Green Chemistry and Sustainability in Pulp and Paper Industry

Green Chemistry and Sustainability in Pulp and Paper Industry

Pratima Bajpai Green Chemistry and Sustainability in Pulp and Paper Industry

Pratima Bajpai C-103 Thapar Centre for Industrial R&D Consultant (Pulp and Paper) Patiala, India ISBN 978-3-319-18743-3 DOI 10.1007/978-3-319-18744-0 ISBN 978-3-319-18744-0 (ebook) Library of Congress Control Number: 2015942906 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 )

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

Contents 1 General Background... 1 References... 8 2 Basic Overview of Pulp and Paper Manufacturing Process... 11 2.1 Raw Material Preparation... 14 2.2 Pulping... 15 2.2.1 Chemical Pulping... 15 2.2.2 Mechanical Pulping... 17 2.2.3 Semi-chemical Pulping... 18 2.2.4 Secondary Fibre Pulping... 19 2.2.5 Dissolving Kraft and Sulphite Pulping Processes... 20 2.2.6 Non-wood Pulping... 20 2.3 Pulp Washing... 21 2.4 Pulp Screening, Cleaning and Fractionation... 23 2.5 Bleaching... 23 2.6 Chemical Recovery... 26 2.6.1 Black Liquor Concentration... 26 2.6.2 Recovery Furnace... 26 2.6.3 Causticizing and Calcining... 27 2.7 Stock Preparation and Papermaking... 27 References... 37 3 Environmental Consequences of Pulp and Paper Manufacture... 41 3.1 Water Pollution... 46 3.2 Atmospheric Pollution... 51 3.3 Sludge and Solid Waste... 56 References... 59 4 Minimum Impact Mill Technologies... 65 4.1 Emission Reduced Wood Handling... 66 4.2 Dry Debarking... 69 4.3 High Yield Pulping... 71 vii

viii Contents 4.4 Extended or Modified Cooking... 73 4.4.1 Batch Cooking... 74 4.4.2 Continuous Cooking... 76 4.4.3 Modifying Kraft Pulping with Additives... 80 4.5 Efficient Brownstock Washing/Improved Pulp Washing... 84 4.6 Oxygen Delignification... 87 4.7 Ozone Bleaching of Chemical Pulps... 96 4.8 Ozone for High Yield Pulping... 106 4.9 Elemental Chlorine-Free Bleaching (ECF) Bleaching... 108 4.9.1 Modified ECF Sequences... 116 4.10 Totally Chlorine-Free (TCF) Bleaching... 119 4.11 Fortification of Extraction Stages with Oxygen and Hydrogen Peroxide... 126 4.12 Removal of Hexenuronic Acids... 128 4.12.1 Hot Acid Stage (Ahot) or Combined Hot Acid and Chlorine Dioxide Stage (AD)hot... 129 4.12.2 High Temperature Chlorine Dioxide Stage (DHT)... 131 4.13 Liquor Loss Management... 132 4.14 Condensate Stripping and Recovery... 134 4.15 Reduction of Sulphur Oxides and Nitrogen Oxides Emissions... 139 4.16 Electrostatic Precipitators... 142 4.17 Installation of Scrubbers on Recovery Boiler... 146 4.18 Increase in the Dry Solids Content of Black Liquor... 148 4.19 Incineration of Odorous Gases in the Lime Kiln... 151 4.20 Installation of Low NOx Technology in Auxiliary Boilers and the Lime Kiln... 154 4.21 Selective Non-Catalytic Reduction on Bark Boilers... 156 4.22 Over Fire Air Technique on Recovery Boilers... 160 4.23 Installation of Improved Washing and Filtration of Lime Mud in Recausticizing... 161 4.24 Technologies That can Help Achieve Practical Minimum Energy Consumption... 163 4.24.1 Impulse Technology for Dewatering of Paper... 163 4.24.2 Energy Efficient Thermo-Mechanical Pulping (TMP) Processes... 165 4.24.3 New Energy Efficient Bleached Chemi-Thermo Mechanical Pulping Processes... 166 4.24.4 Use of Enzymes During the Refining of TMP... 167 4.24.5 Condebelt Process... 168 4.24.6 High Consistency Forming... 170 4.24.7 Black Liquor and Hog Fuel Gasification... 172 4.24.8 Partial Borate Autocaustising... 177 4.24.9 Biorefinery... 179 4.25 Partial System Closure... 180 4.25.1 Control of NPE with Partial Closure... 183

