... 73

2.5 ENERGY CONSUMPTION IN PULP AND PAPER MILLS ... 76

2.5.1 Issues to consider when reading reported energy consumption data ... 77

2.5.2 Examples of total process energy consumption of pulp and paper mills ... 79

2.5.3 Relevance of process units for total process energy consumption ... 82

2.5.4 Energy consumption for supporting activities ... 83

2.6 STEAM AND POWER GENERATION IN PULP AND PAPER MILLS ... 85

2.6.1 Applied combustion processes and techniques ... 85

2.6.1.1 Main fuels utilised and pretreatment... 86

2.6.1.2 Energy production ... 88

2.6.1.2.1 Steam generation plants ... 88

2.6.1.2.2 Combined heat and power (CHP) plants ... 89

2.6.1.2.3 Fluidised bed boilers ... 91

2.6.2 Current emissions to air from steam and power generation ... 93

2.6.2.1 Dust emissions ... 93

2.6.2.2 SO2 emissions and other gaseous pollutants ... 95

2.6.2.3 NOX emissions ... 96

2.6.2.4 CO emissions ... 97

2.7 WASTE WATER TREATMENT PLANTS ... 99

2.8 OVERVIEW OF PRODUCTION RESIDUES AND SOLID WASTE ... 103

2.9 GENERAL TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT COMMON TO ALL MILLS ... 105

2.9.1 Environmental management systems (EMS) ... 105

2.9.2 Handling and storage of raw materials ... 108

2.9.2.1 Reduction of emissions from wood handling ... 108

2.9.2.2 Dry debarking ... 110

2.9.2.3 Safe storage and handling of basic chemicals and chemical additives ... 112

2.9.2.4 Environmental assessment system for chemicals ... 113

2.9.2.5 Substitution of potentially harmful substances with less harmful alternatives ... 114

2.9.3 Optimised water management ... 119

2.9.4 Model-based evaluation of optimisation measures for water circuits ... 122

2.9.5 Energy efficiency analysis, energy management and energy audits ... 125

2.9.6 Reduction of energy consumption applicable to all/most grades ... 128

2.9.6.1 Reduction of thermal energy use ... 129

2.9.6.1.1 Heat recovery from radial blowers used in vacuum systems ... 129

2.9.6.1.2 Use of thermo-compressors ... 129

2.9.6.1.3 Insulation of steam and condensate pipe fittings ... 131

2.9.6.1.4 Drying of biofuel and sludge utilising excess heat ... 131

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2.9.6.2 Reduction of electrical energy use ... 134

2.9.6.2.1 Energy-efficient vacuum systems for dewatering ... 134

2.9.6.2.2 Use of high efficiency electrical motors ... 134

2.9.6.2.3 Energy-efficient frequency inverter for pumps, fans and compressors ... 135

2.9.6.2.4 Further measures for reducing electrical energy ... 136

2.9.6.3 Combined heat and power production ... 136

2.9.7 Reduction of emissions of multifuel, biomass and auxiliary boilers to air ... 141

2.9.7.1 Reduction of dust emissions ... 141

2.9.7.2 Reduction of NOX emissions ... 144

2.9.7.2.1 Primary measures for NOX reduction ... 144

2.9.7.2.2 Selective non-catalytic reduction (SNCR) ... 148

2.9.7.3 Reduction of SO2 and other gaseous pollutants ... 151

2.9.8 Prevention, minimisation, recycling and treatment of process residues – minimising solid waste to landfill ... 155

2.9.9 Reduction of emissions from the use of chelating agents in peroxide-based bleaching technologies ... 162

2.9.10 Ensuring smooth running and minimising accidental releases... 168

2.9.11 Reduction of pollution load of waste water ... 169

2.9.11.1 Primary waste water treatment ... 169

2.9.11.2 Secondary waste water treatment ... 170

2.9.11.2.1 Aerobic biological waste water treatment ... 170

2.9.11.2.2 Anaerobic biological waste water pretreatment ... 173

2.9.11.2.3 Control of biological waste water treatment plants and optimised nutrient supply ... 175

2.9.11.2.4 Techniques for P and N reduction ... 179

2.9.11.3 Tertiary waste water treatment ... 179

2.9.11.3.1 Chemical precipitation ... 179

2.9.11.3.2 Nitrification and denitrification ... 180

2.9.11.3.3 Ozonation and biofiltration ... 180

2.9.11.3.4 Additional techniques for TSS reduction ... 181

2.9.12 Prevention of pollution risks from decommissioning ... 182

2.9.13 Reduction of noise ... 186

2.9.14 Reduction of odour ... 189

2.10 GENERAL TRENDS IN THE PULP AND PAPER SECTOR ... 193

3 THE KRAFT (SULPHATE) PULPING PROCESS... 195

3.1 APPLIED PROCESSES AND TECHNIQUES ... 196

3.1.1 Reception and storage of wood ... 197

3.1.2 Debarking ... 197

3.1.3 Wood chipping and screening ... 197

3.1.4 Cooking and delignification ... 197

3.1.5 Washing and screening ... 199

3.1.6 Oxygen delignification ... 200

3.1.7 Bleaching ... 201

3.1.8 Bleached stock screening ... 203

3.1.9 Drying ... 203

3.1.10 By-products of kraft pulping ... 204

3.1.11 Chemical and energy recovery system ... 204

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3.1.12.1 Chlorine dioxide ... 207

