. . . the stuff of which paper is made!
… the stuff of which paper is made
Paper accompanies you through the day.
When evening falls, you can rest assured that tomorrow there will be enough raw material for all the papers you need . . .
. . . it is a very special material that papers are made of.
Zellstoff- und Papierfabrik Rosenthal GmbH Hauptstraße 16 · D-07366 Rosenthal am Rennsteig Telefon +49 36642 8-0 · Fax +49 36642 8-2000 E-Mail email@example.com · Internet www.zpr.de
SANTANOL FRIESAU ROSENTHAL
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• Around 1.8 million solid cubic meters of wood required per year.
· Approx. 2/3 of which as wood chips, which are a by-product of sawmills.
· Approx. 1/3 as log wood, which corresponds to more than 19,000 log wood trucks.
• At present, approx. 80 % of the wood we process is from certified forests.
5:25 p.m.: Somewhere in Thuringia, Germany.
Jens (15) is carving his heart´s desire
into our most valuable raw material.
But we don’t mind . . .
. . . forests are immensely important for mankind:
As a protection against erosion, as a refuge of silence, to purify the air and to regulate the water cycle, as a recreation area and also as a wonderful place for lovers. That´s why the forest has grown close to our hearts.
And what you love from the heart, you also treat with care.
Spruce and pine wood are our raw materials. We mainly use sawmill by-products in the form of wood chips from surrounding sawmills and industrial wood from the nearby region: Thuringian Forest (Thüringer Wald), Ore Mountains (Erzgebirge), Franconian Forest (Frankenwald) and Fichtel Mountains (Fichtelgebirge).
We also ensure that the wood comes from sustainably managed forests that are managed in accordance with the standards of the
(PEFC/04-31-0411) and other forest certification organisations.
In this way, we make a significant contribution to the vitality, care and sustainable management of the forests.
1 Wood chip storage 2 Log wood yard 3 Log wood conveyor 4 Log wood unloading 5 Wood chip delivery 2
3 4 5
TREES ARE A MATTER OF THE HEART – ALSO FOR US!
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ENVIRONMENTAL PRO- TECTION IS MORE THAN JUST A FEW HEADLINES
• Energy generation from biomass, which is produced in the production process; we genera- te the energy we use ourselves and can even feed surpluses into the public power grid – so much that we could cover the entire energy needs of a small town with it!
• The entire energy is obtained CO2-neutrally from the renewable raw material wood. Fossil fuels are only required for lime burning (calcination) in the chemicals circuit and for trans- port. In this way, we are making a positive contribution to reducing the greenhouse effect.
• The boiler plants are part of the circulation system for chemicals recovery. Apart from water vapour, only slightly polluted exhaust gases are released into the atmosphere via the 120-metre-high chimney. In addition, we operate the entire plant practically odourless to the outside world thanks to special collection and disposal systems.
• In-house wastewater treatment plant: Almost complete reduction of biodegradable sub- stances, waste water values well below the prescribed limit values, also best results in international comparison.
• Since 2004, we have had an environmental management system according to DIN EN ISO 14001, which we check regularly and have certified by an external auditor.
• We have appointed competent and reliable specialist officers to coordinate all tasks in the environmental sector, such as water protection, waste or air pollution control.
8:33 a.m., Manchester, England.
Mr. Morton (53) is having his morning read on the way to work as usual.
And does something good for the environment at the same time. . .
. . . because, like him, millions of people around the world use journals and magazines to get an overview of what is currently going on in the world.
One of the topics that is always mentioned is the protection of the environment.
If the paper for Mr. Morton´s morning read was made with pulp from our com- pany, then it would be part of the solution rather than part of the problem.
We are firmly convinced that successful production and environmental pro- tection are not opposites, but can be mutually beneficial.
Not least the proximity of our location to the natural park “Thüringer Schiefergebirge” and to the largest reservoir in Germany, the
“Bleilochtalsperre” dam, strengthen this opinion. For many years, we have been committed to the preservation of these natural beauties with advice and assistance as well as with financial means.
Our production facilities are designed to the most modern standards for optimal environmental protection.
1 “Bleilochtalsperre” dam
2 Zellstoff- und Papierfabrik Rosenthal 3 Natural park “Thüringer Schiefergebirge”
4 Wastewater treatment plant 1
Val Thoermer · www.fotolia.com
© Henry Czauderna · www.fotolia.com
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6:50 p.m., Moers, Germany.
Lena (3) is happy that mummy reads to her from the book “Struwwelpeter”.
At the time this book was written, nobody was talking about sustainability.
We have already lived it . . .
