iPA 440/1-75/047
iroup I , Phase II
Development Document for
Advanced Notice of Proposed or
Promulgated Rule Making for Effluent
Limitations Guidelines and
New Source Performance Standards
for the
Bleached Kraft, Groundwood, Sulfite, Soda,
Deink, and Non-Integrated Paper Mills
Segment of the
Pulp, Paper, and Paperboard Mills
Point Source Category
3, ^ ^ UJ
O
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
AUGUST 1975
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NOTICE
This document supports the Advanced Notice of Proposed
or Promulgated rulemaking for effluent limitations and
standards of performance and pretreatment standards for new
sources for the bleached kraft, groundwood, sulfite, soda,
deink, and non-integrated paper mills segment of the pulp
and paper industry. It includes technical information and
recommendations regarding the subject industry. It is
being distributed for review and comment only.
The report, including the recommendations, will be
undergoing extensive review by EPA, Federal and State agencies
public interest organizations, and other interested groups
and persons during the coming weeks. The report, and in
particular, the recommended effluent limitations guidelines
and standards of performance are subject to change in any
and all respects.
The regulations to be published by EPA under Section
301, 304, 306, and 307 of the Federal Water Pollution Control
Act, as Amended, will be based to a large extent on the
report and the comments received on it. However, pursuant to
Sections 304(b) and 306 of the Act, EPA will also consider
additional pertinent technical and economic information
which is developed in the course of review of this report by
the public and within EPA. EPA is currently performing an
economic impact analysis regarding the subject industry,
which will be taken into account as part of the review of
the final report. Upon completion of the review process,
and prior to final promulgation of regulations, an EPA
report will be issued setting forth EPA's final conclusions
concerning the subject industry, effluent limitations guidelir
and standards of performance applicable to such industry.
Subject to these limitations, EPA is making this document
available in order to encourage the widest possible participal
of interested persons in the decision making process at the
earliest possible time.
U.S. Environmental Protection Agency
Office of Water & Hazardous Materials
Effluent Guidelines Division
Washington, DC 20460
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DEVELOPMENT DOCUMENT FOR
ADVANCED NOTICE OP PROPOSED OR
PROMULGATED RULEMAKING FOR EFFLUENT
LIMITATIONS GUIDELINES AND
NEW SOURCE PERFORMANCE STANDARDS
FOR THE
BLEACHED KRAFT, GROUNDWOOD, SULFITE SODA
DEINK, AND NON-INTEGRATED PAPER MILLS
SEGMENT OF THE
PULP, PAPER, AND PAPERBOARD MILLS
POINT SOURCE CATEGORY
Russell E. Train
Administrator
James L. Agee
Assistant Administrator
for Water and Hazardous materials
Allen Cywin
Director, Effluent Guidelines Division
Craig Vogt
Project Officer
August 1975
OffinfffiUf7nt Guidelines Division
Office of Water and Hazardous Materials
U. s. Rn^rv^ental Protection Agency
ton, D. C. 20460
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OHL'W
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ABSTRACT
5
1. Bleached Kraft: Dissolving Pulp
2. Bleached Kraft: Market Pulp
3. Bleached Kraft: Fine Papers
<4. Bleached Kraft: B.c.T. Papers
5. Sulfite: Papergrade
6. Sulfite: Dissolving
7. soda
8. Groundwood: Chemi-mechanical (CMP)
9. Groundwood: Thermo-mechanical (TMP)
10. Groundwood: Fine Papers
11. Groundwood: C.M.N. Papers
12. Deink
13. Non-Integrated Fine Papers
14. Non-Integrated Tissue Papers
15. Non-Integrated Tissue Papers (fwp)
The identified technology for July l 1977 ^0 ...
waste water management followed by preliminary scr^n? ln'Plant
-------
The identified technology for July 1, 1983, is in-plant waste
water controls and biological treatment. The identified in-plant
control* may require some major changes in existing processes and
design modifications to existing eguipment. In addition,
filtration with chemical addition and coagulation is identified
for TSS redaction. Physical-chemical treatment for color removal
is identified for five subcategories.
The identified technology for new source performance standards is
in-plant weste water controls, biological treatment, and chemical
addition and coagulation. The identified in-plant controls and
external treatment systems are available for implementation as
they have all been demonstrated at mills within the subcategories
under study.
Supportive data and rationale for development of the effluent
limitation* and standards of performance are contained in this
repcrt.
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Section
I. CONCLUSIONS
II. RECOMMENDATIONS
O
III. INTRODUCTION
IV. INDUSTRY CATEGORISATION
V. WASTE CATEGORIZATION
VI. SELECTION OF POLLUTANT PARAMETERS ]87
VII. CONTROL AND TREATMENT TECHNOLOGY ]g.
VIII. COST, ENERGY, AND NON-WATER QUALITY
ASPECTS
373
f5lT?^IICABLE CO*™0*- TECHNOLOGY CURRENTLY
AVAILABLE, LIMITATIONS
X. BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE, LIMITATIONS
XI. NEW SOURCE PERFORMANCE STANDARDS AND
PRETREATMENT STANDARDS
597
XII. ACKNOWLEDGMENTS
605
XIII. REFERENCES
607
XIV. GLOSSARY
627
XV. TERMINOLOGY INDEX
633
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LIST_QF_TABLES
Tables
1 BPCTCA Effluent Limitations in kg/kkg (Ibs/ton) 4
2 BATEA Effluent Limitations in kg/kkg (Ibs/ton) 5
3 NSPS in kg/kkg (Ibs/ton) 6
4 Summary of Surveyed Mills H
5 Stream Symbols '^
6 Parameters Measured and Abbreviations 15
7 Bleaching Sequences 19
8 products of Subject Industry Segments 22-24
9 Distribution of Mills by Segment 28
10 Tabular Description of Non-Integrated Papermaking
Segments ^
1;L 1972 Production by Pulp Type and Paper Grades 39
12 common Sequences Used to Bleach Kraft Pulp to
Various Degrees of Brightness 62
13 Samples of Shrinkage of Various Types of Paper
on Deinking '2
14 Raw Waste Load Per Subcategory 81
15 Bleached Kraft Segment, wood Type vs Raw Waste Load 84
16 Newsprint Segment 88
17 Bleached Kraft Segment, Age vs Raw Waste Load 89
18 Raw Waste BOD vs Number of Machines 90
ig Raw waste BOD vs Geographical Location 98
20 comparison of 1965 vs 1972-3 Water Use 113
21 Analysis of Hydraulic Barking Effluents 117-11
22 Analysis of wet Drum Barking Effluents 119
23 Raw Waste BOD vs Groundwood Pulp Brightness 123
21t Raw Waste Load - GW-Chemi-Mechanical Subcategory 125
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Tables
Page
25 BOD5 vs Groundwood Yield
26 Raw Waste Load - GW-Fine Papers Subcategory 127
^ ^ WaSte L°ad - GW~C™ Papers Subcategory 129
in a Sulfite Pulp Mill ndividual Processes
29 • 13°
Segment**90162718*105 3nd Raw Waste Loads, Sulfite
30 137
Raw waste Load Papergrade Sulfite Subcategory 13g
" Raw waste Load Dissolving Sulfite Subcategory 142
XiJS (Sf Cha"c^istics of Kraft Bleaching
o:> T 148
Kraft Bleaching Raw Waste Characteristics (stream 1, 149
Raw waste Characteristics of Various stages of Bleaching ,50
C°nStitUentS °' «« 8t«9- Bleaching Effluent ,H
Stream 9 Color Data from Surveyed Mills
'^ C°10r "aSte ^^ - Bl«ch.a Kraft segment ,„
R3W "aSte L0ad' BK: W-olving Pulp Subcategory I57
' ra t-Market Pulp Subcategory i5g
Raw waste Load, Bleached Kraft-BCT Subcategory m
^ Raw Waste Load, BK-BCT 8 Market Mills
a p 161
Raw waste Load, Bleached Kraft-Pine Paper Subcategory ^
143 Raw waste Load - BK-Fine 6 MKT Mills
a a 164
Raw waste Load, Soda Subcategory
U5 o i •^ 167
sol.ds and BODS Loading From Deinking Mil! Operations m
"<• Deink Mill skrinkage
T ~J *\
47 Raw waste Load, Deink Subcategory
48 Estimated Water Usage for Papermaking
no
Estxmated Water Usage for Fourdrinier Showers
5» Estimated Non-Equilibrium Papermaking Losses
179-181
vn
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T U1
Tables
51 Raw Waste Load, NI Fine Subcategory 184
52 Raw Waste Load, NI Tissue Subcategory 185
53 Raw Waste Load, NI Tissue (FWP) Subcategory 186
54 internal Measures Used at Surveyed Mills 200
55 External Measures Used at Surveyed Mills 201
56 External Technologies Currently in Use 231
57 Month of Maximum Average BOD at Final Discharge
for Surveyed Mills with ASB 239
58 Mills Selection for Variability Analysis 248
59 Data Screening 249
60 Symmetry and Kurtosis of BOD Log and Normal Distribution 253
61 Symmetry and Kurtosis of TSS Log Normal Distribution 254
62 TSS Daily Max Relative to 99 and 99.9% Probability
Confidence 255
63 TSS Daily Max Relative to 99 and 99.9% Probability
Confidence 256
64 comparison of Plant Variability to Limitation
Variability 257
65 variability of Mills Complying with the BOD and TSS AA« s 259
66 Variability of Mills Complying with BOD AA and
Not Reporting TSS 259
67 Variability of Mills Complying with BOD AA
and Not Meeting the TSS AA 260
68 Variability of Mills Not Complying with the
BOD AA 260
69 Values for Color Discharged from Various Pulping
Processes (5)
70 contribution of Effluent Sources to Total Mill
Effluent Color ^
71 comparative Effluent Analysis - Control vs APS 274
Comparison of Commercial Treatmer
for Bleach Plant Effluent vs APS
72 comparison of Commercial Treatment Processes
73
977
Bleaching Effluent Survey <-"
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Tables
Page
74 Individual Flow of Effluent During Bleaching 279
75 Individual Flow of Effluent During Bleaching 280
76 Effluent Loading of Pine Kraft, KAPPA No. 35 281
77 Comparison of CEDED Sequence with and without
02 Stage and Replacing CE Stages with 02 Stage 282
78 Comparison of CEHDED w/OGEDED 284
79 Comparison of CEH w/OCE 285
80 Comparison of CEDED w/OCED 285
81 Comparison of CE w/OC
82
86 Color Removal Efficiency
|^°f Recycle °n overall Percent Reductions
Effluent Characteristics by use of an Alternate
Aklali-Oxygen Stage ooc
COD
83 Color and Organic Carbon Removal 290
84 Contribution of Effluent Sources to Total
Mill Effluent Color with Massive Lime Treatment
of Bleach Extraction Stage and Decher Effluent 292
85 Statistical Data
304
311
87 Color Removal in Biological Oxidation Carbon
Adsorption Sequence at 15 GPM (2.13 GPM/FT2) 317
88 Color Removal by Primary Clarification Carbon
Adsorption Sequence
31 8
89 color Removal by Lime Treatment-Carbon Adsorption
Sequence at soluble Calcium Range of 69-83 mg/1 32Q
90 ^T?Va^ Ofr9olor and TOC by FACET Carbon Adsorption
Following Lime Treatment for 12-Day Period 10/20
through 11/6
321
91 Waste Water Renovation - Summary of Results 322
92 Renovated Water Analysis
93 Renovated Water Analysis
94 Color Removals for Various Applied Ozone Doses 327
95 Summary of Available Information on Filtration
in Waste Treatment
331-336
IX
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Page
Tables
96 Effluent Quality from Conventional Filtration
of Various Biologically Treated Wastewaters
97 Solids Captured per Foot of Head Loss Increase
In Direct Filtration of Secondary Effluents
98 Summary of Results of Treatment by Reverse Osmosis 343
99 Total Solids Removal Reverse Osmosis 346
100 Reverse Osmosis of Raw and Partially Renovated
Hardwood Pulp Caustic Extraction Effluent at
600 psig, 20-22°C, pH 5.2 346
101 Reverse Osmosis of Raw and Partially Renovated
Pine Pulp Caustic Extraction Effluent at 600
psig, 23-26°C, pH 5.2 347
102 Water Quality from "DESAL" Ion Exchange Process 349
103 Behavior of Major Chemical Constituents in
Renovation System 350
104 Pretreatment Requirements for Ion Exchange 352
105 Results of Granular Activated Carbon Column
Pilot Plant Treating Unbleached Kraft Mill Waste 354
106 Results of Granular Activated Carbon Column
Pilot Plants and Design Criteria 357
107 Results of Activated Carbon Pilot Plants Treating
Unbleached Kraft Mill Effluent 359
108 Physical-Chemical Treatment Plants 360
109 Tertiary Treatment Plants 361
110 Mill Sizes selected for Costing 374
111 identification of Internal Technology Items 376
112-126 Internal Technologies Used in Costing 377-391
127 External Unit Process Used in Costing 392-394
128 Raw (09) and Final (79) Waste Characteristics 395-397
129-158 Effluent Treatment Costs Aerated Stabilization
Baseline and Waste Activated Sludge
(All Subcategories) 398-431
159 Internal Effluent Treatment Costs for NSPS 432
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Total Mill Energy Requirements
176 BPCTCA Effluent Limitations
.gg
Tables
Page
160 Surveyed Mills used to Determine Retrofit Costs 493-494
161 Basis for Retrofit Cost Determination GW, S, so,
D, F Subcategories
162 Basis for Retrofit Cost Determination BK
Subcategories
163 Basis for Retrofit Cost Determination
T Subcategories
164 Retrofit Effluent Treatment Costs GW,
S, SO S DE Segments ,-QQ
I65 Retrofit Effluent Treatment Costs BK
Segment 5Q1
166 Retrofit Effluent Treatment Costs NI
Segment
167 Unsurveyed Mills Requiring Retrofit,
Bleached Kraft Segment
168 Retrofit Cost for Bleached Kraft Segment
169 Retrofit Cost for Tissue Segment
170 Aerated Stabilization Basin, Electric
Power Cost
517
171 Waste Activated Sludge, Electric Power Cost
172 Aerated Stabilization Basin, Electrical
Energy Requirements for Treatment 519
173 Waste Activated Sludge, Electrical
Energy Requirments for Treatment 520
521
175 Mills Manufacturing Spent Sulfite Liquor
Byproducts 527
540
177 Bleached Kraft Segment, Final Effluent
Characteristics 546-547
178 Bleached Kraft Segment, Final Effluent
BOD5 & TSS Concentrations 543
179 External Treatment Facilities, Bleached
Kraft Segment 551-552
180 Bleached Kraft Segment, Best Mills 553
xi
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Tables Page
Final Effluent BODS 6 TSS 553
181 Bleached Kraft Segment, Type Treatment
vs BODS & TSS 554
182 BPCTCA Variability Factors 555
1S3 Basis for BPCTCA Effluent Limitations
Summary 556
18U Groundwood Segment, Final Effluent
Characteristics 558
185 External Treatment Facilities,
Groundwood Segment 559
186 Sulfite Segment, Final Effluent
Characteristics 561
187 External Treatment Facilities,
Sulfite Segment 562
188 Soda Subcategory, Final Effluent
Characteristics 565
189 External Treatment Facilities, Soda 567
Segment
190 Deink Subcategory, Final Effluent
Characteristics 569
191 External Treatment Facilities, Deink Segment 570
192 NI Fine Paper Subcategory, Final Effluent
Characteristics 572
193 External Treatment Facilities, Non-Integrated
Fine Segment 573
19* NI Tissue Segment, Final Effluent
Characteristics 574
195 BATEA Effluent Limitations 573
196 BATSA Variability Factors 583
197 Basis for BATEA Effluent Limitations 584
198 Bleached Kraft Segment, Best Final
Effluent BODS & TSS Concentrations 535
199 New Source Performance Standards 593
200 Conversion Table 638
XII
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££ST OF FIGURES
Figures ±-i«i*s
Page
1 Distribution of U.S. Groundwood Mills 33
2 Distribution of U.S. Sulfite Mills 34
3 Distribution of U.S. Bleached Kraft and
Soda Mills
35
<* Distribution of U.S. Deinked Mills
36
5 Distribution of U.S. Non-Integrated Fine
Paper Mills
37
6 Distribution of U.S. Non-Integrated Tiasu« ,*
Mills -3O
7 Stone Groundwood Pulp Mill Process Flow
Diagram 43
8 Refiner Groundwood Pulp Mill Process
Flow Diagram
44
9 Brightening and Bleaching Groundwood and
Cold soda Pulps Process Flow Diagram
10 Sulfite Pulp Mill Process Flow Diagram
51
11 Magnesium Base Sulfite Recovery System
Process Flow Diagram
52
12 Bleached Kraft Pulping Process Flow Diagram 55
13 Kraft Chemical Recovery Process 56
14 Kraft Recovery System Process Flow Diagram §7
15 Chemical Reaction Involved in the Soda Pulp
Mill Recovery System
58
16 Four stage Kraft Pulp Bleach Plant Process
Flow Diagram
63
17
64
18 Oxygen Bleach Plant at Surveyed Mill 12<4
DO
19 Oxygen Bleach Plant at Swedish Mill
66
20 Planned Displacement Bleach Plant at
Surveyed Mill 121
68
21 Deinking Plant Process Flow Diagram
/ 3
xi
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Figures Page
22 Three Stage Deinked Pulp Bleach Plant
Process Flow Diagram 74
23 Paper Manufacturing Process Flow Diagram 76
24 subcategorization - Raw Waste Loads 82
25 Bleached Kraft Segment, Production
vs BODS 91
26 Bleached Kraft Segment, Production
vs Flow 92
27 Non-Integrated Fine, Production vs
Flow 93
28 Non-Integrated Fine, Production vs
BODS 94
29 Non-Integrated Tissue, Production vs
Flow 95
30 Non-Integrated Tissue Production vs
BODS 96
31 BOD vs Number of Machines Bleached Kraft
Segment 97
32 Bleach Kraft Segment, Brightness
vs BODS
33 Bleach Kraft Segment, Brightness vs
Flow 1°3
34 NI Fine % C+F vs BODS 108
35 NI Fine X C+F vs Flow 109
36 Effluent Characteristics: Groundwood Mill 121
37 Effluent Characteristics: Sulfite Mill 133
38 Effluent Characteristics: Sulfite
Dissolving Mill 136
39 Effluent Characteristics: Bleached
Kraft Mill 144
40 Effluent Characteristics: Soda
Mill 166
41 Effluent Characteristics: Deink Mill 172
xiv
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Figures Page
42 Alternative Treatment Systems 221
42A Surveyed Mill External Treatment:
Schematics 222-230
43 Effect of Temperature on Biological
Treatment System 241
44 Sludge Dewatering and Disposal 242
45 Daily Effluent BOD Data for Mill 117 247
46 Normal Probability Distribution 250
47 BOD Variability vs Annual Average BOD 258
48 Correlation of Solids Concentration with
Absorbance (at 420 nm) of Untreated Waste 267
49 Effect of pH on Absorbance (at 420 nm)
of Untreated Waste 267
50 Effect of Storage on Absorbance (at pH 7.6)
Untreated Waste 268
51 Rapson Closed Cycle 270
52 Massive Lime Process 288
53 Causticizing Process for a Kraft Pulp
Mill 289
54 Effluent Treatment Plow Diagram 295
55 Stabilization Lake Water & BOD Profile 297
56 Flow Sheet for Plant Design 300
57 Lime Process for Color Removal 303
58 NCASI Lime Mud Process for Color Removal 306
59 Bleach Plant and Ion Exchange System 313
60 Full size Color Removal System 313
61 Activated Carbon Effluent Treatment Pilot
Plant 315
62 Color Removal in Lime Treatment as a Function
of Soluble Ca in Water 3T9
63 Process Flowsheet for Tertiary Treatment by
Light-Catalized Chlorine, Capacity 10 MOD 364
xv
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Page
Figures
64 Ozone Treatment Plant
367
65 schematic Representation of a 10 MGD Plant
for Ozone Treatment of Secondary Effluent 368
65A Internal Controls: Schematics 434-466
66-80 Effluent Treatment Costs (All Subcategories) 477-491
81 Total Water Pollution Control Expenditures 530
82 Waste Water Treatment Equipment Sales 531
83 Engineering News Record Construction
Cost Index
84 Minimum Area Required for Wastewater
Treatment "6
85 Time Requirement to Construct Wastewater
Facilities conventional and Turnkey Contracts 537
86 Bleached Kraft Segment, Secondary Treatment 549
xvi
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SECTION I
CONCLUSIONS
For the purpose of establishing effluent limitations and
standards of performance, the segments of the pulp and paper
industry which were studied have been subcategorized as follows:
Groundwood: Chemi-mechanical
Groundwood: Thermo-mechanical
Groundwood: CMN Papers
Groundwood: Fine Papers
Bleached Kraft: Dissolving Pulp
Bleached Kraft: Market Pulp
Bleached Kraft: BCT Papers
Bleached Kraft: Fine Papers
Soda
Papergrade Sulfite
Dissolving Sulfite
Deink
Non-Integrated Fine Papers
Non-Integrated Tissue Papers
Non-Integrated Tissue Papers (FWP)
Within each identified subcategory, factors such as age, size of
plant, process employed, climate, and waste treatability confirm
and substantiate this subcategorization for the purpose of
establishing effluent limitations and performance standards to be
achieved through the application of identified treatment and
control technologies.
The 1977 requirement of best practicable technology currently
available (BPCTCA) suggests biological waste treatment as the
basic treatment process for all except the non-integrated tissue
paper subcategory. Primary treatment is suggested for the
latter. Limitations for BOD, total suspended solids, zinc, and
pH are set forth.
Best available technology economically achievable (BATEA) is a
requirement for 1983, and a few mills in the subcategories
studied are currently achieving this for most identified
pollutants. This technology level suggests major internal mill
improvements, biological waste treatment, and physical-chemical
waste treatment as the basic treatment and control technologies,,
and limitations for BOD, suspended solids, pH, zinc, and color
are set forth.
New source performance standards (NSPS) reflect internal
improvements which can be achieved through effective design and
layout of mill operations. Standards are set forth for BOD,
suspended solids, pH, and zinc. The basic treatment and control
processes which are suggested as a means of meeting these
performance standards are similar to those proposed for existina
mills by 1983.
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SECTION II
RECOMMENDATIONS
INTRODUCTION
SLn rec°Sm^de? Affluent limitations for existing sources are
shown in Table 1 and Table 2 for BPCTCA and BATEA, respectively
Standards of performance for new sources are shown in ?able 3
no? ™S39+H °f daily values for any 30 consecutive days should
not
no ™+H y
not exceed the maximum 30 day average shown in the tables. The
value for any one day should not exceed the daily maximum as
a±S ^/^ ^bl€S' The limit^ions and standards are in Til"
grams of pollutant per metric ton of production (pounds of
?he *
limitations for mills with wet woodyard operations
Max 30 day Max Daiiy
average average
BOD5 0.5 (1.0) o 9
moo n -7C: ,1 c(
TSS 0.75(1.5) 1%6
rrom^ul^drv^^^ ^°nS) " 2efined as annual ^onnage produced
trom pulp dryers (an the case of market pulp) and paper machines
rr/b0ard d±Vided b the nu
mon number Productionys in th
month period. Pulp production is to be corrected if
necessary, to the -air dry" moisture basis. No such correction
is necessary for paper/board production. correction
The limitations for TSS are for TSS as measured by the techniques
utilizing glass fiber filter discs as specified in
Methods_fothe Examination of Water and Wajtewater
It is also -recommended that color effluent limitation^
developed for all sulfite and dissolving suIfSe mills Sp
be
Sparse
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data indicated that color discharged from these mills contain 200
to 250 kg/ kkg (400 to 500 Ib/ton). No technology is foreseen to
be available prior to 1983 for removing color from these
effluents and thus color removal by sulfite mills is not
practicable or economically achievable at this time.
Table 1
BPCTCA
Subcategory
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Papergrade SuTfite
Dissolving Sulfite
ew-Chemi-Mechanical
GW-Thermo-Mechanical
GW-CMN Papers
GW-Fine Papers
Soda
Deink
NI Fine Papers
NI Tissue Papers
NI Tissue (FV)P)
pH for all subcatagories shall
Subcategory
Effluent
Maximum
B0u5
12.95(25.9)
7.1 (14.2^
6.35(12.7)
4.7 ( 9.4)
15.2 (30.4)
22.7 (45.4)
3.5 ( 7.0)
2.6 ( 5.2)
4.2 ( 8.4)
3.75C7.5)
5.75(11.5)
7.0 (14.0)
4.2 ( 8.4)
4.7 ( 9.4)
4.7 ( 9.4)
not exceed 6.0
Limitations in kg/kkg(lbs/ton)
30 Day Avrraqo
75$-
15.55(31.1)
10.3 (20.6)
10.3 (20.6)
7.35(14.7)
21.15(42.3)
26.25(52.5)
5.9 (11.8)
4.45( 8.9)
7.0 (14.0)
6.45(12.9)
8.3 (16.6)
12.65(25.3)
4.25( 8.5)
4.65( 9.3)
4.65( 9.3)
to 9.0
Maximum
BOD5
21.95(43.9)
12.05(24.1)
10.75(21.5)
7.9 (15.8)
25.75(51.5)
38.5 (77.0)
5.95(11.9)
4.4 (8.8)
7.1 (14.2)
6.35(12.7)
9.75(19.5)
11.9 (23.8)
7.1 (14.2)
7.9 (15.8)
7.9 (15.8)
Day
TSS
34.05(68.1)
22.6 (45.2)
22.6 (45.2)
16.05(32.1)
46.4 (92.8)
57.55(115.1)
12.9 (25.8)
9.7 (19.4)
15.35(30.7)
14.1 (28.2)
18.2 (36.4)
27.7 (55.4)
9.35(18.7)
10.25(20.5)
10.25(20.5)
Zinc
GW:Chemi-mechanical
GW:Thermo-mechanical
GW:CMN Papers
GW:Fine Papers
Maximum 30 Day Average
kg/kkg(lbs/ton)
0.125 (0.25)
0.095 (0.19)
0.150 (0.30)
0.135 (0.27)
Maximum Day
kg/kkgQbs/ton)
0.25 (0.50)
0.19 (0.38)
0.30 (0.60)
0.27 (0.54)
-------
Subcategory
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Papergrade Sulfilc
Dissolvi .3 Sulfitc
GW-Chemi-Mechanical
GW-Thermo-Mechanical
GW-CMN Papers
GW-Fine Papers
Soda
Deink
NI Fine Papers
NI Tissue Papers
NI Tissue (FWP)
pH for all subcategories shall not exceed 6.0 to 9.0
Lf f luont 1.
i'l^vi ,niim 30
L,1,%
5.<:>Ci0.9)
3.35( 0.7)
2.K( 5.7)
1.4 ( 3.8)
f . '", 5 ( 1 2 . 9 )
8.35(16.7)
1.25{ 2.5)
1.1 ( 2.2)
1.75( 3.5)
1.65( 3.3)
2.4 ( 4.8)
2.5 ( 5.0)
1.25( 2.5)
2.0 ( 4.0)
2.0 ( 4.0)
Table 2
PATEA
i; !• ial ;ons in
Pav Avpraao
i§i
3.45( 6.9)
2.25( 4.5)
1.85( 3.7)
1.55( 3.1)
3.15( 6.3)
4.05( 8.1)
1.2 ( 2.4)
0.65( 1.3)
1.3 ( 2.6)
1.2 ( 2.4)
1.55( 3.1)
2.4 ( 4.8)
0.65( 1.3)
0.95( 1.9)
0.95( 1.9)
kq/kkq(lbs/ton)
Maximum
BUD5
11.25(22.5)
6.9 (13.8)
5.9 (11.8)
4.0 ( 8.0)
13.3 (26.6)
17.3 (34.6)
2.6 ( 5.2)
2.25( 4.5)
3.65{ 7.3)
3.45( 6.9)
5.0 (10.0)
5.2 (10.4)
2.6 ( 5.2)
4.15( 8.3)
4.15( 8.3)
Day
TSS
7.6 (15.2)
4.95( 9.9)
4.05( 8.1)
3.35( 6.7)
6.9 (13.8)
8.85(17.7)
2.65( 5.3)
1.4 ( 2.3)
2.8 ( 5.6)
1.0 ( 2.0)
3.35( 6.?)
5.3 (10.6)
1.4 ( 2.3)
2.1 ( 4.2)
2.1- ( 4.2)
Subcategory
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Soda
Color
Maximum 30 Dav Average
kg/kkg(lbs/ton^
125 (250)
95.0 (190)
65.0 (130)
65.0 (130)
65.0 (130)
Maximum Day
kil/kkg(lbs/tonl
250 (500)
190 (380)
130 (260)
130 (260)
130 (260)
Subcategory
GkrChemical-mechanical
GW:Thermo-mechanical
GW-.CMN Papers
GW:Fine Papers
21 nc
Maximum 30 Day Average
kg/kkgQbs/ton)
0.115 (0.23)
0.065 (0.13)
0.120 (0.24)
0.115 (0.23)
Maximum Day
_kg/kkg(lbs/ton)
0.23 (0.46)
0.13 (0.26)
0.24 (0.48)
0.23) (0.46)
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Table 3
NSPS
Effluent Limitation^ in kg/kkg(lbs/ton)
Subcategory
Drsolving Kraft
Market Kraft
BCT Kraft
Fn.e Kraft
Papergrade Sulfite
Dissolving Sulfite
GW- Chemi-Mechanical
GW- Thermo-Mechanical
GW-CMN Papers
GW- -ine Papers
Soda
Deink
MI Fine Papers
N! Tissue Papers
NI Tissue (FWP)
pH for all subcategories
Subcategory
GW:Chemi-mechanical
GW:Thermo-mechanical
GW-.CMN Papers
GW:Fine Papers
Maximum 30 Dav Avpraop
BODS
5.45(10.9)
1.85( 3.7)
2.85( 5.7)
1.9 ( 3.8)
4.1 ( 8.2)
8.35(16.7)
1.251 2.5)
2.6 ( 5.2)
1.75( 3 5)
1.65( 3.3)
2.4 ( 4.8)
3.75( 7.5)
1.25( 2.5)
2.0 ( 4.0)
2.0 ( 4.0)
shall not exceed 6.0
TSS
7.0 (14.0)
2.6 ( 5.?)
3.6 ( 7.2)
3.05( 6.1)
3.95( 7.9)
8.05(16.1)
2.4 ( 4.8)
2.0 ( 4.0)
2.6 ( 5.2)
2.4 ( 4.8)
3.05( 6.1)
3.6 ( 7.2)
1.2 ( 2.4)
1.85( 3.7)
1.85( 3.7)
to 9.0
Zinc
Maximum 30 Dav Average
kg/kkg(1bs/ton)
0.115 (0.23)
0.095 (0.19)
0.120 (0.24)
0.115 (0.23)
Maximum
BODS
11.2^(22.5)
3.8 ( 7.6)
5.9 (11.8)
4.0 ( 8.0)
8.5 (17.0)
17.3 (34.6)
2.6 ( 5.2)
5.35(10.7)
3.65( 7.3)
3.45( 6.9)
5.0 (10.0)
7.8 (15.6)
2.6 ( 5.2)
4.15( 8.3)
4.15( 8.3)
Day
TSS
15.35(30.7)
5.65(11.3)
7.95(15.9)
6.7 (13.4)
8.65(17.3)
17.65(35.3)
5.3 (10.6)
4.4 ( 8.8)
5.65(11.:)
5.3 (10.6)
6.7 (13.4,
7.95(15.9)
2.65( 5.3)
4.25( 8.5)
4.25( 8.5)
Maximum Day
kg/kkgQbs/top)
0.23 (0
0.13 (0
0.24 (0
0.23 -(0
.46)
.26)
.48)
.46)
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SECTION III
INTRODUCTION
PURPOSE AND_AUTHORITY
Section 301 (b) of the Federal Water Pollution Control Act, as
amended in 1972, requires the achievement, by not later than July
1, 1977, of effluent limitations for point sources, other than
publicly owned treatment works, which are based on the
application of the best practicable control technology currently
available (BPCTCA) as defined by the Administrator pursuant to
Section 304 (b) of the Act. Section 301(b) also requires the
achievement, by not later than July 1, 1983, of effluent
limitations for point sources, other than publicly owned
treatment works, which are based on the application of the best
available technology economically achievable (BATEA) which will
result in reasonable further progress toward the national goal of
eliminating the discharge of all pollutants, as determined in
accordance with regulations issued by the Administrator puisuant
to Section 304 (b) of the Act. Section 306 of the Act requires
the achievement by new sources of a federal standard of
performance providing for the control of the discharge of
pollutants which reflects the greatest degree of effluent
reduction which the Administrator determines to be achi:-rvaKle
through the application of the best available demom-/- rated
control technology, processes, operating methods, or other
alternatives, including, wher^ practicable, a standard permitting
no discharge of pollutants. Section 307(b) and (c) of the Act
requires the achievement of pretreatment standards by existing
and new sources for introduction of pollutants into publicly
owned treatment works for those pollutants which are determined
not to be susceptable to treatment by such treatment works or
which would interfere with the operation of such treatment works.
Section 304 (b) of the Act requires the Administrator to publish
within one year of enactment of the Act regulations providing
guidelines for effluent limitations setting forth the degree of
effluent reduction attainable through the application of the best
control measures and practices achievable including treatment
techniques, process and procedure innovations, operation methods,
and other alternatives. The regulations proposed herein set
forth effluent limitations guidelines pursuant to Section 304(b)
of the Act for segments of the pulp, paper, and paperboard point
source categories. They are the groundwood, sulfite, bleached
kraft, soda, and deinked pulping segments and the non-integrated
fine, and tissue papermaking segments.
Section 306 of the Act requires the Administrator, within one
year after a category of sources is included in a list published
pursuant to Section 306 (b) (1) (A) of the Act, to propose
regulations establishing federal standards of performance for new
sources within such categories. The Administrator published in
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the Federal Register of January 16, 1973, (38 F.R. 1624), a list
of 27 source categories. Publication of the list constituted
announcement of the Administrator's intention of establishing,
tinder section 306, standards of performance applicable to new
sources within the pulp, paper, and paperboard point source
categories, which were included within the list published January
16, 1973, This report proposes such standards for the
groundwood, sulfite, bleached kraft, soda, and deinked pulping
segments and the non-integrated fine, and tissue, papermaking
segments.
_USEp_FgR_^^
ANp_STANDARDS_OF_llRFgRMANCE
This study was initiated to gather the necessary information upon
which to base effluent limitations and standards of performance
for the manufacturing facilities included in the following
segments of the pulp and paper industry:
Groundwood
Sulfite
Bleached Kraft
Soda
Deinked
Non- Integrated Paper Mills
These major segments represent significant differences in
produc-cion processes which, experience demonstrates, bear a
direct relationship to the quantity and quality of their waste
waters*
A literature search and screening program were undertaken in
order to identify all the mills in each of the above segments.
Directories which describe the production processes and products
manufactured by each mill in the pulp and paper industry were
utilized, along with industry journals, direct mill contact, and
contractor knowledge. Mills were allocated to the various
segments according to criteria explained in detail later in this
Section.
Next, information describing the waste water treatment facilities
and the quantity and quality of the waste water discharged by
each mill was tabulated. In this effort, the contractor was
assisted by EPA regional offices which provided NPDES data and
other pertinent information from their files. Various state
pollution control agencies also cooperated in furnishing waste
water discharge and additional data. The National Council for
Air and Stream Improvement also provided considerable assistance.
It was particularly valuable in verifying data obtained from
other sources which appeared to need clarification and/or sub-
s+-antiation. In addition, an in-depth literature search was
conducted to strengthen the data base and to provide information
on the internal and external control technologies utilized by the
various mills.
-------
This program culminated in the tabulation of approximately 358
mills that qualify for inclusion in this study. In this to-al
each mill site is counted only once, even though it may encompass
multiple physical facilities housing more than one pulping and/or
papermaking process, while there is considerable variation in
reporting numbers of "mills" within the industry, this approach
was used because of its relationship to the total raw wast<- ioad
of an industrial complex.
Selectipn_of_Mills_fgr_On-Site_SurveY
Screening sheets were prepared for each segment showing, by mill,
all production and waste treatment data available.
Evaluation of this information indicated that it was «-, .-iuwmate
basis upon which to select those mills in each segment that would
provide the broad-based in-depth information necessa^v to
subcategorize the segments and to identify BPCTCA. It- should be
noted that information was subsequently updated and corrected a«?
the study progressed. " - - -
™!- 5ecame candidates for on-site surveys to assure
the reliability and validity of the performance ascribed to them
i.e., a tour and evaluation of the production processes and
waste treatment facilities to verify the quality of the
production and waste water data generated by the mill.
The selection of a mill as a survey candidate was made on a
descending order of priorities. First priority was an operatina
treatment facility that includes biological treatment, of the
entire process waste water. Second priority was the quality of
the final discharge after treatment and the quantity of waste
water generated by the mill in terms of 1 (or kl) /kkg (gallons
per ton) of product. Predicated on these criteria, 74 mills
appeared to be candidates for mill survey; of these, 44 were in
the bleached kraft segment, nine in the groundwood segment, one
in the soda segment, and four each in the remaining five
segments. All of the mills with biological treatment were
selected in each segment except the bleached kraft segment
Twenty-five of the 44 mills in that segment utilizing secondary
treatment were selected, and the remaining 19 mills wer-
eliminated for one or more of the following reasons:
treatment f^iliJIes^16 ^ indicated P°~ Performance of
o,,K«J?" ^?h? mil1 utilized two or more pulping processes invoJvinq
substantial unbleached kraft and/or semi-chemical pulp
5£S£ ' 4. Khe WaSte generated by such complex mills would
therefore not be representative of any single segment included in
tils
,,4.-i high water-use values suggested minimal
utilization of internal controls.
-------
u. Waste water discharge data were not available.
5. Non-standard analytical procedures and/or flow measuring
devices were utilized.
The 25 mills selected for the bleached kraft segment adequately
represented a cross-section of the segment in terms of raw
materials, production processes, geographic locations, internal
and external control practices, and age and size of mill. This
was not the case, however, with the mills with biological
treatment in the other segments. Therefore, it was necessary to
select mills for survey in the segments other than bleached kraft
on the basis of well-operated primary treatment facilities and/or
available raw waste data to broaden the data base for
sulx'ategorisation and to define waste water characteristics for
each subcategory. In addition, considerations of raw material
usage, processes, number of production units, geographic
location, internal and external control practices, and age and
size of mill were balanced among additional selections. As a
result, the total number of mills selected for on-site survey
reached 104, or over 25 percent of all the mills covered by this
study. Records on waste treatment facilities, waste water
discharge, and production processes were also obtained on 10
additional mills.
Following these original data collection efforts, the resulting
data base was evaluated to determine how representative the
available data was of each segment or subcategory. From this
analysis, additional efforts were made to collect data from an
additional 70 mills and further data from approximately 30 mills
previously surveyed. Collection of the additional information
and data involved on-site surveys, written correspondence, and
telephone surveys. The data collected from mills previously
surveyed is identified in this report with the original mill code
followed by an "A" (i.e. 101A). The number of mills surveyed and
the percent that this represents of the total number of mills in
each segment is shown in Table U.
Mill_Survey_Program
A comprehensive mill survey format was developed for completion
at the mill site by a survey team. The format was designed to
make it possible to equate the information obtained at one mill
with that of all mills included in the survey and to evaluate the
many variables associated with their production processes and
waste treatment.
The analytical test procedures utilized by each mill were
documented and the deviations from standard methods employed for
several waste water parameters were noted. The type of flow
measuring and sampling devices used were also recorded and
evaluated as to their reliability. Information regarding the
nominal production capacity and raw materials used by the mill
was obtained, and the dates on which production facilities and/or
10
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Segment
Gro-ndwood
Su.Jfita
Blenched Kraft
Sod:,
Deink
Fine
Tissue
Total No.
of Mills
39
28
74
3
17
46
74
282
Kills vith
Secondary
Trea tu.cn t
8
6
42
1
6
4
4
70
Percent
o£
Se^nient
21
21
56
33
35
9
5
Mo. of
Hills
Surveyed
22
19
40
'•>
J
15
21
25
Percent
of
Segment
56
68
52
100
88
46
34
SI
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waste treatment facilities were installed, modified, or updated
were established.
The survey form was also designed to quantify to the extent
possible the internal and external technologies employed at each
mill and the «xt«nt to which these technologies were utilized.
It was accompanied by single-line block diagrams of the
production process and waste streams generated by each process.
Similar diagrams of the waste treatment facilities were sketched
showing the sampling and flow measurement points for which the
mill had 12 months of records. Such records of data on all
routinely tested streams and parameters were requested.
The production and waste treatment records obtained were
subjected to detailed screening and evaluation to 1) eliminate
obviously erroneous data and 2) code each waste stream for which
mills did have usable records in order to develop a uniform and
consistent data format for computer programming. The code
numbers and waste streams to which they apply are shown in Table
5. The evaluation and coding program culminated in the
completion of Surv%y Form Number 7 . This form provided the
computer programmer with the mill code number, the kkg/day
(tons/day) of production attributable to each mill, the waste
streams described by the data, and the parameters to be utilized
for computer input. Parameters tested by one or more mills are
identified in Table 6, together with the abbreviations used in
computer outputs. It should be noted particularly that non-
standard test methods are identified in the computer analysis by
the letter "N" following the abbreviation. Such data must be
used very cautiously since it is not comparable to data obtained
by standard methods. The definition of standard methods for all
parameters except color was derived from Standard Methods for the
l&SIDisaiiSD 2f W§£e.r. £ W§§£g jgater, 13th edition (191) . In the
case of color, the method outlined in National Council for Air
and Stream Improvement Bulletin 253 (192) was used to define the
standard method (Appendix 15) . For total suspended solids,
either the fiberglas method described in current editions of
Standard ?|4th,2<2§ or the asbestos method described in earlier
editions was taken as the standard method.
The computer program provided the following data output for each
of the "computerized" mills:
1. Annual means for individual waste streams for all
parameters for which there were data.
2. Monthly averages for all available parameters on the
total raw waste, stream No. 9, and the final discharge, stream
No. 79.
3. The 30-maximum-day values for all waste parameters
available for stream No. 79.
12
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4. Three types of statistical plots for all available stream
No. 79 parameters for 45 surveyed nulls. To the extent possible
the mills selected for these plots utilized biological treatment
facilities; for those segments in which few mills have biological
treatment mills with well operated primary treatment facilities
were included. The three plots can be described as follows: (a)
frequency distribution histogram; (b) a cumulative probability
plot; (c) chronological plot.
From the cumulative probability plot the minimum data value,
maximum data value, mean value, standard deviation, coefficient
of variation, and number of data days are determined for each
parameter plotted. The chronological plot is actually three
plots of a given parameter. One plot is of the daily data value;
the next is the average of four calendar days; and the third plot
is the 30-calendar-day moving average. In all cases, missing
data are excluded from th« av«raging calculation and the averages
are determined from the actual data available within the calendar
time specified — i.e., four days or 30 days.
13
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Table 5
STREAM SYMBOLS
Stream_No. Descrip.tion
0 Principally pulp mill waste
1 Principally bleach plant waste
2 Principally paper mill waste
3 to 8 Raw waste stream not otherwise identified
9 TOTAL raw waste streams
10 to IB Individual streams to primary treatment
19 TOTAL streams to primary treatment
20 to 28 Individual sreams after primary treatment
29 TOTAL effluent from primary treatment
30 to 38 individual streams to secondary treatment
39 TOTAL influent to secondary treatment
40 to 48 individual streams after secondary treat-
ment (includes streams from activated
sludge secondary clarifier)
49 TOTAL effluent from secondary treatment
(includes effluent from activated sludge
secondary clarifier)
50 to 58 Individual streams to post storage (hold-
ing ponds, storage oxidation basin, and
other post secondary devices)
59 TOTAL influent to post storage
60 to 68 Individual streams from post storage
69 TOTAL effluent from post storage
70 to 78 Individual streams from treatment
79 TOTAL effluent from treatment to receiv-
ing waters
80 to 88 Individual streams not receiving any treatment
89 SUM of all streams not receiving treatment
14
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Table 6
PARAMETERS MEASURED AND ABBREVIATIONS
Parameter^
5-Day Biochemical
Oxygen Demand
Temperature
Total Suspended Solids
Color
Turbidity
Zinc
Phosphate
PH
Nitrogen
Ammonia Nitrogen
Settleable Solids
Chemical Oxygen Demand
Total Solids
Total Volatile Solids
BOD5 or BOD
Temp
TSS
Color
Turbid
ZINC
P04
PH
N or Nitrogen
NH4 or Ammonia
Setslds
COD
TS
TVS
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GENERAL_1DESCRIPTION_OF_INDUSTRY_SEGMENTS
Paper is made from raw materials which contain adequate amounts
of cellulose fiber, its basic component. The cellulose must
first be separated from other constituents of the fiber source
and fiberized. This is the function of the pulping process.
During the 19th century, wood began to supplant cotton and linen
rags, straw, and other less plentiful fiber sources. Today, wood
accounts for over 98 percent of the virgin fiber used in
papermaking.
This report deals exclusively with wood pulp and products made
primarily from it and the reclamation of used papers, which, in
turn, consist primarily of wood fiber.
There are several methods used for pulping wood. In some, it. is
cooked with chemicals under controlled conditions of temperature,
pressure, time, and liguor composition (1). The various
processes utilize different chemicals or combinations of them.
In other methods, wood is reduced to a fibrous state by
mechanical means alone or by a combination of chemical and
mechanical action.
Mechanical pulp is commonly called groundwood. In the basic
process, stone groundwood, pulp is made by grinding logs, or
short lengths of logs called billets, on a grindstone; pulp
produced by passing wood chips through a disc refiner is termed
refiner groundwood. In the chemi-groundwood process the billets
are first pressure imprenated with a dilute solution of sodium
sulfite before grinding; in cold soda (chemi-mechanicall)
pulping, chips are steeped in a caustic solution and refined.
Such pretreatment softens the wood so that less power is required
for grinding. In a new process, thermo-mechanical pulping, chips
are first softened with heat and then refined under pressure.
These general descriptions are subject to modification in
practice.
Although groundwood pulp was initially shunned by the makers of
fine paper when the basic process was introduced in this country
in the last century, today it is considered a very versatile pulp
and is put to many uses. Its initial success in the manufacture
of paper was its acceptance for newsprint and that is still its
primary market. The major disadvantage of groundwood,
impermanence, is offset by the economy of its production,
especially for the manufacture of the wide range of "throw-away"
products demanded by 20th century Americans -tissues, toweling,
paper plates, etc. — and the millions of "paperbacks" printed
every year. The mechanical pulps of more recent vintage —
refiner, cold soda, chemi-groundwood, and thermo-mechanical
are also components of diversified products.
Both of the major chemical pulping processes in use in the U.S.
today, acid sulfite and kraft (or sulfate), also had their
origins in the 19th century. Kraft, an alkaline process, was
not, however,, fully commercially developed until the early 1900*s
16
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and it was the soda process, the alkaline forebear of kraft
whzch was the early competitor of sulfite pulping Tor some grades
mills conv^J»S * ascendancy of the kraft process, most soda
os
engaged in the manufacture of printing and fine papeX
:
. ncay
'^ ° a™iSe °f many °l<3
Peaneap
limestone (calcium carbonate) . Ironically^ the uSe of
because
spent Jiguor
—
wftich permits recovery or incineration
have switched to the kraft pul p Jng prScJss oaynv
small one, manufactures tissue grades. rouroi, a
.
resulted in a rapid expansion of kraft pulpinq (2) Third n^w
17
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markets with the production of dissolving pulp and greaseproof
and tissue papers (3) . Today, a broad spectrum of printing and
fine papers, tissue, food and milk containers, and boxes and
containers of many other varieties are manufactured from bleached
kraft pulp.
However, acid sulfite pulps do possess distinct properties which
are superior for some products. These include special grades of
dissolving pulps, tissues, and some grades of fine paper.
Although wood supplies the fiber for the great majority of pulp
produced in this country, about 21 percent of the paper and
paperboard produced annually is reused as a raw material for new
products. Of this, large quantities are used in coarser products
such as waste paperboard, building papers, etc., without
extensive pretreatment. (The manufacture of these products is
covered in earlier EPA Development Documents).
However, some reclaimed papers are deinked prior to use in a
pulping process somewhat similar to the chemical pulping of wood.
Deinked pulp provides an important fiber source which is low in
cost, conserves wood resources, and, in some cases, improves
product quality (6) when incorporated in the furnish. Deinking
of waste paper was in commercial operation during the last
century although the large scale operations extant today
developed much more recently. In addition to removing ink,
fillers, coatings, and other non-cellulosic materials must also
be removed in order to reclaim useful pulp. These are added to
modern papers to impart special characteristics (such as superior
printing qualities, gloss, wet strength, grease resistance, etc.)
