ENVIRONMENTAL performance in 2012

Transcription

1 ENVIRONMENTAL performance in 212 UPM Kaukas

2 UPM leads the integration of bio and forest industries into a new, sustainable and innovation-driven future. Our products are made of renewable raw materials and are recyclable. UPM consists of three Business Groups: Energy and pulp, Paper, and Engineered materials. The Group employs around 22, people and it has production plants in 17 countries. UPM s annual sales exceed EUR 1 billion. UPM s shares are listed on the Helsinki stock exchange. UPM The Biofore Company UPM Kaukas mills The Kaukas mills are located on the shore of Lake Saimaa in the City of Lappeenranta in south-east Finland. There are several UPM production facilities and units in the mill area: a pulp mill, paper mill, sawmill, the Research Centre and Kaukaan Voima Oy. The pulp mill produces bleached softwood and birch pulp. The paper mill manufactures coated magazine paper on two production lines. The Kaukas sawmill manufactures sawn redwood, part of which is further processed on site into planed and impregnated products. Kaukaan Voima Oy (KauVo) has a biofuel power plant in the Kaukas mill area. The power plant generates heat and electricity for the Kaukas mills and the power company Lappeenrannan Energia Oy. 8% of the district heating energy required by the City of Lappeenranta is generated with green biofuels. All of UPM s research activities are managed from Lappeenranta. UPM is building a liquid biorefinery on the Kaukas mill site that will produce biodiesel manufactured from tall oil for use in vehicles. The refinery will be completed in 214. The integrated mill site enables the efficient use of wood raw materials, the energy supply and logistics. The mills share an environmental permit that includes wastewater treatment, waste management and a landfill. EMAS covers the Kaukas pulp mill and paper mill. UPM Corporate ENVIRONMENTAL statement 212 UPM pulp and paper mills UPM Kaukas Environmental Performance 212 is a supplement to the Corporate Environmental Statement of UPM s pulp and paper mills (available at and provides mill-specific environmental performance data and trends for the year 212. The annually updated mill supplements and the UPM Corporate Environmental Statement together form the joint EMAS Statement of UPM Corporation. The next Corporate Environmental Statement and also this supplement will be published in 214. Production capacity 61, tonnes coated magazine paper 74, tonnes softwood and birch pulp 5, m 3 of sawn redwood 3, m 3 of further-processed timber Personnel Paper mill 351, pulp mill 162, mill services 183, total 77 Products MWC magazine paper: UPM Star H UPM Star silk H UPM Star G UPM Star silk G LWC magazine paper: UPM Ultra H UPM Ultra G UPM Ultra silk G UPM Cote G Pulp UPM Betula UPM Conifer Further-processed timber UPM Timber UPM Plus UPM Kuohu UPM Silmu Certificates Quality Management System ISO 91 Environmental Management System ISO 141 EMAS Eco Management and Audit Scheme PEFC Programme for the Endorsement of Forest Certification Schemes and FCS Forest Stewardship Council Chain-of-Custody Standards The certificates can be found at > Responsibility > Principles and Performance > Certifi cate Finder. PEFC/ Promoting Sustainable Forest Management Ecolabel European Union Ecolabel FI/11/1 2 UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212

