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Norske Skog Environmental Walsum 2009 Statement Contents THE MILL ENVIRONMENTAL PROTECTION 3 Preface by the General Manager 10 Environmental responsibility has many aspects 4 Norske Skog Environmental policy The environmental aspects 5 Norske Skog Walsum´s Environ- 12 Raw materials and additives mental principles 13 Energy 14 Emissions 6 Quality and customer orientation 15 Water 17 Waste 6 Health and safety 18 Transport 18 Emergency precautions 7 The management system FIGURES AND TARGETS 8 The Duisburg-Walsum mill 19 Milestones of environmental protection 9 Our paper 19 Glossary 9 The production process 20 Target control – programme highlights 21 Current targets 22 Input/output balance sheet 2 Norske Skog Environmental Statement 2009 When we produce paper, we do not only think of paper Environmental protection, sustainable validated according to the EC Eco Audit the top of the BG statistics of the Ger development and climate change are the Regulation. man paper industry. most important topics of our time. They dictate our corporate action and are part The fact that in 2004, the mill gained The ongoing development of our pro of our social responsibility and commit certification according to the PEFC duction and environmental standards ment to future generations. Chain of Custody Code, which checks represents the focus of all our activi the origin of wood and wood products ties. Extensive improvement projects, Our environmental practices are equally and which serves to ensure and conti in which all departments are involved, comprehensive and of high quality: nuously improve sustained forestry, re include energy saving, the efficient use examples are the efficient use of energy presents another milestone. Our inte of raw materials and optimising machi via heat recovery, minimising our water grated management system has become nery and procedures. We have set our consumption and the use of wood from a basic working tool in the mill: any ac selves clear goals for the next few years: sustainably managed forests. We consis tion required is promptly highlighted we hope to contribute towards the avoi tently consider the environment when and the appropriate measures quickly dance of indirect emissions, and thereby ever we invest in modern and innovative implemented. towards climate protection, via further technologies. energy saving coupled with greater en We obviously believe that corporate res ergy efficiency. In addition, ongoing The certifications we have gained to date ponsibility also encompasses the work optimisation of our water management confirm our lengthy tradition in envi safety and health protection of our staff, and a further increase in the proportion ronmental protection: as early as 1995, and we afford top priority to these in of wood from sustainable forestry are the Walsum quality management system the mill. We have a clear goal: to achieve right at the top of our agenda. was certified in line with the ISO 9001 an accidentfree mill! The fact that we standard. The areas of environmental are on the right path is demonstrated In this way, we will be in a position to protection and work safety were inte not only by the OHSAS 18001 that we meet our responsibilities for our environ grated from the outset. The environ attained in 2005, but especially by the ment, the region and future generations. mental management system has been important reduction in the number of certified in line with ISO 14001 since accidents at work. We are proud to re Trond Sverre Flaten 1997. The environmental declaration is port that these results have taken us to General Manager Norske Skog Walsum Norske Skog Environmental Statement 2009 3 Norske Skog environmental policy Norske Skog’s environmental policy supporting the company’s environ is an integral part of the strategy to mental policy and strategic ambition. achieve the overall corporate goal. It • Norske Skog shall expect the same shall support sustainable development high environmental performance from of environment and natural resources. suppliers of goods and services in the The environmental commitments shall value chain as maintained in its own be viewed in context with the company’s activities. Forest certification shall be commitments to health, safety and cor encouraged and certified wood sup porate social responsibility. pliers will be given priority. • Norske Skog shall have an environ Norske Skog’s environmental strategy mental performance that supports its and policy applies to all its business customers in reaching their environ units. Norske Skog will work for similar mental objectives. environmental values in joint ventures • Norske Skog shall operate and develop and partially owned companies. its business units with respect for, and understanding of, the social and cultu • Norske Skog shall operate and deve ral values that exist in the countries in lop its business units by continuously which it operates. improving their environmental per • Norske Skog shall be open to and ac formance, and with a view to reducing tively engage in dialogue with stake the environmental impact to a mini holders and will communicate openly mum. The