An Evaluation of Deinked and Virgin Pulp for Use in ...images.nationalgeographic.com/wpf/media-content/file/HarmRev.of... · HE20121003 National Geographic Society 12.12.12 An Evaluation

HE20121003 National Geographic Society 12.12.12

An Evaluation of Deinked and Virgin Pulp for

Use in Magazine Paper

Prepared for

National Geographic Society

by

Harmony Environmental Olathe, KS

December 2012

An Evaluation of Deinked and Virgin Pulp Summary

HE20121003 National Geographic Society

12.12.12 2

AN EVALUATION OF DEINKED AND VIRGIN PULP

FOR USE IN MAGAZINE PAPER

INTRODUCTION

In 2009, Harmony Environmental completed a life cycle carbon footprint of the National

Geographic magazine for the National Geographic Society (NGS). The Harmony study provided

NGS with specific supply chain information to enable NGS to reduce the magazine’s carbon

footprint. Data were collected from the deinked pulp supplier and the virgin pulp and paper

supplier to NGS. The study included the entire magazine life cycle (cradle-to-grave) and

evaluated the energy use and greenhouse gas (GHG) emissions for magazines made with 0%, 5%

and 10% deinked pulp displacing virgin pulp. The magazine life cycle started with growing and

harvesting trees for paper and ended with final disposal of magazines.

In 2012, Environ International Corporation completed a partial life cycle assessment (LCA)

(cradle-to-paper mill) of deinked and virgin pulp. The Environ study evaluated the relative

impacts of deinked pulp derived from waste paper versus the impacts of virgin pulp produced

from virgin wood sources. Since it was an LCA and not a life cycle carbon footprint, the Environ

study evaluated several types of environmental impacts, as well as energy use and GHG

emissions. However, Environ did not use data from the NGS supply chain. Data for deinked pulp

and virgin paper were obtained from the published U.S. LCI Database. The purpose of the

Environ study was to assist NGS with decision making regarding use of recycled pulp in

magazine paper.

Both studies were completed in accordance with ISO standards for conducting LCA studies. The

Harmony study was also peer reviewed. Each study reports GHG emissions in units of carbon

dioxide equivalents (CO2e) as an indicator of climate change impact. Since climate change is the

only impact category the two studies have in common, this review of the two studies focusses on

GHG emissions results as a measure of potential climate change impact. Harmony results for

deinked pulp and virgin pulp are compared to the Environ cradle-to-paper mill LCA results.

Revisions are recommended to make the Environ study more useful to National Geographic

magazine.

DISCUSSION

Data Availability and Results

The data used in any LCA is critical to the results of the LCA. Average industry results may or

may not be representative of the life cycle of a specific product. In conducting several

confidential studies for various clients, Harmony has observed that specific fuel sources and

regional electricity grid sometimes greatly affect the climate change impact of a product in

comparison to the impact calculated from an average of individual datasets. In comparing

deinked pulp to virgin pulp, we have seen cases where the deinked pulp produced significantly

more, significantly less or about the same quantity of GHG emissions as the displaced virgin



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pulp. Table 1 compares the fossil and biogenic CO2e results for deinked and virgin pulp (50%

mechanical and 50% Kraft) derived from the two studies. Please note that the deinked and virgin

pulp results from the Harmony study were not published prior to this review and Environ did not

have access to this information for their study.

The results shown in Table 1 highlight some important differences in the Harmony and Environ

studies that should affect NGS decision making.

The NGS paper supplier currently has access to cost effective electricity that is generated

from more than 60% hydropower. Thus, not only is the virgin pulp made using a high

percent of wood waste for fuel, but a high percent of hydropower also fuels the making of

the virgin pulp for NGS paper. The virgin pulp going into the NGS magazine generates

only about 60% of the GHG emissions of the average virgin pulp as calculated by

Environ.

The NGS paper supplier currently has access to deinked pulp that generates about 15%

more GHG emissions than the average deinked pulp as calculated by Environ. This may

be due to the location of the deinked pulp facility, which affects the fuels and electricity

grid available to the facility.

The deinked pulp available to the NGS paper supplier produces significantly more

biogenic CO2 than the average deinked pulp calculated by Environ. The biogenic CO2e

for deinked pulp in the Harmony study is due to disposal of the deinked pulp facility

sludge, which is made up of waste materials such as short fibers, ink, etc. This particular

facility disposes of the sludge by land application, which results in biogenic CO2e

emissions. Facilities that dispose sludge to landfills would generate more GHG emissions

due to methane emissions from degradation of the waste in landfills. Environ used an

Ecoinvent dataset that assumes deinked pulp waste is solidified using cement. This

method of disposal would not generate GHG emissions or biogenic CO2 from

degradation of the waste.