3.1.12.2 Ozone ... 210

3.1.12.3 Other bleaching chemicals ... 211

3.2 CURRENT CONSUMPTION AND EMISSION LEVELS ... 212

3.2.1 Overview of input/output for the production of kraft pulp ... 212

3.2.2 Consumption and emission levels arising from process units ... 213

3.2.2.1 Wood consumption ... 213

3.2.2.2 Consumption of chemicals... 213

3.2.2.3 Energy consumption ... 215

3.2.2.4 Water consumption and waste water flow ... 217

3.2.2.5 Emissions to water ... 218

3.2.2.5.1 Waste water from different process steps ... 219

3.2.2.5.2 Main parameters and emission levels ... 222

3.2.2.5.3 Total waste water discharge after biological treatment ... 231

3.2.2.6 Emissions to air ... 234

3.2.2.6.1 Emissions to air from the black liquor recovery boiler ... 234

3.2.2.6.2 Emissions to air from the lime kiln ... 242

3.2.2.6.3 Emissions to air from steam boilers or CHP plants ... 243

3.2.2.6.4 Malodorous gases ... 244

3.2.2.6.5 VOC emissions ... 246

3.2.2.6.6 Chlorine compounds from bleaching and bleaching chemical preparation .. 246

3.2.2.6.7 Total process emissions ... 247

3.2.2.6.7.1 Total sulphuric emissions from the process ... 247

3.2.2.6.7.2 Total NOX emissions from main processes ... 248

3.2.2.7 Solid waste ... 249

3.2.2.8 Noise ... 252

3.2.2.9 Emissions to soil and groundwater ... 252

3.3 TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT ... 253

3.3.1 The relevance of the wood species when determining BAT for kraft pulp mills ... 253

3.3.1.1 Environmental issues specific to eucalyptus-based kraft pulp-making ... 254

3.3.2 Dry debarking ... 255

3.3.3 Modified cooking before bleaching ... 255

3.3.4 Closed brown stock screening ... 258

3.3.5 Oxygen delignification before leaching ... 259

3.3.6 Modern ECF bleaching ... 261

3.3.7 TCF bleaching... 265

3.3.8 Partial process water recycling in the bleach plant ... 268

3.3.9 Effective spill monitoring and containment with a suitable recovery system . 271 3.3.10 Efficient brown stock washing ... 273

3.3.11 Stripping the contaminated (foul) condensates and reusing the condensates in the process ... 274

3.3.12 Use of correctly dimensioned buffer tanks for the storage of concentrated or hot liquids from the process ... 277

3.3.13 Aerobic biological waste water treatment ... 278

3.3.14 Tertiary waste water treatment - chemical precipitation ... 285

3.3.15 Collection systems for strong and weak malodorous gases ... 287

3.3.16 Control of strong and weak non-condensable gases in treatment systems with high availability ... 294

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3.3.16.1 Incineration of strong and/or weak malodorous gases in the recovery boiler ... 296

3.3.16.2 Incineration of collected malodorous gases (strong and weak gases) in the lime kiln ... 297

3.3.16.3 Incineration of collected strong malodorous gases in a dedicated NCG burner equipped with scrubbers for SO2 removal ... 299

3.3.17 Reduction of sulphur emissions (SO2 and TRS) from the black liquor recovery boiler... 301

3.3.17.1 Increasing the dry solids content of black liquor ... 301

3.3.17.2 Installation of scrubbers on the recovery boiler ... 307

3.3.18 Control of NOX emissions from black liquor recovery boilers ... 309

3.3.18.1 Optimised combustion control and control of the NOX-influencing factors ... 309

3.3.18.2 Optimised black liquor recovery boiler air systems ... 318

3.3.19 Reduction of dust emissions from the black liquor recovery boiler ... 321

3.3.19.1 Electrostatic precipitators ... 321

3.3.19.2 Electrostatic precipitators followed by wet scrubbers ... 326

3.3.20 Reduction of sulphur emissions (SO2 and TRS) from the lime kiln ... 328

3.3.20.1 Selection of fuels and control of the excess oxygen ... 328

3.3.20.2 Installation of improved washing and filtration of lime mud in recausticising .... 332

3.3.20.3 Use of an alkaline flue-gas scrubber ... 333

3.3.21 Reduction of NOX emissions from the lime kiln ... 334

3.3.21.1 Selection of fuels, optimised combustion and control of the kiln operation ... 334

3.3.21.2 Installation of low-NOX burners in the lime kiln ... 338

3.3.22 Reduction of dust emissions from the lime kiln ... 339

3.3.22.1 Electrostatic precipitators ... 339

3.3.22.2 Electrostatic precipitators followed by wet scrubbers ... 343

3.3.23 Substitution of fossil fuels used in the lime kiln ... 344

3.3.24 Reduction of NOX emissions from dedicated TRS burners ... 346

3.3.24.1 Staged incineration ... 346

3.3.25 Reduction of emissions from bark or multi-fuel boilers ... 347

3.3.26 Integrated waste management concept ... 347

3.3.27 Measures for increased energy efficiency ... 349

3.3.28 Techniques for noise reduction ... 355

3.4 EMERGING TECHNIQUES ... 356

3.4.1 Enhanced generation of electricity, biomass-based products and the utilisation of excess heat ... 356

3.4.2 Gasification of black liquor ... 358

3.4.3 Selective removal of chloride and potassium by ESP ash treatment ... 359

3.4.4 Partial borate autocausticising ... 360

3.4.5 SNCR or SCR for reducing NOX emissions from the black liquor recovery boiler ... 361

3.4.6 Removal of chelating agents by modest alkaline biological treatment or its recovery by use of kidneys ... 363

3.4.7 Increased system closure combined with the use of kidneys ... 365

4 THE SULPHITE PULPING PROCESS... 369

4.1.1 The major groups of sulphite pulp mills in Europe ... 371

4.1.1.1 Acid bisulphite pulping for papermaking ... 371

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4.1.1.3 Dissolving pulp for the textile industry ... 372

4.1.1.4 Speciality pulp for chemical applications ... 373

4.1.1.5 Neutral sulphite semi-chemical pulp (NSSC) ... 375

4.1.2 Technical processes and units ... 376

4.1.3 Fibre line operations ... 378

4.1.3.1 Wood handling ... 379

4.1.3.2 Cooking and delignification of unbleached pulp ... 379

4.1.3.3 Screening and washing of unbleached pulp ... 379

4.1.3.4 Oxygen delignification and bleaching ... 380

4.1.3.5 Final screening and drying ... 382

4.1.4 Chemical and energy recovery system ... 383

4.1.5 Processing of by-products of sulphite pulping ... 384

4.1.6 Preparation and handling of sulphur dioxide and bleaching chemicals ... 387

4.2.1 Overview of input/output for the production of sulphite pulp ... 389

4.2.2.2 Consumption of chemicals... 392

4.2.2.3 Energy consumption ... 392

4.2.2.4 Waste water flow and emissions to water ... 396

4.2.2.6 Solid waste generation ... 418

4.2.2.7 Noise ... 419

4.3.2 Extended modified cooking before bleaching ... 422

4.3.3 Oxygen delignification before bleaching ... 424

4.3.4 Closed brown stock screening ... 426

4.3.5 Efficient brown stock washing ... 426

4.3.6 Effective spill monitoring and containment, also with chemical and energy recovery system ... 426

4.3.7 Totally chlorine free (TCF) bleaching ... 426

4.3.8 MgO-based bleaching and recirculation of washing liquids from pre-bleaching to brown stock washing ... 429

4.3.9 Closed-loop bleaching (in a sodium-based sulphite mill using ultrafiltration, flotation and separation) ... 431

4.3.10 Reduction of emissions by the use of chelating agents in the peroxide stages of the bleach plant ... 433

4.3.11 pH adjustment of weak liquor before/inside the evaporation plant ... 433

4.3.12 Pretreatment of waste water from the oxygen stages of the bleach plant in an ultrafiltration plant followed by aerobic treatment of the total effluent ... 434