(6). Deinked pulp is used mainly in business, bank, and printing
papers, tissues and toweling, as liner for some paperboards, and
in molded products and newsprint.
Pulp in its natural state is brown in color due primarily to the
lignin content of wood. It is therefore bleached to modify or
remove the color bodies when necessary in order to produce a
light colored or white product. Bleaching techniques are also
used to manufacture dissolving pulps.
The degree of bleaching pulp for paper manufacture is measured in
terms of units of brightness and is determined optically by
established TAPPI methods (7). Partially bleached pulps (semi-
bleached) are employed in newsprint and similar papers,
intermediate for food containers, computer cards, etc., and fully
bleached for white paper products. By different gradations in
treatment, pulp of the desired brightness can be manufactured up
to a level of 92 on the brightness scale of 100. These
techniques are described in detail in a TAPPI monograph (8).
Bleaching is frequently performed in several stages in which
different chemical compounds are applied and separate functions
take place. The symbols commonly used to describe a bleaching
sequence are shown and defined in Table 7. The table may be used
to interpret bleaching "shorthand," which is used extensively in
18
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Table 7
BLEACHING SYMBOLS
A - Acid Treatment or Dechlorination
c - Chlorination
D - Chlorine Dioxide
E - Alkaline Extraction
H - Hypochlorite
HS - Hydrosulfite
° - Oxygen
P - Peroxide
PA - Peracetic Acid
W - Water Soak
( ) - Simultaneous Addition of the Respective
• °f
19
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later sections of this report. For example, a common sequence in
kraft bleaching, CEDED, is thus interpreted:
Chlorination & Washing
Alkaline Extraction & Washing
Chlorine Dioxide 6 Washing
Alkaline Extraction & Washing
Chlorine Dioxide & Washing
Almost all sulfite pulps are bleached, but usually a shorter
sequence such as CEH is sufficient to obtain bright pulps. This
sequence involves chlorination, alkaline extraction, and
hypochlorite application, all followed by washing.
Some mills manufacture paper and/or paperboard which do not
engage in pulping. These are called non-integrated paper mills
and the pulp they utilize is either shipped from another of the
company^ facilities or is purchased. Pulp mills which do not
have attendant papermaking operations are a major source of pulp
for these mills, although some integrated mills also sell
"market" pulp.
The papermaking process is essentially the same regardless of the
type pulp used or the end product produced. A layer of fiber , is
deposited, from a dilute water suspension of pulp, on a fine
screen, called the "wire," which -permits the water to drain
through but which retains the fiber layer (2). This layer is
then removed from the wire, pressed, and dried. Two basic types
of paper machines and variations thereof are commonly employed.
One is the cylinder machine in which the wire is on cylinders
which rotate in the furnish, and the other is the fourdrinier in
which the furnish is deposited upon an endless wire belt.
Generally, the fourdrinier is associated with the manufacture of
paper and the cylinder with paperboard.
Products
Table 8 illustrates the diversity of papers manufactured by
integrated pulp and paper mills and non-integrated paper mills.
The various grades are delineated according to end use and/or
furnish.
Although this list is representative of the production of the
mills subject to this report by grade, a complete tally of their
products as reported to industry directories would include
numerous other terminologies. Since this multiplicity of
nomenclature essentially defines specialized uses of products
which themselves fall within the generic grade classifications of
Table 8, they will not be separately itemized here.
Among the major fundamental differences in the various papers are
durability, basis weight, thickness, flexibility, brightness,
strength, and color. These characteristics are a function of raw
20
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techniques.SeleCti°n' pulpin^ methods, and/or papermaking
aLr^HT/1^^ b?6? noted' soine P«lps are naturally more
adaptable as furnish for certain paper grades than for others.
This is influenced by fiber length, strength, and other factors
which can be controlled by the type of woods employed the
ohl™?oi?o i a m®chanical or chemical pulping process, cooking
chemicals length of cook, etc. With improved techniques and the
ability to mix pulps in stock preparation to achieve desired
properties, however, few paper grades are uniquely a product of
one pulp only. c
on <-hfd™i0n t0 y,ariations in stock preparation and sheet control
on the paper machine, the papermaking operation may enhance the
basic qualities of paper, or achieve other properties - such ll
wet strength, greaseproof ness, printing excellence, etc. —
through the use of additives. These include a variety of
substances such as starch, clay, and resins used as fillers and
*.? Table 8 are' for the most Part, self-
' and Definitions according to industry usage may be
1 97 i Q7u J Jh publl?atlon £aP-§£x Paeerboard, Wood Pulp Capacity
1971-1974 of the American Paper Institute (API) (9f. However
arnnJSrP°T °5 thiS S^^ ' ^he many **V***^ grades have been
?f«S^ ^ r f°Ur maj°r headings: newsprint, fine papers,
tissue, and coarse papers. F^O,
Newsprint is, of course, separately identified in Tabl<* 8
tnfrereno°; ±S ^^ S^ ap^ exc^ that' in ^he Context" of
incfurtS ? ih giassine' greaseproof, and vegetable parchment are
included in the tissue segment. These papers are basically a
tissue sheet treated with additives to serve specific
21
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Table 8
PRODUCTS OF SUBJECT INDUSTRY SEGMENTS (1)
I. Newsprint
II. Printing-Writing Papers
A. Uncoated Groundwood
1. Publishing & Printing
2. converting
B. coated Papers
C. Uncoated Book
1. M.S.,E.F. , Etc. (2) & Super Calendered
2. Offset
3. Envelope
4. Tablet
D. Papers Made from Chemical Wood Pulp
1. Bond & Writing
2. Form Bond
3 . Ledger
4. Mimeograph
5. Duplicator
6. Manifold
7. Papeterie & Wadding
8. Body Stock for Commercial & Copying
9. Other Technical & Reproduction Paper
10. Opaque Circular
11, colored School
E. Cover & Text Papers
(1) Excerpted from PaBer_and_PaEerboard_Statistiss_1213^
American Paper Institute, and API's Pap_erx_Pap.er boar dA_ wood
Pule CaEacitY_1971z1974i
~(2) Machine Finish, English Finish.
22
-------
Table 8 - Cont'd.
F. Thin Papers
1. Carbonizing
2. Condenser
3, Cigarette
G. Bleached Bristols
1. Tabulating Index
2. Tag
3. File Folder
4. Index Bristol
5. Postcard
6. Coated Bristol
III. Unbleached Kraft & Bleached Packaging Papers
A. Unbleached Kraft Papers
1. Wrapping
2. Bag & Sack
3. Shipping Sack
4. other Converting
B. Bleached Packaging Papers
1. Wrapping
2. Bag & Sack
3. Shipping Sack
4. Other Convering
IV. Glassine, Greaseproof, & Vegetable Parchment
V. Special Industrial Papers
VI. Tissue Papers
A. Sanitary Tissue
1. Toilet
2. Facial
3. Napkins
4. Sanitary Napkins
5. Towels
6. Wipers
B. Non-Sanitary Tissue
1. Waxing
2. Wrapping
3. Industrial Cellulose
4. Miscellaneous
23
-------
Table 8 - Cont'd.
PAJPERBOARD
Bleached (3)
Milk Cartons
Folding Cartons
Heavyweight Cup, Rounded Nested Food Containers, & Cup Lids
Plate, Dish, 6 Tray
Other Packaging
Linerboard
Non-Packaging
Unbleached{4)
Linerboard
Boxboard (Folding Carton)
Chip and Filler Boards
(3)Paperboard made from 85% or more bleached chemical wood pulp.
(4)Solid unbleached wood pulp paperboard.
24
-------
Fine papers encompass all of the printing-writing papers. Coarse
papers are considered to include; unbleached and bleached kraft
packaging papers (used for grocery and shopping bags, heavy
wrapping paper, and sacks for shipping sugar, flour, cement, and
other commodities); bleached and unbleached paperboard (the
materials of boxes, cartons, and other containers); and special
industrial papers.
While unbleached kraft linerboard (the smooth facing on
"corrugated boxes") produced by integrated unbleached kraft pulp
and paper mills was the subject of an earlier study, some mills
covered by this investigation also produce linerboard and other
unbleached kraft paperboards. This is true of several non-
integrated mills and a few integrated mills which make other
pulps in addition to unbleached kraft, although their tonnage of
the latter is very small in comparison with the output of the
large unbleached kraft mills.
Special industrial papers include paper and boards of all
weights, calipers, and furnishes designed for specialized end
uses, such as abrasive and absorbent papers, cable papers,
electrical insulation, vulcanized fiber , resin-impregnating
stock, and similar grades (9). Thus, in grouping them in toto as
"coarse" papers, some inconsistencies occur within the usual
meaning of that term. it is felt, however, that their production
is more closely related to coarse paper manufacture than to the
other segments.
Paperboard is, of course, a type of paper and the terms "paper"
and "paperboard" generally imply physical differences only, some
of which overlap in gradation. Further, many mills produce, or
have the capability to produce, both products interchangeably.
Therefore, they will not be treated separately in this report
except when necessary for clarification, and the phrase
"paper/board" or "paper" will be applied for simplification.
Many of the finished products made from the paper grades
enumerated in Table 8 do not arrive directly at the retail market
from the paper mill. While some mills have attendant operations
in which to convert their own stock into boxes, bags, envelopes,
paper plates, wall paper, food and milk containers, etc., much of
the raw stock is sold to manufacturers of these items. Whether
or not the converting operations are conducted on site at the
paper mill, they constitute a separate and dry operation and are
not considered in this report.
Daily._Production_Ca£acitY
The daily production capacity of mills is an especially important
consideration in this report for two reasons. First, it provides
a useful means of classifying mills, as discussed below. Second,
its correlation with waste water data makes it possible to
express pollutants discharged in pounds per ton of product, the
value used in effluent limitations guidelines and standards.
25
-------
Traditionally, limits on waste discharges were based on an
allowable concentration for each pollutant parameter. This type
of value, mg/1 (or ppm) , is also used in this report to
characterize certain waste streams. However, the pounds-per-ton-
of-product concept equalizes the limitations among all mills,
regardless of size. In this report it is often expressed simply
as "pounds per ton" or in the abbreviated metric (English) unit
expression "kg/kkg (Ib/ton)." All waste parameter values
reported in kg/kkg (Ib/ton) are based on an annual average of
daily production. "Ton" means a 907.20-kilogram or (2000-pound)
short ton.
Except as otherwise noted, production includes the total weight
of product off the paper machine (s) plus pulp dryer (s) where
applicable, as reported by mills. Paper machine production
includes the normal moisture content of approximately six
percent. Pulp intended for use offsite is expressed as "air dry"
weight including 10 percent moisture. Where off-machine coaters
were used, the coat weight was included in the production weight
wherever sufficient data were available. In the case of on-
machine coaters, the coat weight is automatically included in the
reported paper machine production weight. Where the data
furnished by mills did not meet these criteria, they were
converted to provide a uniform data base.
Mill_Characterizatign_According
£o_Daily._Production
Numbered among the mills discussed in this report are many so-
called complex mills — i.e., mills which produce more than one
variety of pulp or multiple paper grades. Since the study was
directed to specified segments of the pulp and paper industry, it
was desirable, for working purposes, to characterize all mills
according to segment.
The basis used for classifying or assigning complex pulp and
integrated mills to a segment was the pulping process which
accounts for the largest daily production capacity. For example,
a mill with a daily capacity to produce 340 kkg (375 tons) of
groundwood pulp, 122 kkg (135 tons) of sulfite, 453 kkg (500
tons) of newsprint, and 41 kkg (45 tons) of sulfite specialties
was assigned to the groundwood segment.
Strict application of this criterion, however, would result in
placing some of these mills in segments covered in EPA's
Develogment Document for the Unbleached Kraft and Semi-Chemical
Pulp. Segment of "the Pulp.,Pap.ir, and Pager board Mills Point Source
Category.. This is particularly true where the production of
unbleached kraft is involved. The earlier study of this
subcategory was limited to those mills which produce no pulp
other than unbleached kraft. Thus, mills which have attendant
kraft bleaching or another pulping capacity fall within the scope
of this report although their largest production tonnage may be
unbleached kraft pulp. This is also the case with two mills
26
-------
which produce more substantial quantities of semi-chemical pulp.
another subcategory covered by the above Development Document,
but which by virtue of their other production were subiect to
this investigation. In these instances, the mills have been
assigned to the segment which is most representative of their
other pulping operations.
It is recognized, too, that application of the product tonnage
criterion to some non- integrated paper mills is perhaps somewhat
arbitrary due to the fact that many of these mills report th-
production of many grades encompassing more than one segment
without accompanying tonnage breakdowns. However, it is felt
tLat the general accuracy of allocation to segment is sufficient
to support the statistical estimates of this section of the
The groundwood segment is composed of 38 mills: of thes^ 28
produce groundwood pulp only. Nine additional groundwood
operations appear in the bleached kraft segment and two under
sulfite, making a total of 49 U.S. groundwood mills. (Those
mills producing a different type of groundwood pulp utilized in
building products are not included) .
Twenty-eight mills are designated as sulfite mills, 21 of which
produce sulfite pulp only. Four mills produce sulfite, but in
grOUndwood< and three produce bleached
are
Seventy- four mills are defined as bleached kraft, and five are
™ mK-1? C?n2unction with groundwood operations for a total of
79. Thirty-eight produce bleached kraft only. There are three
mills in the soda pulp segment and an additional very small soda
operation with attendant sulfite and semi-chemical pulping.
f*?hJei?ked ?Jgment encompasses 17 mills, 14 of which reclaim
fiber for the manufacture of fine papers and tissue and three
which Produce newsprint. m addition, there is one
groundwood/deinking mill and one sulfite/deinking combination.
A breakdown of the pulping segments is shown in Table 9.
There are 46 non-integrated fine paper mills and 74 tissue mills.
27
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Table 9
DISTRIBUTION OF MILLS BY SEGMENT
No. of
Segment Mills_ Pulp._Production
Groundwood
Sulfite
2 8 Groundwood
2 Groundwood/Bleached Kraft
1 Groundwood/Unbleached Kraft
3 Groundwood/Bleached/Unbleached Kraft
3 Groundwood/Sulfite
_1 Groundwood/Deinked
38 Total
21 Sulfite
U Sulfite/Groundwood
1 Sulfite/NSSC
1 Sulfite/NSSC/BK
_1 Sulfite/Bleached Kraft
28 Total
Bleached Kraft 38
16
3
6
1
2
5
1
74
Soda
Deink
Bleached Kraft
Bleached/Unbleached Kraft
Bleached Kraft/Groundwood
Bleached/Unbleached Kraft/Groundwood
Bleached/Unbleached Kraft/Sulfite
Bleached Kraft/Semi-Chemical
Bleached/Unbleached Kraft/Semi-Chemical
Bleached_Kraft/Sulfite/Semi-Chemical_
Total
3 Soda
17 Deink
28
-------
In« S*tiVf fize °f mills in each segment which produce only the
one designated type of pulp is illustrated as follows:
Capacity
Groundwood
Sulfite
Bleached Kraft
Soda
Deinked
(Fine Paper & Tissue)
(Newsprint)
Largest
Mill
834
(920)
580
(640)
1379
(1520)
635
(700)
499
(550)
408*
(450) *
Median"
Mill
181
(200)
209
(230)
454
(500)
222
(245)
87
(96)
272*
(300) *
Smallest
Mill
18
(20)
91
(100)
27
(30)
127
(1*0)
37
222*
(245)*
*Paper production; pulp tonnage not published.
When complex mills in the groundwood, sulfite, and bleached kraft
segments are considered the size range is as follows:
Capacity
itonsl_/day_
Largest Median Smallest
Groundwood 102o i72 18
U125) (190) (20)
Sulfite 771 209 25
(850) (230) (28)
Bleached Kraft 1379 49g 2?
(1520) (550) (30)
29
-------
The total daily capacity of the mills listed in Table 9 has been
tabulated by pulp type. These figures, presented below,
represent the best estimates which can be made utilizing
published information and information gathered during the course
of the project. It must be emphasized, however, that they are
approximate only. This is especially the case of the bleached
kraft total because the differential between bleached and
unbleached production is not always clearly identified.
Total Capacity
Groundwood 11,654
(12,850)
Sulfite 8,344
(9,200)
Bleached Kraft 72,379
(79,800)
Soda 907
(1,000)
Deinked 2,721
(3,000)
A separate breakdown is not presented for bleached and unbleached
groundwood and sulfite. There is relatively very little sulfite
pulp which is not bleached before use, and groundwood undergoes
many varying degrees of brightening or bleaching, a tabulation of
which would be imprecise.
Six sulfite mills and three bleached kraft mills produce
dissolving grades of pulp. The total capacity of these sulfxte
mills is 2721 kkg (3000 tons) /day, and the kraft capacity is 2857
kkg (3150) tons; these figures, however, include some bleached
papermaking pulps. These mills are included in the sulfite and
kraft segment tabulations.
The approximate total daily paper/board capacity for all mills
listed in the groundwood segment is 16,417 kkg (18,100 tons) /day;
for the sulfite segment, 5442 kkg (6000 tons) /day; bleached
kraft, 61,676 (68,000); soda, 1270 (1400); and deinked, 4535
(5000) .
Size distribution of the non-integrated papermaking segments of
mills appears in Table 10.
30
-------
Table 10
TABULAR DESCRIPTION OF NON-INI CRATED PAPEPJ!AX1NG SEGMENTS
Segment
Fine Papers
Tissue
Coarse Papers
No. of
Kills
56
72
72
Total Capacity
kkrd-onfO/c'ay-1--
6651
(7333)
5465
(6025)
6295**
(6940) ••••-*
Largest Mill
klcp;fe0nR)/dav
472
(520)
726
(520)
653
(720)
Smallest Mill
10.8
6.3
(7)
2.7
(3)
Median Mj
kkrftor.r) /
81.6
(90)
42.6
54
fCO)
•'Approxinate.
**This figure is low due to nunber of mills not reporting tonnage.
-------
The geographic distribution of the groundwood, sulfite, bleached
kraft and soda, deinked, nonintegrated fine, and nonintegrated
tissue segments are shown in Figures 1-6, respectively. The
numbers refer only to the mills allocated to the designated seg-
ments according to the criteria discussed earlier.
Ann u a 1_ Pro du ct ion
Total annual production for 1972 of the products associated with
the subject industry segments is tabulated in Table 11.
PULPANDPAPERMAKI NG PROC ESS ES
Wood arrives at pulp mills in various forms and consequently must
be handled in a number of different ways. Some mills receive
their wood supply as logs, although the trend is toward the use
of purchased chips, or, in some cases, sawdust and other residues
of sawmill operation. For example, in 1972 reclaimed chips and
wood residues accounted for 84 percent of the total wood volume
consumed in pulp and paper production in the Pacific Northwest
(16).
The use of whole tree chipping (WTC) in the Northeast, Lake
States and South has increased considerably over the past few
years. This practice is particularly useful in mixed stands of
timber and for thin diameter material. It does not require
limbing and topping which are the most expensive parts of wood
handling. The use of cutter knives and blades to cut up tree
bowls, branches and bark greatly increases the yield of material
per acre and 10-100% increases have been found. A side benefit
is that less roads are necessary which are required for heavy-
duty trucks. Thus, there are lower costs per cubic foot of fiber
produced.
Some of the most difficult problems are the inclusion of sand,
dirt, and abrasive materials as well as too much bark in the WTC
chips. This causes problems not only with the cutting blades but
also with mill equipment. The upkeep of the mill equipment
involves an increased cost of $10-$20 for each dollar of field
equipment used for debarking. This equipment upkeep is
necessitated by the unbarked chips included with other material
for pulping. The major pulps produced from barky chips are
semichemical pulp and unbleached kraft. Companies are now using
5 and up to 30% of their WTC chips while unbleached kraft mills
can use 2-5% of WTC chips. Several companies are using pulps
with 5-15% bark at present.
One company currently has in use over 275 WTC chipping units. It
is estimated that up to three times increase in productivity per
man hour can be obtained using field chipping. One company
32
-------
FJGURE 1
\ ^v»
CO
CO
DI-STR'iBUTiON OF U.S. GROUMDVYCOD MJLLS Q Groundwcod
/ .' I
\ .j"""^ /---.._ !
'- —L
.%• — •- : OKLAHOMA ' "1 , /j-'^c'1 ' ' ' '""~v
•ArKAN.-AS :_,"FN ( ,
CLEARTYPE
STATE OITLINE
UNI~"D STAT::? i
-------
FIGURE 2
D'STR!BUT!ON OF U.S. SULFiTE MILLS
/% /""^l—J / •> -NCH'H DAKOTA " "^ '"v.
Dissolving Sulfite
( ^ Papcrgrada Sulfite
•'/
/,
>', .-^',
^{".-^'-\
*"-••>! Wyorvv^A ,'
'-•-,/>. /
/ -^oX^—•
f.bwX ^
/ ^..-i—f\c.-.';~
-------
FIGURE 3
DISTRIBUTION OF U.S. BLEACHED KRAFT O Bleached Kraft
CO
en
CLEAKTYPE
STA ;H Ol.'TLINE :
UNITED STATCS •
-------
FIGURE 4
oo
CTI
K A / V
°^-"—<• I
DISTRIBUTION OF U.S. DEINKED MILLS /\ Deinkcd
A
•NORTH DAKOTA"
; " '•—••.
(MINNESOTA — N •*
/ 'DAHo\
\,.^ ,r~-—•-—•—._._ i
f J
• SOUTH DAKOTA ' '
CAU'^
7'^^—
^s -i
t . \. A \ ; /~\ r *• "^ / 2\ >• i
•' ! x- A A^V iz nr/^ v---o>'
/ L A \ /\ ;/~-J^^--T\ \^~
•-r-_ ; . V-OWA : \ \ *—>> ^/^^'^'- v-x^
• urZZ~—l .'NCUHASKA —'-A S- \ } X/»/'-1'e' ir-•-^
IUT^ . \ S \ILLIN01SX / r-—^'^-^ \ '. 'l
• L '. • Kir^/To-110 A I
i • I . ...^f-^lt«1l \ fc I /O\ _/ . ,...*' .' . %' \ \ • . y
KANSAS
I
-'-•
-------
FIGURE 5
DISTRIBUTION OF U.S. NON-iNTEGRATED (~) Fine
FiiVE PAPER WILLS ^^
',' • \
jt l**"'\
•\_-
-^>._
/..__
© \ jUi-JL.
* I I ^-
/•• OKi-AHOMA ' "| , / fJV. r'c '" -^' " " <^'''
j'tXAS . • AtWANSAS i_-Il'"N -- - >•' __ •>)
A--^-^i3r^^
/ i *. x.
<^
N^-
CLcARTVPE
<,. \ ^n-.o* .r.fi.5 ||
• ••'••-;
c-T--t-^r--- —.-.
V..-S..,..
-------
FIGURE 6
oo
CO
V/V--. DISTRIBUTION OF U.S. NON-INTEGRATED TISSUE MILLS
r
--
r- -
w^OM;N J
v , rtf-. ""-*"---^ I i
-------
Table 11
1972 PRODUCTION BY PULP TYPE AND PAPER GRADES
IOOO_Tons
Special alpha &
dissolving 1,521 1,677
Sulfite 1,931 2,129
Bleached kraft 12,672 13,971
Soda 127 mo
Groundwood 4,188 4,617
Newsprint 2,360 2,602
Tissue 3,106 3,425
Fine papers 9,087(3) 10f,Q19(3)
Coarse papers 10,310 11,367,
(l)U.S. Bureau of the Census data.
(2)Contractor grouping of American Paper Insti-
tute data.
(3)Includes papers of textile fibers not subject
to this report.
39
-------
estimates that in five years 80% of their chips will be field
chipped WTC wood.
Barked logs received at a mill are chipped directly for use or
cut into billets of suitable lengths for the stone and chemi-
groundwood processes. Bark is removed from unbarked logs on the
premises.
Most of the pulpwood used in the United States is small in
diameter and is barked dry in drums. When large diameter or long
wood is used, wet barking may be employed although this practice
is declining. The two most common mechanisms for wet barking are
drum and hydraulic barkers (2)(34) since the wet pocket barker is
now largely outmoded. Slabs are generally handled by hydraulic
units as is the large and longer roundwood.
The wet drum barker consists of a slotted drum equipped with
internal staves which knock the bark from the wood as the drum
rotates in a pool of water. The bark falls through the slots and
is removed with the overflow of water.
Wet, pocket barkers are stationary machines which abrade bark from
timber by jostling and gradually rotating a confined wood stack
against the wood pile allowing bark to pass between the chains.
Water is sprayed through apertures in the side of the pocket.
Hydraulic barkers employ high-pressure water jets to blow the
bark from the timber which is either conveyed past them or
rotated under a moving jet which traverses the log.
40
-------
Typical wood consumption of median size mills is as follows:
Groundwood 120 cords/day
Sulfite 245 cords/day
Bleached Kraft 850 cords/day
Soda 125 cords/day
(It should be noted that conversions between cords and tons
should not be attempted without data on specific situations
The reason for this is that a cord is a measure of volume (4
ft x H ft x 8 ft), while a ton is, of course, a measure of
weight. Variations in wood species, density, diameter,
straightness of log, etc., make conversions between the two
units impossible for general situations.)
Mechanical Pulping
"""* " ..... " '^™ -' «•»—_-—&_«_ .,1
The energy used in producing conventional groundwood pulp --
stone or refiner — is mechanical. Modified groundwood processes
such as the cold soda (chemi-mechanical) and chemi-groundwood
methods employ a mild chemical treatment ahead of mechanical
fibenzing. The latter processes are considered here as
mechanical pulping, however, because the chemical pretreatment is
much milder and the mechanical action more drastic than is the
case in semi-chemical pulping. in thermo- mechanical pulping, an
off -shoot of refiner groundwood, the pretreatment is accomplished
with heat and pressure. The cold soda and chemi-groundwood pulps
are produced and used as a direct substitute for groundwood (10)
or as supplements to special furnishes. All mechanical pulps
contain practically all of the wood substance and yields are
generally 85 to 90 percent of the bone dry weight of the wood
processed while semi-chemical pulps fall within the 60 i-o 80
percent yield range (2).
TSe,.KtYpe °f W°°d econoinically available is a factor in selection
of the groundwood process applied. Softwood does not necessarily
require pretreatment (10) and has thus been the traditional raw
material of the stone groundwood process, and more recently of
nnJ oefTr r^03'* The high 6nergy retirements of grinding
untreated hardwood are overcome by the processes which
incorporate pretreatment. Thus, their development made possible
the use of large stands of hardwood for mechanical pulping
Sawmill wastes are another source of raw material for the
mechanical processes which utilize wood chips
-------
Stgne_Groundwood
In this process, billets are fed to the grinders by hand or
automatically from a belt or chain conveyor (2) and are forced
hydraulically against the large rotating grindstone, specifically
designed for the purpose. The pocket-type grinder is most common
although the magazine, ring, and continuous or chain types are
being installed in new mills (10) . The grinding occurs in the
presence of a large quantity of water which acts as both a
coolant and a carrier to sluice the pulp from the body of the
grinder. The pulp slurry is diluted to a consistency of from 0.6
to 0.8 percent and is passed through coarse and fine screens and
a centri-cleaner to remove dirt and slivers. Over-size rejects
maybe passed through a disc refiner and returned to the system
ahead of the fine screens. The pulp slurry is then thickened on
a lecker to between 10 and 15 percent consistency and discharged
to a stock chest for mill use, bleached, or thickened further for
transport to other mills (2) either in the form of wet lap at
about 25 percent consistency or nodules containing 50 percent
fiber. A diagram of the stone groundwood process is presented in
Figure 7.
The availability of saw mill chips as a low-cost wood source led
to the development and exploitation of the refiner groundwood
process which has the additional advantage of using less power
then stone grinding (11) (12) . The chips are first washed and two
stages of refining are generally employed in the pulp mill, the
fiber receiving a third refining in the paper mill. Disc type
refiners are used which contain one fixed and one rotary disc
between which the wood passes together with a stream of water. A
double-disc type unit is used mainly for refining rejects. The
pulp is discharged from the refiners at a consistency of about
eight percent and moved by a high- density pump to the secondary
units. Here it is diluted to low consistency and subsequently
fine screened and freed of dirt in centri-cleaners. Screen
rejects are refined and returned to process ahead of the screens.
After cleaning the pulp is handled in the same manner as stone
groundwood as shown in the process flow diagram in Figure 8.
Thermo-Mechanical
A recent development in refiner groundwood is equipment in which
the chips are pre- softened with heat and refined under pressure
In the range of 110-130°C (230-266°F) . This process is called
thermo-mechanical pulping. Pulp properties, such as longer
eibers, are developed which make this pulp a suitable replacement
for a percentage of the more expensive chemical pulp added to
newsprint furnish to provide adequate strength (92) . This
Drocess has not been employed in this country although it is
42
-------
FIGURE 7
STONF GRGUiJOWOOD PULP MILL
PROCESS FLOW DIAGRAM
PROCESS
WATER
DEBARKED
RO MDWOOD
GRINDERS
1
F
REJECTS
REFINER
COARSE
SCREENS
rs
^
r~
PULP
DRYER
FINE
SCREENS
WHITE
WATER
CHEST
CENTRICLEANERS-
FIBER
DECKER
I
OVERFLOW
SAVEALL
STOCK
CHEST
I
BLEACH OR
BRIGHTENING
FACILITIES
ALTERNATE
PAPERMAKING
-H
*
SEWER
I
LEGEND:
—— MAIN PROCESS
SECONDARY PROCESS
PROCESS WASTE LINE
43
-------
FIGURE 8
REFINER GROUNDWOQD PULP MILL-PROCESS FLOW DIAGRAM
WOOD CHIPS
REJECTS
REFINER
DCBARKE
ROUNDWOOD
CHIPPER
•~!>i
_JL
CHIP
STORAGE
CHIP
1 I 1
WHITE WATER
TANK
*?
PRIMARY
REFINER
FEED
CONVEYOR
SECONDARY
REFINER
FINE
SCREENS
CENTRICLEANERS
a DECKER
PROCESS WATER
MAKEUP
FIBER
WHITE]
WATER
SAVEALL
STOCK
CHEST
BLEACH OR
BRIGHTENING
FACILITIES
ALTERNATE
PULP
DRYER
L
SEWER
PAPF.RMAKING
LEGEND'-
~—•. MAIN PROCESS
SECONDARY PROCESS
PROCESS WASTE LINE
44
-------
ra272-k in 5111 ±n the Pacific Northwest has
and a 91?kka (WO ton?' T* day-therm°-«>echanical system (93)
<*na a yj. KKg (100-ton) per day unit will be install Pd ir. 1
^^
Cold Soda
'ST
lig§ching_of_Mechanical_Pulp_
Stone_and_Ref iner Groundwood
brightness varies with the characteristics of Vho ^A ^
The most common bleaching agents used for <^^nn0 a^
45
-------
FIGURE 9
BRIGHTENING AND BLEACHING GROUNDWOOD
AND COLD SODA PULPS
PROCESS FLOW DIAGRAM
SULFUR
JiOXIDE
HYDROSULFITE
STOCK
CHEST
CAUSTIC
SODA
- fet
PEROX IDE
MIXER
PEROXIDE
TOWER
NEUTRALIZATION
TANK
ALTERNATE
1
r
PULP DRYER
MIXER
HYDROSULFITE
TOWER
BLEACHED
STOCK
CHEST
PAPERMAKING
PROCESS
WATER
STEAM
LEGEND:
MAIN PROCESS
SECONDARY PROCESS
46
-------
a?*h« h V hing' hydr°9en Peroxide is generally used
although sodxum peroxide is sometimes employed 121(101 A
solution of from 0.5 to 1.5 percent hydrogen peroxide or' its
oxygen equivalent of sodium peroxidJ is applied to the pulp
Frequently a small amount of magnesium sulfate -- 0.24 to 0 48
o
With P«°*iae at be»en 38
Consistencies of bleaching range from
°
wth slfur
witn sulfur dioxide to prevent reversion.
LS sssrs
n-
Peroxide solutions are prepared at the mill bv batch or-
?L hSS m Per°*i<*e solution, sulfuric acid is used tS
the hydrogen peroxide.
When sodium or zinc hydrosulfite is used to bleach or
°
t
of these chemicals has not become established PJac?icf 'in this
47
-------
country (10). The cost of peracetic acid has similarly precluded
its use for groundwood bleaching (15).
There has been no experience in this country as yet with
bleaching thermo-mechanical pulp.
cgld_soda
Due to the alkaline pretreatment they receive, cold joda pulps
are darker than stone and refiner groundwood (2). How^vjrrt^
ness . 2s
Brightness can be obtained from multi-stage bleaching.
Bleaching chemicals are generally ^P1^3/^^^^^^ aS
towers, although peroxide can be added at ^refinw stage and
hypochlorites during the steeping Process. The
wever to a
more chemical, however, to achieve
sulfuric acid.
Chemi-Groundwood
xfrLponds^l ^SSSS S
ng however, and the processes utilized are very
to those for the other types of groundwood pulp.
or,t
?iqSo?is amoved before peroxide is added. It may even then be
ineffective (2) .
Chemical_Pulp.ing_gf_Wood
SSP -MSKS-aS-^S- sr -b
subseguent mechanical devices are necessary.
48
-------
" «**"
varying relative degrees or s??eng?h. ""hanical energy in
-
.
discussion of
"
are ''
3 aio>-a" cookea
containing an excess
at
— ——-•- --ULWA j_uc JLO luaCie <9T -rno m-! 1 i i~ i_ .
?«f aS,e\ " liqUid f°™ -""er^f'wh^H ?^™,^2,,!^LfUr
returned to process
sulfurous acid and is noT usually reco^reT'fro **??** W±th
liquor. in ammonia base mini recovered from the spent
sulfurous acid, if the rhLi^i • q u ammonia is reacted with
form, it is -F.tL !..fne^lcal 1S. Purchased in the
make-up base for the maonf>«5?iim ?^ ^- w re Purchased as
which retain about 90 percent of ?Se h?^ baSe recove^ systems
through recovery. Perce"t of the base ln the system (17)
49
-------
SI
B
Figure 10.
for ammonia base liquor because of its hiqh viscosity.
I» the .agnesiu, base process the ash producea on burning the
S " lection of tL rill (1).
re?u?nedS to the liquor manufacturing section of the mil (1).
is presented in Figure 11.
rne puiy j-= "" » croj-i^T-A-t-p resinous materials
screens for thickening and to separate res=inuu
(159) (180) .
50
-------
SUM- IT;: i'ULP MILL
PROCESS ."LOW DIACi;,:!..;
~*j ABSORPTION
I fOV-.'CR
i
6.
MAIN PROCr.SS
ppocrss
i PROCESS WA:,H:
51
-------
FIGURE 11
MAGNESIUM BASE SULFITE RECOVERY SYSTEM
PROCESS FLOW DIAGRAM
S02.| „ J
SULFUFtOUS
ACID
RECOVERY
*
" MAGNESIUM
OXIDC
RECOVERY
1-7
COOKING 1
LIQUOR
PREPARATION J
MgO
LEGEND;
—— MAIN PROCESS
SECONDARY PROCESS
PROCESS WASTE LINE
52
-------
continuous digesters are employed although 3£'
common in operations in which only one grade
(2)
"'» s
from the digester and the taaft
cooking stage (189? Kraft
under "Bleaching of' cheLcal
drained
introduced to start the
PUlp ±S «•««•« further
nroce
liquor
< 1 ~ «• .
the liquor in high concentration.
53
-------
requires only one or two stages of external washing.
After washing, the pulp is diluted and screened to remove knot3;
The kraft pulping process is illustrated in Figure 12.
The liquor separated from the pulp in the washing
n toto
concentrator .
SSS
SHE
are sometimes used to adjust the sulfldity.
The strong blacK
- ,. ..».» ««
.
re introduction to the recovery cycle
54
-------
BLEAC;;;-D K:;A!:T PULPING
PROCESS i LOW DIAGRAM
V.'OOrj ci-lli'S
—
— (
J — :.•
RECOVERY •» — L
SYSTEM
L
{
! CHIPPER
1— -,—— J
___^ OFF
J GAS
| 1 A
(, n 1 T
DIGESTERS >- TUrtPEi.:. i!!E J
" RECOVERY
' BLOW TANK ! , PROCESS J
WATER
f 1 ACCUMULATOR
FIBERI7ER
1 1 ~£
HOT Y/A1CR
SCREENS L -
1
v t
I 1 1
j REJECTS
f L DISPOSAL ,
STOCK j" 1
WASHERS 1
1
, 1
BLEACH 1
PLAIvT oJ
1 | *j
i L_ i i
R 1 C f< f- 1 • •- f> i V
CHEST 1 SEWER
aITFPr-"\TF I 1 '
i 1 LEGEND:
PULP DRYER
PAf-CRMAK.N7]~l ^r,r°CESS
SLCOIJDAHY PROCESS
-------
FIGURE 13
KRAFT CiiPniCAL RECOVERY PROCESS
Burning:
Ha2S04 + 2 C - *-Ha2S + 2C02
C02 - - — *-
Causticizing:
!!a2C03 + Ca (nu)2 2K3.0U + CaC03
R°burning: (of mud)
CaC03 -- &-CaO + C02
Slaking:
CaO 4- H20 ------ ->-Ca(CH)2
56
-------
FIGURE i/<
KRAPT RECOVER,' SYSTH.: I'ROCCISS FLOV/ DIAGRAM
ELECTROSTATIC
PKECIMTATGR I
DISSOLVING
TANK
SLAKER
GRITS
DISPOSAL
CAUSTICIZING
WHITE
L I Q U 0 ?;
w Hire
LIOUOH
STORAGE
LEGCND-
SEWER
UIGESTl RS
MAIN F'l?OCr SS
SECONDARY I'UOCfSS
TROCCSS WASTE LINE
-------
FIGURE 15
CHEMICAL REACTION INVOLVED II! THE
SODA PULP HILL RECOVERY SYSTEM
Liquor
Combustion
l\ I1U in
c + o2 —
rru -*- Ma^n
N»—
-------
ligure°« ^"TnTVa?? Chemical recovery process are shown in
Figure 14.' recovery system is illustrated in
Soda
SSc^iZ ™J^if^.iy. ,££» bet»«" the soda and Kraft
systems is that sulfur is present in
^ i thif b:j-fck liquor oxidation is
sodprocess ,3^?" " ^ **°*»^ "Uck ash as in
h
e
?
WaShed on countercurrent drum
c
The molten ashr which consists almost entirely of sodiu
carbonate, is dissolved in weak wash water and the make-uo
chemical - purchased and recovered soda ash - is added T
added
«
kiln is equipped with a venturi
II§§ching_of_chemical_Pulp
59
-------
dioxide. Alkalies such as caustic soda and calcium hydroxide are
used for extracting chlorinated reaction products from treated
pulp. In some instances, hydrogen peroxide or sodium peroxide or
peroxyacetic acid are used in the finishing stages of bleaching
(22). Sulfur dioxide or sodium sulfite (1)(8) can be used as
neutralizing and anti-chlor reagents and in some instances to
stabilize pulp brightness. However, the chlorine compounds and
alkalis are the most commonly applied chemicals.
Chlorine and caustic soda are either purchased in liquid form or,
in rare cases, manufactured at the mill by electrolysis of sodium
chloride. Hypochlorites are generally manufactured on site by
treatment of milk of lime or caustic soda with chlorine.
Strengths produced vary with intended use since this chemical is
used not only for bleaching, but, in the case of dissolving
pulps, to control rate of extraction of materials from the pulp
and the ultimate viscosity of it.
Chlorine dioxide, because of its instability, is manufactured at
mills which use it by one of four methods. These are the
Mathieson process, a modification thereof, the R~2 process, and
the Solvay process. They all employ sodium chlorate and sulfuric
acid. Sulfur dioxide is also used in both the Mathieson
processes, and sodium chloride is added in the modified Mathieson
method and R-2 technique. MSthanol is substituted for sulfur
dioxide in the Solvay process (8)(24).
Other bleaching chemicals are purchased in their common form and
treating solutions are prepared according to process needs.
These are employed in relatively small quantities as compared to
the major bleaching agents.
Bleaching is ordinarily performed in a number of stages. This is
done to preserve the strength of the pulp by avoiding excessively
rigorous chemical treatment and to control consistency and
temperature in accordance with the demands of the particular
treatment applied. Each stage consists of a reaction tower in
which the pulp is retained in contact with a particular chemical
agent for the optimum period of time. It is then washed on
vacuum washers or diffusers and discharged to the next stage.
Consistency in the reactors generally ranges from 3.5 to 12
percent and temperatures range from ambient in the chlorination
stage, to 60°C (140°F) in extraction stages, 35°C (95°F) in hypo-
chlorite stages, and 82.2°C (180°F) in chlorine dioxide
treatment.
The chemical concentrations employed depend upon the consistency,
the temperature, the number of stages, the specific chemicals
used, the species of wood from which the pulp was produced, and
the degree to which it was cooked, as well as the quality of
product desired. Three stages are generally used in semibleached
kraft operations and for bleaching of sulfite paper grade pulps.
Since kraft pulps are dark in color, particularly when made from
softwoods, high-bright kraft pulps usually require more stages.
Normally five are used although some mills employ six or more
60
-------
(25)(26). Three stages may be used for low-brightness soda pulp
and four stages for high brightness.
Table 12 shows the most common sequences used to bleach kraft
pulp to various degrees of brightness.
For high bleach kraft pulp, the CEDED sequence appears to be
favored. Ten mills report using it against IH employing other
sequences, most different from the other. CHHD is used by a few
mills as a means of reducing color in the bleaching effluent.
Mills which partially bleach kraft most commonly employ a CED
sequence while a few either modify this procedure or add another
hypochlorite stage. The CEH sequence is frequently used for
bleaching paper grade sulfite pulps, although additional or other
stages may be utilized by mills producing several different
grades. CEH is also used by one mill for semi-bleached soda
pulp; one soda mill employs CEHP for fully bleached pulp and
another utilizes CEHD.
A. typical four stage kraft bleach plant is shown in Figure 16
and Figure 17 illustrates a three stage sulfite bleachery.
Q?£Z3gn_Bleaching
Oxygen bleaching is a very recent development and is presently
used in only six mills throughout the world. Three of these are
in Sweden, where the process was initiated, and there is one each
in France (122), South Africa (40), and the U.S.
The U.S. mill bleaches kraft pulp with a three stage bleaching
sequence, D/C OD, which is illustrated in Figure 18 (187) (188).
It achieves a brightness equivalent to that obtained by the more
costly five and six stage sequences such as CEDED and CEHDED.
The pulp is being used in nearly every paper grade and provides
quality equal to that of conventionally bleached pulp. It is
also reported to be less susceptible to brightness reversion.
Subsequent to the C102/C12 treatment, SO2 is added to the stock
flow and the pulp is then pressed to a consistency of 27 to 52
percent. It next receives a five percent caustic solution. When
it enters the oxyqen reactor the high consistency pulp is fluffed
to increase fiber exposure to the oxygen atmosphere (177). it is
reacted at 121°C (260°F) for 20-30 minutes with oxygen produced
on-site from the atmosphere (23). A final C1O2 stage completes
the sequence.
Another oxygen bleaching stage has been in use in a Swedish kraft
mill since November, 1973. In contrast to the sequence of the
U.S. mill, the process there employs the oxygen stagp first in an
OC/DEDED sequence (140) (Figure 19). The pulp is of high quality
with brightness in excess of 92, and has the same physical
strength as pulp previously bleached by a C/DEDED sequence.
61
-------
Table 12
COMMON SEQUENCES USED TO BLEACH KRAFT PULP
TO VARIOUS DEGREES OF BRIGHTNESS
Range of Bleaching
G._E._ Brightness
70 to 80 CEH
CEHH
80 to 85 CHEH
CEHEH
CC/HEHH
CED
85 to 92 CEHD
CHED
CEHDD
CC/H ED/H
CEDED
CEDHED
Steam and alkali (caustic soda, at present) are added to pressed
stock of approximately 35 percent consistency which is reacted
with oxygen, after fluffing, for 30 minutes at 95-100°C (203-
212°F). In order to meet a requirement of sulfur emission
standards the caustic soda used in the "0" stage can be reclaimed
and used in the cooking liquor preparation to reduce its
sulfidity at a considerable cost saving (140). This stage is
followed by the remaining stages of the sequence in conventional
equipment.
Some experimental work has been done with ozone as a bleaching
agent. Since it is more a delignifying agent than a bleaching
agent (11) , it could be used most effectively as a first stage in
bleaching. However, when large amounts of ozone are charged in
one stage, a dramatic drop in the viscosity of the pulp occurs
(11). This can be overcome with the use of several stages
although at considerable cost. Also, the production capacity of
existing ozone generators is too small for bulk use of this
chemical.
Disglacement_Bleaching
Two U.S. companies are installing a new displacement bleaching
process which has been in pilot operation in Finland. Bleaching
62
-------
FIGURE J6
FOUR STAGE KRAFT PULP BLEACH PLANT Pi/JCFSG FLOW DIAGRAM
I t~'<0'M
STOCK
| _ .CHI^I
STLAM
PROCESS
| WAI EN — j
ALTERN;
. £L~"~
n
PULP DRYCK
i~
•v/
VTI
f [ 1
p. i 1 |
CIILORIME
TOWt li
* V.'ASHCR I » ACID V/AS'E [ ^
| SEAL PIT f *]
| i
. «!__. , " ~n
i —
„. CAUSTIC CAUSTIC
TO'.VER ' SCO.'-.
-,J I«.AOUFR CAUSTIC WASTr'
j t,H3nt^ p srAL p|, j- _- ^
L - .. .
E L
J HYPO -, .OHITC ] HYPOCHLORITE 1
TOWfR PREPARATION f H
zL
i . . ...
n WASHER
| I CHLORl-Tt ]
1 J"S niOXIDF. [— f
* x. t t'RcrARAr ION 1
I CHLORINE
DIOXIDE
| TOAF.R
1 WASHER
*] 1
1
,- * *
HI F AC HT D
LrU1nuS<,V°CK SEWCR
'; LEGEND'
i™ • - •- -I .. -.-... MAIN pi
-------
FIGU
E
THREE STAGE SULFITE PULP BLEACH PLANT
PROCESS FLOW DIAGRAM
PROCESS
WATER
STEAM
BROWN
STOCK
CHEST
T
CHLORINE
TOWER
CHLORINE
WASHER
ACID WASTE
SEAL PIT
J>
,r*v
CAUSTIC
TO W E R
t
F
WASHER
HYPOCHLORITE
TOWER
WASHER
r
ALTERNATE
BLEACHED
STOCK
CHEST
1
PULP
DRYER
PAPERMAKING
CAUSTIC
V/ASTE
SEAL PIT
43 ""• — " " '
^
;TIC
,'ER
CAUSTIC
SODA
HYPOCHLORITE
PREPARATION
SULFUR
DIOXIDE
--*1
SEWER
LEGEND:
i i MAIN PROCESS
SECONDARY PROCESS
PROCCSS WASTE LINE
64
-------
FIGURE J3
OXYCLN bLEACH PLAIJT AT GlJ^VCYCD I/,ILI. 124
i>( SKuX
I CM .— I J
PROCESS j
WATER |_i._
[
*" ~" [ CHI Gf'iilJ ]
1 f-Fir .-,•,() ;j !C'i.' ] I
I cn'.A.-,/ ; n
c'ox,;:;
TO.'.'H
L 1 ". 1
^ -. L J
l CHLCrtli.'E |
1 TCV/EKS
|* nioxioE
, DDC.CC 1 , ^^ . j^
.i. j CAUSTIC 1
' ^" \ SODA j
| MIXIfyS 1
COLUMN
i
J OXYCEI; 1 oxvrrr !
C1 REACTOFi r OX^CCf,
™J
~*\ BLOW TANK
A
J WASHtR *.
j f CHuORII.'E 1
^ 1 PREPAKAT ION j
CHUORKJE 1
— *• DIOXIDE k — i
10V, ER j
JSULf-UR
DIOXIDE ^
WASHER SEWER
-*•_ |
I LEGEND:
STORAGT. PROCLSS VVA^IC LINE
65
-------
FIGURE 19
OXYGEN B'.EACH PLANT AT dWr.D'SH MIL
f_-.
S'ion;
C'1:- "T
i
I-
\
I TAM<
ff
i '
OXYCLIi
REACTCH
i
I
TANK
1
TWO
STAGE
\VAS P r R ?•
I
{,
HIGH DENSITY
STORAGE TANK
u _^ •
t '
L;
[--
MIXING
TANK
1
1
CHLORINE
TOWER
WASHER
1'
r
CAUSTIC
TOWER
I
[ 1
H STEA" I
-- . 6
1
] L- CAUSTIC !
| _ SODA j t
\
1- """ rf
p OXYGEN ]
\
09
- j
P n o r r c* ° I
- . WATER P'
«-- 1
1
j r— CHLORIME
J
I
.