1 Zellstoff- und Papierfabrik Rosenthal around 1931 2 Narrow-gauge railway around 1928
3 Horse-drawn tram around 1908 4 Paper hall around 1935 5 Paper machine around 1935 2
. . . for Lena, sustainability is as natural as electricity from the socket is for us.
Even the paper on which her beloved “Struwwelpeter” is printed has its origins in sustainably managed forests and environmentally friendly production facilities.
And in a double sense, it is a piece of the future for Lena.
Kaiser Wilhelm II. was not yet sitting on his throne when our company was founded as “Wiedes Papierfabrik Rosenthal”.
War and peace, boom and economic crises, traditional production and high- tech – all this and much more has accompanied us and influenced the fate of our company.
The fact that we have successfully mastered everything is the result of a business philosophy that has focussed on sustainability in all business areas from the very beginning.
1883 Start of production at “Wiedes Papierfabrik Rosenthal”
1891 Construction of a sulphite cellulose plant with rotating digesters
1947 Expropriation in the post-war period and declaration as a nationally-owned company
1977 Capacity expanded by 90,000 tons to 140,000 tons per year
1990 Rosenthal produces totally chlorine-free bleached pulp at the mill for the first time
1994 Mercer International Inc. takes over the mill
2000 Project “Rosenthal 2000”: Conversion to Germany´s first kraft pulp mill using the environmentally friendly sulphate process
(total investment: approx. 285 million €);
Increase to 280,000 tons annual production capacity 2001 – 2012 Gradual capacity expansion to 360,000 tons capacity
2008 Operating licence for the expansion of the mill to up to 450,000 tons per year 2016 – 2017 Construction of a rail terminal for the acceptance of wood by rail
SUSTAINABILITY IS NOT A TERM BUT A LIVING TRADITION
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Paper. Nature. Human.
With us, what belongs together has long since
• The heart of production: 65-metre high digester
• 6-shift operation with fully automatic production
• Central measuring stations and control rooms
• Permanent care and maintenance of the entire equipment by the company´s own maintenance teams
• Highly trained, up-to-date and experienced employees
• Quality management according to DIN EN ISO 9001 with annual audit
• Continuous recording and evaluation of all relevant process information
• Comparison of all data in the company-wide information system
• Regular, strict quality controls of the end product
• On request, testing according to special customer parameters
2 Control room recovery line 3 Causticizing
4 Factory view 5 In-house laboratory
11:20 p.m., Florence, Italy.
Signora Petrelli (32) had a brilliant performance as Femme Fatale with her amateur stage.
The fact that she is
the loving mummy at home again
has also something to do with us . . .
. . . among other things, our pulp is the basis for a wide variety of sanitary papers. Such papers must be gentle and skin-friendly, but also tear-resistant, absorbent and wipeable.
The most important thing is the suitable basic raw material.
That is why we are a little bit happier than the other spectators about Signora Petrelli´s performance.
Because we know that our quality will continue to accompany her for a long time to come.
At Mercer Rosenthal, we produce pulp using the so-called sulphate process.
In general, there are two product groups, elemental chlorine-free bleached kraft pulp (ECF) and totally chlorine-free bleached kraft pulp (TCF).
Exactly matched to the requirements of our customers, we produce different types of pulp, which differ in strength and whiteness. Due to its high
strength, our pulp is therefore excellently suited as a reinforcing fibre.
To ensure the consistently high quality of our products, both the material flow and the end product are monitored constantly. In doing so, the most modern technology is used to monitor and ensure compliance with strict national and international standards.
QUALITY TO THE LAST MEANS QUALITY FROM THE BEGINNING!
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© mp1982_06 · www.fotolia.com
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4:30 p.m., Munich, Germany.
Katja (16) relaxes with her favourite music.
We can sit back and relax, because she can look at her favourite musicians
on high-tech paper . . .
• Raw materials are finished wood chips from sawmills and round wood logs from the wood utilisation of local forests.
• Storage takes place separately; the mixing ratio is determined according to the requi- rements of the pulp in question.
• Before the actual cooking process, the wood chips are steamed in the silo and then pre-impregnated.
• Afterwards, they will be decomposed under pressure in an alkaline solution in the digester for approx. 4 hours at approx. 160 ° C; an aqueous pulp suspension is formed.
• Any residues are then removed from the pulp and in the washing and screening stage the pulp is also cleaned.
. . . if we want to relax, we need things that work without further thought:
A comfortable chair, a CD player, a book, a picture . . .
Sometimes the effort that has been put into fulfilling our wishes becomes visi- ble. Sometimes it stays hidden. Just like in the case of the production of pulp.
But we are proud when the effort has been worthwhile.
Katja´s eyes reward us . . .
