ENVIRONMENTAL PERFORMANCE 2011 UPM, Kaukas

ENVIRONMENTAL PERFORMANCE 2011
UPM, Kaukas
UPM in Kaukas
The Kaukas mills are located on the shore of Lake
Saimaa in the city of Lappeenranta in Southeast Finland.
There are several UPM production facilities and units in
the mill area, including a pulp mill, paper mill, sawmill,
UPM Living, the Research Centre and Kaukaan Voima
Oy.
The Kaukas pulp mill produces bleached softwood and
birch pulp. Some of the softwood pulp is used by the
Kaukas paper mill. The paper mill manufactures coated
magazine paper on two production lines. The Kaukas
sawmill manufactures sawn redwood, part of which is
further processed into planed products at Kaukas.
Kaukaan Voima Oy (KauVo) has a biofuel power plant in
the Kaukas mill area. The power plant generates heat
and electricity for the Kaukas mills and the power company Lappeenrannan Energia Oy. 80% of the district
heating energy required by the town of Lappeenranta is
generated using green biofuel.
UPM Kaukas
Paper Mill
•Production capacity
610,000 t
•Products
Coated magazine paper
UPM Research
Centre
•Production capacity
•Personnel
500,000 m of
156
3
sawn redwood
•Personnel
•Personnel
465
Kaukaan Voima
170
•Production capacity
Pulp Mill
UPM Living
•Production capacity
740,000 t
•Production capacity
30,000 m3 of
385 MW
•Products
steam, electricity
and district heating
•Products
further-processed
•Personnel
Softwood and birch pulp
timber
2
•By-products
•Personnel
Tall oil, turpentine, steam, electricity
11
•Personnel
240
2
UPM Kaukas
Sawmill
UPM, KAUKAS, Environmental Performance 2011
UPM CORPORATE ENVIRONMENTAL STATEMENT 2010
UPM paper and pulp mills
This publication, UPM Kaukas Environmental Performance in 2011, is the
mill’s appendix to the shared Environmental Statement 2011 for UPM paper
and pulp mills. The UPM Environmental Statement, together with the mill
appendices, forms UPM’s joint EMAS statement. The Environmental Statement for UPM pulp and paper mills is available at www.upm.com.
UPM’s next joint EMAS statement will be published in the spring of 2013.
The EMAS covers the Kaukas pulp mill and paper mill.
share an environmental permit which includes waste­
Kaukaan Voima’s environmental activities are not
water treatment, waste management and a landfill.
included in the scope of the EMAS, but KauVo’s environmental issues are being managed in a similar manner to
Operations in the Kaukas mills are based on the latest
those at the Kaukas mills. The UPM Research Centre is
production technology, excellent professional skills and
not included in the scope of the EMAS. There is a sepa-
close co-operation with clients. Other prerequisites for
rate environmental system for the Kaukas sawmill.
cost-effective, high-quality operations are the contributions made by employees and ongoing training. Multi-
All of UPM’s research activities are managed at Lappeen-
skilled employees are able to handle a variety of tasks in
ranta.
a flexible manner, so the mental and physical wellbeing
of staff is important. Wellbeing is supported by making
Kaukas is a constantly developing mill site — UPM plans
healthcare services and leisure activities available to
to build a liquid biorefinery in the area which will pro-
employees, for example.
duce biodiesel manufactured from tall oil for use in vehicles. Construction work will begin in the summer of
The mills also play an active role in the surrounding soci-
2012, and the refinery will be completed in 2014.
ety. For decades, the mills have invested in co-operation
with educational institutions and other stakeholders, and
The integrated mill site enables the efficient use of wood
also provide financial support for leisure activities for
raw materials, energy supply and logistics. The mills also
young people in the area.
UPM Kaukas
•Certificates
Quality Management System ISO 9001
Environmental Management System ISO 14001
EMAS Eco Management and Audit Scheme
PEFC Programme for the Endorsement of Forest
PEFC/02-31-80
Promoting Sustainable
Forest Management
Certification Schemes and FCS Forest Stewardship
www.pefc.org
Council Chain-of-Custody Standards
•Ecolabel
European Union Ecolabel:
The products are available on the UPM website at
www.upm.com > Responsibility > Principles and
Performance > Certificates
FI/11/001
UPM, KAUKAS, Environmental Performance 2011
3
Environmental year 2011
2011 was similar to previous years in terms of environ-
to continue building the load-bearing bottom structures of
mental performance. All the mill emissions complied with
the landfill each year so that the entire Haapalahti part
the permit conditions.
of the landfill area will eventually consist of load-bearing
structures. Wood and energy wood is being stored in
UPM launched its Clean Run programme in 2011,
this area. It is also an intermediate storage area for
which aims to reduce exceptional emissions at UPM.
waste which is to be reused.