CHLORINE
1 — 1 DIOXIDE
1 PREPARATION — |
L
« — i
CAUSTIC j
SODA j
r WASHER *i
J
1 1
r rri OHH4E
1 DIOXIDE
[ -;OWER
L,
— c4
I \VASHER
H . ....
i
CAUSTIC
TOWER
r~
— H WASHtP
i
K 1 CHLORINE 1
1 DIOXIDE
5 |_ TOWER j
i
i
?
| WASHER
. .. ... ,
f
\
BLEACHED PULP
STOCK CHEST
SEWER
LEGEND;
«-— — MAIN PROCESS
SECONDARY PROCESS
PROCESS WASTE LINE
66
-------
chemicals are displaced through a pulp mat rather than beinq
conventionally mixed into the pulp (185). Very rapid bleaching
can be accomplished due to high reaction rates. Filtrate
SSfS^L,*1 T°n\ S^age is fortified with make-up chemical and
reused (186). In the first such system in this country, the
bleaching tower will be 15 feet in diameter and 80 feet in height.
(186) . It will accommodate four stages of bleaching, stacked in
the tower so that the unbleached pulp moves sequentially from
bottom to top as shown in Figure 20.
§i§aching_of_Dissolving_Pulp_s
Dissolving pulps are always bleached, and, in addition, usually
must undergo one or more additional reactions such as chemical
purification, deresination, ash removal, etc. Most of these
steps are combined in a complex bleaching and purification
process (2) .
The actual bleaching for both sulfite and prehydrolysis-kraft is
accomplished by standard procedures as described above. CEHD is
used by some sulfite dissolving mills, although others employ a
five-stage process which may or may not include a chlorine
dioxide stage. The use of this chemical, however, is
indispensable for the production of dissolving grades from kraft
The purpose of the caustic extraction stage in bleachina
dissolving sulfite pulps is somewhat different from its function
in bleaching sulfite paper grade pulps. In the latter, this
i9? *S utilized to remove partially bleached material
solubilized in the chlorination stage, m the manufacture of
dissolving pulp, the extraction stage is much more drastic in
terms of caustic concentrations and degree of heat in order to
dissolve a specific fraction of the cellulose itself which is not
suited to the manufacture of rayon (159) . Over 45 kg (100 Ib) of
caustic may be added per kkg (ton) of pulp and reaction
temperatures exceed the boiling point while only about 14 kg (30
inin° M C^Stir "^ V*™ conditions are required for paper grade
pulp (180) . In dissolving pulp bleaching, this step dissolves
approximately 10-16 percent of the pulp, depending on the grad^
of ceu
of cellulose desired.
The final bleaching steps in sulfite dissolving also serve a
different purpose from the last stage in bleaching paper pulp.
In the latter case, the bleaching agent is usually used to
achieve high brightness with minimum effect on the cellulose
itself. in bleaching dissolving pulp, high brightness is only an
incidental requirement and actual modification of the cellulosp
molecule itself is desired. Thus, the dissolving sequence"
usually ends with a relatively harsh bleaching agen? such as
sodium hypochlorite (159) .
For kraft dissolving grades, the unbleached pulp is purified
the bleach plant to remove all traces of lianin 3
67
-------
FIGURE 20
PLANNED DISPLACEMENT BLEACH H-ANT
AT SURVEYED MILL 121
BLEACHED
STOCK CK.EST
LEGEND'-
MAIN PROCESS
SFCOMOARY PROCESS
PROCESS WASTE LINE
68
-------
hemicellulose. This is done by means of a five to eight stage
process, typically consisting of chlorination, caustic
extraction, hypochlorite bleaching, chlorine dioxide bleaching,
further caustic extraction followed by more chlorine dioxide and
hypochlorite. Lignin is removed by chlorine and chlorine dioxide
and hemicellulose by caustic extraction (189). The extreme hot
alkaline extraction conditions designed for sulfite dissolving,
described above, are not useful for the kraft dissolving process
in which the alpha cellulose level is determined largely by
cooking procedures (8).
Deinked_Pulg
A variety of waste papers are deinked to make several grades of
pulp. Most waste paper used in this manner must be sorted and
carefully classified since 1) not all papers are suitable for
deinking; 2) certain types are desirable for some types of
reclaimed pulps and are not suitable for others; and 3) papers
which can be processed successfully by one process could be
troublesome if mixed with papers requiring different treatment
(2) .
Waste paper is preferably sorted at its source (homes, offices,
stores, factories, printers, or manufacturers of paper products
such as boxes, envelopes, etc.); otherwise it must be sorted by
the dealer, or at the mills. Sorting at the source is becoming
more common today for two reasons. One, sorted waste papers
bring higher prices both to the generator and the dealer than
mixed bales. Second, sorting at the mill is an expensive hand
operation.
Some mills are able to buy overruns of specific publications
which are uniform in character. This makes for a successful
operation since sorting is not required and the deinked product
is more uniform.
High groundwood content papers are deinked for use in tissue or
molded products, and for liner in board mills. These papers are
not as suitable for fine or printing paper operations. Papers
which contain plastics, latex, exotic inks, and other non-
dispersible materials cause difficulties in deinking, degrade the
product, or generate troubles on the paper machine. Wet strength
papers are given separate treatment because of their resin
content.
Details of the deinking process used to produce pulp for fine
papers depend upon the characteristics of the waste paper, "but
the process consists primarily of an alkaline cook to which
dispersants, detergents, and solvents are added. The process is
essentially a laundering operation in which the sizes, any
coating binder, and the pigment vehicle in the ink are dissolved
or dispersed and the ink pigment released, along with filler and
coating agents such as clay, calcium carbonate, and titanium
dioxide. Adhesives such as starch and glue are also dissolved
69
-------
and dispersed. The process is essentially the same in all mills
except that somewhat different process units may be used from a
variety of specific pieces of equipment. The equipment and
process are described in detail in a TAPPI monograph (27).
The waste paper is generally cooked in a pulper at a consistency
of between five and eight percent and a temperature ranging from
80J to 99°C (180° to 210°F). Cooking time is determined
generally by examination of a sample from the pulper. During
this step a trash boot and a ragger may be used to remove trash,
ratjS, rope, wire, etc. The stock is then usually screened at
about one to two percent consistency, after which it is ready for
cleaning. This is accomplished by passing the stock at about 0.5
pe/cent consistency through centri-cleaners and fine screens.
Generally countercurrent washing is employed on washers of
various types. Some mills employ flotation for separating the
fiber from the undesirable materials and others use various kinds
ot deckering or thickening equipment. Fiber leaves the washers
an-,- is delivered to a stock chest at six to 15 percent.
De;,.nking practices in a tissue or molded_gulg mill do not vary
appreciably from the above. However, cooking temperatures for
papers high in groundwood content are generally lower — 38° to
1L~°C (100° to 160°F) with a pH below 10. In addition, sodium
peroxide is frequently added to the cooking liquor since its
bleaching action tends to prevent browning of the pulp.
A considerable shrinkage of the raw stock occurs in deinking
because of the filler and coating materials washed from it along
with large quantities of fiber fines when appreciable groundwood
is present. The shrinkage for common grades of waste paper is
shown in Table 13 (27) .
Newsprint is deinked by a proprietary process employing a special
detergent. The pulp produced is suitable for conversion on high-
speed newsprint paper machines with the addition of little, if
any, long fiber stock and may not require bleaching. Shrinkage
is reported to run around 15 percent.
In some non-deinking operations considerable quantities of books,
envelope cuttings, and flyleaf shavings, and similar unprinted
scrap is repulped and washed free of fillers, adhesives, and
sizing materials. Although ink removal is not involved,
shrinkage and attendant sewer losses from such operations are
similar to those from deinking.
At some paper mills relatively small amounts of selected kinds of
waste paper are deinked from time to time for use in furnishes
employed in the production of particular specialties. In such
cases, almost the entire operation, including bleaching, is
carried out in Hollander beaters (28). This may be the case also
with the reclamation of fiber for use as liner in board mills.
70
-------
li§§£hin3_of_Deinked_Pulg
peinked fibers consisting primarily of bleached chemical pulp are
bleached in one stage with chlorine or calcium or sodium
hypochlonte. From two to five percent of available chlorine is
commonly used. Consistencies of the pulp bleached range from
three to as high as 12 percent; tower type bleaching is used for
the higher consistencies. When pulps containing considerable
lignin are bleached after deinking, the threestage CED process
commonly applied to kraft and sulfite pulps is employed (6). in
this process, three percent of chlorine is applied to a dilut-e
?i"rl;Y * ^he pulp at ambient temperature. The pulp is then
thickened and treated with caustic soda at 38°c (100°F) which is
followed by washing and treatment with hypochlorite. A variety
of equipment and variations of this process are in use Pulps
gh Jln Jc'roundwood are bleached by the methods employed for
groundwood alone and variations thereof employing caustic soda
peroxides, and hydrosulfites. Bleaching decreases the yield in
the range of from 2.9 to five percent (28) (8).
A process flow diagram of a deinking operation with single stage
bleaching is presented in Figure 21 and a similar diagram of a
three stage bleaching system for deinked pulp is shown in Figure
In stock preparation, pulp, either purchased or produced on site
is resuspended in water to a consistency of four to six percent!
relink +" HK6^^10^7 treated in beaters or continuous
refiners to "brush" or fray the individual fibers to obtain the
necessary matting which produces the desired strength in the
paper. This process also cuts the fibers to some degree. in
cases where good formation is desired, such as fine papers, the
stock is also pumped through a Jordan which further cuts the
fibers, with a minimum of brushing, to the necessary length The
amount of brushing and cutting varies with the type of pulp and
71
-------
Table 13
SAMPLES OF SHRINKAGE
OF VARIOUS TYPES OF PAPER
ON DEINKING
XAsh ^Shrinkage
Bond 2 10
Ledger 5 15
Offset 12 19
Book 20 34
Gummed 10 40
Coated 25 42
Coated 30 50
Chemical additives may be added either before or after stock
preparation. The most common additives are alum and rosin used
for sizing, which prevents blotting of ink. Fillers such as
clay, calcium carbonate, and titanium dioxide are added where
opacity and brightness of the paper are important. A wide
variety of other additives such as wet strength resins,
dyestuffs, and starches may be used, depending on end-use re-
quirements.
Either a fourdrinier or cylinder forming machine may be used to
make paper/board. The primary operational difference between the
two types is the flat sheet-forming surface of the fourdrinier
and the cylindrical-shaped mold of the cylinder machine. The
type of machine used has little bearing on the raw waste load.
In the fourdrinier operation, dilute pulp, about 0.5 percent
consistency, flows from the headbox onto the endless wire screen
where the sheet is formed and through which the water drains. A
suction pick-up roll transfers the sheet from the wire to two or
more presses which enhance density and smoothness and remove
additional water. It then leaves the "wet end" of the machine at
about 35 to 40 percent consistency and goes through dryers,
heated hollow iron or steel cylinders, in the "dry end."
In the cylinder operation, a revolving wire-mesh cylinder rotates
in a vat of dilute pulp picking up fibers and depositing them on
a moving felt. The pressing and drying operations are the same
as described above. The cylinder machine has the capacity to
72
-------
PLANT PKOCLS5 FLC\V DIAGRAM
wvn r.
PAPER
COOKING !
CHEMICALS T
i.'AChIHE
WHITE
V'ATFP
•ROCES3
WAT E R
A
COOKER
-I STEAM
RECYCLE
r
\
Di? T LAK/.R
CENTRIFUGAL
CLEAMERS
WASHERS
8 DECKER
.1
BRO\YN
STOCK
CHFST
BLEACH
PLANT
BLEACHED
STOCK
CHEST
I
PAPERMAKING
I
-H
SEV/ER
LEGEND:
——•— MAIN PROCESS
SECONDARY PROCESS
PROCESS WASTE LINE
73
-------
3TA.
LEACM HLAN
pROcr-:rr, FLCV; ciACRAf
STC/CK
CHE PT
r
-h Lor; if -
PROCLSK
L
\VA?HER |
T
-J
CAUSTIC
SODA
CAUSTIC i
TOWER
V.'ASHER
p-
HvpCiCHL.ORITE
HRF.'JARATION
i H-rf-'OCHLOR! It"
TOWER
CEIvTRiFLIGAL
CLEANERS
WAS;;ERS
8, DCCKER
, ,\
i!»|
OLEACHED
STUCK
CHFST
SEWER
P A PL R MAKING
LEGEND:
„_-—, MAIN PROCESS
SECONDARY PROCESS
PROCESS WAG'l r LIK'ii
74
-------
make multi -layered sheets which accounts for its princical u^ -
the manufacture of paperboard. principal use ,
Because of its higher speed and greater versatility t~
fourdnnier is in more common use than ?he cylinder Machine'
'
o
ssts
A^flow sheet of the fourarinier operation is presented in Figu,
75
-------
FIGURE 23
PAPER MANUFACTURING PROCESS FLOW DIAGRAM
PURCHASED
PULP
PULPER
I SLUSH PULP
FROM INTEGRATED
PULP MILL
L...
NON-INTEGRATED
PAPER MILL
COATER
SIZE
PRESS
DRYER
SECTION
PULP
CHEST
PROCESS
WATER
REFINERS
JL
FILTERED
WHITE WATER
TANK
ALTERNATE
MACHINE
CHEST
FIBER
MISC. REUSE
SAVEALL
CENTRIFUGAL
CLEANERS
RICH WHITE
WATER TANK
FOURDRINIER
SECTION
COUCH PIT
AND
WIRE PIT
SEWER
LEGEND:
— MAIN PROCES.0
— SECOfiDARY PROCESS
— PROCESS WASTE LINE
76
-------
SECTION IV
SUBCATEGORIZATION OP THE INDUSTRY
FACTORS jOF_CONSIDERATION
.
1. Raw materials
2. Production processes
3. Products produced
<*. Size and age of mills
1. Bleached Kraft: Dissolving Pulp
2. Bleached Kraft: Market Pulp
3. Bleached Kraft: Fine Papers
4. Bleached Kraft: B.c.T. Papers
5. Sulfite; Papergrade
6. Sulfite: Dissolving
7. soda
8. Groundwood: Chemi-mechanical (CMP)
9. Groundwood: Thermo-mechanical (TMP)
10. Groundwood: Fine Papers
11. Groundwood; C.M.N. Papers
12, Deink
13. Non-integrated (NI) Fine Papers
14. Non-Integrated Tissue Papers
15. Non-integrated Tissue Papers (from Waste Paper)
s »s'»r s"~— •"
77
-------
The subcategories are defined as follows:
1. BLEACHED KRAFT: DISSOLVING PULP means the production of
a highly bleached pulp by a" "full cook" process utilizing a
highly alkaline sodium hydroxide and sodium sulfide cooking
liquor. Included in the manufacturing process is a "pre-cook"
operation termed prehydrolysis. The highly bleached and purified
dissolving pulp is used principally for the manufacture of rayon
and other products requiring the virtual absence of lignin and a
very high alpha cellulose content.
2- BLEACHED KRAFT: MARKET_PULP means the production of
bleached pulp by a" "full cook" process utilizing a highly
alkaline sodium hydroxide and sodium sulfide cooking liquor.
Included in this subcategory are mills producing papergrade
market pulp as the only product.
3. BLEACHED KRAFT: FINE PAPERS means the production of
bleached pulp by" a "full-cook"process utilizing a highly
alkaline sodium hydroxide and sodium sulfide cooking liquor.
This pulp is used to manufacture fine papers which are defined as
those papers containing eight per cent clays and fillers or
above.
4. BLEACHED KRAFT: B..C..T.,_PAPERS means the production of
bleached pulp by ~a~ "full cook" process utilizing a highly
alkaline sodium hydroxide and sodium sulfide cooking liquor.
This pulp is used to manufacture a variety of papers with clays
and fillers contents less than eight per cent. Included in this
subcategory are mills producing paperboard (B), coarse (C)
papers, and tissue (T) papers.
5. PAPERGRADE SULFITE means the production of pulp, usually
bleached,~by a "full cook" process using an acidic cooking liquor
of bisulfites of calcium, magnesium, ammonia, or sodium
containing an excess of free sulphur dioxide. This pulp is used
to manufacture a variety of paper products such as tissue and
fine papers.
6. DISSOLVING _SULFITE means the production of highly
bleached and purified pulp by a "full cook" process using very
strong solutions of bisulfites of calcium, magnesium, ammonia, or
sodium containing an excess of free sulphur dioxide. This pulp
is used principally for the manufacture of rayon and other
products requiring the virtual absence of lignin and a very high
alpha cellulose content.
7. SODA means the production of bleached pulp by a "full
cook" process utilizing a highly alkaline sodium hydroxide
cooking liquor. This pulp is used principally to manufacture a
wide variety of papers such as printing and writing papers.
78
-------
puln8" 2^2WQQD: CHEMI^MECHANICAL means the production of
P' Jo ^S^^i911^111?.:.?1!1?^ a chemical cooking
pulp!
^^
10. GRQUNDWQOD: FINE. PAPERS means the production of
H e^N^fAPERs means the production of pulp,
raio
to manufacture coarse (C) papers, molded £" fiber promts
and newspnnt (N) which include papers with clavs and
contents less than eight per cent. Y
- ----
with chemical pulp, to manufacture a wide variety of papers such
as printing, tissue, and newsprint. papers such
^-£^BATIp_FINE.PAPER means the manufacture of
79
-------
RATIONALE_FOR_SELECTION_OF_SOBCATEGORrES
The subcategorization shown above was developed through extensive
efforts in evaluating the factors listed above. Each of these
factors is discussed below as to how the factors relate to the
resultant subcategories.
The basic approach utilized to technically develop the
subcategories was to first segment the industry by manufacturing
process. The resultant broad segments were the following:
A. Chemical Pulping
B. Mechanical Pulping
C. Non-Integrated Paper Mills
These broad segments were further broken into more specific
process segments including the following:
A. Bleached Kraft Pulping
B. Sulfite Pulping
C. Soda Pulping
D. Groundwood Pulping
E. Deink Paper Mills
F. Won-Integrated Paper Mills
Inherent in dividing the pulp and paper industry into the above
specific process segments is the basic assumption that raw waste
loads are related to the specific manufacturing process involved
(Factor No. 2 above).
These specific process segments were then thoroughly evaluated as
to the relationships between factors listed above and the waste
water characteristics of the process effluents within the
segments. These analyses resulted in dividing the above segments
into the 15 subcategories. In addition, two groups of mills
(coarse paper mills and specialty paper mills) within the non-
integrated paper mills segment were eliminated from these
effluent limitations because adequate data was not available to
support (1) subcategorization of these groups of mills and (2)
effluent limitations and standards.
In examination of the relationships between the above factors and
the process segments, the raw waste flow and BOD5 loads were of
primary concern. These two parameters were used as the basis for
subcategorization as the pollution control technologies
applicable to the segments under study are primarily designed as
a function of flow and BOD5. The average raw waste loads for
each of the subcategories are shown in Table 1U and displayed
graphically in Figure 24. The development of the specific
subcategories as to the relationships between the factors and raw
waste loads are discussed below, whereas the development of the
specific raw waste loads per subcategory is discussed in Section
V.
80
-------
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Raw materials were used as a basis for subcategorization. The
primary raw materials used in pulp and paper making can be
generally be classified as follows: (1) wood fiber, (2)
chemicals for cooking and bleaching liquors, and (3) papermaking
additives. These three basic raw materials result in distinctly
different raw waste loads depending upon the closely related
factors of process and products.
Wood is the primary raw material of all virgin fiber pulping
processes. Consideration was given to subcategorization on the
basis of wood type, but this could not be documented from raw
waste data obtained from surveyed mills. For example, bleached
kraft Mill 113 utilizes about equal amounts of southern hardwood
and softwood and has a raw waste load of 30 kg/kkg (60 Ib/ton)
On the other hand. Mill 117 uses western softwood and has similar
BOD waste load of 27.5 kg/kkg (55 Ib/ton) . Table 15 shows Flow
and BOD5 vs. type wood for surveyed mills in the bleached kraft
and groundwood subcategories. It is apparent from these analyses
that no definite relationship can be documented as to the
specific effects of the type of wood on raw waste loads
Inherent in examining the relationships (or lack of) between wood
types and raw waste loads is the geographical location factor, as
the type of wood used by a mill is certainly a function of the
location of that mill.
In addition to the type of wood, consideration was given to
condition of the wood as it arrived at the mill meaning either
chips or logs. This difference in raw materials relates to the
process factor as depending upon the form of the wood, additional
waste loads are generated by some mills using wet log debarking
processes whereas mills receiving wood as chips do not have this
source of waste. Consideration was given to developing
subcategories within each of the segments based upon chips vs.
logs as this operation does result in an effluent waste load not
present in mills using only chips. However, the wet barking
operation is similar for all pulping segments and thus is not.
unique to one segment. Instead of subcategorization, an
additional allowance is included in the BPCTCA effluent
limitations for mills practicing wet barking without regard to
the subcatetgory (See Section IX) .
The source of wood fiber used as the raw material was used as a
basis for subcategorization. The sources of fiber are (1) wood
(as described above), (2) pulp, and (3) waste paper. Again,
subcategorization by these fiber sources relates closely with ^he
process. Non- integrated paper mills do not have wood pulping
facilities and thereby depend upon either pulp or waste paper as
their fiber source. Distinctly differernt BOD5 loads result from
the use of pulp or waste paper as the fiber source. This is
apparent in Table 14 which shows the NI tissue subcategory BODS
waste load of 12.5 kg/kkg (23 Ibs/ton) which by definition usei
purchased pulp as the fiber source. In comparison, the NI tissue
(FWP) subcategory is 14.5 kg/kkg (29 Ibs/ton) which uses waste
83
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paper as the fiber source. Both of these subcategories produce
the same product but were subcategorized on the basis of raw
materials.
The chemicals used in preparation of the cooking liquors and in
the bleaching process can have significant effects upon raw waste
load, but again this is primarily a function of the process and
product factors. The segmentation and subcategorization of the
industry used chemical cooking liquors as a basis and is shown by
the two distinct segments of kraft and sulfite. Bleached kraft
mills use a highly alkaline cooking liquor resulting in raw waste
loads ranging from 20 to 60 kg/kkg (40 to 120 Ibs/ton) depending
upon final product qualities. Sulfite mills, on the other hand,
use highly acidic cooking liquors resulting in raw waste loads
ranging from 70 to 140 kg/kkg (140 to 280 Ibs/ton). Th»
differences between kraft and sulfite relate to the recovery of
the spent cooking chemicals and to the reuse of the condensates.
Papermaking additives were used as a basis for subcategorization
primarily as they related to the final products. The additives
have a discernible effect upon raw waste loads with the most
significant effects shown by the non-integrated paper mills
These mills do not engage in wood pulping, but the wastes reflect
the use of a wide variety of fiber types, fillers, wet strength
agents, starches, rosins, and other additives. The effects upon
raw waste load are shown in Table 14 for NI fine papers and NI
tissue papers subcategories.
The deink subcategory can be used as an example of how the three
basic_ classifications of raw materials (fiber, chemicals,
additives) were used in the development of the subcategories
Deink mills are similar to non-integrated paper mills in that
deink mills have no chemical or mechanical wood pulping on site
In addition, both deink and non-integrated paper mills purchase
their fiber and manufacture similar products by similar process
The most significant differences are in the raw materials and in
the manufacturing process which must be used to produce the final
product qualities. Because waste paper is the fiber source
rather than the relatively much cleaner purchased pulp used by
non-Integrated paper mills, chemicals must be used in the deink
manufacturing process to clean the waste paper to specifications
as demanded by product qualities. (3) Similar products ar^
manufactured by deink mills and non-integrated paper mills using
various papermaking additives, but this has lesser effects upon
the raw waste load than the above two factors. Deink mills were
subcategorized separate from the non-integrated mills primarily
because of the raw materials used, which in turn has a direct
relationship in determining the manufacturing process. Because
of the raw materials, the primary purpose in the repulping of th^
waste paper is to remove the non-fibrous materials, such as
pigments, starches, and inks (paper making additives), and it is
actually a cleaning process. On the other hand, the primary
purpose of non-integrated paper mills in repulping purchased pulp
is merely to separate the fibers previous to forming the sheet of
paper. These differences can have significant effects upon >he
85
-------
raw waste load as can be seen in Table 14 which shows the
effluent flow to be similar for deink mills and non-integrated
paper mills but the BOD5 and TSS are significantly higher for
deink mills (BOD5: 68.5 kg/kkg (137 Ibs/ton) vs. 12.5 kg/kkg (23
Ibs/ton): TSS: 204 kg/kkg (408 Ibs/ton) vs. 34 kg/kkg (68
Ibs/ton)).
P£°. ^iJSt i on_ Processes
Production processes were used as the primary basis for
subcategorization as differences in waste water characteristics
and treatability are most significantly affected by the
manufacturing process. Of course, the manufacturing process is
closely related to raw materials and final products, and these
two factors are inherently included in any evaluations involving
the manufacturing process.
All chemical pulping processes are similar in that each utilizes
digestion of wood chips with a chemical cooking liquor and the
removal of spent liguor from the cellulose pulp. Process
differences among the various pulp types relate primarily to the
preparation, use, and recovery of cooking liquor. Such liquors
are generally not used to make groundwood pulps, although small
quantities are applied in some grades. The deinking process does
not employ cooking liquors, although chemical treatment is
utilized in the separation of cellulose fibers in waste papers.
Non-integrated mills employ no cooking chemicals.
All segments of the industry use similiar paper making and/or
forming equipment to manufacture paper or pulp products, as
described in Sections III and V. Process differences in the
paper making process relate primarily to the additives used to
produce specific product qualities, i.e. book paper vs paperboard
The effects of the process differences on waste characteristics
are shown in Table 14. It should be noted that treatability of
waste wat«=>r is accounted for in the subcategorization process by
subcategorizing on the basis of similar processes and raw
materials which contribute similar types of waste waters.
Products_Produced
The wide variety of products produced by these segments of the
industry is discussed in Section III. Differences in waste water
characteristics generated by their manufacture are substantial
but actually these differences are more attributed to the process
and raw materials rather than to products produced. For example,
tissue papers are manufactured by both bleached kraft and sulfite
mills yet the waste water characteristics of the effluents
generated by the manufacturing processes are significantly
different.
As shown previously, the bleached kraft segment was
subcategorized into four subcategories: (1) dissolving pulp, (2)
36
-------
market pulp, (3) board, coarse, and tissue papers, and (4) fine
papers. Within the bleached kraft segment, the variations of the
process used to produce the above products is the most
significant factor in characterizing the waste water
characteristics rather than the products themselves. Another
example is the subcategorization of the non-integrated paper
mills into NI fine papers and NI tissue papers. The primary
differences in waste water characteristics from these mills
relates to the additives used in the paper making process rather
than to the products. These differences in waste water
characteristics are shown in Table 14.
Newsprint manufacture can also be used as an example of
difference processes producing similar products. Consideration
was given to subcategorization on the basis of newsprint
manufacture as newsprint uses two specific types of pulp: 65-80%
groundwood and 20-35% chemical pulp. Approximately 13 integrated
mills manufacture newsprint; however, these integrated mills that
produce newsprint do not have similar processes and thereby
significant differences in waste water characteristics exist.
Table 16 shows process information for the integrated mills
producing newsprint. The dissimiliarities between the mills
relates primarily to process and products as several mills
produce 100% newsprint using groundwood pulp along with either
bleached kraft, unbleached kraft, or sulfite pulps. In addition,
nine of the 13 mills produce other products besides newsprint.
Also, mills that produce newsprint from on-site groundwood
pulping and purchased chemical pulp are not included in the
table.
Thus, the products themselves were considered and were used as a
basis for subcategorization but only as they related to the
process and raw materials.
Age_and_Size_of_Mills
There is a substantial difference in age as well as size among
mills in the industry. Mills built over 90 years ago are still
in operation along with new ones built within the last two years.
Most of the older mills have been substantially upgraded,
modernized, and expanded, so that they are not "old" in the
production sense. Because of this, differences in waste water
characteristics related to age of mill are not discernible in the
data from surveyed mills. The following examples from the
bleached kraft segment illustrate this point. Mill 111, built in
1912 and modernized as recently as 1973, produced 656 kkg/day
(723 tons/day) with a raw waste BOD load of 22.5 kg/kkg (45
Ib/ton). Mill 112, built in 1969, produces about the same
tonnage, i.e., 544 kkg/day (600 tons/day), with a nearly
identical BOD load of 24.5 kg/kkg (49 lb/ ton). Mill 118 is much
smaller, producing 174 kkg/day (192 tons/day) and was built in
1867 and rebuilt in 1951, and modernized in 1964, but has
approximately the same BOD load, i.e., about 20 kg/kkg (40
87
-------
Table 16
Newsprint Segr.sni
Mi 11
Prod''ction
r33
COS
037
CO
CO ^-.
O'jd
514
072
509
156
165
167
034
141
16:
N Newsprint
B Board
C Ccarse
F FT ",2
5 Sulfite
ki2/-r2Z.
1088
4C3
517
1238
1088
1120
590
1179
635
1451
1292
IOCS
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Ib/ton). Table 17 compares the age of the original facility for
bleached kraft mills with the mills' raw waste loads.
The above data are selected from Figures 25 and 26 which
graphically displays the size and effluent characteristics of
bleached kraft mills. This figure demonstrates the apparent lack
of correlation between size of mill and raw waste flow and BOD
load. To further illustrate the point, Figures 27, 28, 29, and
30 show size verses flow and BOD5 for non-integrated fine and
tissue subcategories. Table 18 compares the number of paper/pulp
machines in a mill with the corresponding raw waste load, and
shows that no significant differences due to this factor may be
detected within the segments. As further substantiation of this
point, it may be seen in Figure 31 that no significant
correlation is apparent between number of machines and raw waste
BOD load within the bleached kraft segment which is used as an
example. To the extent that such a correlation may exist, how-
ever, it is taken into consideration in Section IX through the
selection of mills having various numbers of machines, as used to
determine guidelines.
Any such correlation which may exist, however, is taken into
consideration in Section IX through the selection of various ages
and sizes of mills used to determine effluent limitations.
Thus, age and size of mills were considered but not used as a
basis for subcategorization.
Table 18
RAW WASTE BOD VS. NUMBER OF MACHINES
Mill No. of Raw Waste BOD
Code SgaSgQt Machines kg/kkg __ (lb/tgnl_
2 Groundwood 1 20.5
3 Groundwood 4 16.5 (33)
5 Groundwood 8 18 (36)
112 Bleached Kraft 2 24.5 (49)
119 Bleached Kraft 8 23.5 (47)
150 Soda 2 57 (114)
151 Soda 7 49.5 (99) est
262 Fine 1 9 (18)
265 Fine 6 11 (22)
Lo c at ion
Mills are widely dispersed throughout the United States, from
Maine to Alaska, and from Minnesota to Louisiana. Despite this
dispersion, the data from surveyed mills in the same segments do
90
-------
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(40)
30
(60)
40
(80)
50
(100)
60
(120)
AVERAGE ANNUAL RAW WASTE BOD
Kg/KKg (LB/TON)
FIGURE 31
BOD VS NUMBER OF MACHINES
BLEACHED KRAFT SEGMENT
97
-------
not reveal significant differences in annual BOD loads as
affected by geographical location and is illustrated in Table 19.
Geographical location can have an effect upon BOD5 removal
efficiencies of biological treatment systems as a result of
temperature extremes caused by climatic conditions. The effects
of temperature variations can be minimized through effective
design and operation of the biological treatment facilities (See
Section VII). Any temperature effects upon adeguately designed
and operated facilities are taken into account in the
determination of effluent limitations as discussed in Sections
VII, IX, Xr and XI.
Geographical location was, therefore, considered but not used as
a basis for subcategorization.
Table 19
RAW WASTE BOD VS. GEOGRAPHICAL LOCATION
Mill Raw Waste BOD
Code Segment Location 3sa/JslS3
3 Groundwood Northeast 16.5 (33)
5 Groundwood Northwest 18.0 (36)
51 Sulfite Northwest 91.5 (183)
56 Sulfite North Central 109.0 (218)
101 Bleached Kraft South 27.0 (54)
117 Bleached Kraft Northwest 27.5 (55)
151 soda Northeast 45.5 (99) est.
152 Soda South 48.0 (96) est.
204 Deinked Central 27.5 (55)
205 Deinked East 26.5 (53) est.
265 Fine Northeast 11.0 (22)
270 Fine North Central 11.5 (23)
98
-------
§yBCATEGORY_RATIQNALE
The rationale for subcategorization of the segments under study
is discussed below:
ll.§ached_Kraft_Se3ment
The effluent waste water characteristics generated during pulp
and paper manufacturing can generally be considered to be related
to two basic groupings: (A) process variables and (B) waste water
variables. The "process variables" relates to the specific
manufacturing operations used to produce a specific final product
and affects effluent characteristics as a function of the process
necessary to produce the final end product. The "waste water
variables" relates to the internal measures used to recover
chemicals and fibrous materials and to reuse process waters and
affects effluent characteristics as a direct function of the
extent of recovery and reuse procedures. The difference between
the "process variables" and the "waste water variables" is that
the former are inherent effects upon effluent characteristics as
a function of the raw materials and the product required and th*
latter are controllable effects upon effluent characteristics as
a function of recovery and reuse measures. The two are related
in that the "waste water variables" are a function of •'-he
"process variables".
The "process variables" actually relate to the specific
manufacturing operations utilized for using fibrous raw materials
to produce pulp and paper. The major component parts of the
"process variables" include: (1) digestion, (2) bleaching, and
(3) product making. The variations in these three operations is
a direct response to the raw materials utilized but more so is
primarily a function of the final product qualities. Thes*
variations produce distinct differences in waste water
characteristics. The primary "process variable" for digestion is
simply termed as "the degree of cooking" which can essentially be
characterized by such measurements as yield loss or KAPPA
numbers. The factors affecting digestion include (a) the cook
characteristics, such as the length, and temperature and
pressure, and (b) the strength and chemical makeup of the cooking
liquor. Also included are variations in the kraft digestion
process such as the prehydrolysis step in producing dissolving
kraft pulp. The primary "process variable" for bleaching is
simply termed "the degree of bleaching" which is can be described
by the yield loss or brightness levels. The factors affectina
bleaching include (a) bleaching sequence (number and type of
bleaching steps) and (b) the individual bleach stage
characteristics, such as the strength and chemical makeup of the
bleach liquor and the length {time, temperature, and pressure) of
the bleach. The primary process variable for product making is
if paper or pulp is the final product. For mills producing
paper, an additional process variable includes the types and
quantities of additives utilized in producing the qualities of
the final paper product.
99
-------
The "waste water variables" relate to the recovery of chemicals
and fibers and to the reuse of process waters. The "waste water
variables" are somewhat a function of the "process variables"
since some recovery and reuse practices are limited by the
specifics of the raw materials, manufacturing process, and final
end product qualities. The extent of the recovery and reuse
procedures affects the effluent characteristics. These recovery
and reuse procedures are discussed in Section VII and VIII and
include such items as the following: capacity of the brownstock
washers for recovery of the black liquor; spill control and reuse
systems for recovery and reuse of such items as liquor spills,
evaporator boilout, and evaporator carryover; screen room water
reuse and knots recovery; white liquor preparation; landfill of
grits and dregs; recovery of lime mud; bleach plant jump stage
countercurrent washing; and save-alls and the reuse of white
water.
The above discussion of "process and waste water variables" was
given as a basis for subcategorization of the bleached kraft
segment. As is apparent from the discussion, the "process
variables" are used as the primary basis for subcategorization
since inherent in the process variables are raw materials,
manufacturing operations, and final products. The "waste water
variables" are considered primarily in the establishment of raw
waste loads for each subcategory and in developing effluent
limitations and standards of performance. These are discussed in
Sections V, IX, X, and XI. It should be pointed out that in the
examination of the "process variables" for the purpose of
subcategorization, any relationship between the recovery and
reuse procedures utilized specifically by one type of
manufacturing operation were taken into account (i.e. reuse of
nrehydrolysate from dissolving kraft mills).
Trie bleached kraft segment was subcategorized into four separate
subcategories each described by the final product manufactured:
fl) dissolving pulp, (2) market pulp, (3) fine papers, and (4)
BCT papers. The final end product qualities determines the
specifics of the manufacturing process utilized (the "process
variables"), and thus, the bleached kraft segment was
subcategorized as a result of the process and product factors
effects upon effluent characteristics. In evaluation of the
factors discussed earlier, it was concluded that the most
significant effects upon effluent characteristics were related to
process and product factors rather than to several other factors
such as age, size, location, or raw materials.
As shown previously in Figures 25 and 26, the age or size of
mills do not have any signficant effects upon the waste water
characteristics. In addition. Table 15 shows the type of wood
used in comparison to the effluent characteristics and again no
signficant effect upon effluent characteristics is shown. The
geographical location has no significant effect upon effluent
characteristics. An evaluation of the effect of bleaching upon
effluent characteristics was made and again no signficant effects
were determined. Figures 32 and 33 show effluent characteristics
100
-------
compared to brightness levels for bleached kraft mills.
Extensive analysis showed that the most signfleant effects upon
effluent characteristics related to the manufacturing process
used to produce a specific end product. By subcategorizing based
upon the final product as it relates to the manufacturing
segment, the "process variables" are essentially the same and
variations in effluent characteristics are a function of the
"waste water variables."
The effluent characteristics for the bleached kraft subcategories
are displayed in Figure 2U. The dissolving kraft subcategory has
the highest effluent flows and BOD5 loads due to the final
product qualities. An additional step in the digestion process
is required and extensive pulp washing and bleaching are
necessary to produce a highly purified pulp. These process
factors result in a relatively higher effluent waste load than
for mills producing market pulp. The effluent waste loads of
mills producing market pulp are relatively higher than mills
producing paper, as market pulp mills generally produce a higher
grade pulp (i.e. higher brightness).
Mills that produce bleached kraft papers can generally be divided
into mills that use relatively large amounts of additives (i.e.
fillers, wet strength agents, starches, and rosins) and mills
that use very few additives. Additional effluent waste load
generally results from the use of additives, as for example, use
of starches is a source of BOD5. Also, use of additives can add
as much as 33% additional weight to the sheet of paper. Mills
using large amounts of additives produce fine papers and
generally use upwards of 8 to 10 % by weight of additives. Mills
using less amounts of additives produce such products as
paperboard, coarse papers, and tissue papers. Effluent
characteristics generated by the production of these two
groupings of papers are significantly different and are shown in
Figure 24. The use of additives by mills producing fine papers
is an added source of BOD5 but apparently is more than
compensated for by the additional weight of the additives when
examined on a kilograms per 1000 kilograms (Ibs/ton) basis. The
process factors must also be considered when attempting to
determine the reasons for the differences in effluent
characteristics between mills producing fine papers and those
producing paperboard, tissue, or coarse papers.
Sulfite_Segment_
The sulfite segment was subcategorized into two separate
subcategories, dissolving sulfite and papergrade sulfite, based
upon process factors. The discussion of "process variables" and
"waste water variables" in the bleached kraft section can
generally be applied to the sulfite segment. The "process
variables" distinctly separate two grouping of mills: (1) mills
producing dissolving sulfite pulp and (2) mills producing
papergrade pulp and/or paper.
101
-------
.:• j; T. J i. -. i n 3
CM
o
-------
o
CO
FIGURC 33
-------
Effluent characteristics of dissolving sulfite mills are
considerably higher than mills producing papergrade pulp as shown
in Figure 24. In the dissolving sulfite process, the digestion
and bleaching operations are relatively much more extensive than
papergrade pulping. Because of the more extensive digestion and
bleaching, the pulp yield is considerably lower than papergrade
and thereby corresponding higher effluent loads are generated.
The subcategorization of sulfite mills producing papergrade pulp
or paper into one subcategory was based upon both "process
variables" and "waste water variables". The final products
produced by mills in the papergrade sulfite subcategory include
fine papers, tissue papers, newsprint, coarse paper, paperboard,
and market pulp. In producing these products, seven of the 22
papergrade sulfite mills utilize other pulping processes on-site,
such as groundwood, bleached kraft, or neutral sulfite semi-
chemical. Determination of effluent characteristics specifically
resulting from the sulfite production process at these seven
mills is generally impossible from the available data as waste
waters are not segregated between the processes.
The "waste water variables" unique to sulfite mills include such
internol control measures as spent liquor recovery (evaporation
and Incineration and/or production of by-products), the types of
pu;;,s washing (blow pit or vacuum drum) , and the type of condenser
fbarujr^tric or surface). In this case, these "waste water
variables*' have a more significant impact upon the effluent
characteristics than the "process variables." Table 29 shows some
of the internal recovery and reuse procedures used at sulfite
mills. Thorough examination of the technology information
presented in the table and the flow and BOD5 data (29) could lead
to the conclusion that several subcategories should be created to
account for such "waste water variable" as (1) wet woodyard
operations, (2) blow pit pulp washing, (3) vacuum drum pulp
washing, (4) barometric condensers, (5) surface condensers, and
(6) bleaching sequence variation (actually a "process variable").
However, the identification of the technology in Section VII,
VIII, and IX for BPCTCA and the establishment of the effluent
limitations actually eliminates the need for any further
subcategories. The wet woodyard operations mentioned above are
accounted for in an additional allowance for all mills, exclusive
of the subcategory, practicing wet woodyard operations and is
discussed in Sections V and IX. The identified in plant control
technology for BPCTCA. for papergrade for sulfite mills includes
(1) spent liquor recovery, (2) blow pit pulp washing, and (3)
barometric condensers. As thoroughly discussed in Section V,
these inplant control technologies result in the highest effluent
characteristics and thereby all of the other mills should have
lesser effluent loads. In addition, the bleaching sequence has
an effect upon effluent characteristics, and this is accounted
for in the selection of mills as representative of the higher
effluent loads for the subcategory by using mills which practice
extensive bleaching. Because the "waste water variables" have
more significant effects upon effluent characteristics than the
104
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;
"process variables", subcategorization according to tiie fit
-------
differences in effluent characteristics as shown in Figure 24.
Thus, two subcategories described by the final product were
established.
§QSla_Segment
Because of similarities of the "process variables" between the
three mills in the soda segment, one subcategory was developed.
Each mill produces fine papers by the soda pulping process. In
addition, the mills purchase market pulp to supplement their own
manufactured pulp in making fine papers. Each of the ™ills ^s
relatively old with the newest mill (mill 150) being built in
1923. The bleaching operation at these mills is similiar except
that mill 150 has a shorter sequence and thereby does not bleach
to as high a brightness as mills 151 and 152 Higher bleaching
generally results in higher effluent loads; mill 150 is the
"newest" soda mill with the lowest amount of bleaching yet the
effluent loads from mill 150 are higher than mills 151 and 152
(see Table 44). Thus, one subcategory was developed as "process
variables" were similiar and any differences in effluent
characteristics are taken into account by using data from all
mills in the subcategory to determine the average effluent
character!sties.
Deink_Segment
One subcategory which includes all deink mills was established
fSr the deink segment. The deink manufacturing process uses
waste paper as its primary source of raw materials and as such
the purpose of the pulping process is to separate the fibers and
to remove the unfibrous materials (i.e. papermaking additives,
inks). As such, the deink process has been termed a cleaning
operation. A wide array of products are manufactured including
fine, tissue, and news papers.
The principle effects upon effluent characteristics are related
to U) the type of waste paper used as raw materials and (Z) tne
end product qualities. The data shown in Table 47 is broken into
two products, fine papers and tissue papers, and shows
differences in effluent characteristics between mills producing
the two product types. consideration was given to
subcategorization based upon the type of product produced, but
raw material generally has a more 8l9nj*ican* J^c* *££
effluent characteristics. Because of possibly cha^ing market
conditions for purchase of waste paper, one subcategory was
developed and differences in effluent characteristics are
accounted for through selection of mills which have high effluent
characteristics in relation to the raw waste loads of other mills
in the subcategory (see Section V).
Non-IntegrateJ_Pap_er_Mills_Segment
The non-integrated paper mills segment was s^cf^°^ed. n^°
three subcategories based upon "process variables." The three
subcategories include mills using purchased pulp to produce (1)
106
-------
fine papers and (2) tissue papers and mills using waste paper to
produce (3) tissue papers. Consideration was given to
subcategorization based upon percent C & F but as shown in
Figures 34 and 35 no significant relationship exist between C =•«• F
and effluent characteristics for MI fine paper mills. in
addition, a large number of non-integrated paper mills v^-re
excluded from this study because of a lack of adequate data base
upon which subcategories and effluent limitations could be
establishd. Effluent limitations and standards of performance
will be developed for these mills at a later date. Included in
this group are non-integrated paper mills producing coarse and
specialty papers. The use of additives in the papermaking
process to produce the desired end products of either fine papers
or tissue papers is the most significant factor upon effluent
characteristics, and the subcategories of fine papers and tissue
papers were developed accordingly. The subcategorization of ron-
integrated tissue mills into two subcategories was based upon "-he
type of raw materials used as a source of fiber, purchased pulp
or waste paper. The use of waste paper has significant impact
upon effluent treatability as well as upon effluent
characteristics. The differences in effluent characteristics are
shown in Figure 24 and the differences in treatability are shown
in Section IX.
107
-------
o
C3
K I T
IN A
A C + F vs BODS
FIGURE 34
iC.OO
i?.co ' i7.ro
-------
601
-b
-------
SECTION V
HATER_USE_ANP_WASTE_CHARACTERIZATION
throughout most of their n
similar industry-wid^ althouah h
vary from subcategory \o su£ca?orv
in each subcategory are availahH
ssr
Quantities of it
maj°r Uses
f01?^8 typically used
a °n tOtal USe of
section vii.
as discussed in
to another in the same mill
Previously, an are
section. Similarly to *he lack of
there is also considerabVv
«« described
o K f°rm ln this
n subProcess water use,
-s;
.
data will be presented where it ?s
characteristics of thP ^^n=v
these description^ wfll ^
Uterature, including previous
-
n JhUS'
to describe the
asefernced
pulping
as
6 subPro^sses of each
-------
In the case of wood preparation, variations in waste waters
produced result from very localized conditions, as discussed
below, and are not a function of the pulping or other processes.
Thus, the description of its contribution, which usually accounts
for a very small portion of the total waste, applies to all
pulping subcategories.
Paper and paperboard are made on similar equipment within all
subcategories with similar water uses and sources of waste water.
Therefore, the papermaking operation is also discussed in detail.
In addition, the survey data presented by subcategory will, where
applicable, include the papermaking waste stream unless otherwise
indicated.
In order to obtain an overview of levels of mercury and zinc in
waste waters, grab samples of raw waste and final discharge
streams were collected at surveyed mills and analyzed for these
parameters. The concentration of both metals are generally very
low.
Water usage per kkg (ton) of production has generally declined
dramatically in recent years due to increased emphasis on water
reuse and reduction of fresh water uses. This is demonstrated in
Table 20 which compares 1965 data (87) with data from surveyed
mills. While the subcategorization of mills used in the 1965
data does not agree precisely with that used in this report it
may be seen that water use declined substantially in the eight
years after 1965. For example, the average flow of individual
median flow values for bleached kraft and sulfite segments
decreased by some 20-30 percent over this period. Data for non-
integrated mills are not included in Table 20 because the 1965
subcategorization of these mills is not comparable with that
employed in this report. Of course, these comparisons can only
be considered as generalizations since mill data included in the
1965 figures are probably not all the same as the surveyed mills.
However, the point that effluent volume per kkg (ton) of
production has been significantly reduced between 1965 and 1973
through inplant reuse measures is valid.
The major process applications of fresh and reused water in pulp
and/or paper mills may include where applicable:
Wood_Prep_aration
This is a major factor only where wet barking is employed.
Pulping
Fiberizing of wood and waste paper occurs in the presence of
water in all pulping processes whether this is accomplished in
mechanical grinders, chemical cooking, or pulpers. In mechanical
processes utilizing a grindstone, its surface is cooled, cleaned,
and lubricated with a stream of water which also carries away the
112
-------
TABLC 20
WATfi; [JSF
—"!r <1 J~ flow k] / !^ jj_k q «}_/ ;Q rO
1265(1) J_973(2)
urOU.'i'' '''OC.'j 9pni',io\ ... _, .
i-Uv.' \ 'fO ) 91 ?'?
Sul ri Lt.; 000 / ,.., ,
28t-(f>'.; 208(50)
B i cr, c !";ed I'r j ft i or /,. -, \
180(43) 146(35)
OCOS o n 1 / -7 r> '
290(70; 108(ZG)
Deirik IOO/O-M
138(3o) 87.5(21)
(1) Reference ,JI33
•V2) bsia from Surveyed MiTir.
Note - Gru,nd;;ood Scg,-,^ includos on]v
GW-Fine and Cl'-f:^^' nn'Tls
-• Su'ifite Segmer.t includes SM]fn«
pcpotvrade
- Bleached Krafc inclurios BCT and
Fine mills
113
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pulp; the chips are conveyed through the refiners on a stream of
water in other mechanical processes. Water is added to the
digester along with the chips in chemical pulping, and to the
pulper in deinking. Water is also used to prepare cooking
liquors. Subsequently, water serves to convey the pulp in a
slurry to and through the remaining operations.