The production of our pulp takes place in the fibre line. A modern fibre line like the one at Zellstoff- und Papierfabrik Rosenthal is a masterpiece of pro- cess engineering and corresponds to the current state of the art.
The entire process is computer-controlled and monitored from a central con- trol centre. This enables us to produce pulp around the clock, 7 days a week.
Simplified, the production of pulp can be divided into five steps.
• Elementary chlorine free or totally chlori- ne-free depending on customer require- ments.
• Elementary chlorine-free bleaches with hydrogen peroxide, oxygen and chlorine dioxide.
• Totally chlorine free bleaches with hydro- gen peroxide, oxygen and ozone.
• The aqueous pulp suspension is first dewatered mechanically on a mesh screen and then passed through presses.
• Subsequently, thermal drying is carried out to a final dry content of approx. 90 % in a drying chamber.
• In the baling line, the pulp web is cut lengthwise and crosswise and stacked into 250 kg bales.
• For dispatch, the bales are packaged into units (2-ton units).
1 Log wood storage 2 Debarking drum 3 Bleaching plant 4 Pulp digester 5 Pulp dryer 6 Baling line
With our main product, pulp, we ensure that millions of people all over the world can use paper for a wide variety of purposes.
The raw material we use for this comes from nature.
The knowledge that we need for this is held by people.
People have devised and refined the processes we use.
It is people who benefit from our products.
This is a reason for us to be happy.
Above all, it is the foundation of a great responsibility.
Responsibility towards natural resources, customers and mployees.
We are happy to accept this responsibility. Every day. Seriously.
For the quality of our products.
For the preservation of nature.
For the good of the people.
THE BEST PRODUCT DOESN´T SHOW THE EFFORT OF ITS
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11:15 a.m., Plauen, Germany.
Mrs. Vogt (35) has just put the water for lunch on the stove.
And even that has to do with our pulp . . .
. . . Pulp is important for our daily life.
But its production requires many chemicals and a lot of energy.
These things are also too important to simply be wasted.
This is why we work in a closed system.
We even have enough energy left over for Mrs. Vogt to prepare a warm meal for her loved ones every day. And besides her many other people in about 51,000 households . . .
The recovery line forms a closed chemicals circuit with the fibre line. It must be operated in parallel with the actual pulp production.
The chemicals required for pulp production are recycled and fed back into the production process. By means of a virtually closed chemicals circuit, we are thus able to reduce the cost of chemicals considerably and make a significant contribution to the preservation of our environment. In addition, the recovery line generates the thermal and electrical energy for pulp production.
The recovery line can also be schematically divided into five sub-areas.
• Evaporation plant
• The dissolved wood substance from the cooking process, the so-called “black liquor”, is thickened to a dry content of approx. 75 %. Thick liquor is formed.
• Recovery boiler
• The thick liquor is burned in the recovery boiler.
• Heat is generated, which is used to generate steam.
• The chemicals are reduced and dissolved into weak white liquor.
• The resulting raw green liquor is pumped into the causticizer.
• Anhydrous lime (“burnt lime”) is added to the green liquor from which white liquor is then produced.
• After filtering, this white liquor is returned to the pulp production process.
• The remaining carbonate sludge is washed and dried.
• Lime kiln
• The dried carbonate sludge is burned to calcium oxide (“burnt lime”).
• The “burnt lime” is also returned to the chemicals circuit.
• Energy recovery
• The steam produced in the recovery boiler and the bark incinerator is first used in a steam turbine to generate electricity.
• It is then used as process steam in production.
• As a renewable raw material, wood and the energy generated from it are to be regarded as CO2-neutral.
• Rosenthal generates considerably more energy than the mill needs to operate its plants.
The additionally generated energy of about 180,000 MWh per year is fed into the public power grid and can supply 51,000 households with green electricity.
• In 2012 – on our way to further improving energy efficiency and reducing the energy consumption even more sustainably – a new energy management system according to DIN EN ISO 50001 has been introduced.
©Robert Kneschke · www.fotolia.com 2
1 Recovery boiler 2 Evaporation 3 Causticizing 4 Lime kiln 5 Turbine
WE DO NOT ONLY PRODUCE
PULP: OUR SECOND PRODUCT:
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9:55 a.m., Prague, Czech Republic.
Anna (8) has to tell Karel (7) a matter of the heart.
We too get to you by the fastest route.
Even if we don´t have paper airplanes . . .
1 Round wood unloading at the log wood storage yard in the mill
2 Pulp loading 3 Factory railway 4 Dispatch warehouse 5 Railway delivery of round wood 1
. . . we need raw materials. They need pulp.
