pY f lIffLif Yf J YJ wl fBt

96
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Transcript of pY f lIffLif Yf J YJ wl fBt

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H o 0 oY i Cl n FJjtz PMfJpY b b tif pj fitf KKiif kJ f fifd Vx4n0h J fy0 L Jf f vhi hIiJifJtlW lIffLif 1l07Jj AYM 5 0f6 tJl JJJJf I 7i Lf tifY t Vt7fff crlj1U1 int SWiYk W0t V fui f2iR t lAi1j t Y1 91ttJi l A

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1 Opening and introduction at 9 00 9 30

2 Effluent discharge from different P P processes at 9 30 11 00

Coffee break at 11 00 11 30

3 Effluent treatment processes at 11 30 13 00

Primary treatment

Different secondary treatment solutions

Tertiary treatmentLunch

4 Effluent treatment processes continue5 Sludge dewatering

Break

6 Bleach filtrate recycle in kraft pulp mills7 Zero liquid discharge case presentation

at 13 00 14 30

at 14 30 15 00

at 15 00 16 00at 16 00 16 15

at 16 15 16 45

at 16 45 17 30

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UAJv

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VEOLlA Environnement Turnover Partition

45 20 15

Waste civil workwater FCC Spain

9

11

One Group 4 Business Unitsl Ll

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Veolia Environnement 0

Icormex

VE LIAEnvironnement

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JVeolia Water

Systems

1Veolia Water

Systems Brasil

HPD Aquaflowl Ll

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Veolia KeyF ures 112

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HMH

Data source VE results 2003l Ll

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l LlV i i

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UAJv

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y p ji AiVY kYt0 ytlfiYffYi 11Fhi tO hYf Xic h

HiY df ifjWiHui y fP1

IlfJR0Yfr

Pulp Papero Aracruz Veracel Klabin Cenibra

VCP Champion liP Bahia Sui

Arauco CMPC Cartiere BurgoKimberly Clark Stom Enso

oUPM Kymmene Myllykoski

VW5 The Partner of Industrials

Others marketso HPI CPIo Metal treatment

Powero Microelectronicso Automobileo Pharmaceuticals Cosmeticso Food Beverage industry l Ll

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Present in LA since 1993

Operational Merge of OTV Brasil and USF Brasil

Two business lines

D B

Solutions

2003 revenue Euros 44 million

304 employees 50 in Brazil

40 engineers

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Veolia Water Systems Offerf y Sk

Design Build CapabilitiesDesign build solutions for municipalities and industrial

customers

Integrated water and wastewater systems wastewater

reuse sludge treatment

Engineering Construction services for Turn Keysupplies

Problem identification and treatability analysisProcess designBasic and detailed engineeringProject ManagementLocal equipment manufacturing

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AQF Global Total Water Management

FRavv iVa er mreafrr tEjnJ

Reve Qi mo is

SditerLiWik t r

rFr atmeoi

Stock Preparation and Paper Board Machine

4

P pri

Boco Machin

SV All OAF

i j 9 t litt rip

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III Aquaflow Ltd by VEOLlA Water Systems

l1li USF Aquaflow Ltd

1999

1997

iii Ahlstrom Aquaflow Ltd 1989

III Ahlstrom Corporation 1987

III Enso Gutzeit Oy Stora Enso 1962

AQUAFLOW l LlV i i

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Mr Heimo TOIVIAINEN

III VWS BUSINESS DEVELOPMENT DIRECTOR IN THE

P P INDUSTRY

III 1989 2004 MANAGING DIRECTOR OF AQUAFLOW

III STARTED IN 1974 IN EFFLUENT TREATMENT IN

THE P P ENSO GUTZEIT STORA ENSO

AHLSTROM

AQUAFLOW

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Worldwide Pulp and Paper Production

l1li PRODUCTION

182 million ton pulp per year330 million ton paper per year

l1li WASTEWATER TO TREATMENT

About 30 35 billion m3 wastewater generated peryearAbout 25 30 million ton COD generated per year

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Factors Impacting on Wastewater