Environ Harmony

Displaced Virgin Pulp

Fossil CO2e (kg CO2e/kg pulp) 1.63 0.98

Biogenic CO2e (kg CO2e/kg pulp) 1.24 1.39

Deinked Pulp

Fossil CO2e (kg CO2e/kg pulp) 0.54 0.62

Biogenic CO2e (kg CO2e/kg pulp) 0.06 0.58

Table 1

Deinked and Displaced Virgin (50% Kraft/50% mechanical) pulp

impacts per kilogram (cradle to paper mill) pulp



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Impact of Displacing Virgin Pulp on the Whole Magazine Life Cycle

The climate change impact of displacing deinked pulp with virgin pulp is not nearly as dramatic

as shown in the Environ study when actual supply chain data is used. The Harmony study shows

that deinked pulp used in the NGS magazine produces about 60% of the fossil CO2e emissions of

the virgin pulp used in the magazine, not 33% as calculated by Environ. At the time of the

Harmony study, practical limitations indicated that the most deinked pulp content that could

displace virgin pulp was 10%. When the difference in fossil CO2e savings from using deinked

pulp is applied to 10% of the pulp and the GHG emissions for the rest of the magazine life cycle

are considered, the improvement in GHG emissions is only about 1% for the whole magazine life

cycle. This suggests that NGS and its suppliers may want to use their limited resources to

evaluate other ways to improve the carbon footprint of the magazine. The appendix to this report

updates the life cycle carbon footprint of the NGS magazine by adjusting the virgin pulp and

paper supplier’s fuel use to 2011 values. The supplier has reduced their facility GHG emissions,

which causes about a 4% reduction in total GHG emissions for the life cycle of the NGS

magazine.

Additional Observations

It remains unknown whether the deinked pulp available for the NGS magazine performs

better than the virgin pulp available for the NGS magazine in eight additional impact

categories that Environ studied. These are acidification, carcinogenics, non

carcinogenics, respiratory effects, ozone depletion, ecotoxicity and smog. Differences in

types and quantities of fuel for the specific supply chain compared to the average results

may cause different conclusions for these impact categories. If improving performance in

these impact categories is important to NGS, then an LCA using specific supply chain

data is recommended.

Neither study addresses social or economic impacts associated with choosing raw

materials. Social and economic impacts are also important considerations that NGS may

want to incorporate into their decision making.

Environ completed a separate study for NGS for the purpose of understanding the

availability of recycled paper and best practices for increasing recycled paper supply. The

study highlights the increasing demand for recycled paper in Asia and the resulting

increase in price of recycled paper that could be used as raw material for magazine paper.

The current increasing price of recycled paper is a driver for increasing paper recovery

rates in the United States. Increasing the recovery rate of paper is environmentally

beneficial, as we have seen from the comparison of deinked and virgin pulp. However,

the resulting increase in price of recovered paper may be economically debilitating for

magazine companies who want to use increasing amounts of recycled fiber.

RECOMMENDATIONS

A few recommendations to enhance the usefulness of the Environ LCA report are listed below.



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Include a footnote in Table 4 stating that the study results do not represent the National

Geographic magazine’s or any other magazine’s specific supply chain.

In Table 4, present impact results as a range of values instead of as single values to

further indicate that the results for the supply chain for any specific magazine may be

very different than the average results.

Add sensitivity analyses to evaluate the impact of purchasing electricity from different

local or regional grids, including dedicated hydropower and the Canadian electricity grid.

Review the quantity of sludge disposed by the deinked pulp facility. Evaluate impacts for

more common disposal techniques than solidification with cement. Landfill, incineration

and land application are more common disposal techniques in the United States.

SUMMARY

Both the Harmony and Environ studies provide useful information. The Harmony study

specifically addresses the contribution of the entire NGS magazine life cycle to the impact of

climate change. The Environ study compares cradle-to-paper mill life cycle impacts of average

deinked pulp and average virgin pulp (50% mechanical and 50% Kraft) for several different

impact categories.