Sometimes here, sometimes there. The quality of information or a product is not only determined by its content, but also by its availability at the right time and place.
Karel and Anna know that. And we know that, too.
This is why we not only produce pulp of the highest quality. We also make sure that it reaches you.
No matter where you need pulp: We will bring it to you . . .
As a partner of the manufacturers of high-quality writing and printing papers as well as tissue, we have customers almost everywhere in Europe.
The sale of our products is managed centrally under the umbrella brand
“Mercer Pulp”. Thanks to our own railway sidings, we are able to supply our customers both by rail and by road as required. The mills´s own railway siding enables regular, daily dispatch of ordered goods to our customers.
The raw material supply of Zellstoff- und Papierfabrik Rosenthal is ensured by Mercer Holz, an independent sister company that supplies wood to all German Mercer mills.
Mercer Holz has its own fleet of trucks and wagons, which transport round wood and wood chips to the mills. The vehicles are state-of-the-art and thus minimise exhaust and noise emissions.
We also have our own company railway. In the meantime, more than 85 % of our goods are transported to our customers via the public rail network. In this way, we relieve the small towns in the surrounding area from heavy goods vehicle traffic.
• Sales in almost all of Europe.
• Warehouse for the handling of up to 1,500 tons of pulp per day.
• Loading on truck or train.
• Our own rail siding enables rail shipments twice a day.
• Our own wood forwarding company, which is used in local transport primarily to supply the mill with round wood and wood chips.
• Constant efforts to transport as much material as possible by rail, in order to relieve traffic rou- tes, the environment and the people in the surrounding communities as much as possible.
• Since 2017, there is the possibility again to deliver and unload logs by rail.
OUR PULP IS ON THE RIGHT TRACK.
FROM THE BEGINNING!
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Mercer Peace River is located in Castlegar, Canada – in the province of British Columbia, about 600 km east of Vancouver. The factory has an annual pulp capacity of 520,000 tons and generates approx. 100 MW of bioenergy. www.mercerint.com
Santanol is one of the world´s lea- ding suppliers of sustainably grown East Indian sandalwood oil. Santanol operates sandalwood plantations on approx. 2,000 hectares in the north of Australia. There, in Kununurra the harvested wood is sorted and pro- cessed into wood chips. In Perth, the oil is extracted and further refined in a highly modern steam distillation plant.
Mercer Timber Products in Friesau, Thuringia, is one of the largest soft- wood sawmills in the world. The mill has an annual sawn wood capacity of approx. 1.4 million cubic metres.
Bioelectricity is produced with approx. 13 MW.
… th e st uf f o f w hi ch p ap er i s m ad e!
10:30 a.m., Bad Lobenstein, Thuringia, Germany.
Christian (6) has just embarked on an adventure called “Lifelong learning”.
We are already in the middle of this adventure . . .
. . . only the one who thinks he knows everything is stupid.
Christian does not think so. He is eager to learn new things and learn more about the world.
Although we are a company that is more than 135 years old, we have not lost this curiosity.
Together with our North American parent company, Mercer International Inc., we want to learn something new every day. And become even better for you.
Christian is our role model . . .
Innovation at Zellstoff- und Papierfabrik Rosenthal has always meant two things:
Improving product quality on the one hand and responsibility for the natural bases of life on the other.
This did not change when our company was taken over by the North American Mercer International Inc. in 1994.
That is why we are proud not only to be one of the world´s leading manufac- turers of kraft pulp, but also to be at the forefront of environmental and soci- al commitment.
NOTHING IS AS EXCITING AS LEARNING SOMETHING NEW EVERY DAY!!
Mercer Stendal produces approxi- mately 660,000 tons of NBSK pulp per year. At the same time, Mercer Stendal is the largest biomass power plant of its kind in Germany (solid biomass) with a capacity of 135 MW.
In addition, turpentine and tall oil are produced from the renewable resource wood.
Mercer Celgar is located in Castlegar, Canada – in the province of British Columbia, about 600 km east of Vancouver. The factory has an annu- al pulp capacity of 520,000 tons and generates approx. 100 MW of bio- energy. www.celgar.com
Mercer Rosenthal in Thuringia has an annual pulp capaci- ty of 360,000 tons of NBSK pulp and produces approx. 57 MW of bioelectricity on the basis of solid biomass. In addi- tion, the company produces 5,000 tons of tall oil per year.
Approximately 450 employees (including Mercer Holz) are employed at the location in Rosenthal. www.zpr.de
Mercer operates four state-of-the-art pulp mills that produce pulp for paper production, bioenergy and biochemicals.
Mercer also manufactures high-quality sawn wood products in its Thuringian sawmill.
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