ENVIRONMENTAL PERFORMANCE IN 2011 UPM Schongau

Transcription

1 ENVIRONMENTAL PERFORMANCE IN 2 UPM Schongau

2 UPM CORPORATE ENVIRONMENTAL STATEMENT 2 UPM paper and pulp mills This Environmental Performance Statement is a supplement to the Environmental Statement of UPM s pulp and paper mills (available at and provides mill-specific environmental performance data and trends for the past year. The supplement and the joint Environmental Statement together form the EMAS Statement. The next joint Environmental Statement and the next Environmental Performance Statement for UPM Schongau will be published in the spring of 213. UPM Schongau UPM Schongau is sited on a bend of the Lech river in the Southern German town of Schongau. The site was founded in In 1962, one of the world s first flotation deinking systems went on line in Schongau. This processing technology was a major breakthrough for the recycling of used graphic paper into new printing paper. Today, Schongau produces printing paper in reels for newspapers, newspaper supplements, advertisers, brochures, magazines and catalogues on three paper machines. Recovered paper is in terms of volume the most important raw material at the site. Other raw materials used include sawmill residues and pigments as fillers. Pigments are partly made on the premises by the local supplier SMI. The wastewater from the production process is treated in the on-site effluent treatment plant. Power and steam are generated in two combined heat and power plants. The fluidised bed boiler burns fibrous residues resulting from the deinking and papermaking processes. The second boiler is fuelled by natural gas. A relatively large portion of the thermal energy required is supplied by recovering heat from the TMP plant. A small part of the power consumption is covered with hydropower. UPM Schongau in brief Production capacity Up to 75, tonnes per annum Workforce Approx. 525 Products Standard and improved newsprint Supercalendered uncoated paper UPM Eco UPM Brite UPM News UPM EcoBasic 2 UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2

3 Environmental performance in 2 UPM Schongau has for many years been committed to ecologically sound production processes. As far back as the early sixties, the commissioning of a deinking plant set the scene for sustainable resource conservation. The volume of paper recycled is roughly equivalent to the volume of paper produced. Some paper grades require an input of virgin fibres which, since the end of 24, have come exclusively from sustainable forestry. Nearly closedloop water circuits, heat recovery systems as well as a high recovery rate of process residue generated at the site have for a long time been the results of our environmentally responsible way of operating. In 2 extensive recultivation work was completed at the Roesenau landfill to restore the area to its natural state. The final inspection and approval of the works by the authorities is expected to take place by mid-212. Groundwater monitoring will continue throughout the after-closure period. There were no complaints or objections raised during the reporting year. Owing to the favourable chemical and physical properties of the ash from the mill, which is generated by incineration for energy of process residues in our power plants, we were able to identify further options for its utilisation, such as using it as a replacement for soda lye. For some applications, ash has already gained products status. 2 was marked by activities to improve energy consumption, energy use and energy efficiency. We made preparations for implementing the DIN EN ISO 51 standard and carried out group-wide energy efficiency audits. Additionally, we worked intensively on planning a new lower-emission co-generation plant which will replace the existing steam power plant. Winfried Schaur General Manager Ute Soller Senior Specialist Environment & Managementsystem Certification Quality Management System: ISO 91 Environmental Management System: ISO 141 and EMAS Occupational Health and Safety System: OHSAS 181 Chain-of-Custody: PEFC and FSC Ecolabel Blue Angel for UPM News and UPM EcoBasic H European Ecolabel (EU Flower) for copying and graphic paper Promoting Sustainable Forest Management UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2 3

4 Airborne emissions In 2, airborne emissions remained largely constant on a low level. Energy generated from the incineration of process residue and used wood reduced our natural gas usage. The high proportion of mostly renewable fuels contributes to cutting fossil CO 2 emissions. However, unfortunately, our overall high wastepaper recovery rate negatively affects the energy yield from process residues (deinking sludge), which are high in filler and low in combustible wood fibre. As a result, specific CO 2 emissions increased. By optimising the operation of the solid fuel boiler in the no. 2 CHP, we were able to further reduce its already low emissions. It should be noted in particular that, in addition to consistently very low particulate emissions, CO and Hg emissions were also down. In the natural gas-fuelled steam power plant, the measures to reduce NO X emissions, taken mainly in 2, fully materialised in 2. Annual average NO X emissions from the steam power plant fell to less than half the 2 level. NO X emissions were 42 % below the permitted limit. That we were able to reduce both CO and NO X emissions at the same time demonstrates that the measures taken were successful and is an indication of optimum power plant design and operation. In 2, there was one breach of the permissible half hourly mean value of 5 μg/m³ for mercury (52.9 μg/ m³). This was due to problems with the fuel supply that caused higher CO contents and resulted in mercury being released into the sampling tube. EMISSIONS FROM THE COMBINED HEAT AND POWER PLANT, 2 Limit value (mg/m³ Ntr) FLUIDISED BED BOILER/CONTINUOUS MEASUREMENT CO Particulates.62 SO NO X Hg total.3.23 HCI.6.9 FLUIDISED BED BOILER/ONE-TIME MEASUREMENT C total 2 < 2 HF 1 <.2 Cd, Tl.5 <.1 Sb, As, Pb, Co, Cr, Cu, Mn, Ni, V, Sn.5.1 PCDD, PCDF.1 ng/m³ Ntr.2 STEAM BOILER/CONTINUOS MEASUREMENT CO 3.31 NO X Mean value of measurements (mg/m³ Ntr) With the decision taken in February of 212 to replace the steam power plant by a highly efficient gas and steam turbine plant, UPM sets the course for sustainable energy supply, while at the same time increasing its power generation capacity and reducing its carbon footprint. 4 UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2