Clean Run was launched at the integrated pulp mills in
2011, and paper mills were included in the scope of
An independent company measured air emissions at the
the programme in early 2012.
end of the year. Most air emissions had decreased yearon-year.
A new five-tier classification system has been created for
environmental non-conformances, which is based on
Environment-related feedback received includes seven
their environmental impact. A larger number of non-con-
complaints about odour, one notice about a snag in a
formances will be recorded than previously as a result of
shipping channel, one complaint about noise, one notice
the change. The new reporting tool will be available for
about the water of Lake Saimaa foaming around two
use by the end of 2012.
kilo­metres from the mill effluent unloading site and one
complaint about boating problems at the Vehkataipale
A Clean Run audit took place at Kaukas in autumn, and
pumping plant canal. The amount of environment-related
an action plan was drawn up for 2012 based on the
feedback received was lower than the previous year.
issues observed. More internal non-conformances will be
recorded and studied than previously, and employees’
The high level of environmental performance has been
environmental awareness will improve.
achieved through several years of systematic work and
timely investments in various parts of the mill. These activ-
The waste volume disposed of in a landfill from the Kau-
ities will also be continued in the future.
kas mills, in wet tonnes, was reduced by 17%. The
paper mill’s waste volume increased by 4.9%, but that of
Paper mill
the pulp mill was reduced by 30%. The waste volumes
The volume of fibrous solid waste going to the wastewa-
are given as wet tonnes here because that is the form in
ter treatment plant was 15.9 tonnes per day, compared
which the waste is transported to the landfill. The waste
to 13.1 tonnes per day the previous year. The target
volumes listed below in this report are given as calcu-
level was 12.6 tonnes per day. The volume of excep-
lated dry tonnes. The pulp mill’s waste volume was
tional emissions was reduced to 129 tonnes per month
reduced because more waste could be reused. One
due to interruptions to production and sticky problems.
objective for 2012 is to further increase the volume of
The actual volume last year was 64 tonnes per month.
waste reused. Most of the waste disposed of in a landfill
The volume remained at the target level of less than 50
is coating colour sludge from the paper mill. The volume
tonnes per month during three months.
of coating colour sludge will be reduced through the
implementation of changes to technical processes or by
The water consumption level without the share of the
finding new ways to reuse the sludge.
ground wood debarking mill was 14.7 m3 per tonne —
the target level was 13.6 m3 per tonne. A water con-
4
The new field structure of the Tuosa landfill, which was
sumption level of 13.7 m3 per tonne was achieved the
implemented in 2010, was found to be functional and
previous year. The ground wood debarking mill’s water
the construction of the landfill using a mixture of fly ash
consumption was 1.0 m3 per tonne. Options available
and green liquor dregs continued in 2011. The plan is
to reduce the water consumption level were studied dur-
UPM, KAUKAS, Environmental Performance 2011
ing 2011. This was done by analysing where fresh
tions in 2011; consumption of process water remained
water could be replaced with filtrated water.
at almost the same level as that of the previous year at
43 m3 per one tonne of pulp. One of the pulp mill’s long-
The volume of fibrous waste going to the landfill was
term objectives is to reduce water consumption.
reduced to below the target level; the actual volume was
1.7 tonnes per day, compared to the target of 2.2
Emissions to water systems remained at the same level as
tonnes per day and compared to 1.5 tonnes per day the
in 2010. However, specific emissions were reduced pro-
previous year. The volume of waste containing coating
portionate to the production level.
colour going to the landfill was reduced: the actual volume was 7.2 tonnes per day, compared to 8.5 tonnes
Kaukas sawmill and UPM Living
per day the previous year. The challenging target level to
A work hygiene survey was conducted in 2011 at the
be met was 6.0 tonnes per day.
Kaukas sawmill. The amount of inhaled sawdust, volatile
terpene compounds in tree resin, endotoxins, mould fungi
Pulp mill
and bacteria were measured to find out the compounds
The pulp mill’s environmental objectives for 2011
to which employees are exposed. Noise levels at the GS
included reducing consumption of electrical energy by
line and in other parts of the production facilities were
1% per one tonne of pulp, minimising the amount of
also measured.
waste transported to the Tuosa landfill by burning all the
sludge generated at the effluent treatment plant, for
Work to prevent noise and dust was continued in 2011
example, and constructing the load-bearing storage field
through the improvement of maintenance equipment and
at the Tuosa landfill from ash and green liquor dregs.
activities.