basic requirement is comp on environmental matters. liance with laws and regulations. • Efficient production processes with high yield on raw material and energy utilisation shall be key objectives in all production units. Environmental aspects shall be integrated in strategic considerations and operational decisi ons. • Environmental responsibilities and tasks shall be clearly defined and ad hered to throughout the organisation. The business units shall educate and train their employees to know and under stand the policy, its require ments and the work performance ex pectations. • Certifiable internationally acknow ledged environmental management systems shall be actively applied in the management in all production units. • Norske Skog´s production units shall have environmental programs with clear objectives and annually set targets 4 Norske Skog Environmental Statement 2009 Norske Skog Walsum´s environmental principles Norske Skog is one of the world´s lea • continually improving our environ ding suppliers of wood containing pu mental performance within the orga blication papers. The Walsum mill is nisation and also in our cooperation committed to the Norske Skog Envi with customers, suppliers, authorities ronmental Policy. We demonstrate this and the public. commitment by • defining, auditing and reviewing envi • operating our business units in a res ronmental objectives and targets. ponsible and efficient manner in terms • maintaining ISO 14001 certification of raw material, paper production, wa and the validation according to the ste disposal, emissions and effluent. EMAS Audit regulation by registra • complying with all laws, regulations tion into the local register through the and official notifications which are re IHK. levant for our mill. • ensuring that we and our suppliers • documenting our environmental ac are certified in line with PEFC Chain tivities in a transparent and compre of Custody and thus guaranteeing that hensive way, and communicating them only wood and chemical pulp from su openly and honestly, both internally stained forestry are used for producing and externally. our paper. • taking care that our management • making our contribution to the decrease system is a living entity, that all em of greenhouse gas emission by applying ployees are aware of this, and that they an efficient power management. themselves constantly work to develop it further. Management Team Norske Skog Walsum GmbH Norske Skog Environmental Statement 2009 5 Our responsibility QUALITY AND CUSTOMER HEALTH AND SAFETY: THE EMPLOYEE sible means of training and communi ORIENTATION IS OUR FIRST CONCERN cation are used: e. g. the carrying out of Behaviour Based Audits (BBA) and • The customer is the focal point of all • Health and safety of our employees is the use of an IT programme for the re our actions. We set out to satisfy their for us an essential integral part of wor gistration and statistical analysis of in specifications with regard to the qua king life and overall corporate respon cidents. Clearly health and safety is of lity and environmental friendliness of sibility. Health and safety at work co the highest priority to everyone. our paper. mes before production. For us, safety at • We aim to improve our products by the workplace means technical safety as guaranteeing and further developing well as health protection, for example our quality standards when acquiring by environmental or fire protection. raw materials, in production, as well as • Everyone must be aware of his or her service. Through flexibility and inno responsibility for his or her own safety vation we aim to meet the needs of our as well as that of his or her fellow em clients and offer an optimal price in re ployees and colleagues. Measures ai lation to service provided. med at improving levels of safety are Development of accident occurred • We operate in a targetoriented way. implemented immediately. 60 A wideranging programme of opti • Prevention has the highest priority for misation, to which every employee can us. We know from the analysis of ac 40 contribute, and where production and cident incidence statistics that most work processes can be checked, contri accidents are not caused by technical 20 butes to a continuing cycle of impro problems, but by inappropriate beha vement. All processes are documented viour. Extensive training and informa and therefore transparent. tion, the leading example of superiors 2001 02 03 04 05 06 07 08 • Years of experience indicate that we are and active involvement of the work Notifiable occupational accidents* not mistaken in our emphasis on cu force are prerequisites for safety at the Accidents on the way to and from work* stomer orientation. workplace. With this in mind, all pos * Off time > 3 days 6 Norske Skog Environmental Statement 2009 Complete environmental management OUR INTEGRATED MANAGEMENT PERSONNEL ORGANISATION water. A team of auditors consisting of SYSTEM employees from all departments regu The mill management carries overall larly monitors the operating methods Quality, the environment, health and responsibility for environmental pro and their relevance to the present spe safety are elements that are of equal