PROJECT SUMMARY and ENVIRONMENTAL ISSUES For Visy Pulp and Paper, Tumut Mill Expansion pptx

PROJECT SUMMARY and ENVIRONMENTAL ISSUES
For Visy Pulp and Paper, Tumut
Mill Expansion

Prepared for NSW Department of Planning
May 2006

Visy Tumut – Mill Expansion ii
Project summary
TABLE OF CONTENTS
1 INTRODUCTION 1
1.1 Background 1
1.2 Increase in Production Capacity 1
1.3 Part 3A EP&A Act 1979 1
1.4 Concept Plan Approval Application 2
2 THE PROPOSED EXPANSION 3
2.1 Overview 3
2.2 Phased Installation 3
2.2.1 Initial Installation 4
2.2.2 Future Installation 5
2.3 Likely Environmental Impacts of the Expansion 8
2.3.1 Air Emissions 10
2.3.2 Odour Management 11
2.3.3 By-products 11
2.3.4 Traffic and Transport 12
2.3.5 Noise 13
2.3.6 Water Management 13
2.3.7 Wastewater Management 13
2.3.8 Socio-Economic Aspects 14
2.3.9 Other 14
2.4 Approvals Required for the Proposed Expansion 14
2.5 Environmental Impacts of Existing Operations 15
2.5.1 Environmental Management 15
2.5.2 Air Quality 15
2.5.3 Odour Management 17
2.5.4 Noise Management 19
2.5.5 By-products 19

2.5.6 Water/Wastewater Management 20
2.5.7 Traffic 21
2.5.8 Community Consultation 22
2.6 Other 23
2.7 Director General’s Requirements 23

Visy Tumut – Mill Expansion 1
Project summary
1 INTRODUCTION
1.1 Background
The Visy Pulp and Paper Mill in Tumut NSW commenced operations in 2001. The original EIS
submitted for the existing operations outlined the preliminary plans for a future mill expansion. A
specialist project feasibility team was appointed in February 2005 to undertake the feasibility study
required for submission to Visy Management for an investment decision in 2007. A pre-condition
for the feasibility decision making is obtaining the appropriate government approvals to enable the
investment to be undertaken
The current timetable is as follows:
♦ Finalise Environmental Assessments
by Q3/2006
♦ Development Approval
by Q4/2006
♦ Detailed Feasibility
by Q1/2007
♦ Final investment decision
by Q3/2007
♦ Construction begins
by Q3/2007
♦ Commissioning
by mid 2009
1.2 Increase in Production Capacity

Visy Pulp and Paper wishes to increase paper production from its Tumut Plant from the currently
approved 300,000 tonnes per annum to 700,000 tonnes per annum.

While the existing Development Consent permits an increase of paper production to 450,000
tonnes per annum subject to a further approval in terms of that consent, a new approval is required
to increase paper production to 700,000 tonnes per annum.
1.3 Part 3A EP&A Act 1979
The proposed development is a project within the terms of Part 3A of the Environmental Planning
and Assessment Act 1979. It comes within Item 4 to Group 1 to Schedule 1 of the State
Environmental Planning Policy Major Projects 2005. In this regard, it is a development having a
capital investment value of more than $30 million for the purpose of the manufacture of paper pulp
and involves paper recycling. The estimated cost of the expansion of the plant is a maximum of
$450 million. This amount will bring the overall investment in the plant to over $800 million, and
see a further 50 jobs created at the mill and a further 350 flow on jobs in supply and service
activities.

Visy Tumut – Mill Expansion 2
Project summary
1.4 Concept Plan Approval Application
For the reasons given below, Visy Pulp and Paper seeks the Minister’s authorisation to lodge an
application for a concept plan approval which will give approval to commence specified aspects of
the development on receipt of the approval.

The concept approval approach is required for Visy Tumut’s future expansion as it is necessary to
have up-front certainty for this project as it develops over time. The facility itself is a complex one,
which also exists within a complex wider framework. For example, aspects of Visy’s operations are
subject to ongoing changes in critical production technology, some of which are as yet only partly
defined. The plant is also exposed to changes in the relative availability of recycled paper fibre and
virgin fibre, respectively. In addition, important factors such as transport, which are external to the
facility itself but which have a major bearing on long-term cost competitiveness and regional

impacts, need to be taken into account during the project’s medium- to longer-term development.

In terms of the facility itself, there are presently a mix of technologies and processing solutions
required for the future aspects of the project which may necessitate a number of successive
development phases being implemented. Hence, some components may be able to be constructed
immediately upon receiving approval, whilst others may not be required until later in the facility's
overall development. For example, the immediate future may require construction of a recycled
fibre (RCF) plant, while an anticipated new fibre pulping line component might not be required until
supplementary plantation-grown virgin fibre sources become available. There are other aspects of
the plant that fall within the "immediate" and "later development" classes.

Visy’s expansion of its Tumut operation will require significant additional capital expenditure to be
raised and committed. Visy therefore requires the overall endorsement of the NSW Government,
via the planning process, to enable the component parts of this project to proceed with both
bankable security and with certainty as to the types of environmental assessments and controls
that may be required for components to be developed at a later date than the immediate expansion
elements. Visy Pulp and Paper is in a good position to assess the likely environmental impacts of
the proposed expansion given that it is an expansion of an existing plant which itself was the
subject of thorough environmental assessments and was approved subject to a number of
conditions.

