ENVIRONMENTAL performance in 2012

Transcription

1 ENVIRONMENTAL performance in 212 UPM Plattling

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. UPM is present in 67 countries and have production units 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 Plattling UPM Plattling is located north of Plattling, a small town at the foot of the Bavarian Forest, where the Isar fl ows into the Danube. With a workforce of some 45 people and three paper machines, UPM Plattling produces up to 78, tonnes annually of uncoated (SC) and coated (LWC) supercalendered printing papers in reels and sheets for magazines, newspaper supplements, advertising brochures and sales and mail order catalogues. The organisation of UPM Plattling includes the paper mills of MD Papier GmbH and Rhein Papier GmbH. Production and administration of the two mills having already been closely interlinked for two years, they are reporting on their environmental performance in 212 jointly. The Plattling site was founded in the open countryside in It was originally comprised of the paper machine (PM) 1 to which the PM 11 was added in In 27 the mill was expanded to include Rhein Papier GmbH s PM 1. UPM Corporate ENVIRONMENTAL statement 212 UPM pulp and paper mills UPM Plattling 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. The raw materials used for papermaking include groundwood pulp, recovered paper, chemical pulp and natural pigments. Groundwood pulp is mainly made from forest thinnings from the Bavarian Forest. All wood fi bres used in our production come from sustainable forestry. The great majority of the water required for papermaking is taken from the Isar and only to a very small extent from a well on the premises. Process effl uents are cleaned in two on-site treatment plants before they are discharged back into the Isar. All of the steam and the majority of the power for the production processes are generated in the mills own combined heat and power plants running on natural gas. The remainder of the power is supplied via the public grid. Production capacity up to 78, tonnes per annum Personnel approx. 45 Products Magazin papers (SC and LWC) UPM Max UPM Ultra UPM Cat UPM Cote UPM Smart UPM Star UPM Sol UPM Nova Certificates Quality Management System: ISO 91 Environmental Management System: ISO 141 and EMAS III Energy Management: EN 51 Occupational Health and Safety System: OHSAS 181 Chain-of-Custody: PEFC and FSC The certifi cates can be found at > Responsibility > Principles and Performance > Certifi cate Finder. Environmental labels EU Eco-label FI/11/1 PEFC/ UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212

3 Environmental year 212 UPM Plattling has reported its environmental performance since as far back as 2, when the site successfully gained certifi cation to ISO 141 and the EU Eco-Management and Audit Scheme (EMAS). In 21, the site s energy management system was additionally certifi ed to DIN 51. Every year, we set ourselves ambitious new environmental goals. In the areas of water and energy use, we only partly achieved the targets we set ourselves for 212. On the positive side, we implemented several measures to reduce our energy demand. In September of 212 a team of specialists from other UPM mills carried out an energy effi ciency audit at the site, which identifi ed a large potential for improvements. Having verifi ed the feasibility of the audit fi ndings, we will implement them over the coming years through energy saving targets and projects. Already in January 212 an audit was carried out within the framework of the Group-wide Clean Run campaign to evaluate and improve the site s environmental performance. The audit found that there were both examples of best practices (chemical management) and potential for improvements (risk assessments, effi ciency of effl uent treatment). There was a complaint about odour nuisance from the effl uent treatment plant. Although the complaint was immediately investigated, it was not possible to identify a source of odour. The authorities were notifi ed of the complaint. In October, as a precautionary measure, we installed equipment to minimise odour emissions from the loading of sludge. In July were fi led charges against MD Papier GmbH for apparent water pollution. An investigation of the matter found that the water was the typical reddish brown colour of cleaned effl uent. Thereupon the charges were withdrawn. There are no complaints on record from the neighbourhoods north of the mill. Strict practices are in place to avoid noise from manufacturing or from the grounds. UPM Plattling is in close contact with stakeholders and local authorities. In fi ve instances the carbon monoxide concentration in the exhaust gas from the gas-fi red steam boilers of the LWC line was higher than the permissible limit. These steam boilers were operated in holding mode as a back-up source in the event of a power plant failure or standstill. The CO limit value was exceeded under temporary partial load conditions. However, in all instances the level of CO emitted into the ambient air was very low. Two boilers are no longer operated in holding mode, to be followed by another two in 213, to ensure that this kind of operating mode will not continue. At the beginning of the year there were several violations of the limit values in the effl uent treatment plant of the SC line. As in the previous year, this was due to the plant being overloaded, whilst the treatment plant of the LWC line was not used to full capacity. Since 212, the previously technically and legally distinct treatment plants have been operated under a joint permit issued to MD Papier GmbH. This was a prerequisite for better using free capacities in the two treatment plants and signifi cantly reduced violations of limit values during the rest of the year. To respond to the increasing COD load in the infl uent to the LWC treatment plant, resulting from the rising volume of sheet production, we are planning to additionally install a third treatment stage in 213. We decided on a two-stage pressure-less ozone treatment with subsequent biofi ltration. The project has already been started with funds from the environmental innovation programme of the Federal Environment Ministry. Wolfgang Ohnesorg, General Manager Wolfgang Haase, Manager Environment UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212 3