GHG Emissions

Both the Harmony study and the Environ study show that deinked pulp generates less GHG

emissions than virgin pulp. The Harmony study shows that the difference in GHG emissions for

cradle-to-paper mill deinked and virgin pulp is not as dramatic for the specific NGS magazine

supply chain compared to the deinked and virgin pulp facilities represented in the U.S. LCI

database. Furthermore, the Harmony study shows that displacing up to 10% virgin pulp with

deinked pulp does not significantly affect the NGS magazine life cycle carbon footprint when the

entire magazine life cycle is considered.

Other LCA Impacts

The Harmony study does not address other LCA impacts. The Environ study shows that average

deinked pulp in the U.S. LCA database has a lower relative impact than the average virgin pulp

in the U.S. LCA database in all environmental categories analyzed by Environ. It is not certain

that the same results would be generated using specific supply chain data for the NGS magazine.

If the impact categories studied by Environ follow the same trend as the GHG emissions, the

improvement for each category when the entire NGS magazine life cycle is evaluated is likely

very small (1% to 2% improvement).

Conclusion

A sustainable product system balances environmental, economic and social impacts to create the

best product life cycle possible. In addition to considering how deinked pulp affects the



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sustainability of the NGS magazine, NGS may want to further evaluate other potential

environmental improvements, as well as economic and social issues.



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APPENDIX

REVISED TABLES AND FIGURES FOR THE NATIONAL GEOGRAPHIC

MAGAZINE LIFE CYCLE GHG STUDY USING SUPPLIER FUEL AND

ELECTRICITY ADJUSTMENTS FOR 2011.

INTRODUCTION

Though increasing the amount of recycled paper may not be economically viable at this time,

NGS and its paper supplier are making progress in reducing the life cycle carbon footprint of the

magazine. Harmony Environmental updated the NGS magazine LCA model to adjust the pulp

and paper mill fuel and electricity consumption to reflect 2011 facility conditions. The

adjustments were made according to actual fuel consumption records for 2008 and 2011 using

the factors shown below.

Canada Grid Electricity 1.7369

Diesel 0.9532

Distillate 1.0072

Gasoline 0.8521

Hydro Electricity 0.1847

Wood 1.0017

LPG 1.2511

Natural Gas 0.8711

Residual 0.6208

The tables and figures below are the same tables and figures presented in the 2009 Life Cycle

Carbon Footprint of the National Geographic Magazine report, except the results are calculated

using adjusted pulp and paper mill electricity and fuel values, as described above. The

adjustments to fuel use by the supplier facility cause a 4% decrease in GHG emissions for the

National Geographic magazine life cycle, as calculated by the Harmony LCA model. The

previous result for one magazine was 1.82 pounds (0.82 kg) CO2e.

This improvement in GHG emissions is greater than the improvement anticipated by displacing

10% virgin pulp with deinked pulp.



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Life Cycle Steps

One

Magazine

One Million

Magazines

Annual

Production

(2008)

Using 5% recycled content paper

Scope 1 (NGS direct combustion) 0.01 7,620 595,476

Scope 2 (NGS purchased electricity) 0.01 13,826 1,080,425

Scope 3 (Other) 1.73 1,729,136 135,119,366

TOTAL 1.75 1,750,583 136,795,267

Source: Harmony Environmental, LLC

Table ES-1. Global Warming Potential for Different Quantities of Magazines

(pounds of Carbon Dioxide Equivalents)

(Verso energy sources updated to 2011)

Life Cycle Steps

One

Magazine

One Million

Magazines

Annual

Production

(2008)



Scope 2 (NGS purchased electricity) 0.0063 6,270 489,989

Scope 3 (Other) 0.78 784,189 61,278,624

TOTAL 0.79 793,915 62,038,670



(kilograms of Carbon Dioxide Equivalents)

Table ES-2. Global Warming Potential for Different Quantities of Magazines



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Figure ES-1. System Boundaries



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Life Cycle Steps

Process

Energy

Transport

Energy

Energy of

Material

Resource

TOTAL

ENERGY

Percent of

Total


Coated Magazine Paper 18.6 0.74 0.0027 19.3 79%

Printing 2.72 1.43 0.055 4.21 17%

Transport by USPS and others 0.098 0.26 0 0.36 1%

NGS Operations and Travel 0.15 0.019 0 0.17 1%

Pallets and Packaging 0.35 0.027 0.33 0.71 3%

Disposal and Landfill Operations 0 0.12 0 0.12 0%

Combustion Credit -0.31 -0.31 -1%

TOTAL 21.6 2.60 0.39 24.5 100%



Printing 2.72 1.43 0.055 4.21 17%





Combustion Energy Credit -0.31 -0.31 -1%

TOTAL 21.2 2.62 0.39 24.3 100%



Printing 2.72 1.43 0.055 4.21 18%





-0.31 -0.31 -1%

TOTAL 20.9 2.65 0.39 24.0 100%

Source: Harmony Environmental

Table 3-1. Energy Results by Category

(Million BTU per 1,000 pound of National Geographic Magazines)




