APP Sustainability Report 2008-2009 - Asia Pulp and Paper

Sustainable Products
Sustainable Products
Key Process inputs
We examine in more detail our two
pulpwood suppliers, who provide the key
raw material for our pulp mills, in chapter
five. All APP pulp and pulpwood suppliers
must meet the strict requirements of our
procurement policy, which demand that
both domestic and imported pulpwood and
pulp raw materials are confirmed / certified
from sustainably managed sources. APP’s
environmental credentials also include the
adoption of, and compliance with, a number
of national and international standards as
detailed in the product labelling section of
the report.
Pulping Raw Materials
Sustainably managed, plantation-grown
acacia and eucalyptus pulpwood log account
for more than 80 percent of our total pulping
raw material. There is also a small (and
diminishing) percentage of mixed wood
residues arising from plantation preparation
activities. We aim to be entirely supplied by
forest certified wood under the mandatory
certification scheme in 2015.
The predominant raw material used in
manufacturing APP’s high-quality printing,
writing and tissue papers is bleached pulp.
Our own short-fibre hardwood pulp, (Leaf
Bleached Kraft Pulp / LBKP), produced at
Indah Kiat Perawang and Lontar Papyrus
mills, must be augmented with a limited
percentage of purchased, imported longfibre
softwood kraft pulp (Needle Bleached
Kraft Pulp / NBKP) when used on most of
APP’s paper machines. This is necessary
to achieve enhanced sheet strength and
to improve the “runnability” or smooth
operation of our high-speed paper machines.
Recycling of fibre at APP’s mills is done in
several ways. Paper mills are able to re-pulp
any substandard paper that results from
machine operation or paper specification
problems, and to incorporate it into the
pulp raw material used in production. The
concern for the mill here is not any loss of
raw material, but the loss of operational
efficiency that this material – always referred
to as “broke” – represents. Two mills, Indah
Kiat Serang and Ekamas Fortuna, purchase
and recycle low-grade, post-consumer
wastepaper to produce packaging papers.
Graphic 2 - APP Raw Material Composition
* Imported fiber
third party verified
non- controversial
sources that meet
PEFC guidelines
verified legal origin
(legally harvested
under Indonesian law)
10%
25%
We also de-ink a small percentage of the
repulped post-consumer waste to produce
an upgraded pulp that can displace virgin
wood pulp fibre in some paper grades.
The Energy Mix
Our two integrated pulp and paper
operations, Lontar Papyrus and Indah Kiat
Perawang, together generate about 4 million
MWHr of electricity a year, in addition to all
of their process steam requirements. Lontar
Papyrus is essentially energy self-sufficient,
while Indah Kiat Perawang does require
some supplementary energy inputs. This
high level of energy independence is largely
due to the incineration of renewable, woodderived,
process-related by-products.
Much of this renewable fuel resource is in
the form of “black liquor,” which comprises
dissolved organic matter generated in the
pulping process, plus the associated and
recycleable pulping chemicals. Incineration
of this material as a concentrated liquor in
our recovery boilers enables us to reclaim
some pulping chemicals for reuse and
simultaneously contributes most of the
energy needed at both mills. Black liquor is
augmented as a fuel in separate, multi-fuel
boilers with bark and other wood waste
resulting from on-site wood preparation, and
with other purchased, waste-derived fuels,
such as palm-oil mills and sawmill residues.
30%
35%
recyled fibres
and paper
certified under one
of the various leading
certification programs:
LEI, PEFC, FSC* or PHPL
Indah Kiat Perawang mill converts a
substantial percentage of the pulp it
produces to paper on-site, and this requires
some supplementary use of coal to meet
that site’s overall power and process steam
needs. This coal-fired generation represents
approximately 20 percent of total energy
inputs.
To meet their energy requirements, APP’s
six paper mills rely to varying degrees
on a range of fossil fuels, including coal,
natural gas, diesel oil and marine fuel oil,
and on both purchased and self-generated
electricity. In the case of Pindo Deli mill,
70 percent of total steam and power
requirement is generated using natural gas.
At Indah Kiat Tangerang mill, waste heat
from a sophisticated gas turbine power
generation unit is used to augment coal-fired
process steam. In addition, wastewater
treatment plant sludge was also used at
Indah Kiat in 2008 and 2009 as a source of
renewable fuel.
We are currently in the planning and
development stages of enabling all our
paper mills to use wastewater treatment
plant sludge to produce energy. The
implementation will take place as soon as
practicable.