4 Air Waste Energy generation is the primary source of airborne emissions from the paper mills. Through improving the energy effi ciency of our production lines and using nothing but natural gas as a fuel we were able to reduce emissions over the years. As far back as 29 the out-dated bark boilers of the LWC line were shut down to signifi cantly reduce particulate, SO 2 and NO X emissions from coated paper production. In April of 21, a new gas and steam turbine power plant service the whole site went on line, replacing eight gas fi red steam boilers which are now used as a backup source in the event of a power plant failure. Thanks to the effi - ciency of combined power and steam generation, the new power plant is much more effi cient (by up to 85% in terms of primary energy use) than steamonly boilers. There was a rise in CO 2 emissions generated from the site resulting from the high share of self generation, but owing to the high energy yield of co-generation the paper mill s total CO 2 emissions from energy generation are now much lower than when all of the power was supplied via the public grid. UPM Plattling has set itself the goal to further reduce specifi c CO 2 emissions by effi cient energy use. To this effect several measures were implemented in 212. We replaced the ventilation system of the effl uent treatment plant, optimised the vacuum system of the PM 1 and reduced the hood exhaust air temperature on the drying section of the PM 11. EMISSIONS FROM THE POWER PLANT 212 FOSSIL CARBON DIOXIDE, CO 2 % Limit value (mg/nm³) CO NO X 5 (variable depending on supplementary fi ring) 26.4 EMISSIONS FROM THE STEAM BOILER 212 Limit value (mg/nm³) CO NO X In keeping with the concept of circular economy, the majority of production waste is recycled locally. Hazardous wastes are forwarded exclusively to specialised waste management companies to be disposed of in accordance with legal requirements. The specifi c volume of waste corresponded to that of the previous year. With 99.97% the recovery rate in 212 reached the same high level as in 211. No waste went to landfi ll. DUST % Mean value measured 212 (mg/nm³) Mean value measured 212 (mg/nm³) The increase in particulate emissions (from the steam boiler and the SC portion of the power plant), which is computed from the amount of fuel burnt, results from the commissioning of the power plant. The same goes for NO X and SO 2, with an improvement in SO 2 emissions after three years of power plant operation. In 212 the method for calculating the NO X load of the power plant was revised, increasing the load in comparison with previous years SULPHUR DIOXIDE, SO 2 % NITROGEN OXIDES, NO X % LWC SC All graphs show the specific emissions per tonne of paper, in comparison with 22 and 28 respectively. 4 UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212

5 Water UPM Plattling draws 99.4% of the water required for the production process from the Isar, with the remaining.6% to cover temporary demand peaks coming from a well on the mill premises. The process water is fi rst used for cooling and then for the paper production process. The effl uent treatment plants of the LWC and SC production lines operated stably during the whole of the year. However, process-related problems caused limit values to be exceeded as follows: On the SC line, the limit value for N was exceeded in January and April. This was due to the dissolution of nutrients and beginning nitrifi cation during a plant standstill. In the period February March the permissible discharge volume was sporadically exceeded. This was due to effl uents from fresh water treatment, fi ltrate from the sludge dewatering in the LWC line and power plant effl uents being discharged into the treatment plant. In the period May December (joint discharge), the temperature of the effl uents was too high in August and in September. We will look into the capacity of the cooling equipment and possible expansions. In addition, we improved the programme for need-based cleaning of the cooling towers. In December the permissible discharge volume from the paper maschine was exceeded. The limit values for N and P were exceeded because of the dissolution of nutrients and beginning nitrifi cation. However, the discharge volume and thus the resulting loads were very small. In all relevant cases we agreed appropriate corrective action with the authorities to prevent violations of limit values in future. EMISSIONS MAY DECEMBER 212 Parameter Unit Limit value Mean value May Dec 212 COD BOD N tot P tot AOX T C EMISSIONS UNTIL APRIL 212 CHEMICAL OXYGEN DEMAND, COD BIOLOGICAL OXYGEN DEMAND, BOD ADSORBABLE ORGANIC HALOGEN COMPOUNDS, AOX NITROGEN, N TOTAL INORGANIC PHOSPHOROUS, P TOTAL PROCESS WASTEWATER VOLUME m 3 /d , , , 2.5 5, LWC SC Limit value, LWC, until April 212 Limit value, SC, until April 212 UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212 5