This document is designed to provide:
a. An outline of the proposed development (its scale and nature);
b. Likely environmental impacts of the proposed development if it is carried out;
c. A list of other approvals that are required;
Visy Tumut – Mill Expansion 3
Project summary
d. An outline of the existing operations of the mill; and
e. In doing so, provide information to assist the Department to determine applicable Director-
General’s requirements for the project.

2 THE PROPOSED EXPANSION
2.1 Overview
Visy Pulp and Paper proposes to expand the existing facility at Tumut NSW by installing a second
paper machine and associated pulping capacity. This would bring the total approved site
production of paper to 700,000 tonnes per year.

A number of product options are currently being investigated for proposed mill expansion in order
to address the export market including:

1) A lightweight Kraft Liner Board (as produced by current mill)
2) A lightweight “Kraft Top” sheet, moving to Kraft Liner Board depending on wood supply
availability in the future (mainly recycle sheet with kraft top layer)
3) A white liner

A phased approach is proposed for the mill expansion. This will enable some plant components to
be installed immediately, with others being progressively installed over time to meet the project’s
expected production milestones. Note that it is anticipated to achieve 700,000 tonnes per annum
paper production as quickly as possible and required changes will come about from feedstock
flexibility. A summary of the nature and scope of the proposed development is outlined below.

2.2 Phased Installation
Set out below is an indicative description of the expansion phasing and is not intended to be
prescriptive. The exact phasing of the proposal in terms of the combination of components
installed at each phase, and timing of the installation will be subject to the availability of virgin fibre
as well as economic and market forces at the time. Therefore, prospects for the “Future
Installation” contemplated in 2.2.2 may be brought forward to the “Initial Installation” phase
described in 2.2.1 and subsequently enhanced as supplementary wood fibre becomes available.
As such it will be necessary that the approval for the expansion takes into account this need for
flexibility.

Visy Tumut – Mill Expansion 4
Project summary
The environmental impacts may change between the phases, based on the installed components
but the “maximum impact case” will be the benchmark adopted for the purposes of the
environmental assessments. That is the environmental assessments will be based on the
combination of the greatest impacts of each phase, even though the final configuration may not
necessarily result in all such impacts.

2.2.1 Initial Installation
Visy proposes to initially install a new Paper Machine, Fibre Line and Multi-fuel Power Boiler.
Production through the existing pulp mill would be increased from 750t/day to 1000t/day. This
would include modification to the existing Recovery Boiler, Fibre Line, Digester, Lime Kiln,
Recasuticising Plant and Evaporation Plant to allow for the increased production. The woodyard
will be expanded to allow for the increased tonnage of pulpwood, saw mill chips and boiler fuel.
The mill will continue to operate 24 hours per day, 7 days per week and chipping and debarking
operations in the woodyard will continue to run 15 hours per day 7 days per week.

Wood and Wastepaper Supply

Depending on availability, the initial installation will utilise approximately 60% virgin fibre and 40%
wastepaper. This will consist of sawmill residues, softwood pulp logs from State Forests and
private plantations, and waste paper from kerbside collections from Sydney and Melbourne. In
order to produce the white liner product, approximately 30,000 tonne per year of white purchased
pulp will be used.

Energy and Steam

Initially a new multi-fuel power boiler is proposed for power and steam generation. The proposed
fuel for the multi-fuel boiler includes paper machine residues from the existing mill including coarse

residues, de-inking and de-ashing sludge. De-inking and de-ashing sludge are two streams of
residues that are not currently produced by the existing mill and are associated with the use of a
higher proportion of wastepaper that is derived from kerbside collection. Additionally it is also
proposed to utilise paper machine residues from Visy’s existing mills in Sydney and Melbourne as
fuel for the multi-fuel boiler. The multi-fuel power boiler will be designed to utilise this increased
quantity of non standard fuels and will include best available technology for emissions controls.
There will be an additional stack installed for the emissions from the new multi-fuel power boiler.

Water and Wastewater

Fresh water will be supplied via the existing pipeline from Tumut River and stored in the existing
fresh water dam onsite. The additional quantity of fresh water can be accommodated by the
existing pipeline capacity and fresh water dam on site. A maximum of 1,600 ML/year of additional
Visy Tumut – Mill Expansion 5
Project summary
freshwater is required for the expansion giving a total freshwater demand of 2700ML/year for the
full plant.

Approximately 600 ML/year of additional effluent will be generated from the expanded mill,
resulting in approximately 1000 ML/year of total effluent from the full plant. The additional effluent
will also be treated onsite and irrigated onto Visy owned pastures using Centre Pivot irrigators.

Utilities

Natural gas will be utilised as the auxiliary fuel for the new multi-fuel power boiler. The additional
natural gas requirements can be accommodated by the existing capacity of the natural gas pipeline
and metering system on site.