im tection. The management team with its cifications. Appointed safety specialists portance in our management system. main and technical departments is re carry out their duties in the individual We have obtained DIN EN ISO 9001 sponsible at the location for the obser departments. Additional safety experts and 14001 certification as well as valida vance of environmental regulations and have also been trained. tion under the EC Eco Audit Regulation. for implementing these measures. They The required recertification and sur are supported by the environmental re veillance audits are carried out regularly. presentative, who works as the appointed FURTHER DEVELOPMENT specialist responsible for the manage Targets and measures aimed at conti ment system as well as for immission, In addition to the daily morning meeting nuously improving product quality, the water protection, waste and hazardous the mill manager, executive staff, works environmental performance and work materials. Company representatives are council, environmental representative safety are documented and reviewed at also appointed for radiation protection, and safety engineer meet periodically to regular intervals. dangerous goods and the use of well discuss current issues in quality, the en vironment and health and safety. Neces sary measures are agreed upon and their Duisburg-Walsum mill implementation monitored. Our em ployees are given further education with General Manager Officer according to BImSchG § 52a regular instruction and training courses Radiation protection officer on topics specifically relating to the en vironment or health and safety. The Environmental representative Management representative Technical department company’s suggestion scheme, a wide ranging programme of optimisation and Safety Engineer direct dialogue with the employees are Safety appointees further means of bringing about impro Head of mill fire brigade Internal auditors vements. Appointee • Radiation protection • Hazardous material staff/ linear organisation • Removal of well water technical co-operation Norske Skog Environmental Statement 2009 7 The Duisburg-Walsum mill Paper bridging industry and nature In the DuisburgWalsum mill 520 em ployees produce around 400 000 tonnes of printing paper in reels on two pro duction lines (each consisting of a paper machine and a coating unit). The mill is located in the industrial area of the DuisburgWalsum district. Its premises cover a surface area of 44 hec tares half of which is developed. Situated directly on the bank of the River Rhine, the mill has a quay of its own and is bor dered by residential areas on two sides. In the immediate vicinity of the plant is the 550 hectare “Rheinaue Walsum”, which has belonged to the internatio nal wetland “Unterer Niederrhein” since 1993. The “Rheinaue” became an envi ronmental conservation area in 1990. There are over 200 types of birds and 380 different types of fauna to be seen in the area. 8 Norske Skog Environmental Statement 2009 Our paper At the DuisburgWalsum mill, we pro The grammages of our paper grades Production duce highquality, lightweight coated range from 39 to 80 g/m2. They are ca [t] 500.000 printing paper in reels. The products tegorised as lightweight paper grades, carry the brand name “Norcote” and which means, in relation to the printable 400.000 are used for magazines, catalogues, ad raw material used, less wrapping and vertising supplements and brochures. a lower transport weight than it is the 300.000 Our customers are publishers, printing case with higher grammage paper. The plants and advertisers that use paper in annual production volume of the Duis 200.000 heatsetoffset and rotogravure printing. burgWalsum mill is equivalent to a 100.000 Approximately 45 per cent of produc printable surface of about 1,4 million tion is destined for domestic consump hectares, corresponding to more than 2001 02 03 04 05 06 07 08 tion, about 40 per cent for Europe and one third of the area of North Rhine Paper about 15 per cent for overseas. Westphalia. The production process Fresh Factory Additives Electricity Steam Natural water supplies gas Wood Pre- Mechanical plup Pulping Screening Bleaching Postrefining chips steaming Chemical Chemical pulp Suspension Refining pulp Filler Pigments Suspension Raw material processing Paper production Central Press Dryer Pope Coating Dryer Pope Former Roller pulp store section section roller unit section roller Fresh water Water Water Coating Slitting, Paper wrapping processing treatment plant purification calender in reels Waste Cooling Exhaust Waste water water air Norske Skog Environmental Statement 2009 9 Environmental responsibility has many aspects Evaluation of direct and indirect environmental impacts In order to achieve a comprehensive ex The following environmental aspect areas amination and evaluation of the environ with the described environmental impacts mental impacts of our paper production were analysed: process, all direct and indirect environ mental aspects which are relevant to the location are selected and assessed. Environmental Aspect Examined Aspect Areas Environmental impact 1) Raw materials Raw wood materials, pigments, Consumption of