Some of these objectives were achieved. The consumption of electricity per one tonne of pulp was reduced by
Kaukaan Voima Oy (KauVo)
4.3% to 0.67 MWh. As in the previous year, green liq-
Established in 2009, the Kaukaan Voima Oy biofuel
uor dregs, fly ash and kiln ash were used in the field
power plant uses wood-based fuels, peat and natural
structures at Tuosa landfill instead of the traditional earth-
gas. Less than 20% of the fuel used at the plant each
work materials. 62.6% of the green liquor dregs gener-
year is fossil fuel.
ated in 2011 were reused. Some of the sludge generated during the summer had still not been burned by the
Kaukaan Voima Oy’s operations in 2011 were environ-
end of the year, and combustion of this sludge will con-
mentally sound. Management of NOx emissions—
tinue during the first half of 2012.
which was determined as one of the company’s goals—
has improved since 2010: No permit condition levels
The logics of the wastewater treatment plant’s air com-
were exceeded during normal operation. 100% of the
pressors were updated and the air feed to the aeration
ash generated by the Kaukaan Voima power plant was
basin was automated so that the compressors now sup-
reused in 2011. Improving the reuse of ash is Kaukaan
ply compressed air based on the oxygen content of the
Voima Oy’s environmental focus area for 2012.
aeration basin. In addition, the aeration basin’s compressed air trunk lines were replaced. The aeration basin
In 2011, Kaukaan Voima consumed 1.8 TWh of fuel.
is the most energy-consuming part of the treatment plant.
These changes achieved a reduction of 10% in the electricity consumption of the compressors per one tonne of
COD.
The water system load did not exceed the permit condiUPM, KAUKAS, Environmental Performance 2011
5
Air
Air emissions remained below the permit conditions in
The total annual sulphur dioxide, nitrogen oxide, particle
2011. Malodorous gases were burned more than 99%
and fossil carbon dioxide emissions of the UPM Kaukas
of the time. There were short-term disturbances in the mal-
pulp mills and power production unit are shown in the
odorous gas combustion process, though, and the malo-
attached graphs. The proportion of the KauVo total emis-
dorous sulphur compound content (TRS emissions)
sions estimated for UPM from KauVo is included in the
exceeded the permit limit during these rare occurrences.
energy production figures.
However, exceeding the permit limit when a plant is
being started up or shut down, or in connection with dis-
The sulphur and particle emissions from pulp production
turbances, is not considered to be exceeding the permit
were clearly lower in 2011 than in 2010. Nitrogen
conditions.
oxide emissions were higher than in 2010 due to the
emissions INTO THE AIR
(including air emissions from Kaukas and the share of KauVo energy used by Kaukas)
GASEOUS SULPHUR, SO2
NITROGEN OXIDES, NO2
t/d
t/a
1500
2500
1200
2000
900
1500
600
1000
300
500
0
0
02 03 04 05 06 07 08 09 10 11
02 03 04 05 06 07 08 09 10 11
CARBON DIOXIDE
FROM FOSSIL FUELS, CO2
PARTICULATES
t/a
t/a
300
250000
250
200000
200
150000
150
100000
100
50
50000
0
0
02 03 04 05 06 07 08 09 10 11
02 03 04 05 06 07 08 09 10 11
All the permit conditions for air emissions were reached.
6
UPM, KAUKAS, Environmental Performance 2011
higher operating speed in pulp production and at the soda
INCINERATION OF MALODOROUS GASES
recovery boiler. Specific nitrogen oxide emissions per one
tonne of pulp remained almost at the same level as in 2010.
2011
Permit condition
% of time
% of time
Carbon monoxide emissions remained at the same level as in
Concentrated
99,8
98
2010 when taking into account the increased operating speed.
Dilute
99,2
95
There was an increase of approximately 7% in CO2 emissions
due to the increased operating speed. CO2 emissions from fossil fuels were reduced by around 4% because less natural gas
had to be used as a secondary fuel than in the previous year.
CO2 emissions produced from fossil fuels during energy production were reduced, as less natural gas had to be used in the
production of energy than previously. Most of the energy was
produced using biofuels.