4.3.13 Evaporation of effluents from the hot alkaline extraction stage and incineration of the concentrates in a soda boiler ... 437

4.3.14 Use of emergency and buffer tanks for concentrated liquids ... 440

4.3.15 Anaerobic treatment of the condensates and the high COD load in the effluent from the bleach plant ... 440

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4.3.18 Optimising the recovery boiler by controlling the firing conditions ... 461

4.3.19 Staged injection of spent liquor ... 464

4.3.20 SNCR (ammonia or urea injection) in the recovery boiler ... 464

4.3.21 ESP or multistage cyclone and multistage venturi scrubbers or multistage double inlet downstream scrubbers on the recovery boiler ... 470

4.3.22 Collection of odorous gases and diffuse process SO2 emissions and combustion in the recovery boiler or washing in scrubbers ... 479

4.3.23 Measures to prevent uncontrolled operating conditions and to reduce the consequences of accidents ... 481

4.3.24 Reduction of energy consumption (energy efficiency) ... 483

4.3.25 Techniques for noise reduction ... 485

5 MECHANICAL PULPING AND CHEMIMECHANICAL PULPING... 487

5.1.1 Wood handling ... 489

5.1.2 Groundwood pulping... 489

5.1.2.1 Grinding ... 489

5.1.3 Refiner mechanical pulps ... 490

5.1.4 Thermomechanical pulping (TMP) ... 492

5.1.5 Chemithermomechanical and chemimechanical pulping ... 493

5.1.6 Screening and cleaning ... 495

5.1.7 Bleaching of mechanical pulps ... 496

5.2.1 Overview of input/output for the production of mechanical and chemimechanical pulp ... 499

5.2.2.2 Water use ... 502

5.2.2.3 Waste water and emissions to water ... 503

5.2.2.6 Consumption of chemicals ... 514

5.2.2.7 Energy use ... 515

5.2.2.8 Noise ... 520

5.3.1 Emission control from the wood yard ... 522

5.3.3 Minimisation of fibre losses when removing impurities from the mechanical pulping process ... 522

5.3.4 Minimisation of the disposal of process residues and sludge to landfill by efficient dewatering and incineration with energy recovery ... 523

5.3.5 Efficient washing and process control... 525

5.3.6 Water recirculation in pulp and paper mills ... 526

5.3.7 Substitution of NaOH by Ca(OH)2 or Mg(OH) 2 as the alkali in peroxide bleaching ... 529

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5.3.8 CTMP mill effluent treatment – closing up the water circuits by use of

evaporation and burning of the concentrates ... 530

5.3.9 Extensive recovery of secondary heat from TMP and CTMP refiners and reuse of recovered steam in paper or pulp drying ... 534

5.3.10 Emission-optimised incineration of solid waste and energy recovery ... 537

5.3.11 Use of sufficiently large buffer tanks for the storage of concentrated or hot liquids from the process ... 539

5.4.1 New energy-efficient TMP processes ... 545

5.4.2 New energy-efficient bleached CTMP processes ... 546

5.4.3 Use of enzymes during the refining of TMP ... 546

6 PROCESSING OF PAPER FOR RECYCLING ... 549

6.1.1 Sorting, handling and storage of paper for recycling ... 550

6.1.2 Major processes ... 551

6.1.3 Examples of systems for processing paper for recycling ... 554

6.1.3.1 Packaging paper and board ... 555

6.1.3.2 Newsprint and simple writing and printing paper ... 556

6.1.3.3 LWC/SC paper ... 558

6.1.3.4 Tissue paper ... 558

6.2 CURRENT CONSUMPTION AND EMISSION LEVELS OF RCF-BASED PAPER MILLS ... 561

6.2.1 Overview of input/output for the production of RCF paper ... 561

6.2.2 Consumption and emission levels arising from individual process units ... 564

6.2.2.1 Consumption of paper for recycling ... 564

6.2.2.2 Water use and waste water flow ... 564

6.2.2.3 Use of chemical additives ... 569

6.2.2.4 Energy demand ... 570

6.2.2.5 Waste water emissions ... 575

6.2.2.8 Noise and vibration from paper machines ... 594

6.3.1 Good housekeeping in handling and storage of paper for recycling ... 596

6.3.2 Separation of sealing and cooling water from contaminated process water and water reuse ... 598

6.3.3 Optimal water management, water loop separation and arrangement, counter-current flows and internal water clarification ... 600

6.3.4 In-line biological process water treatment for closed water loops ... 604

6.3.5 Removal of calcium from process waters ... 607

6.3.6 Installation of an equalisation basin and primary treatment of waste water .... 609

6.3.7 Anaerobic biological waste water pretreatment ... 609

6.3.9 Combined ozonation and biofiltration ... 621

6.3.10 Examples of energy-saving techniques ... 626

6.3.10.1 High consistency pulping for disintegrating paper for recycling into separated fibre ... 627

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6.3.10.2 Energy-saving screening techniques ... 628

6.3.10.3 Upgrade of stock preparation plants for decreased electricity consumption and emissions ... 630

6.3.11 Clarification of white water ... 635

6.3.12 Prevention and elimination of biofilms by using methods that minimise emissions of biocides ... 637

6.3.13 Effective reject and sludge handling and processing (dewatering) on site... 639

6.3.14 Environmentally sound residue utilisation and energy recovery ... 642

7 PAPERMAKING AND RELATED PROCESSES ... 659

7.1.1 Stock preparation... 660

7.1.2 Paper machine ... 661

7.1.3 Water circuits and fibre recovery ... 663

7.1.4 Broke system ... 665

7.1.5 Sizing (optional) ... 666

7.1.6 Coating (optional) ... 667

7.1.7 Dyeing of paper (optional) ... 668

7.1.8 Addition of chemicals ... 669

7.1.9 Calendering (optional) ... 669

7.1.10 Reeling/cutting/dispatch ... 670

7.1.11 Examples of non-integrated paper mills in Europe ... 670

7.1.11.1 Uncoated wood-free printing and writing papers ... 671

7.1.11.2 Coated wood-free printing and writing paper ... 671

7.1.11.3 Tissue paper ... 672

7.1.11.4 Speciality paper ... 674

7.1.11.5 Paperboards ... 677

7.2 CURRENT CONSUMPTION AND EMISSION LEVELS OF PAPER MILLS ... 678

7.2.1 Overview of input/output for the production of paper and board ... 678

7.2.2 Consumption and emission levels ... 682

7.2.2.1 Consumption of major raw materials ... 683

7.2.2.2 Water use ... 683

7.2.2.3 Use of chemical additives ... 687

7.2.2.4 Energy demand... 689

7.2.2.5 Waste water and emissions to waste water... 696

7.2.2.8 Noise from paper machines (local) ... 715

7.3.1 Water management and minimising water usage for different paper grades .. 718

7.3.2 Control of potential negative side effects from closing water circuits ... 720

7.3.3 Internal treatment of white water by use of membrane filtration and recycling of treated process water ... 723

7.3.4 Efficient fibre and filler recovery and broke system ... 728

7.3.5 Recovery of coating colours/recycling of pigments ... 730

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7.3.7 Optimum design and construction of tanks and chests ... 736