Pule_Washing
The degree of washing required and the method used, and thus
quantities of water, vary with type of pulp, end products
produced, recovery system design, and other factors.
Dilution
Water is used to dilute the pulp slurry to facilitate screening,
cleaning, and other processes.
Deckering
Although this is primarily a thickening operation, one of the
common practices is to use the equipment to provides a final wash
shower.
Chemical_Recovery.
In kraft and soda pulp mills water is used in the recovery system
for several purposes such as dissolving the molten smelt from the
furnace, lime mud washing, and lime kiln scrubbing (see Section
III). In sulfite recovery systems, water is used to dissolve
smelt, to absorb recovered sulfur dioxide, and for scrubbing off-
gases. This is not a comparatively large use in either case.
Bleaching
Water is used in preparing bleach solutions and in washing
between stages and at the end of the process. The amount of
water use ranges the spectrum from a simple one stage brightening
of groundwood pulp with no washing to a complex five and six
stages of chemical pulp bleaching.
Papermaking
Water is used in stock preparation which may involve several
steps such as beating and refining to develop desired pulp
characteristics for specific grades of paper. It is also
employed to dilute the furnish to appropriate consistency for
application on the paper machine, and for solution and conveyance
of additives.
114
-------
The non-process water uses may include lubrication and sealing of
moving parts such as shafts and vacuum pumps, steam for the
process and space heating, cooling equipment and process fluids,
and for washing equipment and floor areas.
HQQD_PREPARATION
Little, if any, water is employed in the preparation of delivered
chips or the chipping of barked logs and no effluent is produced
Unbarked logs are frequently washed before dry or wet barking in
order to remove silt (32) . In most installations a water shower
is activated by the log itself while on the conveyer so that a
minimum of water is used. The limited data available indicate
that this flow amounts to about 378 to 1135 1 (100 to 300 gal)
per cord of wood washed and the range of losses is as follows
(33) .
BOD5 0.5-4.0 kg/kkg (1-8 Ib/ton)
TSS 2.5-27.5 kg/kkg (5-55 Ib/ton)
Color Less than 50 Units
Spent process water is frequently us-d in wet drum barkers and
recycling within the barking unit itself is often practiced.
Barkers of this type contribute from 7.5 to 10 kg of BOD (15 to
20 Ib) and from 15 to 50 kg (30 to 100 Ib) of suspended solids
per kkg (ton) of wood barked.
The volume of water employed by the high-pressure jets of
hydraulic barkers is generally from 19,000 to 45,400 1 (5000 to
12,000 gal) per cord of wood barked depending upon log diameter
In wet pocket barkers, water is sprayed through apertures in the
!o?n °l ™e P°cket at rates of between 1.25 and 2.27 cu m/min
(J30 and 600 gpm) for pockets of 2.8 and 5.7 cords per hour
respectively. '
Water discharged from all three types of wet barking is usually
combined with log wash water, and coarse screens are used to
remove the large pieces of bark and wood slivers. The flow th^n
passes to fine screens. Screenings are removed and mixed with
the coarse materials from the initial screenings and the mixture
is dewatered in a press prior to burning in the bark boiler
Press water, which is combined with the fine screen effluent is
very minor in volume. The total waste flow, which amounts to
about 19,000 to 26,500 1 (5000 to 7000 gal) a cord, generally
carries from 0.5 to 5.0 kg/kkg (1 to 10 Ib/ton) of BODS and 3.0
to 27.5 kg/kkg (6 to 55 Ib/ton) of suspended solids. ~
The combined discharge contains bark fines and silt. The
quantity of the latter varies greatly from wet to dry weather
since its presence is due mainly to soil adhering to the logs
115
-------
The fine screen effluents following hydraulic barkers
(32)(33)(35) of eight wood handling operations are analyzed in
Table 21 which indicates a total suspended solids content ranging
from 520 to 2350 mg/1 with the ash content running from 11 to 27
percent. The latter is generally below 15 percent for clean
logs. BOD5 values range between 56 and 250 mg/1. These low
values are due to the fact that the contact of the water with the
bark is short and no grinding action on the wood takes place.
Also, the water employed is all fresh process water. Also
included in Table 21 are effluent characteristics of clarifier
effluents treating hydraulic barker waste waters for seven mills.
Such low BOD values are not the case with drum and pocket
grinding which involve attrition in contact with water over an
appreciable period of time and frequently utilize spent pulping
process waters already high in BOD and color (35) (36). The
suspended solids content is not appreciably different. The wet
drum barking effluents of three operations are analyzed in Table
22.
BOD values of barking effluents are also greatly affected by the
species of wood barked and the season in which the wood was cut
due to variables in wood juices and water extractables. That
contributed by the suspended matter present is a minor fraction
of the total BOD.
It is estimated that approximately 27 pulp mills in the subject
subcategories presently practice wet barking.
£ULPING_PROCESSES
GEQUNDWOOD_SEGMENT
As discussed in Section III, the types of groundwood and
chemical-mechanical pulps produced by grinding wood billets or
chips are as follows:
1. Stone groundwood
2. Refiner groundwood
3. Chemi-groundwood
4. Cold soda
5. Thermo-mechanical
Mechanical power is the essential force in the production of all
five although the latter three processes involve a pre-softening
step which, in the case of chemi-groundwood and cold soda,
includes the use of chemicals. This reduces the power
requirement and produces pulps with somewhat different
characteristics (2) (5) .
Effluents produced by all of these pulping methods contain
suspended solids and dissolved organic matter, both of which
contribute to the BOD (5) (37). In addition, chemi-groundwood and
cold soda process waters contribute electrolytes which contain
116
-------
Table 21
ANALYSIS OF HYDRAULIC BARKING EFFLUENTS *
Mill
Code
AS
CD
EF
GH
IJ
KL
J"iN
OP
TSS
nig /I
2362
889
1391
550
521
2017
2COO
600
NO N- SET.
SOLIDS
mg/1
141
101
180
66
53
69
<200
41
% ASH
OF
SS
/- /
14
17
11
13
21
1"
BCD5
r> —
101
ha
ra
i: i
C 7
o c r-.
COLOR
UNITS
< ^p
< .0
< CrQ
<; j Q
•i ^
*Flow data not available
-------
MJLLL
AA
cc
DO
FE
FF
FF
TSS
Product ion
]2/0(V;GO}
118
71
58
72
114
34**
29
I'D
128
116
135
183
234**
64
940
38!)
910
1130
330
NA
NA
* DC.La re;-resc;!ri: clarlf'k,- efTluents treating hydraul 'c barker waste waters.
* Clerifler inlluant.
118
-------
Table 22
AKALYSIS OF WET DRUM BARKING E"~LUENTS
i-D
TSS
tng/1
2017
317
2375
NON-SET.
SOLIDS
69
57
80
% ASH
OF r
^j*~ n
4
21
13 o
BOD
-------
some ions in the form of residual and spent chemicals. Most of
these are combined with organic matter.
Raw waste characteristics of a groundwood mills are summarized in
Figure 36 which is presented as an example of a groundwood mill
with the effluent characteristics shown as to how the pulping and
papermaking operations contribute to the total raw waste load.
Effluent volume from the pulp mill can be expected to range
between 8346 and 16,692 1/kkg (2000 and 4000 gal/ton) of product.
For example. Mill 13 had an effluent volume from the pulp mill of
13,600 1/kkg (3.26 kgal/ton). Differences in discharge volume
are generally due to equipment variations and the species of wood
pulped, with more fresh water usually required for resinous wood.
Clarified white water from papermaking operations is frequently a
partial source of process water and contains additional
electrolytes in the form of papermaking additives (2).
The suspended solids present in groundwood effluents consist
primarily of fiber fines, ray cells, and hydrated wood dust.
They are over 90 percent combustible, and while they are
generally over 80 percent settleable, they will not thicken to a
substantial degree and seldom produce a sludge of over two
percent solids (5). This is due to hydration produced by
grinding and the small particle size of these solids. Data
gathered during an earlier study (5) shows a range of total
suspended solids in groundwood pulping effluents alone as
follows:
Total Suspended Solids Range
T.y.p_e_gf_Pu.Lp.
Stone 5.5 - 10.5 (11-21)
Refiner 15 - 29.5 (30-59)
Chemi- groundwood 7.5 - 16 (15-32)
Cold Soda 12 - 18.5 (24-37)
There are no data from surveyed mills to verify the above TSS
ranges, since very few mills measure pulp mill wastes alone.
Surveyed mill data on total raw waste TSS, however, show no
discernible relationship between TSS and types of groundwood
pulping processes. These Stream 9 data for TSS show a range of
21 kg/kkg (42 Ib/ton) to 80.5 kg/kkg (161 Ib/ton) , with chemi-
mechanical Mills 1 and 12 at the low and high ends of this range,
i.e., 23.3 kg/kkg (46.6 Ib/ton) and 80.5 kg/kkg (161 Ib/ton)
respectively. Mills 4 and 2 on the other hand, fall in the
middle of this range with TSS values of 37.8 kg/kkg (75.6 Ib/ton)
and 62.4 kg/kkg (124.9 Ib/ton), respectively. These mills are
refiner and stone groundwood mills, respectively.
Dissolved organic materials present in groundwood waste waters
consist of wood sugars and cellulose degradation products as well
120
-------
LT: : .r
PROCES:
WATER
PULP f/ILL
PA per; ULL
3,000 GAL/TON
36 LB TSS/TON
21,000 GAL/TOfJ
92 LB TSS/TON1
V
RAW
WASTE
24,000 GAL/TON
38 LB BOD.-/TON
128 LB 1SS°/TON
G.I PH
121
-------
as resinous substances. In effluents free of appreciable fiber
the dissolved organics account for about three-quarters of the
BOD5. The BOD5 discharge of the various groundwood pulping
processes range, according to the above study (5) , as follows:
BOD5
Ty.E§_gf_Pulp.
Stone 4-9.5 (18-32)
Refiner 9-16 (18-32)
Chemi-groundwood 34.5 - 40.5 (69-81)
Cold Soda 36.5 - 50.5 (73-101)
The higher values observed for pulps whose manufacture involves
the use of conditioning chemicals are due to the solubilizing and
peptizing effects on the organics present in the wood. Data from
surveyed mills tend to support this conclusion through comparison
of Stream 9 values. Mills 1 and 12, which add chemicals and are
in the chemi-mechanical subcategory, have raw waste BOD's of 48.4
kg/kkg (96.9 Ib/ton) and 53 kg/kkg (106 Ib/ton) , respectively.
Mills not employing chemicals or a "pre-softening" step, on the
other hand, generally have a much lower BOD, with a typical value
of about 17.5 kg/kkg (35 Ib/ton).
In cold soda pulping 18 to 45 kg (40 to 80 Ib) of sodium ion are
added per kkg (ton) of product. Some of this ion remains
adsorbed on or chemically bound to the pulp; another portion
appears in the effluent chemically bonded to organics such as
resins and lignins; and a third is a residual of unreacted
chemical also present in the effluent. The chemi-groundwood
process which employs sodium sulfite and caustic soda contributes
sulfur as well, in the range of 2.5 to 5 kg (5 to 10 Ib) per kkg
(ton) of product.
The pH of all groundwood effluents, except cold soda, is in the
neutral range, somewhat on the alkaline side.
The color ot groundwood effluents from most of the woods pulped
is low, under 100 mg/1.
A.S discussed in Section III, groundwood pulp is generally
bleached or brightened with hydrogen or sodium peroxide, sodium
or zinc hydrosulf ite, or sodium sulfite. In practice, the pH is
usually adjusted to between 4.5 and 7.0 depending upon the
bleaching agent and sometimes complexing chemicals are added to
overcome the effect of heavy metals that may be present, such as
iron and manganese. Buffers and catalytic agents in trace
quantities are also sometimes used. Since groundwood can be
bleached at high consistency, it is frequently accomplished in
stock chests. Bleaching agents are not washed from the pulp and
thus, the residues of bleaching appear in the white water of the
122
-------
paper machine system. Data from surveyed mills do not
demonstrate a clear relationship between degree of bleaching, as
measured by pulp brightness, and resulting raw waste BOD. Table
23 shows that mills with nearly identical brightness, in the 73-
74 range, vary in BOD load from 12.5 to 20.4 kg/kkg (25 to 40.0
Ib/ton).
The somewhat higher concentration of zinc in groundwood effluents
is undoubtedly attributable to the use of zinc hydrosulfite.
Most mills are now abandoning the use of this chemical.
Table 23
RAW WASTE BOD VS. GROUNDWOOD PULP BRIGHTNESS
Raw Waste BOD Pulp
Mill - --
2 20.4 40.9 74
15 19.5 39.0 60
5 18.1 36.3 67
3 16.2 32.5 73
13 12.5 25 73
Develogment_of_SubcateggrY_Raw_Waste_Lgads
The development of the raw waste loads (RWL) for each of the
groundwood subcategories is discussed below. The resultant raw
waste loads were used in developing the effluent limitations for
each subcategory and in determining the costs presented in
Section VIII.
GW: Chemi-Mechanical Subcategory
Two mills are included in the chemi-mechanical subcategory.
These mills utilize similar pulping processes to manufacture
distinctly different products, fine papers and molded pulp
products. Both mills purchase in varying amounts market pulp and
waste paper as additional sources of fiber. The effluent raw
waste BOD5 characteristics and effluent flow volume for the mills
is very similar; as discussed in Section IV, this indicates that
the most significant effect upon the RWL is the pulping process.
Mill 01 has a BOD5 RWL of 48.5 kg/kkg (97.0 Ibs/ton) whereas mill
12 has a BOD5 RWL of 53.0 kg/kkg (106 Ibs/ton). Similarly,
effluent flow values are 84.6 kl/kkg (20.3 kgal/ton) and 81.3
kl/kkg (19.5 kgal/ton), respectively. As discussed previously,
TSS values do not correlate between mills. The RWL for these
mills are summarized in Table 24 with the resulting subcat^gorv
RWL shown.
GW: Thermo-Mechanical Subcategory
123
-------
The -thermo-mechanical process is relatively new in this country,
and thus data from foreign mills was used as the principle source
of data on which the subcategory RWL was based. It has been
reported that at least seven mills were using the thermo-
mechanical process in early 1975 and at least six more mills were
to begin thermo-mechanical systems by the end of 1975 in this
country. (38). The mills presently operating thermo-mechanical
systems are operating in conjunction with some pulping process
such as bleached kraft, sulfite, or stone groundwood. Because of
the mixture of pulping operations at these mills, waste water
data representing exclusively that discharged by the thermo-
mechanical process is non-existant. However, a 100% thermo-
mechanical mill in the Pacific Northwest is scheduled for start
up in the Fall of 1975 and data should be available at a later
date.
Thermo-mechanical pulping has been practiced in the Swedish pulp
and paper industry since 1967. Data received from IVL (Swedish
Pollution Control Company), Stockholm, Sweden, showed that BOD7
RWL for thermo-mechanical pulping was 16-18 kg/kkg (32-36 Ib/ton)
and an additional 15 kg/kkg (30 Ibs/ton) if peroxide bleaching
were practiced. IVL reports a conversion factor for BOD7 to BOD5
of 0.85. The above data were based upon sampling of effluents
from two thermo-mechanical mills in Sweden. Thus, the maximum
BOD5 that would be expected from mills practicing thermo-
mechanical pulping and peroxide bleaching is 28.0 kg/kkg (56.0
Ibs/ton).
During an on-site plant survey by the EPA to a thermo-mechanical
mill in Sweden, the RWL BOD5 was reported to be 21.25 kg/kkg
(42.5 Ibs/ton) with an effluent flow of 17.1 to 27.5 kl/kkg (4.1
to 6.6 kgal/ton). However, extensive data was not available to
support these effluent characteristics.
The thermo-mechanical mill which will begin operations in the
Fall of 1975 has reported that the effluent treatment facilities
have been designed for a flow of approximately 41.7 kl/kkg (10.0
kgal/ton) with hopes of actually opera-ting at 20.8 kl/kkg (5.0
kgal/ton) (39) .
Based upon consideration and evaluation of the above data, the
RWL for the thermo-mechanical which were used in the development
of the effluent limitations and costs of technology are shown
below:
Flow 62.5 kl/kkg (15.0 kgal/ton)
BODS 28.0 kg/kkg (56.0 Ibs/ton)
TSS~ 48.5 kg/kkg (97.0 Ibs/ton)
Because of the stage of development of the thermo-mechanical
process in this country, the above flow values were selected as a
very conservative estimate. The flow values for the surveyed
mill in Sweden and the mill which will soon begin operations are
well below this estimate. The TSS value is from the chemi-
mechanical subcategory as no data was available from any source
124
-------
TABLE 24
•!anufacture(%)*
RAW WASTE LOAD - G'^-CHCU-ficCHANTCAL SUBCATEG3RY
Size
hill
Cl
12
GW PP WP kkq/dayftons/d'i
65
45
5
45
'•V f~l
Oo
1C
57
32S
007)
(353)
FLOW
K * / v ^ f 1 f '^ ("* "-1
£r1 /*" ' ''"' r"> , ,
-T.O \-_',:..j;
R" "5, ' ! O C \
o • . -j v •-••-' y
OO o 'T^- *"^^
R X. 0 > •-( Q !
* GK!: Groundwood Pulp
PP: Purchased Pulp
WP: Waste Paper
^
^9/^'(;'f ^S/tOP)_
1'" ^ t' r "7 "i v
4o.o ('j/,0;
53-0 (iC5)
-------
and the two processes are somewhat sinyllar. The BOD5 value was
based upon the IVL data since was it is felt to be more reliable
than the conservative estimate of the mill to soon begin
operations. Support for the IVL data in apparent by evaluating
the operational characteristics between chemi-mechanical process,
t he rmo- mechanical processes, and groundwood processes.
In mechanical pulping, the yield gives a excellent indication of
the effluent BOD5 characteristics. Generally, the higher the
yield, the less the BOD5 RWL will be. Table 25 shows the yields
and BOD5 RWL for chemi-mechanical, thermo-mechanical, and
groundwood processes, and as shown the yield is related to the
inclusion of the pre-softening step.
Table 25
BOD5 vs Groundwood Yield
Pre-Softening Chemical Yield BOD5
Addition %
Chemi-Mechanical 20 mins. Yes 80 50.5 (101)
Thermo-Mechanical 2-5 mins. No 90-95 28 (56)
Groundwood None No 90-98 17.5 (35)
GW: Fine Papers Subcategory
Table 26 is a summary of the data from which the groundwood fine
papers subcategory RWL were developed. As shown in Table 26 many
of these mills purchase market pulp and/or waste paper as a
supplementary source of fiber. Also, the papermaking additives
content of the final products ranges from 10 to 35% by weight.
Since groundwood mills producing fine papers generally purchase
supplementary fiber (market pulp or waste paper) and since no
significant relationships exist for the mills in Table 26 between
RWL and the amount of fiber purchased, the subcategory RWL was
developed by averaging the flow, BOD5_, and TSS data shown in the
table. Mill 21, as noted in the table, uses the thermo-
mechanical process for 10% of their total production and since
the flow value of 51.7 kl/kkg (12. U kgal/ton) is significantly
lower than the other mills flows, the RWL for mill 21 was not
included in the calculation of the subcategory averages. The
subcategory RWL would, however, be lower if mill 21 were
included.
GW: CMN Papers Subcategory
Table 27 shows manufacturing information and effluent
characteristics for groundwood mills producing coarse (c) papers,
molded pulp products (M) , and/or news (N) papers. Also, shown is
mill 17 which is a small mill producing 29 kkg (32 tons) per day
of market (mkt) groundwood pulp.
126
-------
Manufacture (%)
TABLE 26
RAW WASTE LOAD - GW-FINE PAPERS SUBCATZGORY
Size
Mill
03
19
05
?G
02
13
21
GW
30
30
30
33
55
55
40*
PP
40
ZD
55
33
30
30
'•"> ,—
C3
HP
10
10
5
0
0
0
15
C+F
20
35
10
23
15
15
20
kkg/day
492
453
498
537
193
457
517
(tons/day)
(542)
(493)
(549)
(592)
(213)
(504)
(570)
FLOW
kl/kkg(kgal/ton)
106.3 (?'5.5)
78.8 (18.9)
93.0 (23.5)
83.0 (19.9)
97.2 (23.3)
83.0 (19.9)
51.7 (12.*}
BO 05
kq/kkqfibs/tor)
20.9 (11.8)
17.9 (35,°)
12.5 (25.5)
20.2 (40.4)
13.5 (27.C)
15.2 (30.4)
TSS
kg/kkaObs/ton;
^2.9 (35.0)
51.5 (103)f
^1.4 (22. £)
49.0 (93!'N
(3*
32.7 (63.5)
Average
90.9 (21.8)
15.9 (33.8)
52.0 (104)
10% of total production is reported as therrr.o-mechan i cal.
-------
As shown in Table 27, mills in the GW: CMN subcategory purchase
additional fiber to supplement the groundwood pulp produced on-
site which is similar to groundwood mills producing fine papers.
However, the amount of purchased additional fiber is
significantly different between mills producing CMN papers and
mills producing fine papers. As shown in Tables 26 and 27,
respectively, mills in the GW: fine papers subcategory
manufacture 30-55% of their total product by on-site groundwood
pulping whereas mills in the GW: CMN papers subcategory
generally manufacture 55-9016 on-site. The amount of market pulp
purchased to supplement the groundwood pulp produced on-site is
generally a function of the type of paper produced; i.e.
manufacture of newspapers requires a blend of 65-80% groundwood
pulp (short fibers) and 20-35% chemical pulp (long-fibers) .
The GW: CMN papers subcategory RWL was determined by averaging
the RWL data presented in Table 27. Data for mill 17 were not
included as the mill produces market pulp and the data showed
effluent flows of 12.5 kl/kkg (3.0 kgal/ton) which were
significantly below all other mills in the subcategory.
SULIITE_SEGMEOTS
The Sulfite segment of the pulp and paper industry was
subcategorized into papergrade sulfite and dissolving sulfite
subcategories and the effluent .characteristics are discussed
below.
Modernized sulfite pulp mills which employ chemical recovery
and/or spent liquor burning discharge between 63,000 and 125,000
1 (15,000 and 30,000 gal) of effluent per kkg (ton) of pulp. This
volume approaches 208,655 1 (50,000 gal) for older mills (2) (5).
(It should be noted that the survey data discussed below
represents the total waste stream.) The major pollutional
characteristics of this effluent are BOD, suspended solids,
color, and acidity.
Typical data given in the literature on the individual waste
streams emanating from the pulping process are shown in Table 28
(41) (42) (44) . Overall losses amount to about 600 pounds of total
solids, 45 pounds of suspended solids, and close to 300 pounds of
BOD5 per ton of pulp produced. The pH value is in the range of
2.5 to 3.2. Solubles present consist of lignosulf onates, lower
fatty acids, alcohols, ketones, and pentose and hexose sugars
(43) as well as a number of miscellaneous complex compounds such
as cymene (30) . The lignin fraction is largely responsible for
the color of the effluent, the degree of which depends upon the
efficiency of the liquor separation and recovery system as well
as the base employed and the wood species pulped (44) . Effluent
color values on the chloroplatinate scale generally range from
100 to 750 mg/1 (45) ; the lower value is typical of magnesium
base pulping and the higher, the ammonia base.
128
-------
ro
ID
TABLE 27
RAW WASTE LOAD - GW-CMN PAPERS SUBCATEGORY
Manufacture (%)
Size
Mill
09
10
03
14
04
16
15
17
GW
80
80
70
75
55
65
90
100
PP
20
20
30
25
20
30
0
0
WP
0
0
0
0
25
5
10
0
Product
N
N
N
N, C
C
M
M
Mkt
kkg/daj
342
904
374
96
72
69
113
29
/(tons/da
(377)
(997)
(412)
(105)
( 79)
( 76)
(125)
(32)
Average
FLOW
kl/kkg(kgl/ton)
52.9 (12.7)
112.6 (27.0)
115.1 (27.6)
107.6 (25.8)
113.0 (27.1)
86.3 (20.7)
107.6 (25.8)
12.51 (3.0)*
99.2 (23.8)
BODS
kg/kkg(lhs/ton)
19.6 (39.2)
21.4 (42.9)
20.3 (40.7)
^2.0 (24.0)
9.9 P9.9)
19.1 (3G.2)
•19.5 (39.0)
9./ (19.5)*
17.4 (34.8)
TSS
kg/kkgQbs/ton)
21.0 (42.C)
68.0 (136);\
63.0 (126),N
33.0 (66.0)
62.0 (124)
78.0 (i56)
12.5 (25.0)*
48.5 (97.0)
Not included in subcategory average
-------
Table 20
TYPICAL EFFLUENT L )ADINGS FROM INDIVIDUAL
PROCESSES IN A SULr'ITK IULP HIM,
Process Source
Blow Tsnk
Condensates
GJ
o
Liquor Losses
Screening
Washing & Thickening
Acid Plant Wastes
Boiler Blow Down
Total
Bleaching
Volume
1/kkg
(gal /ton)
(l' 900)
4,590
(1,100)
31,298
(7,500)
25,038
(6,030)
31,298
(7,500)
1,251
(300)
417
(100)
101,823
(24,400)
50,077
(12,000)
Tonal
Solids
kg/kkg
(Ib/ton)
; ;;3. 5
(247)
23.5
(47)
52.5
(105)
13.5
(27)
65.5
(131)
5
(10)
11
(22)
294.5
(589)
100
(200)
Suspended
Soi.jd."
k^/ki'-K
(Je/Um)
0,5
(1.0)
0 , 05
(0.1)
10.5
(21.G)
4.0
(tJ.o)
4.0
(8.0)
2.5
(5.0)
1.0
(2.0)
22.5
(45.1)
7.5
(15.G)
Bon5
k^/i-Jc pll
(Ib/Tn) Rnr-re
, T — ^ C,
(13 ' )
33 2.3-3.1
(( c?)
26.5 2,2-2. 6
(5?)
4 5.4-5.7
(£)
9 2 . ^-—3 . °
(12)
1.2
Nc > .
Neg .
120.5 2.5-3.2
(261)
15 5.0-5.8
(30)
-------
Various aquatic and marine biology problems have been ascribed to
the discharge of sulfite pulping wastes into surface waters
(50) (51). These include deoxygenation, toxicity to fish, thin
eggs, and interference with shell fish spawning.
Such difficulties appear to have been caused to a large degree by
the discharge of spent liquor. It has been demonstrated (49)
that recovery systems alone have remarkably reduced effluent
toxicity to sensitive species of fish.
Biological imbalance in streams has also occurred due to slime
growths engendered by wood sugars and fatty acids present in the
wastes (53)(54) (55). Such growths clog fishing nets and thus
shorten fishing time and pose a difficult net cleaning problem.
In many cases, unsightly accumulations develop upon or become
attached to objects in contact with the water. Field and
laboratory studies have demonstrated that slime growth can be
inhibited by any process capable of reducing the amount of sugar
and related compounds discharged and that waste receiving
effective biological treatment will not normally cause
infestations of these organisms (56).
A further stream problem is the presence of ammonia in effluents
from ammonia base sulfite pulping. The effluent from one such
mill was found to contain from 96 to 189 mg/1 of NH3-N (57).
This must be considered both in terms of the ultimate maximum
concentration which will result in a body of fresh water from its
utilization of oxygen in oxidizing to nitrates and the public
health significance of the latter in relation to downstream use
of the water for potable purposes.
As discussed in Section III, the most common method for bleaching
paper grades of sulfite pulp is the three stage chlorine-alkaline
extraction-hypochlorite (CEH) sequence (8), although in recent
years, some sulfite mills have used a stage of chlorine dioxide.
Generally, the chemical requirements of the CEH sequence range
from two to six percent of chlorine, 1.0 percent of caustic soda,
and from 0.5 to 0.9 percent calcium hypochlorite for bleaching
most paper grade sulfite pulps (2). Some mills produce a
partially bleached pulp with a single chlorine or hypochlorite
treatment. Others produce a variety of specialty grades by
adjusting the number of sequences and degrees of chemical
treatment in accordance with the type of pulp desired (91). As
many as six stages are employed for high grade pulps. The
bleached pulp is sometimes treated with sulfur dioxide to remove
heavy metals and retard reversion.
A three stage bleaching operation which does not recycle
discharges about 50,072 I (12,000 gal) of waste water per kkg
(ton) of production. Recycling the hypochlorite stage effluent
as wash water in the caustic extraction step can reduce this
quantity to below 41,676 1 (10,000 gal). single stage bleaching
produces about 16,692 1 (4,000 gal) of effluent per kkg (ton) of
product while 125,193 to 250,386 1 (30,000 to 60,000 gal) per kkg
(ton) is discharged from bleach plants producing specialty pulps.
131
-------
The total solids content of the combined effluent of a three
stage bleaching operation ranges from 100 to 125 kg/kkg (200 to
250 Ib/ton) of product and the total suspended solids from 7.5 to
15 kg (15 to 30 Ib). The latter are largely fiber fines which
have passed through washer wires. The BOD5 runs from 5 to 30
kg/kkg (10 to 60 Ib/ton) of product (4) and color from 10 to 20
kg (20 to 40 Ib) (77). The pH is on the acid side generally
ranging from 2.5 to 3.5. The major electrolytes present in these
waste waters are the chlorides of sodium and calcium which amount
to about 20 to 25 kg (40 to 50 Ib) per kkg (ton) of product.
Effluents from one stage bleacheries contain from 50 to 87.5 kg
(100 to 175 Ib) of total solids per kkg (ton) of product and 2.5
to 5 kg (5 to 10 Ib) of total suspended solids. The BOD5 ranges
between 3.5 and 5 kg (7 and 10 Ib) per ton and color from 7.5 to
10 kg (15 to 20 .Ib) (90) .
Wastes from the on-site manufacture of bleaching chemicals, such
as calcium hypochlorite, are described in the ensuing section on
kraft bleaching.
Figure 37 is presented to show the basic contributing waste
streams for a sulfite mill with the effluent characteristics
shown. Total raw waste (Stream 9) varies in flow from 169. 4 to
234.5 kl/kkg (U0.6 to 56.2 kgal/ton) and BOD varies from 91 to
109 kg/kkg (182 to 218 Ib/ton). TSS data are available from only
two of these mills, and reveal a wide variation from 29.9 kg/kkg
(59.9 Ib/ton) for Mill 56 to 83.1 kg/kkg (166.2 Ib/ton) for Mill
51. All the surveyed sulfite mills practice recovery of spent
cooking liquor. This procedure reduces raw waste BOD
significantly although sulfite liquor recovery is not as
affective as that for kraft due to the presence of a considerable
quantity of acetic acid in the condensates (46) .
Mills 51 and 52 are ammonia base, while Mill 56 is calcium base.
The flow and raw waste BOD loads from all three mills are
similar, indicating that there are no significant variations in
pollution load ascribable to the type of base used. A possible
exception is nitrogen in the raw waste from ammonia base mills.
No nitrogen data are available on effluents from the surveyed
mills in the sulfite subcategory. Nitrogen data are available
from Mill 6, however, which is in the groundwood subcategory, but
has an ammonia base sulfite process which manufactures about 40
percent of its total pulp. Data from this mill shows an ammonia
nitrogen level of 2.8 kg/kkg (5.6 Ib/ton) in the influent to its
ASB, dropping to 1.24 kg/kkg (2.48 Ib/ton) in the final effluent.
132
-------
rOUDE 37
EFfLUEWr CHARACTERISTICS: SULFITC MILL
PROCCSG
WATER
1»
PULP MILL
RECOVERY UNIT
BLEACH PLANT
35,000 GAL/TON
ISO LB BOijr/TON
SO LB TSS/TON
PAPER MILL
15,000 GAL/TON
!0 LB BOD5/TON
110 LB TSS~/TON
V
RAW
WASTE
50,000 GAL/TOM
190 LB BOD5/TOf.'
160 LB TSS/TON
133
-------
Dissolving Sulfite Subcategory
Dissolving sulfite mills require large quantities of water. The
stringent requirements of product purity inhibit reuse,
recycling, or reclamation of water (180).
Over 50 percent — possibly up to 65 percent — of the wood used
to produce sulfite dissolving pulp becomes waste. This largely
biodegradable organic material is carried away in the effluent
streams (159) . The major areas of its concentration are the
spenr cooking liquor ("red liquor") evaporator condensates, side-
hill screen rejects, and bleach plant effluent (159).
In this pulping process, the spent liquor carries a very heavy
solids load since cooking is continued until most of the lignin
and part of the cellulose are dissolved (180). As a result, four
stages of washing, usually countercurrent, are generally
required. This removes about 95 percent of the lignin from the
pulp (180) which in turn generates a considerably larger solids
load In the evaporator condensate of dissolving sulfite mills
than is the case with sulfite mills producing papermaking grades.
The side-hill screens -- equipment unique to dissolving pulp
manufacture which is used in addition to conventional screens —
thicken the pulp and can account for approximately 18,925 1/min
(5000 gpm) of waste water which contains about three percent of
the pulp, ray cells, sand, and residual red liquor (180) (159).
A great deal of material, including beta and gamma cellulose, is
extracted from dissolving pulp in bleaching (5)(52). The caustic
extraction stage alone dissolves about 10-16 percent of the pulp,
depending on the grade of cellulose desired (180). The wash
water from this stage is much higher in BOD than the comparable
stream in the bleaching of sulfite papermaking pulps.
The hypochlorite stages create further losses but little BOD load
since the cellulose modification they perform is an oxidizing
process (180) .
Sulfite dissolving bleachery effluents contain from 50 to 100 kg
(100 to 200 Ib) of total suspended solids per kkg (ton) of
product. The BOD ranges from 100 to 225 kg (200 to 450 Ib) per
kkg (ton) and the color unit content approaches 500 kg (1000 Ib)
per kkg (ton) (91)(5). The pH value ranges between 2.0 and 3.0
and the electrolyte content is usually about double that of
sulfite papermaking bleachery effluents.
Mills 401 and 511 practice recovery and obtain raw waste BOD
loadings of 143.5 kg/ kkg (287 Ib/ton) and 133.5 kg/kkg (267
Ib/ton), respectively. This is in contrast to Mill 50 which does
not practice recovery of spent liquor. This mill has a much
higher BOD loading of 740 kg/kkg (1480 Ib/ton), although the mill
projects that this value will drop to 137.5 kg/kkg (265 Ib/ton)
upon completion of its recovery system.
134
-------
,^ cdlssolving sulfite mills varies from 235.6 to 331.6
(56.5 to 79.5 kgal/ton) . TSS varies widely between th*
two mills having data, with Mill 511 at 100 kg/kkg (200 Ib/tonf
and Mill 512 at 11 kg/kkg (22 Ib/ton) . A portion of this
apparent variation may be explained by the fact that Mill 512
measures TSS (N) rather than TSS.
Figure 38 is presented to show the relative contributions of the
basic unit processes to the total waste load for a dissolving
sulfite mill with the effluent characteristics shown.
Development 2f Subcateggry Raw Waste Loads
The development of the raw waste loads (RWL) for each of the
sulfite subcategories is discussed below. The resultant raw
waste loads were used in developing the effluent limitations for
each subcategory and in determining the costs presented in
Section VIII.
As discussed in Section in, mill visits were made to 13 of the
ZZ mills in this subcategory with regard to gathering information
and data concerning manufacturing operations and efflu^n*
characteristics. in addition. information and data on ever-v
papergrade sulfite mill was available from Reference 29. B-yond
that contained within the published report, the raw data sheets
were available to support the information and data summarized in
the report. Thus, the subcategory RWL was based upon ^h*
information and data accumulated from the plant surveys and upon
the supporting information and data from Reference 29.
Table 29 shows information and data for each mill in the
papergrade sulfite subcategory (also the dissolving sulfite
subcategory which will be discussed later) and was derived from
Reference 29 as well as from the supporting raw data sheets. The
effluent flow and BOD5 values presented are from the published
report. The symbols used in the columns entitled "Products" and
"Other Pulping Processes" can be interpreted as follows: F- fine
papers, N: Newspapers, T: Tissue papers, P: Market pulp, c-
Coarse papers, B: paperboard GW: groundwood, NSSC: Neutral
Sulfite Semi-chemical, BK: bleached kraft, and WP- wast^
paperboard. In addition, the column entitled "Woodyard- Water
Use" indicates the use of wet barking procedures at th* mills
Also, the column entitled "Type Condenser" shows if mills are
using barometric (B) or Surface (S) type condensers in their
P™ MU°rK rec°Yerv systems. The column entitled "Liquor
*tTllllL^ % J"formation °« w*at «ill personnel reported as
the percentage of their spent sulfite liquor (SSL) which is
collected (C), converted to by products (B) . and incinerated (I)?
Mills with partial or no SSL recovery systems can be interpreted
from the amount of liquor collected, such as mills L-4 and £-11
which show 25* and 0%, respectively. It should be noted
however, that the percentages are based on information received
135
-------
PGUUC 38
EFFLUENT CHARACTERISTICS. SULFITE DISSOLVING MILL
PROCESS
WATER
PULP MILL
AND
LIQUOR RECOVERY
25,000 GAL/TON
60 LB BOD.-/TON
BLEACH PLANT
AND
PULP DRYER
41,000 GAL/TON
205 LB BQD5/TON
RAW
WASTE
66,000 GAL/TON
2G5 LB BOD5/TON
185 LB TSS/l'ON
136
-------
Table 29
Mill Characteristics and Raw Waste Loads
Sulfite Segment
»* , 7 "*
Dissolving
r _•; ^
L - * /
* - O
L- I 'j
i _ * f
L-10
L-13
L-l 1
L-1 °
L-19
l--\
I-3
L--2S
L-;
L— J
t _j
L-J;
L-24
_• ~.''J
L-:;
.-3
L-6
.-12
.-27
L-25
Sprite Total
Prod':c7'!on FrocSctiup
Sulfite
£71 (HO)
449(495)
440(485)
Sulfite
cv,,.
&K)
iconic}
209(230}
127(140!
330(430;
135(150)
151(177;
103(114)
92(102}
218(240)
118(130)
571(630)
435(450)
^-17(460)
449(495}
440(485)
335(;?0)
512(564)
1CO(1 10)
268(295)
127(143)
307(1000)
1032(1160}
272(300)
136(150)
335(369)
136(15;-''
221(244)
131(145)
399(440)
195(215)
Pllln
Pulo
Pulp
Pulp
Pi.' Ip
Pulp
c N
F T
F
P,N
N
C,3
F
T
P
T.3.P
T, P
T
B.C.F.P
P
F
T
T
T
F
F
F
T,F
Other
PiT.oing
tsProcasse
-
NSSC
GU
GW.WP
BK
BK.NSSC
-
-
Koodyard Pulping 'Washing
- %ChipS Use Pit- Drum
0
0
0
0
0
0
60
06
10
60
100
100
ICO
10
10
50
100
33
43
23
77
67
0
0
0
20
100
0
Wat
Wet
Dry
Wet
Wet
Wet
Dry
Dry
Wet
Wet
D,-y
Ifet
list
Wet
Dry
Dry
D-y
Dry
Wat
Wet
Dry
Dry
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
— • .
4-stage
4-stage
4-stage
4-stage
3-stage
1 -stage
continu6us
3-stage
3-stage
2-stage
3-stage
4-stage
3-stage
2-stage
2-sUge
2-stage
Bleaching
Sequence
Type
Condense
CEHH v
CEBH c
CEHD s
CEH, CEDP, CEHP s
CECHD, CHED B
S
NOHE
CEH, H
CEH
NONE
CEH**
NONE
CEH
H
C-H
CEKOP
CEH
CH, CEH, CEHD
CEH, CNH, CEHD
CFH
CEH
H
H
H
CEH
CEH
CEH
CEH
S
NONE
B
S
B
B
B
S
NONE
B, S
S
6
B
B
3
S
B
B
B
S
S
B
Liquor Recovery
rr . a T*
W Flow
BODS
— — - — : — = kl/kkg(kqal/ton} kg/kkg(l
97 0 100
- 0 97
00 0
98 0 , 100
98 5-10: 70
90 0 : 100
99
0
80
99
99
85
81
98
0
85
25
81
70
96
92
°0
4b
86
60
95
95
: 0
: 0
: 0
: 0
:40
: 5
: 0
: 0
:78
: 0
: 0
:70
: 0
:92
: 5
:100
:86
:60
: 0
:100
100
0
100
100
100
60
100
95-100
0
0
94
TOO
0
100
0
100
0
0
0
100
0
279.4(67.0) 129(258)
221.0(53.0)***' -( - )
304.4(73.0) 150(300;
291.9(70.0) 226(451)
216.8(52.0)**** 423(845}"'
229.4(55.0)
208.5(50.0)
112.6(27.0)
133.4(32.0)
157.6(37.8)
291.9(70.0)
229.4(55.0}
329.4(79.0)
395.3(94.8)
241.7(58.0)
221.0(53.0)
329.4(79.0)
-( _ j
383.6(92.0)
184.3(44.2)
208.5(50.0)
700.6(168)
75.0(150}
150(900)
62.5(125)
63.5(127}
81 .0(162)
110(220}
99(198)
450(900)
106(211)
420(340)
115(230}
70.0(140)
123(245)
-( - )
140(280)
139(278)
380(760)
93.0(185)
Collected: By products: Incinerated
"•' 0-20" of Ti.Tie
SSL REcovery
-------
in questionaires and as such do not jiecessarily represent precise
figures of the extent of the SSL recovery systems presently in
use.
The most significant effects upon effluent characteristics
involve the following operations: (1) woodyard, (2) pulp
washing, (3) spent sulfite liquor recovery, (4) type of condensor
(5) bleaching, and (6) papermaking. As discussed in Section IV,
the effluent waste loads from woodyard operations are considered
in developing effluent limitations by the establishment in
Section IX of separate allowances for all woodyard operations.
The efficiency of SSL removal from the pulp has significant
impacts on RWL and the two types of systems primarily in use are
(a) blow pit and (b) vacuum drum. Blow pit washing systems do
not separate the SSL from the pulp ao efficiently as vacuum drum
washers and thereby higher effluent characteristics generally
result from mills using blow pit washing systems. Certainly, the
most significant effect upon RWL is the SSL recovery system as to
(a) the use of and (b) the capacity of. There are still several
mills continuing to operate without SSL recovery or with only
partial recovery systems. The use of barometric type condensers
in the SSL recovery system results in higher flows than the use
of surface type condensers. In addition, the extent of bleaching
ranging from one to five stages can have significant impacts on
effluent characteristics. As discussed previously in the
bleached kraft discussion, papermaking can have significant
impacts on RWL but for sulfite mills is relatively less
significant than the other factors discussed above.
Table 29 presents information on the above process factors for
each papergrade sulfite mill. Mentioned above, most mills
utilize SSL recovery systems or are presently installing these
systems. As shown in the Table, 18 of the 22 mills presently
have SSL recovery systems and thereby, as discussed in Section
VII and VTII, is considered as part of BPCTCA which includes
internal controls commonly practiced by the industry. For mills
with SSL recovery systems, the highest effluent characteristics
would result from mills using a combination of blow pit washing,
barometric condensers, and three or more stages of bleaching.
Consideration was given to subcategorization to account for the
effects of mills using SSL recovery systems and various
combinations of (a) blow pit vs vacuum drum, (b) barometric vs
surface condensers, and (3) the extent of bleaching. However,
one subcategory was established for papergrade sulfite mills (See
Section IV) and the selection of mills from which the subcategory
RWL was developed encompassed mills with combinations of the
above process factors resulting in the highest RWL.
Table 30 shows the raw waste loads used for determination of the
subcategory RWL. The mills were selected as representative of
mills with SSL recovery and varying combinations of process
factors which resulted in the higher waste loads. Mill 51 (L-9)
is probably the most representative mill in the papergrade
sulfite industry of a mill with a combination of process factors
which theoretically should result in a relatively high RWL. For
138
-------
o
t— - ^ i LO I_T) L.O O
•--, >^j- o -- o
L.. ;--. 09 o~i :•")
O
O T
C2 --; i_-> UT O O
O
O
"O
c.
4->
u
--' i CM
CO
C\J
o
r?
OJ j— O> Cv! ,—
( 1 I i .3
—I —1 1 1C.
4) T3
CD
oo
«-- O
O -i->
C-l i —
C CTl O> CTl Ol
•i- CM CM CM CM ~O
oj ra rs
a, -- ;"..— r - "Jj ^~ .J3
TI _n _c^ x: _"; 'o o v.
3 r,J •-:• .3 .-a O i- - *J
— I— I— 1— i~ >— r3 Vi
O Q C_> ra
t; c" c: c: z.
^~ i— O> Oj
, r i • i
.—: __! _' _J .__'
O O O O
-------
example and as shown in Table 29, mill 51 (L-9) employs SSL
recovery, blow pit washing, barometric condensers, a bleaching
sequence of CEH, and produces fine papers. As shown in Table 30,
mill 51«s BODS RWL was 115 kg/kkg (230 Ibs/ton) and flow was
210.2 kl/kkg (50.4 kgaI/ton) which are essentially equal to the
subcategory RWL of 115.75 kg/kkg (231.5 Ibs/ton) and 208.1 kl/kkg
(49.9 kgal/ton), respectively. The other mills in the table
produce either tissue papers, fine papers, or market pulp and
employ SSL recovery systems with blow pit washing except for mill
(L-26) which uses vacuum drum washing. The mills included in
Table 29 that were not selected as representative were excluded
for a variety of reasons, some of which include the following:
(1) seven mills were excluded because other types of pulping
operations, such as bleached kraft or groundwood, were conducted
on-site and waste waters were not necessarily separate between
the processes resulting in effluent data that does not represent
the effluent characteristics of the sulfite process; (2) one mill
was unique in that it was constructed in the late 1960's and the
in plant control measures were beyond those commonly practiced
and thereby was not considered as representative of BPCTCA; (3)
four mills did not have full SSL recovery systems; (4) mills
using various combinations of vacuum drum washing and surface
condensers were excluded (with the exception of mill (L-26)
which had RWL nearly equal to mill 51) ; (5) one mill was excluded
for the primary reason that no bleaching was practiced at the
mill- and (6) extensive data was unavailable for a number of
mills. Thus, four mills were selected following extensive
evaluations of the available information and data for each mill.
These mills represent sulfite mills producing a wide variety of
products using a SSL recovery system (with or without by product
recovery) and generally unit process operations (i.e. blow pit
washing, barometric condensers, extensive bleaching) that result
in the higher RWL.
Dissolying_Sulfite_Subcate2orY
The dissolving sulfite subcategory includes six mills, five of
which are located in the Pacific Northest (and Alaska) and one is
located in Florida. Information and data on manufacturing
operations and effluent characteristics were collected for
effluent limitations development by on-site surveys at all six
mills. In addition to the information and data collected during
the mill surveys. Reference 29 provided supplementary information
and data. As for the papergrade sulfite mills, the raw data
sheets were available from the dissolving sulfite mills which
supported the information and data summarized in the report.
Table 29 presents the information and data contained in the
report and in the supporting data files. At the time when the
information and data in Table 29 were being collected, mills L-
15 L-16, and L-14 were the only mills with full SSL recovery
systems in use. Mill L-10 has recently installed full SSL
recovery as indicated in the table but the RWL data represents
mill operations without SSL recovery. In addition, mill L-17 has
partial SSL recovery and mill L-20 is presently installing full
140
-------
recovery. AS shown in the Table 29, the only
°f mil L2°'S SSL reCOv
orhP « Barometric condensors is mill L-1U and
for the dissolving sulfite subcategory includes full
recovery with four stage vacuum drum pulp LsMng uling surface
condensors (see sections VII and VTII) . The selection of ^he
internal controls portion of BPCTCA as abSve represent a
somewhat different situation for dissolving sulfi?e mills I'han
r - -
Table 31 presents effluent characteristics for the mills used
developing the dissolving sulfite subcategory RWL? EfflueS?