Contents ix 4.26 Water Recycling/Reuse... 187 4.27 Primary, Secondary and Tertiary Waste Treatment... 192 4.27.1 Primary Treatment... 192 4.27.2 Secondary Waste Water Treatment... 193 4.27.3 Tertiary Treatment... 196 References... 197 5 State-of-the-Art Pulp Mills... 217 5.1 Celulosa Arauco y Constitución S.A. Nueva Aldea, Chile... 219 5.2 Veracel Celulose... 221 5.3 Hainan Jinhai Pulp mill... 223 5.4 Cellulosa Arauco Valdivia... 226 5.5 APRIL/SSYMB Rizhao Greenfield Mill... 228 5.6 Aracruz, Line C, Brazil... 230 5.7 Mercal Stendal, Germany... 231 5.8 Bowater, Catawba SC, USA... 233 5.9 Zhanjiang Chenming Greenfield Pulp Mill, China... 236 5.10 Eldorado Celulose e Papel S.A. s New Greenfield Pulp Mill in Três Lagoas, Brazil... 236 5.11 Montes del Plata Mill in Uruguay... 237 5.12 Oji Holdings Nantong Pulp Mill Jiangsu Province, China... 238 5.13 Aracruz s Pulp Line, at Their Guaiba Mill in Rio Grande do Sul, Brazil... 238 5.14 Ilim Group s New Kraft Pulp Mill, in Bratsk, Irkutsk Oblast, Russia... 239 5.15 Metsa-Botnia, Rauma Mill... 240 5.16 Metsa-Botnia Joutseno Mill... 240 5.17 Stora Enso s Nymölla Mill... 241 5.18 UPM Fray Bentos Pulp Mill... 242 5.19 New Projects... 243 References... 245 6 The Future... 247 References... 250 Index... 251

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

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

List of Figures Fig. 2.1 Overview of kraft pulping mill with papermaking system... 13 Fig. 2.2 A flow diagram for a typical papermaking process... 30 Fig. 2.3 Details of papermaking process... 31 Fig. 2.4 Schematic of Fourdrinier paper machine... 32 Fig. 3.1 Polychlorinated dibenzodioxins (PCDD) and polychlorinated dibenzofurans (PCDF)... 49 Fig. 4.1 AQ catalytic cycle... 80 Fig. 4.2 Benefits of using anthraquinone and surfactants... 84 Fig. 4.3 Incorporation of the oxygen delignification stage Fig. 4.4 in brownstock washing and cooking liquor recovery cycle... 89 Flowsheet of typical medium-consistency oxygen delignification... 90 Fig. 4.5 Equipment of medium-consistency oxygen delignification... 90 Fig. 4.6 Flowsheet of typical high-consistency oxygen delignification... 91 Fig. 4.7 High-consistency oxygen delignification reactor... 91 Fig. 4.8 Two-stage oxygen delignification... 92 Fig. 4.9 Typical OxyTrac system set up... 93 Fig. 4.10 Typical configuration of medium-consistency ozone stage... 100 Fig. 4.11 HC Ozone bleaching in 1990s and today... 101 Fig. 4.12 Oxygen-reinforced alkaline extraction (EOP) stage... 126 Fig. 4.13 Schematic of Condebelt drying process... 169 Fig. 4.14 Integrated gasification and combined cycle (IGCC)... 173 Fig. 4.15 The CHEMREC DP-1 plant... 175 Fig. 5.1 Nueva Aldea, Pulp Mill, Chile... 220 Fig. 5.2 Veracel fibre line.... 222 Fig. 5.3 Hainan Jinhai pulp mill... 224 Fig. 5.4 Celulosa Arauco y Constitucion s new facility in Valdivia Province, Chile... 226 Fig. 5.5 Arauco Valdivia fibre line... 227 xiii