3 Environmental year 212 In 212, the production and environmental impacts of the UPM Kaukas mills were greatest environmental challenge at the pulp emissions did not see major changes. The similar to what they have been since 2. mill is the reliability of the treatment of malodorous gases. As the gas flows change, The mill emissions complied with the environmental permit conditions with one exception. In December, the level of total reduced the emergency burner does not always start the malodorous gas burner shuts down and sulphur (TRS) compounds in the air emissions immediately. The emergency burner was of the lime kiln exceeded the permit limit for used more in 212 than in previous years, a period of 48 hours. which resulted in elevated sulphur dioxide The environmental objectives of the integrated mill site included carrying out the The environmental objectives of the pulp emissions, among other things. Clean Run programme, improving the environmental awareness of all employees and consumption of process water and the vol- mill were to reduce odour emissions, the reducing abnormal emissions. ume of excess steam. In terms of waste management, the goal was to increase the reuse The Clean Run programme was part of the mill site s normal operations in 212. of green liquor dregs. The odour emissions Environmental non-conformances were monitored and the reasons behind them exam- sulphur (TRS) compounds, showed a signifi- of the pulp mill, measured in total reduced ined more frequently than before. A larger cant increase and amounted to 19.6 tonnes number of internal non-conformances were (11.3 tonnes in 211). The consumption of recorded than previously. Environmental process water increased. The management education was provided to the employees of the steam network improved and the volume of excess steam removed from the sys- of the pulp mill, the supervisors of the paper mill and all summer trainees and other trainees. green liquor dregs generated in the process tem decreased. In total, 46.3% of the The amount of environmental feedback were reused. This is 8.6 percentage points from neighbouring areas decreased compared to previous years and feedback was more than in the previous year. only received about odour. A total of four Paper mill odour complaints were recorded. The paper mill has set internal targets for The bottom of the biological treatment plant basins were dredged in order plant, waste components generated dur- solid emissions to the effluent treatment to remove sediment formed by solid emissions. The dredged solid matter was used cess water. The mill goals for 212 also ing the process and the consumption of pro- to create a noise barrier next to the aeration basin. The noise barrier protects housment and determining potential energy-sav- included performing a chemical risk assessing from the noise caused by the treatment ing opportunities. plant. The solid emissions to the treatment plant Waste reuse increased significantly over were on average 17.5 tonnes per day. the year. New areas of reuse included the landscaping of forest sites and the acidity regulation of field sites. Co-operation contracts were made with various operators. The reuse percentage of UPM waste generated at the integrated mill site was 86%. This includes UPM s share of the Kaukaan Voima ashes. Pulp mill The pulp mill set a new production record in 212. The mill ran smoothly for almost of the year: the whole plant was only stopped for a week in September due to maintenance. The growth in production increased Juha Kääriäinen, General Manager, Kymi-Kaukas integrates total emissions to air and water. Specific The target is 12.6 tonnes. Compared to the previous year, the emissions increased by 1% (15.9 tonnes per day in 211). The increase in solid emissions was caused by problems in the runnability of the paper machines and discontinuous runs: there were several short downtimes. Solid emissions decreased towards the end of the year. The target level was achieved for two months of the year. A target value of 13.6 cubic metres per paper tonne was set for the consumption of water, excluding the water used by the debarking plant. This target was not achieved. However, consumption did decrease compared to the previous year. The water consumption of the debarking plant remained at the same level as for the previous year. The target levels set for waste generated during the process per day were 6. tonnes for coating colour sludge and 2.2 tonnes for fibre sludge. The amount of generated fibre sludge remained the same as the previous year and the amount of generated coating colour sludge was reduced by 17%. Only a small amount of the coating colour sludge was taken to landfill for final disposal. The sludge was used as raw material for the construction of a noise barrier at the effluent treatment plant and was also delivered to an external operator to be used as a sealing material at a landfill. The fibre sludge was placed in intermediate storage and will be reused in coming years. UPM is currently preparing its own safety standard and code of conduct for the surveying of chemical risks. The implementation of the measures required in these documents will begin in 213. As such, a separate chemical risk assessment was not performed in 212. Energy-saving measures, on the other hand, were implemented in various areas: the vacuum system of paper machine 1 was optimised and the circulating pumps of the mechanical pulp storage towers were switched off, and the post-refining of mechanical pulp and the IR dryers of the coater were switched off. Minna Maunus-Tiihonen, Environmental Manager UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212 3