-23 SS2r£TSS3.'SlSJSS.'SSBa2 i£»
-
baeS. =30^ TSTS SP ^
the calcuSi^n mh S i are aPParentlV due to differences in
tne calculation methodologies (i.e. Table 29 gives
. a
Ibs/ton), and 92.5 kg/kkg (185 Ibs/ton) , restively
2LEACHED_KRAFT_SEGMENT
cooling water requirements. The latter vary with
P
"
rartl ,58
141
-------
M
TABLE 31
RAH UASTE LOAD
DISSOLVING SULFITE SUBCAThGORY
Product!en FLOW BOD5 TSS
kg/kkfid'os/tonl ^/^slI^ll^U-
bll(L-15) 579 (633) 268.5 (64.4) 128.5 (257) 92.5 (135)
401(L-16) 376 (415) 275.2 (66.0) 135.5 (271) 26.5 (53)N
Average 271.9 (65.2) 132 (264) 92.5 (185)
142
-------
plant effluent although in some of the older mills these
individual streams are seldom separated (59) (60) (54) The
recovery stream generally contains miscellaneous waste waters
n^f=irtaS i°°r^/nd tank apr°n ^inings and storage tank
overflows. in addition, boiler plant and water treatment plant
wastes are sometimes sewered with the recovery unit. m other
mills they are discharged to lagoons with the water-borne solid
wastes such as fly ashr grits, and dregs.
gUr! ^3? summarizes the unit process waste characteristics of a
snown Thf" I** Wlth the effluent characteristics ttat arJ
shown. The figure is presented to show the rela+ivp
to the total raw wlste loa^
** representing the typical
The quantity of the various materials in <-he pffluen^- stream
depends to a considerable degree on the efficiency of" *he
recovery and associated operations as well as the ef fec
of provisions for handling cleaning operations, process
and euim
aons, process
and equipment failures. The very high efficiency of
recovery installations results, as a general rule, in low-
losses than those of older units. Many older mills havS com-
pletely rebuilt or replaced the original equipment and reach
efficiency levels similar to those of new mills (58) Examples
from surveyed mill data support this conclusion and hfveTe^n
presented in Section IV. High sewer losses will invariably
When.these svs^ «e overloaded irrespective of
^^^
Pollutional components of kraft pulping effluents
suspended solids, dissolved organics, and IlectrolyJes.
*
The quantity of total suspended solids can vary widely bu^- on the
average runs between 20 and 30 kg (40 and 60 lb) per kkg (ton) Si
P ? .f?r Wel1 °Perated mills. They are largely fib-r fines
wood debris plus about five to 10 percent lisersed
percent
10 ?° 2°
ckesr e
cakes are low in ash and can be incinerated (64) (65)
The dissolved organics fall into two classes- thos- whi ch
amenable to biological decomposition and those' which" Ir^
_,^ cooking liquor origin (681 (60)
^action accounts for over 80 percent of the BODS of kraft
effluent. The average BOD5 load amounts from 12.5 to 25 kg
143
-------
ncu;:i:. 39
i K'i CII/'HACIi ^ISnCb: DLUAU1LD "RAFT MILL
PROCESS
SVATL-t;
V/OODYAHD
1,000 G,M /TON
2 LB KODr/T;N
6 LB TSS/TON
15 LB COLOR/TO'-J
7.0 ?H
&».
6,000 CAL/TON
23 L3 QODjj/TO
17 LB TSS/TON
PULP IfllUL
65 Lb UUUUK/ I uw
O.SpH
RECOVERY
AND
CAUSTICIZIMG
BLEACH PLANT
PAPER MILL
5,000 GAL/TON
10 L!3 DOD5/TOM
27 LB TSS/TON
5 LB COLOR/TON
8,4pH
I (,000 GAL/TON
16 LB BOU5/TON
9 LB TSS/TON
65 LE COLOR/TON
?. 0 pM
(ACID WASTE)
(ALKALINE WASTE)
8,000 GAL /10i\l
15 LB BOD5/TON
5 LB TSS/TON
145 LB COLOS?/TON
!0.2pH
8,000 GAL/TON
12 LB BODQ/TON
34 LB TSS/TON RMV
5 LB COLOR/TON WASTE
7.1 PH 39,000 CAL/TON
78 LB nOD5/TON
100 LB Tf.S/TON
^,00 LB COLOR/TON
144
-------
the ^inal^Uinf*1^ (t°n) ?if product and the concentration of
^Si i*ii n 5 ? n ?enerallY ranges from 15° *> 300 mg/1
py) (54) . Data from three surveyed mills tends to support these
fxgures Mill 103, for example, has a pulp mill effluent BOD
load (Stream 0) of 18.45 kg/kkg (36.9 Ib/ton) . The comparable
figure for Mill 108 which is a dissolving pulp mill is 23 5
"
kg/kg
The non-degradable organic fraction is largely responsible for
the color of kraft effluents. it is generally caused^y lignlns
n?^™™;^;: I* . X! Commonly measured by comparison with the
platinum-cobalt standards. Based on this standard, kraft pulping
effluents normally contain from 500 to 2000 mg/1 of color units
n n nn?^PpnJ°f S, °f ^n°rTal °Peration- This amounts to 50 to 400 kg
™!L ?° lb) °f C0l°r UnitS per kkg of Product are ususally discharged from
"" e<3 ratl° between the BOD^ and COD has been
psablished
A number of other oxidation methods have been employed for
a?a^£q-krafj P"1? mil1 waste ^ters (72). The mSs? SjgJSrSy
of these is a technique using combustion and infrared detection
carbon ^TcT S^1^/^^ (?3) ' This techn^^ measures total
carbon (TC) , but it has been modified to measure total organic
carbon (TOC) and total organic matter (TOM) from which the ???al
oxygen demand (TOD) can be computed. TOD values developed by
this method correlate well with COD test data (72) However
since the BOD5 values measure only readily biologically oxidized
materials and the ratio of these substances to the total organic
content of kraft effluents fluctuates continually, no correlaSon
antTotn^T- nnd tOtal chemical °^en consumption can Ce
anticipated. Because of the complexity of operation and
instrument cost, the infrared methods have been largely ?imi?ed
an application to research and as a measure of the effectiveness
of advanced waste treatment systems. However, when fully
developed they may be adapted to effluent monitoring (74) .
Substances harmful in very low concentrations to aquatic life
oaVesn??^fOUnd ±n kraft PUlping efflue^s- These consist mainlj
of sulfides, mercaptans, resin acid, fatty acid soaps and
turpenes (75) (76) , but some less common and more complex
compounds demonstrating toxic properties have been iden^fild
_ 7jw —•«..,». •*_ f-*~ ^ j-'N--J- i»-j_ cro
of lPssenth^lyftheSe S?bstances are Present in concentrations
morcan^n. -!??71* S°me °f them' such as s^fides and
o?he?s ™nh rapldly dest^yed by natural oxidation but
others, such as resin acid soaps, are more stable. They are,
145
-------
however, removed by biological treatment and it has been
demonstrated that treated kraft effluents do not affect fish
propagation or growth at the concentrations at which they exist
in surface waters (78) .
The electrolyte content of kraft mill effluent normally ranges
from 1500 to 3000 mg/1. The salts comprising this fraction of
the waste derive from the mill's water supply, paper machine
white water used in the pulp mill, the pulping process, and
boiler blow-down. Those contributed by process are mainly
sulfates and carbonates of sodium and calcium together with some
more complex sodium compounds containing sulfur. Most effluents
are almost devoid of nitrogen and phosphorus compounds although
in some instances, phosphates are present due to their use in
boilers and as detergents.
The pH of the pulping effluent is on the alkaline side ranging
normally from 9.0 to 10.0 due to the presence of sodium
carbonate. From time to time a small amount of sodium hydroxide
drives this value somewhat higher. Ordinarily, however, the
total alkalinity is low particularly when paper machine white
water which contains some acidity is used in the pulp mill.
The condensates and drainings from prehydrolysis of the chips in
kraft dissolving pulp mills contain wood solubles with a BOD5
value of 30 to 60 kg (60 to 120 Ib) per kkg (ton) for softwoods
and 90 to 100 kg (180 to 200 Ib) for hardwoods and amount to
approximately 127 1 (300 gal) per kkg (ton) in volume (79) . They
contain little in the way of suspended solids.
The manufacture of chlorine or caustic soda for pulp bleaching
produces a small amount of inorganic waste containing impurities
from the purchased salt (mainly salts of the alkaline earth
metals) together with some unreacted sodium chloride. Pulp mills
no longer employ mercury cells in producing chlorine (94).
Therefore, generally only very low levels of mercury are found in
the effluent. There are two operations located adjacent to pulp
mills in which chlorine and caustic are produced by this method
but these are classified as chemical plants and are subject to
separate EPA effluent limitations (45) .
The only waste produced by hypochlorite manufacture is washout
from the absorption towers employed. The solids contained in the
waste are inorganic in nature, containing insoluble impurities
present in the chemicals, such as silica and sulfates of alkaline
earth metals.
The wastes from the manufacture of chlorine dioxide are
concentrated solutions which amount to 4.17 to 8.3 1 (0.5 to 1.0
gal) per kg (Ib) of C102 produced, or about 25 to 42 1 (6 to 10
gal) per kkg (ton) of pulp bleached. They consist primarily of
sodium sulfate and sulfuric acid, together with a small quantity
of residual chemicals which vary with the process employed.
Because of their sulfuric acid content, they are sometimes
employed in converting soap skimmings to tall oil before they are
146
-------
i,5*rodu£ed *nto the kr*ft recover^ system as chemical make-up
(24) m this step the acid present is converted to sodium
sultate, the primary make-up compound, and, on the average, such
wastes can supply up to 25 percent of the total salt cake make-up
of the kraft mill.
™ ali bS fiV6 °f- 67 mills Producing chlorine dioxide
disposed of the waste in the recovery system, although there is
wide variation as to the point where it is introduced. Through
this procedure most of the inorganic chemical is converted to
white liquor constituents (NaOH and Na2S) , and when unreacted
metnanol is present, it is burned in the recovery furnace.
Other chemicals are used in the bleaching process in relatively
small quantities and contribute to the mill effluent only to a
very minor degree. y
Effluent from modern bleach plants is normally discharged only
from the chlorination and extraction stages since effluents from
other stages are reused utilizing countercurrent washing
techniques. ^
The combined effluent contains the impurities from the process
*** J .suPPlv' substances extracted from the pulp, and chemicals
added in the process in modified form. For example, caustic soda
appears as the cation of the extracted organics. Because of the
dilute nature of the effluents and t he
-------
Table 3k?
VOLUME AND CHARACTERISTICS OF KRAFT BLEACHERY WASTES (5)
TO
Effluent
Volume
1000 1/kkg
(100 sal. ton)
Semi-Bleaching
High-Bleaching
Dissolving Pulp (Soft Wood)
Dissolving Pulp (Hard Wood)
75-104
(18-25)
104-146
(25-35)
209-250
(50-60)
230-289
(55-70)
BOD
kg/kkg
(Ib/ton)
15-17.5
(30-35)
20-30
(40-60)
60-75
(120-150)
250-350
:soo-/oo)
Total S..sp.
Solids Color
kg/kkg mg/1
7.5-10 2500-3000
(15-20)
10-15 4000-6000
(20-30)
65-75 >5000
(130-150)
95-100 >5000
(190-200)
pH
Range
4-5
3-4
2-3
2-3
-------
Table 33
KRAFT BLEACHING RAW WASTEJ3JIARACTERISTICS (STREAM 1)
MILL
CODE
100
101
103
104
108
117
122
124
125
FLOW
kl/kk*
23.7
30.2
70.3
40.0
90.4
39.1
23.9
6.0
42.2
(kgal/ton)
(5.69)
(7.24)
(16.86)
(9.59)
(21.67)
(9.37)
(5.73)
(1.44)
(10.12)
4.55
10.9
12.9
1.25
12.11
16.0
4.78
2.52
7.52
BOD
(-, f, /l-r-n^,
(9.09)
(21.83)
(25.77)
(2.50)
(24.23)
(32.0)
(9.55)
(5.04)
(15.03)
TSS
2.24
3.21
0.°>6
1 . '• 5
4, "-,5
2.9'+
9.31
1-95
c/toii) ,-,-r/l
(5.76)
(4.48)* :>2j
(6.43)*
ft I')}
fo i --'-•; -~r
(5.88)
(19.02)* 1397
(3.90)*
COLC?.
15.9 (3:
r - n / ", -\ '•
J -L . ^ ( 1 , ' ^
3.4 (lc
Average 25.4 (50.8)
* TSS(N)
-------
Table 34
RAW WASTE CHARACTERISTICS OF
VARIOUS STAGES OF BLEACHING
en
o
Bleaching Stage
kg/kkg
Ob/ton)
BOD5
Color (-DI-)
Chlorination
Extraction
Finishing Stages C°ED)
5.0
(10.0)
7.1
(14.2)
5.5
142.2
21.9
Total
17.6
(35.2)
-------
and chloride losses for this type bleaching are shown in Table
35.
Effluent concentrations at a water usage of 41,731 1 (10,000 gal)
per kkg (ton) will amount to around 400 mg/1 of BOD5, 1600 mg/1
COD, and 2400 mg/1 of color for the combined waste of a five-
staqe bleachery. Since water usage has little effect upon the
total amount of material removed from the pulp, the concentration
of these constituents will be directly proportional to water
consumption.
The pH value of the combined waste is on the acid side due to
mineral acidity from hydrochloric acid formed by reaction of the
chlorine compounds employed. The degree of acidity depends upon
the amount of active alkali remaining in the caustic extract and
the neutralizing chemical used after the final chlorine dioxide
stage. These effluents generally range from pH 3.0 to 4.0.
The overall shrinkage in kraft pulp weight during bleaching
ranges from four to ten percent and is due mainly to the removal
of dissolved substances since fiber losses are generally less
than 0.5 percent. This accounts for the normally lower suspended
solids content of kraft bleaching effluents and explains why
these wastes are frequently by-passed around clarification
devices at pulp mills.
The simple dissolved organics present in bleachery effluents are
low molecular weight substances (83). They primarily include
methanol, methy-ethyl ketone, and formic acid although small
quantities of oxalic, malonic, fumaricF and succinic acids, and
acetaldehyde are also present as well as some chlorinated
compounds.
The complex dissolved organics have been found to represent only
two percent of the total non-volatile organics. These are color
bodies present in chlorination and caustic extraction wastes.
They are described in NCASI bulletins (84)(85) reporting on
studies conducted at the New York State University College of
Forestry. The color bodies produced by chlorination were
chlorine-containing lignin, i.e., unsaturated acidic lignin
fragments having few of the aromatic properties of the lignins
themselves although lignin derived. Those color bodies found in
caustic extract were comparatively low molecular weight,
chlorine-substituted acidic materials displaying no aromatic
characteristics. It appears then that the chlorination stage
forms color bodies by lignin oxidation and the extraction stage
produces them by chlorine substitution.
Raw waste color data of bleach plant effluents from surveyed
mills have been presented in Table 33. Total raw waste color
data (Stream 9) from these mills are shown in Table 36. Total
raw waste color data (Stream 9) and final treated effluent data
(Stream 79) for surveyed mills are presented in Table 37.
Included in the table are mills in each of the four bleached
kraft subcategories, and as such considerable ranges of color
151
-------
Table 35
CONSTITUENTS OF FIVE STAGE BLEACHING EFFLUENT
#/ten
7% gllZlJ-P.'
Total Dissolved Solids 340
Dissolved Ino: ganics 205
Dissolved Organics 1-°
Cl - from Chlorine 123
Cl - from Dioxide -'6
NaOH 5 ?
Na2S04 14
-------
Table 36
STREAM 9 COLOR DATA FROM SURVEYED MILLS
en
CO
MILL
CODE
101
117
119
irg/1
843
634
616
COLOR
k'v'kkg nb/rcrO
135.5 (271)
122 (2/4)
60 p;ro
Average 106
-------
TABLE 37
COLOR WASTE LOADS - BLEACHED KRAFT SEGMENT
FLOW
Kill Si'bcatesory jd/dayf Real /day)
F, Mkt 153.5 (3S.O)
1C 5 BC7 152. 2 (38.9)
775 F,!'kt 157.2 (37.7)
1^0 F, K'
-------
values are shown. Differences between raw waste data and final
effluent data indicate a reduction in color across biological
treatment from 10 to 50% which is higher than previously reported
reductions of around 10% (86). The color for the final effluent
values varies from a low of 45.5 kg/kkg (91.0 Ibs/ton) to a high
of U13 kg/kkg (827 Ibs/ton) with a range of color units from 468
to 2032. The relatively wide range of values reported can be
partially explained by (1) the extent of pulping and bleaching at
a particular mill as indicated by the subcategory and by (2) the
type of analytical procedures used in measuring the color. The
test methods used by the surveyed mills are shown in Table 37 and
the effects, if any, on the color values reported have not been
reconciled at this time. The highest color values of 413.5
kg/kkg (827 Ibs/ton) in Table 37 is for surveyed mill 127 which a
dissolving kraft mill and should be at the high end of the range
due to the characteristics of the dissolving kraft process; i.e.
low yield, high bleaching. In comparing Tables 33 and 36, it may
be seen that Stream 1 color as measured in kg/kkg (Ib/ton) is
only about 25 percent of Stream 9 color. This percentage is
substantially lower than the 70 to 80 percent rule-of-thumb
figure. The explanation may be in the difficulty of separating .
bleach plant flows in order to obtain representative samples, or
in the fact that only three surveyed mills reported bleach plant
effluent color data.
One undesirable characteristic of bleachery waste water is
foaming. The caustic extraction effluent is primarily
responsible for this propensity which increases if the caustic
and chlorination stage effluents are directly mixed. The effect
is avoided to a considerable degree if the two streams are mixed
with the pulp and paper mill effluents at different points in the
effluent collection system to allow dilution of the extraction
stream before mixing occurs. However, some foaming cannot be
entirely avoided and measures may need to be taken for its con-
trol.
The only kraft bleach plant in the country using oxygen as one
stage is designed so that except during startup it uses fresh
water only for equipment seals, washer and press wire cleaning
showers, and chemical supply (chlorine and chlorine dioxide water
and caustic dilution) (190). This amounts to about 6258.3 1
(1500 gal) of fresh water per kkg (ton). Approximately 11,355 1
(3000 gal) of white water per kkg (ton) are used in addition for
wash water and seal tank make-up (177).
Currently, approximately 378.5-757 1 (100-200 gpm) of the "O2"
stage effluent which contains highly concentrated BOD losses and
color is sent to treatment (177). The remainder is used
internally to dilute the stock from 28 percent consistency as it
enters the »O2" stage to 12 percent as it leaves (177).
While there has been no operating experience yet with
displacement bleaching two such systems are being installed, as
discussed in Section III. Pilot plant operations indicate that
bleached pulps of market quality can be produced by this process
155
-------
without washing between stages and that effluent flow can be
reduced to the amount of water introduced with fresh chemicals
(185).
2§Y§logment_of_SubcategorY_Raw_Waste_Loads
The development of the raw waste loads (RWL) for the four
bleached kraft subcategories is discussed below. The resultant
raw waste loads were used in developing the effluent limitations
for each subcategory and in determining the costs presented in
Section VIII.
BK-Dissolving Pulp Subcategory
Each of the three mills in the bleached kraft-dissolving pulp
subcategory were surveyed and extensive data were available for
two of the three mills. Table 38 summarizes the raw waste
effluent characteristics for mill 108 and 127. A.S shown, the
effluent volume for the two mills is relatively close with an
average of 241 kl/kkg (57.7 kgal/ton). The differences in BODS
RWL may possibly be attributable to the differences in in-plant
control measures utilized for disposal of prehydrolysate.
BK-Market Pulp Subcategory
The data from surveyed mills in the bleached kraft market pulp
subcategory are summarized in Table 39. The mills in Table 39
represent market pulp mills in all sectors of the country. The
mills are relatively new (1960s) with no significant correlation
between age of the mill and the RWL. The size of the mills
ranged from around 272 kkg (300 tons) to nearly 907 (1000 tons)
of pulp per day with no significant correlation between size and
RWL. Each of the mills produces exclusively highly bleached
market pulp by similar manufacturing operations. The differences
in BOD5 RWL and effluent volumes is attributed to the extent of
internal pollution control measures as discussed in Section VII.
Mill 140 was not included in calculating the subcategory effluent
flows or BOD5 as both values were significantly less than the
other mills in Table 39. The TSS data for mill 140, however, was
used in calculating the average TSS RWL because data was
unavailable for mills 126 and 114, and mill 130 RWL TSS data was
determined by non-standard methods. It should be pointed out
that data from mill 139 was included in the subcategory average
since even though the flow was close to that for mill 140, the
BODS value was very comparable to mills 126 and 114. Inclusion
of data in the subcategory average of four of the five mills
resulted in an average effluent flow of 176.8 kl/kkg (42.4
kgal/ton). If the low and high flow values were eliminated, the
average would than be 183.5 kl/kkg (44.0 kgal/ton) which is very
comparable to the average for the four mills. Being
representative of four mills, the value of 176.8 kl/kkg (42.5
kgal/ton) was used as the subcategory RWL in developing costs and
effluent limitations; the average RWL flow for all five mills was
157.6 kl/kkg (37.8 kgal/ton). The average BOD5 RWL shown in the
156
-------
TABLE 33
RAH WAS1F. LOAD
BK: DISSOLVING PULP SbBCATilGuIJY
Size FLOW
Mill kkQ/day(tor../(igy) !L/jl^O\9ll/'-fb
BOD5
108 824 (908)
127 *
Average
251 (GO. 2)
230 (55.1)
2/il (57.7)
69.5 (139;
40.0 (00.0)
55.0 (110)
TSS
kn/kkcjQbr-./ton;
139 (277)
87.0(174)
113 (226)
*Trade Secret
157
-------
Table 39
Raw Waste Load
Bleached Kraft - Market Pulp Subcategory
Mill Size Flow BODs TSS
kkg/day(tons/day) kl/kkg(kgal/ton) "_
(91.0) - (
(93.2) - (
(31.4)* 70 (
125
114
139
140
130
Average
480
669
883
288
366
(529)
(737)
(973)
(318)
(404)
194.3
172.6
85.1
79.2
256.4
175.3
(46.6)
(41.4)
(20.4)
(19.0)**
(61.5)
(42.4)
45.5
46.6
40.7
27.7
31.6
41.1
en
CO
^Calculated using 15% primary treatment removal.
**Not included in subcategory average (see text).
(55.4)** 72.5 ( 145)
(63.2) 17.9 (35.5):
(82.2) 7'
-------
table is 41.1 kg/kkg (82.2 Ibs/ton) and is essentially the median
value for the five mills.
BK-BCT Papers Subcategory
Raw waste effluent characteristics are summarized in Table 40 for
surveyed mills in the BK-BCT Papers subcategory. The four mills
in Table 40 produce a wide variety of products including coarse
papers, paperboard, and tissue papers. Mills 105, 109, and 111
also produce some unbleached kraft products while mill 121
produces a small amount of market pulp. The age of the mills
ranges from being built in 1912 to 1954 while the size ranges
from 698 kkg (770 tons) per day to over 1179 kkg (1300 tons) per
day. This apparent wide range of products, ages, and sizes,
however, is not shown to have significant impacts of raw waste
characteristics as shown in Table 40. The average effluent flow
is 152 kl/kkg (36.5 kgal/ton) with a relatively narrow range
between 134 kl/kkg (32.3 kgal/ton) and 163 kl/kkg (39.1
kgal/ton). The BOD5 RWL is 33.4 kg/kkg (66.9 Ibs/ton) with a
similarly narrow range. TSS RWL data was only available from
mill 111, but appears to be representative as discussed below.
Table 41 shows effluent characteristics of bleached kraft mills
producing both market pulp and BCT papers. The column entitled
"Subcategory (%)" shows the various percentages of total
production of either market pulp or BCT papers that are made at
the mills. Comparison of RWL for BK-BCT papers subcategory and
BK-Market Pulp subcategory with the averages presented in Table
41 confirms the representativeness of the effluent flow averages
for the subcategories. Using a ratio of the subcategory averages
for BK-market pulp and BK-BCT papers of 177 kl/kkg (42.5
kgal/ton) and 152 kl/kkg (36.5 kgal/ton), respectively, with the
average percentages of product in Table 41 (30% Mkt, 70% BCT),
the predicted effluent flow for the mills in Table 41 is 159.7
kl/kkg (38.3 kgal/ton) which compares very closely to the actual
average of 159.3 kl/kkg (38.2 kgal/ton). By this same
methodology, the predicted BOD5 value is not as close and
possible is a result of having BOD5 data for only five of the
seven mills. The average TSS RWL for mills represented in Table
41 is 47.2 kg/kkg (94.4 Ibs/ton) which is less than would be
predicted with the methodology used above and is an indication
that the TSS RWL for the BK-BCT subcategory of 51.5 kg/kkg (103
Ibs/ton) is conservative. However, as discussed previously,
significant correlations between TSS RWL and production processes
do not exist as a general rule because of the internal practices
on fiber control in use by pulp and paper mills.
159
-------
09 L
(£01) 9' IS
( - ) -
(£01) S'L9
N(i7S2) Lzt
( - ) -
'99) fr'
ssi
(9' 19
(9'9£) Z9L
('tyS£) 61/L
(L"^) l?tl
(L'bC) eoi.
291
(GUI)
(1211)
GOZ
ZLOL
121
ILL
ooi
901
i i./w cn!!jv:na
i i;yj
-------
Tah'c 41
Raw !.;?ste Load
3!C - BCT & ,'ictrket Mills
Mill Subcategcry Size Flow BODs TSS
% ' Ma/^ll(i2jQl/.(il,Yl !<1/kkg(k(-al/:on) ko/'Li-r(lbs/to;i) ko/hkg( Ibs/trn)
501 60MKT, 403CT 1256 M38C) 193.9 (-17 7) - ( - ) - ( - j
117 30MKT, 703CT 297 ( 327) 203.9 (48.9) ,'.7.5 (55.0)* 65 ( 130)
113 30MKT, 703CT 1058 (1177) 140.9 (33.S) 38.4 (76.9) - ( - )
122 30MKT, 70BCT 542 ( 598) 120.9 (29.0) 45.7 (91.4) 52 ( 104)
100 20MKT, 80BCT 931 (1027) 150.5 (36.1) 44.8 (89.7) 31.8 (63.7)
138 20MKT, 80BCT 894 ( 986) 139.7 (33.5) 49.0 (98.0) 40 ( 80)
131 20MKT 80BCT 717 ( 791) 158.9 (38.1) - ( - ) - ( - )
Average 159.3 (38.2) 41.1 (82.2) 47.2 (94.4)
Calculated
161
-------
BK-Fine Papers Subcategory
Table 42 presents summarized data for mills in the BK-Fine Papers
subcategory. The mills included in Table 42 produce fine papers
with the size of mills ranging from about 363 kkg (400 tons) per
day to over 1450 kkg (1600 tons) per day. Mills 136 and 104 also
manufacture some paperboard and tissue products, respectively.
The age of the mills in the table varies from 1864 to 1970; mill
119, built in 1864, has a lower RWL than mill 112, built in 1969
which serves to demonstrate that old mills have generally been
upgraded and relationships between age and RWL are generally non-
existent. Many of the mills in the BK-fine papers subcategory
purchase pulp as an additional fiber source. The flow and BOD5
data presented in Table 42 represents the RWL without any
purchased pulp. Using conservative RWL flow and BOD5 values from
non-integrated fine paper mills, the actual effluent data for
mills purchasing pulp as a supplementary source of fiber were
adjusted to represent the manufacture of fine papers from
bleached kraft pulp manufactured on-site. In every case, the
mill effluent flow and BOD5 values were increased by the
adjustment.
The average subcategory RWL as shown in Table 42 do not include
mills 116, 132, or 104. Mill 116 flow, BOD5, and TSS values are
significantly higher than all of the other mills in the
subcategory except for mill 132 which was also eliminated from
the calculations because the flow value was significantly less
than the other mills. Mill 104 produces both fine papers and
tissue papers and thus does not fit precisely within the fine
papers subcategory. Table 43 shows RWL data for mills which
manufacture both market pulp and fine papers. Comparison by the
methodology described in the above discussion of BK-BCT papers
using ratios of the percentages of product manufactured in Table
43 with RWL averages for BK-market pulp and BK-fine papers
subcategories shows a predicted flow and BOD5 of 135 kl/kkg (32.4
kgal/ton) and 34.3 kg/kkg (68.6 Ibs/ton), respectively. These
values are relatively close to the actual values of 145.5 kl/kkg
(34.9 kgal/ton) and 36.1 kg/kkg (72.3 Ibs/ton), respectively,
which indicates that the BK-fine papers subcategory RWL averages
are representative.
SQDA_SEGMENT
Approximatley 83,461 to 125,193 1 (20,000 to 30,000 gal) of
effluent are produced per kkg (ton) of soda pulp, the specific
volume depending largely on cooling requirements. Reuse of paper
machine water in the pulp mill is limited by the fillers used in
the manufacture of printing papers from soda pulp which render
this water unsuitable unless it is clarified to a high degree.
There are four major effluent streams from the pulp production
process: the decker seal pit water, the digester relief
condensates, the bleach plant effluent, and the recovery plant
discharge which includes miscellaneous waste waters such as
boiler plant and water treatment plant effluents. In Figure 40,
162
-------
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cri
TABLE 43
RAW WASTE LOAD - BK-FINE & MKT MILLS
Size FLOW BOD5 TSS
Mill Subcategory(%) kkg/day(tons/day) k1/kkg(kcial/ton) kgAkgQbs/ton) kg/';::o'Ibs/torQ
103 45 MKT, 55 F 285 (425) 181.0(43./I) 37.4 (74.9) - (-)
135 40 MKT, 60 F 580 (640) 167.5(40.2) 37.7 (75.4)* 73.00-5)
106 55 MKT, 45 F 473 (522) 161.4 (38.7) 33.2 (66.4)* 40.3 [30.6)
101 45 MKT, 55 F 517 (570) 150.9 (36.2) 30.3 (60.6) 53.0 (1C6)N
107 25 MKT, 75 F 281 (310) 126.3 (30.3) - ( - ) - ( - )
110 30 MKT, 70 F 1027 (1132) 102.6(24.6) 30.3 (50.6) 53.0(127)
120 35 MKT, 65 F 1052 (1160) 129.7(31.1) 40.0 (?5.0) - (-)
Average 145.5 (34.9) 36.2 (72.3) 59.0 (118)
Calculated
-------
>
the first two flows are combined into the "pulp mill" flow, since
waste data are not available for the individual streams. The
major pollutional characteristics of the combined effluents are
suspended solids, BOD, and color. The suspended solids —fiber
fines and debris — are mostly settleable and are more than 90
percent combustible (5). Normal concentration ranges from 200 to
300 mg/1 or about 20 to 30 kg (40 to 60 Ib) per kkg (ton) of AD
pulp produced. BOD5 values are in the same range. Color ranges
from 800 to 1500 mg/1 during periods of normal operation.
Soda pulping effluents contain some components inimical to
aquatic life (50). These are resin acid soaps and turpene
derivatives. Since sulfur is not used in the process, the
effluent appears to have a lower toxicity level than kraft.
However, like kraft effluents it can give rise to foaming.
Soda pulp bleaching effluents are similar to those of kraft and
contain 10 to 20 kg (20 to 40 Ib) of BOD5 per kkg (ton) of air
dry pulp bleached. See Figure 40. The volume ranges between
50,077 to 75,116 1 (12,000 and 18,000 gal) per kkg (ton). Color
of these effluents will vary widely with the species of wood from
which the pulp was produced, as is the case with kraft.
The above data cited from literature sources for soda pulping
operations tends to be somewhat higher than more recent data
obtained from the three surveyed mills which reflects the efforts
in recent years to reduce pollution loads. Figure 40 is
presented as an example of a soda pulp and paper mill with the
effluent characteristics shown to show the relative contributions
of the unit process operations to the total raw waste load.
B§Ygi225D§nt_2f_Soda_SubcategorY_Raw_Waste_Loads
The development of the raw waste loads (RWL) for the soda
subcategory is discussed below. The resultant raw waste loads
were used in developing the effluent limitations for the soda
subcategory and in determining the costs presented in Section
VTII.
All the surveyed soda mills are old, but have been modernized
since 1965. All make fine papers from various percentages of
purchased pulp and of soda pulp manufactured on-site.
Table 44 presents the raw waste effluent characteristics for the
three mills in the soda subcategory. As mentioned above all
three mills purchase pulp as a supplementary fiber source and has
some effects on the effluent characteristics when evaluating RWL
on a (kg/kkg (Ibs/ton) basis. However, since all three mills
purchase pulp in varying quantities, this factor was not excluded
in developing the subcategory RWL. As shown in Table 44, th*=»
subcategory flow, BOD5, and TSS RWL are 123 kl/kkg (29.5
kgal/ton), 42.7 kg/kkg (85.4 Ibs/ton), and 105.5 kg/kkg (211
Ibs/ton), respectively. It should be pointed out that mill 151
165
-------
riCURE 40
PK-LULIMT ci
s. :.ODA MILL
WATER
PULP WILL
LIQUOR RECOVERY
BLEACH PLANT
PAPER MILL
13,000 GAL/TON
29 LB BOD^/TGU
49 LB TSS/TON
9.3pH
2,000 GAL/TOU
8 LB BOD5/TOM
31 LB TSS/TCtJ
9.9pH
7,500 GAL/TON
29 LB
7 LB TSS/TON
6.3 pH
BOD5/TON
7,500 GAL/TON
30 LB BODg/TON
GO LD TSS/TOIJ
5.7 pH
V
RAV/
WASTE
30,000 GAL/TON
96 LD BOD5/TON
155 LB TSS/TON
8.2 pH
166
-------
TACLu 44
RA'-.' WSTil LOAO
SODA
Size
FLOW
Mill
150
151
152
kkg/doy(torr>/day)
262 (289)
620 (684)
548 (604)
kl/kkc
158.0
1 0 i . /
104.7
(kcial/to
(37.9)
(24.4)
(26.3)
Average
123.0 (29.5)
BOD 5
5G.7 (113.5)
47.6 ( ,b.3)
23.7 ( 47.4)
42,7 (85.4)
TSS
7.Ql>:LL
63.5 (Ik?)
( - )
147.5 (295)
105.5 (211)
167
-------
which only uses about 12% purchased pulp is well below the
subcategory flow and relatively close to the BOD5 RWL.
DEINK_SEGMENT
The major sources of effluent from the deinking process are the
washers and centri-cleaners; the remaining streams consist mainly
of miscellaneous white water overflows, floor drainage, washup,
and cooling waters. In older operations deinking fine papers,
the total effluent ranged between 62,596 and 104,327 1 (15,000
and 25,000 gal) per kkg (ton) of waste paper processed depending
upon the quality of the product produced and equipment used.
More recent data from surveyed mills indicates that several mills
have substantially reduced their flows in recent years. Mills
217 and 204 which manufacture fine papers and mills 213 and 215
which manufacture tissue papers all have flows of about 50.0 to
54.2 kl/kkg (12.0 to 13.0 kgal/ton). Approximately 41,730 1
(10,000 gal) of water are required per kkg (ton) of newsprint
deinked (6). In decoating operations producing a crude pulp for
use in board products, the wash water is sometimes settled and
reused cutting the total discharge to under 20,865 1 (5000 gal)
per kkg (ton) of waste paper processed.
Clarified white water from papermaking operations may supply a
considerable portion of the water used for washing and cleaning.
The entire waste water flow from a single-stage bleaching
operation can also be used in deinking for dilution and
preliminary wash water. However, effluent discharged from three
stage bleacheries, 50,077 to 83,463 1 (12,000 to 20,000 gal) per
kkg (ton) of pulp bleached, is not generally suitable for reuse
because of its color.
The major polluting characteristics of deinking effluents are BOD
and suspended solids, both settleable and dispersed (88) (89) .
organics present include adhesives, products of hydrolysis and
fiber lost in the process. Inorganics derive from mineral
fillers, ink pigments, and other materials separated from the
fiber in waste paper as well as chemicals utilized in the
process. Included in the latter are dissolved electrolytes and
detergents which add to the total solids and foaming propensities
of receiving waters.
The electrolytes are primarily sodium salts. Op to 60 pounds of
these salts as Na+ are added to the cooking liquor per ton of
waste paper processed and most appear in the effluent. Cooking
also contributes other inorganics present in the waste paper such
as aluminum hydrate.
Sodium silicate used as a cooking liquor component will account
for the presence of silica in the effluent and calcium can be
present as a product of calcium hypochlorite bleaching.
Bleaching may also contribute some chloride ion. Color can be a
factor in deinking and attendant bleaching operations although it
is a minor one in comparison to the color values which result
from the manufacture and bleaching of chemical pulps. Data for
168
-------
color of deinking wastes are not available. However. it is
normally not a problem after the waste is diluted with white
water and is obscured by the extremely finely dispersed particles
present even in highly treated effluents.
Table 45 gives a range of values for the solids and BODS consent
of total deinking waste, including bleaching. This data is not
directly comparable to the surveyed mill data, since the former
is based upon kkg (tons) of waste paper handled, while the latter
is based upon kkg (tons) of paper produced. Table 45 indicates
^?AA ?? TSS aPPear to be in the neighborhood of 50 kg/kkq
(100 Ib/ton) and 150 kg/kkg (300 Ib/ton) , respectively, on the
basis of weight of waste paper handled. These high losses can be
expected when considering the shrinkage 'data obtained from
surveyed mills. Shrinkage is the percent loss of weight of waste
paper in the deinking process. This loss appears in the waste
water primarily as BOD and TSS. As shown in Table 46, shrinkage
values range from 18 to 25 percent. mxage
= «-, iSL Presented as an example of a deink mill with the
final effluent characteristics shown in order to show the
relative contributions of the deink mill and the paper mill to
the total raw waste load.
D§v§iOE2)§nt_gf_peink_Subcategory._Raw_Waste_Lgad
The development of the raw waste loads (RWL) for the deink
subcategory is discussed below. The resultant raw waste loaSs
were used in developing effluent limitations and in determining
the costs presented in Section VIII.
The raw waste load data for mills in the deink subcategory are
summarized in Table 47. As shown, data was available for 14 of
the approximately 17 mills in the subcategory. As discussed in
l^1?1 ™' c£nsideration was given to establishing two
subcategories for the deink segment and as such, Table 47 is
divided into two groups of mills. The mills manufacturing fine
i-fl EaP!™f are Sh°Wn in the top grouP and those manufacturing
*i !SKi( } ?apers are shown in ^e lower group. Also, shown in
2 4-v. Z ,1S manufacturing information including the percentage
of the total product as made up by purchased pulp, waste "paper
(not deink), deinked waste papers, and clays and fillers. As
shown in the table, the average RWLs for deink mills producing
fine papers are less than for mills producing tissue papers. The
subcategory RWL was thereby based upon mills producing tissue
fS 1S rePrese"ts the higher RWL of the two groups. The
K ups.
methodology used for developing the deink subcategory RWL
differed slightly from that used in developing the other
JlSSn?0?'*./"^ , * Vhat the deink subcategory waste load was an
a*XanJl°J f WJ °f, m±11S 2°5' 2°6' and 216 which employ
external treatment and generally have the higher RWL shown in th-
aS^oo Avera9an9 their RWL resulted in the following flow, BOD5 '
ah2/to./ y o^-0,kl/kkg (22'6 *gal/ton), 68.5 kg/kkg (it?
Ibs/ton), and 204 kg/kkg (408 Ibs/ton) , respectively These
values are all higher than the average for' all Pmills shown in
169
-------
Table 45
SOLIDS AND BODS LOADING FROM
DEINKING MILL OPERATIONS
Effluent
Volume
1000 1/kkg
(1000 sal/ton)
(Based on Waste Paper Handled)
TSS
///ton
// /ton
117
(28)
104
(25)
125
(30)
71
(17)
50
(12)
88
(21)
100
(200;
250
(500)
225
(450)
195
(390)
300
(600)
380
(760)
39
(73)
', 7
, J
59
(100)
37-5
40
(80)
57.5
(113)
-------
Table 46
Delnk Mill Shrinkage
PERCENT
MILL S HRINKAGE
203 05
204 7X
207 1,3
208 2Q
-------
FlGOKi: ft 1
EFFLUL-m C::ARACTL i;,STIC3: DEINK IYIILL
PROCU'JS
WATER
DP-INK
MILL
PAPER MILL
11,000 GAL/TOM
71 LB BOD5/rC:J
SCO LB
10.5 p.!
0,000 GAL/TON
f, LB BODr,/TON
GO LB T.SS/TON
8.9pH
RAW
WASTE
20,000 GAL/TON
75 LB BODb/TON
260 LB TSS/TOU
9.3 pH
172
-------
Table 47
RAW WASTE LOAD
DEINK SUBCATEGORY
iii ;
203
217
204
210
207
212
214
5 2C5
205
215
213
215
211
i r
D
35
75
25
25
15
Average
100
100
100
70
60
50
25
^3
Average
lanur
FP
33
0
50
50
70
0
0
0
20
20
0
10
0
acture
l-.'P
12
0
5
5
0
0
0
0
10
20
50
65
57
a („)
C&F
20
25
20
20
15
0
0
0
0
0
0
0
0
Products
F
F
F
F
F
T
T
T
T
T
T
T
T
kkg/dj,
349
293
181
291
245
82
44
717
89
72
30
120
7C
Size
v (tens/day)
(?c5)
(323)
(200)
(321)
(270)
( 90)
. ( 43)
(790)
( 93)
( 79)
( 33)
(132)
! 77}
\ ' i i
F
kl/kkg
i-,,1. 1J..
73.1
55.0
55.5
80.1
162.6
85.5
100.5
149.7
93.4
30.9
K5.3
50.4
52.9
197 9
\ {~t . L.
95.5
1 ow
08
(13
(13
(13
(39
(20
(24
(35.
(23,
0?
(25.
(12.
(12.
IT
(o(j.
(22.
/ion)
1 ,./-
-0)
.2)
• 3)
-2)
-0)
-5)
.1)
.9)
.6)
4)
5}
.1)
7)
r ~\
~>)
9)
DCIP- TCC
uU LJ v^ i ^> N
kg/k'f n PEs/tin) ^'-;^ ' ^c ' ~ '•^ /~r '
53.5 (107) 15? (310)
91-5 (1?3) 19.:. 5 (sc.Vi
27.5 ( 35) ?9.5 (IS"'1
34.7 ( 5?. 4) 9? (I-..)
( - ) 89 (17E;.:
52 (10O 1-7 (;o:;
92.5 (135; 295.5 (5?3):,
( - ) - ( - )
61.1 ''122) 15- ^3'0)
( - } ,; . ;,
72.5 ,1^5) 233 (~:>,
( . ) . , . ;
16.8 (33.6) 55.5 (-.",'/.,
G2 (12 1) "••" '> '2J_",.',
46.5 f ^ 204 (4C3)
Average (all mills)
91.7 (22.0)
57 (1,4)
-------
Table 47 and were used because of the nature of the deinking
process (i.e. the type of waste paper used as the fiber source
has significant effects upon the effluent characteristics, and
changes in market conditions have direct effects upon the
availability and use of the type of waste paper) . It should be
pointed out that since nearly all mills purchase pulp in varying
quantities the effects of purchased pulp are included in the
subcategory RWL.
PAPERMAKING
As used in this discussion, the term "paper making" includes stock
preparation as well as the forming, drying, and ancillary
processes which occur on the paper machine itself. Paper/board
is made on similar equipment within all subcategories, with
similar water uses and similar sources of waste water.
Therefore, papermaking for all subcategories is discussed
together, but attention will be drawn to significant differences
among the subcategories.
Water is used for a wide variety of purposes in papermaking.
Definitive data on quantities used are lacking for two principal
reasons. First, there has been an increasing trend toward reuse
within the industry involving the transport of waste water from
one subprocess for use in one or more different subprocesses.
For example, machine white water is used for consistency
regulator dilution in both the stock preparation and papermaking
areas. Reuse quantities are rarely metered separately. Second,
the complexity of the subprocesses and their interconnections,
together with the many individual use points of fresh water,
makes it almost impossible to meter each usage of fresh water.
The overall effect of reuse, however, is to reduce the quantity
of fresh water, and hence the quantity of waste water leaving the
entire process. This effect is discussed later in this section.
Because of the paucity of published data, estimates have been
made of individual usages of water based upon general engineering
design values and upon information obtained at surveyed mills.
The use points and their estimated flows are shown in Table 48.
It must be emphasized that these are gross values, including, in
most cases, substantial reuse. Therefore, as discussed below,
the sum of individual uses will exceed the total fresh water
usage by a substantial amount.
The extent of reuse depends on many factors including product
requirements, manufacturing demands, length of production run,
and engineering considerations. Every surveyed mill engaged in
papermaking reuses water in the process to some extent, and most
of them reported continuing programs to reuse more. All of them
reuse furnish dilution water which is the largest use shown in
Table 48. Because considerable effort has been made by some
mills to minimize fresh water use for cleaning of fourdrinier
174
-------
en
Table 48
ESTIMATED WATER USAGE FOR PAPEBMAKING
•[Top,
—— , Flo-, Eal/.:c
1. To fiberize stock and convey it from one subproc^ss to another
2. To clean equipment such as wires, cylinder molds, and felts durin- pro
duction, and to knock down foam °
length CUt ^ flberS t0 Pr°Vide Pr°per strfi"3th and fiber
4. To dilute the furnish for cleaning, forming, ;nd for consistency reflation
5' aners01"' dlSPerSC' dllute' and/°r COOTey additives alu:n, starch, and
6. To lubricate and seal moving parts such as shafts and vacuum pumps
7. To provide steam for processing and space heating (net)
8. To cool equipment and process fluids
9. To wash up equipment and adjacent floor areas after production runs
-------
wires, estimates of this use and reuse were obtained from some
surveyed mills and are shown separately in Table 49. Further
discussion of these results is deferred to section VII.
WASTE_WATER_CHARACTERISTICS
In a papermaking area, the principal waste water discharges are
as follows:
1. Excess white water from seal pits or other tank overflows
2. Rejects from stock cleaning devices (centrifugal cleaners,
screens, and junk traps)
3. Felt and wire cleaning waters
4. Spills, washups, discharge of tank dregs, and other non-
equilibrium losses
5. Cooling water discharges
6. Boiler blowdown and other miscellaneous discharges.
In addition, sanitary wastes are almost always collected
separately, and either directed to a municipal system or treated
separately. Because of this, and the fact that such flows are
small compared to process losses, sanitary wastes will not be
discussed further in this report.
Sources of BOD in waste waters are the organic raw materials used
as the constituents of paper. Cellulose is foremost, comprising
80 percent or more of the weight of most papers. Rosxn sizings
and starch or protein adhesives also contribute to BOD loadings,
as do many special organic chemicals such as wet strength resins.
some or all of these constituents, including cellulose fibers,
are in the solid or precipitated state, and therefore also
contribute to TSS loadings. Fillers and coating pigments such as
clay and titanium dioxide are responsible for virtually no BOD,
but add to TSS loadings.
Most losses from papermaking are undesirable from the economic as
well as the pollution viewpoint, since they are valuable
materials which could otherwise be incorporated in the sheet and
sold. Data breakdowns on principal losses as listed above are
not available because of sewer interconnections and reuse
complications. Each item is discussed below, with estimates of
such losses where available.
Excess white water results from necessary additions of fresh
water to the process system. While measures are available to
reduce these losses by means of savealls, as discussed in Section
VII, some material inevitably escapes to sewer. The saveall
effluent contains some remaining TSS, and may have significant
BOD since ^he saveall cannot remove dissolved BOD. Centrifugal
176
-------
Tnble 49
ESTIMATED UATER UP/ 'T, FOR ,'OUr.DUJNIER JttG^
Du;jw\i LA^JKi
Groundwood
Sulfite
Bleached Kraft
Soda
Deirik
Non- Integrated
Fine Papers
Non- Integrated
Tissue Papers
Non-Integrated
Coarse Papers
<•<">> V.'IUTE WA'< J;K
00"
012 2.0
013 (some)
014
050
053
056
105 3.9
124
125 1.8
126 0.5
151 1.0
205 6.8
207
250
252 5.8
257 4.3
261
262
265 3.0
267
300
305
309
310
312 5.0
351 5.4
353
J:JM,/-JI; \;,\
3,2
0.8
1 3
2.7
2,2
32
10
2.6
2.2
1.8
0.4
7.2
1.2
0.2
4.3
1.0
6.8
12
90
6.3
(some)
14
1.CU TPT\T
. J_ j-jj k J V_( j_ t li_j
3.7
2.8
1.3+
2.7
2.2
32
10
6.5
2.2
3.6
0.5
1.4
14
5.5
1.2
6.0
8.6
2.7
1.0
9.8
12
10
90
18
6.3
5.0+
5.4
14
177
-------
cleaner rejects are reduced -to approximately 0.1-1.0 percent of
production, but nevertheless represent a significant source of
TSS loss. Rejects also contain significant BOD. Felt and wire
cleaning waters are frequently diverted to sewer, and usually
contain only minor loadings of TSS and BOD.
Non-equilibrium losses can be very significant. Generally, one-
quarter to one-half of total paper mill BOD and TSS loadings are
due to these losses which are related to production upsets due to
machine startups, shutdowns, and washups, dumping of tank
remnants at end of runs, electrical and steam outages, and
equipment failure. Because of interconnected sewers, data
breakdowns within the above list are not available.
A special effort was made at surveyed mills to obtain estimates
of nonequilibrium losses, since these may have a significant
surge impact upon treatment facilities. Few data were available,
however. Those obtained are shown in Table 50.
Water is used to cool condensate from paper machine steam-heated
dryers. This use may account for 8.3 to 16.6 cu. m per kkg (2000
to 4000 gal/ton). In addition, water is used to cool gear boxes,
brake drums, lubricating oil systems, bearings, and other
miscellaneous equipment. Mills which generate electricity from
steam may use large volumes of water for condenser^cooling.