Composition and Characterists

1 Fibre raw material

2 Pulping and paper making process

3 Process status

4 Process operation

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piA j Y i kC

Yk0 i SVYf fiX42 tii hJ WYii d

iP i V W yJ N iiN PI A

ihlii P

Yh fPJf Pulping and Paper MillsMarket pulp mills

Raw material Pulp to free market or

To own paper mills

Integrated mills

Raw material Paperproduction

m m m m m m m m m m m m Pu I p

Non integrated paper millsRaw material r j

l

@tf J JPulp l Llv

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Pulping Processes

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piA j Y i kC

Yk0 i SVYf fiX42 tii hJ WYii d

iP ii V W yHY J N Z h

n i3Y Paper Grades

I Coated woodfree

7 7

I Kraftliner

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c Y ifH t1ihlWi xj f

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ll 0lJBleachedKraft Pulping

Wood handling CookingandW1lshing IScreeting

Oxygendelignification

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Bleached Kraft Pulping Discharges

Process COD

kg t pulpDebarking 0 10

Brovvnstock area 0 7

Bleach plant 25 55

Evaporation condensates 3 15

Spills 3 8

Total 31 95

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Main CompositionOrganic

Suspended

Dissolved

Inorganic

lignin derlVatilles

o bh ltllrlar 01 ra es sugilrsOnrga Ie aCh s

Chlor t cloIna e 9jlnJosNutrients N PJ

x c s A i y s P i Llv

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

J N iiN PI Ai

hA JH6 I0P PV iPJ

JA

Debarking

Wet vs dry debarking processWet debarking has higher discharge figures

Softwood higher Hardwood lower loads

Wastewater containsTSS bark residuai fibres inorganic matter

COD BOD dissolved and suspended material from logsNutrients P and N

Toxic compounds resin acids fatty acids

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Kraft Pulp Bleaching

GENERAL

Objective to bleach pulp from brown to white with oxidationchemicals Chlorine Dioxide Peroxide Ozone

Many processes most typical is Elemental Chlorine Free ECF

bleaching using Chlorine Dioxide

Total Chlorine Free TCF processes employ Peroxide Ozoneas oxidation chemicals

Bleach plant excess filtrate normally sewered since containsChlorides Heavy Metals and other inorganics that mayaccumulate in recovery cycle

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

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hA JH6 I0P PV iPJ

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Kraft Pulp Bleaching

BLEACHING WASTEWATER COMPOSITION ANDLOADS ARE DEPENDENT ON

Washing loss Amount of COD entering the Bleach plantII Kappa factor Amount of lignin in pulp

III Cooking process Modified cookingIII Oxygen Delignification 00

iii Bleaching process Chemicals usedl1li C stage

III Elemental chlorine stageII Chlorine Dioxide

III TCF bleaching l UAv

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Summary Bleached Kraft Pulping

Most common pulping process

Main organic load originating from bleach plantAbout 50 of the COD is caused by lignin productsthat are non or slowly biodegradableChlorinated organic compounds in bleach planteffluents AOX

Toxic compounds resin and fatty acids in

debarking and bleach plant effluents

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Sulphite Pulping

P ibarklng q9Qki E 7J III sllit19 BI tIi Q J iiJgPulpWood

Sulphurl99k lni liQu r

prm @ti m EWPQtion

1 lqtwBQlI

Totreatrrent

obarkjngemuentSmpendedE oiids

OrQanir rJ6ter

Extradjls

Nurients

CondensateAcgiCacidFurfural

Eleach ftltrate

CoIo0ffldsubsarces

NUtrientsMelais safts

r Vl QHJAV

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Sulphite Pulping Discharges

Dissolving pulp mills may have high dischargesHemicelulose

Cooking process generally driven further than inkraft pulping why bleach plant discharges are

normally lower

TCF bleaching common no chlorinated

compoundsCondenstes contain high amount of acetic acid andfurfural

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Summary Sulphite Pulping

Common in Central Europe and China but beingoutphased in other areas

Main organic load originating from condensates andbleach plantCondensates high in COD concentration