4 Air Water In 212, the sulphur dioxide (SO 2 ) and particle emissions to air increased. The levels of carbon dioxide and nitrogen oxides from fossil fuels decreased. Malodorous gases were burnt more than 99.7% of the time. The pulp mill ran smoothly, reaching a new production record, and only had a small number of downtime days. The major increase in SO 2 emissions was due to the emergency burner for malodorous gases: it accounted for 84% of the pulp mill s SO 2 emissions and the emissions grew by 279% compared to the previous year. At other emission points, the SO 2 emissions decreased. The emergency burner was in use for 54 days in 212 whereas it had only been used for approximately 6 days in the previous year. The emergency burner was kept on more often to secure the burning of malodorous gases during disturbances in the main burner. Particle emissions increased at all measurement points because the running speed was higher than that of the previous year. Carbon dioxide emissions were reduced as less natural gas was used as a secondary fuel compared to the previous year. One of the air emissions did not comply with the environmental permit conditions: the TRS emissions of the lime kiln exceeded the permit limit for a period of 48 hours. The limit was exceeded due to problems in the lime sludge filtering process, which resulted in a situation where the lime sludge was too wet when it entered the kiln. This led to imperfect combustion, which manifested itself as elevated TRS levels. The total annual air emissions of the UPM Kaukas pulp mill and power production unit are presented in the following graphs. The proportion of the KauVo total emissions estimated for UPM is included in the figures. In 212, the Kaukas mill site used a total of 83 million cubic metres of water. Approximately 48% of this water was used as process water and treated at the biological effluent treatment plant. The water consumption at the mill site increased compared to the previous year. The increase was partly due to increased production and partly to the fact that more water was used for cooling the effluent treatment plant this summer than during previous summers. The effluent load to the lake remained below all the environmental permit limits throughout the year. The effluent loads of both pulp and paper production remained within the BAT limits. Compared to the previous year, emissions into the lake increased for biological oxygen demand (BOD), chemical oxygen demand (COD), solid emissions and the nitrogen load. The phosphorus load decreased and the AOX level remained FOSSIL CARBON DIOXIDE, CO 2 1, t/a SULPHUR DIOXIDE, SO 2 t/a 1,5 1, BIOLOGICAL OXYGEN DEMAND, BOD 7 t/d NITROGEN OXIDES, NO X t/a PARTICULATES t/a NITROGEN, N kg/d 2,5 2, 1,5 1, Permit Monthly limit 4 UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212

5 75 CHEMICAL OXYGEN DEMAND, COD t/d roughly the same. The performance of the biological treatment plant was good. The increase in emissions was due to an increase in production. The treatment plant s ability to treat water is given as a reduction value that illustrates how big a portion of the load that arrived at the treatment plant was removed. The BOD reduction value was 99% and the COD reduction value 81%. In total, 87% of the phosphorus and 64% of the nitrogen that arrived at the treatment plant was removed. In these areas, the treatment efficiency was better than in 211. The solids reduction value fell slightly short of the previous year s value. The reason for this was the dredging of the containment and equalising basin that took place in the spring of 212. The aim of the dredging was to remove sediment that had accumulated at the bottom of the basins over the years. The operation resulted in an internal load at the treatment plant and some problems with the settling of sludge. Once the situation had stabilised, the solids load to the actual treatment process decreased. The dredging will provide the biological treatment plant with years of stable operation. Reducing water consumption has been a long term environmental objective at Kaukas for years. In 212, a master s thesis on the reduction of water consumption was commissioned and further investigations on how the target levels could be achieved were also carried out. The consumption of water did not decreasing significantly in 212. At the pulp mill, the amount of water consumed per tonne of pulp produced actually increased. One of the reasons for this development is temperature control at the treatment plant. The operation of the biological treatment plant is disturbed if the temperature becomes too high so there was more substantial cooling in 212 than in previous years in order to avoid process problems. The cooling water of the treatment plant has been counted as pulp mill process water. 6. TOTAL SUSPENDED SOLIDS, TSS t/d Waste The amount of waste taken to the Tuosa landfill decreased in 212. A total of tonnes of waste was taken to landfill for final disposal (as dry matter). Compared to the previous year, the amount was reduced by 42.7%. The amount of process waste generated at the mills remained approximately the same as in previous years (3,783 tonnes), but the amount of waste taken to landfill was reduced by increasing reuse. A mixture of green liquor dregs and fly ash was used at the Tuosa landfill where the creation of a field structure continued. Coating colour sludge and bottom ash were used to stabilise the structure of the treatment plant noise barrier formed using dredging masses. Primary sludge was used in the landscaping of an external forest site and hydrated lime was used to regulate the acidity of a field site. The lime and primary sludge were registered with Evira. A co-operation contract for the year 213 was made with an external operator to improve the reuse of process waste WASTE TO tuosa LANDFILL BD t/a , , , 8, 4, PHOSPHORUS, P kg/d.6.48 ADSORBABLE ORGANIC HALOGEN COMPOUNDS, AOX t/d Ash Others Green liquor dregs Coating color sludge The weights included in the figure are dry weights UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212 5