A second transformer will be required and, together with associated high voltage equipment; this
transformer will be housed in the existing substation on site. A connection agreement with

Transgrid will be required when activation of the transformer is needed.

Stormwater and drainage associated with mill expansion will be connected to the current system
since the new components will be within the existing mill footprint. The stormwater detention pond
may need modification and run off from the expanded woodyard areas may require an additional
woodyard first flush dam.

2.2.2 Future Installation
When sufficient virgin fibre is available, Visy proposes to shift the fibre mix to approximately 80%
virgin fibre and 20% wastepaper and install additional pulp mill capacity. This would involve the
installation of a new Recovery Boiler, Lime Kiln and Recausticising Plant, Evaporation Plant, and
Batch Digester Plant. Mill operating hours would continue as per existing operations. It is noted
that the paper production will remain at 700,000 tonnes per annum.

Wood and Wastepaper Supply

As outlined above, this installation will utilise approximately 80% virgin fibre and 20% wastepaper.
On site de-inking of wastepaper is proposed as a process mechanism to enable replacement of
purchased white pulp.

Energy and Steam

In addition to the multi-fuel power boiler, an additional recovery boiler will be installed. The
emissions from the new recovery boiler will be directed to the stack servicing the emissions from
the multi-fuel power boiler and the new lime kiln. A natural gas turbine is proposed to be installed
Visy Tumut – Mill Expansion 6
Project summary
which would result in the mill being 100% self generating with the excess power exported to the
grid. The emissions from the natural gas turbine will be directed to a separate new stack.

Water and Wastewater

The freshwater demand and effluent production will not increase from the initial installation.

Utilities

An additional section of natural gas pipeline and a new pressure let down station may be required
for the supply of additional gas for the natural gas turbine.

Other

Visy proposes to establish a truck staging facility on the Hume Highway to regulate the flow of
trucks to and from the site carrying finished product and waste paper. The staging facility will
involve a warehouse for storage of finished product and wastepaper and truck parking/standing
areas for loading and unloading of material.

A list of the additional plant components proposed for the mill expansion is provided in Table 1
over the page. A preliminary layout showing existing plant and the proposed expansion
components is illustrated in Figure 1.






Visy Tumut – Mill Expansion 7
Project summary
Table 1: Mill Expansion – Proposed Plant and Equipment for Phased Installation
Initial Installation Future Installation

1

 Paper Machine–400,000TPY capacity
 Fibre Line
 80t/hr Multi-fuel Power Boiler fuelled by standard fuel and non standard fuels such
as urban wood residues and paper machine residues from Visy Tumut, Sydney and
Melbourne Mills
 Emissions stack servicing emissions from new Multi-fuel Boiler
 Log Crane, Stacker Reclaimers, Chipper and fibre storage areas
 Recycled Stock Preparation Line
 3 additional cooling towers
 Transformer, switch gear and cabling
 Digester (Batch or Continuous)
 750t/day Black Liquor Recovery Boiler
 Recausticising Plant and Lime Kiln
 Additional Evaporation Line
 2 additional cooling towers
 Recrystallisation Plant
 Wastepaper de-inking plant
 40MW Natural Gas Turbine and waste heat boiler
 Emissions stack servicing emissions from Natural Gas Turbine
 Visy Logistics truck staging facility on Hume Highway to regulate the movements of
finished paper and wastepaper to and from the site.

Expand/Modify Existing Components
 Paper Machine
 Fibre line
 Evaporation Plant
 Recausticising Plant and Lime Kiln
 Recovery Boiler

 NCG Collection System
 Condensate Treatment System
 Reel Store
 Woodyard
 Wastepaper Storage Yard
 Wastewater Treatment Plant
 Winter Storage Dam and Irrigation Areas
 Onsite stormwater drainage
 Natural Gas supply arrangement – pipeline and metering station on site for natural
gas turbine
 NCG Collection System
 Condensate Treatment System

1
Note that some components of the Future Installation Phase may be brought forward to the Initial Installation Phase subject to wood fibre availability.

Visy Tumut – Mill Expansion 8
Project summary
2.3 Likely Environmental Impacts of the Expansion
Expansion of the mill will have a number of general environmental impacts associated with it.
These include:
• Increase in energy and steam requirements for the process therefore an increase in
air emissions associated with combustion sources such as boilers and lime kiln
• Increase in noise levels from mill processes due to additional plant and equipment
• Increase in freshwater demand as production is increased
• Increase in fibre resource requirements
• Increase in traffic movements associated with additional fibre resources, boiler fuel,
and finished product etc.
• Increase in liquid effluent production. Associated with this is increasing irrigation
infrastructure and irrigation area for the treated effluent.

• Increase in the production of solid wastes from the process

Table 2 over the page outlines the maximum key operating parameters for the expanded mill.

