Environmentally Friendly Production of Pulp and Paper PDF
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P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan Environmentally Friendly Production of Pulp and Paper i P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan Environmentally Friendly Production of Pulp and Paper Pratima Bajpai AJOHNWILEY&SONS,INC.,PUBLICATION iii P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan Copyright(cid:1)C 2010byJohnWiley&Sons,Inc.Allrightsreserved. PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJersey. PublishedsimultaneouslyinCanada. Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformor byanymeans,electronic,mechanical,photocopying,recording,scanning,orotherwise,exceptas permittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,withouteithertheprior writtenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfeeto theCopyrightClearanceCenter,Inc.,222RosewoodDrive,Danvers,MA01923,(978)750-8400, fax(978)750-4470,oronthewebatwww.copyright.com.RequeststothePublisherforpermission shouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet,Hoboken, NJ07030,(201)748-6011,fax(201)748-6008,oronlineathttp://www.wiley.com/go/permission. LimitofLiability/DisclaimerofWarranty:Whilethepublisherandauthorhaveusedtheirbesteffortsin preparingthisbook,theymakenorepresentationsorwarrantieswithrespecttotheaccuracyor completenessofthecontentsofthisbookandspecificallydisclaimanyimpliedwarrantiesof merchantabilityorfitnessforaparticularpurpose.Nowarrantymaybecreatedorextendedbysales representativesorwrittensalesmaterials.Theadviceandstrategiescontainedhereinmaynotbesuitable foryoursituation.Youshouldconsultwithaprofessionalwhereappropriate.Neitherthepublishernor authorshallbeliableforanylossofprofitoranyothercommercialdamages,includingbutnotlimitedto special,incidental,consequential,orotherdamages. Forgeneralinformationonourotherproductsandservicesorfortechnicalsupport,pleasecontactour CustomerCareDepartmentwithintheUnitedStatesat(800)762-2974,outsidetheUnitedStatesat (317)572-3993orfax(317)572-4002. Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmay notbeavailableinelectronicformats.FormoreinformationaboutWileyproducts,visitourwebsiteat www.wiley.com LibraryofCongressCataloging-in-PublicationData Bajpai,P.(Pratima) Environmentally-friendlyproductionofpulpandpaper/PratimaBajpai. p. cm. Includesindex. ISBN978-0-470-52810-5(cloth) 1.Pulping–Environmentalaspects. 2.Papermaking–Environmentalaspects. 3.Sustainableengineering. I.Title. TS1109.B24 2010 676(cid:2).042–dc22 2010005156 PrintedintheUnitedStatesofAmerica 10 9 8 7 6 5 4 3 2 1 iv P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan Contents Preface vii 1. Introduction 1 1.1 SuperiorOperatingProcedures 5 1.2 ProcessModifications 5 1.3 ProcessRedesign 5 1.4 Recycling 6 References 7 2. OverviewofPulpandPapermakingProcesses 8 2.1 RawMaterialPreparationandHandling 8 2.2 PulpManufacturing 11 2.3 PulpWashingandScreening 17 2.4 PulpBleaching 20 2.5 StockPreparation 22 2.6 Papermaking 32 2.7 ChemicalRecovery 40 References 43 3. EnvironmentalIssuesofthePulpandPaperIndustry 46 3.1 EffluentToxicity 48 3.2 AirEmissions 54 References 58 4. EmissionsfromPulpandPapermaking 62 4.1 KraftPulping 62 4.2 SulfitePulping 79 4.3 MechanicalPulping 84 4.4 RecycledFiberProcessing 89 4.5 Papermaking 99 References 107 5. CleanerProductionMeasuresinPulpandPaperProcessing 110 5.1 KraftPulping 110 5.2 SulfitePulping 170 v P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan vi Contents 5.3 MechanicalandChemimechanicalPulping 177 5.4 RecycledPaperProcessing 190 5.5 Papermaking 213 References 254 6. RecentDevelopmentsinCleanerProduction 264 6.1 UseofCookingCatalyst 264 6.2 OrganoSolventPulping 268 6.3 BlackLiquorGasification 269 6.4 RemovalofChelatingAgents 273 6.5 Energy-EfficientThermomechanicalPulpingProcesses 274 6.6 RecoveryofBoilerAshandCarbonDioxideGastoProduce RecycledMineralFillers 276 6.7 ImpulseTechnologyforDewateringofPaper 277 6.8 CondebeltProcess 278 6.9 InternalHeatPumps 280 6.10 TotalSiteIntegrationTools 280 6.11 WastewaterTreatmentforWaterRecoveryandReuse 281 6.12 BiotechnologiesforCleanerPaperProduction 305 References 334 GlossaryandAbbreviations 345 SubjectIndex 357 P1:OTA FM JWBS031-Bajpai June8,2010 16:57 PrinterName:Sheridan Preface