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Best Available Techniques (BAT)

Reference Document for the

Production of Pulp, Paper and Board

Industrial Emissions Directive

2010/75/EU

(Integrated Pollution

Prevention and Control)

Michael Suhr, Gabriele Klein, Ioanna Kourti,

Miguel Rodrigo Gonzalo, Germán Giner Santonja,

Serge Roudier, Luis Delgado Sancho

2015

Report EUR 27235 EN

European Commission

Joint Research Centre

Institute for Prospective Technological Studies

Contact information

European IPPC Bureau

Address: Joint Research Centre, Edificio Expo c/ Inca Garcilaso 3, E-41092 Seville, Spain

E-mail: JRC-IPTS-EIPPCB@ec.europa.eu

Tel.: +34 95 4488 284

Fax: +34 95 4488 426

http://eippcb.jrc.ec.europa.eu

Legal Notice

Under the Commission Decision of 12 December 2011 on the Re-use of Commission Documents (2011/833/EU), the present

BREF document is subject to free re-use, except for parts covered by any third-party rights which may be present in the

document (such as images, tables, data, written material, or similar, the rights to which need to be acquired separately from

their respective rights-holders for further use). The European Commission is not liable for any consequence stemming from

the re-use of this publication. Any re-use is subject to the acknowledgement of the source and non-distortion of the original

meaning or message

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lnzyx; 2. © Fotolia.com YMoreno Soppelsa; 3. © Fotolia.com YEyeMark; 4. © Fotolia.com Yitrija; 5. © Fotolia.com YMoreno

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EUR 27235 EN

ISBN 978-92-79-48167-3 (PDF)

ISSN 1831-9424 (online)

doi:10.2791/370629 Luxembourg: Publications Office of the European Union, 2015

© European Union, 2015

Reproduction is authorised provided the source is acknowledged.

Abstract

an exchange of information between EU Member States, the industries concerned, non-governmental organisations

promoting environmental protection, and the Commission, to draw up, review and, where necessary, update BAT reference

documents as required by Article 13(1) of the Directive 2010/75/EU on industrial emissions. This document is published by

the European Commission pursuant to Article 13(6) of the Directive. This BREF for the production of

pulp, paper and board covers the activities specified in Sections 6.1(a) and 6.1(b) of Annex I to Directive 2010/75/EU, i.e.

the integrated and non-integrated production in industrial installations of: (a) pulp from timber or other fibrous materials; (b) paper or cardboard with a production capacity exceeding 20 tonnes per day. In particular, this document covers the following processes and activities: - chemical pulping: (a) kraft (sulphate) pulping process (b) sulphite pulping process - mechanical and chemimechanical pulping - processing paper for recycling with and without deinking - papermaking and related processes - all recovery boilers and lime kilns operated in pulp and paper mills.

Important issues for the implementation of Directive 2010/75/EU in the pulp, paper and board industry are the emissions

to air of nitrogen oxides, sulphur oxides, dust, total reduced sulphur and ammonia; emissions to water of organic carbon,

suspended solids, nitrogen, phosphorus and adsorbable organically bound halogens. The BREF contains nine chapters.

Chapters 1 and 2 provide general information on the pulp, paper and board industry and on the common industrial

processes and techniques used within the whole sector. Chapters 3, 4, 5, 6 and 7 correspond to the following specific

sectors: kraft (sulphate) pulping process, sulphite pulping process, mechanical and chemimechanical pulping, processing of

paper for recycling with and without deinking, and papermaking and related processes. For each sector, these five chapters

provide information and data concerning the applied processes and techniques; the environmental performance of

installations in terms of current emissions, consumption of raw materials, water and energy, and generation of waste; the

techniques to prevent or reduce the environmental impact of installations; and the emerging techniques. In Chapter 8 the

BAT conclusions, as defined in Article 3(12) of the Directive, are presented for the pulp, paper and board industry.

Chapter 9 is dedicated to concluding remarks and recommendations for future work regarding the sector.

Best Available Techniques (BAT)

Reference Document for the

Production of Pulp, Paper and Board

Industrial Emissions Directive 2010/75/EU

Integrated Pollution Prevention and control

Authors:

Michael Suhr

Gabriele Klein

Ioanna Kourti

Miguel Rodrigo Gonzalo

Germán Giner Santonja

Serge Roudier

Luis Delgado Sancho

2015

EUR 27235 EN

Acknowledgements

This report was produced by the European Integrated Pollution Prevention and Control Bureau (EIPPCB) at the European

Commission's Joint Research Centre Y Institute for Prospective Technological Studies (IPTS) under the supervision of

Serge Roudier (Head of the EIPPCB) and Luis Delgado Sancho (Head of the Sustainable Production and Consumption Unit).