Acetic acid and furfural in condensates

Toxic compounds resin and fatty acids in

debarking and effluents

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

J N iiN PI Ai

hA JH6 I0P PV iPJ

JA

Mechanical Pulping Processes

Processes include

Chemi thermomechanical pulping CTMPThermo mechanical pulping TMP

Stone Groundwood SGW or GW

Pressurised Groundwood PGW

Mechanical defibration in refiners or with stone

Chemical pretreatment in CTMP process Na2S03and or NaOH and Na2C03

Typical for mechanical processes is high yield on

wood

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Mechanical Pulping Processes

Mechanical pulping is normally INTEGRATED with

paper production

Newsprint paper TMP paper machine

Journal paper GW TMP paper machine

Some CTMP mills are stand alone others integrated

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P Process

CHIPWOoSHING IMREGNATION lSTSTA REFINING 2ND STAG REFlNING H RECOVERY

IPSCD 82 21 MN CD 82 11 MN

FRESHSmmmn

1 T

1 C

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Wastewater from Pul and Pa er P

wondH dling

DebarkingSuspended solids

Organic matter

Ex rEiet ves

Nutrients

P Process

Chemicals

lhipWashing

Chip WashingWood

OrganicmafferNutrients

Fi finjng

tieFl ecQle Y

Chemicals

IWashinj J BI j1JhinriTo board machine

Totreatm

Excess process water

Fibres

SulphurcompondsOrganicmatter

Nutrients

r Vl fj l lAV

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Mechanical Pulping Discharges

Discharges from mechanical pulping processes are

primarily dependent on

Pulp yield

Pulp bleaching method

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ix Ldfi hLRJtt0 y XiZP fY s 1Fh111t 0tMJ f 1iI s

HiY df ifjfJpicuf 1 UfyjfP

1 l pJ5yJ

vhpJJA

Recycled FibreTwo main cartegories

Mechanical cleaning pulping of wastepaperlboard onlyTestliner

Corrugated mediumUncoated board

Mechanical cleaning and de InkingTissue

Printing and copy paperMagazineCoated board and cartonboard

Market DIP

Wastewater quality much dependent on wastepaperqualityMay have almost closed water loops l Ll

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Recycled Fibre Processes

II

I

II

IIII

II

11

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

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Papermaking

In paper making processes water are recirculated ata high degree only excess water whitewater andrejects are normally discharged

Wastewater contaminants originate from

PulpRefining of pulpSizing agents starch

Fillers and Coating material caoline CaC03 etc

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Paoermakina

1OJDLY

QUu o aid DJ

HORTC CU ON

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2 A

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mmmmmmmmmmmmmmmmmmmmmmmm mnm

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

J N iiN PI Ai

hA JHlit P

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Special Features and Critical Topics

General

All mill departments must be reviewedWhich processes are applied debarking pulpingbleaching etc

Mill status old mills have generally considerablehigher discharges than new

level of spill control

level of water conservationReview actual variations of loads

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piA j Y i kC

Yk0 i SVYf fiX42 tii hJ WYii d

iP i V W yJ N iiN PI A

ihlii P

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Special Features and Critical Topics

Process specific issues

Bleached kraft pulpingMost common chemical pulping processMain portion of organic load from bleachingBleach plant COD hard to degrade biologicallyOrganic load mainly dependent on wood specie kappa to BP andbleaching process

Unbleached kraft pulpingLevel of spills and washing loss of inmportanceWater use sometimes very high

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Special Features and Critical Topics

Sulphite pulpingMain organic load originating from condensates and bleach plantCondensates high in COD concentration

Acetic acid and furfural in condensates

Toxic compounds resin and fatty acids in debarking andeffluents

Mechanical pulping integrated with papermakingWastewater loads originates primarily from mechical pulpingHigh amount of collodial matter

Inorganic matter clay if filiers or coating applied in papermaking

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Special Features and Critical TopicsProcess specific issues

Recycled fibre

Discharges vary within wide range depending on technical

status

Some mills are almost effluent free

Non integrated papermakingLow amounts of organic matter

Wastewaters may be colored if colored paper are producedrvl ffA

V

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TIm

To

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VA AISU

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Aquaflow Competence Centerin the pap Industry

