Application of Life Cycle Assessment in the Zimbabwean Pulp and Paper industry L. MASHOKO and C. MBOHWA

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1 Application of Life Cycle Assessment in the Zimbabwean Pulp and Paper industry L. MASHOKO and C. MBOHWA Acknowledgements Pre Consultants and UNEP/SETAC Life Cycle Initiative support with SIMAPRO software award

2 Justification Paper industry consumes a lot of resources LCA stimulates conservation, resources are finite, trees, recycled paper, energy Energy depletion, global energy crisis possibility Adverse climate changes due to industrial emissions

3 Objectives Identify processes where resources can be optimized Estimate system s overall resource use, energy consumption, chemical consumption and environmental impacts Development of new processes, or activities toward reduction of resource requirements and emissions Promoting green design and manufacturing in newspaper production

4 Methodology ISO Principles and framework, ISO Goal and scope definition and inventory analysis, ISO Life cycle impact assessment and ISO Life cycle interpretation Four steps- Goal and scope definition, Inventory analysis, Impact assessment, Interpretation Data from pulp and paper industry in Zimbabwecollected through questionnaires, site visits and from databases Used SimaPro software- provided by Pre consultants of Netherlands through UNEP

5 Methodology Impact categories assessed using the Ecoindicator 99 (H), Version 2.03 of the SimaPro software version 7.0. Non-renewable resource depletion (NRRD) determined using the Cumulative Energy Demand, Version 1.03 of the SimaPro software.

6 Process flow chart for production of newsprint paper INPUT: Raw materials: wood, water, and chemicals: Energy: coal, diesel, and electricity Raw material and energy acquisition Wood, energy, water, chemicals Manufacturing, processing: pulping, papermaking, and packaging Distribution, transportation Use, reuse, maintenance Recover, recycle OUTPUT Usable products Newsprint paper Bi- products: paper for butcheries, wood for domestic purposes Environmental impacts Airborne emissions: CO 2, SO 2, NO X, etc Water effluents: BOD, COD, metals Solid wastes: bark, sludge, paper, etc Other environmental releases

7 Impact categories/ Characterisation Renewable resource- hydropower, water, Non-renewable resources- coal Environmental impact categories-green house effect due to CO 2, CH 4, N 2 O, CCl 4 - stratospheric ozone deletion due to CFCs, HCFs, halons, CO, N 2 O, COS - acidification due to SO 2, No x, HCl

8 Data Collection Material Inputs into Pulp Production Chemicals for pulp production Unit Quantity (Wet Mass) Cl 2 Kg/t 0.12 NaHSO 4 Kg/t 14 Caustic soda Kg/t 2 Starch Kg/t 15 Defoamers Kg/t 2

9 Water input Process water Unit Quantity Data type Borehole water m 3 /t 7.28 C Reclaimed water m 3 /t C Municipal m 3 /t 6.44 C A=annual mean C=calculated value D=design value

10 Chemicals for waste water treatment Chemicals for waste water treatment Unit Quantity Data type A=annual mean C=calculated value D=design value Aluminium sulphate Calcium carbonate kg/t 6.25 A kg/t 6.25 A Chlorine kg/t 1.04 A

11 Process Inputs The functional unit in the tables is 1 tonne of 53gsm newsprint (39-100gsm) Unit Quantity Pinewood Tonnes 3 (6) (m 3 sub) Chemical pulp Kilograms 210 Electric Power Kwh 1797

12 Inputs and Outputs Per tonne of 53 gsm newsprint Material Unit Quantity Coal Tonnes CO 2 Tonnes 366 SO2 Kg 5.5 NOx Kg Particulates Kg 0.782

13 Process network production of newsprint 1 kg MBPM paper kg wood harvesting kg hwange colliery coal 0.16 kg Cellulose sulphate BCC tkm Truck 28t B MJ ZESA POWER 3.38E s Chain sawing 0.82 MJ Heat diesel B E kg Petrol B E-6 kg Oil light B E E-7

14 Impact assessment results % IPCC GWP 100a MBPM paper wood harvesting hwange colliery coal Cellulose sulphate BCC Truck 28t B250 ZESA POWER Analysing 1 kg material 'MBPM paper'; Method: IPCC 2001 GWP 100a V1.02 / characterisation

15 Characterisation and damage assessment % Carcinoge ns Resp. orga nics Resp. inor ganics Climate change Radiation Ozone layer Ecotoxicit y Acidificati on/ Eutro Land use Minerals Fossil fuels MBPM paper wood harvesting hwange colliery coal Cellulose sulphate BCC Truck 28t B250 ZESA POWER Analysing 1 kg material 'MBPM paper'; Method: Eco-indicator 99 (H) V2.03 / Europe EI 99 H/A / characterisation

16 Results for cumulative energy demand % Non renewable, fossil Non-renewable, nuclear Renewable, biomass Renewable, wind, solar, geothe Renewable, water MBPM paper wood harvesting hwange colliery coal Cellulose sulphate BCC Truck 28t B250 ZESA POWER Analysing 1 kg material 'MBPM paper'; Method: Cumulative Energy Demand V1.03 / Cumulative energy demand / characterisation

17 Results of impact assessment Greatest contributor to CO 2 emission- pulping and paper making processes- coal to produce steam Pulping- predominant role in global warming impact category due to carbon dioxide emissions Transportation main source of NOX impact categories-eutrophication and acidification categories. Contribution of disposal stage not explored due to lack of data and system boundaries Conclusions agreed with earlier Cleaner Production Assessment and rough cut Excel analysis. More accuracy needed

18 Recommendations Improve boiler efficiencies and reduce steam leaks Improve metering systems in factory- generates real data instead of estimations and approximations. Carry out a feasibility assessment for investment in a wood or bark fired boilers. 23 tonnes of bark and offcuts produced daily at one of the factories Transportation- Use railway system where applicablemore fuel-efficient compared to road. Modify models and software to accommodate specific data and location

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