The authors of this BREF were Mr Michael Suhr, Ms Gabriele Klein, Ms Ioanna Kourti, Mr Miguel Rodrigo Gonzalo and Mr Germán

Giner Santonja. Mr Michael Parth participated in the reactivation of the Technical Working Group and started the review of the

BREF.

This report was drawn up in the framework of the implementation of the Industrial Emissions Directive (2010/75/EU) and is the

result of the exchange of information provided for in Article 13 of the Directive.

Major contributors of information were:

among industry, the Confederation of European Paper Industries (CEPI); among environmental NGOs, the European Environmental Bureau (EEB);

among EU Member States, Austria, Denmark, Finland, France, Germany, Italy, the Netherlands, Poland, Portugal, Spain,

Sweden, and the United Kingdom;

among non-EU EEA Member States, Norway. The whole EIPPCB team provided contributions and peer reviewing. This document is one from the series of foreseen documents listed below (at the time of writing not all of the documents have been drafted):

Best Available Techniques Reference Document Code

Ceramic Manufacturing Industry CER

Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical

Sector CWW

Emissions from Storage EFS

Energy Efficiency ENE

Ferrous Metals Processing Industry FMP

Food, Drink and Milk Industries FDM

Industrial Cooling Systems ICS

Intensive Rearing of Poultry and Pigs IRPP

Iron and Steel Production IS

Large Combustion Plants LCP

Large Volume Inorganic Chemicals Ammonia, Acids and Fertilisers Industries LVIC-AAF Large Volume Inorganic Chemicals Solids and Others industry LVIC-S

Large Volume Organic Chemical Industry LVOC

Management of Tailings and Waste-rock in Mining Activities MTWR

Manufacture of Glass GLS

Manufacture of Organic Fine Chemicals OFC

Non-ferrous Metals Industries NFM

Production of Cement, Lime and Magnesium Oxide CLM

Production of Chlor-alkali CAK

Production of Polymers POL

Production of Pulp, Paper and Board PP

Production of Speciality Inorganic Chemicals SIC

Refining of Mineral Oil and Gas REF

Slaughterhouses and Animals By-products Industries SA

Smitheries and Foundries Industry SF

Surface Treatment of Metals and Plastics STM

Surface Treatment Using Organic Solvents STS

Tanning of Hides and Skins TAN

Textiles Industry TXT

Waste Incineration WI

Waste Treatments Industries WT

Wood and Wood Products Preservation with Chemicals WPC

Wood-based Panels Production WBP

Reference Document

Economics and Cross-media Effects ECM

General Principles of Monitoring MON

Electronic versions of draft and finalised documents are publicly available and can be downloaded from http://eippcb.jrc.ec.europa.eu/.

Preface

Production of Pulp, Paper and Board i

PREFACE

1. Status of this document

2010/75/EU of the European Parliament and the Council on industrial emissions (integrated

pollution prevention and control) (Recast). The original best available techniques (BAT) reference document (BREF) on Production of Pulp, Paper and Board was adopted by the European Commission in 2001. This document is the result of a review of that BREF. The review commenced in April 2006. This BAT reference document for the Production of Pulp, Paper and Board forms part of a series presenting the results of an exchange of information between EU Member States, the industries concerned, non-governmental organisations promoting environmental protection and the Commission, to draw up, review, and where necessary, update BAT reference documents as required by Article 13(1) of the Directive. This document is published by the European Commission pursuant to Article 13(6) of the Directive. As set out in Article 13(5) of the Directive, the Commission Implementing Decision

2014/687/EU on the BAT conclusions contained in Chapter 8 was adopted on 26 September

2014 and published on 30 September 2014.1

2. Participants in the information exchange

As required in Article 13(3) of the Directive, the Commission has established a forum to

promote the exchange of information, which is composed of representatives from Member States, the industries concerned and non-governmental organisations promoting environmental protection (Commission Decision of 16 May 2011 establishing a forum for the exchange of information pursuant to Article 13 of the Directive 2010/75/EU on industrial emissions (2011/C

146/03), OJ C 146, 17.05.2011, p. 3).

Forum members have nominated technical experts constituting the technical working group (TWG) that was the main source of information for drafting this document. The work of the TWG was led by the European IPPC Bureau (of the Commission's Joint Research Centre).

