HELP and GUIDANCE FILE for the FPAC Pulp and Paper Energy Survey

Transcription

1 HELP and GUIDANCE FILE for the FPAC Pulp and Paper Energy Survey Production Boxboard refers to board (plain, lined or clay coated) used for fabricating boxes. Building paper refers to all types of paper produced from strong fibre stocks, processed and treated for use in the building trade. Corrugating medium refers to board to be fluted for use in the manufacture of corrugated board products or for wrapping. Kraft papers to papers made predominantly from wood pulp produced by the sulphate pulping process. Linerboard refers to board used as liners or as facing material in the manufacture of shipping containers and other types of corrugated board products. Mechanical Market Pulp refers to stone groundwood pulp, refiner mechanical pulp, thermomechanical pulp, chemi-thermomechanical pulp, defibrated pulp and exploded pulp produced for sale as market pulp (not used for on-site production of paper/board products). Newsprint refers to paper between 40 g/m 3 and 57 g/m 3 generally used in the production of newspapers. Printing and writing papers refers to coated and uncoated papers containing at most 10% mechanical pulp fibre termed woodfree as well as coated papers containing more than 10% mechanical pulp fibre. Recycled Market Pulp refers to pulp made from deinked and other recycled fibre produced for sale as market pulp (not used for on-site production of paper/board products). Sulphate Market Pulp refers to pulps produced by the sulphate process, and includes kraft pulps, all for sale as market pulp (not used for on-site production of paper/board products). Sulphite Market Pulp (incl. Dissolving Pulp) refers to pulps produced by the sulphite process for sale as market pulp (not used for on-site production of paper/board products).

2 Tissue and special papers include all sanitary papers, greaseproof papers, gassine papers, as well as all other special papers. Uncoated groundwood specialties refers to uncoated paper containing more than 10% mechanical pulp fibre, excluding newsprint. Transformative/Innovative Products As the industry is transforming, FPAC would like to track newer classes and types of products used. For example, types of products produced could include, but are not limited to the following: Ethanol Tall Oil Lignin Turpentine Alcohol Sugars Etc. Fuels The four categories of consumption use are based on the Statistics Canada Industrial Consumption of Energy (ICE) survey. For mills with a common steam distribution system please estimate the breakdown among the uses as outlined below. (ie. common steam distribution system for process, electrical generation, and/or steam sales.) As Fuel refers to all fuel used to generate heat for the process or on-site use. Included in this category would be steam generation (excluding sales), building/air heating, lime kilns, and dryers. The amount of fuel used to produce electricity should not be reported in this category. To produce steam for sale refers to all fuel used to generate steam sold to third parties. To produce electricity refers to all fuel used to generate electricity on-site (i.e. gas/steam turbines or back up generators). For non-fuel use (feedstock) refers to feedstock use of energy. This is not applicable to the pulp and paper sector.

3 When reporting fuel use please specify the energy content on a Higher Heating Value basis. Default energy content factors are provided in the table below. If you have more accurate factors based on on-site measurements/calculations please use those by overwriting the defaults, otherwise use the default factors. The total energy column is used to convert all energy forms into a common unit. Fuel Source Energy Content (HHV) Coal GJ/t Petroleum Coke GJ/t Sludge GJ/BDt Wood/Hog Fuel GJ/BDt Spent Pulping Liquor GJ/BDt Tire Derived Fuel GJ/t Pulping Soap GJ/t Crude Tall Oil GJ/t Turpentine GJ/t Biogas MJ/m 3 Diesel MJ/L Other Middle Distillates MJ/L Heavy Fuel Oil MJ/L LPG Ethane MJ/L LPG - Butane MJ/L Propane MJ/L Natural Gas MJ/m 3 By-Product Gas MJ/m 3 Please report your energy use according to the following definitions: Solids: Coal refers to all types of coal and coke forms including bituminous, sub-bituminous, lignite, anthracite, coal coke, coke on catalytic cracking catalyst. Please be sure to include the energy content appropriate for your use of coals. If there is a combination of coal forms used, please estimate the average energy content of the mix. Petroleum Coke refers to marketable grades of coke produced in delayed or fluid cokers that may be recovered as relatively pure carbon. Also a residue that is the final product in the condensation process in cracking. May be sold as is or is further purified by calcination.