Visy Tumut – Mill Expansion 9
Project summary
Table 2: Maximum Key Plant Operating Parameters for Expanded Mill
Operating Parameter Mill Expansion
(Maximum
input/output)
Annual Production (Air Dried TPY) 700,000
Wood Demand (incl pulp logs, saw mill residue and purchased pulp)
(Green TPY)
1,950,000
Wastepaper Demand (Air Dried TPY) 330,000
Internal Power Boiler Fuel Supply (GTPY)
1
265,000
2

External Power Boiler Fuel Supply (GTPY)
3
200,000
Mill Power Demand (MW) 71
Mill Power Generation (MW) 95
Average Power Export (MW) 24
Gas Usage (TG/yr) 4400
Traffic Movements (per day)
4
570

Freshwater Input (ML/yr) 2700
Effluent Production (ML/yr) 1000
By-products (TPY)
5
62,000
1
Internal Fuel = Bark, fines and Tumut Mill paper machine residue
2
Includes de-inking sludge from proposed future de-inking plant
3
External Fuel = UWR, forest residues, saw mill residues, paper machine residues from Visy Mills in Sydney and
Melbourne
4
Preliminary traffic movements for the mill expansion assumes no back loading and a combination of the maximum
tonnages from the immediate and future installation phases.
5
This includes power boiler fly ash and bottom ash, dregs, grits, lime mud, and saltcake. Paper Machine residues
from the current Tumut paper machine and the new Tumut paper machine including coarse residues, de-ashing
sludge and de-inking sludge are assumed to be used as fuel for the Multi-fuel Boiler proposed for the mill expansion.
The amount of by-products may decrease in the future as virgin fibre sources become more available and less
wastepaper is used which results in reduced production of paper machine residues and therefore less fly ash and
bottom ash is produced.






Visy Tumut – Mill Expansion 10
Project summary

2.3.1 Air Emissions
There will be additional combustion sources introduced to the site as part of the mill expansion
which will result in an increase in the total volume of air emissions to atmosphere. The following
combustion sources will contribute to the increased emissions volume:

Figure 2: Mill Expansion Combustion Sources





















The existing power boiler utilises the mill’s paper machine residues as fuel together with woodyard
residues and is permitted to use up to 50% urban wood residues. A broader utilisation of non
standard fuels is proposed for the multi-fuel power boiler including urban wood residues, paper

machine residues from the Visy Tumut paper mills and residues from other Visy paper mills in
Sydney and Melbourne. Utilising these fuels has the benefit of landfill avoidance of these materials
as well as fossil fuel avoidance thereby minimising fossil fuel based carbon dioxide emissions to
atmosphere.




Existing
Power Boiler
Existing
Recovery Boiler
Existing
Lime Kiln
Main
Stack
Increase flow
by 33%
Initial Installation
New Multi-fuel
Power Boiler
Stack
#2
Future Installation
Existing
Power Boiler
Existing
Recovery Boiler
Existing
Lime Kiln

Main
Stack
Flow returns to
current levels
New Multi-fuel
Power Boiler
Stack
#2
New Recovery
Boiler
New
Lime Kiln
Stack
#3
New Natural
Gas Turbine
Existing
Power Boiler
Existing
Recovery Boiler
Existing
Lime Kiln
Main
Stack
Increase flow
by 33%
Initial Installation
New Multi-fuel
Power Boiler
Stack

#2
Existing
Power Boiler
Existing
Recovery Boiler
Existing
Lime Kiln
Main
Stack
Increase flow
by 33%
Initial Installation
New Multi-fuel
Power Boiler
Stack
#2
New Multi-fuel
Power Boiler
Stack
#2
Future Installation
Existing
Power Boiler
Existing
Recovery Boiler
Existing
Lime Kiln
Main
Stack
Flow returns to

current levels
New Multi-fuel
Power Boiler
Stack
#2
New Recovery
Boiler
New
Lime Kiln
Stack
#3
New Natural
Gas Turbine

Visy Tumut – Mill Expansion 11
Project summary
The installation of the natural gas turbine will result in the mill being completely energy self
sufficient. In terms of environmental impact, natural gas is the cleanest of the fossil fuels,
particularly compared to coal fired generation in terms of:
• Low Nitrogen Oxides
• Low Particulate Matter without particulate matter control

Process design and pollution control equipment will ensure emissions will be compliant with the
NSW Protection of the Environment Operations Act and ambient air quality objectives will be met.
Holmes Air Sciences has been commissioned to conduct air dispersion modelling in accordance
with DEC (2005) Approved Methods for the Modelling and Assessment of Air Pollution in NSW.
2.3.2 Odour Management
Odour management will continue to be a high priority for the expanded operations. The NCG
collection will be replicated for the expanded plant. All odour improvements works that have been
made to the existing mill will be incorporated into the design of the new components including the

new Multi-fuel Boiler as secondary NCG management to the Recovery Boiler. Subject to
performance confirmation, the recently installed condensate treatment system will be replicated for
expanded operations to minimise odours from sources such as the Paper Machine, Cooling
Towers and Cooling Ponds. Odour modelling will be conducted in accordance with DEC (2005)
Approved Methods for the Modelling and Assessment of Air Pollution in NSW and DEC (2001)
Technical Notes – Draft Policy: Assessment and Management of Odour from Stationary Sources in
NSW.
2.3.3 By-products
There will be an increase in the quantity of process by-products from the mill expansion including:
• Power Boiler Fly Ash
• Power Boiler Bottom Ash
• Lime Mud
• Grits and Dregs
• Recrystallised Recovery Boiler Fly Ash
• Paper Machine Residues
• Wastewater Plant Sludge

Initially the new paper machine may utilise a larger proportion of wastepaper which is derived from
kerbside collections as opposed to box plant clippings which are used by the current paper
machine. This will produce two types of residue streams, both of which are proposed as fuel for
the new multi-fuel boiler. The de-inking plant will generate an additional sludge stream which is
also proposed as a fuel for the multi-fuel boiler. The amount of paper machine residues produced
Visy Tumut – Mill Expansion 12
Project summary
will depend on the type and quantity of wastepaper utilised. The amount of boiler ash produced will
depend on the degree of utilisation of mill residues as boiler fuel.

