Green Chemistry and Sustainability in Pulp and Paper Industry

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1 Green Chemistry and Sustainability in Pulp and Paper Industry

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3 Pratima Bajpai Green Chemistry and Sustainability in Pulp and Paper Industry

4 Pratima Bajpai C-103 Thapar Centre for Industrial R&D Consultant (Pulp and Paper) Patiala, India ISBN DOI / ISBN (ebook) Library of Congress Control Number: Springer Cham Heidelberg New York Dordrecht London Springer International Publishing Switzerland 2015 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper Springer International Publishing AG Switzerland is part of Springer Science+Business Media ( www. springer.com )

5 Preface Rising raw material prices, increasing waste disposal costs and expanding legislation are the major drivers behind the rise of sustainable technologies. Producers around the world are forced to evaluate their production processes and to search for alternative technologies with lower environmental impact. A comprehensive technology mapping can help producers to compare sustainable technologies and to select viable alternatives. With increasing regulatory pressure and growing market demand for better products, the pulp and paper industry faces many challenges and must find new ways to improve environmental and process performance and reduce operating costs. There has been a growing demand in the pulp and paper industry to adopt waste minimization strategies in order to create a minimum impact mill. A minimum impact mill does not strictly mean a zero-discharge mill, but rather one which either has no discharge or whose effluent discharge has a minimum or no impact on the environment. The goal of minimum impact mills is to minimize natural resource consumption (wood, water, energy) and minimize the quantity and maximize the quality of releases to air, water and land taking into account economic aspects and working environments. The minimum impact mill makes optimal use of its raw materials; reduces air emissions, water usage, and waste generation; and is a net producer of electricity. The vision of minimum impact manufacturing has captured the imaginations of industry leaders and the environmental community alike. This book gives updated information on minimum impact mill technologies which can meet the environmental challenges of the pulp and paper industry and describes some of the newest twenty first-century fibre lines. Patiala, India Pratima Bajpai v

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7 Contents 1 General Background... 1 References Basic Overview of Pulp and Paper Manufacturing Process Raw Material Preparation Pulping Chemical Pulping Mechanical Pulping Semi-chemical Pulping Secondary Fibre Pulping Dissolving Kraft and Sulphite Pulping Processes Non-wood Pulping Pulp Washing Pulp Screening, Cleaning and Fractionation Bleaching Chemical Recovery Black Liquor Concentration Recovery Furnace Causticizing and Calcining Stock Preparation and Papermaking References Environmental Consequences of Pulp and Paper Manufacture Water Pollution Atmospheric Pollution Sludge and Solid Waste References Minimum Impact Mill Technologies Emission Reduced Wood Handling Dry Debarking High Yield Pulping vii

8 viii Contents 4.4 Extended or Modified Cooking Batch Cooking Continuous Cooking Modifying Kraft Pulping with Additives Efficient Brownstock Washing/Improved Pulp Washing Oxygen Delignification Ozone Bleaching of Chemical Pulps Ozone for High Yield Pulping Elemental Chlorine-Free Bleaching (ECF) Bleaching Modified ECF Sequences Totally Chlorine-Free (TCF) Bleaching Fortification of Extraction Stages with Oxygen and Hydrogen Peroxide Removal of Hexenuronic Acids Hot Acid Stage (Ahot) or Combined Hot Acid and Chlorine Dioxide Stage (AD)hot High Temperature Chlorine Dioxide Stage (DHT) Liquor Loss Management Condensate Stripping and Recovery Reduction of Sulphur Oxides and Nitrogen Oxides Emissions Electrostatic Precipitators Installation of Scrubbers on Recovery Boiler Increase in the Dry Solids Content of Black Liquor Incineration of Odorous Gases in the Lime Kiln Installation of Low NOx Technology in Auxiliary Boilers and the Lime Kiln Selective Non-Catalytic Reduction on Bark Boilers Over Fire Air Technique on Recovery Boilers Installation of Improved Washing and Filtration of Lime Mud in Recausticizing Technologies That can Help Achieve Practical Minimum Energy Consumption Impulse Technology for Dewatering of Paper Energy Efficient Thermo-Mechanical Pulping (TMP) Processes New Energy Efficient Bleached Chemi-Thermo Mechanical Pulping Processes Use of Enzymes During the Refining of TMP Condebelt Process High Consistency Forming Black Liquor and Hog Fuel Gasification Partial Borate Autocaustising Biorefinery Partial System Closure Control of NPE with Partial Closure