7.3.8 Measurement and automation ... 738

7.3.9 Use of chemicals ... 740

7.3.10 Installation of an equalisation basin and primary treatment of waste water .... 740

7.3.12 Tertiary waste water treatment - chemical precipitation ... 746

7.3.13 Dewatering and thickening of sludge before final disposal or incineration... 748

7.3.14 Prevention, reuse, recycling and treatment of process residues ... 750

7.3.15 Energy saving in papermaking ... 750

7.3.15.1 Optimisation of dewatering in the press section of the paper machine (wide nip press) ... 755

7.3.15.2 Use of high efficiency refiners or optimisation of existing refiners ... 758

7.3.15.3 Steam condensate recovery and use of efficient exhaust air heat recovery systems ... 759

7.3.16 Measures for noise reduction ... 762

7.4.1 Minimum effluent paper mills - optimised design of water loops and advanced waste water treatment techniques ... 770

7.4.2 High-consistency papermaking (lean water processing) ... 772

7.4.3 Heat recovery with heat pumps ... 774

7.4.4 Total site integration tools ... 775

8 BEST AVAILABLE TECHNIQUES (BAT) CONCLUSIONS ... 777

SCOPE ... 777

GENERAL CONSIDERATIONS ... 777

EMISSION LEVELS ASSOCIATED WITH BAT ... 778

AVERAGING PERIODS FOR EMISSIONS TO WATER ... 778

REFERENCE CONDITIONS FOR AIR EMISSIONS ... 778

AVERAGING PERIODS FOR EMISSIONS TO AIR ... 779

DEFINITIONS ... 779

8.1 GENERAL BAT CONCLUSIONS FOR THE PULP AND PAPER INDUSTRY ... 782

8.1.1 Environmental management system ... 782

8.1.2 Materials management and good housekeeping ... 783

8.1.3 Water and waste water management... 784

8.1.4 Energy consumption and efficiency... 785

8.1.5 Emissions of odour ... 786

8.1.6 Monitoring of key process parameters and of emissions to water and air ... 787

8.1.7 Waste management ... 789

8.1.8 Emissions to water ... 789

8.1.9 Emissions of noise ... 790

8.1.10 Decommissioning ... 791

8.2 BAT CONCLUSIONS FOR KRAFT PULPING PROCESS ... 792

8.2.1 Waste water and emissions to water ... 792

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8.2.2.1 Reduction of emissions in strong and weak odorous gases ... 793

8.2.2.2 Reduction of emissions from a recovery boiler ... 794

8.2.2.3 Reduction of emissions from a lime kiln ... 796

8.2.2.4 Reduction of emissions from a burner for strong odorous gases (dedicated TRS burner) ... 798

8.2.3 Waste generation ... 799

8.2.4 Energy consumption and efficiency ... 799

8.3 BAT CONCLUSIONS FOR THE SULPHITE PULPING PROCESS ... 800

8.3.1 Waste water and emissions to water... 800

8.3.2 Emissions to air ... 802

8.4 BAT CONCLUSIONS FOR MECHANICAL PULPING AND CHEMIMECHANICAL PULPING805 8.4.1 Waste water and emissions to water... 805

8.5 BAT CONCLUSIONS FOR PROCESSING PAPER FOR RECYCLING ... 807

8.5.1 Materials management ... 807

8.6 BAT CONCLUSIONS FOR PAPERMAKING AND RELATED PROCESSES... 810

8.6.2 Emissions to air ... 812

8.6.3 Waste generation ... 812

8.7 DESCRIPTION OF TECHNIQUES ... 814

8.7.1 Description of techniques for the prevention and control of emissions to air . 814 8.7.1.1 Dust ... 814

8.7.1.2 NOX ... 814

8.7.1.3 SO2 /TRS emissions prevention and control ... 815

8.7.2 Description of techniques to reduce fresh water use/waste water flow and the pollution load in waste water ... 816

8.7.2.1 Process-integrated techniques ... 816

8.7.2.2 Waste water treatment ... 820

8.7.3 Description of techniques for waste generation prevention and waste management ... 821

9 CONCLUDING REMARKS AND RECOMMENDATIONS FOR FUTURE

WORK... 823

10 ANNEXES... 827

10.1 ANNEX I:DETERMINATION OF EMISSIONS FOR SPECIFIC WASTE WATER DISCHARGES FROM INTEGRATED CHEMICAL PULP MILLS AND/OR MULTIPRODUCT MILLS ... 827

10.2 ANNEX II:VARIATIONS OF EMISSIONS OVER TIME ... 831

10.2.1 Variation of emissions during different reference periods ... 831

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GLOSSARY ... 837

I. ISO COUNTRY CODES ... 837 II. UNITS AND CONVERSION FACTORS ... 838 III. CHEMICAL ELEMENTS ... 839 IV. CHEMICAL FORMULAE COMMONLY USED IN THIS DOCUMENT ... 839 V. ACRONYMS AND DEFINITIONS ... 840 PULP AND PAPER GRADE DEFINITIONS ACCORDING TO CEPI ... 850

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List of figures

Figure 1.1: Paper consumption by region in 2007 ... 3 Figure 1.2: The papermaking process ... 5 Figure 1.3: Pulp production by region in 2008 ... 7 Figure 1.4: Total pulp production by grade in Europe in 2008 (CEPI-associated countries) ... 8 Figure 1.5: Pulp production by grade in Europe (CEPI-associated countries) ... 9 Figure 1.6: Geographical and size distribution across Europe for pulp mills... 9 Figure 1.7: Number of pulp mills by volume in Europe in 1998 and 2008 (CEPI-associated

European countries) ... 10 Figure 1.8: Trade flows of pulp to and from CEPI-associated European countries in 2008 ... 10 Figure 1.9: Utilisation of paper for recycling of 18 CEPI-associated countries in 2008 ... 11 Figure 1.10: Trade flows of paper for recycling to and from Europe in 2008... 12 Figure 1.11: Paper production by region in the global context in 2008 ... 13 Figure 1.12: An overview of the distribution of the paper manufacturing industry across Europe for