Visy intends to maximise the reuse or recycling of the mill by-products produced by the process.
Some of the by-products produced during the current operations (dregs, grits, lime mud and
wastewater treatment plant sludge) have proven to be useful soil amendment products and it is

anticipated that the additional quantities produced during the expanded operation will be used in a
similar manner. Other by-products have been sold for the manufacture of secondary products and
the additional quantities will be similarly utilised ie turpentine, sodium sulphate.

Table 1 in Appendix A shows the maximum expected tonnages of the above by-products from the
mill during the expanded mill operations.
2.3.4 Traffic and Transport

There will be an increase in the overall existing traffic movements associated with the mill
operations. This is associated with the increase in transport of raw materials such as wood fibre,
boiler fuel, wastepaper and chemicals as well as an increase in the production of finished product
and wastes. The use of B-doubles will be maximised and back loading of trucks will be carried out
as much as possible to minimise truck movements. The existing routes to and from the mill will be
utilised. The following table outlines the number of truck movements (two way daily truck
movements) predicted in the original EIS for the current operation, actual movements from
weighbridge data for current operations, original EIS predictions for the mill expansion and a
preliminary
estimation of movements from the expanded plant based on the combined maximum of
both the initial and future installation phases.

Table 3: Two Way Traffic Movements–Original EIS, Current Operations and
Mill Expansion Estimate
Current Operations Mill Expansion

EIS Actual
(2005)
EIS Prediction for
Mill Expansion
1

Estimated w
back loading
2

Estimated w/out
back loading
2

Two Way
Traffic
Movements

410

284

624

475

570
1
Original EIS predicted 624 two way daily truck movements without back loading and with a production tonnage of
450,000TPY.
2
The expanded plant is now proposed as 700,000TPY production. The estimated truck movements are based on
50,000TPY of by-products transported offsite to landfill or for re-use and assumes all paper machine residues
produced on site are used as fuel for the multi-fuel boiler.

Visy Tumut – Mill Expansion 13

Project summary
To minimise impacts, Visy is exploring the option of placing a staging facility on the Hume Highway
so that truck movements associated with finished product and wastepaper can be evenly
distributed along the Snowy Mountains Highway via Adelong and Gocup Road routes through out
the day to lessen the likelihood of having peak movement periods.
2.3.5 Noise

The expanded mill will continue to operate 24 hours per day, 7 days per week except during
required maintenance shut down periods. However the chipping and debarking operations in the
woodyard will continue to operate 15 hours per day 7 days per week. There will be an increase in
noise emissions from the mill processes however acoustical treatment of these components will
assist in minimising the noise impact from the mill site. The Benbow Group has been
commissioned to conduct an operational noise assessment in accordance with the DEC Industrial
Noise Policy to determine the necessary acoustic reduction that will be required for the expanded
plant to minimise noise impacts from the mill site.
2.3.6 Water Management

There will be an increase in freshwater requirements from Tumut River for the expanded mill
process. The existing infrastructure including the pipeline and dam capacity was initially sized to
take into consideration this proposed expansion. Therefore this infrastructure will not need to be
altered to accommodate the additional flow. An additional pump may need to be placed at the
extraction point on Tumut River. Filtration at the Tumut River pumps will also need improvement.

Visy’s current water licence allocation is 1,360 ML/yr of high security water (100%) and 76ML/yr of
general security water (38%) which gives a total of 1,389ML/yr. Additional water allocation will be
required for up to 2700ML/yr for the total freshwater use for the process.
2.3.7 Wastewater Management

There will be an increase in the production of wastewater by the mill facility. To accommodate the
storage of treated effluent during winter months, the Winter Storage Dam may need to be

expanded. This can be achieved by increasing the wall height and/or the footprint of the existing
dam. Geotechnical studies are required to determine the optimal method to increase the dam
capacity. A further option is the installation of an additional dam on the Visy property.

Visy intends to expand the irrigation of wastewater on the existing Visy property across the Snowy
Mountains Highway. This land has always been intended for irrigation of treated effluent from the
expanded plant or as a contingency for current irrigation operations. The development of this land
for irrigation would involve the installation of Centre pivot irrigators, pumping equipment, run off
dams and stormwater diversion drains.
Visy Tumut – Mill Expansion 14
Project summary
The International Centre for WATER (Water for Agriculture Technology and Environmental
Research) under the Charles Sturt University Institute for Land, Water and Society has been
commissioned to conduct an irrigation evaluation study to examine the soil, groundwater and
surface water impacts of the combined current and expanded irrigation operations.
2.3.8 Socio-Economic Aspects

When completed, the expansion will require an additional investment by Visy Industries of some
$450m at Tumut, which would bring the total site investment since 2000 to over $800m. It would
see a further 50 direct jobs within the mill itself, and a further 350 direct new jobs in supply and
service activities. Most of these will be associated with plantation establishment, management,
harvesting and transport.

