ECONOMY

BUSINESS: 333 PRACTICES


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Initiative

Applied Sustainable Development in Industry

Applied Sustainable Development in Industry
SUBMITTED FROM:

KOMOTINI PAPERMILL

Komotini Paper Mill SA has been producing, trading and exporting tissue paper from its facilities in the Industrial Area of Komotini in NE Greece since 1979, committed to long-standing customer relationships and respect to the local community and the environment.

 

Read more: www.komotinipaper.gr


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Objective Action

The action aims to contribute to the growth of an environmentally sustainable industrial paradigm and the gradual adjustment of past dominant production models to the necessity of reducing the environmental footprint of industrialization. Specifically, paper production is an energy- and water-intensive process while it also requires forest management,wood being the raw material in the form of pulp. The latter is internationally treated by introducing purposely cultivated timber and FSC accredited feedstock from managed forests. Minimizing cellulose fiber effluent in process wastewater remains a critical parameter in papermaking and tissue paper mills in particular. By adopting innovative practices from heterogeneous sectors or developing custom solutions, Komotini Paper Mill undertook the goal to minimize its environmental footprint - energy, water, fiber – and thus related costs, alas proving in parallel what can be realistically achieved by a European SME in the short to medium term with today’s tools.

 

Target Audience

  • Local by reducing the footprint in the locality of the installation.
  • European-wide through the reduction of Green House Gases (GHG) as capped and traded under EC’s ETS.
 

Duration

Initiated 2010, materialised 2012-13.

In operation over the past 3 years with a vision to expand to 1MW CHP and utilise local agricultural waste.


Description

Komotini Paper Mill SA is a tissue papermaker and an exporting enterprise established in 1979, located in the Industrial Area of Komotini in Thrace, Greece. Up to 30% of turnover is exported to countries such as Turkey, Bulgaria, Albania, Macedonia, Cyprus and Romania. In its current phase KPM focusses in the production jumbo rolls (aka parent reels) which serves as raw material to paper converters who prepare the final product for the consumer’s shelf. Paper making is an energy and water intensive process and KPM committed to a continuous program of reducing its production costs through interventions in its environmental footprint and the efficient use of its business and environmental resources. In this context it achieved excellent rate of reuse of its process wastewater and the retention of cellulose fibers achieving the lowest band of the European BATs in cubic water per tonne of paper with a view of theoretically closing its water circuit.

In 2010, as a part of this strategy, KPM studied options for steam production with mild means to replace 11 tons of fuel oil per day (approx. Equivalent of 11.000 tCO 2) burnt in its steam boiler.

After selecting a suitable contractor the company proceeded to exploit the small but significant national expertise in burning dried olive pomace in refined olive oil installations and some large greenhouses. The design specs included a multi-fuel biomass boiler for industrial grade steam production (production 10 tn steam per hour at 18 bar pressure) for 24/7 use. As KPM did not have its own waste for incineration and should procure the biomass fuel by conventional trade, it was necessary to optimize the design for a multitude of biomass sources. The biomass boiler was fired up  in November 2012, went into trial operation in February 2013 and operates almost continuously from March 2013. 

It was the only industrial application of a biomass boiler in Greece without own residues and an innovative  application for an SME at European level. The result is a minimum 20% savings in financial resources in relation to the previous fossil fuel, reinforcing the viability of the company and its export orientation  while almost  eliminated pollutants of greenhouse gases  making it perhaps the first really  green industrial 'carbon neutral' paper industry in Greece. Since then in order to manifest the willingness to spread this innovation, a variety of industries in Greece visited the unit and several followed the example of creating a virtuous cycle of environmental protection and competitive business advantage. 

Komotini Paper Mill is in the process of expanding its biomass experience with the gradual exploitation of rural  residues in the region (cotton) and already has an  approved  program  from the Greek General Secretariat of Technology in collaboration with the research centre CERTH entitled "Optimization  biomass system in papermaking for increasing KPM boiler’s efficiency and availability ". Furthermore, KPM studied and is about to execute the utilisation of exhaust gasses to generate electricity and aims to a comprehensive 1MW CHP plant in the near future.

In parallel, Komotini Paper Mill has completed a study for an Artificial Wetland (aka Constructed Wetland) in order to reuse 100% of its wastewater, provide a local habitat for birds and other aquatic life while the reeds of the wetland will be harvested for use in the biomass boiler, in a world class synergy. In 2013, it also installed a 100kW PV park on its roof.


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Impact on Society

Beyond the tangible results presented below, the action drastically reduces the local release of pollutants from burning fossil fuels and enables continuous improvement of residual biomass combustion from industry. In paraller, the company has been testing the collection and use of agricultural and forestry residues thus avoiding unregulated incineration in the fields. Finally, in the next stage of development, the action will strengthen financially the local economy through the contractual cultivation of energy seedlings (i.e. short rotation coppice) in arid land.

Regarding water supply, the action saves great amounts of the water table in a purely rural area that already suffers from intrusion of brackish water in the boreholes.

At European level, the contribution is a substantial revision of steam production processes demanded by industry, especially SMEs that are usually limited to the amount of risk they can take on innovative practices and methods.

Measurable results:

  • About 8000 tons of CO2 equivalent in the European Trading System (ETS) per year
  • 36000 cubic meters of water saved based on the average of EC BATs per year


Initiative Location

Komotini, Rodope, Northern Greece.


Working with Organization

CERTH, NB Energy Contractors.


Workers Participation

Throughout the operation and management processes.


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Benefits for Οrganization

The action resulted in a significant reduction of industrial costs and rendered the company competitive in a time of great economic crisis in Greece. It promoted exports, allowing the company to meet a significant part of the increased cost of transport to third countries and also increased the distance range for exports providing access to new markets.

At the same time, the action estabished a new strong culture of continuous improvement and environmental protection to the company's management and employees.




Connection with Global Goals



No Connection with Global Goals found




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