5 Waste Ash from the fluidised bed boiler operating on solids constitutes the largest waste fraction at UPM Schongau. In 2. % of the ash was sold to the construction materials and cement industries for reuse. However, the recovery rate is subject to seasonal and cyclical variations. RECOVERY RATE % Effluents A considerable amount of water from the river Lech is required to cool power stations, steam turbines, production machinery and heat recovery systems. Cooling water is not contaminated during use and can be discharged back directly into the river. The process water used in paper production is bank filtrate from the Lech river. Only a fraction of the water is discharged as wastewater after it has been recycled within the process several times. The capacity of the on-site multi-stage effluent treatment plant corresponds to that of a treatment plant for 42, people. Effluents are first cleaned in a chemical-mechanical treatment stage and then in an anaerobic IC reactor. Finally, they are treated aerobically in an activated sludge tank and a clarifier tank. The quality of the treated effluents is continuously monitored, both internally and by the authorities in charge. With nitrogen at, the limit value of 7.5 was exceeded in one instance due to an excessive nutrient load. EFFLUENT VOLUME 25, m³/day COD, CHEMICAL OXYGEN DEMAND 1, BOD 5, BIOLOGICAL OXYGEN DEMAND 25 2, , 6 15, 4 5, P, PHOSPHORUS N, NITROGEN (INORGANIC) AOX, ADSORBABLE ORGANIC HALOGEN COMPOUNDS Annual average Limit value UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2 5

6 Environmental parameters 2 Data on production volumes and raw material and energy consumption as well as specific indicators per tonne of paper are given as a total figure. They can be found in the joint Environmental Statement of UPM s paper and pulp mills. Production capacity Paper 75, t Raw materials and additives Energy Airborne emissions Recovered paper Wood chips Process chemicals Operating supplies Renewable fuels Fossil fuels Purchased power Hydropower Carbon dioxide, CO 2 (fossil) Nitrogen oxide, NO X Sulphur dioxide, SO 2 Particulate matter Carbon monoxide, CO See UPM Corporate Environmental Statement for more information 36 % 64 % See UPM Corporate Environmental Statement for more information 222,722 t 198 t.6 t.28 t 9.5 t Water consumption Process and cooling water 51,355, m³ of which 45,3,8 m³ cooling water Emissions to water Waste* Mill area Effluent volume COD BOD 5 Phosphorus Nitrogen (inorganic) AOX Total volume of which ash fluidised bed sand metal other Recovery rate Hazardous waste 5,324,2 m³ 1,539 t 28 t 3.7 t.5 t.4 t 98,58 t 9,69 t 3,26 t 1,43 t 3,2 t 99.9 % 323 t 35 ha * incl. moisture COD : chemical oxygen demand BOD 5 : biological oxygen demand AOX: adsorbable organic halogen compounds 6 UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2

7 Performance against targets in 2 Targets Waste Further develop solid waste management Explore thermal and material recovery options for labelstock waste Waste Improve value creation from ash, explore further options for the use of ash, drive product development Energy Reduce energy consumption by TMP process Develop energy saving measures Run trials for preliminary treatment of wood chips Chemical use Substitute sodium hydroxide solution implement investment Target achieved? Achieved, project to be continued Achieved, project to be continued Project still under way Achieved Current targets Targets and measures Deadline Department(s) responsible Energy Successfully implement 51 energy management system Improve energy yield of process residue by 5 % through drying and pelletising Reduce specific energy consumption by 5 % Waste Continue product development for ash, gain product status for % Run trial for production of CDEM ash with no. 2 CHP Chemical use Optimise % sodium hydroxide substitution in peroxide bleaching during continuous operations and investigate possible uses at other sites 4/212 12/212 12/212 12/212 /212 Management Representative Energy/Planning Pulp Preparation Mill Development Energy 12/212 Mill Development Environmental verifier s declaration on verification and validation activities Environmental verifier Dr. Detlef Nehm (DE-V-223), acting for TÜV NORD CERT Umweltgutachter GmbH, licensed for the scope NACE Code (papermaking), declares to have verified whether the site UPM GmbH, Schongau mill, Friedrich-Haindl-Str., Schongau, Germany, as indicated in the Environmental Statement 2 of the mentioned site, meets all requirements of Regulation (EC) No 1221/29 of the European Parliament and of the Council of 25 November 29 on the voluntary participation by organisations in a Community Eco-Management and Audit Scheme (EMAS). By signing this declaration, I declare that: the verification and validation has been carried out in full compliance with the requirements of Regulation (EC) No 1221/29, the outcome of the verification and validation confirms that there is no evidence of non-compliance with applicable legal requirements relating to the environment, the data and information of the Environmental Statement 2 of UPM GmbH, Schongau mill mill, reflect a reliable, credible and correct image of all the activities of UPM GmbH, Schongau mill, within the scope mentioned in the Environmental Statement 2. This document is not equivalent to EMAS registration. EMAS registration can only be granted by a Competent Body under Regulation (EC) No 1221/29. This document shall not be used as a stand-alone piece of public communication. Schongau, 13 March 212 REG.NO. FI - 58 Dr. Detlef Nehm Environmental verifier DE-V-223 TÜV NORD CERT Umweltgutachter GmbH UPM SCHONGAU, ENVIRONMENTAL PERFORMANCE IN 2 7

8 UPM GmbH Friedrich-Haindl-Straße Schongau Germany Tel Fax For further information, please contact: Winfried Schaur General Manager Tel Ute Soller Environment and Management System Tel /212