WR1210 Sustainable Paper
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www.defra.gov.uk Project WR1210 – How can paper be made more sustainable? A desk-based review February 2012 Acknowledgements Defra would like to thank the Confederation of Paper Industries (CPI) and Waste and Resources Action Programme (WRAP) for providing valuable information and input to this project. Executive Summary Globally, 1Mt of paper are consumed every day, making paper both a very important commodity and a significant resource. From its production to its end-of-life paper has the potential to cause significant negative environmental effects. The UK paper industry has made, and continues to make, good progress towards minimising its environmental impacts and the Government is keen to continue to work with the industry to make it even more sustainable. The aim of this project is to draw together, via a literature review, a robust evidence base to help inform and direct future policy development. The literature review focuses on: The paper making process, including the technical, financial and market implications associated with the use of recovered fibre (RCF). The profile of the UK paper industry and the flow of fibre through the UK. Material inputs and outputs to the UK paper industry, including water, energy and waste, quantifying them where possible. The environmental impacts associated with each stage of the life cycle of paper, from forestry to end-of-life. The report focuses on the environmental aspects of the paper industry‟s performance and, to a lesser extent, the economic and social aspects. Paper making process Overall, UK paper mills use approximately 75% recovered fibre and 25% virgin fibre. The virgin fibre used in UK paper manufacturing is mostly imported, as virgin fibre production in the UK is limited to two sites, both of which use all the virgin fibre they produce for their own paper products. Virgin paper production and paper recycling are fully dependant on each other for paper production to remain sustainable. There is a minimum fibre length requirement for recycling of paper to be feasible and since the re-pulping process shortens the paper fibre, virgin fibre or high quality recovered fibre (RCF) must be introduced to the paper loop to compensate for the loss of fibre. Newsprint manufacturing uses the highest percentage of RCF, with almost 100% of newsprint produced in the UK made from recovered fibre. The lowest recycled contents, on the other hand, are found in printings and writings (P&W) and tissue paper, mostly because of customer perceptions and requirements. Although virgin fibre in P&W can be recycled, virgin fibre used in tissue and other hygienic products is lost after its first use. Therefore, an opportunity exists to work with industry and the public to promote the greater use of RCF in these products. To further increase paper recycling the industry must overcome the important barrier of contamination. While paper contamination can occur either before or after use of the paper product, post-consumer contamination is most easily avoidable. The most important paper contaminants are glass and grease/food. Glass is broken down to an abrasive dust 1 causing wear and tear of the mill equipment whereas grease and food contamination impacts on the strength and presentation of the finished product. Other contaminants include difficult to remove inks and integral additives used to make paper and paper products. Profile of the UK paper industry The UK paper industry is comprised of 52 active mills and contributes about 2% to the UK‟s manufacturing economy. The UK is in fact the 8th largest European paper producer and the 5th largest European RCF consumer. In 2009, 12.1 Mt of paper were consumed in the UK. Some of this paper was produced domestically, mainly from recovered fibre, although the majority was imported as unconverted paper (7.0 Mt), as packaging around products (1.2 Mt) and as converted and printed paper products (0.5 Mt). A total of 8.2 Mt of waste paper were collected in the UK in 2009 and slightly less (8 Mt) in 2010. The UK paper collection rate (amount collected/amount in circulation) has been increasing steadily year-on-year, reaching 68% in 2009, although 2010 saw a small decrease to about 65%. This was probably due to a typical lag between an increase in consumption and an increase in collection of waste paper; the collection rate is likely to increase in 2011 to reflect the increase in paper consumption in 2010. There is a practical limit to the amount of paper that can be collected for recycling, due to the fact that much of the uncollected paper either remains in circulation (e.g. banknotes and in libraries) or is unrecoverable for hygienic or practical reasons (e.g. tissue paper). However, over 1 Mt of paper still