Waste into Value
INSTEAD OF LANDFILLS, THE WASTE PAPER IN DISPOSED AT OUR PAPER MILL
The paper mill of Hamburger Hungaria turns waste paper into value instead of disposing it in incineration plants or landfills. Waste paper fibers can be recycled six times a year, which enables – by means of a well-organized collection system – major primary raw material savings. Thus, it is worth collecting waste paper selectively.
WE RECOVER 95% OF THE WASTE GENERATED DURING PRODUCTION
Not only production but the whole of the production process is characterized by recovery, as 95% of the waste generated during production is further recovered. The majority of the waste is utilized in our power plant for energetic purposes.
Efficient and Green Energy Management
WE USE HALF AS MUCH ENERGY THAN WE DID 20 YEARS AGO
Due to the continuous technological and energy efficiency developments, we use approximately half the amount of energy for the production of one ton of product than we did 20 years ago.
WE USE ENERGY PRODUCED BY OWN
In order to increase the waste recycling rate and self-sufficiency, with a 15 million euro investment in 2016, our own power plant was put into service, which can also utilize raw materials obtained from domestic waste. Our high-tech power plant has the capacity to produce 158 MW thermal energy and 42 MW electricity ensuring the plant’s energy self-sufficiency for the operation of the paper mill as well as promotes the utilization of residual waste from paper production that was previously disposed at landfill sites.
Power Plant at Hamburger Hungaria Site
OUR PLANT CHIMNEYS DO NOT EMIT ANY SMOKE
To minimize the environmental impact, modern exhaust gas cleaning equipment is operated in the power plant, consequently, exhaust gas virtually remains unnoticed for the residents of nearby settlements. 97% of waste – slag, fly ash, metal, plastic – generated by the operation of the power plant is recycled in, for example, recultivation or road construction.
The power plant uses coal, biomass, paper mill wastes, biogas and natural gas as fuels and consists of three main units:
1. The fuel handling system consists of the receiving stations and the storage units of the materials that are used as fuel, and preparing them for firing. The fuels are transported from the receiving stations and storages to the boiler through the processing systems with the aid of conveyors.
2. The nominal output of the boiler is 172 MW. The boiler is implemented with circulating fluidized technology which means upwards jets of air cause the fuel particles to be suspended in a hot fluidized bed together with bed ash and sand. The combustion air gets into the furnace through nozzles installed at the bottom of the fluidized bed. Thus, the solid fuels and gases mix intensively and quickly which results in good heat transfer and chemical reactions.
3. The maximum capacity of the extraction condensing turbine is 45 MW. The nominal speed of the machine is 5500 rpm. The rotor is made of solid forged steel, whereas the high pressure front casing is made of cast steel, and the low pressure casing is a welded construction. The required amount of steam (120-160 t/h) is supplied with 7.5 bar pressure for paper production from the turbine extraction. Generator data: nominal output 52,6 MVA, nominal voltage 11,0 kV, current 2760 A, and speed 1500 rpm. The wet cooling tower has three units. Nominal capacity: 45 MW, surface requirement 30 * 10 m. The diameter of the fans is 6 m.
Responsible Water Management
CLEAN WATER IS RELEASED INTO THE DANUBE
By means of our modern wastewater treatment plant, the water used for production is returned to nature just as clean as it was taken.
The water demand of the paper industry is extremely high. When it comes to environmental aspects, it is a huge challenge to establish a sustainable water management system. The water utilization model introduced by Hamburger Hungaria is in compliance with the highest technological expectations.
Due to our model, the natural water demand of the paper mill has not increased since 2015. Projected to one ton of paper produced, our water use has not exceeded the value of 7 m3/t in the course of recent years, while the reference value for the best available technologies in the industry is as high as 10 m3/t.
WE ARE ALSO AT THE TOP IN WASTEWATER MANAGEMENT
Due to the significant water demand of paper production, it is of the utmost importance to reduce the consumption of fresh water and the volume of released treated water by the recycling of waters with high fiber content. In order to achieve this, we continuously set out to modernize our wastewater management process.
Our paper mill has its own wastewater treatment plant where the released wastewater is treated in a two-phase biodegradation system. Regulatory reviews support the fact that the quality of the released water is more favorable than the prescribed limit value, moreover, it is in compliance with the requirements posed by “Best Available Techniques” in all respects.
WE PLAN TO FURTHER DEVELOP GREEN TECHNOLOGY
Due to investments of recent years, wastewater management does not only constitute a cost for our company, but it is also a new way to create value, because we are able to produce certifiably green electricity by our biogas fuelled small power station, utilizing the biogas originating from wastewater treatment.
Biogas fuelled small power station
During the treatment of waste water from the production lines of Hamburger Hungaria Ltd., approximately 23.3 MJ/m3 biogas with a calorific value is generated, what is used for production of electricity and heat. as renewable source of energy. The efficiency of conversion is 86.3%.
The two gas-fuelled engines are equipped with generators of 1200 kW nominal power each. The heat derived from the cooling of the gas-fuelled engines and from the flue gas (2 x 1321 kW) is utilized for the pre-heating of the CFB boiler feed-water.
- Biogas cleaning system
- Biogas transport system, pressure boosters
- Gas-fuelled engines, generators
- Cooling systems, heat exchangers
- Switching apparatus for connection to the electricity network and 22/0,4 kV transformers
- 1120 m long, 22 kV electric line at the production site