VE lIIAViin

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rx Ldfi hLRJl 0i 6fZf Y iJJ42NJlfy NJtr53 iirYJiP iiV U V W Y

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jWPj Content of Presentation

PRIMARY TREATMENTII P P charasterlstlcsIII EquipmentIII Process selection

SECONDARY TREATMENTII P P charasterlstlcsIII MBP processIII Process selection

TERTIARY TREATMENTIII Need of tertiary treatmentIII Chemicals and processes

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What is Typical for Primary Treatment inP P Industry

l1li High and variable amount of suspended solids in the inlet

effluent

III good functioning of primary treatment is emphasized in specialsituations start ups stops and problems in the mill

III occasionally high amount of heavy inorganic material in the

effluent fillers coating DIP sludge lime mud

III poor sedimentation in certain effluents GW TMP CTMP coatingagents

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What is Typical for Primary Treatment inP P Industry

l1li Neutralization is normally requiredIII all the time

III or only for washing waters in mill stops

III Cooling is normally requiredIII effluent temperature is normally 40800C

III wood chips extractives and biological foulingl Ll

V

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Pri

Aquaflow Equipment

III Bucket screen

III Primary clarifiers

III Primary flotations

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Pri Treatment

Removes oversize solids which may interfere later

processes I I

I

go

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Pri

Primary Clarifier

I Walkway

Ec

Orivemechanism

Sludge pocket Overflow weir

Cone scraper

Rake arm Cage

Center column

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AF Float Flotation Unit DAF

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III Circular

III lJ 3 8 m up to 24 m

III Depth 1 3 m 1 8 m

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iii RectangularIII 4 2 m x 4 3 m 18 3 m2 up to 7 2 m x 14 7 m 105 m2

III Depth 1 3 m 1 8 m

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Priw

Equipment are Designed Just for P P

Industry Needs

III Robust equipment for 24 hid 365 d a

III Maintenance designed for 1 line systemsIII Capabilities to handle

III High 55 capacityIII Heavy sludgeIII Hot effluents

III Corrosive effluents

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iJ XjJ0it SYk H ih

h7 tk3liJiiLgZfCi H3f i7Y HA

Ni f iA chsAZ j 0 W I

Primary Sedimentation Selection Criteria

Low operating costsGood buffer capacity for solids

Simple processSuitable for very high solid contents

Big footprintLong retention time anaerobic acidification smells floatingLong suction line for sludge plugging of primary sludge

pumps

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S iYii lhi i LRJ if i0S hSj0 f01hli BNX

18 144ikN S5f30L jfiYi4P VxuW YX

Primary Flotation Selection Criteria

Pri

Small footprintNot sensitive for gases no anaerobic acidificationless smells

Good function with chemicals good results with small

light or charged particlesLower civil costs

Higher operating costsNo buffer capacity for solids

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C n W A ifhN WYii d n b

h X i i CC

PtiAi0 fiiq JihhwY

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lflExpected Purification Results in nmaryuSedimentation without Chemicals

Effluent type 55 content after

sedimentation mg l

Kraft pulp 70120

Paper board 40150

uncoated

Paper board 100300

coated

TMP GW 150400

CTMP 3001000

DIP 50200IIVEQ

Semichemical NSSC 3001000V it

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Treatment0 0 2

cfi0V b 0 i JR

Ii h fd N F b LM

vc01 Y i U YJYxt J jpif A J i

n hY ii0iiyfhh n

What is Typical for Secondary Treafmertf6ift L

P P Industry

Relatively high COD concentration 500 13000 mg l

High temperature 35380C

Normally lack of nutrients 7 N P must be added

Some effluents are very sensitive for filament problemsIII VFA sugars resin and fatty acids TMP CTMP RCF OCC NSSCIII variation of produced paper or pulp grades

Variation of harmful chemicals for biologyIII biosidesIII washing agents and dispersing agentsIII coloursIII hydraulic oilIII black liqueur and soap spills chemical pulp miils