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Life Cycle Steps

Fossil

Energy

Non-Fossil

Energy

TOTAL

ENERGY

Percent

Fossil Energy


Coated Magazine Paper 7.78 11.5 19.3 40%

Printing 3.89 0.32 4.21 92%

Transport by USPS and others 0.34 0.019 0.36 95%

NGS Operations and Travel 0.13 0.039 0.17 76%

Pallets and Packaging 0.62 0.092 0.71 87%

Disposal and Landfill Operations 0.11 0.0010 0.12 99%

Combustion Energy Credit -0.31 -0.31

TOTAL 12.6 12.0 24.5 51%



Printing 3.89 0.32 4.21 92%




Disposal and Landfill Operations 0.11 0.0010 0.12 99%


TOTAL 12.5 11.8 24.3 51%



Printing 3.89 0.32 4.21 92%




Disposal and Landfill Operations 0.11 0 0.12 99%


TOTAL 12.4 11.6 24.0 52%


Table 3-2. Fossil and Non-Fossil Energy Results





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Life Cycle Steps Nat. Gas Petroleum Coal Hydropower Nuclear Wood Other

WTE

energy

Credit Total


Coated Magazine Paper 3.31 3.02 1.44 0.93 0.57 9.91 0.108 19.3

Printing 0.98 1.46 1.45 0.0046 0.29 0 0.020 4.21

Transport by USPS and others 0.039 0.25 0.057 0.0024 0.013 0 0.0037 0.36

NGS Operations and Travel 0.036 0.026 0.065 0.0015 0.034 0 0.0033 0.17

Pallets and Packaging 0.32 0.18 0.11 0.0027 0.015 0.071 0.0041 0.71

Disposal and Landfill Operations 0 0.11 0 0 0.00069 0 0.00020 -0.31 -0.20

TOTAL 4.70 5.04 3.13 0.94 0.92 9.98 0.14 -0.31 24.5



Printing 0.98 1.46 1.45 0.0046 0.29 0 0.020 4.21




Disposal and Landfill Operations 0.0054 0.11 0.0030 0.00013 0.00069 0 0.00020 -0.31 -0.20

TOTAL 4.66 5.01 3.12 0.91 0.92 9.81 0.14 -0.31 24.3



Printing 0.98 1.46 1.45 0.0046 0.29 0 0.020 4.21




Disposal and Landfill Operations 0 0.11 0 0 0 0 0 -0.31 -0.20

TOTAL 4.62 4.98 3.11 0.88 0.91 9.65 0.14 -0.31 24.0


Table 3-3. Energy Profile





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Life Cycle Steps Process Fuel Self-Reported Total


Coated Magazine Paper 73.6 1302 198 1574

Printing 0.22 614 0 614

Transport by USPS and others 0 58.2 0 58.2

NGS Operations and Travel 7.25 23.8 3.39 34.4

Pallets and Packaging 5.99 46.5 0 52.5

Disposal and Landfill Operations Fuels 0.00 18.9 0 18.9

End-of-Life Management * -57.6 -57.6

TOTAL 29.4 2063 201 2294

Percent of Total 1.3% 90% 8.8% 100%



Printing 0.22 613.9 0 614.1






TOTAL 29.2 2051 201 2281




Printing 0.22 614 0 614






TOTAL 29.0 2038 201 2268


* Emissions from WTE and landfill decomposition/sequestration


(pounds of CO2-equiv per 1,000 pound of National Geographic Magazines)

Table 3-4. Global Warming Potential by Category




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Fossil CO2 Methane Nitrous Oxide HFCs

CO2-Equiv

(self-

reported)

CO2-Equiv

(IPCC 1996)

Life Cycle Steps (lb) (lb) (lb) (lb) (lb) (lb)