non-regenerative resources, creation of intensified additives transport, indirect environmental impact at our suppliers Energy Consumption of power, steam, natural gas Consumption of non-regenerative resources, heat emission Emissions Air emissions (CO2, solids), odour, noise Contribution to the greenhouse effect, harm to employees and neighbours Water/waste water Fresh water, well water, Consumption of non-regenerative resources, waste water from production impact of draining canal Waste Disposal methods, waste requiring Emission during waste incineration, special monitoring creation of intensified transport Transport Outgoing, incoming, production transport Air contamination caused by transport, energy consumption Product Transport, development, packaging Creation of intensified transport Emergencies Accidents with water-polluting materials, Risk to the ground, rivers and groundwater should an oil leaks accident occur 1) In the following chapters, measures which have already been taken for minimising possible environmental impact are described in more detail. Measures for further improvement are listed in the objectives programme regarding environmental protection, work and health safety on Page 21. 10 Norske Skog Environmental Statement 2009 To evaluate our environmental aspects, we regard to both their environmental signi PORTFOLIO: ENVIRONMENTAL set down criteria, for example company ficance and their improvement potential. SIGNIFICANCE AND IMPROVEMENT specific environmental characteristics, The improvement potential was classified POTENTIAL OF OUR ENVIRONMENTAL which took into account the effect on the based on the technical, economic and or ASPECTS employees, neighbours, nature and the ganisational implementation opportuni current legal situation. The environmen ties and its possible influences. The result We regard the environmental aspect tal aspects were classified using the cate can be displayed in the portfolio. “waste water from production” as being gories “low”, “medium” and “high” with extremely important. Even though we keep to the monitoring parameters in our waste water legal permit, the reduc tion of our waste water volume and the impact of our waste water are treated Waste water with priority. In addition to this, all high from production other environmental aspects are given ENVIRONMENTAL SIGNIFICANCE our utmost attention and are an integral part of our continual improvement pro Energy cess. Additives Raw materials medium Emergencies consumption Waste Transport Odour and noise emissions Well water Production transport Fresh water low comsumption Air emissions Product low medium high IMPROVEMENT POTENTIAL Norske Skog Environmental Statement 2009 11 Raw materials and additives Spruce chips are the most important originate from sustained forests. This Additives are used for bleaching mecha raw material by quantity. Wood chips means that the forest owners maintain nical pulp and coating the paper web. are a byproduct of round wood being the biological diversity on the basis of On average, about 100 kg/t of additi cut to measure in saw mills. We use them defined management processes, take the ves are used annually for producing to produce pulp in a thermomechanical forest’s productivity into consideration our products. The respective amounts process. and take numerous other values into ac used for processing raw materials and The wood chips are pretreated with count which are related to a forest which bleach, for the production and finishing steam in order to soften the lignin which is cultivated in a responsible manner. of paper mainly depend on our custo is contained in the wood as a binding mers‘ quality requirements. In order substance. Then they are broken up into Pigments are applied to the surface of to produce a marketable paper which individual fibres between rotating grind the paper as a coating and used as a filler also corresponds with environmental stones. The fibre yield is about 95 per in base paper, improving its whiteness requirements, we constantly work on cent. and opacity. The paper is then passed improving the need for additives. Of through calender rolls to provide a course, we purchase and use all additives Readymade chemical pulp is brought smooth surface finish. The pigments we and chemicals in such a way as to mini in from Scandinavia. Chemical pulp use are natural minerals such as kaolin mise the environmental impact asso from Nordic countries that is made and calcium carbonate. ciated with them. from slowgrowing and consequently longfibred wood has the quality charac teristics we need for our paper grades. We use sulphate pulp bleached without chlorine compounds (totally chlorine Additives Raw materials free pulp). Additives [kg/t] [kg/t] 150 [kg/t] 400 The Walsum mill is certified in line with 150 the PEFC Chain of Custody Code which 100 300 checks the origin of wood and wood 100 products in the product chain. Within 50 200 this scope, we ensure that the raw wood 50 materials used in our production process 2001 02 03 04 05 06 07 08 2001 02 03 04 05 06 07 08 2001 02 03 04 05 06 07 08 Additives per tonne of paper (merchandising) Pulp bdt per tonne of paper Additives per tonne of paper (merchandising) Chemical pulp adt per tonne of paper [t] (merchan- dising)[t] [t] (merchan- 50.000 dising) 700.000 50.000 40.000 40.000 500.000 certified raw wood materials 30.000 30.000 [%] 20.000 300.000 100 20.000 10.000 10.000 50 100.000 2001 02 03 04 05 06 07 08 2001 02 03 04 05 06 07 Processing of raw materials and bleach 08 2001 02 03 04 05 06 07 08 2006 07 08 Processing of raw Paper production materials and bleach Paper finishing Wood chips (adt) Pigments (bdt) Paper production (line) finishing Paper Pulp (adt) % of PEFC Chain-of-Custody (line) 12 Norske Skog Environmental Statement 2009 Energy ENERGY REQUIREMENT HEAT RECOVERY For paper production we require energy Most of the energy used for driving the in the form of power, steam and natural refiners in the TMP plant is recovered gas. in the form of thermal energy. On an annual average, this corresponds to over Power is used mainly to operate the pa 40 percent of TMP’s power consump per machines and coating units and to tion. The TMP process needs high tem pulp the wood chips in the TMP plant. peratures and high pressure. Therefore, The entire power requirement is obtai it is possible to use the frictional heat ned from public power supply. During resulting from the refining process to the past years, the specific power supply generate steam, which is then fed into Energy required was approximately 2 000 kWh/t the steam network and used in the dryer [kWh/t] and depends mainly on the production section of the paper machine. Moreover, 2200 facilities‘ capacity utilisation and the ty it can be used to dry paper slurry from pes of paper. the mill’s waste water purification plant. 2000 Finally, we reclaim thermal energy by in Steam is used for drying the paper at the stalling heat exchangers in the water cir 1800 paper machines and in the equipment cuits or in the dryer section of the paper area. We cover about 40 per cent of our machine. steam requirements with steam which 2001 02 03 04 05 06 07 08 we obtain from the TMP facility‘s recy Power required per tonne of paper cling process. We obtain the remaining percentage of the required steam from [MWh] the cogeneration process of the neigh 1.500.000 bouring hardcoal fired power plant. Af ter the steam has been used, the conden sate with the remaining energy content 1.000.000 is returned to the power station. We use natural gas to operate the infra 500.000 red dryers and hot air hoods in the coa ting units. Small quantities of heating fuel are used in mobile heaters. 2001 02 03 04 05 06 07 08 external power supply Natural gas external steam supply (net) Norske Skog Environmental Statement 2009 13 Emissions EMISSIONS TO AIR NOISE EMISSION Emissions to air play only a minor role The type and size of our production at the DuisburgWalsum mill. As we do facilities as well as aroundtheclock, not operate a power plant of our own, 7daysaweek operation demand spe a major source of emissions is excluded cial noise protection measures, espe from the outset. Thanks to our require cially as residential areas are situated in ment for heating energy, the coalfuelled the immediate vicinity of the mill. In power plant nearby can use the principle 1985, a concrete noise barrier was built of combined heat and power, enabling it between the mill and the adjoining resi to generate energy in a much more en dential area. All outgoing air pipes have Emissions vironmentally friendly way than if coal been fitted with sound insulators. Reno were just converted into electric en vations were carried out with maximum [t CO2] 30.000 ergy. Energyrelated emissions are only noise protection in mind. Measurements caused by the use of natural gas in the prove that the maximum values are dryer sections of the coating units. being observed at all times. 20.000 Because of the carbon dioxide released during combustion, the drying aggre 10.000 gates and the coating units must com ply with the greenhouse gas emission trading act (TEHG). With less than 25 000 tons annually, the carbon dioxide 2001 02 03 04 05 06 07 08 emissions at the Walsum site are compa carbon dioxide emissions ratively low. ODOUR EMISSION High temperatures and anaerobic con ditions in the closed water circuits of pa per mills may cause organic substances to “rot” quickly. Sulphate contained in the process materials is transformed into sulphide that is then discernible as a hy drogen sulphide odour. In order to prevent this odour, we make sure that the circuit water flows at a high speed and that all water equalising and buffer tanks are sufficiently ventilated. 14 Norske Skog Environmental Statement 2009 Water FRESH WATER PRODUCTION WATER CIRCUIT We cover 85 per cent of our fresh water In the production process, water is used requirements from the Rhine and 15 per as a diluting and transporting agent. The cent with groundwater. Water from the paper pulp (mixture of fibres and filler) River Rhine undergoes sedimentation must be strongly diluted in order to form in a big round basin and is filtered by a highquality, smooth sheet on the pa a chemicalmechanical process before per machine. As production water is re being used for paper production and circulated several times, only a fraction for cooling machinery and aggregates. of it leaves the process as waste water and Some of the fresh water used for cooling is replaced by fresh water. is directly returned in a clean state to the Rhine after use. The remainder goes into the production water circuit. Ground water is used exclusively as cooling water. River Well Rhine approx. approx. 