ENVIRONMENTAL PERFORMANCE IN 2011 UPM, Kymi

Transcription

1 ENVIRONMENTAL PERFORMANCE IN 2011 UPM, Kymi

2 UPM, Kymi The Kymi mill in Kuusankoski, Kouvola, Finland consists of a paper and pulp mill. The Kymi mills form a modern integrated production site, whose core products are uncoated and coated fine paper. In 2011, Kymi employed a total of 599 people. The paper mill is divided into two production units. Paper machine 8 and coater 3 create a production line manufacturing high-quality coated fine paper for printing that is shipped on reels. Paper machine 9 produces uncoated fine paper on reels and in sheets to be used as printing paper, forms and envelopes as well as copier/printer paper. The pulp mill manufactures the fibre raw material required in the manufacture of paper on two production lines. The UPM mill site also includes Kymin Voima Oy s power plant, Schaefer Kalk Finland Oy s PCC plant and Kemiran Chemicals Oy s chlorine dioxide plant, all of which are directly linked to Kymi s production plants. In addition, Solvay Chemicals Finland Oy s production plant in Kuusankoski provides the peroxide used for bleaching pulp. None of these plants are included in this publication. UPM Kymi Paper mill Production capacity 830,000 t Production and products Coated and uncoated fine paper: UPM Finesse, UPM Fine, UPM PreLaser, UPM PrePersonal, UPM Form, UPM Letter UPM Office, Future, Yes, KymLux UPM Digi Laser, UPM Digi Finesse, UPM JetLabel, UPM Vellum Pulp mill Production capacity 570,000 t Production and products Birch and pine pulp: UPM Betula and UPM Conifer Thermal energy and electricity Production residues Tall oil, turpentine The mills employed a total of 599 people. 2

3 UPM CORPORATE ENVIRONMENTAL STATEMENT 2010 UPM paper and pulp mills This Environmental Performance 2011 report of UPM, Kymi is the mill supplement of the UPM Corporate Environmental Statement UPM Corporate Environmental Statement 2011 together with mill supplements comprise the global EMAS statement of UPM Corporation. UPM Corporate Environmental Statement is available is available at The next global EMAS statement will be published in the spring of Environmental year 2011 The market situation for UPM products in 2011 was slightly worse than the situation in The production volume of both pulp and paper remained lower than in mills in December to define the starting level. Issues studied in the audit included management of environmental issues, water protection, air protection, noise, waste management and chemicals. The environmental protection obligations were systematically covered in compliance with the environmental permit. The environmental load was reduced from the previous year for BOD, COD, AOX and TRS air emissions. Stakeholders did not submit any feedback in In 2011, UPM launched a project called Clean Run that aims to significantly improve the mills environmental performance. A Clean Run audit was performed at the Kymi A decision on building a new oxygen bleaching stage for the mill s birch fibre line was made in autumn Design started in autumn 2011 and the oxygen bleaching stage will be commissioned in autumn The purpose of this investment is to achieve a lower AOX load per tonne of pulp. The changes will also result in savings in wood and bleaching chemical costs and reduce the effluent load discharged to the river. Certificates Quality Management System ISO 9001 Environmental Management System ISO Occupational Health and Safety Management System OHSAS EMAS Eco Management and Audit Scheme Chain of custody systems PE, FC and FSC PEFC/ Promoting Sustainable Forest Management European Union Eco-label UPM Finesse, UPM Fine, UPM PreLaser, UPM PrePersonal, UPM Form, UPM Letter UPM Office, Future, Yes, KymLux UPM Digi Laser, UPM Digi Finesse 3