18 CEPI-associated countries (2008) ... 14 Figure 1.13: Number of paper mills by volume in Europe in 2008 ... 15 Figure 1.14: Number of paper mills by volume in CEPI-associated countries 1998 and 2008 ... 16 Figure 1.15: Trade flows of paper to and from Europe in 2008 (95 % of production for

CEPI-associated European countries) ... 17 Figure 1.16: Classification of pulp and paper mills in Europe for this document including the

relevant chapters for those mills ... 19 Figure 1.17: Typical variation of prices for market pulp ... 21 Figure 1.18: Total employment evolution in Europe (CEPI-associated countries) 1991 – 2008 ... 22 Figure 1.19: Manufacturing cost structure for the European pulp and paper industry in 2009 ... 23 Figure 1.20: Evolution of specific consumption and emissions (kg pollutant/t of product) in the

European pulp and paper industry from 1990 to 2008 ... 24 Figure 1.21: Evolution of the absolute consumption and emissions in the European pulp and paper

industry from 1990 to 2008 ... 25 Figure 1.22: Aerial view of an integrated kraft pulp, mechanical pulp and paper site with a power

plant and a waste water treatment plant ... 25 Figure 1.23: Raw materials consumption in papermaking in CEPI-associated countries 1991 – 2008 ... 27 Figure 1.24: Non-fibrous material consumption in CEPI-associated countries 1991 – 2008 ... 28 Figure 1.25: Shares of primary energy consumption in the European pulp and paper industry in 2008 .. 29 Figure 2.1: Overview of the different processes in a multiproduct mill and where they are described

in this document ... 35 Figure 2.2: Different forms of data production and reporting of emission data from pulp and paper

mills ... 39 Figure 2.3: Example for the conversion of the concentration of a water pollutant of concern (mg/l)

into daily emission loads and specific emission loads and flows ... 48 Figure 2.4: Example for the conversion of the concentration of an air pollutant of concern

(mg/Nm3) into the specific emission factor (e.g. kg dust/ADt) ... 59 Figure 2.5: Example: Chip pile with concrete paving at M-real Hallein AG ... 64 Figure 2.6: Raw material consumption of paper and board in relation to world paper production in

2005 (volume shares) ... 66 Figure 2.7: Market share of speciality chemicals for world paper and board production (dry volume

shares) ... 67 Figure 2.8: Fate of chemical additives in the paper manufacturing process for biocides ... 68 Figure 2.9: Options for use and discharge of cooling water ... 75 Figure 2.10: Schematic overview of subsystems to consider when comparing energy balances of pulp

and paper mills ... 78 Figure 2.11: Water-steam cycle of an installation with pure steam generation ... 89 Figure 2.12: Example of a CHP plant at a pulp/paper mill ... 90 Figure 2.13: Example of a CCGT unit as a CHP producing unit at a mill with both a back-pressure

steam turbine and a saturated steam circuit ... 91 Figure 2.14: Different concepts of biological waste water treatment applications for different paper

grades and simplistic trends of the organic loads ... 100 Figure 2.15: Main processes for the treatment of pulp and paper mill waste water and the ranges of

suitable application ... 100 Figure 2.16: Continuous improvement in an EMS model ... 106 Figure 2.17: Pragmatic approach for assessment of the amount of not readily biodegradable additives

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Figure 2.18: Schematic presentation of the fate of chemical additives in paper manufacturing

including external treatment ... 116 Figure 2.19: Steps towards lower water consumption and lower pollution load to the environment ... 120 Figure 2.20: Approach of data analysis and simulation ... 123 Figure 2.21: Systematic evaluation of and improvement of the energy use in paper mills ... 126 Figure 2.22: Management method for continuous monitoring and optimisation of energy use ... 127 Figure 2.23: Schematic of a thermo-compressor ... 130 Figure 2.24: Interrelationship between fuel efficiency and the chosen heat to power ratio for CCGT

utilities ... 138 Figure 2.25: Daily average emission data for the bubbling fluidised bed boiler equipped with SNCR

from the KRAFT SE 1 pulp mill ... 150 Figure 2.26: Flow diagram of the circulating fluidised bed boiler of UPM-Kymmene Austria ... 154 Figure 2.27: Possible decision-making tree for waste management of paper mill waste... 156 Figure 2.28: Options for material recycling of paper mill residues and factors governing treatment

options choice... 157 Figure 2.29: Fuel triangle for waste and residues from the paper industry (provided by IFP) ... 159 Figure 2.30: Emissions levels according to how the mill is operated ... 168 Figure 2.31: Simplified scheme of a combined anaerobic-aerobic waste water treatment plant ... 173 Figure 3.1: Overview of the main processes of a kraft pulp mill ... 196 Figure 3.2: Example of a continuous digester ... 199 Figure 3.3: Recovery circuit of chemicals for a kraft mill ... 205 Figure 3.4: Mass stream overview of input and output of a kraft pulp mill ... 212 Figure 3.5: Specific waste water flow of bleached kraft pulp mills ... 217 Figure 3.6: Specific waste water flow of unbleached kraft pulp mills ... 218 Figure 3.7: Emissions to water from a kraft pulp mill ... 219 Figure 3.8: Specific AOX emissions from bleached kraft pulp mills ... 223 Figure 3.9: Short-term averages of AOX emissions from bleached kraft pulp mills ... 223 Figure 3.10: Specific emissions of total phosphorus from bleached kraft pulp mills ... 225 Figure 3.11: Specific emissions of total phosphorus from unbleached kraft pulp mills ... 225 Figure 3.12: Short-term averages of tot-P emissions from bleached and unbleached kraft pulp mills ... 226 Figure 3.13: Specific emissions of total nitrogen from bleached kraft pulp mills ... 227 Figure 3.14: Specific emissions of total nitrogen from unbleached kraft pulp mills ... 227 Figure 3.15: Short-term averages of tot-N emissions from bleached and unbleached kraft pulp mills .. 228 Figure 3.16: Specific emissions of total suspended solids from bleached kraft pulp mills after

biological treatment and biomass removal ... 229 Figure 3.17: Specific emissions of total suspended solids from unbleached kraft pulp mills after

biological treatment and biomass removal ... 230 Figure 3.18: Short-term averages of TSS emissions from bleached and unbleached kraft pulp mills .... 230 Figure 3.19: Specific COD emissions from bleached kraft pulp mills after biological treatment ... 231 Figure 3.20: Specific COD emissions from unbleached kraft pulp mills after biological treatment ... 232 Figure 3.21: Short-term COD emissions from bleached and unbleached kraft pulp mills ... 232 Figure 3.22: Short-term BOD emissions from bleached and unbleached kraft pulp mills ... 233 Figure 3.23: Emissions to air from kraft pulp mills ... 234 Figure 3.24: Principal chemical reactions in a recovery boiler ... 236 Figure 3.25: Simplified nitrogen reaction paths from black liquor ... 237 Figure 3.26: NOX loads from recovery boilers in kraft pulp mills ... 239