Chemical Inputs and Process Expertise
Most chemicals from the pulp cooking
process can be recovered and reused,
supplemented with a small amount of
fresh chemicals to maintain the correct
chemical conditions and concentrations
for subsequent cooking cycles. Our key
process-chemical inputs include salt,
limestone and sodium sulphate, and these
basic, un-reactive chemical compounds
are converted on-site to the highly reactive
chemicals needed for the cooking and
bleaching processes. The relative remoteness
of our two pulp mills in Sumatra means
that virtually all pulping chemicals must
be produced on-site. This has implications
both in terms of energy requirements and
sophisticated chemical engineering and
maintenance. High-specification construction
materials are needed for all the chemical
processing and containment required.
In our paper mills, we use a range of
additives to impart specific properties to
our different papers. These include fillers,
such as calcium carbonate for opacity and
smoothness; sizes, which help manage
ink penetration; starches, which provide
stiffness, strength and surface properties;
optical bleaching agents, used to enhance
whiteness and brightness, and dyestuffs,
which are used for both pastel tints and
highly-coloured grades. Other additives are
used to enhance paper machine operational
performance, improve machine drainage and
maintain system cleanliness.
Our Tjiwi Kimia and Pindo Deli mills have a
particular expertise in the coating of papers
with finely ground mineral matter to produce
paper surface properties suitable for a wide
range of high-quality printing techniques and
finishes.
Indah Kiat Serang and Ekamas Fortuna mills
specialise in the production of packaging
papers using, predominantly, lower-grade,
post-consumer wastepaper as their raw
material. And there is now a general move
towards recycling at other APP fine-paper
sites through the incorporation of some
higher grades of wastepaper in response
to market demands for recycled-content
products.
Any sub-standard or rejected product
within paper mills (broke) – is recycled
internally, ensuring the material is not lost
from the system or wasted. Some pulpingprocess-related
chemicals, surplus to on-site
requirements – particularly hydrochloric
acid (HCl) – are marketed externally. And
two of our paper mills in Java, which are
close to major urban population centres,
produce chlorine on-site for sale to local
municipal water purification systems and
industrial companies. The sodium hydroxide
co-product is sold within APP to our two pulp
mills for use in production.
External sale of chemicals increased by some
6 percent in value and tonnage in 2009, in
comparison to 2008, but this represents less
than 2 percent of total APP sales revenue.
In recent decades, there have been growing
international concerns about traces of
dioxins found in wastewater discharges from
pulp mills. This has been tentatively linked
to excessive use of elemental chlorine for
pulp bleaching, and has led, over time, to a
marked reduction in chlorine usage worldwide,
and the introduction of elementalchlorine-free
(ECF) bleaching, usually in
conjunction with alkaline / oxygen (A/O)
and/or peroxide (H 2
O 2
) bleaching stages.
ECF bleaching uses a diluted solution of
chlorine dioxide gas – generated on-site in a
sequence of electro-chemical and chemical
reactions – rather than gaseous chlorine.
Elemental Chlorine Free (ECF) bleaching
was introduced to APP pulp mills starting
1996 and have markedly increased their CF
bleaching ever since.
Water Management
APP’s mills are typical of pulp and paper
manufacturing operations in using
substantial quantities of water. Indeed, pulp
and paper mills worldwide are invariably
located adjacent to substantial watercourses.
About 85 percent to 90 percent of the water
used in both integrated and stand-alone
paper mills is for process purposes with
some 10 percent to 15 percent used to
produce steam, and for cooling associated
with power generation. In aggregate, APP
mills drew 262 million m 3 of raw water in
2009, an increase of 12 percent over the
previous year. Meanwhile, water discharged
directly back into rivers after wastewater
treatment rose by 14 percent, to an
aggregate of 190 million m 3 . The differential
between raw water withdrawn from rivers
and wastewater discharged is accounted for
both by evaporation and by the amount of
uncontaminated water used only for cooling
purposes, which by-passes our wastewater
treatment plants.
All of our mills are legally required to
monitor the composition of their wastewater
discharges, with respect to the biological
oxygen demand (BOD), chemical oxygen
demand (COD), suspended solids and pH
values. We must also monitor river water
quality upstream and downstream of our
plants. Frequently, both the upstream and
downstream waters are found to be outside
national river water quality standards. This
can be due to agricultural or industrial
activities upstream of our operations, and
requires us to operate extensive raw water
treatment plants, to ensure the purity of our
process water.
Water consumption per tonne across all of
our paper mill operations increased from
an average of 9.1 m 3 /tonne of production in
2008 to 9.9 m 3 /tonne in 2009.
Water usage and wastewater discharge
considerations are further discussed in the
individual mill sections of this report.
[EN 5]
[EN 10, PR 3, PR 4]
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