Solid waste / waste water of the German paper industry their disposal and reuse Chair of Paper Technology and Mechanical Process Engineering PMV Technische Universität Darmstadt Prof. Dr.-Ing. Samuel Schabel ABTCP-ZELLCHEMING 2007 São Paulo Brazil, October 15-18, 2007
Total amount: 4 million tons (estimated) RP rejects 15 % PF rejects 1% Incineration residues 15% Other residues 1% WTP sludges 31% Bark 11% Deinking sludges 30% RP: recovered paper processing PF: primary fibre processing WTP: waste water- / process water treatment plant Solid waste of the German paper industry in 2006 Fig. 2
Total amount: 3.6 million tons External energy recovery 13 % In-mill energy recovery 36% Composting 7% Landfilling 7 % Other utilization 2 % Other use for construction materials 7 % Cement industry 7% Brick industry 17% Other biological utilization 4% Fig. 3 Utilization and disposal of solid waste of the German paper industry in 2004
60 50 40 Proportion in % by weight 51 43 1987 (Old Federal States) 1990 1992 1994 1997 2001 50 49 2004 36 38 35 30 20 10 0 31 27 26 24 21 22 23 2021 19 18 16 15 13 13 10 10 10 11 8 6 7 7 5 5 1 2 2 Landfilling Biological utilization Construction material Energy recovery Other utilization Fig. 4 Utilization and disposal of solid waste of the German paper industry from 1987 to 2004
Total amount: 250,000 tons RP rejects 34 % Incineration residues 36 % WTP sludges 2 % Deinking sludges 28 % RP: recovered paper processing WTP: waste water-/ process water treatment Fig. 5 Landfilling of solid waste of the German paper industry in 2004
Discharge - Storage Rejects Plastics Ragger rope Fe-Separation Crushing Waste water treatment Mechanical Dewatering Fe-Separation Crushing 1. Stage Crushing Fe-Separation Scrap Rejects Scrap Scrap-Conditioning Crushing 2. Stage Shipment waste derived fuel Scrap-Utilization Fig. 6 Processing rejects and ragger ropes to waste derived fuel
Fig. 7 Costs of solid waste disposal in Germany in 2006/2007 in /ton (black: rejects; blue: sludge)
Fig. 8 Small-scaled reject incineration plant with grate firing
Spec. Waste Water Volume in m³/t 50 45 46 40 35 30 36 34 25 24 20 20 15 16 14 12 11 10 10 5 0 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2001 2002 2003 2004 Fig. 9 Average Specific Waste Water Volume of the German paper industry
Fresh water consumption high Introduction of save-all equipment (sedimentation, filtration, flotation) and the separation of white water and solids (fibres, fillers) Installation of sufficient process water storage Separation of streams of different water quality Counter-flow of clean water from paper machine Installation of in-line-kidneys All-over improved process design low Use of more efficient machinery Fig. 10 Measures for reduction of fresh water consumption
Spec. Waste Water Flow in m³/ton 40 25 20 20 15 14 11 10 10 5 5 0 Speciality Grades Woodfree Wood- Containing Coated Woodfree Recycled Fibre Based with Deinking Recycled Fibre Based without Deinking Spec. Waste water volume of different paper grades of the German paper industry in 2004 Fig. 11
Directly discharged with biological treatment 75 % Directly discharged without biological treatment 6 % Closed circuit effluent-free 4 % Indirectly discharged 15 % Types of effluent discharge in the German paper industry in 2004 Figures based on Production Volume Fig. 12
COD load in kg/ton paper 1.5 1 1.0 1.1 0.9 BREF- BAT range 0.6 0.7 0.6 0.5 0 1 2 3 4 5 6 Mill number Fig. 13 Comparison of BREF-BAT level with annual average emission of German RCF mills producing corrugating medium and testliner (2006)
Specific waste water volume in m³/ton paper 8 6 5.1 5.7 4.4 4 2.6 3.7 3.3 BREF- BAT range 2 0 1 2 3 4 5 6 Mill number Fig. 14 Comparison of BREF-BAT level with annual average specific waste water volume of German RCF mills producing corrugating medium and testliner (2006)
Parameter Unit BREF-BAT German Mills (n=9) Min. Max. Average COD kg/t of paper 0.5 1.5 0.52 1.1 0.83 BOD 5 kg/t of paper < 0.05 0.15 0.01 0.10 0.07 TSS kg/t of paper 0.05 0.15 0.001 0.10 0.06 AOX kg/t of paper < 0.005 0.0003 0.001 0.0007 Total P kg/t of paper 0.002 0.005 0.002 0.008 0.004 Total N kg/t of paper 0.02 0.05 0.003 0.064 0.02 Waste water amount m³/t paper < 7 2.6 10.5 5.0 Fig. 15 Comparison of BREF-BAT levels of biological treated effluents for RCF packaging paper mills with annual average emission and consumption levels of German paper mills (2006)
Exhaust Air Biogas Utilization Fresh Water Aeration 1 Recovered Paper Paper Production UASB- Reactors Paper Aeration 2 Bio Water to Production Sand Filter Secondary Clarifying Fig. 16 Effluent-free Process Water System of Smurfit Kappa Zülpich Mill, Germany
German paper industry has reached a good level on environmental protection Future challenge in solid waste management: treatment and incineration of plastic-containing rejects from recovered paper processing Need for incineration technologies for smaller units German paper industry has reached a very low level in fresh water consumption Experiences with totally closed water circuits are not yet satisfactory. Further optimisation is required Conclusions Fig. 17
Projected onto the entire German paper production (24 million tons) a total of 4.0 million tons of waste (rejects, sludges) can be assumed in 2006. This volume refers to the wastes in their original state Most wastes from paper manufacturing contain a high proportion of organic substances. A disposal by dumping was not longer possible since 2005 Increased utilisation of waste for energetic and building material purposes Energetic utilisation in power plants is of special importance for highcaloric rejects from recovered paper processing Biological utilisation (composting, land spreading) will drop significantly due to declining acceptance and changed legislation (biowaste Ordinance) Waste management in the German paper industry (I) Fig. 18