xiv List of Figures Fig. 5.6 Super batch digesters at Cellulosa Arauco Valdivia... 228 Fig. 5.7 Twin roll presses at Cellulosa Arauco Valdivia... 229 Fig. 5.8 The twin-wire pulp machine at Aracruz Celulose S.A. s new C line at its Barra do Riacho mill... 231 Fig. 5.9 Recausticizing plant at Aracruz Celulose S.A. s new C line at its Barra do Riacho mill... 232 Fig. 5.10 Evaporation plant at Stendal... 232 Fig. 5.11 Fibre line at Catawba... 234 Fig. 5.12 Continuous digester, Catawba s new fibre line, uses low solids cooking for lowest kappa number and highest fibre quality... 235 Fig. 5.13 Fray Bentos Pulp mill fibre line... 243

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... 13 Table 2.2 Types of pulping... 16 Table 2.3 Unit processes in stock preparation... 28 Table 2.4 Common pulp stock additives... 30 Table 3.1 Important parameters followed in order to demonstrate improvements towards a minimum impact mill... 43 Table 3.2 Chlorinated organic compounds in bleach plant effluents... 47 Table 3.3 Regulated chlorophenols... 47 Table 3.4 Solid waste generated in pulp and paper mills... 56 Table 3.5 Generation of waste in a kraft mill... 56 Table 4.1 Measures to reduce environmental impacts from wood handling... 68 Table 4.2 Important feature of HYP... 72 Table 4.3 Modified cooking principles... 74 Table 4.4 Modified continuous cooking systems... 78 Table 4.5 World market share of modified cooking processes... 79 Table 4.6 Typical operating data ranges for oxygen Table 4.7 delignification process... 92 Effect of different delignification technologies on kappa number and effluent COD... 95 Table 4.8 Mills using ozone bleaching... 97 Table 4.9 Mills using ZeTrac technology... 102 Table 4.10 World bleached chemical pulp production: 1990 2012... 110 Table 4.11 Modern ECF bleaching sequences... 112 Table 4.12 Chemical consumption in bleaching of softwood kraft pulp in D(EOP)D(ED) sequence mill results... 113 xv

xvi List of Tables Table 4.13 Brightness development in different chlorine dioxide bleaching sequences... 114 Table 4.14 Brightness development in a sequence replacing the first D-stage with a Z-stage... 114 Table 4.15 Effect of peroxide use in a chlorine dioxide bleaching sequence... 114 Table 4.16 Modern bleaching sequences of eucalyptus-based kraft pulp mills... 115 Table 4.17 (DZ) and (ZD) treatments of an unbleached softwood kraft pulp... 117 Table 4.18 Environmental aspects of ECF and TCF effluent quality... 118 Table 4.19 Environmental aspects of ECF pulp properties... 118 Table 4.20 Bleaching sequences for TCF bleaching... 120 Table 4.21 Chemical consumption in bleaching of softwood kraft pulp in Q(OP)(ZQ)(PO) sequence... 120 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... 121 Table 4.23 Effect of kappa number after ozone delignification when bleaching softwood kraft pulp in a Q(ZQ)(PO) sequence... 121 Table 4.24 BKP mills using TCF bleaching... 122 Table 4.25 Mills using both ECF and TCF bleaching... 122 Table 4.26 Advantages with oxygen-reinforced alkaline extraction... 126 Table 4.27 Conditions in an EOP stage... 128 Table 4.28 Undesirable effects of HexA in bleaching... 129 Table 4.29 Typical conditions for (A) hot and (AD) hot stages... 130 Table 4.30 Benefits of using hot acid stage in bleached eucalyptus kraft mills... 131 Table 4.31 Typical pollutant loads in foul condensates in bleached kraft mill (softwood)... 135 Table 4.32 Heat value of pollutants... 135 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)... 140 Range of observed emissions of SOx and NOx from recovery furnace and lime kiln... 141 Typical noncondensable gas analysis by volume % of an NCG gas stream... 152 NOx emission from fluidised bed boilers of paper mills using primary and/or secondary measures for NOx reduction... 158 Kraft mills (paper grade) practising bleach plant filtrate recovery... 182 Table 4.38 Advantages of waste water recycling... 188 Table 4.39 Water conservation measures adopted in the pulp mill... 188