4 ACHIEVEMENT OF KYMI S ENVIRONMENTAL OBJECTIVES 1. Reducing water consumption Pulp mill Paper mill Target Target - process water, m 3 / tonne of output Reducing solids losses from the paper mill (%) Pulp and paper mills combined 3. Reducing the amount of waste for final disposal (dry tonnes) 10,530 11,498 Training and improved sorting of waste 4. Compliance with environmental permit In 2011, air emissions and waste management at Kymi complied with the environmental permit conditions. The monthly permit limit for phosphorus was exceeded in August. However, phosphorus emissions remained within the annual permit limit in Reducing energy consumption The energy-efficiency goals set for the pulp mill s chemical recovery plant have been achieved. Furthermore, energy consumption has been decreased by changing the operations methods and implementing minor investments in other areas of the mill. 4

5 Air and noise The mill met all environmental permit limits for air emissions. Gaseous sulphur emissions and odorous sulphur compound emissions decreased from Total NOx emissions remained at the same level as the previous year. NOx emissions totalled at 1.74 kg per tonne of pulp, which is very close to the mill s internal goal of 1.7 kg per tonne of pulp. Processes of the pulp mill s chemical recovery plant that was commissioned in the summer of 2008 continued in Improvements made in the boiler operation parameters have clearly assisted the mill in compliance with the permit limits. In May, problems with blockages in the odorous gas boiler s sampling line caused measuring uncertainties when measuring the TRS of the odorous gas boiler. TRS emissions at the Kouvola City Environmental Services measuring station in the centre of Kouvola remained very low. The average hourly content only exceeded five micrograms per cubic metre during 0.03% of the total hours in EMISSIONS INTO THE AIR SO, and odorous sulphur emissions as sulphur dioxide * Includes the amount of Kymin Voima Oy s emissions corresponding to the energy consumed by the mills. 5

6 Waste Slightly more waste was taken to landfill than in The most major waste fraction was green liquor dregs generated during the recovery process. No viable solution for recycling of green liquor dregs has been achieved. However, one of the key objectives is to find recycling options for the waste fraction. As before, ash created during the generation of bioenergy was delivered for granulation, after which it was applied to forests owned by UPM. The idea is to recycle nutrients brought to the mill in the wood back into the forest. Another recycling target in 2011 was road construction. Ash was also stored at the Kymi mill area in The stored ash will be utilised in the foundation structures of a pedestrian and bicycle route in the summer of ** ** Includes the amount of Kymin Voima Oy s ash corresponding to the energy consumed by the mills. A bark conveyor. Bark from wood processing is utilised in the generation of energy. 6

7 More than 80% of the fuels used at Kymi are renewable, i.e. fuels that do not generate any fossil CO2. The pulp mill s new chemical recovery plant has improved the integrated mill site s self-sufficiency and the amount of bioelectricity used. 7

8 Water Effluent load remained at almost the same level as previous years. BOD, COD and AOX loads were lower than in Nitrogen and phosphorus loads were higher than last year but still significantly below the annual permit limits. The monthly permit limit for phosphorus was exceeded in August because of disturbances in the processes during the summer and equipment malfunctions that caused the effluent volume to the treatment plant to fluctuate much more than normal. Corrective measures were implemented, and the phosphorus load by September was once again compliant with the permit conditions. The paper mill s solids loss was slightly higher than in The actual solids loss was 1.2%. The solids loss increased because uninterrupted operation of the paper machines was not achieved due to the lower order volume. The plan is to further decrease the amount of solids. Specific effluent consumption per tonne of paper remained at almost the same level as last year. Actual water consumption at the paper mill was 10.7 m 3 per tonne of paper. The pulp mill s water consumption also remained at almost the same level as last year. The actual water consumption level of the pulp mill was 48.2 m 3 per tonne of pulp. The mill s internal goals 9 m 3 per tonne of paper and 45 m 3 per tonne of pulp were not achieved. The results achieved remain below the upper effluent limit of the BAT (Best Available Techniques) reference. To summarise, the effluent load of the pulp and paper mill remained at or below the BAT reference limit all through the year. 8