3. Structure and contents of this document

Chapter 1, the Sections 2.1 to 2.8 of Chapter 2 and the first sections of Chapters 3 to 7 provide general information on the production of pulp, paper and board and on the industrial processes used within this sector. The second sections of Chapters 3 to 7 and Section 2.6.2 provide data and information concerning the environmental performance of installations within the sector, and in operation at the time of writing, in terms of current emissions, consumption and nature of raw materials, water consumption, use of energy and the generation of waste. Section 2.9 and the third sections of Chapters 3 to 7 describe in more detail the techniques to prevent or, where this is not practicable, to reduce the environmental impact of installations in this sector that were considered in determining the BAT. This information includes, where relevant, the environmental performance levels (e.g. emission and consumption levels) that can be achieved by using the techniques, the associated monitoring and the costs and the cross- media issues associated with the techniques.

1 OJ L 284, 30.9.2014, p. 76.

Preface

ii Production of Pulp, Paper and Board Chapter 8 presents the BAT conclusions as defined in Article 3(12) of the Directive. The fourth sections of Chapters 3 to 7 present information on 'emerging techniques' as defined in Article 3(14) of the Directive. Concluding remarks and recommendations for future work are presented in Chapter 9.

4. Information sources and the derivation of BAT

This document is based on information collected from a number of sources, in particular through the TWG that was established specifically for the exchange of information under Article 13 of the Directive. The information has been collated and assessed by the European IPPC Bureau (of the Commission's Joint Research Centre) who led the work on determining BAT, guided by the principles of technical expertise, transparency and neutrality. The work of the TWG and all other contributors is gratefully acknowledged. The BAT conclusions have been established through an iterative process involving the following steps: identification of the key environmental issues for the sector (e.g. emissions to water, especially organic load, total suspended solids, etc.; emissions to air from recovery boilers, lime kilns or combustion plants for the production of steam and power; odour and noise nuisance); examination of the techniques most relevant to address these key issues; identification of the best environmental performance levels, on the basis of the available data in the European Union and worldwide; examination of the conditions under which these environmental performance levels were achieved, such as costs, cross-media effects, and the main driving forces involved in the implementation of the techniques; selection of the best available techniques (BAT), their associated emission levels (and other environmental performance levels) and the associated monitoring for this sector according to Article 3(10) of, and Annex III to, the Directive. Expert judgement by the European IPPC Bureau and the TWG has played a key role in each of these steps and the way in which the information is presented here. Where available, economic data have been given together with the descriptions of the techniques presented in Chapters 3, 4, 5, 6 and 7. These data give a rough indication of the

magnitude of the costs and benefits. However, the actual costs and benefits of applying a

technique may depend strongly on the specific situation of the installation concerned, which cannot be evaluated fully in this document. In the absence of data concerning costs, conclusions on the economic viability of techniques are drawn from observations on existing installations.

5. Review of BAT reference documents (BREFs)

BAT is a dynamic concept and so the review of BREFs is a continuing process. For example, new measures and techniques may emerge, science and technologies are continuously developing and new or emerging processes are being successfully introduced into the industries. In order to reflect such changes and their consequences for BAT, this document will be periodically reviewed and, if necessary, updated accordingly.

Preface

Production of Pulp, Paper and Board iii

6. Contact information

All comments and suggestions should be made to the European IPPC Bureau at the Institute for Prospective Technological Studies at the following address:

European Commission

Institute for Prospective Technological Studies

European IPPC Bureau

Edificio Expo

c/ Inca Garcilaso, 3

E-41092 Seville, Spain

Telephone: +34 95 4488 284

Fax: +34 95 4488 426

E-mail: JRC-IPTS-EIPPCB@ec.europa.eu

Internet: http://eippcb.jrc.ec.europa.eu

iv Production of Pulp, Paper and Board

Production of Pulp, Paper and Board v

Best Available Techniques Reference Document for the

Production of Pulp, Paper and Board

PREFACE ........................................................................................................................ I

SCOPE ..................................................................................................................... XXXI

1 GENERAL INFORMATION ................................................................................. 1

1.1 PAPER CONSUMPTION IN EUROPE ................................................................................. 1

1.2 OVERVIEW OF PULP, PAPER AND BOARD MANUFACTURING ......................................... 4

1.3 THE EUROPEAN PULP INDUSTRY .................................................................................. 7

1.4 THE EUROPEAN PAPER INDUSTRY .............................................................................. 13

1.5 CLASSIFICATION OF PULP AND PAPER MILLS FOR THE PURPOSE OF THIS DOCUMENT 18

1.6 ECONOMICS AND EMPLOYMENT IN THE EU PULP AND PAPER INDUSTRY ................... 20

1.7 MAIN ENVIRONMENTAL ISSUES OF THE PRODUCTION OF PULP AND PAPER ............... 24

2 COMMON PROCESSES AND TECHNIQUES FOR THE WHOLE PULP

AND PAPER SECTOR ......................................................................................... 33

2.1 INTEGRATED AND/OR MULTIPRODUCT PULP AND PAPER MILLS ................................. 34

2.1.1 Definition of non-integrated, integrated and multiproduct mills ....................... 34

2.1.2 Proposed approach to estimate emissions for integrated chemical pulp mills

and/or multiproduct mills .................................................................................. 36