9 Contents ix 4.26 Water Recycling/Reuse Primary, Secondary and Tertiary Waste Treatment Primary Treatment Secondary Waste Water Treatment Tertiary Treatment References State-of-the-Art Pulp Mills Celulosa Arauco y Constitución S.A. Nueva Aldea, Chile Veracel Celulose Hainan Jinhai Pulp mill Cellulosa Arauco Valdivia APRIL/SSYMB Rizhao Greenfield Mill Aracruz, Line C, Brazil Mercal Stendal, Germany Bowater, Catawba SC, USA Zhanjiang Chenming Greenfield Pulp Mill, China Eldorado Celulose e Papel S.A. s New Greenfield Pulp Mill in Três Lagoas, Brazil Montes del Plata Mill in Uruguay Oji Holdings Nantong Pulp Mill Jiangsu Province, China Aracruz s Pulp Line, at Their Guaiba Mill in Rio Grande do Sul, Brazil Ilim Group s New Kraft Pulp Mill, in Bratsk, Irkutsk Oblast, Russia Metsa-Botnia, Rauma Mill Metsa-Botnia Joutseno Mill Stora Enso s Nymölla Mill UPM Fray Bentos Pulp Mill New Projects References The Future References Index

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11 Abbreviations AOX APMP BCTMP BFR BLS BOD CBC CLB COD CTMP DD DIP DS DSC DTPA EDTA EGSB EPA ESP GHG HAPs HYP IC MBBR MCC MIM NSSC PCDDS PCDFS P-RC Adsorbable organic halides Alkaline peroxide mechanical pulp Bleached chemi-thermo-mechanical pulp Bleach filtrate recovery Black liquor solids Biochemical oxygen demand Continuous batch cooking Closed loop bleaching Chemical oxygen demand Chem-thermo-mechanical pulp/pulping Drum displacer Deinked pulp Dry solids Dry solids content Diethylene triamine pentaacetic acid Ethylenediaminetetraacetic acid Expanded granular sludge blanket Environment protection agency Electrostatic precipitator Greenhouse gas Hazardous air pollutants High-yield pulp Internal circulation reactor Moving bed biofilm reactor Modified continuous cooking The minimum-impact mill; minimum-impact manufacturing Neutral sulfite semi-chemical Polychlorinated dibenzodioxins Polychlorinated dibenzofurans APMP preconditioning refiner chemical-treatment alkaline peroxide mechanical pulp xi

12 xii Abbreviations RDH SS TCDD TCDF TEF TMP TRI TRS TSS UASB VOC Rapid displacement heating Suspended solids Tetrachlorodibenzodioxin Tetrachlorodibenzofuran Totally effluent-free Thermomechanical pulp/pulping Toxics release inventory Total reduced sulphur Total suspended solids Upflow anaerobic sludge blanket Volatile organic compounds

13 List of Figures Fig. 2.1 Overview of kraft pulping mill with papermaking system Fig. 2.2 A flow diagram for a typical papermaking process Fig. 2.3 Details of papermaking process Fig. 2.4 Schematic of Fourdrinier paper machine Fig. 3.1 Polychlorinated dibenzodioxins (PCDD) and polychlorinated dibenzofurans (PCDF) Fig. 4.1 AQ catalytic cycle Fig. 4.2 Benefits of using anthraquinone and surfactants Fig. 4.3 Incorporation of the oxygen delignification stage Fig. 4.4 in brownstock washing and cooking liquor recovery cycle Flowsheet of typical medium-consistency oxygen delignification Fig. 4.5 Equipment of medium-consistency oxygen delignification Fig. 4.6 Flowsheet of typical high-consistency oxygen delignification Fig. 4.7 High-consistency oxygen delignification reactor Fig. 4.8 Two-stage oxygen delignification Fig. 4.9 Typical OxyTrac system set up Fig Typical configuration of medium-consistency ozone stage Fig HC Ozone bleaching in 1990s and today Fig Oxygen-reinforced alkaline extraction (EOP) stage Fig Schematic of Condebelt drying process Fig Integrated gasification and combined cycle (IGCC) Fig The CHEMREC DP-1 plant Fig. 5.1 Nueva Aldea, Pulp Mill, Chile Fig. 5.2 Veracel fibre line Fig. 5.3 Hainan Jinhai pulp mill Fig. 5.4 Celulosa Arauco y Constitucion s new facility in Valdivia Province, Chile Fig. 5.5 Arauco Valdivia fibre line xiii