3 000 m3/day average 20 000 m3/day flow Fresh water Cooling of of water processing machinery Evaporation and aggregates approx. approx. 8 000 m3/day 215 Mio. m3/day Paper production Evaporation approx. 15 000 m3/day Effluent treat- Raw material ment plant processing Evaporation Norske Skog Environmental Statement 2009 15 WASTE WATER TREATMENT Waste water volume and waste water load in 2008 In the production process, water is 1.000 500 25 10 2 0,1 < 0,1 mixed with fibres, pigments and soluble substances from wood and additives. The water from the production process goes to an onsite effluent treatment 624 plant where it is first cleaned mechani 277 cally from solid substances and then by a threestaged biological process. The ca 3,4 pacity of our onsite treatment plant 6 corresponds to that of a public effluent 0,4 treatment plant for 180 000 inhabitants. The purified water is reintroduced into the River Rhine. The quality of our efflu Waste water COD BOD5 N P AOX [m3/h] [mg/l] [mg/l] [mg/l] [mg/l] [mg/l] ents is examined at regular intervals. Limit Average value of the measurements from self-monitoring EVAPORATION A part of the production water evapora tes during the drying of the paper web or during the cooling of machinery and aggregates. We recover as much of the thermal energy in the exhaust air as pos sible in order to reutilise it. The remain der is released to the ambient air in the form of water vapour. 16 Norske Skog Environmental Statement 2009 Waste EXTERNAL RECOVERY AND DISPOSAL WASTE REQUIRING MONITORING Around 20 000 tonnes of waste per year Between 150 and 200 tonnes of waste accumulates in the DuisburgWalsum requiring special supervision under the mill. Fibre and pigment residues, which terms of the German Recycling Manage are removed from the production water ment and Waste Act (KrW/AbfG) accu in the effluent treatment plant and then mulates annually at the Walsum mill. dried, make up about 80 per cent. The This “hazardous waste” is essentially bulk of these production residues is in made up of oleaginous residues, the con cinerated. Accounting for almost 15 per tent of oil and petrol strainers and used cent, saw dust from the screening of machine oil. wood chips is used, for example, in the production of chipboard. All other wa ste is also recovered as far as possible. Waste [kg/t] All waste is delivered only to licensed 70 waste disposal contractors, and its dis 60 posal is documented as required by law. 50 40 30 20 10 2001 02 03 04 05 06 07 08 esp. amout of waste Norske Skog Environmental Statement 2009 17 Transport We take delivery of approx. 600 000 tonnes transported by train, lorry or container of raw materials, additives and process to the respective harbour and from there materials annually. About 400 000 tonnes to their destination. More than 15 % of of printing paper are delivered every the transport is carried out via water. year to our customers in Germany and abroad. Some 20 000 tonnes of produc As regards the transport by lorry, our lo tion residues are supplied to recovery gistics department cooperates with our and disposal facilities. (The difference in preferred haulage contractor. They en weight between incoming materials and deavour to ensure that the delivery and dispatch of finished paper is due to the collection traffic is combined through high moisture content of the raw mate cooperating with the Norske Skog rials and material losses during the pro mills in Golbey (France) and Parenco duction process). (Netherlands) to try and avoid transport vehicles setting out or returning empty About 50 per cent of the incoming raw in order to reduce the volume of traf materials, additives and process mate fic. It is rather difficult to increase the rials are delivered via our own quay on percentage of rail transport, the reasons the Rhine. Depending on the country being limited supply possibilities due to of destination, embarkment of the reels the absence of railway connections at of paper is carried out at the Duisburg the printing plants, the frequently desi harbour, in Zeebrugge (Belgium) or in red “justintime” supplies as well as the Eemshaven (Netherlands). The reels are higher costs of transport by rail. Our emergency precautions Equipped for all eventualities Our chief target is to avoid incidents comprise the following, among other which may have an effect on the health things – an alarm and emergency plan, of our employees and the environ fire prevention plans, a fire preven ment. However, it is also vital to set up tion order, storage of only the smallest an emergency organisation so that we amounts of environmentally significant can be prepared, should an unexpec materials and job instructions regarding ted emergency occur. Emergency pre behaviour to be displayed should envi cautions taken for the Walsum location ronmentally significant incidents occur. 