UPM, KAUKAS, Environmental Performance 2011
7
Waste
The Kaukas mills’ joint environmental objective in 2011
SOLID WASTE (dry weight, t/a)
was to further reduce the amount of waste by 5% from
the previous year’s level. This objective was achieved:
The amount of waste in dry tonnes was reduced by 25%
and in wet tonnes by 17% from 2010. In 2011, 9536
Pulp mill
5800 t dry tonnes of waste was transported to the Tuosa landfill.
Paper mill 3728 t
670 t
The amount of waste generated during the process
KauVo
8 t
21,625 t
depends on the production level, which was higher in
Integrate
Tuosa
Reuse
% of
landfill
total
100 %
77 %
2011 than in the previous year. The most efficient way
pulp mill
67 %
to reduce the amount of waste taken to the landfill is to
paper mill
15 %
increase the reuse of waste.
The pulp mill generated 5800 tonnes of waste to be
taken to the Tuosa landfill, which was 36% less than in
2010. The paper mill’s waste volume increased by 16%
from 2010 to 3,728 tonnes because the sludge settling
WASTE (dry weight)
1000 t/a
tank at the treatment plant was emptied. The amount of
50
waste generated at that time is divided equally between
40
the pulp and paper mill. The volume of coating colour
sludge, which is the paper mill’s largest proportion of
process waste, was reduced by 2% from the previous
year. The pulp mill’s share of the waste transported to the
Tuosa landfill amounted to 60%. In dry tonnes, the largest proportion of waste was the green liquor dregs from
the pulp mill, and the waste that took up the most space
was the paper mill’s coating colour sludge. Research is
being conducted into the options available for reuse.
In 2011, 34,232 tonnes of the waste generated by the
Kaukas integrated mills was reused, which amounted to
77% of the total waste volume. Virtually all (99.96%) of
the waste generated by Kaukaan Voima Oy was reused.
67% of the pulp mill’s waste and 15.2% of the paper
mill’s waste was reused. Finding opportunities to reuse
the paper mill’s waste has proven to be quite challenging.
The storage field at the Tuosa landfill was further
expanded by approximately one hectare in the summer
of 2011. As in 2010, a mixture of green liquor dregs
and fly ash was used as the earthwork construction material and fly ash was used as the foundation material. The
plan is to continue expanding the field structure each
year.
8
11,937 t
UPM, KAUKAS, Environmental Performance 2011
30
20
10
0
02 03 04 05 06 07 08 09 10 11
Reuse
Tuosa landfill
Water
EMISSIONS TO WATER
The effluent load to Lake Saimaa remained below all the environmental permit limits. In 2011, the Kaukas mills consumed a
total of 76 million cubic metres of water from Lake Saimaa.
Annual
Permit
49% of this water volume was used as process water, and
mean value 2010
condition
was treated after use at the biological treatment plant before
COD, t/d
30,76
45
being returned to Lake Saimaa. These water volume figures
BOD7, t/d
0,59
5
also include the water used by Kaukaan Voima Oy.
Typpi, kg/d
334
500
The treatment plant is extremely well operated, which is dem-
AOX, t/d
Fosfori, kg/d
16,5
30
0,270
0,4
onstrated by the fact that the load figures are slightly lower
than the previous year. Biological oxygen demand decreased
by 13% from 2010 to an average of 0.59 tonnes per day.
Chemical oxygen demand decreased by 2% to 30.76 tonnes
per day. The oxygen demand figures represent the effluent
Kaukas generated a nutrient load of 334 kg of nitrogen per
load to the water systems. The efficiency of the biological efflu-
day and 16.5 kg of phosphorus per day to Lake Saimaa. The
ent treatment plant is demonstrated by its reduction ratio,
nitrogen load decreased by 11% and phosphorus load
which was 80% in the case of chemical oxygen demand and
increased by 1%. Nutrient loads did not exceed the permit
99% in the case of biological oxygen demand in Kaukas in
conditions in 2011.
2011. The treatment plant is therefore operating quite efficiently. Furthermore, the load at the treatment plant when the
The effluent loads of both the pulp mill and the paper mill
mill was being operated at a steady load was controlled bet-
remained within the BAT load limits.
ter than previously.