14 xiv List of Figures Fig. 5.6 Super batch digesters at Cellulosa Arauco Valdivia Fig. 5.7 Twin roll presses at Cellulosa Arauco Valdivia Fig. 5.8 The twin-wire pulp machine at Aracruz Celulose S.A. s new C line at its Barra do Riacho mill Fig. 5.9 Recausticizing plant at Aracruz Celulose S.A. s new C line at its Barra do Riacho mill Fig Evaporation plant at Stendal Fig Fibre line at Catawba Fig Continuous digester, Catawba s new fibre line, uses low solids cooking for lowest kappa number and highest fibre quality Fig Fray Bentos Pulp mill fibre line

15 List of Tables Table 1.1 Goals in pursuit of an environmentally and socially sustainable paper production and consumption system... 5 Table 2.1 Steps involved in the manufacturing of pulp and paper Table 2.2 Types of pulping Table 2.3 Unit processes in stock preparation Table 2.4 Common pulp stock additives Table 3.1 Important parameters followed in order to demonstrate improvements towards a minimum impact mill Table 3.2 Chlorinated organic compounds in bleach plant effluents Table 3.3 Regulated chlorophenols Table 3.4 Solid waste generated in pulp and paper mills Table 3.5 Generation of waste in a kraft mill Table 4.1 Measures to reduce environmental impacts from wood handling Table 4.2 Important feature of HYP Table 4.3 Modified cooking principles Table 4.4 Modified continuous cooking systems Table 4.5 World market share of modified cooking processes Table 4.6 Typical operating data ranges for oxygen Table 4.7 delignification process Effect of different delignification technologies on kappa number and effluent COD Table 4.8 Mills using ozone bleaching Table 4.9 Mills using ZeTrac technology Table 4.10 World bleached chemical pulp production: Table 4.11 Modern ECF bleaching sequences Table 4.12 Chemical consumption in bleaching of softwood kraft pulp in D(EOP)D(ED) sequence mill results xv

16 xvi List of Tables Table 4.13 Brightness development in different chlorine dioxide bleaching sequences Table 4.14 Brightness development in a sequence replacing the first D-stage with a Z-stage Table 4.15 Effect of peroxide use in a chlorine dioxide bleaching sequence Table 4.16 Modern bleaching sequences of eucalyptus-based kraft pulp mills Table 4.17 (DZ) and (ZD) treatments of an unbleached softwood kraft pulp Table 4.18 Environmental aspects of ECF and TCF effluent quality Table 4.19 Environmental aspects of ECF pulp properties Table 4.20 Bleaching sequences for TCF bleaching Table 4.21 Chemical consumption in bleaching of softwood kraft pulp in Q(OP)(ZQ)(PO) sequence Table 4.22 A comparison of some oxygen chemical bleaching sequences applied to a softwood kraft pulp when the ozone charge is 5 kg/adt Table 4.23 Effect of kappa number after ozone delignification when bleaching softwood kraft pulp in a Q(ZQ)(PO) sequence Table 4.24 BKP mills using TCF bleaching Table 4.25 Mills using both ECF and TCF bleaching Table 4.26 Advantages with oxygen-reinforced alkaline extraction Table 4.27 Conditions in an EOP stage Table 4.28 Undesirable effects of HexA in bleaching Table 4.29 Typical conditions for (A) hot and (AD) hot stages Table 4.30 Benefits of using hot acid stage in bleached eucalyptus kraft mills Table 4.31 Typical pollutant loads in foul condensates in bleached kraft mill (softwood) Table 4.32 Heat value of pollutants Table 4.33 Table 4.34 Table 4.35 Table 4.36 Table 4.37 Prominent Pulp and Paper Industry sources of SOx and NOx (10 3 tons) Range of observed emissions of SOx and NOx from recovery furnace and lime kiln Typical noncondensable gas analysis by volume % of an NCG gas stream NOx emission from fluidised bed boilers of paper mills using primary and/or secondary measures for NOx reduction Kraft mills (paper grade) practising bleach plant filtrate recovery Table 4.38 Advantages of waste water recycling Table 4.39 Water conservation measures adopted in the pulp mill