These are normally discharged separately and not admitted to
process sewers or treatment facilities. Normally fresh water is
used for cooling to minimize fouling problems on heat exchangers
and because it is the lowest temperature water available.
Several mills collect the major cooling water effluents to
supplement fresh water process needs. Cooling waters rarely
contain significant loadings of BOD or TSS.
Boiler blowdowns and other miscellaneous discharges also rarely
contain significant amounts of BOD and TSS. Phosphates used in
boiler water treatment and discharged in the blowdowns are
beneficial to biological treatment systems as a partial source of
phosphorus nutrient. Data for papermaking operations of mills
surveyed in integrated — i.e., pulping subcategories — have
been presented above. It is probably that these losses are not
completely representative, however, since some pulp mill losses
may be included. On the other hand, some papermaking white
waters may be returned to the pulp mill and therefore not t
represented as papermaking losses.
178
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Table 50
ESTIMATED NON-EQUILILRIUN PAPERMAKING LOSSES
to
SUBCATEGORY
Groundwood
Suifite
Bleached
Kraft
Soda
Deink
Fine Paper
Tissue
Coarse Paper
MILL START IT
CODE BOD- TSS
010 0.25(0.5)-2
012
014
052
101
102
107
113 4.5(9)-208
116 0.35(0.7)-1248 0. 65(1.3)-1248
119
121 0.3(0.6)
126 1.5(3) 1.5(3)
151
152 0.6(1.2)-12 1.2(2.4)-12
204
205
261
266
267
306
308
315 2.45(4.9)-! 4.9(9.8)-!
353 15.5(31)-365
360
SHUTDO'.'N
BOD- ISS
5
0.25(0.5)-S
(5.5)11 11(22)
4-5(9)
1.5 (3) -36
2. 25 (''-.5) -2
1(2) 4(o)
^ . 5(?,--2:3
0.65 (1.3) -1248 1.3: \t'- >-i ~ H,
12 / ~ • )
O.J3U.3)
1.5(3) 1.5(3)
1.05(2.1) 0.65(1.3)
1.6(3.2)-6 3.5"(7.I)-6
23'40}--5
2.5(5)-24
2. 15 (4. 3) -104 4.3(S.6)-1C4
9 (13: -52
1.^5(2. 9)-26
2.45(4.9)-! 4.9(9.8)-!
8(15)-365
0.8(1.6) 0.1(0.2)
NOTE: Numbers following hyphen indicate estimated number of occurrences per year.
-------
Table. 50 Coat'd.
MILL
SUBCATEGORY CODE
Groundwood 010
012
014
Sulfite 052
Bleached
Kraft 101
102
107
113
116
119
121
oo 126
0
Soda 151
152
Deink 204
205
Fine Paper 261
266
267
Tissue 306
308
315
Coarse Paper 353
360
GRADE CHANGE
BOD5 TSS
-5.5(ll)-224 ll(22)-224
15(30)-120
0.85(1.7)-288 1.75(3.5)-288
0.4(0.8) 0.55(1.1)
1.2(2.4)-52 2.-'. (4.8)-52
9(18)
4.3(8.6)-1095 8.5(17)-1095
9(18)-104
4.15(8.3)-52
8(16)-365
WIRE CHANGE
BODc TSS
0.15 (0.3) -45
5.5(ll)-33 ll(22)-33
j- . 5 (3) — 6
0.9(1.8)
4.5(9)-5
0.65(1.3)-36 1.3(2.6)-36
0.05(1.3)
1.5(3) 1.5(3)
1.2(2.4)-12 24(48)-12
2.25(4.5)-2
1.45(2.9)-6
0.8(1.6) 0.1(0.2)
NOTE: Numbers following hyphen indicate estimated number of occurrences per year.
-------
Tabla 5QCont'd.
SUB CATEGORY
Groundwood
Sulfite
Bleached
Kraft
Soda
Deink
Fine Paper
Tissue
Coarse Paper
MILL
CODS
010
012
014
052
101
102
107
113
116
119
121
126
151
152
204
205
261
266
267
306
308
315
353
360
WASHUP
BOD5 TSS
0.05(0. 1)-310
5.5(ll)-248 11(22)-24S
2.5(5)-100
1.5(3)-36
3.75(7.5)
1.5(3) 1.5(3)
,0.6(1. 2)-52 2.0(4.0)-52
0.05(0.1)-52 0.3(0. 6)-52
1.45(2.9)-26
5.5(ll)-35
0.35(0.7) 0.05(0.1)
NOTE: Numbers following hyphen indicate estimated number of .ccurrences per year.
-------
DEVELOPMENT QE SUBCATEGORY RAW WASTE LOADS
The development of the raw waste loads (RWL) for the non-
integrated paper mill subcategories is discussed below. The
resultant raw waste loads were used in developing effluent
limitations for each subcategory and in determining the costs
presented in Section VIII.
Non-Integrated Fine Papers Subcateggry
The raw waste loads on the surveyed non-integrated fine paper
mills are shown in Table 51. The mills included in Table 51
produce fine papers with the percentage of clays and fillers
shown. As shown the flow ranges from 25.8 to 137.6 kl/kkg (6.2
to 33.0 kgal/ton) with an average of 63.4 kl/kkg (15.2 kgal/ton).
The BOD5 PWL has a range from 7.15 to 19.15 kg/kkg (14.3 to 38.3
Ibs/ton) with an average of 10.75 kg/kkg (21.5 Ibs/ton). The TSS
RWL has an average of 30.8 kg/kkg (61.6 Ibs/ton).
Non-:Integrated_Tissue_PaBers_SubcategorY
Information and data on the surveyed non-integrated tissue mills
are shown in Appendix 8 and summarized in Table 52. Table 52 is
divided into two groups of mills, one using 100% purchased pulp
and the other using varying percentages of purchased pulp and
waste paper. The averages for each group show no difference in
effluent flow volumes with a slightly higher BOD5 RWL for mills
using some waste paper, the flow, BOD5, and TSS RWL for the NI
tissue subcategory are, as shown in Table 52, 95.9 kl/kkg (22.9
kgal/ton), 11.55 kg/kkg (23.1 Ibs/ton), and 34.05 kg/kkg (68.1
Ibs/ton), respectively. Consideration was given to
subcategorizing on the basis of waste paper usage because of the
slightly higher RWL attributed to mills using waste paper.
Evaluation of final effluent data following external treatment
showed that similar final effluent characteristics could be
achieved by similar treatment systems for mills using varying
percentages of purchased pulp and waste paper and thereby further
subcategorization was not warrented. However, mills using 100%
waste paper showed significantly higher external treatment
effluent characteristics due to increased proportions of soluble
BOD5 in the waste water. Thus, a separate subcategory was
established for mills using 100% waste paper to produce tissue
papers.
Non-Integrated_Tissue_Pa2ers_ifwp.l__Subcateggry
Information and data were available from only four mills using
100% waste paper to produce tissue papers. Table 53 summarizes
the RWL data for these four mills. As shown, the data is based
upon very few data points except for mill 320. The average for
all mills irregardless of the number of data points was 105
kl/kkg (25.2 kgal/ton) with an extremely large range of values
from 27.9 to 205 kl/kkg (6.7 to 49.1 kgal/ton). Because of the
large range in flow and the minimal number of data points, the
flow value from NI tissue mills was used as the NI tissue (fwp)
182
-------
subcategory RWL. Mills 330 and 313 both have flow values less
than the NI tissue flow of 95.9 kl/kkg (23.0 kgal/ton). The BOD5
data shown in Table 53 is also quite limited as the mills 330 and
313 only have primary treatment effluent data. A BODS removal
rate of 20% through primary treatment was used to calculate the
BOD5 RWL of 11.5 kg/kkg (29.0 Ibs/ton). The TSS RWL was based
upon NI tissue mills TSS RWL (See Table 52).
183
-------
Table 51
Raw Waste Load
NI Fine Subcategory
Mill
272
253
266
261
257
2C5
250
276
281
275
27,
265
284
402
269
277
279
274
Average
+F(%)
5
9
9
10
10
10
10
10
10
10
12
15
15
20
20
25
25
Size
Ji/tGii}.
23.6 (47.2)N
31.1
22.8
22.1
38.4
-
-
38.4
-
-
31.0
29.2
30.3
43.5
18.2
123.5
-
-
30.8
(62.3)
(45.7)
(44.3)N
(76.8)N
-( - )
( - )
(76.9)
( - )
( - )
(62. o;
(58.4)N
(60.7)
(87.1)
(36.4)
( 247 )N
( - )
( - )
(61.6)
184
-------
Tablj 52
RAH WASr: LOAD
NI TISSUE SUDCATECORY
oo
en
(for
;-.P
G
G
C
0
0
0
0
40
33
-• '
-j ~
33
33
33
23
20
15
Rills)
kkq/da;
141
111
113
926
20
94
67
235
42
258
71
229
13
148
176
59
5120
(156)
(122)
(!25)
(1021)
( * )
( * )
( 22)
(104)
( 74)
(226)
( 46)
(?85)
( 78)
(253)
( 20)
(163)
(194)
( 65)
Flow
k]/kkq(kaa1/tnn'l
115.5
130.9
140,5
66.3
43.4
47.9
120.1
95.1
61.3
153.9
50.9
96.7
97.2
150.5
94.6
69.6
133.4
73.8
72.5
95.9
95.5
(27.7)
(31.4)
(33.7)
(15.9)
(10.4)
(11-5)
(28.8)
(22.8)
(14.7)
(36.9)
(12.2)
(23.2)
(23.3)
(36.1)
(22.7)
(16.7)
(32.0
(17.7)
07.4)
(23.0)
(22.9)
EOD.s
!cn /Urn 11 Kc y-f-^^A
MJ / K. K (j |i i D S / I Q n )
15.7 (33.4)
( - )
- ' ( - )
8.7 (17.4)
( - )
( - )
7.3 (14.7)
10.9 (21.8)
22.8 (45.7)**
( - )
11.7 (23.5)
7.4 (14.8)
15.9 (31.8)
10.0 (20.0)
13.6 (27.3)
14.6 (29.3)
( - )
9.6 (19.2)
( - )
U-3 (23.7)
11.5 (23.1)
TSS
kkg/kkq(1bs/ton)
30.1 (50.3)
- ( - )
(
25.7 (51.5)*
( - )
-
35.3 (71.7,.,
30.1 (60.3)
72 ( 145)**
- ( - )
36.6 (73.3}N
22.4 (44.8)
35.6 (71.2).V
10.4 (20.9).\
51.5 ( 103)
25.2 (50.4).,
-
32.1 (64.3)
- ( - )
35.3 (70.7)
24.0 (68.1)
average-
-------
TABLE 53
RAH WASTE LOADS
HI TISSUE (Mir) SUBCM'LCOir/
Production
Mill
330
320
313
312
kkq/cjc
IS
60
34
14
!y(ton
(20)
(66)
(37)
(15)
FLC.MiOV*
79.2 (]9.0)-NA
109.0 (?6.1)-3
27.9 (6.7J-345
205.0 (49.1J-29
BOD 5
k £/kj< c] ( 1 b s / t
I1. 6 (2?. 2)**
13.0 (26.0)
n.: (23.0)**
rss
kg/kkg(lbs/!:onN
88.0 (176)
133.0 (266)
*NOV-^Number of Values reported
**Primary treetment effluent
186
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SECTION VI
SELECTION OF POLLUTANT PARAMETERS
WASTE_WATER_PARAMETERS_OF_SIGNIFICANCE
A thorough analysis of the literature, mill records, sampling
data which has been derived from this study, and the NPDES data
demonstrate that the following constituents represent pollutants
according to the Water Pollution Control Act for the
subcategories under study:
BOD 5
Total Suspended Solids
PH
Color (Not including Groundwood, Deinked, and Non-Integrated
subcategories)
Ammonia Nitrogen (Ammonia base Sulfite and Ammonia Base
Dissolving Sulfite only)
Zinc (Groundwood subcategories only)
Selection .of Pollutant Parameters
The U.S. Environmental Protection Agency published (Federal
Register, Volume 38, No. 199, pp. 28758-28670, October 16, 1973)
40 CFR 136 "Guidelines Establishing Test Procedures for the
Analysis of Pollutants." Seventy-one pollutant parameters were
covered. This list with the addition of pH, which was not
included, provides the basis for the selection of pollutant
parameters for the purpose of developing effluent limitations and
standards. All listed parameters are selected except for those
excluded for one or more of the following reasons:
1. Not harmful when selected parameters are controlled
2. Not present in significant units
3. Not controllable
4. Control substitutes a more harmful pollutant
5. Insufficient data available
6. Indirectly controlled when selected parameters are
controlled.
7. Indirectly measured by another parameter
187
-------
Biochemical_Oxxgen_Demand_JBOpl.
Two general types of pollutants can exert a demand on the
dissolved oxygen regime of a body of received water. These are:
(1) chemical species which exert an immediate dissolved oxygen
demand (IDOD) on the water body due to chemical reactions; and
(2) organic substances which indirectly cause a demand to be
exerted on the system because indigenous microorganisms utilizing
the organic wastes as substrate flourish and proliferate; their
natural respiratory activity utilizing the surround dissolved
oxygen.
The biological oxygen demand is usually defined as the amount of
oxygen required by bacteria while stabilizing decomposable
organic matter under aerobic conditions. The term "decomposable"
may be interpreted as meaning that the organic matter can serve
as food for the bacteria and energy is derived from this
oxidation.
The BOD does not in itself cause direct harm to a water system,
but it does exert an indirect effect by depressing the oxygen
content of the water. Organic effluents exert a BOD during their
processes of decomposition which can have a catastrophic effect
on the ecosystem by depleting the oxygen supply. Conditions are
reached frequently where all of the oxygen is used and the
continuing decay process causes the production of noxious gases
such as hydrogen sulfide and methane. Water with a high BOD
indicates the presence of decomposing organic matter and
subsequent high bacterial counts that degrade its quality and
potential uses.
Dissolved oxygen (DO) is a water quality constituent that, in
appropriate concentrations, is essential not only to keep
organisms living but also to sustain species reproduction, vigor,
and the development of populations. Organisms undergo stress at
reduced DO concentrations that make them less competitive and
less able to sustain their species within the aquatic
environment. For example, reduced DO concentrations have been
shown to interfere with fish population through delayed hatching
of eggs, reduced size and vigor of embryos, production of
deformities in young, interference with food digestion,
acceleration or blood clotting, decreased tolerance to certain
toxicants, reduced food efficiency and growth rate, and reduced
maximum sustained swimming speed. Fish food organisms are
likewise affected adversely in conditions with suppressed DO.
Since all aerobic aquatic organisms need a certain amount of
oxygen, the consequences of total lack of dissolved oxygen due to
a high BOD can kill all inhabitants of the affected area.
If a high BOD is prespnt, the quality of the water is usually
visually degraded by the presence of decomposing materials and
algae blooms due to the uptake of degraded materials that form
the foodstuffs of the algal populations.
188
-------
The BOD5 test is widely used to determine the pollutional
strength of domestic and industrial wastes in terms of the oxygen
that they will require if discharged into natural watercourses in
which aerobic conditions exist. The test is one of the most
important in stream pollution control activities. By its use, it
is possible to determine the degree of pollution in streams at
any time. This test is of prime importance in regulatory work
and in studies designed to evaluate the purification capacities
of receiving bodies of water.
The BOD5 test is essentially a bioassay procedure involving the
measure of oxygen consumed by living organisms while utilizing
the organic matter present in a waste under conditions as similar
as possible to those that occur in nature. The problem arises
when the test must be standardized to permit its use (for
comparative purposes) on different samples, at different times,
and in different locations. Once "standard conditions" have been
defined, as they have (Standard Methods , 1971) (191) for the
BOD5 test, then the original assumptions that the analysis
simulated natural conditions in the receiving waters no longer
applies, except only occasionally.
In order to make the test quantitative the samples must be
protected from the air to prevent reaeration as the dissolved
oxygen level diminishes. In addition, because of the limited
solubility of oxygen in water (about 9 mg/1 at 20°C), strong
wastes must be diluted to levels of demand consistent with this
value to ensure that dissolved oxygen will be present throughout
the period of the test.
Since this is a bioassay procedure, it is extremely important
that environmental conditions be suitable for the living
organisms to function in an unhindered manner at all times. This
requirement means that toxic substances must be absent and that
accessory nutrients needed for microbial growth (such as
nitrogen, phosphorus and certain trace elements) must be present.
Biological degradation of organic matter under natural conditions
is brought about by a diverse group of organisms that carry the
oxidation essentially to completion (i.e., almost entirely to
carbon dioxide and water). Therefore, it is important that a
mixed group of organisms commonly called "seed" be present in the
test.
The BOD5 test may be considered as a wet oxidation procedure in
which the living organisms serve as the medium for oxidation of
the organic matter to carbon dioxide and water. A quantitative
relationship exists between the amount of oxygen required to
convert a definite amount of any given organic compound to carbon
dioxide and water which can be represented by a generalized
equation. On the basis of this relationship it is possible to
interpret BOD5 data in terms of organic matter as well as in
terms of the amount of oxygen used during its oxidation. This
189
-------
concept is fundamental to an understanding of the rate at which
BOD5_ is exerted.
The oxidative reactions involved in the BOD5 test are results of
biological activity and the rate at which the reactions proceed
is governed to a major extent by population numbers and
temperature. Temperature effects are held constant by performing
the test at 20°C, which is more or less a median value for
natural bodies of water. The predominant organisms responsible
for the stabilization of most organic matter in natural waters
are native to the soil.
The rate of their metabolic processes at 20°C and under the
conditions of the test (total darkness, quiescence, etc.) is such
that time must be reckoned in days. Theoreticallly, an infinite
time is required for complete biological oxidation of organic
matter, but for all practical purposes the reaction may be
considered to be complete in 20 days. A BOD test conducted over
the 20 day period is normally considered a good estimate of the
"ultimate BOD." However, a 20 day period is too long to wait for
results in most instances. It has been found by experience with
domestic sewage that a reasonably large percentage of the total
BOD is exerted in five days. Consequently, the test has been
developed on the basis of a 5-day incubation period. It should
be remembered, therefore, that 5-day BOD values represent only a
portion of the total BOD. The exact percentage depends on the
character of the "seed" and the nature of the organic matter and
can be determined only by experiment. In the case of domestic
and some industrial waste waters it has been found that the BOD5
value is about 70 to 80 percent of the total BOD.
Although the amount of BOD per kkg (ton) of product in the
discharge from an industrial process varies to a large degree
between subcategories, and even significantly from mill to mill
within a given subcategory, the waste waters can essentially be
treated by the same treatment systems.
Total_Susp_ended_Solids
Suspended solids include both organic and inorganic materials.
The inorganic components discharged by pulp and paper mills
include sand, silt, clay and other papermaking additives. The
organic fraction includes such materials as fiber and other wood
components such as lignin, tannins, and sugars. These solids
may settle out rapidly creating bottom deposits which often are
a mixture of both organic and inorganic solids. This bottom
deposit may cover the bottom of the recieving stream with a
blanket of material that adversely affects the fish-food bottom
fauna or the spawning ground of the fish.
The organic fraction of this bottom deposit will have several
adverse effects. It will exert an oxygen demand depleting the
available supply of oxygen. Also anoxic or anaerobic conditions
may be produced which would result in dark colored areas with gas
190
-------
evolution. Another factor attributable to the organic fraction
is the excessive nutrient load associated with high suspended
solids. This can cause aquatic vascular plants to increase to a
nuisance proportions with subsequent interference with
recreational opportunities, development of breeding areas for
insects, and occurrence of an objectionable odor from plant
decay.
The inorganic fraction of the bottom deposit has a major impact
on the toxic materials concentration. Clay minerals and other
inorganic particles have the ability to adsorb materials and hold
them tightly. When toxins are present they will be adsorbed to
the inorganics and an increase in the concentration of dissolved
toxic materials will be realized due to existing waste
discharges.
Of special interest is the BOD or oxygen demand exerted due to
the microbial floe which are discharged from secondary treatment
facilities. The microbial solids in secondary effluent are not
inert and will exert an oxygen demand as the microbes continue to
metabolize. The predominant metabolic reaction is endogenous
respiration which exerts the remaining oxygen demand. The
endogenous oxygen demand is exerted at a slow, continuing rate.
The traditional five day BOD test will not provide a complete
estimate of the total demand of the solids. The total oxygen
demand will be exerted after a long period of time and hence a
long term BOD test is necessary to obtain a reasonable estimate
of such a demand. Therefore it is in the best interest of the
receiving water to reduce the suspended solids level of a
discharge to as low a level as possible.
State and regional agencies generally specify that suspended
solids in raw water sources for domestic use shall not be present
in sufficient concentration to be objectionable or to interfere
with normal treatment processes. Suspended solids in water may
also interfere with many industrial processes and thus
necessitate more extensive treatment before use. Suspended
particles also serve as a transport mechanism for pesticides and
other substances which are readily sorbed into or onto clay
particles. While in suspension, they increase the turbidity of
the ' water, reduce light penetration, and impair the
photosynthetic activity of aquatic plants.
This parameter is a measure of nondissolved solids in the waste
water which are trapped or "suspended" on a test filter medium.
Total suspended solids are divided into settleable and
nonsettleable fractions, the former being those solids which will
settle in one hour under quiescent conditions. Pulp and paper
mill effluents are normally analyzed for total suspended solids.
Most suspended solids of mill origin can be removed by proper
treatment, as described in Section VII. Suspended solids of
biological origin which are generated by biological treatment are
included in the test, but are generally more difficult to remove.
191
-------
The term pH is a negative logarithmic expression of the
concentration of hydrogen ions. At a pH of 7, the hydrogen and
hydroxyl ion concentrations are essentially equal and the water
is neutral. Lower pH values indicate acidity while higher values
indicate alkalinity. The relationship between pH and acidity or
alkalinity is not necessarily linear or direct.
Waters with a pH below 6.0 are corrosive to water works
structures, distribution lines, and household plumbing fixtures
and can thus add such constituents to drinking water as iron,
copper, zinc, cadmium, and lead. The hydrogen ion concentration
can affect the "taste" of the water. The bactericidal effect of
chlorine is weakened as the pH increases, and it is advantageous
in providing safe drinking water to keep the pH close to 7.
Extremes of pH or rapid pH changes can exert stress conditions or
kill aquatic life outright. Even moderate changes from
"acceptable" criteria limits of pH are deleterious to some
species. The relative toxicity to aquatic life of many materials
is increased by changes in pH. For example, ammonia is more
lethal with a higher pH.
As shown in Section VII, the pH of biologically treated wastes is
normally within the 6.0 to 9.0 range, which is not detrimental to
most receiving waters,
Color
Color is defined as either "true" or "apparent" color. In
Standard Methods for the Examination of Water and Wastewater
(191), the true color of water is defined as "the color of water
from which the turbidity has been removed." Apparent color
includes "not only the color due to substances in solution, but
also due to suspended matter." In the various chemical pulping
processes, lignin and lignin derivatives are solubilized and
removed from the wood during the cooking process. The spent
cooking liquors containing these highly colored compounds are
removed from the pulp in a washing sequence following the cooking
process. The wash water is highly colored, and large amounts of
color are ultimately discharged to the receiving stream despite
some recovery operations.
Colored effluents may have the following detrimental effects upon
receiving waters; 1) color retards sunlight transmission and may
interfere with photosynthesis thereby reducing the productivity
of the aquatic community; 2) natural stream color is altered,
thus detracting from the visual appeal and recreational value of
the receiving waters; 3) color has effects upon downstream
municipal and industrial water users, such as higher water treat-
ment costs, difficulties in water treatment, and a multitude of
industrial process operating problems; 4) color bodies complex
with metal ions, such as iron or copper, forming tar-like
residues which remove the metals from the stock available to
stream organisms for normal metabolism, and the complexes can
192
-------
have direct inhibitory effects on some of the lower scale of
organisms in the aquatic community and thereby reduce the
productivity of the receiving water; 5) color, derived from
lignin, is an indicator of the presence of potentially inhibitory
compounds and in addition may have direct inhibitory effects upon
some of the lower scale organisms in the food chain, 6) color in
receiving waters may affect fish movements and fish productivity
7) color bodies exert a long term BOD (20-60 days up to 100 days)
not measured by the BOD5 test.
Ammonia
Ammonia is a common product of the decomposition of organic
matter. Ammonia exists in its non-ionized form only at higher pH
levels and is the most toxic in this state. in more natural
water the pH range is such that ammonia ions (NHU+) predominate
In alkaline waters, however, high concentrations of non-ionized
ammonia in undissociated ammonium hydroxide increase the ^oxicitv
of ammonia solutions. '
Ammonia, in the presence of dissolved oxygen, is converted to
nitrate (NO3) by nitrifying bacteria. Nitrates are considered to
be among the objectionable ingredients of mineralized waters
with potassium nitrate being more deleterious than sodium
nitrate. Excess nitrates cause irritation of the mucous linings
of the gastrointestinal tract and the bladder; the symptoms ar-
diarrhea and diuresis, and drinking one liter of water containing
500 mg/1 of nitrate can cause such symptoms.
Infant methemoglobinemia, a disease charecterized by c^r^-ain
specific blood changes and cyanosis, may be caused by high
nitrate concentrations in the water used for preparing feeding
formulae. While it is still impossible to state pr-cise
concentration limits, it has been widely recommended that water
containing more than 10 mg/1 of nitrate nitrogen (NO3-N) should
not be used for infants. Ammonia can also exist in several other
chemical combinations including ammonium chloride and oth^r
salts. Evidence indicates that ammonia exerts a considerable
toxic effect on all aquatic life within a range of less than 1.0
mg/1 to 25 mg/1, depending on the pH and dissolved oxygen level
present.
Ammonia can add to the problem of eutrophication by supplying
nitrogen through its breakdown products.
Pulp and papermaking waste flows normally contain only minor
concentrations of this nutrient, and nitrogen compound! muJt
of ten be added to provide desired biological waste treatm-nr
efficiencies. As a result, effluent limitations on nitrogen ar-
not considered necessary except for ammonia base sulfi^-e and
ammonia base dissolving sulfite mills.
ioan K representative ammonia
nitrogen levels discharged by these mills, but sparse data
indicate that their effluents contain 1 to 3 kg/kkg (2 to ~6
193
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Ib/ton). No technology is currently available or anticipated for
1983 for removing ammonia nitroqen at the flows and
concentrations found in these effluents.
Zinc
Occurring abundantly in rocks and ores, zinc is readily refined
into a stable pure metal and is used extensively for galvanizing,
in alloys, for electrical purposes, in printing plats, for dye-
manufacture and for dyeing processes, and for many other
industrial purposes. Zinc salts are used in paint pigments,
cosmetics, Pharmaceuticals, dyes, insecticides, and other
products too numerous to list herein. Many of these salts (e.g.,
zinc chloride and zinc sulfate) are highly soluble in water;
hence it is to be expected that zinc might occur in many
industrial wastes. On the other hand, some zinc salts (zinc
carbonate, zinc oxide, zinc sulfide) are insoluble in water and
consequently it is to be expected that some zinc will precipitate
and be removed readily in most natural waters.
In zinc mining areas, zinc has been found in waters in
concentrations as high as 50 mg/1. In most surface and ground
waters, it is present only in trace amounts. There is some
evidence that zinc ions are adsorbed strongly and permanently on
silt, resulting in inactivation of the zinc.
Concentrations of zinc in excess of 5 mg/1 in raw water used for
drinking water supplies cause an undesirable taste which persists
through conventional treatment. Zinc can have an adverse effect
on man and animals in high concentrations.
In soft water, concentrations of zinc ranging from 0.1 to 1.0
mg/1 have been reported to be lethal to fish. Zinc is thought to
exert its toxic action by forming insoluble compounds with the
mucous that covers the gills, by damage to the gill epithelium,
or possibly by acting as an internal poison. The sensitiviity of
fish to zinc varies with species, age and condition, as well as
the physical and chemical characteristics of the water. Some
acclimatization to the presence of zinc is possible. It has also
been observed that the effects of zinc poisoning may not become
apparent immediately, so that fish moved from zinc-contaminated
to zinc-free water (after 4-6 hours of exposure to zinc) may die
48 hours later. The presence of copper in water may increase the
toxicity of zinc to aquatic organisms, but the presence of
calcium or hardness may decrease the relative toxicity.
Observed values for the distribution of zinc in ocean waters vary
widelyl The major concern with zinc compounds in marine waters
is not one of acute toxicity, but rather of the long-term sub-
lethal effects of the metallic compounds and complexes. From an
acute toxicity point of view, invertebrate marine animals seem to
be the most sensitive organisms tested. The growth of the sea
urchin, for example, has been retarded by as little as 30 ug/1 of
zinc.
-------
Zinc sulfate has also been found to be lethal to many plants, and
it could impair agricultural uses.
RATigNALE_FOR_PARAMETERS_NOT_SELECTED
S§ttleable_Solids
Settleable solids are a measure of that fraction of suspended
solids which settles after one hour in a quiescent vessel. While
a few mills have measured settleable solids, reliable data are
not generally or widely available. Since settleable solids are
measured as a part of the suspended solids, settleable solids are
not considered a separate pollutant.
Turbidity,
Turbidity is an expression of the optical property of the fine
suspended matter in a sample of water. The suspended matter may
be clay, silt, finely divided organic and inorganic matter^
plankton, and other microscopic organisms. The suspended matter
causes light to be scattered and absorbed rather than transmitted
in straight lines through the sample. Turbidity is in part.
measured by the total suspeneded solids test and thereby,
turbidity is not considered as a separate pollutant.
Chemical_OxYgen_pemand_JCODl_
The chemical oxygen demand (COD) represents an alternative to the
biochemical oxygen demand, which in many respects is superior.
The test is widely used and allows measurements of a waste in
terms of the total quantity of oxygen required for oxidation to
carbon dioxide and water under severe chemical and physical
conditions. It is based on the fact that all organic compounds,
with a few exceptions, can be oxidized by the action of strong
oxidizing agents under acid conditions. Although amino nitrogen
will be converted to ammonia nitrogen, organic nitrogen in higher
oxidation states will be converted to nitrates that is, it will
be oxidized.
During the COD test, organic matter is converted to carbon
dioxide and water regardless of the biological assimilability of
the substances; for instance, glucose and lignin are both
oxidized completely. As a result, COD values are greater than
BOD values and may be much greater when significant amounts of
biologically resistant organic matter is present.
One drawback of the COD test is its inability to demonstrate the
rate at which the biologically active material would be
stabilized under conditions that exist in nature.
Another drawback of the chemical oxygen demand is analogous to a
problem encountered with the BOD also; that is, high levels of
chloride interfere with the analysis. Normally, O.U grams of
mercuric sulfate are added to each sample being analyzed for
195
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chemical oxygen demand. This eliminates the chloride
interference in the sample up to a chloride level of 40 mg/1. At
concentrations above this level, further mercuric sulfate must be
added. However, studies by the National Marine Fisheries Service
Technological Laboratory in Kodiak, Alaska, have indicated that
above certain chloride concentrations the added mercuric sulfate
itself causes interference.
The major advantage of the COD test is the short time required
for evaluation. The determination can be made in about 3 hours
rather than the 5 days required for the measurements of BOD.
Furthermore, the COD requires less sophisticated equipment, less
highly-trained personnel, a smaller working area, and less
investment in laboratory facilities. Another major advantage of
the COD test is that seed acclimation need not be a problem.
With the BOD test, the seed used to inoculate the culture should
have been acclimated for a period of several days, using
carefully prescribed procedures, to assure that the normal lag
time (exhibited by all microorganims when subjected to a new
substrate) can be minimized. No acclimation, of course, is
required in the COD test.
The relationship between COD and BOD5 before treatment is not
necessarily the same after treatment. Therefore, the effluent
limitations will include the BODS parameter, since insufficient
information is available on the COD effluent levels after
treatment.
Coliform_Organisms
The fecal coliform test is the most valid microbiological
parameter for pulp and paper effluents presently available. The
excessive densities of fecal coliforms and more specifically,
Klebsiella pneumoniae, as measured by the fecal coliform test, in
pulp and paper mill effluents are significant. Klebsiella can
complicate E. coli detection, they can be pathogenic, and they
are coliforms by definition. In addition, Klebsiella are found
in the intestinal tract of approximately 30% of humans and 40%
of animals. Klebsiella reflect the high nutrient levels in pulp
and paper mill wastes. With adequate treatment for reduction of
nutrients, densities of Klebsiella and also total coliforms
should be significantly reduced.
A geometric mean density of fecal coliforms of 1000/lOOmls or
less is generally indicative of adequate treatment.
196
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Acids
soaps of resin acids (isopimaric, abietric, and dehydroabietric)
have been identified as causing biologically deleterious effect
in kraft mill effluents. Studies in Canada indicate that these
compounds are contained mainly in combined condensates rather
r£S!U^ * liq^r. The most recent studies indicate that a
reduction in adverse effects can be achieved by a well designed
and operated biological treatment system. This parameter is not
considered as a separate pollutant parameter for any of *he
^;at??0rie?i becaUSe adec*uate biological treatment systems
generally will reduce resin acids.
PolYChlorinated_Bip_henvls
ah .(PCB'S) are che*icallY and thermally
stable compounds found in paper and paperboard manufacture and
are known to cause deleterious effects upon biological organisms
Exposure to PCB is known to cause skin lesions and to increa^
liver enzyme activity that may have a secondary effec^ on
reproductive processes. it is not clear whether the effects are
due to the PCB's or their contaminants, the chlorinated
dibenzofurans, that are very harmful, while chlorinated
S^£ IS*118 are a byProduct of BCP Production, it is not known
whether they are also produced by the degradation of PCB's. They
have been shown to concentrate in food chains and few
restrictions for their control exist at present. Recycled office
Pi?h™S nare m^n source in the PaPer industry at present,
although occasionally paperboard extracts show evidence of
Monsanto- s Aroclor 1254 (PCB) from environmental and other
S^f'i QUT^ieS,°f^ PCB ±n rec*cled PaPer are generally
between 1 and 10 mg/1, but may be more or less.
Seavv_Metals
o™*o meta3s .occur in paper mill effluents as corrosion
products, contaminants of bleach chemicals and caustic solutions
and as a result concentrating trace metals in cooking and recycle
S^nXi1?18; x?°We^r' With the
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SECTION VII
CONTROL AND TREATMENT TECHNOLOGIES
The pollution loads of effluents discharged to receiving waters
from all subject subcategories can be reduced to required levels
by conscientious application of established in- plant process
controls and water recycle measures together with well designed
and properly operated external treatment facilities.
This section describes both the internal and external
technologies which are either presently available or under
intensive development to achieve various levels o* pollutan4-
reduction for each of the subcategories. in some casps »in-
plant" and "external" technologies merge. For exampl-, a mill
may employ extensive suspended solids removal eguipm°nt
internally, reusing the clarified water in the process and the
recovered solids in the product, whereas another similar mill may
depend to a greater extent on "external" suspended solids removal
to arrive at a similar end point.
Tables 54 and 55 summarize present use of alternative internal
and external technologies among the mills surveyed Th<=>
percentage of use of the internal methods by the surveyed mills
can be expected to be representative of the degree of utilization
by all mills in a subcategory. The use of various external
treatment technologies in each subcategory is discussed more
specifically later in this section.
In those discussions, and in the internal control subcategory
discussions, where numbers of mills are given by type of pulp
produced, these numbers refer to the mills assigned to that
particular subcategory according to the criteria discussed in
Section Hi. This is done to eliminate the duplication of mills
which would occur if complex pulping operations were reported in
more than one subcategory.
Present control and treatment technology precludes zero discharge
of pollutants in virtually all subcategories although a few non-
integrated paper mills have approached this goal. As discussed
in Section V, significant water use reductions have occurred
in
™ f!fbcjtec?ory during recent years and new means are
continually being found for increased water reuse.
The products manufactured are a crucial determinant in the degree
of recycle possible for a given operation (181) . For example, in
contrast to the non-integrated papermaking operations mentioned
S u * !*ere 1S n° Proven combination of systems by which
bleached kraft and other chemical pulp mills can be designed and
operated at zero discharge on a continuous basis (182) . One of
the surveyed paper mills, on the other hand, has no pulping
capacity and produces less than 18.14 kkg/day (20 tpd) of coarse
toweling paper, a product whose specifications permit complete
199
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Table 54
INTERNAL MEASURES USED AT SURVEYED MILLS
o
o
[Percent Used* _ —
Knots collecting and disposal
Fn-.irth stage brown stock washer
Decker filtrate for stock
washer showers _
Pulp mill spill collection
Jump stage counter current
washing in bleach plant
Evaporators boil out tank
GWD
14
S E
7 22
14
14
BK
26
S
46
0 Q
Jo
38
O ~J
LI
76
_=LL
E
73
62
1?
0 "I
jJL
30
3
S E
33 34
f\ i j f
34 66
00 "If,
100
s_
so
50
50
50
S DS
4 4
E S E
50
25 50
25 50
25
25 100
D F T C
9 17 16 9
SE SE SE SE
11 56
11 56
??. 34
Liquor storage tank spill
collection
27 19 33 34 50 25
Reuse of blow steam & evaporators
condensate
Green liquor dregs filtering
High level alarms for chemical
tanks
Hot water collection and reuse
Paper machine saveall
54 27 33 34
46 24 33 34
27 19 33 34 50 25
22 34
71 fi2 30 66 34 75 25 50 50 "?? 44 56 17 31 25
14 43 23 62 _346650L50__2L-^1L^_5JO2^5J9
Paper machine high pressure
showers
Paper machine white water
showers
8 11 33 34 50
75
22
Vacuum pump seal water reuse
Cooling water segregation and
reuse
58 35 54 l\r- 34 36 50 50 100
75
24 38 11 ..33.
38 62 56 33
7
19 19 34
_____
44 44 28 16 18 44 11.3_3_
7 7
34
75
Felt hair removal
Sulfite liquor recovery
or incinerat
7 /
19 19 34
75
Ji*_A*__-2SL.16_JJL±A_1LJ1
44 44 28 16 18 44 11 33
50
25
* % S = % of Mills using to some degree
% E = % of Mills using to an extensive degree
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Table 55
EXTERNAL MEASURES USED AT SURVEYED MILLS
Number of Mills
Kuaber and percent used*
Bar screen
Continuous sampler flow measurement
Air flotation
Activated sludge
Aerated stabilization basin
Secondary clarifier
Mechanical dewatering
Sludge press
Incineration
Landfill
Sludge lagoon
Post storaee
6
Mixed media filtration
Sludge lagoon (emergency)
Trickling filter
Spray irrigation
Thickeners
Sludge dryers
GWD BK
19 36
f Z
9 47 10 73
1 5
3 16 4 11
5 26 35 97
2 11 38
SEGMENT
SO S D
3 11 15
# % . # % # %
2 18 1 7
^36 1 7
X Q "17
1 33 5 45 5 33
1917
1 9
1 9
F T
21 25
8 38 12 43
, ^ ^
•i- 5 14
3 14 3 12
5
•>! CQ
2J. 58
33
AS
3 14
*Additional Deink Mills which manufacture news not included.
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recycle of process water. Another mill, producing 36.28 kkg/day
<40 tpd) of tissue, accomplishes zero discharge by clarifying and
filtering white water for use as paper machine showers and seal
water, although some white water is directly recycled for stock
preparation and dilution. This is economic for this small mill
because of its product and size in relation to its arid
geographic location.
It is also a much simpler system than would be required for
chemical pulp and fine paper mills. This is especially true
where there are numerous changes in product grades, a situation
where there presently appears no way that high levels of reuse
can be consistently achieved (181) .
The difficulties encountered by mills in all subcategories as a
result of extensive recirculation are discussed in more detail
later in this section.
Briefly, in addition to variable product quality, they include
scaling corrosion, foaming, slime deposits, paper formation
problems, and decreasing wet felt life. Perhaps the most
significant factor is that recycle processes tend to concentrate
wastes and the concentrates still require disposal. In order to
burn this material, and thus convert it to gases, it must be
evaporated in most experimental zero discharge technology.
Evaporation requires cooling, cooling at these temperatures re-
quires water, and recycling the water will necessitate heat
removal (183) . These processes in turn will increase power
requirements.
INTERNAL_TECHNOLOGIES
General
mtorna control measures are procedures to reduce pollutant
Sscnarges at thSir origin, som? of which result in the recovery
of chemicals, fiber, and by-products and in conservation of heat
and water. Similar methods are available *° *" *ub^*
subcategories and include, where applicable, effective pulp
washing, chemical and fiber recovery, treatment and reuse of
selected waste streams, collection of spills and prevention of
accidental discharges. New processes to reduce P°Uutant s
.
are continually being developed and are being JJ0^"*!* j£°
new mills and, where feasible are being retrofitted into existing
mills.
Generally, mills which reduce raw waste loads concomitantly
reduce effluent flow through recycle.
A waste management program should include control of losses w
occur when the production process is not in equilibrium sucn as
soills overflow! and wash-up. These losses may account for one-
?hird to one-half of ^suspended solids and BOD^ of the raw
waste and can result from a variety of factors, as discussed in
202
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section V. These include breakdown of equipment, routine
maintenance, planned shutdowns and startups, power failures, and
grade changes. Where as mill production operations mav be
regarded as a continuous sequential balanced series of unit
operations, in fact there exists a discontinuity in practice
making spills, overflows, and accidental discharges a common
problem as regards both internal control and influences on
external waste treatment facilities. Continuous monito-ing
within mill sewers (especially conductivity) should be employed
to give immediate warning of unknown spills so that corrective
action can be taken promptly. Personnel should be trained to re-
spond with immediate remedial procedures in addition to avoiding
such spills where possible. In some instances automatic
diversion devices operated by conductivity measuring instruments
are employed.
Good practice also includes the use of storage facilities
adequately sized to avoid overflows of spent liquor and
recovering plant chemicals in approximately 90 percent of process
upsets. Provision should be made to return these stored
materials to the originating subprocess at a later time.
If overflows would cause treatment plant upset or increased
discharge of pollutants, production should be curtailed as
necessary if the overflows cannot be prevented by some orher
means. Sewer segregation can be utilized, especially in new
mills, to minimize these impacts, in conjunction with ad
storage.
to
Storage lagoons located prior to treatment may be provided ru
accept longer term shock loads, the contents of which" can then be
gradually returned to the process or diverted to treatment
without detriment to treatment operations. Provision of sto-age
lagoons also provides some period of time to correct malfunction
of external treatment operations or offers temporary facilities
for solids sedimentation if properly designed to satisfy such
uses.
A storage tank should also be provided to contain material
flushed from the evaporators during periodic "boil out," a
maintenance procedure to remove scale and incrustations which
interfere with efficient evaporator operation. This material can
then be slowly returned to the process when it is again in
operation.
Fresh water used to cool bearings, variable speed couplings,
brake linings in paper rewind applications, and similar areas
throughout a mill can be collected and reused. It is not
contaminated ar.d can be recycled either directly after heat
removal or indirectly by discharge into the fresh water system if
heat buildup is not a problem.
Water used to cool condensate from steam dryers can similarly be
reused but because of high heat loads it is usually necessary to
cool this water with cooling towers or other means. it is
203
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practical in some cases to return dryer condensate directly to
the feed water heater at the boiler plant under 1.2 - 1.34 atm
pressure (3-5 psig pressure) , thereby reducing the cooling water
requirement. This approach is more feasible where dryers are
operated at pressures above 1.34 atm (5 psig). While a reduction
in cooling water discharge does not minimize the pollutant load,
it does reduce the total volume of waste water to be treated,
thus decreasing the capital and, in some instances, operating
cost of waste treatment facilities.
Seal water is used on packing glands of process pumps, agitators,
and other equipment employing rotating shafts. It cools
bearings, lubricates the packing, and minimizes leakage of the
process fluid. Even though the amount of water used per packing
is small — generally in the range of 2 to 11 1/min (0.5 to 3
gpm) — the total utilized is quite extensive because of the
large number of rotating shafts involved and may approximate
4173-8346 1 (1000-2000 gal) per kkg (ton) of product. Methods
used to reduce quantities of water required include proper
maintenance of packings and flow control of individual seal water
lines. In some cases, seal water which leaks from the packing
can be collected and reused, usually after filtering.
As discussed in Section III, barking of wood prior to pulping is
most commonly performed by dry processes which require very
little water. This practice is more desirable than wet barking
since raw waste loadings are considerably reduced. The small
amounts of effluent from dry barking are preferably settled and
recycled but are normally disposed of on the land or combined
with the general flow of mill effluent.
Reduction of waste loads from wet barking can be achieved through
recycle of most of the barking water. If recycled water is to be
used in hydraulic barking, however, a high degree of solids
removal must be obtained to prevent erosion within pumps and
barker nozzles.
As the forest products industry continues its trend toward
maximum utilization of the tree, it is likely that more wood will
be delivered as chips and less roundwood will be barked by pulp
mills, thus reducing or eliminating waste water discharges from
this source.
There is little documentation to quantify the magnitude of
reductions in raw waste due to the application of a particular
technology. However, the reduction in raw waste loads
experienced over the past 10 to 15 years is attributable to the
successful application of the control measures described in Table
54. This table summarizes, by percentage, the application of
internal control measures in the mills surveyed. Blank spaces in
this summary indicate that the particular technology is not
applicable in that subcategory.
204
-------
hn0 fr°m 9roundwood mills can be reduced by aood
housekeeping water reuse, and recycling of screen reject!. SSst
of the nails studied practice good housekeeping, keeping spills
to a minimum and controlling the use of gland seal wa?er so that
quantities are minimized. To the contrary, howev.rTi? was found
shou^!^3 frSm^UlP *creenlng are sewered in some mills? ?£y
should be passed through a reject refiner as described in Section
III and returned to the process ahead of the screens. bectl°n
The groundwood mills surveyed represent 40 percent of the total
s
percent of these mills are reusing vacuum pump seal wa?Sr
coolzng waters. A more detailed description of ?he techno l
0
. as
arss ^tS-
expensive corrosion resistant material throughout.
205
-------
Sulfite_and_Dissolying_Sulfite_Subcat.eaories
The eiqht sulfite pulp mills surveyed represent 32 percent of the
mills in the sulfite and dissolving sulfite subcategones and
were divided equally between them. The waste load of this
subcategory is being reduced through switching to kraft pulping,
Changing from a calcium to a soluble base and burning the liquor
"(with or without chemical recovery) , and producing byproducts
from it.
As discussed in Section V, the performance of sulfite recovery
systems is less effective in reducing sewer losses than that ot
kraft systems because of the large quantity of acetates and
formates appearing in the condensates. Although methods for the
recovery of acetic and formic acid in soluble form have been
developed (47) (48) (49), the market for these acids is such .hat
it does not represent a dependable means of solving the problem
of their disposal on a continuous basis for more than an
occasional mill. Presently on-going research (290) involving
steam stripping and activated carbon adsorption of volatiles for
fractionation may produce a commercial process for removal of
methanol, acetic acid and furfural from sulfite condensates.
However, by pre-neutralizing the spent liquor, 90 percent of the
BOD normally contained in the condensates can be retained in the
liguor and ultimately burned.
At present, fifteen of the operating mills, representing
approximately half the total sulfite production, burn the liquor.
The continued operation of eight others for much longer is
doubtful and most of the remainder are definitely committed to
burning in the near future.
A total of eight mills manufacture byproducts ranging from simple
evaporates used for road binder and cattle food additives to some
more sophisticated formulations and intermediates used in
adhesives, dispersants, tanning agents, drilling mud additives,
etc Since all of these products account for only about 10
percent of the liquor solids produced and for other reasons as
well, they do not represent a complete or permanent solution to
the liquor problem. Two mills produce food yeast and one mill
alcohol from fermentation processes utilizing the wood sugars
contained in sulfite liquors.
Two mills (95) which have converted from calcium to magnesium
base and incorporated liquor recovery have achieved BOD5
reduction of 82 and 87 percent.
Of the eight surveyed mills five are presently using liquor
incineration or recovery, one disposes of its liquor by ,he
manufacture of byproducts; and the other two are presently
installing recovery systems.
The ma-jority of sulfite and dissolving sulfite mills were found
to r"euse filtrates on brownstock washers. Seventy-five percent
206
-------
of them have liquor and stock spill collection and storage while
50 percent utilize steam stripping and reuse of condensates.
All of the mills surveyed recirculate some white water for use on
machine showers and the majority of them use high pressure
showers. These mills also collect and reuse some process hot
water. Paper machines in the surveyed sulfite mills all
incorporate savealls to reduce suspended solids in their
effluent.
Internal technology for effluent reduction in the bleaching of
sulfite pulps is included in a later section. Bleaching of
Chemical Pulps.