Figure 3.27: NOX concentrations from recovery boilers in kraft pulp mills ... 240

Figure 3.28: Example of the particle size distribution of dust from recovery boilers measured

upstream of the electrostatic precipitators ... 241 Figure 3.29: Total S emission load (as kg S/ADt) from major processes (recovery boiler, lime kiln,

NCG burner) including uncollected or untreated weak gases ... 247 Figure 3.30: Total NOX emission load (as NO2/ADt) from major processes (recovery boiler, lime

kiln, NCG burner) ... 249 Figure 3.31: Kappa trends in Finnish kraft pulp mills ... 257 Figure 3.32: Single-stage oxygen delignification ... 260 Figure 3.33: Two-stage oxygen delignification ... 260 Figure 3.34: Example of a bleach plant concept with low effluent volume and COD load ... 270 Figure 3.35: COD concentrations of the effluents of a bleached kraft pulp mill after biological

treatment for different reference periods ... 279 Figure 3.36: COD load of the effluents of a bleached kraft pulp mill after biological treatment for

different reference periods ... 280 Figure 3.37: TSS, BOD5, Ninorganic concentrations of kraft pulp mill effluents after biological

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Figure 3.38: COD load of effluents for an unbleached kraft pulp mill after biological treatment for different reference periods (KRAFT SE 1) ... 282 Figure 3.39: Treatment and collection systems of strong malodorous gases (Botnia Rauma mill) ... 288 Figure 3.40: Treatment and collection systems of strong malodorous gases (Botnia Joutseno mill) ... 288 Figure 3.41: Treatment and collection of dilute malodorous gases in the fibre line (Botnia Rauma

mill) ... 289 Figure 3.42: Collection and treatment of light odorous gases from the evaporation area and the tall

oil cooking area (Botnia Rauma mill) ... 290 Figure 3.43: Collection and treatment of weak odorous gases of the causticisation area (Botnia

Rauma mill) ... 291 Figure 3.44: Example of a CNCG treatment system ... 295 Figure 3.45: Example of a DNCG treatment system ... 295 Figure 3.46: Example of permit requirements and achieved availability of an odorous gas treatment

system ... 298 Figure 3.47: Emissions to air from a dedicated TRS burner equipped with a scrubber ... 300 Figure 3.48: SO2 emission concentrations and loads from recovery boilers with different dry solids

contents (%) of black liquor and different softwood/hardwood use ... 303 Figure 3.49: TRS-S emission concentrations and loads from recovery boilers with different dry

solids contents (%) of black liquor and different softwood/hardwood use ... 303 Figure 3.50: Gaseous S emissions from recovery boilers with the corresponding dry solids content

(%) of black liquor, SO2 concentration and waste gas flow ... 304 Figure 3.51: Continuously measured daily average data for SO2 emissions from a kraft pulp recovery

boiler ... 305 Figure 3.52: SO2 emissions from the recovery boiler as short-term average ... 305 Figure 3.53: TRS emissions from the recovery boiler as short-term average ... 306 Figure 3.54: Flue-gas scrubber for recovery boilers ... 307 Figure 3.55: Continuously measured daily average data of SO2 emissions of a kraft pulp recovery

boiler equipped with an ESP and a scrubber... 308 Figure 3.56: Complete view of a boiler and schematic view of the lower and middle part of the

furnace of a recovery boiler of a kraft pulp mill ... 310 Figure 3.57: Specific NOX emission load (kg NO2/ADt) from recovery boilers as a function of black

liquor dry solids content (%) ... 311 Figure 3.58: Relationship between the CO concentration and the specific NOX emission from black

liquor recovery boilers ... 312 Figure 3.59: Relationship between the N content in black liquor (%) and the NOX emission load from

recovery boilers ... 313 Figure 3.60: NOX concentration (as NO2), at 6 % O2 from black liquor recovery boilers ... 314

Figure 3.61: Specific NOX emissions from black liquor recovery boilers ... 315

Figure 3.62: Daily average NOX and CO values over a full year from a kraft pulp black liquor

recovery boiler ... 316 Figure 3.63: NOX emissions from the recovery boiler as short-term average ... 317

Figure 3.64: CO emissions from the recovery boiler as short-term average ... 317 Figure 3.65: Continuously measured daily average data for the NOX and CO emissions of a black

liquor recovery boiler ... 319 Figure 3.66: Continuously measured daily average data for the NOX and CO emissions of the

recovery boiler of the Södra Värö kraft pulp mill ... 320 Figure 3.67: Yearly average concentration of dust emissions from recovery boilers after the ESP or

the ESP and wet scrubbers ... 322 Figure 3.68: Continuously measured daily average dust emissions downstream of the ESP of a kraft

pulp recovery boiler ... 323 Figure 3.69: Dust emissions from recovery boilers as short-term average ... 323 Figure 3.70: Yearly average dust emission loads from recovery boilers after the ESP or the ESP and

wet scrubbers ... 324 Figure 3.71: Continuously measured daily average data for dust emissions downstream of the ESPs

of a kraft pulp recovery boiler ... 327 Figure 3.72: TRS and SO2 emission concentrations from lime kilns fired with different fuels ... 329

Figure 3.73: SO2 and TRS emission loads from lime kilns fired with different fuels ... 330

Figure 3.74: SO2 emissions from lime kilns as short-term averages ... 331 Figure 3.75: TRS emissions from lime kilns as short-term averages ... 331 Figure 3.76: NOX emission concentrations from lime kilns for various fuels ... 335

Figure 3.77: NOX emission loads from lime kilns for various fuels... 336

Figure 3.78: NOX emissions from lime kilns as short-term averages ... 337

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Figure 3.80: Dust emission concentrations from lime kilns including applied dust abatement

technique ... 340 Figure 3.81: Dust emission loads from lime kilns including applied dust abatement technique ... 340 Figure 3.82: Continuously measured daily average data for dust emissions downstream of the ESPs

of a kraft mill's lime kiln ... 341 Figure 3.83: Dust emissions from the lime kiln as short-term average... 342 Figure 3.84: Daily average data over a full year for dust emissions from a lime kiln equipped with an

ESP and a wet scrubber (CO emissions are also included) ... 343 Figure 3.85: NOX emission concentrations from dedicated TRS burners ... 346