Construction could generate similar numbers of jobs as were generated during construction of the
existing mill, which at its peak neared 800 people on site. There will be a short term increase in
demand on local services and infrastructure during the construction period.
2.3.9 Other

The mill expansion will generally remain within the current mill footprint. As such the flora/fauna
and heritage studies undertaken during the original EIS cover the area within which the impacts

would occur for the expanded mill. Therefore additional impacts are unlikely for these aspects.
However one plant layout option involves the re-alignment of the internal mill road through the
identified conservation curtilage around the Gadara Homestead located to the north of the mill site.
Assessment of the impact of this road re-alignment on the Gadara Homestead may be required.
Visual impacts will be associated with additional structures superimposed on the existing mill
infrastructure.

2.4 Approvals Required for the Proposed Expansion
The existing mill’s Development Consent Conditions and POEO Licence will need to be modified to
allow for the mill expansion in a manner that maintains the mill’s competitiveness in the
increasingly global pulp & paper market environment. Expansion of the existing winter storage
dam or construction of an additional winter storage dam may require construction works in the
vicinity of Sandy Creek and therefore may require a permit under Part 3A of the Rivers and
Foreshores Improvement Act 1948.
Visy Tumut – Mill Expansion 15
Project summary
2.5 Environmental Impacts of Existing Operations
2.5.1 Environmental Management

The current mill operates under a Development Consent with over 100 Conditions of Consent
issued by the NSW Department Planning (then Department of Urban Affairs and Planning) and a
Protection of the Environment Operations (POEO) Licence administered by the Department of
Environment and Conservation (DEC) (then NSW Environment Protection Authority) covering
discharge conditions relating to air, water, noise, waste and boiler fuel. Visy has demonstrated a
high level of compliance with these conditions and limits. Non compliances have occurred at times
during both the commissioning and operational phase of the current mill. These have been largely
in relation to air emissions and odour as a result of start up, shut downs and non steady state
operating conditions, and the Adelong transport curfew imposed by the conditions of consent.

The mill has in place a comprehensive Environmental Management System, accredited to ISO

14001. Environmental issues are discussed on a day to day basis, including complaints and
incidents. All activities relating to environmental management of the mill are reported annually in
the Annual Compliance and Monitoring Report which is submitted to government and the Visy
Community Consultative Committee.
2.5.2 Air Quality

Air emissions from the Main Stack, which is the combined discharge point for emissions from all
combustion sources (Power Boiler, Lime Kiln and Recovery Boiler), have complied with the POEO
Licence limits apart from occasional exceedences associated mainly with non steady state
conditions such as commissioning, start up and shut downs. In 2005, the Power Boiler duct was
added as a licence point for a number of parameters in association with the approval of utilising
urban wood residues as boiler fuel. A high level of compliance with the Licence Limits has also
been achieved for the emissions from the Power Boiler. Table 4 below outlines the Main Stack
emissions performance during the 2004-2005 reporting period compared to the POEO Licence
limits.

Table 2 indicates that the emissions from the Main Stack comply with the POEO Licence limits
based on the average of all samples taken throughout the year, whether periodically or on a
continuous basis. There have been some occasional exceedences of the limits mainly for opacity
and intermittently for TRS, SO2 and HCl which have been reported in the DEC Annual Return
2004-2005.

Visy Tumut – Mill Expansion 16
Project summary
Table 4: Average Main Stack Emissions and Licence Limits 2004-2005
Analyte Units of
Measure
License Limit Mean of Samples % of Limit
Cadmium mg/Nm3 0.5 <0.0003 0.06
Chlorine mg/Nm3 100 <0.6 0.6

Chromium mg/Nm3 Na 0.00075 Na
Mercury mg/Nm3 0.5 0.00015 0.03
Nitrogen Oxides mg/Nm3 400 131 32
Hydrogen Chloride mg/Nm3 50 4.8 9.6
Sulphur Dioxide mg/Nm3 250 4.8 1.9
Total Solid Particles mg/Nm3 50 23.3 46.4
Sulphuric Acid Mist and/or
Sulphur Trioxide
mg/Nm3 20 <0.1 0.5
Opacity % Opacity 20 8.03 40
TCDD ng/Nm3 0.1 0.0087 8.7
Hydrogen Fluoride mg/Nm3 20 <0.3 1.5
Hazardous Substances mg/Nm3 1 0.034 3.4
TRS as H2S mg/Nm3 3.6 0.68 19

Visy Tumut – Mill Expansion 17
Project summary
2.5.3 Odour Management
Management of odours has been a continual focus for mill management since commencement of
operations in 2001. Figure 2 below illustrates the cumulative odour complaints received per month
from the public from 2001 through to April 2006.