Bleached Kraft Subcategorv
•^ "*•••*•••'• "' ' !•••••-• I II • | _» ^ ^-..^.^.^_—^ J»»__ J^
In older practice, the decker filtrate accounted for a major
portion of the sewer losses in bleached kraft mills. After
washing, the pulp was diluted to about one percent consistency in
order to promote effective screening for the removal of knots and
shives. Thickening on a decker was then required to raise the
consistency for storage purposes. The water removed by the
decker which contained spent liquor not removed in the washing
process typically accounted for one-third or more of the total
BOD5 loss from the mill. Improved washing techniques have now
reduced this loss to below a third of the total loss in terms of
BOD.
Attempts to apply hot stock refining to reduce the dilution
requirement before screening have not been successful in bleached
pulp production. Newer type deckers actually provide an
additional washing stage which is beneficial to the bleaching
operation and lowers the pollution load contained in the bleach
plant effluent due to spent liquor carryover (297). in addition
less bleaching chemical is required when the brown stock is well
washed (298) (8) .
While there is a potential for further reducing the pollutants in
the decker filtrate by providing greater washing capacity, it has
been pointed out (20) that this procedure, if carried too far,
succumbs to the law of diminishing returns. Beyond a range of
soda loss of 7.5 to 10 kg (15 to 20 Ib) per kkg (ton) of pulp,
the recovered liquor is diluted to a point where evaporation
capacity and attending heat requirements exceed the benefits
derived.
Digester and evaporator condensates are also recognized as
principal BOD contributors to the effluent load from kraft mills
Consequently, considerable effort is expended in most kraft
operations to consume as much of these condensates internally as
possible by substituting them for normal fresh water make-up
applications. The condensates are more frequently used in brown
stock washing and in causticizing make-up. Use of condensates in
207
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lime kiln stack scrubbers and dissolving tank make-up is also a
common practice (58) .
Despite the extensive condensate recycling practices, these waste
streams still constitute, collectively, a serious source of air
and water pollution from kraft operations. Many of the problems
related to condensates evolve from the recycling practices
themselves. In ideal waste recycle the waste stream would be
totally consumed in the process ~ i.e., the polluting materials
destroyed by incineration or homogeneously assimilated into the
process streams. This, of course, is not entirely the case with
condensates. Since condensates in general are black liquor dis-
tillates, a large fraction of the offending chemical substances
involved are volatile substances which are not amenable to the
basic black liquor processing scheme. If this were not so, the
materials would not have distilled during the formation of the
condensate steam. Recycling the condensate may thus result in a
gradual increase in the concentration of the volatiles in the
process stream involved, consequently, distillate slip s^'reamf
from the process may become enriched with these volatiles to the
extent that serious air and water pollution problems occur in
areas where no serious problems exist without the recycling
practices. The observed increase in BOD concentration of multi-
effect evaporator condensate with extensive recycling of
condensates to brown stock washers may serve as an example.
Recycling of condensates to the causticizing system may also
result in similar problems. Elevated temperatures at the
recovery dissolving tank, slaking and causticizing area, and lime
kiln area may provide a means for purging recycled volatiles from
comLnsa?es to the atmosphere. Since many of these volatiles are
maloSrous, it is obvious that the kraft mill odor problem may be
greatly enhanced by the recycling practice. Normally innocuous
emission sources, such as tank vents and vacuum pump exhausts,
may also become fortified through extensive condensate recycling.
Extensive condensate recycling may also create operational
problems. For example, the necessity for increasing wet strength
additive usage has been linked to multi-effect evaporator
condensate in brown stock washing. In addition, momentary black
liquor carry-over in condensate streams recycled to the
causticizing area may seriously disrupt the normal liquor -making
process. Unquestionably, many of the side effects of the
recycling practices have yet to be defined.
The condensate streams from the continuous Pulping
markedly from those of batch operations. The continuous
blow generally occurs at a lower temperature and pressure than
tnat or the batch cook. Thus, the evolution of distillates in
this function is inconsequential in comparison to their
production by a batch counterpart. On the other hand, relief
condense, characteristic of the batch cook, does ^ occur as
such in the continuous cook. However, condensates from
continues digester steaming vessels may be compared with batch
digester relief condensate.
208
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Methanol accounts for about 80 percent of the organic content of
evaporator condensates and for most of the BODS (96^ S-her
alcohols, ketones, and small quantities of phenolic substanc^
sulfur compounds, and turpenes account for the remainder'
Because of the odorous compounds, reuse of those condenses has
been restricted by air pollution considerations. This led, "aboS?
10 years ago, to a search for technology to remov- such
St?nSvX Steam stripping of condensates has been studied
extensively for this purpose (97) (98) (591 rqqi anri ^=,0 K^~
successfully applied at tw£ bleac'he^krLS iinL in this^ountry
and by several abroad. Recently reported application of s?eal
7Srip?i^ technology applied to kraft condensates indicates that
75 percent of the condensate BOD5, due principally to methanol
may be removed without difficulty and without odor problems
\£ j J.) .
iiTva?^^01 ^ readily o«idiZed by biological treatment there
is a valid question as to whether it is more economical to remove
that7 ^ripplng or in the effluent treatment plant. it is lik°Iy
±\ "?L a?!rL!" ^i!.questi0" is different from mill to mm
Inert materials originating in the wood and make-up chemical <,
must be removed from the kraft chemical recovery and
ra
Vr!Parat°n Proc*ss- T^se are contained n e rg
settled from the green liquor and in the grits separate? in -'fa-
lime slaker. Separate land disposal of these nJ-erialS **
'
it3rnatiVf m?thod of kr*ft chemical recovery is und-r study
hydropyrolysis recovery process (101) subjects the black
liquor to pretreatment which produces a low ash char and a liuSr
u.e K °f the S°diUm- A standard pwr
used to burn the char and recover its heat value and
conventional recausticizing converts the liquor to white
'
as ith r e
as we^l as the opportunity to produce new byproducts
particularly activated carbon from the char?? A recen- Fp
report (292) on this work indicates development of a
n^
oxygen pulping produced a nontoxic waste water which waS low ?^
ssu-s tS-.^-L^: ne^s?L^-n:ffint-£ - -a
several oxygen pulping means under investigation ifevidSnt in
209
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this country as well as Japan and the Scandinavian countries. A
recen? symposium (293) served to update progress xn this area of
research.
Thirtv-six percent of the 74 bleached kraft mills were surveyed
to provldeP dSS for this report. All of the surveyed mills are
Sa •r.sss
pollutants discharged.
. useor
flllta+ll for countercurrent washing. Sixty-two percent of the
mills are making extensive use of these methods.
seal water
Soda_Subcateggry.
~ rU»c.Ptl» discharge of pollutants.
cooling water.
210
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II§§Siiin3_of_Qheinical_ Pulps
oi!™-redUCt^°n °f the P°llution ^sses from bleacheries handling
chemical pulps can only be effected by process change despite the
drastic reductions in effluent volume frequently possible "to
achieve. While water recycle in bleach plants has advance?
remarkably in recent years, with flow from high brigSnSss
bleaches dropping to as low as 25,000 1 (6000 gal) of fresh water
per kkg (ton) of product (104), no reduction in polluJJon load
accompanies water economy. This is because^ conventional
bleaching is dependent upon the removal of color bodies and in
?^n?0 S" chemically some hydrolysis occurs and some materials
are leached from the pulp. These pollutants are not normally
"SI6? ^ *eCaUSe Of their dilu^ nature and high chlo?i£
content which is corrosive to recovery systems (299) and which in
rlcvcJrdo^H10* ^ the, Smelt Can Cause ^Plosions. water
£rS?ipn? V£°WeVer' redUCe thS t0tal VOlUme of water requiring
plants? consequent savings in size and cost of treatment
Some reduction of bleach plant pollution load can be achieved by
controlling digestion where possible in order to remove *
bLaSh
Reduction in effluent flows can be achieved by countercurr^nt
recycling of shower and seal box waters. This is pSslible in
f^rt ? Plant conf ^rations, eliminating Ilows?oiew4s
from downstream stages. Three main types of countercurreSt
washing are used in bleacheries -direct, split-f?^ and iS
ertlu^n, DTCt COUntercurrent washing produces the Last
S ^ M some cfunter cur rent washing is practiced by 90 p-rcent
ull^L i ^—^ mlllS surveVed- The jump stagj process is
utilized by a majority of the surveyed sulfite and dissolvina
sulfite mills and to some extent by 111 three soda mills g
re1tric?ed°fn J°u"tercurrent "^ in existing mills, however, is
restricted in that serious corrosion problems are encountered
stra±r r^aCt6d ^ chlorine ^o^i^e filtrates are not o?
stainless steel. Partial or jumpstage washing can be used
*
washer and pipeiine
Paper mill white water or excess mill hot water can be used as
Snlv"?n ? ?r f°r the f±nal Stage Washer and fresh water
only in time of process problems. The use of 317 stainless
eliminates shower corrosion but shower pluggage haT
problems in some mills, some readjustment of chemical
rates are required as is PH adjustment in some systems
washfnaralh^11S in addijio" to limiting water use countercur-ent
washing has considerably reduced steam requirements fioui
Laboratory and mill trials have shown (105) a Sten?ial for
n a
considerable reduction in water use in bleacheries b? emnatna
some pulp washing without, affecting brightness ^nd Semical
211
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consumption. In a five stage operation bleaching softwood kraft
pulp, it was possible to eliminate washing after the first
chlorine dioxide stage. In a five stage hardwood kraft
bleachery, the washing following both the first chlorine dioxide
and the second caustic extraction stages was successfully
eliminated. countercurrent washing should be discontinued when
dirt is encountered in the bleach plant to avoid prolonged dirt
problems.
Rapid chlorine dioxide bleaching at intermediate consistency has
been found to be chemically feasible and appears practical
economically, using less chemicals, water, and steam (108).
Operating conditions, especially temperature and pH, are more
critical and must be controlled more carefully. Suitable
equipment is being developed for this process and is being
installed in a southern mill.
In kraft mills where prehydrolysis is practiced, as is the case
in all kraft dissolving mills, the bleachery losses can be
reduced if the prehydrolysis step is accompanied by a soft cook.
In this case more organic matter goes to the recovery furnace
with the spent cooking liquor. In some instances the
prehydrolysate is added to the weak black liquor as a means of
disposal. Because of the low solids content of the hydrolysate
this is a relatively high cost practice and requires that higher
than normal evaporation capacity be provided. While low in
solids compared to weak liquor, the prehydrolysate contains wood
sugars and wood acids providing an added BOD5 load if discharged
to external treatment facilities. It appears possible that
membrane processes might provide suitable fractionation of the
several components to produce byproducts of value.
Prehydrolysate is used as a nutrient source for growth of food
yeasts in the USSR.
A process change for reducing high losses from the production of
sodium base sulfite dissolving pulp is being installed in a
southern mill (118). In simplified terms, soda based pulp from
the digester stage is drained of a portion of the waste liquor
and passed directly to the hot caustic extraction stage without
washing. After hot caustic extraction, the pulp is washed and
the wastes removed in washing are added to the digester waste and
the combined wastes are then concentrated and burned. It is also
possible to utilize the concentrated caustic liquor as salt cake
make-up in the kraft process. This is expected to achieve 90
percent reduction in BOD and color.
Other process changes such as oxygen bleaching give promise of
reducing bleachery losses, especially with respect to color
bodies and inorganic materials, particularly chlorides. There
are indications (106) (117) that the wash water from oxygen
bleaching stages can be introduced into the kraft recovery system
since it is relatively free of chlorides. However, magnesia is
added in this process (140) and it could result in accumulative
problems in the liquor system. A change to oxygen bleaching
involves high capital investment in the bleachery and a plant to
212
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produce oxygen and, since other bleaching stages continue to
utilize chlorine compounds, not all bleach plant effluent is
eliminated. However, the existance of a mill operated oxygen
production plant, producing in excess of that needed for
bleaching, allows for other oxygen uses as black liquor oxidation
or supplemental addition to the lime kiln as required. °XiaatlOn
Laboratory studies do indicate (105) , with 100% reuse of oxygen
color 1aJUq?«; f JedUCti°nS in BOD (81«) . COD, chlorides and
h= ^ <89-92%). Such oxygen stage effluent is evidently easily
handled by conventional secondary treatment facilities as BOD
reductions ranging from 75-97% were obtained employing aeration
periods of 1 to 10 days. The U.S. krafr mill with In opting
Sflili: Alea£hlng Systf.m P^icts that recycling the oxyge^ Jtagl
effluent to brown stock washing could result in BOD and color
reductions of about 60 and 90 percent respectively from ^he
levels produced by the conventional CEDED sequence (177) As a
^J* refinement on this approach, experiments have indicated
that the use of an oxygen stage alone as part of a brown stock
S3 n9pnSy8tr TUld reSUlt in Ver^ clean beaching (81) . and
reduce BOD and color of total mill raw waste load by lo and 70%
respectively obtained by a reduction in the bleach load of 70-80%
BOD and in excess of 90% color difference as compared to
conventional bleaching sequences. v-wny«ea ro
ren9Q oxv<*en bleaching have been more fully
BOD? anrt n(i } ^ SUpP°rt ^rller information as to significant
BOD5 and color reductions when oxygen bleaching is employed.
A Swedish kraft mill employing oxygen bleaching as a first stage
has incorporated a large surge tank 510,000 1 (135,000 gal) for
Sffi^ C°n*r01- By. containing the oxygen stage wash wlter with
tSfIonrioaf weening system effluent, it anticipates reducing
the BOD load more then 50 percent and discharged color by 70
percent over conventional systems. Y
f?Und, (110) (111) that ox^en Beaching can also be
ouns mpl°yed as a Pre-bleaching stage for sulphitJ
pulps. The oxygen stage is capable of delignifying pulps to a
low lignin content with simultaneous preservation of viscosity
nollu?^oanta9;S -,°f *he1 process in chemical recovery and wat^
pollution control are only achieved with a sodium base cooking
process in which the oxygen bleaching stage provides sodium
wLh?™e5Uin Se^ti0n V' pilot Plant experience indicates that
washing between stages may be eliminated by the new displacement
bleaching process and effluents reduced to the amount of water
introduced with new chemicals. cu-iuunr or water
H-K - the Rapson
rrvr M« • . 2 * h bleaching ^stes concentrated by
recycling are introduced into the recovery system with the black
liquor. Chloride content of the liquor system is controlled £y
evaporating white liquor to a sufficiently high concentration to
213
-------
allow sodium chloride to crystalize out (115) . Total chlorides
in the system are reduced by replacing most of the chlorine used
in the chlorination stage by an equivalent amount of chlorine
dioxide (116) . The salt obtained can be used in the production
of chlorine dioxide by the R-4 process (117) . The Rapson process
has been tested in a pilot plant and a full scale operation is
planned at a Canadian mill. Both of these processes are
described in Section III.
No dominant system for secondary fiber pulping and deinking has
emerged from the many different systems developed for these
processes. The significant differentiations are whether the
process is batch or continuous, hot or cold, low consistency or
high consistency, and whether it uses countercurrent washing or
flotation as the main ink separation process. Technology for the
reduction of pollution within these systems differs greatly and
is often unique to a single mill. Hence only general comments
are included in this section.
Pulp which is still contaminated after the process should not ^be
discharged to the sewer but should be run over a wet lap machine
for disposal or sale to a mill capable of using a lower grade of
stock.
The flotation deinking system does not remove clay and dissolved
contaminants so it has a cleaner effluent than a washing system.
However, these contaminants appear in the paper mill effluent
unless a closed water system is used in this area. A special
solvent process is the only truly closed system (119) ; the
contaminant removal operation generates no liquid effluent, and
the contaminants are discharged in a dry state. The economics of
this process, however, are such that only one small plant is in
operation in the U.S.
Survey data was obtained from 53 percent of the 17 mills in this
subcategory. Of these nine mills, 67 percent reported using
countercurrent brownstock washing and 50 percent were found to be
operating spill collection systems. Seventy-five percent of the
mills using multistage bleaching are making extensive use of
countercurrent washing in the bleachery. Process changes have
recently been made in 22 percent of the surveyed mills to reduce
the liquid effluent.
All paper machines associated with the surveyed deinking plants
recycle white water with 66 percent using extensive recycle and
50 percent using high pressure showers. Paper machine savealls
are used in 66 percent of these mills and almost 90 percent of
those surveyed reuse some cooling water and vacuum pump seal
water.
214
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Since the papermaking process is virtually identical in all
subcategories, this discussion is applicable to each of them.
Recycling of white water within the stock preparation/papermaking
process has long been practiced in the industry. in the last 10
years further strides in reuse have been made. Problems
associated with increased reuse usually manifest themselves in
reduced machine speed and/ or product quality. Slime growth du«
to increase of BOD5 and temperature has been encountered This
problem can be reduced by the proper application of biocides, by
better housekeeping, and by design for higher liquid velociti-s
in pipelines, shorter detention time in tanks, and avoidance of
pockets in the system. Scale buildup is another problem which
can be reduced, principally by chemical and mechanical design
techniques. Buildup of dissolved solids can also cause produc-
guality problems, but in the typical case, reuse is limited by
slime growth and scale buildup. Combinations of temperature " and
dissolved solids buildup interfere with sizing and other chemical
reactions. In addition, corrosion is a significant factor in
increased recycling within the white water system.
Most mills employ a saveall to recover fibrous and oPr
suspended material escaping from the paper machine. Thi-~ is
considered by many mills to be a necessity for both economic "and
pollution control reasons, although some mills can obtain
equivalent results by other means. Savealls ar- of three
principal types. The older type consists of a screen covered
drum immersed in a vat through which the water passes leaving a
mat of fiber. This is removed continuously for reuse directly in
the manufacturing process. A number of improved variations of
f if i?e are ^ rS WhiCh emPlQY filtration through the mat of
fiber These include the cloudy port drum vacuum filter and
-raveling wire devices operating on the same principle. Second
is the newer disc type, which utilizes a series of scr-en-covered
discs on a rotating shaft immersed in the vat. The action is
similar to the drum saveall, but the disc type has the advantages
both of ^ * ring area Per Unit V°lume and the use of vacuum,
both of which reduce space requirements. in both of ^hese typos
of savealls a side-stream of "sweetener" fibrous stock is add-d
removal % ?h tO impr°Ve^he efficiency of suspended solids
removal in the main influent feed. The third type is *h«
dissolved air flotation saveall (DAF) . In this type unit air
bubbles, formed on the dissolution of air under pressure, at-ach
themselves to the fibers, causing them to floa* to -he surface
where a continuous mechanical rake collects them for reuse.
its f?i*?MvTe Sa^alK haS en^0ved rec-nt Popularity because of
its flexibility and higher removal efficiencies in most cases
In addition it _ provides a positive barrier for fibers
., . . , , --r- ------ " ^oj_cj.vc uctxzier ror rioers prev^ntina
their introduction into the clarified white water thus preventing
problems arising on reuse. fj-cvfu ing
215
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Clarified effluent from savealls is on the order of 10,433-25,038
1 (2500-6000 qal) per kkg (ton) (58), with a suspended solids
content of 120 mg/1 or less, whereas the influent may contain
2398 mg/1 or more.
All or a part of the clarified effluent may be discharged
directly to an outfall sewer, but most mills reuse a significant
portion of it for such services as (58):
1. Vacuum pump seals
2. Machine showeis
3. Stock cleaner e3 utr i ation
U. Cooling waters
5. Pulp washing
6. Wash-ups
7. Consistency regulation dilution
8. Barometric evaporator condensers (pulp mill)
9. Repulping of broke and purchased fiber
Water showers are used in both the forming and pressing sections
of the paper machine to clean the wire, felts, and other machine
elements subject to contact with the stock. Formerly, large
volumes of fresh water were used for this purpose. In recent
years, attention has focused on the use of recycled white water
on showers, and this trend has increased with the development of
self-cleaning showers. Even with self-cleaning showers, however,
a suspended solids content of less than 120 mg/1 is generally
desired to avoid plugging. Concurrently, the use of high
pressure (up to 52 atm or 750 psig), low volume showers using
fresh water has increased. These are employed where_product,
operability, cleanliness, or other factors mitigate against the
use of white water showers. In many such cases, it is possible
to operate these high pressure showers on a time cycle, so that
flow occurs only a small percentage, (10 to 20 percent) of the
time.
Showers are also used on grooved presses to keep the grooves
clean and operable. These presses were developed within the last
10 years and have enjoyed increasing popularity because of their
efficiency in water removal, and lower capital and operating cost
than the suction (i.e., vacuum) presses which they replace.
Recycle of this shower water, usually after filtering to remove
fibrous and other suspended solids, is commonly employed.
Since the 1950's, free-discharge cleaners have been used
increasingly to remove dirt and other undesirable materials from
the dilute stock prior to its application to the paper machine.
These cleaners are the cyclonic type and operate on the
centrifugal force principle, utilizing hydraulic pressure drop as
the source of energy. They increase cleaning efficiency through
a continuous discharge of rejects although significant quantities
of usable fiber are also rejected. To reduce such losses, the
cleaners are usually arranged in stages, so that rejects from
previous stages are sent through subsequent stages of smaller
size. Rejects from the last stage have a consistency of about
216
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three percent and are usually sewered. Well designed and
operated cleaner systems reject one-half to one weight percent of
the feed to the primary stage. To reduce such losses further,
elutriation water is added at the final stage. In some cases, a
closeddischarge cleaner replaces the free-discharge unit in the
final stage.
Vacuum pumps are utilized in paper mills to provide a vacuum
source to accelerate the removal of water from fourdrinier
machines, presses, savealls, and other devices and thus the
vacuum pump demand for water is somewhat product dependent. Most
such pumps are of the ring seal type which require large amounts
of water. This water provides a seal between the moving and
stationary parts of the pump,, and is necessary to avoid joackflow
of air to the vacuum side. Water used for this purpose approxi-
mates 10,433 to 16,692 1/kkg (2500 to 4000 gal/ton). It must be
sufficiently free of suspended solids to avoid plugging of the
orifices or other control devices used to meter it to the pump.
Further, it must not promote formation of scale inside the pumps
or corrode their mechanical parts., and it must be relatively cool
(typically less than 34°c (90°F) to permit development of high
vacuums of 0.67-0.74 atm (20-22 in, Hg) . For lower vacuum
requirements 0.17-0.40 atm (5-12 in Hg) . somewhat higher
temperatures are permissible.,
As more extensive recycling is empj oyed in machine systems, the
significance of water used to seal 01 lubricate packings for
rotating shafts increases. These shafts are used for pumps,
agitators, refiners, and other rotating equipment. The use of
mechanical seals as an alternative has reduced the volume of seal
water, but they have so far not proven satisfactory in many
applications. Reduction of seal water usage is an area which
requires more study and development.
Meantime several methods are used to minimize fresh water
requirements depending on product as well as mill configuration.
Seal water is collected arid passed through for reuse directly
back to the pumps or to another water-using system. The use of
excess white water for vacuum pump sealing, before discharge to
sewer or back to process , is also practiced. Another procedure
is to utilize the discharged vacuum pump water for cooling of
heat exchangers.
All modern fine paper mills recycle most of the machine waters
and employ a saveall system to capture materials lost through the
fourdrinier wire (120) . These employ sedimentation, filtration,
and flotation with the separated materials being returned to the
papermaking process and a portion of the clarified water returned
for stock preparation and other uses in the paper machine system.
In the 32 percent of the 56 mills in the non-integrated fine
paper subcategory surveyed, the most common factor limiting water
217
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reuse was found to be product quality. Many mills experienced a
reduction in product quality when excessive recycle produced a
build-up of dirt or high dissolved solids in the process water.
Three mills are experimenting with total recycle by using mixed
media filtration or other fine filtration processes after
conventional solids removal in a clarifier or flotation unit.
This equipment is normally associated with fresh water treatment
plants rather than waste water treatment.
Ninety-four percent of the mills surveyed are recycling white
water and 89 percent utilize savealls to some extent with 39
percent using them extensively. Some hot water is collected and
reused in 73 percent of survey mills while vacuum pump seal water
or cooling water is reused in 41 percent of mills.
There are 72 tissue mills in this subcategory and 26 percent of
them were included in the survey. All the mills surveyed are
recycling at least a portion of machine white water and more than
50 percent are using high pressure showers to reduce water use.
Ninety-four percent of survey mills are using savealls to reduce
effluent solids with the flotation saveall being widely used.
While the flotation units give poor results on many effluents,
this is not the case in tissue mills where solids removal up to
90 percent are consistently obtained and one mill with two stages
of flotation averages 94 percent removal.
Pilot tests using a lean-water system successfully improved the
performance and increased the capacity of the saveall in one
tissue mill (121) . This system involves taking rich white water
from the wire trap and feeding it onto the sheet by means of a
secondary headbox. A final white water of lower consistency than
that of conventional methods was produced.
More than 60 percent of the tissue mills surveyed reuse cooling
waters and vacuum pump seal water.
Summary
The entire area of in-plant control provides for the industry
both a means to partially satisfy effluent limitations, and to
reduce both volume and pollutional materials in the raw waste
discharges with resulting reduced scale, and some reduction in
operating cost, of external treatment facilities.
While the principal presently functioning in-plant control
technologies are covered in previous paragraphs, as well as yet
unproven but developing means of in-plant waste control, it is
evident that significant advances in continued reduction of
wastes from the industry must be found through further advances
in partial closure of the various unit processes employed by the
various segments of the industry. The principal waste sources as
218
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barking, pulping, bleaching and papermaking are all vulnerable to
altered technology which will reduce or eliminate the discharge
of waste loadings from the process. some of this technology is
only appearing on the horizon and some is yet buried in research
laboratories of the industry and industry research organizations.
The awareness the industry shows concerning environmental matters
will certainly see any new means, as for example pulping or
bleaching, evaluated as to its impact on the environment.
While waste reduction is of prime interest in meeting
environmental obligations in air and water pollution control, the
areas of energy consumption, fiber conservation, increased yield
and reduced production costs also dictate the research avenues
and routes considered most rewarding for development.
Some portion of the new technology will probably first appear in
new mills although significant advances in demonstrated
profitability, if only from the pollution control standpoint, may
encourage installation of process changes and in-plant waste
control measures by older mills. Table 54 covers the in-plant
control processes, now practiced in the industry in varying
degrees. The number of mills surveyed in the separate
categories, and the percent of those mills employing the
specified in-plant measures is tabulated. Evidently there exists
considerable opportunity for th.e addition of present day accepted
in-plant control measures based upon the percentage of mills not
employing a specific waste control technology. One must question
why only 27% of bleached kraft mills employ high level alarms for
chemical tanks to avoid spills, why only 62% of bleached kraft
mills use a four stage washer, why only 50% of sulfite mills
employ a pulp mill spill collection system, why only 43% of the
groundwood subcategory employs paper machine savealls, etc. '
Alternately, one may similarly question why those mills
installing and operating such in-plant control facilities decided
on this route of action. The question elicits a generally
obvious answer.
219
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EXTERNAL_TECHNOLOGIES
External technologies are those processes which are employed
after the effluent leaves a mill for the reduction of suspended
solids, BOD, color, etc., before it enters the receiving waters.
These technologies are first described in terms of their general
application in the industry and are illustrated in Figure 42
Subsequently, use of these technologies by mills in the Carious
subcategories is discussed. This information for all mills
sSbjert to this report is summarized in Table 56 and schematics
drawings of treatment systems in use by surveyed mills are shown
in Figure U2A.
Removal_of_SusEended_Solids
Screening is always necessary to remove trash materials which
could seriously damage or clog treatment equipment
Automatically cleaned screens, operating in response ^ level
control, are commonly employed and generally represent Preferred
practice. Screens are particularly useful for barking and wood
washing effluents where screenings can be recovered as boiler
fuel.
The physical process of removing suspended organic and ^organic
materials is accomplished by sedimentation (with or without
flocculants or coagulants), flotation, or filtration.
Sedimentation can be accomplished in mech*^al clarifiers^
flotation units, or sedimentation lagoons. Although the latter
enjoy-d wide-spread use in the past, the large land requirement
1 Supled with inefficient performance and high cost of cleaning
has made them less popular in recent years (5).
The most widely used method for sedimentation of pulp and paper
wasteS is the mechanically-cleaned quiescent sedimentation basin
^5) Large circular tanks of concrete construction are normally
utilized with rotating sludge scraper mechanisms mounted in the
center Effluent usually enters the tank through a well which is
locaSd on a center pier! Settled sludge is raked to a center
sump or concentric hopper and is conveyed to fur her
concentration or disposal by solids handling pumps. Floating
material is collected by a surface skimmer attached to the
rotating mechanism and discharged to a hopper.
Dissolved air flotation has been applied to effluents from palp
anHaper mills and has achieved removal efficiencies of up to 98
percSr of the suspended solids (123). The relatively high cost
of rotation equipment, however, along with its requirements for
flocculating chemicals, high power requirements, and its
mechanical complexity make it unsuitable for application in other
than the capacity of a saveall, except where space is at a
premium? Its ability to handle high concentrations and shock
?oads of solids is^omewhat limited It normally is not
efficient on wastes containing pigments, fillers, or tines.
220
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FIGURE 42
ALTERMATIV: TRRATM'iK'T SYSTEMS
SPILL
TOKAGE I
COARSE
SCREENING
ALTER-.'AT IVF.
MILL RAW
WASTE
AJ-JjER jN AT IVr. S
STATIONARY
TRAVELING
SUSPENDED J
SOLIDS -"— 'H CHEMICAL
[ NATIVE] DEFOAMER
r-^
DIFFUSER
OUTFALL
221
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Figure 42A
EXTERNAL TREATMENT FACILITIES
Bleached Kraft Segment
BLvrh Plant
'
^ t (
•>- 735i,;j'J''
Ext Ble--;n P'jnt Ac'd Stwt."
Pond
2 days
14 days
750 Hp
222
-------
Figure 4?A (Cont'd)
EXTERNAL TREATMENT FACILITIES
Bleached Kraft Segment
Bloacn Plant
1GG
107
C A-ASB
108
C-A
vlill
IDS
C-ASB
^~\
(372 gpd/ft2)
3225 Hj
110
Nutrients
223
-------
Figure 42A (Cont'd)
EXTERNAL TREATMENT FACILITIES
Bleached Kraft Segment
224
-------
Figure 42A (Cont'd)
EXTERNAL TREATMENT FACILITIES
Bleached Kraft Segment
Nutrients
119
C-A
120
C-A i
-1 700 gpd/ft2 ) •
Cooling
Towers
Return Sludge
121
C-ASB-PS i
Bleach Plant
122
197 days
125
Biojch Plant
C-AS3
225
-------
Figure 42A (Cont'd)
EXTERNAL TREATMENT FACILITIES
Bleached Kraft Segment
Mill Cod
130
C-ASB
131
C-ASB
136
C-A-C
226
-------
Figure 42A (Cont'd)
203
C-ASB
C-ASB
EXTERNAL TREATMENT FACILITIES
DEINK Segment
Nutrients
j
204
C-ASS
^\
»_- 245 gpd/ft2 ^_
V J
1 4 days
20S
C-ASB C
By Pa
MOO Hp
216
C-A
5 3 noars
445 mil gal
Return Sludge
J
227
-------
Figure 42A (Oont'd)
EXTERNAL TREATMENT FACILITIES
Sulfite Saament
Wsak 'Wash, Yeast Plant, Recovery, & Bleach Plant
C-AS3
7 5 days
1500 Hp
^- — -"
Nutnents
Nutrients
/ \
/ \
C-ASB
C-A-C
7 hours
10 days
375 Hp
Nutrient:,
Paper Making
^^. ' Flotation
^~~ . Units
y Return Sludge
Nutnents
228
-------
Figure 42A (Cont'd)
EXTERNAL TREATMENT FACILITIES
GroundwoodSegment
001
C-ASB-PS
OC2
003
CTF-C
Tncklmj
Filter
Sludge Return
005
C-ASB
-------
Figure 42?. (Cont'd)
EXTERNAL TREATMENT FACILITIES
rine Segment
C-ASB
2G Hp
45 days
! 257
C-AS3-C !
22 hou-s
150 Hp
Sludge
3 5 days
60 Hp
152
C-A33
<50
EXTERNAL TREATMENT FACILITIES
Soda Segment
Tr.cklmg Filter \ .+- 870 qpd/'ft2
2091 npd/ft'
230
-------
SI
s
s
OT
0? 0<7
J10V>IOIS v-^TSV v-V
isoa i;r:i;ivTii T/DJOO:
a°?nTS po:iBAi:T.ov^
52 3SWOD
s
01
01
08
05
09
C9
'JfiSSII
VCIOS
"; nvjio;
T ^ r~ " ^ ' ' 'Mrrn'"1
^X'-1 '.J !.J. , ^/liUO
jo
-------
Because of the blinding and plugging nature of pulp and paper
wastes, fine screens, micro-strainers, and pressure filters are
not commonly used for suspended solids removal. Adequate
screening systems cost approximately the same as an equivalent
clarifier and have more inherent problems (12U) .
Because of the biodegradable nature of a portion of the
settleable solids present in the effluent of these mills,
clarification results in some BOD reduction.
B§c|uction_of_BOp
BOD5 reduction is generally accomplished by biological means
because of the relative biodegradability of most of the organic
substances in the waste except lignin. Too, advances in reducing
internal chemical losses and recycling have removed most of the
factors which interfere with biological activity.
While BOD5 reduction by biological methods represents common
practice today, it should be understood that other methods
discussed under "Color Removal" and "Advanced Waste Treatment"
may, in the future, avoid the need for biological treatment.
Currently the most common biological treatments utilized in the
pulp and paper industry include the use of large storage
oxidation basins, aerated stabilization basins, and the activated
sludge process and modifications thereof. Biochemical oxygen
demanding materials can be precipitated from most pulp and paper
mill wastes by the use of coagulating chemicals but the
percentage reduction obtained is small compared to that obtained
in biological treatment.
The principal benefit obtained from biological treatment is to
avoid depletion of dissolved oxygen in receiving waters. Fish
are particularly sensitive to depressed levels of dissolved
oxygen, as are many other forms of aquatic life. Other benefits
include the destruction of toxicity to aquatic life (125)
reduction in foaming tendencies (126), and reduction of
turbidity-producing inorganic coating additives. High degree
treatment also eliminates the tendency of pulping effluents to
stimulate slime production in receiving waters (55). Biological
treatment fails to remove color since color bodies are not
oxidiz-d and at best only a fraction of them are absorbed into
the biomass. In fact, there is frequently a slight rise in color
level after biological treatment.
The first type of biological treatment adopted in the industry
was storage oxidation. This consists of large natural or man-
made basins of various depths which rely on natural reaeration
from the atmosphere. Since storage oxidation is a relatively
low-rate process, large land areas of suitable topography and
remoteness from dwellings are required, making it unsuitable for
many locations. Because of the availability of land and the
warmer climate which helps to maintain consistent biological
232
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activity, most oxidation basins are found in the southern states
Nutrients do not accelerate the slow oxidation occurring under
these conditions so they are not employed.
It is imperative that settleable solids be effectively removed
ahead of these basins since if they are deposited therein they
will decompose and add a large BOD load to the wastewater.
BOD loadings for which these basins are designed are from 56 to
67 kg/ha surface area/day (50 to 60 Ib/ac/day). Retention times
range from 20 to over 60 days giving BOD reductions up to 50
percent or more.
This method of treatment has two principal advantages. It is
capable of handling (buffering) accidental discharges of strong
wastes without upset and has no mechanical devices with inherent
maintenance problems. Thus they perform well on a continuous
basis. Generally this method also accomplishes significant
removal of suspended solids.
Aerated_Stabilization_Basins_iASBl_
The aerated stabilization basin, as used in all subcategories,
evolved out of the necessity of increasing performance of
existing oxidation basins due to increasing effluent flows and/or
more stringent water quality standards. Induced aeration
provides a greater supply of oxygen and allows a substantial
reduction of retention time over the oxidation basin. To fully
realize the potential of this method nitrogen and phosphorus
nutrients must usually be added since most pulp and paper Afflu-
ents are deficient in these elements. These additions are
usually made in the form of ammonia and phosphoric acid. The
longer the retention period of the waste undergoing biological
oxidation, the lower the nutrient requirement. Five to 10 days
retention are normally used in order to obtain a BOD reduction of
more than 80 percent (127) (128) (129) .
Aeration is normally accomplished using either gear-driven
turbine type surface aerators or direct-drive axial flow-pump
aerators. Diffused air can be employed but is less efficient
Recently a downflow bubble aerator has been developed for use in
deep basins. Oxygenation efficiencies under actual operating
conditions range from 0.61 to 1.52 kg of oxygen/ kw/hr (1.0 to
2.5 Ib of oxygen hp/hr) depending on the type of equipment used
the amount of aeration power per unit lagoon volume, basin con-
figuration, and the biological characteristics of the system
(130) (131). it is necessary to maintain a dissolved oxygen (DO)
level of 0.5 mg/1 in the lagoon to sustain aerobic conditions.
30D5 and suspended solids levels, oxygen uptake, and dissolved
oxygen levels throughout the basins are related to aerator
location and performance and basin configuration. Ther« have
been extensive studies of (132) eleven existing basins which have
developed aids for the design of future basins.
233
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The world's largest ASB system covers 98.8 ha (244 ac) and has
43- 56 kw (75-hp) aerators installed. It treats a flow of 295
million 1 (78 million gal) per day with a BOD5 loading of 77,180
kg (170,000 Ib) per day. BOD5 removal is 66,284 kg (146,000 Ib)
per day or 86 percent.
Some sludge accumulates in the bottom of these basins but is
relatively inert and can be removed with periodic cleaning.
Sludge accumulation diminishes as the detention time and degree
of mixing within the basin increases. At some mills a settling
basin or clarifier follows the aeration unit in order to improve
effluent clarity.
Aerated stabilization basins provide a high degree of BOD
reduction without very extensive land use and at capital ana
operating costs lower than those for highly accelerated oxidation
processes.
Activated_Sludge_^AJ_
The activated sludge process is similar to the ASB except that it
is much faster, usually being designed for four to eight hours of
total retention. The biological mass grown in the aeration tanks
is settled in a secondary chamber and returned to the aeration
tanks, building up a large concentration of active biological
material. Since there are approximately 3000-4000 mg/1 of active
sludge mass in the aeration section of this process as opposed to
50-200 mg/1 in the aerated stabilization basin, oxidation is much
more rapid. Loadings in excess of 1.6 kg of BOD/cu m (100 Ib of
BOD/1000 cu ft) of aeration capacity per day are obtainable,
allowing the use of relatively small aeration tanks. Since
biological organisms are in continuous circulation throughout the
process, complete mixing and suspension of solids in the aeration
basin is required. Mechanical surface aerators similar to those
used in aerated stabilization basins are normally used although
diffused air is used in some cases.
Rates of about 24,445 1/day/sq m (600 gal/day/sq ft) are used for
the secondary clarifier settling the activated sludge. The waste
activated sludge is the major difficulty of this process as it is
extremely slimy and must be mixed with more freely draining
materials such as primary sludge, bark, or fly ash before it can
be successfully dewatered. Experimental work employing
centrifugal thickening and heat treatment is now underway in the
hope of finding a solution to this problem. Carry-over of
suspended solids has also been a problem with this process.
Short detention times and low volumes make the activated sludge
process more susceptible to upset due to shock loads. When the
process is disrupted, several days are usually required to return
the biological activity and high BOD5 removal rates back to
normal. Thus, particular attention is required to avoid such
shock loads in mills utilizing this process. The greater shock
load tolerance of aerated stabilization basins, lower nutrient
234
-------
requirements, reduced sludge handling problems, and lower cost,
explains their general popularity. Exceptions occur particularly
where the high cost or unavailability of land dictates th=> us- of
the activated sludge process with its much lower land regu .-«-
ment.
The contact stabilization process is a variation of activated
sludge in which two aeration steps are utilized rather than one
First, the incoming waste is contacted for a short period with
active organisms prior to sedimentation. Settled solids are «-h«n
aerated for a longer period to complete waste assimilation
Contact stabilization has been applied successfully to integrated
kraft mill effluent while conventional activated sludge is used
at most other mills.
Another form of the activated sludge process uses high purity
oxygen for oxygenation within a closed activated sludge t*nk
Pilot plant studies (133) indicate that such plants can ope ^e
at very high active sludge levels (5000-7000 mg/1) at high
dissolved oxygen concentrations (greater than 5 mg/1) with nigh
overall utilization of oxygen feed gas (greater than 90 percent)
and give BOD5 removal in excess of 90 percent. The amoun^r of
secondary sludge produced is reported to be less thar is
generated by conventional activated sludge and can be
successfully dewatered on a vacuum filter at low primary
secondary ratios at low feed consistencies without
conditioning.
Mill 124 has recently installed the first such system in th-
and paper industry.
Aeration
is
e
o
The oxidation ditch treatment process is essentially an extended
aeration or activated sludge process providing aeration in excess
of 24 hours. For economy and simplicity, an earthen ditch ir th*
shape of a racetrack is used for the aeration tank and air is
provided by a horizontally mounted aeration rotor or brush
aerator. The ditch overflow is clarified and the settled sludoo
returned to the aeration basin.
A pilot plant using nutrient addition on kraft effluent (13 a l
demonstrated 68 to 80 percent BOD5 removal at one-day det-n^Lon
and 80 to 94 percent efficiency at two-day detention.
B2tating_Biglogical_ Surf aces
Pilot studies have been done on the application of the rotating
biological surface (RBS) concept for biological treatment of pulp
and paper effluents (135) . The RBS process can be described as a
dynamic trickling filter. Plastic discs, supported on a common
shaft rotating at from 7 to 17 rpm, serve as a media for
biological growth. The rotating discs are approximately 40
235
-------
percent submerged in a vat having a constant flow of waste water.
In pilot tests, the RBS process has demonstrated its ability to
provide high levels of BOD5 and TSS reduction (301) (302) .
Biological solids generated have a low sludge volume and exhibit
good settling characteristics although dewatering properties are
similar to those of activated sludge. The RBS process recovers
guickly from organic and hydraulic overloads, has no major
operational difficulties, and has low maintenance and manpower
requirements. Ninety percent BOD removal has been demonstrated
(300) with a BOD loading of 1.2 kg/100 sq m (2.5 lb/1000 sq ft)
of disc surface area per day and detention time greater than 2
hr. One mill reportedly plans to install a full scale RBS
system.
Trickling_Filters
The use of trickling filters in all subcategories is very
limited, primarily due to the inability of such systems to
accomplish high degrees of BOD5 removal at high loading levels
(136). A kraft mill employing trickling filters with artificial
plastic media achieved 50 percent reduction of BOD5 with 50
percent recycle at a loading rate of 64.3 kg of BOD5/cu m of
media/day (500 Ib of BOD5/ 100 cu ft of media/day) (136).
Small plastic media filters are sometimes used as pre-cooling
towers and as such also remove some BOD.
One mill surveyed during this project uses a trickling filter for
treatment of effluent from an integrated groundwood and kraft
pulping and papermaking operation. This installation suffered
from a continual problem of filter media plugging with fungus
growths until a satisfactory biocide was developed and utilized.
One pilot study (300) reported up to 72 percent BOD removal at
loadings of 1 kg/cu m (62 Ib BOD/1000 cu ft) per day but, the
percent dropped sharply as the loading was increased. When the
loading exceeded 3.2 kg/ cu m (200 lb/1000 cu ft) per day the BOD
removal was below HO percent.
Two-Stagg EiologicalJTreatment
Two stage biological treatment, consisting of two biological
treatment systems, usually in series can be employed in an
attempt to enhance the BOD removal obtained with either single
stage. For example, a trickling filter may precede an aerated
stabilization basin or an activated sludge system. This
arrangement may be employed where the second stage is required
because of insufficient performance of the trickling filter
alone. It may also be used in cases where cooling of the waste
is desired the trickling filter serves as a partial cooling
tower, and also accomplishes some BOD5 reduction.
236
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Two stage aerated stabilization basins, operated in series, have
recently been employed in this industry to minimize adverse
temperature effects. Examples include Mills 006 and 007. For
the first stage, a detention time of two days or more is typical
and up to 10 days or more for the second stage. If sufficient
land is available at reasonable cost, this system is usually a
less expensive approach than a two stage system involving
activated sludge, it has the further advantage of providing mor«
detention time which is helpful in handling surges of flow or
pollutant load. Under conditions of proper design and operation,
including nutrient addition, BODS removals of 90 percent can be
expected with these systems.
currently employed by some southern
ii« * mills utilizes an aerated stabilization basin
followed by storage oxidation. Typically, detention time of the
former is eight to 14 days and for the latter is eight to 40
days. In these installations, overall BODS removal (compared to
raw waste) of over 85 percent is being achieved, with 70 percent
removal after the first stage. These data do not, however^
reflect usage of nutrients, it is probable that the addition of
nutrients, proper aeration, and mixing capacity, will ultimatplv
permit BODS reductions of 90 percent. For mills with adequa'I
economical ™1""1* faCt°rS' thi8 ^^ ™y ^ the
Other combinations of two biological treatments are, of course
possible, but many would not be practical or economical.
Temp.erature_ Effects
All biological treatment systems are sensitive to temperature
in support of this statement, Pelczar and Reid (138) in their
text "Microbiology", stated that all the processes of growth arl
dependent on chemical reactions, and the rates of these reactions
™^- inf,1!fencjd ^ temperature, it follows that temperature, in
S^h Determine the rate of growth and the total amount of
growth as well as the metabolism and morphology of the organism
This is applicable to the design and operation of a biological
!£™% treatment facility through the following relationship.
Because temperature, inpart, will control the rate and total
b?oSL^fh1baCteJial qrowth' the a*ou»t and speed with which
biodegradable waste materials will be consumed or oxidized bv
bacteria in a mixed environment, such as an aerated stabilization
basin, will be directly related to the activity at the biological
population. if the basin temperature is at the optimum ?or
biological growth then a maximum amount of waste material will be
consumed If the basin temperature is not at the' optimum for
« am°Unt °f ^terial consumed wll be
less than maximum, the amount of variance from the maximum
consumption being dependent on the degree to which ™"
temperature has varied from the optimum,
237
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An optimum range of temperatures exist in which bacteria will
grow best and the biological treatment systems will operate at
its highest efficiency. This range is 16°C to UO°C (61°F to
104°F). However, theoretically a biological treatment plant will
yield maximum effiency when operated isothermally at an optimum
temperature. This is not feasible for practical application,
however, it shows the need to maintain stable temperatures as
frequently as possible.
Problems encountered due to temperature variations are related to
the bacterial population's ability to acclimate to the variance
in temperature. If the temperature falls outside of the optimum
range a certain acclimation period must be incorporated to allow
for the recovery of normal bacterial functions. The failure at
most biological treatment units related to temperature variance
is due to the lack of a sufficiently long acclimation period.
The necessary acclimation period for mixed cultures at low
temperatures has been reported at 2 weeks after a temperature
change of 10° to 15°C (139). For high temperatures the
acclimation period is on the order of months, with these
necessary time periods for acclimation it is obvious that
biological upsets will occur if biodegradable material is loaded
at a normal rate while there has been a significant temperature
change.
Temperature over 40°C (104°F) may be encountered in warm climates
where heat is also added to the waste stream during processing.
Cooling towers or trickling filters have been employed to reduce
these higher temperatures prior to biological treatment. In
colder climates, waste water temperature is likely to drop below
16°C (61°F) in the winter. Particularly susceptible to this
temperature drop are treatment units with detention times greater
than 12 to 24 hours.
An aerated stabilization basin is one such unit. It's
temperature related problems stem from the large surface area
available for heat tranfer and from the action of the mechanical
aerators creating more contact between the atmosphere and the
surface of the liquid therefore, accelerating heat loss. This
problem could be corrected through the use of surface insula-i-ion
or by the addition of heat to the waste stream initially.
Techniques are available to control and compensate for all
undesirable temperature related effects on effluent quality, and
to create a margin of safety in order to assure that high
effluent quality is maintained.
Of the mills surveyed in this study 22 with aerated stabilization
basins had temperature data available at their final discharge.
A tabulation of the months in which the maximum monthly average
BOD at final discharge occurs for these mills (Table 57) shows
that 77 percent had their maximum BOD discharge during the colder
months, December to March, with a remainder randomly distributed
throughout the year.
238
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Table 57
MONTH OF 11AXJMU1-' AVLTJiGE BOI' AT FINAL DISCSIARGK
FOR SUKYTYr.D MILLS UITII ASE
Month Of . Of MncM
Max. BOD At -,r Month Of
Mill Code Final Discharre i'ax. ROD °C
001 Feb. 20.2
005 Nov. 18.1
006 Feb. 16.5
007 Feb. 17.6
051 April 17.8
052 Wov. if.6
100 Feb. 16.3
101 Feb. 4.4
106 liar. 14.2
109 June 36.°
110 Feb. 10;4
113 Feb 15.2
114 llay 25.1
116 Mat. 27.7
117 Jan. 14.6
121 Dec. 17.0
125 Feb. 13.6
203 Jan. 10.5
204 Sept. 27.6
205 Dec. 5.8
263 Mar. 13.1
359 Jan. 5.6
239
-------
In an attempt to quantify this apparent low temperature effect,
monthly average final BOD was plotted against temperature and a
correlation of BOD versus temperature was obtained for 13 ASB's.