6 Environmental parameters 212 The fi gures related to production as well as raw material and energy consumption are published as aggregated fi gures on group level in the UPM Corporate Environmental Statement. * Incl. moisture COD: chemical oxygen demand BOD: biological oxygen demand AOX: adsorbable organic halogen compounds MD Papier GmbH (LWC) Production capacity Paper Approx. 4, t (2 paper machines) Raw materials and additives Energy Emissions to air Water intake Discharges to water Waste* Recovered paper Roundwood Chemical pulp Pigments Process chemicals Operating supplies Fossil fuels Purchased power Carbon dioxide, CO 2 (fossil) Nitrogen oxide, NO X Carbon monoxide, CO Sulpur dioxide, SO 2 Dust Process water Cooling water Process wastewater volume COD BOD 5 Phosphorus (total) Nitrogen (Inorganic) AOX Total volume of which Deinking sludge Fibre residues Biosludge Bark and wood residues Others Hazardous waste Recovery rate Rhein Papier GmbH (SC) Approx. 38, t (1 paper machine) See UPM Corporate Environmental Statement for more information 1% See UPM Corporate Environmental Statement for more information 215,583 t 71 t 33 t 1.7 t.13 t 4,85,23 m³ 4,97,297 m³ 86 t 69.5 t 2.3 t 15.8 t.57 t 14,629 t 35,242 t 12,748 t 15,517 t 39,72 t 2,51 t 52.2 t 99.96% 155,614 t 48 t 21 t 1.2 t.1 t 4,173,649 m³ 4,437,256 m³ 1,94 t 51.7 t 1.4 t 12.8 t.7 t 15,283 t 6,574 t 21,125 t 76,818 t 766 t 37.4 t 99.98% Size of mill area Built on or sealed 156,4 m² 147,3 m² 6 UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212

7 Performance against targets in 212 TARGETS AND MEASURES TARGET ACHIEVED? COMMENTS Water Reduce specifi c process water consumption of paper machines and auxiliary equipment by 5% in comparison with 21. Implement various sub-projects relating to internal water management. No Low capacity utilisation of production plants resulted in increased water consumption. Water and air Ensure compliance with permissible discharge limits. No Number of limit violations down by 6% in comparison with 211 Raw materials Reduce material losses through creation of monitoring concept and improvement of paper machine operation. Chemical use Continue exploring ways to reduce specifi c COD load of effl uents by changing chemicals used for bleaching groundwood pulp (PGW). Energy Reduce specifi c power consumption by 3 MWh per tonne of groundwood pulp through new grinding technology. Reduce energy consumption by 5, MWh/a through various technical improvements. No Yes Yes Monitoring carried out, but low capacity utilisation of production plants results in increased material losses. Successful industrial trial with alternative complexing agent Introduction of new groundwood technology postponed because of technical problems. Specifi c energy consumption reduced beyond target level. Current targets TARGETS AND MEASURES DEADLINE DEPARTMENT(S) RESPONSIBLE Water Reduce specifi c process water consumption of paper machines and auxiliary equipment by 5% in comparison with 21. Implement various sub-projects relating to internal water management. 12/214 Production, Fresh Water Treatment, Effl uent Treatment Water and air Ensure permanent compliance with permissible discharge limits. 12/213 Effl uent Treatment, Energy Generation Raw materials Reduce material losses by 1% through improved pulp screening and paper machine operation. Chemical use Continue exploring ways to reduce specifi c COD load of effl u- ents by changing chemicals used for bleaching groundwood pulp (PGW). Energy Reduce energy consumption by 1, MWh/a through various technical improvements. 12/213 Production 12/213 Production 12/213 Groundwood Pulping, Production, Energy Generation Environmental verifier s declaration on verification and validation activities REG.NO. FI - 58 Environmental verifier Dr. Detlef Nehm (DE-V-223), acting for TÜV NORD CERT Umweltgutachter GmbH, licensed for the scope NACE Code (papermaking), declares to have verified whether the site UPM Plattling (MD Papier GmbH und Rhein Papier GmbH) in Plattling, Nicolausstraße 7, Germany, as indicated in the Environmental Statement 212 of the mentioned site (registration number FI-58), meets all requirements of Regulation (EC) No 1221/29 of the European Parliament and of the Council of 25 November 29 on the voluntary participation by organisations in a Community Eco-Management and Audit Scheme (EMAS). By signing this declaration, I declare that: the verification and validation has been carried out in full compliance with the requirements of Regulation (EC) No 1221/29, the outcome of the verification and validation confirms that there is no evidence of non-compliance with applicable legal requirements relating to the environment, the data and information of the Environmental Statement 212 of UPM Plattling reflect a reliable, credible and correct image of all the activities of UPM Plattling within the scope mentioned in the Environmental Statement 212. This document is not equivalent to EMAS registration. EMAS registration can only be granted by a Competent Body under Regulation (EC) No 1221/29. This document shall not be used as a stand-alone piece of public communication. Plattling, 13 June 213 Dr. Detlef Nehm Environmental verifier DE-V-223 TÜV NORD CERT Umweltgutachter GmbH UPM PLATTLING, ENVIRONMENTAL PERFORMANCE IN 212 7

8 UPM Plattling MD Papier GmbH Nicolausstrasse Plattling Germany Tel Fax Rhein Papier GmbH Operating Site Plattling Nicolausstrasse Plattling Germany Tel Fax For further information, please contact: Wolfgang Ohnesorg General Manager Tel Wolfgang Haase Manager Environment Tel info.plattling@upm.com 7/213