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i

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Minimum Biosludge Production MBPPrimary Clarifier Aerobic Process Secondary Clarifier

I IXXXXI1 1

PrimarySludg

Air02

WasteActivatedSluclae

l fJAV i i

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Minimum Biosludge Production

Dispersed Bacteria in MBP Reactor

MBP

1st stage in the food chainl Ll

V

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Minimum Biosludge ProductionColony of Stalked Ciliates Eating

MBP

2nd stage in the food chainl Ll

V

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Minimum Biosludge ProductionCiliates and Suctoria

MBP

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Minimum Biosludge ProductionRotifers

MBP

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Minimum Biosludge ProductionSludge Production Factor

MBP

Sludge p oduction factor

Slart g MBP mod

C

I

ml

1

I

I

o

g g0

g g g0

g g g g0 0

0 0 00 0 0 0 0

0 0 0

Month

000

O

020

oo

O 15

0 10

105

000

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Treatment0i i iH

Minimum Biosludge Production MBPBenefits of MBP

l1li 30 50 lower sludge yieldl1li good settleability lexcellent effluent qualityl1li stable operation in fluctuating loading conditions

l1li less chemicals in sludge dewateringl1li higher dry solids in slude dewatering

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Treatment iMW

ifN y iJ

fk4VLfffjy Jftf iAjfl YjY

V G 0 1i 1 p

MBBR Moving Bed Biofilm Reactorv

Process

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Treatment

MBBR Moving Bed Biofilm ReactorProcess

IIIIThe process is based on the biofilm principle and the core of the

process is the biofilm carrier elements made from

polyethylene or polypropylene with a density close to that of water

IIIIIThe carriers are designed to provide a larqe protected surface for the

bacteria culture

IIIIThe reactors are filled up to 67 of their volume with these carrier

elements

IIIIThe biofilm carrier elements are kept suspended in the water by air

from the diffusers in the aerobic reactors and by means of a mixer in the

anoxic reactors

i iz ii AMNW i

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74ljII0 JA y 1h0 Y fk Y 1 YcVtP i CA Ai s

i41Il IfR ProcessJk il

Moving Bed Biofilm Reactor

j X iti

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Treatment

i 0 JhPi1 9 i N ld i Jb 0 I

W D T vJt d

j Lifd VViti cA f oK f

MBBR Moving Bed Biofilm ReactorProcess Different Carriers

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TreatmentUL d Ri

MBBR Moving Bed Biofilm Reactor Process

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TreatmentfS y i Xi

MBBR Moving Bed Biofilm ReactorProcess Mixing in Reactors

Aerobic reactor Anoxic reactor

v v

p000

o

60o

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Treatment ti 1@0 0 kMj iii

yn ti 1 04Y ifE iA t HB rJiJ2j1 Ttf ii t d

L Ddj08LiiA Y f J

PjM XiiJ Wk jPs

MBBR Moving Bed Biofilm Reactor ProcessMBBR as solebiotreatment

MBBR as pretreatment

roughingBAS

MBBR as posttreatment

polishing

MBBR in

activated

sludgeHYBASjIFAS

l 1i M

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Q iJ C Y

MBBR Moving Bed Biofilm ReactorProcess Future Expansion

100

kgd

Increase filling degree by adding more

biomedia

200

kgd

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Needs of Tertiary Treatment

III environmental requirements for

III PhosphorousIII COD

IIIIAOX

III Colour

III High SS

III 80D

III Nitrogenl Ll

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Needs of Tertiary Treatment

III Renovation of old lagoon based biological processes

III Much lower investment costs than completely new

biological process

IIIIPolishing process for difficult or filamentous sensitive

effluents

IIIIAfter high loaded processes

WELL DESIGNED TERTIARY TREATMENT GIVES

SAFETY FOR TOTAL TREATMENT PROCESS l LlV

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Processes

III Chemical coagulation and or flocculation

III Filtration

II Sand filtration

II Microfiltration

II Membrane processes

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Chemical Coagulation and Flocculation