Figure 3.86: NOX emission loads from dedicated TRS burners ... 347

Figure 3.87: Forest biorefinery pathways ... 357 Figure 3.88: Recovery of chelating agents in bleach plant filtrates by use of a kidney ... 364 Figure 4.1: Process flow of a sulphite mill producing speciality pulp and various products based on

the conversion of the spent sulphite liquor ... 374 Figure 4.2: Production scheme of a neutral sulphite semi-chemical mill (300 000 t/yr) with

chemical and energy recovery units ... 376 Figure 4.3: Aerial view of an integrated sulphite pulp mill producing coated fine paper including

the power plant (centre) and the waste water treatment plant (back right) ... 376 Figure 4.4: Main processes for the manufacturing of magnesium sulphite pulp showing the fibre

line operations and the chemical and energy recovery ... 377 Figure 4.5: Typical fibre line of a sulphite pulp mill manufacturing pulp for papermaking ... 378 Figure 4.6: Example of a wash filter (left) and a wash press (right) in brown stock washing ... 380 Figure 4.7: Pressure screens for final screening ... 383 Figure 4.8: Recovery cycles of chemicals and energy for a magnesium-based sulphite mill ... 384 Figure 4.9: Basic principle of the flow of pulp and spent liquor in mills applying the biorefinery

concept ... 385 Figure 4.10: Scheme of the manufacture of fodder yeast and separation of lignosulphonates from the

spent sulphite liquor ... 386 Figure 4.11: Preparation of chlorine dioxide by the Kesting method ... 388 Figure 4.12: Mass stream overview of the inputs and outputs of a sulphite pulp mill ... 389 Figure 4.13: Major sources of emissions to water from sulphite pulping ... 396 Figure 4.14: Waste water discharged (yearly averages) from different sulphite pulp mills ... 397 Figure 4.15: Yearly averages of specific COD loads from sulphite pulp mills (excluding NSSC) ... 398 Figure 4.16: Yearly averages of specific COD loads from NSSC pulp mills ... 398 Figure 4.17: Short-term averages of COD emissions from sulphite pulp mills ... 400 Figure 4.18: Short-term averages of BOD emissions from sulphite pulp mills ... 401 Figure 4.19: Yearly averages of specific TSS loads from sulphite pulp mills (excluding NSSC) ... 402 Figure 4.20: Yearly averages of TSS emissions from NSSC pulp mills... 402 Figure 4.21: Short-term averages of TSS emissions from sulphite pulp mills ... 403 Figure 4.22: Yearly averages of tot-P emissions from sulphite pulp mills (excluding NSSC) ... 404 Figure 4.23: Yearly averages of tot-P emissions from NSSC pulp mills ... 404 Figure 4.24: Short-term averages of tot-P emissions from sulphite pulp mills ... 405 Figure 4.25: Yearly averages of tot-N emissions from sulphite pulp mills (excluding NSSC) ... 405 Figure 4.26: Yearly averages of tot-N emissions from NSSC pulp mills ... 406 Figure 4.27: Short-term averages of tot-N emissions from sulphite pulp mills ... 406 Figure 4.28: Yearly averages of AOX loads from sulphite pulp mills (excluding NSSC) ... 407 Figure 4.29: Short-term averages of AOX emissions from sulphite pulp mills ... 408 Figure 4.30: Example of the collection of sulphur dioxide-containing and odorous gases and their

treatment ... 409 Figure 4.31: Example of SO2 emissions from recovery boilers for 'normal operation' and 'acid

operation mode' ... 411 Figure 4.32: SO2 emissions from the recovery boiler ... 412 Figure 4.33: SO2 emissions from the recovery boiler as short-term averages ... 412 Figure 4.34: Dust emissions from the recovery boiler as yearly averages ... 413 Figure 4.35: NOX emissions from the recovery boiler as yearly averages ... 414 Figure 4.36: NOX emissions from the recovery boiler as short-term averages ... 414

Figure 4.37: CO emissions from the recovery boiler as yearly averages ... 415 Figure 4.38: CO emissions from the recovery boiler as short-term averages ... 415 Figure 4.39: Example of a fibre line with O2 delignification including the COD and DCM extract

values before and after O2 delignification ... 424 Figure 4.40: Closed-loop pre-bleaching with MgO as a base (M-real Hallein, AT) ... 430 Figure 4.41: Ultrafiltration system in a dissolving pulp mill, Domsjö Fabriker AB, SE ... 432 Figure 4.42: Flowsheet of the use of the ultrafiltration plant in the Nymölla pulp mill ... 435

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Figure 4.43: Simplified scheme of the evaporation and incineration of the EOP effluents ... 438 Figure 4.44: Example of organic loads and removal efficiencies of anaerobic and aerobic waste water

treatment in Sappi Fine Paper Europe ... 441 Figure 4.45: Process diagram of the effluent treatment plant for an integrated pulp and paper mill

manufacturing magnesium bisulphite pulp ... 443 Figure 4.46: Process diagram of the waste water treatment plant for a pulp mill manufacturing

magnesium bisulphite market pulp ... 448 Figure 4.47: Process diagram of the waste water treatment plant of an integrated mill producing

NSSC pulp and SC fluting ... 453 Figure 4.48: Process diagram of the effluent treatment plant (aerated lagoon) for a pulp mill

manufacturing ammonium bisulphite speciality pulp ... 458 Figure 4.49: Schematic view of a recovery boiler of a sulphite pulp mill (M-real Hallein, 1985) ... 462 Figure 4.50: Schematic view of the ammonia injection into the recovery boiler ... 465 Figure 4.51: Daily mean NOX emissions from the recovery boiler as determined by the automatic

emission monitoring system during 2008 ... 467 Figure 4.52: Simplified flow chart of a flue-gas desulphurisation plant (multistage scrubbers and

final washer) and its integration in cooking chemical preparation ... 471 Figure 4.53: Reported duration of acid operation ... 473 Figure 4.54: SO2 circuit in a sulphite mill and major sources of the diffuse SO2 emissions that are

collected and burnt in the recovery boiler ... 480 Figure 5.1: Main steps in mechanical pulping... 488 Figure 5.2: Flow scheme for a pressure groundwood process mill ... 489 Figure 5.3: Schematic of the TMP process and emissions ... 492 Figure 5.4: Schematic of the main unit operations of the CTMP process ... 494 Figure 5.5: Modern high-consistency peroxide bleaching system in a SGW pulp-based LWC paper

mill ... 498 Figure 5.6: Mass stream overview of an integrated mechanical pulp and paper mill ... 499 Figure 5.7: Specific waste water discharge from individual mechanical and chemimechanical pulp