ends up in the residual stream. It could be possible to increase the UK‟s paper collection rate by focusing efforts on historically difficult to reach sources such as recycling on the go, SMEs, densely populated areas such as high rise flats etc. In 2009 and 2010, about 54% of the UK collected RCF was exported for reprocessing primarily to the Far East markets and particularly to China, although 2010 saw a marked increase in European demand for UK RCF. The 2008 recession highlighted the volatility of RCF prices when a decrease in demand caused a significant dip in prices and a short stockpiling of collected RCF. Although the market recovered, the recession demonstrated the importance of taking action to secure the UK‟s position in supplying RCF to the global market. By ensuring that high quality RCF is collected (e.g. minimising contamination by non-target material), UK exports will become more competitive in the international paper market. Material inputs and outputs Virgin fibre (1.2 Mt), recovered fibre (3.8 Mt) and non-fibrous additives (0.3 Mt) were the main raw material inputs to the UK paper industry in 2009. Water is another important input for the industry as it is used for pulp and paper production but also for cooling down the equipment. About 60% of the industry‟s water intake is from the mains with the remaining 40% coming from direct abstraction. Water consumption is about 12.5 million m3 per year; approximately 15% of the industry‟s total water intake. The gross energy demand for the production of paper from virgin fibre is generally higher than for the production of RCF, but the production of virgin pulps can result in a net gain of energy as process by-products are normally used to produce energy (and surplus energy is 2 exported to the grid). Energy from waste is becoming important for recovered mills as well, with RCF residues being used for energy production. The energy source within a mill is a key factor in determining its overall environmental impact. The principal energy sources for papermaking in the UK are natural gas and electricity, although other sources such as coal, oil and biomass are also used to generate energy on site. The amount of energy consumed by each mill depends on its products and on the processes employed within the mill. The industry‟s energy consumption in 2009 was 1,705 thousand tonnes of oil equivalents (toe) accounting for approximately 6.4% of the UK industrial consumption and about 0.8% of the total UK energy consumption. Pulp and paper mill energy efficiencies have improved greatly over the years achieving a 42% reduction in specific energy consumption when comparing the industry‟s 2010 performance to its 1990 performance. This is due to the increased use of more energy efficient technologies and combined heat and power (CHP). Currently, there are nineteen operational CHP plants either in the pulp and paper manufacturing sector in the UK or servicing the sector and, although the majority currently run on gas, an increasing number use biomass. These CHP plants exported approximately 731 GWh of electricity to the grid in 2009. In 2009, the UK paper industry produced 1.1 Mt of newsprint, 0.5 Mt of P&W, 1.7 Mt of Packaging, 0.7 Mt of Sanitary and Household and 0.3 Mt of other paper grades (such as specialities), for a total paper production of 4.3 Mt. Other main industry outputs are wastewater, discharge of which lies within 16 and 17 m3/t product, and waste. In 2009, about 1.0 Mt of waste was produced during the production of paper (production loss) but more detailed waste data for the sector are not available. Data from 2002/03 suggest that about 1/3 of the sector‟s waste is card and paper that is usually sent for recycling, 1/3 is rejects from sorting and pulping and 1/3 is sludge. The industry‟s waste in 2002/03 amounted to 1.8 Mt. Environmental impacts Over the years the UK paper industry has greatly improved its environmental credentials. Starting from sourcing of raw materials, significant efforts have been made to reduce the amount of illegally sourced timber that is imported into the UK. Although the industry only uses a very small amount of virgin pulp, arising mostly from European countries and thus legally sourced, large amounts of converted and unconverted paper and paper products enter the UK. It is often very difficult to determine whether the raw materials for these products were legally sourced or not. New European regulations on the banning of illegal timber and timber products, coupled with chain of custody certifications, should help to significantly minimise the amount of illegally sourced wood and paper entering the UK, either directly or indirectly. UK emissions to air and water arising from the production of pulp, paper and paper products have also been significantly reduced.