Water circuits and water balances

Almut Reichart
German Federal Environment Agency
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Outline

 BAT for water circuits and water balances

 Closed water cycles
 Concluding remarks

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Best Available Techniques (BAT) water

consumption and narrow water circuits

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Reduction of specific water intake by 50% since 1990 also

because of more recycling of fibres and water

Source: CEPI Annual statistics 2012

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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History of waste water in German paper mills

(Jung H. et al. 2009)

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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BAT associated environmental performance levels for the

waste water flow at the point of discharge
BAT is to close the water system to the
subsector BAT –AEPL in  degree technically feasible by using a
m³/ Air dried  combination of the techniques:
ton
a. Separation of the water systems
Recycled fibre (RCF)  1.5 ‐ 10
b. Countercurrent flow of process water and
paper mills without 
water recirculation
deinking
c. Partial recycling of treated waste water after
RCF paper mills with  8 ‐ 15 biological treatment
deinking
d. Clarification of white water
RCF‐ based tissue mills  10 ‐ 25
e. Continuous control of process water quality
with deinking
f. Prevention of biofilms by using methods that
non‐integrated paper  3.5 ‐ 20 minimise emissions of biocides
mills
g. Removal of calcium by a controlled
precipitation of calcium carbonate
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Counter current flow

 Countercurrent flow:
Consumption of water is 250 -1.000 l/kg paper. White water goes into the
Largest portion can be used again. opposite direction than
Different paper grades require different quality of the product flow
reused white water  determines the maximum of
water recycling and the minimum water of water
consumption per t of product  In many paper mills fresh
water is only used for
dilution of chemicals and
at the paper machine for
clean spray pipes and
edge sprays

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Separation of water cycles

 Short circulation on the paper machine
 Long circulation to the stock preparation
 Separation is done by thickeners and
save-alls via filtration, sedimentation,
centrifugation, flotation.
 units to separate the water from fibers etc.:
dewatering screws, wire and presses,
drum filters, vacuum disc filters,
microfiltration
Advantages:
 less water consumption, (RCF
without deinking 2-6 m³/t, RCF with
deinking below 10 m³/t)
 Lower volumes for effluent
treatment,
 decreased fibre an filler losses,
 elevated process temperature 
reduced energy demand
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Consequences of reduced fresh water consumption

without internal treatment

Higher concentration of
organic and inorganic
substances
Higher temperatures
Increased growth of
microorganisms  smell
hydrogen sulphide,
organic acids
Decrease of pH
Dark color in white water
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Experience in German mills with closed water circuits

(source: Julius Schulte)
type 1 type 2 type 3
without internal biological with internal biological With internal biological treatment
treatment treatment and membrane technology

mills Small and medium size Medium size mills Medium and bigger mills
<100.000 t/a) >500.000 t/a 600.000 t/a

products Brown packaging paper >100 brown packaging paper >100 g/m Brown packaging paper and
g/m² graphic RCF grades >70 g/m²

CSB very high COD (up to 40.000 normal COD load in whitewater normal COD load in whitewater
mg/l) 5.000 – 8.000 mg/l 5.000 – 8.000 mg/l

odor problems with smell and product normal smell and product quality normal smell of water and product
quality quality

problems Corrosion Corrosion, calcium deposits High cost for membran techn.
Built up of salts and organic some cost for treatment Calcium deposits, corrosion

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Example plant closed water cycle plant 1

 Stable production since 9 years with the following values:

 COD : 5.000 mg/l (inkl. 1.000 non biodegradable COD)
 Conductivity: 6.8 mS/cm
 temperature :43 C
 Calcium: 470 mg/l
 Chloride: 1.000 mg/l
 Sulphate: 600 mg/l
 Advantages: saving costs for fresh and waste water,
energy efficiency (use of biogas)
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Closed water circuit with internal treatment 1 German mill

Fresh water

short circ.

Waste Stock paper

paper machines
paper preparation

long circ.

Save all Internal

treatment

discharge

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Internal white water treatment Power station

Biogas cleaning

Dosing of nutrients

N P Aeration
tank I

preacidification
IC-Reaktor Sand filter
after heat exchange
(cooler)

Aeration
tank II

Excess sludge back

to production

Biowater recycling to production

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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2. Example of in-line biological process water treatment for

closed water loop

 1 mill Germany Production of 400.000 t/a case material and testliner, 2 paper
machines, zero effluent
 Partial stream of process water is cooled acified  anaerobic reactors
(UASB) (optional decarbonisation stage)  aerobic treatment 
sedimentation sand filter COD concentration in the water circuit 7 000 – 8 000
mg/l
 Benefits: less excess sludge, energy for aeration can be saved, Biogas from
anaerobic treatment can be used for steam production on site , high load
treatment without final clarification
 Risks: uncontrolled precipitation of calcium, optimisation of water-fibre system is
complex and needs years , choice of resistant materials steel etc.
 Costs: capital and operational costs total EUR 1.8/ton paper and 0.7/m³ process
water
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Concluding remarks

 Counter current flow and separation of water cycles is state of the art in
Europe
 Recycling of process water is possible, extent depends on paper grade
and required quality.
 Closed water circuits are possible for certain paper grades (brown
packaging)
 Closed water circuits perform better if inline white water treatment is applied
 From German experience a combination of anaerobic and aerobic treatment
works well
 Solutions for calcium deposits are available
 Membrane technology

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Thank you for your attention!

[email protected]
“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt
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Possible water circuits in paper mills direct vs. counter current

STA – Stock preparation; PM - paper machine; EW - dewatering unit; FW - fresh water;

AW - waste water; SW - white water; CSB – COD Chemical Oxygen Demand
(Geller, Sangl and Baumgarten et al 1993)

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt

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Example for water circuit in a system producing graphic paper

[Helble and Moebius (2001)]

“BAT in textile and pulp and paper sector” – 18th – 29th November 2013  A. Reichart, Umweltbundesamt