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10 Environmental indicators 2011 The environmental indicators in this table are based on the total pulp and paper production volume of the UPM Kymi mill. The figures on production and the consumption of raw materials and energy are given as whole figures at group level in the environmental statement 2011 for UPM s pulp and paper mills. Production capacity Coated adn uncoated fine paper 830,000 t Pulp 570,000 t Raw materials Wood See UPM Corporate Environmental Purchase pulp Statement for information Chemicals Energy Biofuels biogenic 85% Fossil fuels fossil 15 % (Contains natural gas used for drying in the paper machine) Emissions into air Sulphur SO 2 70 t (SO 2 and odorous sulphur) Nitrogen oxides Carbon dioxide fos Particulates 1,062 t 71,710 t (Reduced amount bound to PCC) 13 t Water intake Cooling water 68,000,000 m³ Discharges to water Effluent 35,875,888 m³ COD Cr 8,278 t BOD t AOX 93 t Phosphorus 8.9 t Nitrogen 86 t Waste to landfill Ash 1,328 t (Dry weight) Soda residue 9,750 t Process waste 371 t Domestic waste 49 t Waste recycled Ash 2,266 t (Dry weight) Metal 677 t Waste paper and board 1,224 t Combustible waste 132 t Intermediate storage of waste Ash 1,224 t for utilization (dry weight) Hazardous waste 96.5 t Mill area 250 ha 10

11 Kymi environmental impact reduction objectives 1. Energy conservation and effective use of biofuels The target is to reduce the characteristic energy consumption of production by 18% from the level of 2009 by the year Ideas originating in the energy-saving campaign (of 2009 and 2010) will be utilised wherever possible. The effective use of biofuels will be implemented through Kymin Voima s targets. 2. Use of wood raw materials based on sustainable forestry The objectives will be implemented through the goals of the UPM Forest. 3. Reducing the use of environmentally hazardous chemicals When choosing chemicals, biodegradability, environmental impact and impacts relating to occupational health and safety are taken into account. The goal is to replace detrimental chemicals with less hazardous ones and reduce the overall use of chemicals. The target is to reduce the use of environmentally hazardous chemicals through the approval and procurement procedure associated with the new chemical database. 4. Reducing environmental impact of transportation The product transport objectives will be implemented through the goals of UPM Logistics. The local objective is to transport 75% of products by rail by the year Reducing air emissions Odour problems will be reduced in the surroundings of the mill. The goal is to reduce concentrations measured at the odour measurement points so that there will be no hourly average values of odorous sulphur compounds over five micrograms per cubic metre in The pulp mill s NOx emissions will be reduced in such a manner that in 2013, the emissions will be 1.7 kg per tonne of pulp produced. In compliance with Clean Run, all air emissions will be reported and their causes studied. The objective is to further reduce air emissions. 6. Reducing the load on water systems The target is to keep emissions of oxygen-consuming organic materials (COD Cr ), nitrogen, phosphorus, and organic halogens (AOX) into water within the limits specified in the BAT reference document drawn up on the basis of the EU IPPC directive. Furthermore, all abnormal effluent emissions will be reported and their causes studied in compliance with Clean Run. The objective is to significantly reduce the effluent load. Water consumption will be reduced in pulp production to 40 m 3 per tonne of pulp and in paper production to 9 m 3 per tonne of paper by Reducing the amount of waste for final disposal at a landfill The objective is to completely eliminate the need to transport waste to a landfill for final disposal by Verified environmental management REG.NO. FI VERIFICATION DECISION As the accredited verifier, Inspecta Sertifiointi Oy (FI-V-0001) has audited the UPM Kymi environmental management system, the environmental performance in 2011 report and the environmental statement for 2011 for UPM paper and pulp mills. On the basis of this audit, it was stated on 27 April 2012 that the environmental management system of UPM Kymi, this environmental performance in 2011 report and the information regarding UPM Kymi in the environmental statement 2011 of UPM s pulp and paper mills comply with the requirements of the EU s EMAS regulation (EC) no. 1221/

12 Kymi FI Kuusankoski Tel Further information Päivi Hyvärinen Environmental Manager Tel (0) Teija Ahola Environmental Technician Tel (0) Irma Niemi Communications Manager Tel (0)