Figure 2 demonstrates notable reduction in the number of complaints received in 2006. This has
been due to the implementation of odour improvement works through the years since 2001.
Odours from the mill can be linked to situations where non steady state operations are occurring
which may be as a result of shut down, start up or upset conditions. The odour study conducted in
2003 found that the most significant odour sources during steady state operations were the Paper
Machine, Cooling Towers and the Wastewater Treatment Plant. The main cause of odours from
these sources was found to be due to odourous compounds in the clean condensate which is used
in these areas.

To address these odour emissions a Condensate Treatment System was developed during the
2003 odour project and fully installed on site in 2005. The aim of the system is to treat condensates
from the process by forcing the odourous sulphide compounds from solution into a gaseous phase
so they can be collected and destroyed in the Recovery Boiler. The treated condensates from the
system would then result in lower odour emissions. Verification of the odour reduction achieved
will be conducted shortly by odour sampling from sources such as the Cooling Towers, Cooling
Ponds and Paper Machine building. Visy’s considerable expenditure on capital items to improve
environmental performance and address community concerns is outlined in Appendix B.
0
50
100
150
200
250
300

350
400
450
July
August
Septemb
er
October
Novem
ber
Dece
m
ber
January
F
ebruary
Marc
h
April
Ma
y
June
Month
No of Complaint
s
2001/02
2002/03
2003/04
2004/05
2005/06

Figure 2: Cumulative Odour

Complaints YEJ 2001-

March 2006
Visy Tumut – Mill Expansion 18
Project summary
A further historical analysis shows that the majority of complaints regarding odour have been made
by residents within a 5km radius from the mill. An overall decreasing trend in the number of
complaints from all areas is evident over the last 4 years. See Figure 3 below.











The site maintains a 24-hour free hotline service for fielding of comments and complaints from any
person. An effort is always made to visit the complainant when possible (and if the complainant
agrees) and to return the complainant’s call to advise of the results of the investigations.
Operational staff has developed a checklist of potential odour sources and routine inspections of
these items are undertaken. All complaints, notifications or comments are logged and electronically
entered into the Visy E Alert system. Regular visits to nearby neighbours are also carried out by
Visy personnel to ensure that any concerns or issues raised have been satisfactorily addressed.

Figure 3: Complaints by Distance from Mill

0
50
100
150
200
250
300
YEJ2003 YEJ2004 YEJ2005 YE Apr 2006
Year Ending June
No. Complaints
<2.5km
2.5 - 5km
>5km
Visy Tumut – Mill Expansion 19
Project summary
2.5.4 Noise Management
The existing mill operations comply with the POEO Licence’s day and night time noise limits as
assessed in a noise compliance study conducted in July 2005 during adverse weather conditions
(nocturnal inversions). The only exception was the property “Woomera” where noise limits were
not met. Daytime noise levels were ~46dBA and night time noise levels were 40-41dBA. This was
initially identified in the original EIS as a location where noise limits may not be compliant due to
the close proximity to the mill. Visy is working closely with this resident to minimise impacts. The
following is a summary of the results from the noise compliance audit.
Table 5: Noise Levels Recorded at Neighbouring Properties July 2005
Parameter POEO Licence Limits “Pleasant View” “Reka” “Clee”
Daytime
LA10
40 dBA <36 dBA
1
36 dBA

2
21 dBA
2

Night time
LA10
38 dBA 27 dBA
2
35.5 dBA
1
34 dBA
1

Observed Levels (at night) (dBA)
3
<36dBA 31-32dBA 30dBA
1 = LA10 readings based on attended monitoring
2 = Readings based on minimum LA90 from unattended monitoring
3 = Observed levels during attended monitoring when mill was audible

2.5.5 By-products
In accordance with the mill’s POEO Licence and Development Consent Conditions, Visy has
conducted soil amendment trials on site utilising mill by-products such as dregs, grits and lime
mud. Results have shown the by-products have beneficially increased the topsoil pH to near
neutral levels. A slower increase in subsoil pH is also becoming evident.
Table 6: Topsoil and subsoil pH, 2000 and 2005
Year SMS1 SMS2 SMS3 SMS4 SMS5 SMS6 SMS7
2000 3.8 3.9 3.76 3.8 4.14 3.88 4.5 Topsoil (0-15cm)
2005 7.3 7.1 7.1 7.4 7.4 7.3 5.7
2000 3.94 4.89 3.98 3.99 3.93 3.99 4.07 Subsoil (15-100cm)

2004 5.00 4.30 4.6 5.3 4.5 4.4 4.5

The introduction of the Protection of the Environment Operations (Waste) Amendment (Residue
Wastes) Regulation 2005 in December 2005, has forced all potential soil amendment by-products
to now be landfilled until an exemption for their continued reuse is obtained from DEC. Saltcake
Visy Tumut – Mill Expansion 20
Project summary
produced from the recrystallisation of the recovery boiler fly ash, is bagged and stored in a
warehouse and has been sold for the manufacture of soap and detergent.