Thepulpandpaperindustryislargeandgrowing,reflectingtheworld’sdemandfor paper.Itisacapital-andresource-intensiveindustrythatcontributestomanyenvi- ronmentalproblems,includingglobalwarming,humantoxicity,ecotoxicity,photo- chemical oxidation, acidification, nutrification, and solid wastes. Public concern is resulting in increased pressure on industry to focus on pollution prevention rather thanonend-of-pipecleanup.Industryisrespondingbymodifyingexistingproduc- tion processes or developing entirely new ones to achieve cleaner production (i.e., greater energy efficiency as well as reduced emissions of greenhouse gases and toxic substances). Many companies are beginning to find that cleaner production notonlyreducesenvironmentalliabilitiesbutalsoreducescostsandincreasesboth productivity and competitiveness. Minimizing or eliminating the causes of wastes andemissionsmakesiteasiertomeetexistingenvironmentalregulationsandreduces theenvironmentalimpactofthemill.Cleanerproductionisalsoattractivebecauseof concernsaboutthelackofeffectivenessofend-of-pipesolutions.Cleanerproduction andrelatedapproacheswillbeincreasinglyimportantinenvironmentalmanagement in the future. The introduction of cleaner production is an ongoing process. As re- sourcepricesanddisposalcostscontinuetorise,newopportunitiesariseforpollution preventionandreductionsintreatmentcosts.Forthisreason,cleanerproductioncan belinkedcloselywithenvironmentalmanagementsystems.Thisbookgivesupdated informationoncleanerproductionmeasuresinpulpandpaperindustry.Variouschap- tersdealwithcleanerproductionmeasuresinrawmaterialstorageandpreparation,in pulpingprocesses(kraft,sulfite,andmechanical),inbleaching,recovery,papermak- ing,inemissiontreatmentprocesses,andinrecycledfiberprocessing.Inaddition,it includesadiscussiononnewercleanertechnologiesandtheirimplementationstatus andbenefitsinthepulpandpaperindustry. vii P1:OTA/XYZ P2:ABC c01 JWBS031-Bajpai June8,2010 7:2 PrinterName:Sheridan 1 Chapter Introduction “Cleaner production” is an international term for reducing environmental impacts fromprocesses,products,andservicesbyusingbettermanagementstrategies,meth- ods,andtools.Itisaglobalmovementforimprovingbusinessperformanceandaprof- itable,cleaner,andsustainablefuture.AccordingtotheUnitedNationsEnvironment Programme(UNEP)definitionof“cleanerproduction”andtheoneinmostcommon useis,“Cleanerproductionisthecontinuousapplicationofanintegratedpreventive strategytoprocesses,productsandservices,toincreaseecoefficiencyandtoreduce riskstohumansandtheenvironment”(AIT,1999).Anumberofrelatedtermsarealso used,includingpollutionprevention,low-orno-wastetechnologies,wasteminimiza- tion,wasteandemissionprevention,sourcereduction,ecoefficiency,andenvironmen- tallysoundtechnology.Allthesetermsbasicallyrefertothesameconceptofintegrat- ingpollutionreductionintotheproductionprocessandeventhedesignoftheproduct. The meaning of the term “cleaner production” varies from the perspective in which it is used. For production processes, cleaner production involves conserving rawmaterialsandenergy,eliminatingtheuseoftoxicsubstancesasmuchaspossible, andreducingthequantityaswellasthetoxicityofallemissionsandwastesbefore they leave any given process. For products, it means reducing their environmental impactsduringtheentirelifecycle,fromrawmaterialextractiontoultimatedisposal. For services, it means incorporating environmental concerns when designing and deliveringservices(Fig.1.1). Theadoptionofcleanerproductionintheindustryleadstomultifoldadvantages toanoperatingindustry.Cleanerproductionleadstobetterefficiencyofproduction, which means more output of products per unit input of raw materials. This helps in improving the financial performance of the mill. The ultimate goal of cleaner production is to minimize the generation of emissions and waste that needs to be treatedandtheassociatedcosts.Giventheincreasingcostofrawmaterialsandthe growingscarcityofgood-qualitywater,noindustrycanaffordtousetheseresources inefficiently.Cleanerproductionmeasureshelpinovercomingconstraintsposedby scarceorever-increasingcostlyrawmaterials,water,andenergy. Cleanerproductionminimizestheamountandtoxicityofwasteandemissions and renders products that are more agreeable from an environmental standpoint. The direct effect is that the pollution load on the environment is decreased