2.1.3 Proposed method for assessing emissions for specific waste water discharges 37

2.2 MONITORING .............................................................................................................. 39

2.2.1 General aspects of emission monitoring in pulp and paper mills ...................... 39

2.2.1.1 Emission sources covered ...................................................................................... 40

2.2.1.2 Operating conditions covered ................................................................................. 40

2.2.1.3 Data processing ...................................................................................................... 41

2.2.1.4 Presentation of emission data ................................................................................. 42

2.2.2 Emission data production in pulp and paper mills ............................................ 42

2.2.2.1 Monitoring of waste water discharges .................................................................... 42

2.2.2.1.1 The sampling points ....................................................................................... 43

2.2.2.1.2 Sampling methods and periods and frequency of analysis ............................. 43

2.2.2.1.3 Major parameters and analytical methods ...................................................... 46

2.2.2.1.4 Interrelationship between measured concentrations and calculated

emission loads ................................................................................................ 47

2.2.2.1.5 Special issue that influences the comparability of emission data ................... 50

2.2.2.2 Monitoring of emissions to air ............................................................................... 50

2.2.2.2.1 The sampling points ....................................................................................... 50

2.2.2.2.2 Sampling and continuous/discontinuous measurement methods .................... 51

2.2.2.2.3 Major parameters and analytical methods ...................................................... 56

2.2.2.2.4 Reference conditions ...................................................................................... 58

2.2.2.2.5 Interrelationship between concentration and specific emission loads ............ 59

2.2.2.2.6 Measurement of diffuse emissions in kraft pulp mills .................................... 60

2.2.2.3 Monitoring of solid waste ...................................................................................... 62

2.3 RECEIPT, STORAGE AND HANDLING OF FIBROUS MATERIALS AND CHEMICALS ......... 63

2.3.1 Wood handling .................................................................................................. 63

2.3.1.1 Wood yard operations ............................................................................................ 63

2.3.1.2 Debarking ............................................................................................................... 65

vi Production of Pulp, Paper and Board

2.3.2 Storage and handling of chemicals and chemical additives ............................... 65

2.3.2.1 Use of basic chemicals and chemical additives ...................................................... 65

2.3.2.2 EU regulations on the storage, handling and use of chemicals ............................... 69

2.3.2.3 Storage, handling and transportation of chemicals ................................................. 71

2.4 WATER SUPPLY FOR PROCESSES AND COOLING .......................................................... 72

2.4.1 Raw water treatment .......................................................................................... 72

2.4.1.1 Process water treatment .......................................................................................... 72

2.4.1.2 Boiler feedwater treatment...................................................................................... 72

2.4.2 Cooling systems and use of cooling water ......................................................... 73

2.4.2.1 Types of cooling systems in pulp and paper mills .................................................. 73

2.5 ENERGY CONSUMPTION IN PULP AND PAPER MILLS .................................................... 76

2.5.1 Issues to consider when reading reported energy consumption data ................. 77

2.5.2 Examples of total process energy consumption of pulp and paper mills ........... 79

2.5.3 Relevance of process units for total process energy consumption ..................... 82

2.5.4 Energy consumption for supporting activities ................................................... 83

2.6 STEAM AND POWER GENERATION IN PULP AND PAPER MILLS ..................................... 85

2.6.1 Applied combustion processes and techniques .................................................. 85

2.6.1.1 Main fuels utilised and pretreatment....................................................................... 86

2.6.1.2 Energy production .................................................................................................. 88

2.6.1.2.1 Steam generation plants .................................................................................. 88

2.6.1.2.2 Combined heat and power (CHP) plants ......................................................... 89

2.6.1.2.3 Fluidised bed boilers ....................................................................................... 91

2.6.2 Current emissions to air from steam and power generation ............................... 93

2.6.2.1 Dust emissions ........................................................................................................ 93

2.6.2.2 SO2 emissions and other gaseous pollutants ........................................................... 95

2.6.2.3 NOX emissions ........................................................................................................ 96

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