6 Environmental parameters 212 The environmental indicators in this table are based on the total pulp and paper production volume of the UPM Kaukas mills. The figures on production and the consumption of raw materials and energy are given as whole figures at group level in the environmental statement 212 for UPM s pulp and paper mills. Production capacity Raw materials Energy Air emissions, including UPM s share of Kaukaan Voima emissions Magazine paper Pulp - Softwood pulp - Birch pulp Wood, cooking chemicals, bleaching chemicals, filler and coating pigments, pigments in paper manufacturing Biofuels Fossil fuels Purchased electricity Fossil carbon dioxide, CO 2 Nitrogen oxides, NO x Sulphur dioxide, SO 2 Dust particles Total reduced sulphur, TRS 61, t 74, t 42, t 32, t See UPM Corporate Environmental Statement for more information 86% 14% See UPM Corporate Environmental Statement for more information 14,212 t 1341 t 667 t 115 t 2 t Water consumption Process and cooling water 83.1 million cubic metres Emissions to water Waste* Effluent BOD 7 COD Solids Phosphorus, P Nitrogen, N AOX Waste to landfill - Green liquor dregs - Coating colour sludge - Mixed waste 39.4 million cubic metres 321 t 11,923 t 854 t 5.1 t 162 t 97 t 5496 t 4418 t 684 t 394 t Hazardous waste Mill area Reused waste - Cleaned wood waste - Green liquor dregs and lime - Coating colour sludge - Fibre sludge - Sludge from effluent treatment plant - Lime kiln ash - Slightly contaminated soil - Fly ash and bottom ash 33,141 t 583 t 5213 t 3159 t 138 t 5116 t 1833 t 3125 t 7854 t 15 t 2 ha The figures include the calculated share of Kaukas biofuel power plant emissions. * Dry weight 6 UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212

7 Achievement of objectives for 212 OBJECTIVE ACHIEVED COMMENTS Objectives of integrated mill site Carrying out the Clean Run programme as planned Reducing abnormal emissions Improving environmental awareness of all employees Objectives of paper mill Reducing consumption of water to 15 cubic metres per tonne of paper Amount of solids to the treatment plant 12.6 tonnes per day, max. Chemical risk assessment for treatment plant performed Investigation into potential energy-saving opportunities Objectives of pulp mill Increasing the reuse of generated green liquor dregs; target: 42% Reducing odour emissions Reducing consumption of water; target for process water consumption: 4 cubic metres per tonne Reducing volume of excess steam Become part of normal operations at Kaukas. Operations have not caused abnormal emissions outside the mill area; internal non-conformances will be recorded and monitored more carefully than before. Training sessions arranged for employees. Was not achieved as intermittent runs and usability problems made optimising the consumption of water challenging. Runnability problems and intermittent runs have resulted in larger amounts of solids at the treatment plant. The situation improved during the last months of the year. The annual average was 17.5 tonnes per day. The UPM standard for the risk assessment of chemicals will come into effect in 213 so the mill has been waiting for this standard to be finalised. Energy-efficiency has been improved in several areas. Achieved level: 46%, used as raw material in field structure. Odour emissions have increased. Water consumption has increased. The operation of the effluent treatment plant has, for instance, been secured by cooling water. The volume of excess steam removed from the system has decreased. Objectives for 213 OBJECTIVES AND INDICATORS SCHEDULE RESPONSIBILITIES Reducing abnormal emissions 213 Paper mill: solids to treatment plant 12.6 tonnes per day, max. Pulp mill: smooth running of treatment plant controlling air emissions Increasing the percentage of waste reuse target: reuse 9% of generated process waste 213 Co-operation with external operators Reducing the consumption of process water by 5% 213 Paper mill target 15 cubic metres per tonne, pulp mill target 4 cubic metres per tonne VERIFICATION DECISION: As the accredited verifier, Inspecta Sertifiointi Oy (FI-V-1) has audited the UPM Kaukas environmental management system, the Environmental Performance in 212 report and the environmental statement for 212 for UPM paper and pulp mills. Based on the inspection, it was noted on that the UPM Kaukas environmental management system, this Environmental Performance in 212 report and the information on UPM Kaukas in the environmental statement for 212 for UPM paper and pulp mills comply with the requirements set forth in EU EMAS Regulation (EC) no. 1221/29. UPM KAUKAS, ENVIRONMENTAL PERFORMANCE 212 7

8 UPM-Kymmene Corporation Kaukas Kaukaantie 16 FI-532 Lappeenranta, Finland Tel Fax For further information, please contact: Minna Maunus-Tiihonen Environmental Manager Tel Antti Ratia Communications Manager Tel /213