18 Norske Skog Environmental Statement 2009 Milestones of environmental protection 1978 Extension of the mechanical effluent treatment plant to include a biological stage 1985 Construction of a sound barrier between the mill and the adjoining residential area 1986 First heat recovery in the TMP plant 1991 Extension of the effluent treatment plant to include a peak load stage, a Biofor filter and a buffer basin 1993 First use of recovered paper 1995 DIN EN ISO 9001 certification of the quality management system 1997 Integration of environmental protection and health and safety into the quality management system DIN EN ISO 14001 certification of the environmental management system 1998 Validation of the DuisburgWalsum location under the EU Eco Audit Regulation Increasing heat recovery in the TMP plant 1999 Valuation of basins for the storage of additives harmful to water 2000 Construction of a highconsistency bleaching unit, a circuit separation with secondary bleaching and a dosing unit for hydrosulphite 2001/2002 Refurbishment of the effluent treatment plant from aeration tanks to a fluidized bed reactor. 2004 The Walsum mill receives certification according to the PEFC Chain of Custody Code which checks the origin of wood and wood products in the product chain 2005 Increase in the capacity of the TMP plant Increase in the performance of the effluent treatment plant Glossary AOX: COD: TMP: The measure for the sum of all absor Chemical oxygen demand. Indicates Thermomechanical pulp. Wood chips bable organic halogen compounds in the amount of oxygen required to previously treated with steam are me the water. completely degrade the slowly de chanically broken up into individual composing organic compounds con fibres between rotating refiner plates BOD5: tained in the waste water. under high pressure and at high tem Biochemical oxygen demand. Indi peratures. cates the amount of oxygen that is LWC paper: consumed within 5 days by micro Lightweight coated paper. A smooth, Adt: organisms during the degrading of uniform surface is achieved by app Air dry tonnes the fastdecomposing organic com lying a layer of coating to the surface pounds contained in the waste water. of printing paper. Bdt: bone dry tonnes Norske Skog Environmental Statement 2009 19 Target control – programme highlights Targets Target achieved? Raw materials and additives Reduction of paste losses to max. 1 tonne /day No Continuation in 2009 with new target Water Dropping below a specific waste water volume of 13.5 m3 /tonne of paper No 13.6 m3 /tonne paper could be achieved. Continuation in 2009 Implementation of the requirements resulting from the canal self-monitoring directive dated 1995 after the first recording Yes of the canal condition Continuing measure Continuation in 2009 Emissions Reduction of traffic-related emissions by increasing the transport by rail when shipping paper using combined freight transport Yes Reducing combustion-related emissions at the coating facilities by optimisation of natural gas combustion during delivery Yes and removal processes of coating facilities 4 and 10 Energy Reduction of the specific energy use to <12 GJ per tonne of product Yes Emergency precautions Improvement of the emergency reaction capability on the occasion of environmental accidents by ascertaining and assessment Yes of potential emergency situations, definitions of protective and emergency measures and if applicable, conducting exercises Avoiding oil leakages by purchasing a new oil cooler for the hydraulics of the press section and the calender stack of line 10. No Investment has been postponed indefinitely No continuation Indirect effects on the environment Increasing the transparency of the direct and indirect environmental effects of the Walsum mill by calculating and No publishing the carbon footprint of the Walsum paper products using the calculation guidelines of the Confederation Continuation in 2009 of European Paper Industries (CEPI) 20 Norske Skog Environmental Statement 2009 Current environmental, health and safety targets No. Targets Measures Deadlines Responsible departments Raw materials and additives 1 Reduction of paste losses to max. 1.5 t/day Optimisation of paste recovery plants of the coating 12/2009 Production (continuation from 2008) facilities and procedures during change of qualities, paper tears and delivery/removal processes 2 Increase in the proportion in the product Primary acquisition of raw wood material offering a high 12/2009 Dept. Environment/ of raw wood material certified acc. to proportion of PEFC-Chain of Custody Purchasing the PEFC Chain of Custody Code Water 3 Dropping below a specific waste water Developing potentials for improvement and their 12/2009 Raw materials volume of 13.5 m3 /t of paper implementation to reduce the waste water quantity and (continuation from 2008) optimise the use of water. 4 Dropping below a specific waste water Developing potentials for improvement and their 12/2010 Raw materials COD volume of 3.8 kg/tonne implementation to reduce the chemical oxygen demand (COD) of the waste water cleaning facility. 5 Implementation of requirements resulting Implementation of measures to fulfil the requirements. 