Coated Magazine Paper 1191 6.56 0.15 2.3E-06 198 1574

Printing 579.7 1.43 0.014 1.5E-06 0 614

Transport by USPS and others 55.8 0.092 0.0015 0 0 58.2

NGS Operations and Travel 22.5 0.052 0.00054 0.0055 3.39 34.4

Pallets and Packaging 43.1 0.25 0.013 0 0 52.5

Disposal and Landfill Operations Fuels 18.2 0.02 0.00063 0 0 18.9

End-of-Life Management * -202 6.88 0 0 0 -57.6

TOTAL 1708 15.3 0.18 0.0055 201 2294



Printing 579.7 1.43 0.014 1.5E-06 0 614






TOTAL 1697 15.2 0.18 0.0055 201 2281



Printing 579.7 1.43 0.014 1.5E-06 0 614






TOTAL 1685 15.2 0.18 0.0055 201 2268




Table 3-5. Global Warming Potential by Chemical

(pounds per 1,000 pound of National Geographic Magazines)



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CO2-Equiv

(IPCC 1996)

CO2-Equiv

(IPCC 2001)

CO2-Equiv

(IPCC 2007)

(lb) (lb) (lb)

Life Cycle Step


Coated Magazine Paper 1574 1674 1688

Printing 614 617 620

Transport by USPS and others 58.2 58.4 58.5

NGS Operations and Travel 34.4 34.5 34.6

Pallets and Packaging 52.5 52.8 53.3

Disposal and Landfill Operations Fuels 18.9 26.1 19.0

End-of-Life Management * -57.6 -43.9 -30.1

TOTAL 2294 2419 2443









TOTAL 2281 2406 2430









TOTAL 2268 2392 2416



Table 3-6. Comparison of GWP Results using Different IPCC Estimates





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Fossil CO2 Methane Nitrous Oxide HFCs

CO2-Equiv

(self-

reported)

CO2-Equiv

(IPCC 1996)

Life Cycle Steps (lb) (lb) (lb) (lb) (lb) (lb)


Scope 1 (NGS direct combustion) 2.43 0.011 4.4E-05 0.0055 0 9.93

Scope 2 (NGS purchased electricity) 17.1 0.037 0.00041 0 0 18.0

Scope 3 (Other) 1688 15.2 0.18 3.8E-06 201 2266

TOTAL 1708 15.3 0.18 0.0055 201 2294


Coated Magazine Paper

Scope 1 (NGS direct combustion) 2.43 0.011 4.4E-05 5.5E-03 0 9.93


Scope 3 (Other) 1677 15.2 0.18 3.80E-06 201 2253

TOTAL 1697 15.2 0.18 0.0055 201 2281


Scope 1 (NGS direct combustion) 2.43 0.011 4.4E-05 0.0055 0 9.93


Scope 3 (Other) 1666 15.2 0.18 3.8E-06 201 2240

TOTAL 1685 15.2 0.18 0.0055 201 2268



Table 3-7. Global Warming Potential by GHG Protocol Scope




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0%

Recycled

Content

Paper

5%

Recycled

Content

Paper

10%

Recycled

Content

Paper

Life Cycle Step (lb) (lb) (lb)


Printing 4.35 4.35 4.35





End-of-Life Management * 117 117 117

TOTAL 2082 2069 2055



(pounds of biomass CO2-equiv per 1,000 pound of magazines)


Table 3-8. Carbon Dioxide Emissions from Biomass (Carbon Neutral)

Life Cycle Steps

One

Magazine

One Million

Magazines

Annual

Production

(2008)


Coated Magazine Paper 1.20 1,197,673 93,589,435

Printing 0.47 471,271 36,826,401

Transport by USPS and others 0.04 44,657 3,489,607

NGS Operations and Travel 0.03 26,419 2,064,429

Pallets and Packaging 0.04 40,259 3,145,975

Disposal and Landfill Operations Fuels 0.01 14,538 1,136,027

End-of-Life Management * -0.04 -44,235 -3,456,607

TOTAL 1.75 1,750,583 136,795,267



Table 3-9. Global Warming Potential for Different Quantities of Magazines




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Life Cycle Steps

One

Magazine

One Million

Magazines

Annual

Production

(2008)



Scope 2 (NGS purchased electricity) 0.01 13,826 1,080,425

Scope 3 (Other) 1.73 1,729,136 135,119,366

TOTAL 1.75 1,750,583 136,795,267


Table 3-10. Global Warming Potential for Different Quantities of Magazines



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An Evaluation of Deinked and Virgin Pulp for Use in ...images.nationalgeographic.com/wpf/media-content/file/HarmRev.of... · HE20121003 National Geographic Society 12.12.12 An Evaluation