Coagulation chemicals used

III Aluminium sulphate AVR optimum pH 5 5 5

III Polyaluminiumchloride PAC optimum pH 5 5 5

III Ferric sulphate optimum pH 4 5

III Ferrous sulphate H202 Fenton or Fennotriox

III Optimum pH 3 3 5

III Organic coagulantsillUme

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Chemical Coagulation and Flocculation

Flocculation chemicals used

III Polyacrylamides PolymersIII Bentonite

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Chemical Coagulation and Flocculation

Alternative separation processes

l1li FlotationIII Very reliable process for P P effluents

II1II Sedimentation

II1II FiltrationIII Can be alternative only for low COD effluents

III Not suitable for filamentous bulking problems

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VM JY PWiX rJfhWp i1 fAsp 5AffU

Wf i0 jY jZft t41ijf3 JD

JyF rjtyytHjd fJ

YiFiltration Process

IIIIIPossibility to very low 55 content P N

IIIIOnly for low 55 content effluents

IliSand filtration microfilters

l1li No reduction of dissolved substances without

l1li chemicals

III Membrane processesl1li selective treatment based on molecular size

l1li high investment and operating costs

l1li reject disposall1li fouling

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UAJv

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P T Riau Andalan Pulp Paper Sumatra Indonesia

Kraft pulp mill 330 000 m3 d flow

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2 IiVR

I P 21t iiifJ Ji ygiik1 NW0J1

y8YJ Y Yil fhW

JWt 3V1

Stora Enso Port Hawkesbury MillCanada

y Zy

Nova Scotia

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J iiyxY MAt w iiifJ0fJM d dY lW Jh 1

yf 10Yj Ycii dYfP AhPd hVY d VYh

1 33V ir 1i flY

Stora Enso Norrsundet Mill Sweden Modification ofAerated Lagoon to Advanced AST Plant

MBP selector process

chlorate removal

selector pluf flow

SVI60

70 mg I

Sludge yield 0 14 kg kg COD

All targets of the mill were met

excellent treatment results

excellent availability

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Celulosa Arauco y Constitucion S A Valdivia MillsChile

MBP Selector Process

Enchanced chlorate

removal

Selector plug flow

Tertiary treatment

Yidfi1 i G A Jd j l

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iiAZ lf 2

l JJEW0J G fij fSH6

h Hb

ytelulosa Arauco y Constitucion S A

Nueva Aldea Mills Chile

Production 555 000 t a of pine and eucalyptus pulp l fJAV i i

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Mondi Ltd Richards Bay Pulp Mill South Africa

Minimization of Polution ofthe Rebuild Mill Based on BAT

Treatment

Aquaflow MBP selector process

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1 JR

YjjjJ iJj lpY iZ0jlF 4 0itiiJptt fiit 3 Js

V JiiJSJt vi6kQj A Y

j sPF Hi01i3I

11W y

0

Kappa Kraftliner Pitea Sweden

Production 700 000 ita of paper and paperboard500 000 ita of pulp kraft linerboard l Ll

V

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A o hVY j4f bfh jJ v

f F0 Anilfji8 J k XV S W WXZs YhmSij A Y

1ly WiA Vfv j 01w

8tora Enso Celbi Pulp Mill Portugal

Production 295 000 Adtla ECF bleached

eucalyptus market kraft pulp l Llv

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it 3 i iYGN Wiil

yCd lJ 5t yYy 1 Vi

2M t fhA M J0 w 1 y S 1iFW

Two Stage MBBR at Backhammar Kraft Mill Sweden

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Pro

Activated Sludge treatment BAS

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o 0 JRY 4f2Nf F0 Anilfji8 J k XV S W WXZs YhmSij A Y

1ly WiA Vfv j 01w

8tora Enso Varkaus Mills Finland

Aquaflow s AF Float tertiary flotation planttreating 60 000 m3 d biologically treated effluent

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J1

i0t101Jk gvkk4 1 10

iAj V

1 5

M reallielahti Mills Finland

AF Float 9 5 1 3 tertiary treatment DAF final

protection against sludge bulking problemsChemical COD and P removal r V

rrA