4 Sludge refers to the Bone Dry measure of primary and secondary effluent sludges used for energy generation. Wood/Hog Fuel refers to the Bone Dry measure of all wood wastes, including roundwood, lignin, wood scraps from furniture and window frame manufacturing, wood chips, bark, sawdust, forest residues, charcoal and pulp waste (excluding spent pulping liquor), used for energy generation. Include all wood residues both purchased and generated by the mill that are used as fuel. Spent Pulping Liquor refers to the Bone Dry measure of spent pulping liquor (black liquor) formed during the chemical pulping process. It is primarily made up of lignin and other wood constituents and chemicals. It is burned in a recovery boiler which produces steam for process and/or electricity. Refuse refers to solid or liquid waste materials used as a combustible energy source. This would include the burning of wastepaper, packing materials, garbage, bagasse, sewerage gas, biogas (from anaerobic processes), tire derived fuel, waste oil, contaminates and other industrial, agricultural and urban refuse often used to generate electricity. Unlike the Statistics Canada survey, we have provided greater specificity for refuse fuels to separate out the more common ones used in the pulp and paper industry as follows: o Tire Derived Fuel refers to fuel comprised of shredded scrap tires. o Pulping Soap refers to a foam containing resin and fatty acids removed from pulping liquor during the evaporation stage. o Crude Tall Oil refers to acidified pulping soap. o Turpentine is a resinous by-product of pulping softwood fibre which can be used as a fuel. o Biogas refers to captured methane from landfill. Liquids: Middle Distillates is broken down into two categories: Diesel refers to all grades of distillate fuel used for diesel engines including low sulphur content (lower than 0.05%). Does not include diesel used for transportation off the plant site. Other refers to light fuel oil (No. 1, 2 and 3), kerosene, mineral lamp oil, stove oil, furnace fuel oil, gas oils, gasoline, and light industrial fuel. Does not include gasoline used for transportation off the plant site. Please be sure to include the energy content appropriate for your use of these fuels. If there is a combination of types, please estimate the average energy content of the mix. Heavy (residual) Fuel Oil refers to all grades of residual type fuels including low sulphur. Usually used for steam and electric power generation and diesel motors.

5 Includes fuel oil No. 4, 5 and 6, and Bunker C. Combine Canadian sourced fuel and foreign sourced fuel if applicable, and report as one. LPG (Liquid Petroleum Gases) refers to ethane and butane. Report quantity used onsite. Do not include consumption for off-site transportation. Propane - report quantity used on-site. Do not include consumption for off-site transportation. Gaseous: Natural Gas report separately from methane By-Product Gas includes hydrogen but excludes gases that are reported under Refuse above. Methane refers to purchased methane. Report separately from biogas and natural gas. Non-Condensable Gases refers to off-gases from the chemical pulping process which can be used as reburn fuel, typically in lime kilns. Calculation Formulas: Fuel Unit of Measure Energy Multiplier Total Energy Solids: t GJ/t / 1000 = TJ Liquids: 10 3 L 10 6 J/L / 1000 = TJ Natural Gas: 10 6 m J/m 3 n/a = TJ Gaseous: 10 3 m J/m 3 / 1000 = TJ Electricity & Steam Electricity Purchased Electricity refers to all electricity that is imported onto the mill s grid and is purchased from a third party. This includes quantities received as compensation, special arrangement or donation. This also includes electricity that has been generated by the mill, sold to the utility and then repurchased. This does not include electricity that is wheeled from a mill-owned hydraulic generating unit to the mill on a third party s grid (ie. from a hydro dam) Self-Generated Hydraulic Energy Electrical refers to all electricity generated from on-site or associated hydraulic generating units that are owned and operated by the mill.

6 Electricity Sales refers to all electricity sales (or provided as compensation, special arrangement or donation), regardless of whether the electricity was originally purchased or self-generated. It refers to any electricity exported from the mill s grid for use by a third party. It includes electricity that is sold to the grid which will be repurchased by the mill. This does not include electricity that is wheeled from a mill owned hydraulic generating unit to the mill on a third party s grid (ie. from a hydro dam). Electricity Self-Generated from fuel and steam refers to the net electricity (exclude energy required for station service) and is broken down as follows: Gas Turbine Electricity refers to the net electricity generated on-site from natural gas turbines that are owned and operated by the mill. Back pressure turbine electricity refers to net electricity generated on-site from back pressure steam turbines that are owned and operated by the mill. Back pressure turbine mechanical energy refers to net mechanical energy generated onsite via turbine(s) directly used to run pumps or machinery and not generate electricity. Condensing turbine electricity refers to net electricity generated on-site from condensing turbines that are owned and operated by the mill. Turbine Heat Rate refers to the relationship between the steam or fuel energy consumed by the turbine and the electrical or mechanical energy generated by the turbine (ie. it is an indication of the thermodynamic efficiency of the turbine). Steam/Fuel consumed by a turbine while it is not generating electricity should not be taken into account when developing heat rate. Total Electricity Consumed is the sum of Purchased Electricity, Self-Generated Hydraulic Energy-Electrical, Self-Generated Electricity from Fuel and Steam, Gas-Turbine Electricity, Back- Pressure Turbine Electricity and Mechanical Energy, and Condensing Turbine Electricity. Steam Purchased Steam refers to all steam that is purchased from a third party. In other words, any steam which is imported onto the mill s steam system that has been delivered by a third party. This includes quantities received as compensation, special arrangement or donation. This includes quantities purchased from a third party to whom you sell biomass which is used to generate the steam This also includes steam that is sold to a third party for electrical generation and is then repurchased to be used by the mill. This does not include condensate purchased from a third party. Self-generated steam refers to all steam generated on site. This includes steam generated via electricity, fossil fuel, biomass or heat exchangers (ie. reboiler or HRU). The team quantity