12/2009 Engineering from the canal self-monitoring directive dated 1995 after the first recording of the canal condition (continuation from 2008) Energy 6 Reduction of the specific energy use • Reduction of power consumption for compressed air 12/2009 Raw materials to <11.9 GJ/tonne of product production by implementing a work group to reduce compressed air leakages and create sustainable solutions to avoid losses of compressed air. • Stabilisation of heat recovery quote of TMP facility 12/2009 Raw materials to over 46% • Perfoming a project study and, if required, its 12/2009 Planning/ implementation aiming at using water separations more Raw materials efficiently at the waste water end. Indirect effects on the environment 7 Increasing the transparency of the direct Calculation and publication of the carbon footprint (CO2 ) 06/2009 Dept. Environment and indirect effects of the Walsum mill of Walsum paper products using the calculation guidelines (continuation from 2008) of the CEPI (Confederation of European Paper Industries) 8 Supplier audits in terms of quality services Performing supplier audits 12/2009 Purchasing and environmental services Health and occupational safety 9 The Walsum mill shall be accident-free Implementation of the activity plan on health and 12/2009 all departments (zero-accident) occupational safety 2008/2009 Norske Skog Environmental Statement 2009 21 Input-/Output balance sheet INPUT OUTPUT 2006 2007 2008 2006 2007 2008 Raw materials [t] Production [t] Wood chips (approx. 50% humidity) 362 036 375 294 368 152 Paper in reels (ready for dispatch) 378 174 400 383 402 527 Pulp 65 150 66 422 64 664 Pigments (bdt) 134 353 148 796 156 426 Waste [t] Fibre/pigment residues1) 18 081 17 019 19 065 Process materials [t] Wood residues 2 903 2 589 3 181 Additives for processing of Paper residues 607 575 639 raw materials and bleach 17 774 16 262 15 558 Metal 476 340 352 Additives for paper production 1 911 2 248 2 214 Building rubble 168 51 179 Additives for paper finishing 19 196 22 735 22 501 Domestic type commercial waste 170 184 138 Wrappers and cores 3 236 3 457 3 450 Other types of commercial waste 9 8 12 Process materials for purification 2 492 1 986 1 840 Other secondary materials 250 276 315 Lubricants 110 85 97 Waste which particularly Other process materials 2 1 1 requires supervision 178 167 158 Energy [MWh] Energy [MWh] Natural gas 112 714 114 523 117 440 Condensate returned 40 563 39 321 35 280 Fuel oil (extra light) 1 334 1 498 1 488 External power supply 792 806 797 330 783 054 Water [m3] External steam supply2) 422 960 428 914 457 165 Production waste water 5 525 222 5 713 384 5 482 904 Fuels 1 282 1 400 1 252 Cooling water3) 3 367 126 3 272 083 3 953 830 Water [m3] Emissions to water [t] Ground water 1 084 772 939 213 1 147 428 BOD5 61 46 71 Surface water 7 945 057 8 204 517 8 140 673 COD 1 449 1 529 1 517 Drinking water 74 622 75 825 75 173 AOX < 0,5 < 0,5 < 0,5 Nitrogen (inorganic) 20 19,1 18,4 Phosphor 2,4 2,3 2,2 1) Humidity content of the accumulated fibre/pigment residues (2006: 39 %, 2007: 35 %, 2008: 36 %). 2) The increase in consumption in 2008 resulted from feeding external steam into the paper machine water circuits to achieve an improved seasonal uniformity of the circuit temperature thus ensuring a higher process stability. 3) Calculated by water balancing, higher cooling water quantity in 2008 results from a changed balance calculation and optimisation of measures taken on cooling units in the area of the TMP facility. 22 Norske Skog Environmental Statement 2009 VALIDATION Based on site inspections, conversations with the company’s staff, documents and records perused, I confirm that the environmental policy, the environmental targets, the environmental program, the environmental management system and the procedures for assessing the environmental impact of the Organization Norske Skog Walsum GmbH TheodorHeussStraße 228, 47179 Duisburg (Germany) correspond with the regulation (EEC) 761/01 in its version dated February 3, 2006. The data and details of the consolidated environmental declaration are reliable. They provide an adequate and correct image of the environmental relevance of all actions at the respective sites. This was verified by random onsite inspec tions. There is no evidence of any deviation from legal provisions. The next simplified environmental declarations will be published in November 2010, 2011. Dr. Nehm TÜV Nord Umweltgutachter GmbH DEV0223 Essen, September 21, 2009 This site has an environmental management system. The operative environmental performance of the site is reported to the public in accordance with the community ecomanagement and audit scheme. Reg. Nr.: D-120-00013 Norske Skog Environmental Statement 2009 23 Norske Skog Walsum GmbH Theodor-Heuss-Straße 228 D – 47179 Duisburg Phone +49 (0) 2 03 /49 92-0 Fax +49 (0) 2 03 /49 92-1 80 www.norskeskog.com Contact for environmental affairs Dr. Frank Hamacher Phone +49 (0) 2 03/49 92-2 77 E-mail firstname.lastname@example.org Please contact the person above if you wish to be informed regularly about environmental projects at the Duisburg-Walsum location or if you require further information material.
"Norske Skog Walsum Environmental Statement EMAS"