and paper mills ... 503 Figure 5.8: Sources of emissions to water from a CTMP mill ... 504 Figure 5.9 Yearly averages of specific COD loads from individual mechanical and

chemimechanical pulp mills ... 506 Figure 5.10: Short-term averages of BOD emissions from mechanical pulp mills ... 507 Figure 5.11: Yearly averages of specific TSS loads from individual mechanical and

chemimechanical pulp mills ... 508 Figure 5.12: Yearly averages of tot-P loads from individual mechanical and chemimechanical pulp

mills ... 509 Figure 5.13: Short-term averages of tot-P emissions from mechanical pulp mills ... 509 Figure 5.14: Yearly averages of tot-N loads from individual mechanical and chemimechanical pulp

mills ... 510 Figure 5.15: Short-term averages of tot-N emissions from mechanical pulp mills ... 510 Figure 5.16: Yearly averages of AOX loads from individual mechanical and chemimechanical pulp

mills ... 511 Figure 5.17: Emissions to the atmosphere from CTMP mills ... 512 Figure 5.18: Main water sources and sinks in an integrated mechanical pulp and paper mill ... 527 Figure 5.19: Water recycling system at the Meadow Lake BCTMP mill ... 531 Figure 5.20: Zero liquid effluent process concept at the Meadow Lake BCTMP mill ... 532 Figure 5.21: Energy and mass flows as well as energy flows bound to mass flows in a SD or CD

refiner ... 534 Figure 5.22: Energy and mass flows as well as energy flows bound to mass flows in a twin or DD

refiner ... 535 Figure 6.1: Flowsheet of an example stock preparation plant for processing paper for recycling for

case-making material (two-ply Testliner) ... 552 Figure 6.2: Example of an overall plant concept for Testliner (two-loop system) ... 555 Figure 6.3: Example of an overall plant concept for (improved) newsprint, SC or LWC paper ... 557 Figure 6.4: Example of an overall plant concept for a paper for recycling preparation plant for tissue

paper ... 560 Figure 6.5: Mass stream overview of an integrated mill for processing paper for recycling ... 561 Figure 6.6: Basic flow chart of the paper and board production processing paper for recycling ... 565 Figure 6.7: Example of water circuits for an integrated RCF mill for corrugated medium without

deinking ... 566 Figure 6.8: Example of an optimised stock-water system for the integrated production of deinked

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Figure 6.9: Specific waste water flow of European RCF paper mills without deinking ... 568 Figure 6.10: Specific waste water flow of European RCF paper mills with deinking ... 569 Figure 6.11: Specific energy consumption of a newsprint mill for processing paper for recycling ... 574 Figure 6.12: Specific COD load as a yearly average after waste water treatment from mills

processing paper for recycling without deinking ... 577 Figure 6.13: Specific COD load as a yearly average after waste water treatment from mills

processing paper for recycling with deinking... 578 Figure 6.14: Short-term averages of COD emissions from mills processing paper for recycling

without deinking ... 579 Figure 6.15: Daily COD loads over one year from a mill processing paper for recycling with

deinking (RCF DE 18) ... 579 Figure 6.16: Short-term averages of BOD emissions from mills processing paper for recycling

without deinking ... 580 Figure 6.17: Daily BOD concentrations over one year from a mill processing paper for recycling

with deinking (RCF DE 18) ... 581 Figure 6.18: Specific tot-P load as a yearly average after waste water treatment from mills processing

paper for recycling without deinking, with indication of waste water flow ... 582 Figure 6.19: Specific tot-P load as a yearly average after waste water treatment from mills processing

paper for recycling with deinking ... 582 Figure 6.20: Short-term averages of tot-P emissions from mills processing paper for recycling

without deinking ... 583 Figure 6.21: Daily tot-P concentrations over one year from a mill processing paper for recycling with

deinking (RCF DE 18) ... 583 Figure 6.22: Specific tot-N or TNb load as a yearly average after waste water treatment from mills

processing paper for recycling without deinking ... 584 Figure 6.23: Specific tot-N or TNb load as a yearly average after waste water treatment of mills

processing paper for recycling with deinking... 585 Figure 6.24: Short-term averages of tot-N emissions from mills processing paper for recycling

without deinking ... 585 Figure 6.25: Daily tot-N concentrations over one year from a mill processing paper for recycling

with deinking (RCF DE 18) ... 586 Figure 6.26: Specific load of suspended solids as a yearly average after waste water treatment of

mills processing paper for recycling without deinking... 587 Figure 6.27: Specific load of suspended solids as a yearly average after waste water treatment of

mills processing paper for recycling with deinking ... 587 Figure 6.28: Annual averages of AOX loads for individual mills processing paper for recycling

without deinking ... 588 Figure 6.29: Unloading and storage of loose paper for recycling in an enclosed facility with a roof .... 596 Figure 6.30: Outdoor storage of paper for recycling with concrete paving ... 596 Figure 6.31: Storage of paper for recycling in bales under a roof ... 597 Figure 6.32: Scheme of water loops in paper mills... 600 Figure 6.33: Layout of water loops in a paper mill with separation of water loops and counter-current

flows ... 601 Figure 6.34: Example for the in-line treatment of closed water loops, process water treatment system

of RCF DE 6... 605 Figure 6.35: Daily average COD load over a complete year (RCF NL 1) ... 612 Figure 6.36: COD load of a RCF newsprint mill with deinking after anaerobic-aerobic biological

treatment for different reference periods ... 614 Figure 6.37: Concentration of tot-P and tot-N after anaerobic/aerobic biological treatment and partial

tertiary treatment of the waste water of a RCF newsprint mill ... 615 Figure 6.38: Flow chart of the process water treatment at the Köhler Pappen mill including MBR ... 617 Figure 6.39: Layout of the ozonation stage with a subsequent biofilter ... 622 Figure 6.40: Development of COD and BOD5 concentration during ozonation and biofiltration ... 623 Figure 6.41: Typical production and emission data before and after ozonation and biofiltration ... 624 Figure 6.42: Process steps (subsystems) of the example RCF-processing mill without deinking ... 627 Figure 6.43: Process steps (subsystems) of the example RCF-processing mill with deinking ... 629 Figure 6.44: Two examples of stock preparation plant concepts for processing paper for recycling for

two-ply Testliner ... 632 Figure 6.45: Operating principle of dissolved air flotation (DAF) ... 636 Figure 6.46: Example of the generic process steps of an effective reject and sludge handling concept

for a brown paper RCF mill ... 640 Figure 6.47: Simplified scheme for the incineration of rejects in a multiple-hearth incinerator ... 644 Figure 6.48: Simplified scheme for co-incineration of rejects in a brown coal-fired power plant ... 648