7 should be measured at the output of the steam generating device(s) and should include steam used for sootblowing, atomization, and fuel or feedwater pre-treatment. Steam Sales refers to all steam sales (or provided as compensation, special arrangement or donation), regardless of whether the steam was originally purchased or self-generated. This refers to any steam exported from the mill s steam system for use by a third party. This does not include condensed or vented steam, or condensate sold to a third party. Steam Energy Content (Enthalpy) - refers to the energy content of the steam per unit mass. Enthalpy is devised based on steam properties (ie. pressure and temperature). Please note that the gross enthalpy of the steam is to be used. Enthalpy for self-generated steam is to be taken at the output of the boiler (ie. before any letdown stations or turbines). The enthalpy of sold or purchased steam is to be based on the properties of the steam when it enters or exits mill property. If more then one type of steam exists for a steam category, calculate a hybrid steam enthalpy based on the weighted average of the steam types. Calculation Formulas: Energy Source Electricity: Self-Generated Electricity: Steam: Unit of Measure GWh GWh t Energy Content / Total Multiplier Heat Rate Energy kj/wh n/a = TJ kj/wh / 1000 = TJ GJ/t / 1000 = TJ Lime Kiln Fuels used in the lime kiln are to be included in the "As Fuel" energy quantity reported in the Fuel Data page. See the Fuel Data section above for fuel definitions. Calculation Formulas: Fuel Unit of Energy Content / Heat Total Multiplier Measure Rate Energy Liquids: 10 3 L 10 6 J/L / 1000 = TJ Natural Gas: 10 6 m J/m 3 n/a = TJ Wood/Hog Fuel: BDt GJ/t / 1000 = TJ Solids: t GJ/t / 1000 = TJ

8 Water use Process Wastewater to Surface Water: in most cases, this is primarily process wastewater that the mill treats and then discharges to surface water. It may sometimes include more than just process wastewater. Everything that is collected with process wastewater, treated and discharged in combination with process wastewater should be included (unless reported elsewhere). Process Wastewater to POTW: This is the total of all wastewaters being discharged to a Publicly Owned Treatment Works (POTW) for treatment, regardless of whether they have first been treated by the mill. These wastewaters may include process wastewaters and other wastewaters. If, however, the only discharge to the POTW is sanitary wastes, these should not be reported. Report the annual flow. Process Wastewater to Other Mill (specify mill): Some mills treat the effluent from a neighbouring mill. FPAC must be careful not to double count this wastewater flow in the database. Please specify the name of the mill that treats their effluent in your system. Non-Contact Cooling Water: This is water that is used only for cooling and discharge to surface water through a non-contact cooling water discharge. This also includes situations where the non-contact cooling water bypasses the treatment plant, but is combined with treated mill process water immediately before being discharged. Report only the flow of non-contact cooling water discharged to surface water. Other Wastewater: other effluents could include storm water or perhaps leachates from landfill or other storage. To avoid distorting the loading calculations, please do not include these other effluent flows in the POTW, process, or cooling water flows. Effluent Discharge Report the total annual discharge of BOD, COD, Total Suspended Solids (TSS) and AOX in metric tonnes per year. FPAC will calculate the kg/tonne for the total industry in Canada using all the reported Canadian production. Some mills send effluent to a publicly owned treatment works (POTW). If you are one of these mills please report that separately. Do not include that value in the process water to surface water. Residuals Generated

9 Disposal methods include: 1) Methods with Energy Recovery or Beneficial Use Energy Generation: report the % of residuals that were used to generate electricity Land-Spreading: report the % of residuals that were used for landspreading Composting: report the % of residuals that were used for composting Other Beneficial Use: report the % of residuals that were used for any other beneficial use (re-use/recycling), including useful by-products produced at an off-site location 2) Methods without Energy Recovery Incineration: report the % of residuals that were incinerated without energy generation Land-filling: report the % of residuals that were landfilled or sent to longterm storage Other: report the % of of residues that were disposed of by other means (please specify method) Glossary Unit - Definitions t = tonne = metric tonne = 1000 kilograms (2205 pounds) BDt = Bone Dry tonne (zero moisture content) m 3 = metres cubed kj = kilojoule = 10 3 Joules MJ = MegaJoule = 10 6 Joules GJ = GigaJoule = 10 9 Joules TJ = TeraJoule = Joules MWh = Mega Watt hour = 10 6 Watt hours (One watt-hour is equivalent to one watt of power used for one hour.) GWh = Giga Watt hour = 10 9 Watt hours