Effluent load
CHEMICAL OXYGEN DEMAND
BIOLOGICAL OXYGEN DEMAND
t/d
PHOSPHORUS
t/d
kg/d
6
75
60
5
60
50
4
40
45
3
30
30
2
20
15
1
10
0
0
02 03 04 05 06 07 08 09 10 11
BOD7/5
Permit
0
02 03 04 05 06 07 08 09 10 11
COD
Permit
Monthly limit
ORGANIC
CHLORINE COMPOUNDS
02 03 04 05 06 07 08 09 10 11
P
Permit
Monthly limit
Monthly limit
NITROGEN
kg/d
t/d
0,6
750
0,5
600
0,4
450
0,3
300
0,2
150
0,1
0
0,0
02 03 04 05 06 07 08 09 10 11
AOX
Permit
Monthly limit
02 03 04 05 06 07 08 09 10 11
N
Permit
Monthly limit
UPM, KAUKAS, Environmental Performance 2011
9
Key environmental figures for 2011
10
The environmental figures detailed in the table are based
The figures for production and the consumption of raw ¬materials
on the total production of pulp, paper and sawn timber
and energy are given as whole figures at the Group level in the
at UPM Kaukas.
Environmental Statement 2011 for the UPM pulp and paper mills.
Production capacity
magazine paper
610,000 tonnes
Pulp
740,000 tonnes
- Softwood pulp
- 420,000 tonnes
- Birch pulp
- 320,000 tonnes
Sawn redwood
500,000 m3
Further processed timber
30,000 m3
Raw materials
Wood, cooking chemicals, bleaching chemicals,
filler and coating pigments,
pigments in manufacture of paper
Included in Core Indicator report
Energy
Biofuels
Please see UPM Group Environmental Report
Fossil fuels
Please see UPM Group Environmental Report
Purchased electricity
Please see UPM Group Environmental Report
Air emissions
Sulphur dioxide SO2
376 t
Nitrogen oxides NOX
1439 t
Fossil carbon dioxide, CO2
151,651 t
Dust particles
78.3 t
Water consumption
Process and cooling water
75.9 million m3
Emissions into water
Effluent
37.3 million m3
BOD7
0.59 t/d
COD
30.76 t/d
Solids
1.44 t/d
Phosphorus, P
16.5 kg/d
Nitrogen, N
334 kg/d
AOX
0.270 t/d
Waste to landfill
Green liquor dregs
4800 t
(as dry matter)
Coating colour sludge
2724 t
Mixed waste
2079 t
Reuse
Cleaned wood waste
5987 t
(as dry matter)
Green liquor dregs and lime
4376 t
Fibre sludge
Sludge from effluent treatment plant
7561 t
Lime kiln ash
2443 t
Slightly contaminated soil
11,767 t
670 t
Hazardous waste
146 t
Factory area
200 ha
UPM, KAUKAS, Environmental Performance 2011
Environmental objectives for 2012
Kaukas integrated mills
•Carry out Clean Run programme as planned
VERIFICATION DECISION
As the accredited verifier, Inspecta Sertifiointi Oy
(FI-V-0001) has audited the UPM Kaukas environmental management system, the Environmental Performance in 2011 report and the environmental statement for 2011 for UPM paper and pulp mills.
Based on the inspection, it was noted on 2012-0510 that the UPM Kaukas environmental management system, this Environmental Performance in
2011 report and the information on UPM Kaukas in
the environmental statement for 2011 for UPM paper and pulp mills comply with the requirements set
forth in EU EMAS Regulation (EC) no. 1221/2009.
•Minimise abnormal emissions
•Improve all employees’ environmental awareness
Paper mill
•Reduce consumption of water; target for process water consumption: 15 m3 per tonne
•Reduce amount of solids taken to the treatment plant; target level:
12.6 tonnes per day
•Survey risks posed by all chemicals used at the treatment plant
•Research opportunities for saving energy
Pulp mill
•Improve reuse of green liquor dregs; target: reuse 42% of green
Kaukas sawmill and UPM Living
liquor dregs
Continue to work on preventing noise by improving
•Reduce odour emissions
maintenance equipment and activities.
•Reduce consumption of water; target: 40 m3 per tonne
•Reduce volume of excess steam
Long-term environmental objectives of the Kaukas
mills
Kaukaan Voima
The long-term environmental objectives of the Kaukas
•Improve reuse of ash
mills are to promote awareness of environmental issues,
reduce emissions and develop waste management.
UPM, KAUKAS, Environmental Performance 2011
11
Kaukas
FI-53200 Lappeenranta, Finland
Tel. +358 (0)2041 5161
Fax +358 (0)2041 5160
For further information, please contact:
info.kaukas@upm.com
www.upm.com
Mariitta Stenbäck
Manager, Communications
Tel. +358 (0)2041 54465
mariitta.stenback@upm.com
05/2012
Minna Maunus-Tiihonen
Environmental Manager
Tel. +358 (0)2041 54011
minna.maunus-tiihonen@upm.com