and EnvironmentallyFriendlyProductionofPulpandPaper, byPratimaBajpai Copyright(cid:1)C 2010JohnWiley&Sons,Inc. 1 P1:OTA/XYZ P2:ABC c01 JWBS031-Bajpai June8,2010 7:2 PrinterName:Sheridan 2 Chapter1 Introduction Cleaner production It is a preventive integrated environmental policy applied to the entire production and service cycle Processes: Products: (cid:127) Conservation of raw materials, Services: - Reduction of waste energy, and water - Efficient through better (cid:127) Reduction of emission at environmental design source management in - Use of waste for (cid:127) Evaluation of technology design and delivery new products option (cid:127) Reduction of costs and risks Impacts: Improved efficiency Better environmental performance Increased competitive advantage Figure1.1 Cleanerproduction. environmentalqualityisimproved.Itfocusesonminimizingresourceuseandavoid- ingthecreationofpollutants,ratherthantryingtomanagepollutantsaftertheyhave beencreated.Itinvolvesrethinkingproducts,processes,andservicestomovetoward sustainabledevelopment.Sustainabledevelopmentconcernsessentialhumanactivi- ties,andsustainabledevelopmentgoalsareoftenexpectedtodramaticallyaffectboth individualandpublicchoicestomodifyproductionandconsumptionpatterns(OECD, 2002;WorldBank,1998).Sustainabledevelopmentisofcriticalimportanceforallcit- izens;itengageschoicesthatwillaffectessentialaspectsofourlifestyles,and,being typicallycrosscutting,itshouldtakeintoconsiderationvariousconflictinginterests. Consumers, suppliers, governments, and the market at large are increasingly demandingenvironmentalresponsibilitybythebusinesscommunity.Businessesig- noringthistrendandrejectingtheopportunitytoimprovetheirenvironmentalperfor- mancemayfindthemselvesleftbehindinthehighlycompetitiveglobalmarketplace. Cleaner production is set to become an integral part of the business strategies of enlightened companies that want to embrace the ongoing challenges of industry leadership and continuous improvement. Cleaner production can reduce operating costs,improveprofitabilityandworkersafety,andreducetheenvironmentalimpact ofourbusiness.Companiesarefrequentlysurprisedatthecostreductionsachievable through the adoption of cleaner production techniques. Frequently, minimal or no P1:OTA/XYZ P2:ABC c01 JWBS031-Bajpai June8,2010 7:2 PrinterName:Sheridan Chapter1 Introduction 3 capitalexpenditureisrequiredtoachieveworthwhilegains,withfastpaybackperi- ods. Waste handling and charges, raw material usage, and insurance premiums can oftenbecut,alongwithpotentialrisks. Onabroaderscale,cleanerproductioncanhelpalleviatetheseriousandincreas- ingproblemsofairandwaterpollution,ozonedepletion,globalwarming,landscape degradation,solidandliquidwastes,resourcedepletion,acidificationofthenatural andbuiltenvironment,visualpollution,andreducedbiodiversity. It is proved from the past records that there lies a great potential for reduction inthepollutionlevelsinthepulpandpapermills.Fromthedifferentdemonstration projects,itisestablishedthatadoptiontothecleanerproductionhasnotonlyreduced the pollution loads but also helped in generating revenues by controlling the waste goingdownthedrain(Nath,1997;Radka,1994;Satyanarayanaetal.,2004). Themaindifferencebetweenpollutioncontrolandcleanerproductionisoneof timing. Pollution control is an after-the-event, “react and treat” approach, whereas cleanerproductionreflectsaproactive,“anticipateandprevent”philosophy.Preven- tion is always better than cure. This does not mean, however, that “end-of-pipe” technologies will never be required. By using a cleaner production philosophy to tacklepollutionandwasteproblems,thedependenceon“end-of-pipe”solutionsmay bereducedor,insomecases,eliminatedaltogether. Investing in cleaner production to prevent pollution and reduce resource con- sumptionismorecost-effectivethancontinuingtorelyontheincreasinglyexpensive “end-of-pipe”solutions.Whencleanerproductionandpollutioncontroloptionsare carefully evaluated and compared, the cleaner production options are often more cost-effective overall. The initial investment for cleaner production options and for installingpollutioncontroltechnologiesmaybesimilar,buttheongoingcostsofpol- lutioncontroltechnologieswillgenerallybegreaterthanthoseofcleanerproduction. Furthermore, the cleaner production option will generate savings