Table 1 in Appendix A outlines the management of mill by-products from the existing mill
operations.
2.5.6 Water/Wastewater Management
The current average fresh water consumption by the mill is below what was predicted in the original
EIS (4.8m3/ADt). The following table provides an outline of the freshwater usage for each year
since 2002.

Table 7: Average Freshwater Usage per Year since 2002.
Year Freshwater Used
(m
3
/Air Dried Tonne of Paper Produced)
July 2002 – June 2003 5.75
July 2003 – June 2004 4.38
July 2004 – June 2005 3.85
Overall Average 4.66

Annual average freshwater usage in the mill has decreased since commencement of steady state
operations (2002). The mill has implemented process improvements which have resulted in
improvements to the quality of clean condensate and thereby allowing increased amounts of clean

condensate to be recycled within the process which then reduces the demand for freshwater.

Although Visy is permitted to discharge treated wastewater to Sandy Creek in the event that
irrigation is not possible (due to a 1 in 10 wet year), this has not needed to occur to date. Irrigation
is managed utilising soil moisture and weather data. Groundwater, surface water and soils are
monitored in accordance with the POEO Licence and reported in the DEC Annual Return and
Environmental Compliance and Monitoring Report required by Development Consent Condition
number 12.

Wastewater quality has generally met the POEO Licence conditions. Table 8 outlines the
wastewater quality results for 2004-2005 reporting period compared to the POEO Licence.

Visy Tumut – Mill Expansion 21
Project summary
Table 8: Wastewater Results 2004-2005
Analyte Units License Limit Mean of Samples % of Limit
Manganese mg/L N.A 0.034 N.A
pH 5.5-9.5 7.3 N.A
SAR NA 3 N.A
TDS mg/L NA 489 N.A
Nitrogen mg/L 20 <2 10
Phosphorus mg/L 5 0.37 7.4
Zinc mg/L NA 0.178 N.A
BOD mg/L 40 2 5
TSS mg/L 45 15.7 35
Total OCP mg/L NA <1 N.A
Oil and Grease mg/L 5 3.2 65
Quantity Irrigated KL/day 16000 3830 24

2.5.7 Traffic

On average there are currently 284 two way daily traffic movements recorded over the
weighbridge. This includes some back loading of trucks delivering waste paper and boiler fuel with
finished product. Table 9 below outlines the average number of two way daily truck movements
per route.
Table 9: Two Way Daily Truck Movements – Current Operations
Route Weighbridge Data (Jul-Dec 2005)
Via Snowy Mountains Highway – Adelong 39
Via Batlow Road – Wondalga 62
Via Gocup Road – Gundagai 44
Via Bombowlee Creek Road – Buccleuch 75
Via Snowy Mountains Highway – Talbingo 2
From Tumut Township 62
TOTAL 284

The most trafficked routes are; via Bombowlee Creek Road - Buccleuch followed by Tumut
Township, and Batlow Road - Wondalga. The first and third routes cover log deliveries for the
process coming from the major forest area to the north and south of the Tumut township
respectively. The second route covers wood chip and products/services sourced from within the
Tumut area.

Visy Tumut – Mill Expansion 22
Project summary
The original EIS estimated the maximum two way daily loaded truck volume to and from the mill
would be 410 trucks per day assuming no back loading. Therefore the actual daily two way
movements are significantly less than estimated in the original EIS. This is due to back loading of
boiler fuel and wastepaper trucks with finished paper and the use of a higher proportion of B-
doubles compared to what was assumed in the original EIS.

Table 10: Two Way Traffic Movements - Current Operations and Original EIS Predictions
Current Ops Actual EIS Prediction*

Two Way Daily Traffic Movements 284 410
*Original EIS predicted maximum one way daily loaded truck volume to and from mill was 205 trucks/day and to
double this number in order to estimate the two way movements with no back loading (410).


***

In summary, it is expected that based on current operations, the environmental impacts associated
with the mill expansion will be within acceptable limits.

2.5.8 Community Consultation
As a condition of the Development Consent, the Visy Community Consultative Committee (VCCC)
was formed in October 1999. The role of the VCCC is to monitor Visy’s compliance with the
conditions of the Development Consent. The VCCC meets monthly and has achieved a number of
objectives since its formation. The VCCC represents the interests of neighbours, local progress
association bodies, Tumut Shire Council and the broader community as well as Visy’s interest.

In 2004, the Visy Community Consultative Committee in partnership with Visy commissioned an
extensive independent community survey of the Tumut and surrounding districts to gauge people’s
views on how Visy has impacted the community in regards to Economic, Social and Environmental
matters. The survey also sought to gauge the communities understanding of the role of the VCCC,
and its effectiveness. The Questionnaire was prepared assisted by Social Science researchers
from Charles Sturt University, Wagga and was mailed out to over 6,000 households in April 2004.
The aim of the survey was to:
• Find out how the communities perceives Visy’s overall performance on economic,
social and environmental matters
• Ensure the communities concerns are being addressed
• Ensure a benchmark on how Visy’s performance is perceived by the community
• Raise community awareness of their voice to Visy – the VCCC; and
• Further develop the relationship between Visy and its community (recognising that

Visy employees are a part of that community too.)