through reduced costsofrawmaterials,energy,wastetreatment,andregulatorycompliance. Theenvironmentalbenefitsofcleanerproductioncanbetranslatedintomarket opportunities for “greener” products. Companies that factor environmental consid- erations into the design stage of a product will be well placed to benefit from the marketingadvantagesofanyfutureecolabelingschemes. Increasing consumer awareness of environmental issues has brought about a needforthecompaniestodemonstratetheenvironmentalfriendlinessoftheirprod- uctsandmanufacturingprocesses,particularlyininternationalmarkets.Byadopting the cleaner production approach, many of the market requirements are met and a company’sabilitytocompeteandgetaccesstothe“greenmarket”increases. Cleanerproductionnotonlyimprovestheenvironmentoutsidethemillbutalso improvesworkingconditions.Keepingthemillcleanandfreeofwaste,spilledwater, and chemicals not only reduces the likelihood of accidents but also motivates the workforcetocontrolnewleaksandmateriallosses. As public awareness of the need for environmental protection is growing each day,itbecomesmoreandmoreimportantfortheindustrytorespondandreacttothe questionsanddemandsposedbythepublic.Theenvironmentalprofileofacompany isanincreasinglyimportantpartofitsoverallreputation.Adoptingcleanerproduction isaproactive,positivemeasureandcanhelptheconcernedcompanybuildconfidence P1:OTA/XYZ P2:ABC c01 JWBS031-Bajpai June8,2010 7:2 PrinterName:Sheridan 4 Chapter1 Introduction in the public regarding its environmental responsibility. Some reasons to invest in cleanerproductionare (cid:1) Improvementstoproductsandprocesses (cid:1) Savingsonrawmaterialsandenergy,thusreducingproductioncosts (cid:1) Increasedcompetitivenessthroughtheuseofnewandimprovedtechnologies (cid:1) Reducedconcernsoverenvironmentallegislation (cid:1) Reduced liability associated with the treatment, storage, and disposal of hazardouswastes (cid:1) Improvedhealth,safety,andmoraleofemployees (cid:1) Improvedthecompany’simage (cid:1) Reducedcostsofend-of-pipesolutions Cleanerproductiondependsonlypartlyonneworalternativetechnologies.Itcan alsobeachievedthroughimprovedmanagementtechniques,differentworkpractices, andmanyother“soft”approaches.Cleanerproductionisasmuchaboutattitudes,ap- proaches,andmanagementasitisabouttechnology.Cleanerproductionapproaches arewidelyandreadilyavailable,andmethodologiesexistforitsapplication.Whileit istruethatcleanerproductiontechnologiesdonotyetexistforallindustrialprocesses andproducts,itisestimatedthatmorethan70%ofallcurrentwastesandemissions fromindustrialprocessescanbepreventedatsourcebytheuseoftechnicallysound andeconomicallyprofitableprocedures(Baasetal.,1992). Cleanerproductioncancontributetosustainabledevelopment.Cleanerproduc- tion can reduce or eliminate the need to trade off environmental protection against economic growth, occupational safety against productivity, and consumer safety againstcompetitionininternationalmarkets.Settinggoalsacrossarangeofsustain- abilityissuesleadstowin–winsituationsthatbenefiteveryone.Cleanerproductionis suchawin–winstrategy—itprotectstheenvironment,theconsumer,andtheworker. Italsoimprovesindustrialefficiency,profitability,andcompetitiveness. Cleanerproductioncanbeespeciallybeneficialtodevelopingcountriesandthose undergoingeconomictransitionbyplanning,design,andmanagementpracticesthat facilitate innovative approaches to the reuse, remanufacturing, and recycling of the limitedamountsofwastethatcannotbeavoided(Gavrilescu,2004). Cleanerproductioninvolvesinitiatingstepstoreducetheintensityofpollution atvariouslevels.Thiscanbeaccomplishedbyreducingthegenerationofwastesat its source and reusing and recycling the resources. Pollution prevention is of envi- ronmentalandeconomicsignificancebecauseitmakesjudicioususeoftheexisting resourcessuchaschemicalsandwaterandeliminatestherecurringcostsinvolvedin wastetreatmentanddisposal.Mostcompaniesacrosstheglobehavechartedoutpollu- tionpreventionprogramssuitabletotheirindustryrequirements.RecentR&Dinitia- tivesundertakenbyvariouscompaniesincludeformaldehyde-freeproducts,organic biocides,biotechnologyproductssuchasmicrobes,enzymes,andnaturalpigments. Figure 1.2 shows the key initiatives taken by the pulp and paper industries to minimizepollutionatvariouslevels.
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