The ratio of final BOD during cold months to final BOD for the
warmer months for the 13 was plotted against detention time in
the biological treatment system as shown in Figure 43.
This figure also includes similar plots for eight hour short
detention biological treatment plants. These eight results give
a scatter of results around 1.0 indicating little temperature
dependence of these treatment systems.
The plots for ASB systems do show, a temperature dependence but
the scatter of results and the small number of mills with
adequate data make any numerical evaluation impossible. Also a
large number of other factors can and will influence these
results, thereby concealing the true temperature effect.
Sludae_Handling_and_Dis2gsal
The disposal of sludges obtained from the clarification of pulp
and papermaking effluents is still a major problem despite many
years of research, development work, field studies, and
applications. In early practice, these sludges were placed in
holding basins from which free water from natural compaction and
rainfall was decanted. When a basin was full it was abandoned,
or if sufficient drying took place the sludge cake was excavated
and dumped on waste land and the basin was returned to service.
Odor problems from drying as well as land limitations have now
demanded the adoption of more advanced practices (64) such as
sludge thickening, dewatering, and incineration. The alternative
uses of these processes are shown in Figure 44.
In practically all systems, the dewatering operation is more
efficient and economic when the feed sludge solids content is
high. Hence, it is desirable, even if not necessary, to
pre-thicken sludge. This is accomplished by providing a^high
level of sludge storage capacity within the mechanical clarifier
or by gravity thickeners of the "picket-fence" type. Small mills
sometimes employ high conical tanks which contain no mechanism
but have wall slopes in excess of 60° and which act as both
storage tanks and thickeners.
Vacuum filters are in common use for dewatering sludges from
pulping and papermaking and produce cakes ranging from 20 to 30
percent solids. The filtration rates vary greatly depending on
the nature of the sludge. The range of rates for each
subcategory is shown in Table 57.
Observed capacities for the poorly filterable sludges can
generally be about doubled by chemical conditioning with ferric
chloride, alum, or polyelectrolytes at a cost of from $3.30 to
$5.50 per metric ton ($3.00 to $5.00 per short ton) of dry
solids. Such treatment is generally necessary when activated
sludge is included in the sludge to be dewatered since the
240
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C.. • -TJ
•• '. (-.'
CD', a
'r-
2.0 I
o
0 I DAY 2 DAYS
4 DAYS 6M?i ^ -
DETENTION TIME THROUGH TREATMENT SYSTEM
16 DAYS 18 DAYS
FIGURE 43
EFFECT OF TEMPERATURE ON BIOLOGICAL TREATMENT SYSTEMS
-------
FIGURE 44
SLUDCi:- DF.V/ATCmUG AUD DISPOSAL
^ILTP.AT^ TO
PI AivT
K-HOM
TprATUFUT
PLANT
4
LAGOON
NATIVES
GRAVITY
THICKENER
u
r:
DRYING
BED
ALTEKNATIVES
FILTER
AIDS
FILTE0
[DRUM, BELT, TOIL
ALTERNATIVES
SANITARY
LANDFILL
LEGEND--
SOLIDS
FILTRATES
ALTERNATIVES
SL.UOPF.
PRESS
INCINERATOR
ASH
LANDFILL
CENTRIFUGE
GAS
242
-------
addition of 20 percent of this material on a dry solids basis can
reduce filtration rates as much as 50 percent. S0-Lias Dasis can
A number of different types of filters are in service, with the
continuous rotary vacuum filter, similar to the drum filter used
1^ K ?as*lng being widely used- Among recent installations
or belt types are the most popular.
haV€ Proved successful in dewatering pulp and
^ generally Produced c**es ^th lower m
« efated by vacuum fibers. Cakes range from 25 to
35 percent dry the solids in the feed stream.
The application of drying beds for dewatering sludges is limited
thosTemnTi ^ ^ ^ *" nOt co«s^ucted al elaboratly „ are
of mnvfJ T K°J Sanjtary sewacre- They generally consist only
'
Additional water can be removed from vacuum filter and centrifuae
be ob?a?nel? Y preSSing: Cakes Broaching 50 percent solils can
Recent efforts have been toward direct use of presses on
au1?^6* SlUdge- thus eliminating the first dewaSring step
Eiy'f Pre!sinor 1S normally employed when incineration is to be
used for disposal since it reduces or eliminat-s the need for
supplementary fuel to maintain combustion. iim:Lna1:~S the need for
Land disposal, via dumping or lagooning, has been a common means
of disposing of waste sludges and other solid wastes from Sny
a mil3 '
Several factors have made such
?h2se mater, ae?fab^' however' odors form upon dacompo
these materials, there is a potential for pollution of
affected lands a^ eliminated from
fuueu n
hnw^! .If Pf0per sanitary landfill techniques are applied
however, most solids from the pulp and paper industry should
create no environmental problems. in the rare cases where
sludges contain leachable quantities of taste- or odor-imparting
!*n^' n°r Otherwise Desirable substances, simple sanitary
"111 ma ^ ^ sufficient ^ protect ground water
a rleini e
these methods are successful but costs are relatively high and
technical problems are encountered in the incinerators Jf aSh
b^? S /^ ^- A nUmber °f Other me^od8 ofcombStioS have
been tried including multiple hearth, kiln types, wet air SxidI!
promising fluidized bed al^ough only Y?he' latter appears
243
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A fluidized bed has been successfully used to dispose of
qroundwood and sulfite mill sludges at 25 percent solids in
combination with waste wood debris and surplus bark (143) . The
system operates without producing any air pollution problems.
Interest has been stimulated in utilizing sludge from kraft mills
in low grade products such as roofing felts, but lack of
uniformity mitigates against such practice. Several researchers
(144) experimented with the use of this material as an organic
soil supplement and with hydromulching. The incorporation of
high sludge levels into soil, after permitting it to stand for a
year, increased bean and corn crops for two successive plantings
as compared to control crops. However, eguivalent amounts of
sludge added to the soil each successive year caused a reduction
in crop yields which was apparently due to nitrogen
unavailability. In the hydromulching tests when sludge was
applied to a simulated highway cut, sludge with or without the
addition of bark dust was found to be competitive with a
commercial product for establishing a grass stand.
Several mills are presently experimenting with using the sludge
as a soil supplement in reclaiming land for growing pulp wood.
Primary sludge is being applied to the land at loads (dry solids)
of 224-448 kkg/ha (100-200 tons/ac) . Cottonwoods are planted
with planned harvest and reapplication of sludge in three to five
years.
Production of bacterial protein from cellulosic sludges continues
to attract the attention of researchers despite the failure to
date of similar products to gain a foothold in the market in this
country. A satisfactory product has been produced by growing
*hermo-monospora fusca, srongly cellulolytic thermophylic
o"rga"nism~~o"n ~lo"w lignin pulp mill fines (145) . This process is
attractive in that acid hydrolysis of the cellulose prior .0
fermentation is not required. The substantial reduction of
organic matter attained is of considerable interest. Preliminary
tests show that the thermg-monosp.ora fusca is palatable and
nontoxic as animal feed and could be competitive in cost with
other protein sources.
lrrigatign_and_Land_Disp.osal_gf_Ef fluents
Total effluents of some non- integrated paper mills, have been
disposed of by means of irrigation and land disposal. Specific
effluents from pulp mills such as cooking liquors, foul
condensatesr and turpentine decanter water, have also been
treated in this manner.
The advantage of land disposal, when properly
a very high degree of purification occurs as the water
through the soil. Approximately 20 percent or more of the waste
is evaporated by this process. When the remaining waste finally
reaches either the adjacent stream or ground water it is
practically devoid of suspended matter, BOD, and color. The
244
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disadvantages are I) the relatively small volume that can be
disposed of per acre per day, 37,850 to 113,550 1 (10,000 to
30,000 gal) under most soil conditions, and 2) freezing problems
during the winter months. in some instances, this process is
applied only during the critical months when temperatures are
high, stream flowages low, and crops, which increase the
allowable application rate appreciably, can be grown.
The use of land for the disposal of pulp and paper mill effluents
has been applied in the following forms:
1. Seepage ponds
2. Direct application to fallow soil with a wide range of
textures by both spray and ridge-and-furrow distribution
3. Application by similar means to soils whose absorption
capacity has been modified by development of suitable
cover vegetation
4. Controlled effluent application designed to produce
crops by use of suitable irrigation practices.
Since these effluents contain little in the way of basic
fertilizer elements, any value they add to the soil other than
their irrigating effect is the increased water-holding capacity
and friability induced by the stable organic matter present. Th«
use of land disposal and irrigation for disposing of these wastes
has been described in detail in the literature (1U6) An
assessment of the effectiveness of irrigation on crop growth and
the parameters for application of water, BOD, cellulose, and
sodium for soils of different character and textures are set
forth.
Effluent foaming in receiving waters is a problem experienced
particularly by kraft and soda pulp mills since alkaline liquors
have a strong propensity to impart this quality to water. other
waste constituents can do likewise but these are the most common
offenders in both treatment plants and receiving streams. Some
paper mill wastes can also cause this effect due to residual
amounts of additives present in the white water discharged as
can coating kitchen wash waters.
There is relatively little literature on the measurement of
foaming capacity or its control in pulp and paper effluents
despite the fact that control methods are well established,
^of Jy*USe ' and quite effective. A method has been developed
(126) for comparing foaming potential based upon methods employed
in the detergent industry which appears to be the only technique
presently available to measure this factor in pulp and paper
d i xu — riTzs •
245
-------
Foaming problems are common within kraft and soda mills
themselves and these difficulties are frequently the cause of the
problem in effluents, foam or black liquor being carried directly
into sewers. In-mill sewering arrangements can also give rise to
foaming. This can be avoided by rearranging the sewer system to
prevent direct admixture of alkaline and acid waste waters within
them and correcting arrangements and pumping systems which give
rise to air entrapment, a major cause of foaming in itself.
Maximum control of black liquor losses is mandatory if foaming is
to be kept at a reasonable level both during effluent treatment
and in discharge.
Since some biological treatment processes depend upon aeration of
the waste, foam is bound to develop. Under normal conditions
with most wastes this can be maintained at a minimum level by in-
plant control or by the use of surface sprays installed in
treatment basins. In most instances with good mill loss control,
foam levels will stabilize in treatment units and not become
unmanageable. Biological treatment is effective in itself in
reducing foaming tendencies.
Variabilitx_of_Effluent_Discharges_from_SurveYed_Mills
The treated effluent from pulp and paper mills varies on a daily
basis. This is demonstrated by examining data from the mills, as
illustrated by Figure 45 which gives the effluent BOD5 from an
ASB for mill 117. In developing effluent limitations,
consideration was given to the annual average, the 30 day
average, and dasily maximum.
Of major importance in establishing maximum 30 day averages and
daily maximums is the technique of data analysis. A variety of
approaches were analyzed. A summary of these techniques is as
follows:
Plant Selection
Data Screening
Normal Probability
Log-Normal Probability
Number of Standard Deviations
Actual 30 Day Maximum
Actual Daily Maximum
Variability of Mill Effluent
Variability of the Mill relative
to Annual Average Bases
Application of analysis (i.e. taking the
max, ave, etc.)
In addition, a number of factors are felt to possibly have an
effect upon the effluent variability, of which the major are:
Temperature
Process
Treatment System
246
-------
n.c
j
I
8.0 1
7.0 ]
i
i
6.0 i.
! ,
5.0
3-3
j
2.0J
I
1.0 1
Figure 45
Daily Effluent 3CD5 Data for Mill 117
1
Get
Nov
30
31
Jan
Feb
28
Mar
31
Aor
-------
The purpose of the analysis of these factors was to evaluate
their effect or lack thereof on variability and then to consider
them within the regulations, or to set the limitations at a level
in which mills affected by these factors can reasonably achieve
compliance.
Plant Selection
The selection of mills for variability is based upon whether the
mill has historically complied with the annual average basis.
Other mills which are not in compliance with the annual averages
were examined; however, they are considered to be unreliable
representations of the variability which would occur if the
annual average limitations were met.
The selection of mills for BOD variability is more extensive than
for TSS because many mills report TSS measured by non-standard
methods. The mills utilized are as shown in Table 58.
Table 58
Mill Selection For Variability Analysis
Mill Cornp.lYing_with_BOD_AA ComelYing_with_TSS_AA*
! yes Yes
5 yes yes
101 yes Yes
]_05 yes N.U.
106
yes N.D.
yes yes
112
113 yes
yes yes
yes Yes
^ yes
*N.D. refers to no data
The first criteria for mill selection is compliance with the
annual average BOD and TSS (if data is available). The mills
which comply with both the annual average BOD and TSS were be
strongly weiahed during variability analysis.
248
-------
Screening Data
The recommendation has been made to EPA not to screen any data,
however situations do arise for which data points do not reflect
proper operations and should be excluded. EPA expects that some
occurrances are not preventable such as one aerator breaking down
and thereby resulting in a slightly higher pollutant discharge.
This type of case has not been excluded from analysis. Other
cases such as a substantial number of aerators being shut down is
not considered normal operation and therefore is not included in
the data base. As an example, mill 113 has a daily BOD maximum
of 19.6 kg/kkg (39.2 Ibs/ton); however, aerators were reported by
the mill to be down from 12/72 thru 3/73. Examination of data
outside this tim period yields 8.U kg/kkg (16.8 Ibs/ton) for a
daily maximum. The difference in the two maximums is
substantial; 19.6 kg/kkg ( 39.2 Ibs/ton) is not an acceptable
outside this time period yields 8.4 kg/kkg (16.8 Ibs/ton) for a
BOD5 daily maximum. The difference in the limit. Besides
aerator shut downs other factors can create excessive
variability; mill 121 had an acid spill which caused poor
biological treatment for two months. For mill 121 data during
this time span was excluded. Most of the mills analyzed had no
periods of time where data was excluded; indicating that the
causes of exclusion were not typical or frequent. In most
instances, plants neglected to make an indication as to why
certain peaks occured. These unexplained peaks were included
within the data analysis, however the possibility does exist that
preventable actions were the source of these peaks and therefore
EPA has over estimated the 30 day and daily maximum. The
variability of most of the mills appears consistant; groups of
mills have peaks in the same range indicating a common phenomenon
which should be included. If. an isolated mill with high peaks
occurs and no justification is known, greater concern would be
needed.
A breakdown of the data screening is as shown in Table 59.
Table 59
Data Screening
^iii 2§£§_Screening_Justification
2 no da-t-a was excluded, however there is a
general lack of confidence in BOD and TSS
peaks - composite sampler malfunctions,
ammoniator failures, and sample mix-ups
occurred.
106 Data from January thru March 1973 excluded
because aerators were down.
113 Excluded data from 12/72 - 3/73
aerators down.
249
-------
Probability Distribution
The most commonly utilized probability is the normal distribution
which describes occurrances further from the mean as less
probable.
Figure 46
Normal Probability Distribution
250
-------
log normal provides a more accurate description o? 4h= Lta ?or
'
, , , - . - . ^ „.,.,, ti.n.y Vjj.j ius/-cons) . A ail^mma ic
For mill 106
Ibs BOD_5/ton
log mean log S.D.
0.8211 0.3635
251
-------
log (Daily Max) = log (35. 49) = 1.5501
From probability tables the probability of a value being
greater than 1.5501 (log scale) is 0.022d
What is now desired is to find the probability tha^ non<=
of the 315 values would exceed 35.49.
The probability of getting x successes in n independent
•'•rial? is qi ven bv
/(a;) = "V (1 - P)"~z forx--=0,l,a,...,n
p is *he cor-stan* probability of a success for each
individual trial.
x = 0
n = 315
p = 0.0228
solving for f (x)
f (o) = 0.0006995 = 0.0007
This indicates that the probability of no4: obtaining a data point
higher than 35. 49 out of 315 trials is 7 in 10,000 (less than 1
in a 1000) .
The previous example utilized data which was not screened. As
indicated previously screening is justified for this mill and the
BOD5 daily maximum during proper operations is only 7.33 kg/kkg
(14.65 Ibs/ton) . Mill 106 appears to require a daily maximum of
7.33 kg/Vkg (14.65 Ibs/tor.) during proper operations and not 40.8
kg/kkg (81.6 Ibs/ton) indicated by statistical analysis without
data screening.
The abov<= analysis was based upon log normal being an accurate
description of the data. Factors do exist for mills which render
log normal probability distribution analysis improper, as
illustrated above. From a non-theoretical viewpoint a strong
point should be made for examining the actual daily maximum
(^specially from large data sets where values becom<=
statistically significant . Permitting and possible subsequent
prosecution of violations will be based on actual numbers not on
log normal or any other type of curve fif-ing and therefore a
close examination shall be made of -*-he actual maximums.
Afrer establishing the daily maximum, actual or statistical the
us^ of th«= numbers has a great effect on *-he final regulations.
typically, the maximum is rationed to the plant's yearly average,
and sets of ratios are examined. EPA considered a possible flaw
in *his approach with the following hypothesis: Plants achieving
effluent qualities substantially lower than BPCTCA limitations
may have a higher variability. If this theory is correct, the
^ransfer of "plant variability to the limitations would be
improper and would result in limitations which would be
252
-------
Table 60
Symmetry and Kurtosis of BOD Log and Normal Distributions
BOD
Kurtosis
Normal_ Loc;
2.28 2.18
3.92 3.22
9.11 3.^9
2.11 4.-6
S •"" ''cu ~u-u^ 3.60 2.06
22.32 6.50
2.90 8.98
10.55 5.22
5.17 2.20
3.88 2.68
3.82 10.41
7.27 3.32
Mill
1
5
101
105
105
107
111
112
113
114
117
119
sy
Normal
0.50
1.09
1.93
0.27
1.20
3.67
0.55
2.24
1.40
1.02
0.57
1.52
BOD
mmetry
Log
-0.15
-0.26
-0.31
-0.88
-0.02
-0.30
-1.50
-1.03
0.01
-0.13
-1.85
-0.10
-------
ro
CJl
Table 61
Symmetry and Kurtosis of TSS Log and Normal Distributions
TSS TSS
Symmetry Kurtosis
Mill
1
5
101
106
114
117
119
Normal
0.83
0.52
1.39
0.86
0.56
1.02
2.22
Log
-0.46
-1.2:4
-0.66
-1.19
-1.10
-0.28
-0.15
Normal
3.49
2.91
4.75
4.38
3.45
3.70
10.85
Log
2.74
5.89
4.59
4.39
4.77
3.45
3.75
-------
Table 62
BOD Daily Maximum Relative to 99 and 99.9% Probability Confidence
Mean + ?.33 Mean +3.0
Mill Maximum Standard Deviation Standard Deviation
13.55
10.93
14.47
19.42
81.61
21.36
20.22
21.77
60.57
21.68
12.50
7.20
1
5
101
105
106
107
ro
01
111
112
113
114
117
119
8.47
12.54
12.86
8.91
35.49
25.96
11.88
12.45
39.16
14.53
13.07
7.26
10.19
14.53
9.37
14.11
46.57
15.56
14.90
13.19
37.64
15.81
1C 98
5.39
-------
Table 63
TSS Daily Maximum Relative to 99 and 99.9% Probability Confidence
Mean - 2.33 Mean +3.0
Mill Maximum Standard Deviation St?nda"d Deviation
ro
en
CT>
]
K
101
106
114
117
119
20.37
8.99
8.97
35.24
26.43
24.98
32.11
22.92
14.06
12.21
44.23
17.92
28.01
22.93
34.85
20. 5 i
1 5 . 98
73.55
20.84
39.10
34.7*
-------
erroneously high.
were examined:
The bleached kraft mills listed in Table 64
Table 64
Comparison of Plant Variability to Limitations Variability
2§ily._Max/AA_Basis Daily._Max/Plant_AA Plant AA
105
121
109
117
113
114
101
106
107
120
110
119
112
1.2
2.5
4.5
1.39
2.44
2.67
1,
2.
2.
,86
03
,83
4.83
2.63
1.30
2.22
1.74
2.01
2.56
2.17
1.84
1.80
5.21
1.59
3.33
4.49
2.70
3.36
4.29
5.13
9.23
13.01
4.36
9.10
12.64
2.47
9.22
5.4
7,12
6.29
2.16
2.90
»n T M le 64 and Fis limitations firmly
illustrates the achievability of these limitations.
Variability Results
both
the Sii1™?^ ±n Ta?le 65 have historically complied with
the BOD and TSS annual average bases.
257
-------
6.0
.5.0
4.0
3.0
2.0
X
X
X
X
1.0
4 6
BOD AA (Ibs/Lon)
BOO VARIABILITY VS ANNUAL AVniACC BOU
258
-------
Table 65
Variability of Mills Complying with the BOD and TSS AA's
117
Ill
5
1.71
1.97
1.30
1.61
1.79
o co
3.53
1 13
l'13
1.24
0.57
1.02
0.9U
1.61
I'.M
0.82
Some of the mills do not renor-i- TQC
been able to judge whethe? they wouf?
annual average TSS. From this aronn if
66 comply wi?h the BOD annual a?e?a?e?
, EPA haS n0t
compliance with
m±lls in Table
Table 66
Variability of Mills Complying with the BOD
105
112
113
1.20
2.22
2 HH
SHHSbS"
1.06
°-62
....
259
-------
Table 67
Variability of Mills Complying with the BOD AA and Not Meeting the TSS AA
BOD_Daily,_Max
Mill BOD AA Basis
206 3.11
TSS_Daily__Max
TSS~AA Basis
8.62
BOD_30_Day__Max TSS_30_Day,_Max
BOD AA Basis TSS AA Basis
1.30
2.49
The following mills do not comply with the BOD annual average but
are examined to find out what value the daily and 30 day average
maximums would have to be for them to be in compliance. These
are presented in Table 68 in increasing order for mills with
secondary treatment.
Table 68
Variability of Mills not Complying with the BOD AA
Mill
IQD_Daily._Max
BOD AA Basis
TSS Daily^Max
TSS AA~Basis
BOD_ 30 _Day__Max
BOD AA Basis
TSS_30_Day__Max
TSS AA Basis
110
51
284
204
205
257
109
14
2
120
203
118
116
122
104
100
103
2.24
2.56
2.63
2.87
3.39
3.53
4.50
4.58
4.67
4.84
5.32
5.53
5.77
5.86
9.42
14.76
15.87
3.45
2.55
2.73
N. D.
N.D.
N.D.
N.D.
N.D
36.27
19.33
N.D.
N.D.
19.88
6.27
7.06
2.61
4.87
1.74
2.14
1.96
1.86
2.15
2.50
2.94
2.66
1.63
3.62
2.95
3.54
10.00
7.99
2.27
1.72
4.61
5.30
11.39
1.24
4.17
0.48
1.39
Variability limitations will be set such that all the mills
listed as not violating the BOD and TSS annual average will also
not violate the thirty day average and daily maximums. Included
are those mills which do not report TSS. From this list of 13
mills, 2565 BOD data points were utilized as well as 1501 TSS
data points. None of the 30 day averages or daily values
violated the limitations. Included within this data base are
260
-------
"orthern climates, and C - ASB's C - A's and o^her
TemS; .By utilizin<> the highest value, EPA has si?
limitations which should be achievable by all mills
annUal average- The BPCTCA variability ratios are as
I°.P._2aily._Max
BOD Annual Ave = 2.83
iQP._30_Day__Max
BOD Annual Ave = 1.67
l§S_Daily_Max
TSS Annual Ave = 3.53
TSS_30_Day__Max
TSS Annual Ave = 1.61
Non-integrated tissue mills should be capable of meeting th-
limitations with primary treatment. The variability oTthil tw
of technology for the non-integrated tissue subcategory may hj
different Limited data from mill 306 indicates the Bol Daily
M o,ot0/°D ** equal °'77' while for mil1 309 this ratio is 2 Jo
No TSS data was available from these mills, since the dJta on
the oth^% K treatment is limited, the variability allowed for
the other subcategories will also be allowed for non-inteara-ed
gories w also be allowed for non-inteara-ed
inicate The.BOD J^ ava ilable f™ "iH« 30^30? does
subca?egory achievab^^y of the variability utilized for this
BATEA and NSPS Variability
Haying analyzed 30-day and daily maximum levels for BPCTCA
Sn S8 PPAUf S6 COmPuted for BA^EA and NSPS. For pulp and P^r
rednrJ has demonstrated a tendency for higher variabilJt/fTom
the ?^?° ^ discharge. However, BATEA limitations include
the addition of mixed media filtration which may stronalv
variaMlItv /^iability- Dailvdat* "hich is necessJry for
variability analysis is not available on mixed media filtration
raon
a!!d Paper mi11S' Theref0^, the method of calculation
° "
available alternative and that is o"
MM currently achieving these limitations withou?
MMF have the same or greater variability as mills which will
with MMF. since BATEA describes beat available
economically achievable, EPA will utilize the best
°f BATEA limitations. Ony
c ving
cou l lower^s^ ^^ ^ U ±S3-36- A-- ha this ml
maint,,n fhltS annU^ avera
-------
utilized for BPCTCA, however, the higher number will be utilized
(1.67 versus 1.49). The system is a C-Ar clarifier followed by
activated sludge, and as stated previously does not have the add
on of MMF; however, it is close to the BOD limitation with just
secondary treatment and therefore presents a currently achievable
variability with an alternative treatment system. No current
evidence exists that a OASB-MMF or C-A-MMF would be more or less
variable. Analysis of TSS indicates that levels of variability
achieved by the best mill in the range of BATEA and NSPS annual
average limitations is less than the BPCTCA ratios. Due to the
limited information currently available on BATEA and NSPS
variability the higher TSS ratios from BPCTCA will be utilized.
The BATEA and NSPS variability ratios are as follows:
lQD_Daily_Max
BOD Annual Ave = 3.46
!9JL_30_Day._Max
BOD Annual Ave = 1.67
X§S_DailY Max
TSS Annual Ave = 3.53
T_SS_30_Day._Max
TSS Annual Ave = 1.61
The generation of color bearing waste waters by the pulp and
paper industry is caused by three distinct operations: 1)
chemical pulping, 2) pulp bleaching, and 3) colored paper
production. The majority of the color comes from the pulping and
bleaching sequences. It is not uncommon to realize the
generation of 272.16-317.52 kg (600-700 Ib) of color per ton of
bleached pulp produced, especially in the bleached kraft segment
of the industry.
Because of this, technology is being developed to minimize the
industry's color discharges. This technology includes both the
internal management of waste generation and external treatment.
Internal process modifications are being proposed which minimize
the volume and/or color intensity of the waters in question as
well as promise recovery of chemicals used in the various pulping
and papermaking operations. On the other hand, new and existing
advanced waste treatment techniques are being developed for the
industry which hold promise of yielding effluents containing less
color. The purpose of this subsection is to identify, document,
and verify the full range of control and treatment technologies
applicable to color reduction including potential technologies.
It is applicable to all subject subcategories, unless otherwise
indicated, because of possible transferability from subcategory
to subcategory. Also for this reason, work performed on pulping
262
-------
wastes not subject to this report is included. Any consider-
ations peculiar to specific subcategories will be noted.
Sources _of_color
In the various chemical pulping processes, highly colored ligriin
and lignin derivatives are solubilized during the cooking
process. The spent cooking liquors, containing these hiqhly
colored compounds, are removed from the pulp in a washing
sequence following the cooking process. in various types of
pulping processes, this wash water is sent to a recovery area
where the cooking chemicals are recovered and the organic
materials are burned in a recovery furnace. The washing and
recovery operations are efficient; however, small losses of
cooking liquor and the discharge of evaporator condensate result
in colored effluents. Additionally, most pulp mills discharge
the water removed from the pulp in the last operation before it
goes to the paper mill or bleach plant. This water is known as
unbleached stock decker seal pit overflow. This effluent can be
the most significant colored discharge from the production of
unbleached pulp. Average values of color discharged from various
pulping operations are shown in Table 69 (5).
The caustic extraction stage of kraft bleaching produces a highly
colored effluent since the caustic soda employed leaches
previously chlorinated lignins from the fiber. The color
significance of this discharge from one mill can b^ s^ap in Table
70 (247) . " ' ' '
Characteristics_of_Color
Color is defined as either "true" or "apparent" color. In
Standard Methods (191) color of water is defined as "the color of
water from which the turbidity has been removed." Apparent color
includes "not only the color due to substances in solution, but
also due to suspended matter." The National Council for Air and
Stream Improvement has published a tentative procedure for the
measurement of color in pulping wastes (192). This procedure
measures the "true" color of the waste by spectrophotom^ric
comparison of a waste sample with a standard curve of potassium
chloroplatinate solutions of varying concentrations. The
procedure first adjusts the pH of the sample to 7.6. The color
of the effluent is pH sensitive, increasing with increasing pH.
The sample is next filtered through a 0.8 micron membrane filW
to remove turbidity which also affects the color determination.
The sample is then analyzed in a spectrophotometer using a
wavelength of 465 nm. The color of the sample is determined by
comparing the absorbance with a standard curve.
In a laboratory investigation of the characteristics of kraft
effluent color, eight series of samples of decker filtrate
collected over a period of fifteen months were anlyzed (248)
The absorption characteristics of the samples through the visible
263
-------
Table 69
VALUES FOP, COLOR DISCHARGED FROM VARIOUS PULPING PROCESSES [5]
Effluent
Pounds of Color Units r^.Jgon of Product
ro
CTl
Kraft Pulping
Kraft Papenaaking
Kraft Bleaching
NSSC Pulping (Recovery)
Sulfite Pulping (Recovery)
Sulfite Bleaching
50 to 3n
3 to 8
200 to 300
2CO to 2.50
30 to 200
50 t<- 330
-------
Table 70
CONTRIBUTION OF EFFLUENT SOURCES TO TOTAL MILL EFFLUENT COLOR [231]
ro
o->
en
Source of Effluent
Pulp ni.ll—general
Paper Mill
Bleach chlorination stage
Bleach caustic extraction stage
Remainder of bleaching process
Total
Color Load
(Ib color/bl ton)
31
5
111
460
27
634
Contribution to
Combined Effluent
Color
^A_P_":1A_ Cc 1 or units)
12'-)
21
462
1916
113
2641
-------
(750-350 nm) and ultraviolet (350-230 nm) spectra were measured.
Generally, the samples exhibited an increase in absorbance with a
decrease in wavelength. The investigators concluded that no
single color is present in the waste, rather, they are mixtures
of different colors.
The investigators also measured the effect of dilution, pH, and
time on the absorbance characteristics of the samples. It was
found that absorbance of diluted samples was linear, following
the Beer-Lambert law, and that a direct correlation existed
between absorbance and dilution. This is shown in Figure 48.
The effect of pH was measured between 2.0 and 11.0. It was found
that the absorbance at pH 2.0 was the lowest and that the
absorbance was pH sensitive, increasing up to pH 5.0, decreasing
between 5.0 and 7.0-8.0, and then increasing to pH 11.0. The
reason for the erratic behavior was beyond the scope of the
investigation. Figure 49 gives the results of the pH analysis.
The effect of time was measured at three wavelengths for periods
of one, three, six, and 24 days. As shown in Figure 50, the
absorbance increased up to a storage time of three days,
decreased sharply between three and six days, and then decreased
slowly from six to 24 days. The reason for this was not known;
however, it was suggested that limited oxidation might tend to
increase color.
The investigators also conducted experiments to characterize the
color bodies in the effluent. Two classes were identified. The
first were the high molecular weight, acid-insoluble bodies, and
the second were the low molecular weight, acid-soluble bodies.
The acid-insoluble bodies were found to have molecular weights
from 400 to 30,000 and contained a high proportion of carboxyl
groups conjugated with an aromatic ring. The acid-soluble bodies
were found to have molecular weights from 400 to 5000 and
contained nonconjugated carboxyl groups, apparently associated
with carbohydrate material. The investigations further showed
that most of the color bodies were ligninlike in character,
apparently consisting of lignins degraded to varying degrees, and
were negatively charged. An important aspect of this
investigation was a comparison of the character of color bodies
before and after lime treatment. The significant conclusions
will be covered in subsequent sections of this report.
Internal_Mj5thods_of_Cglor_Redu^tion
The methods of effluent color reduction through in-plant
operations considered here include modifications to the kraft
pulping process, processes to replace kraft pulping, spill
controls, and bleach plant modifications.
Kraft Process Modifications
266
-------
0
L L l L
246 8 10 12
TOTAL SOLIDS CONCENTRATION x I02, g/l
Figure 48 Correlation of Solids Concentration vith
Absorbance (at tec ma) of Untreated Waste [233]
O
x
E
c
O
UJ
O
CD
CC
O
CO
CD
0
J L
-L J L
^ ^ 6 8 tO 12
pH OF UNTREATED SAMPLE AT CONSTANT DILUTION
Figure 49 Effect of pH on Absorbance (at k20 run)
of Untreated Waste [23 J]
267
-------
40-
o
L'J
UJ ^
u
en 4
-------
Most efforts to modify the kraft pulping process have been aimed
at increasing pulp yield. Since there is essentially no
published data on resulting color reduction, they will not be
reviewed in detail. These systems include hydrogen sulfide
pretreatment, addition of polysulfide to white liguor as used by
several companies in the United States, and irradiation of wood
chips (249) .
In the mid 1960 »s Dr. W. Howard Rapson of the Univeristy of
Toronto, proposed the completely closed pulp bleaching and
chemical recovery system. The system would utilize compl^t<=
countercurrent washing from the bleach plant through brown stock
washing with sufficient recycling to reduce total water
consumption to 12.5-16.7 kl/kkg (3000-4000 gal/ton) of pulp.
The bleach plant effluent passes to the black liquor and through
the evaporators to the recovery furnace, where color bodies are
burned. Digester and evaporator condensate stripping with strain
or air are used to remove the total reduced sulfur compounds and
the condensates are returned to the system, with the evaporator
condensate fraction returned to the last washer in the bleach
plant (see Figure 51) .
The use of countercurrent washing in the bleach plant results in
a high chlorination stage temperature. Serious pulp degradation
could result. This problem is eliminated by replacing about 70
percent of the chlorine with an equivalent of chlorine dioxide
The use of chlorine dioxide also results in a reduced caustic
requirement in the first caustic extraction stage. The sodium
chloride in the spent bleaching chemical (resulting from the use
of chlorine and sodium hydroxide) must be removed from th«
system. The salt would be removed by evaporating white liauor
and crystalizing out the bulk of the sodium chloride present as
part of the liquor reconstitution process. The recovery of -i-h<=>
salt prevents the concentration of chlorides from building up
within the process and consequently causing problems in ^he
recovery furnace and corrosion of equipment. The recovered
sodium chloride would be used in the C102 generation process
\ £. O U ) •
The total enclosed system was proposed with the DcEDED sequence
since this is most similar to the commonly used CEDED. However
the proposed system would be compatible with an oxygen bleaching
sequence or hypochlorite in place of the standard caustic
extraction second stage (251) . Hypochlorite is not recommended
because it introduces more sodium chloride into the system than
the standard caustic extraction stage.
™i a ""i*1 Pricing special grades of paper, such as
colored grades, would have trouble completely closing their water
S,o*o?m and S°me f0rm °f internal wat«r treatment may be necessary
(^2) . It is also indicated that a groundwood and kraft mill
combination could be closed more easily than a kraft mill alon^
This approach has not been applied and research on specific
aspects of it are underway.
269
-------
Figure 51
Rapson Close:; Cycle
/
FORGE _-r /
IKTAL -•-•'
10;! 3
(DittOS?
PURGE
C02K2° «&.-%—'
TO
ATMOSPHERE
k
H20
(WHITE i IO-JOR
C EVAPORATOR 1
A
M RECYCLE
I SOLUTION
-Y_J LIQUOR 1 *,£ )
[PREPARATION 1 *
IT
\
- i
l-H FURNACE
L_ 1
^ {BLACK LI3UOR L*s$r PULPING 1H2°
H_o 1 tVAPORATOR -- p^
i if\f\r\ • — '" ^&*- ' ' • \—
H20
•3, * >
- — ^ HaCL i
' 1
V4' BLEACHING
] CHEMICAL
PULP|NG MANUFACTURE"
CHEMICALS T
HaCH 1 C10?
? NaOH
**••* BLEACH 1 II G H2° ^.* J
"•".*»•• 1 -*?Sc» — —
UNBLEACHED
PULP
-*~CONDEHS
FRESH
WATCR,
BLEACHED
PULP
270
-------
New_ExBerimental_Prgcesses_in_yarious_Stages_of_DeveloEment
Oxygen and soda-oxygen pulping is being investigated by Syracuse
University, University of Washington, Forest Products Laboratory,
North Caroline State University, and Toyo Pulp Co. (249). Mill
trials have been run at the SAPPI mill in Enstra, South Africa.
The pulps produced by oxygen pulping are generally comparable,
but inferior in specific guality parameters to bleach kraft pulp
(253). The Toyo Pulp Co. of Japan has been operating a 1.81 kkg
(2-ton) per day plant for several years and has a 90.72 kkg/day
(100-tpd) plant under construction. The oxygen for this process
is normally ordinary air (2U9) .
MacMillan Bloedel has reported on a high yield, two stage,
alkaline sulfite-oxygen pulping process to produce a pulp that
could be used as linerboard base sheet furnish. Canadian
International Paper Co. and others have been developing an
alkaline sulfite process that produces a pulp similar to kraft
without the associated air pollution problems. A chemical
recovery process must be developed to make the alkaline sulfite
process commercially attractive. Other contenders to replace
kraft pulping include holopulping, developed in the late 1960's
at the Institute of Paper Chemistry, Owens-Illinois' sulf:t~-
sulfide pulping, nitric acid pulping marketed by Alscope
Consolidated Ltd., and several chemical solvent processes which
include Weyerhaeuser's ammonia-ketone process and J. N
Kleinert's aqueous alcohol process (249). it is unlikely tha+ a
substantial number of the kraft mills in the U.S. will radically
alter their present pulping process.
lDternal_Sgill_Control
Internal "spills" may be designated as continuous and
intermittent. The continuous losses are part of the accepted
method of operation and the pollution load they impose is
therefore, predictable. These are losses incurred through th-
law of diminishing returns as applied to such processes as pulp
washing and liquor evaporation. The intermittent spills ar«
caused by system upsets and equipment failures, and are normally
unpredictable. The intermittent spills can amount to 30 percent
of the effluent load from a bleached kraft pulp and paper mill
(20) .
A significant amount of color can result from caustic or black
liquor carry-over in the pulp from the brown stock washers. Most
of this color normally finds its way to the sewer with the screen
rejects and decker filtrate. Where the caustic carry-over is
substantial, the addition of a brown stock washing stage or use
of the decker filtrate on the brown stock washers can r^duc-
effluent color. Pulp mills that sewer their knots can eliminate
a small but concentrated stream of color and BOD by incinerating
the knots, returning them to th<=> digester, or hauling th-^m ^o
271
-------
landfill. Washed green liquor dregs is another small stream with
high color and BOD. Filtering the dregs and hauling them to
landfill results in chemical savings and a better weak wash
liquor balance in the causticizing and lime recovery area.
A black liquor boil-out tank to hold some of the weak liquor at
the end of an evaporator boil-out can be used to keep colored
effluent out of the sewers. The liquor is meter ed back to the
recovery system during normal plant operation. Evaporator
capacity must be available or added in order to handle the
additional evaporation load.
Black liquor spills also occur because of liquor carry-over in
the evaporators. This liquor could be recovered and pumped to a
holding tank (e.g. boil-out tank) and returned to the weak black
liquor system during normal operation.
Stock spills from upsets on the brown stock washers can result in
a significant color load going to the sewer. Collecting these
spills and returning them to the blow tank would eliminate this
source.
In order to minimize the duration of chemical and liquor spill,
high level alarms may be used to alert operators of overflowing
tanks. Spillage collected from tank aprons can be returned to
recovery or collected and metered into the treatment system.
Color can also be kept out of the mill sewer by closing up -he
brown stock screening operation. There is a limitation on the
amount of water recycling that can be utilized in a bleach plant.
This is normally determined by pulp quality requirements and
chemical consumption (254) (255) . The number of bleaching stages
and the sequence used also affects the effluent quality and
color. A survey of 22 North American bleached kraft pulp mills
conducted in 1971 (255) determined that bleach plants using the
CEDED bleaching sequence has an effluent volume of 30.67 kl to
51.78 kl (8000 to 13,680 gal) per air dry kkg (ton) of pulp,
compared to 53.63 kl to 85.73 kl (14,170 to 22,650 gal) per air
dry kkg (ton) of pulp for the CEHDED bleaching sequence.
Direct countercurrent washing cannot normally be used in existing
mills sinc^ the materials of construction used for the caustic
and hypochlorite stages are attacked by chlorides. Mills may use
jump stage countercurrent washing where the caustic and acid
filtrates are kept separate or a combination of direct and
s^-age or split-flow countercurrent washing. Effluent from
finishing stages can be employed for washing first stages and
extraction stages can be recycled.
Benefits of countercurrent washing are reduced volume and high
concentration of pollutants. Laboratory tests have shown the
possibility of reducing the bleachery effluent volume to 637.8 1
(1685 gal) per air dry kkg (ton) of bleached pulp on a DcEDED
bleaching sequence by closing the bleach plant filtrate operation
through recycling, including using chlorination stage effluent
272
-------
for decker stock dilution. To achieve this, the modern mill
would require modification and changes in materials of
construction, along with additional chemical requirements. The
color reduction achieved would amount to HO percent (256) For
the CDEDED sequence, effluent was reduced to 14,762 1 (3900 cral)
per air dry kkg (ton) . Color reduction achieved is not discussed
Alter ation_gf_Bleaching_Seguence
Oxygen bleaching is a primary avenue through which effluent color
trom the bleach plant may be reduced. This aspect of the process
is discussed separately in ensuing pages.
The standard CEDED bleach plant effluent color can be reduced
significantly by replacing the first caustic extraction stage
^tnr-ia^S m. hypochlorite stage and replacing the normal
chlorination stage with a sequential chlorine dioxide-
chlorination stage (257). These modifications are called the
anti-pollution sequence or APS. Table 71 presents a laboratory
comparison of the effluent from various conventional and APS
bleaching sequences on both hardwoods and softwoods.
On the basis of laboratory tests it is claimed that the APS is
equivalent to the lime processes in pollutant reduction and is
also superior from an economic aspect. The color reduction is
equivalent to that obtained through ion exchange with both a
lower capital and operating cost. in addition, it is estimated
rfan* «^?r r^Cti°^ ^Uivalent to that of recovering bleach
plant effluent through the recovery system by use of oxyq-n
bleaching can be achieved. However, the capital requirement for
an oxygen bleaching system is much greater than for the APS
2S K7?- Presents a tabulated comparison of color reduction
through lime treatment, ion exchange, oxygen bleaching, and the
APS sequence. The application of the APS process may be limited
however, in that it produces pulp low in strength and thus is 'not
suitable for all pulps.
Dynamic (displacement) bleaching is discussed in other Sections
of the report. However, there is no published data on ?he
effluent color resulting from this process.
The patented Papribleach Process* (258) was developed at The Pulp
and Paper Research Institute of Canada. The process reduces the
reaction time required to produce a pulp of 90 brightness from
ten hours in a conventional bleach plant to forty-two minutes for
Kraft pulps, and twenty-two minutes for sulfite pulps.
use
orM P?Pri*>lea^h Process* utilizes chlorine gas at 25-35°C (77
95°F) in the first stage which takes about one minute. The
?L in^o? ?hS e"fbl€S the PulP to have a stable Kappa number at
the end of the chlorination as well as keeping chemical costs at
a minimum and providing stable brightness levels. The second
stage uses ammonia gas and steam for extraction of the
273
-------
Table 71
COMPARATIVE EFFLUENT ANALYSIS - CONTROL VS. APS [242]
,
Softwood
Hardwoc'Jls
—•i — -
"CEDEDDCHSDED CEHD
Vn/t-on Z Red Ib/ton Ib/ton.
a - Hypochlorite in Hs stage 1.3 to 2.0%
b - Does not include organically bound chlorine
% Red
Ib/ton
Chlorides
Analyzed13 136
Calculated 157
-------
Table 72
COrTA^r.rr; OF r,-,; •.;;-(-/,!. 'nVAT-r .r iv-nrr^r
Foil KLI;AC-! a.:- rri-vun;! -v;> APS [2.;/f"
Pollution deduction %
IjLt.^ctJ on_5tr:-o Ipt,'Ji_PJ.£ach_J^ "'It Cf fIUPPt
l2£___CO^3_>OD___colo;1^01" COD" BOD~ ~"
Primary &
Secondary
External Treatment
Lime 80 to 70 to 25 to 65 to 25 to 15 m
L_e5______75 _ 4.5 90 30 ?_5
Ion 85 to 85 to 55 to 75 to 2 to 45 to 25 to
J^?hanse_95_____90__6p §5__J__L__65_ __30
• _ Internal Treatment
60 to 55 to 70 to 30 to
85 85 80 35
APS 85 to 35 to 30 to 60 to 15 to 15 to
9^ ZO__JO 85 25 35 25
275
-------
chlorinated lignins. This offers mechanical advantages since it
is achieved in ten seconds. Ammonia dissolves chlorinated
liqnins without attacking the carbohydrate of the cellulose. The
third stage uses chlorine dioxide gas at 100°C <212°F) for twenty
minutes. This permits more accurate control of bleaching as well
as lower chemical costs. The second and third stages would be
repeated when bleaching kraft pulp to 90+ brightness. Sodium
hydroxide can be substituted for ammonia in the second stage
using a five-minute detention time.
The Papribleach Process (use of a trade name does not constitute
endorsement.) has many advantages over the conventional bleaching
process. As already mentioned, the time required for bleaching
is greatly reduced; second, higher yields are possible; and,
third, costs, both initial investment and operating costs, are
considerably less; and, fourth, water and steam requirements are
drastically reduced. Consequently, mill bleach plant effluent is
reduced. There are no known full scale applications of this
process,
OxY2§n_Bleaching
Five mills that have used or are using oxygen bleaching include
the SAPPI kraft mill at Enstra, South Africa, the Chesapeake
Corporation of Virginia in West Point, Virginia, LaCellulos
d'Aquitaine in St. Gaudens, France, Munksjo AB in Aspa Bruk,
Sweden, and Billingsfors Bruk AB in Husum, Sweden. Another
Swedish mill has recently installed an oxygen stage.
From September of 1970 to September 1972, the 136.1 kkg (150
ton)/day oxygen bleach plant now owned by Billingsfors was
operated by MoDoCell AB in Husum. The plant used the OCEDED
bleaching sequence. COD, BOD, and color values were determined
and compared with a CEHDED bleaching sequence. These are
presented in Table 73.
Assuming an 80 percent washing efficiency on the washer following
the oxygen bleaching stage, a 70 percent reduction in color in
the total bleach plant effluent can be achieved according to .he
work at the Husum mill (259). A 45 percent reduction in BOD was
also achieved.
Additional work at the Husum mill showed that in the production
of chemical pulp for newsprint using an oxygen bleaching stage
followed by two stages of washing, more than 90 percent of the
color could be removed from the bleach plant effluent. This
would be accompanied by a 70-80 percent reduction in BOD and a 79
percent reduction in COD (81) .
The original bleaching sequence at Enstra, South Africa was
AODED; however, because of a shortage of chlorine dioxide, their
bleaching sequence was changed to AOCEH. When using the AODED
sequence, the mill operated at a production rate of 258.6 kkg
(285 tons) per day on hardwood (gum) and 195.1 kkg (215 tons) per
276
-------
Table 73
EFFLUENT SURVEY [244]
NO.
1
2
3
4
5
6
7
8
9
10
11
Effluent or T>uli> Stream
OCEDED
Unblivclied nu3p f/'-terinj
0 start* press lirujpr
0 stage reactor <--xit
C stage
E stnp.e
Pulp leaving E stage
washer
Total effluent
(2+3+4+5)
CEIIDED
Unbleached pulp entering
C sta^e
E stage
H stage
Pulp leaving H stage
washer
Total effluent (8+0-1-10)
Ratio- of totals OCE/CF.H
BOD;
Sequence
y
8.0
31.9
3.2
4.6
1.2
27.7
Sequence
1.4
5.4
8.1
5.2
1.1
18.7
1.48
COD
ko/J
-------
day on pine. After brown stock washing and screening the brown
stock was acidified with sulfuric acid, then treated with
magnesium oxide before oxygen bleaching. Data taken from the
individual bleaching stage filtrate are presented in Tables 74
and 75. The necessity of sending the filtrate from the oxygen
stage through the pulp mill to the recovery boiler is illustrated
in these tables (106) .
The data shows an 85 percent reduction of color in the bleach
plant effluent and there was also an associated 75 percent
reduction in total dissolved solids (106). When recycling or
recovering all of the oxygen stage filtrate, the reductions shown
in Table 76 can be achieved.
The only U.S. mill utilizing oxygen bleaching, Chesapeake Corp.
of Virginia, is also discussed in other sections of this report.
High process water and screened stock temperatures have forced
the mill to use a sequential chlorine dioxide-chlorine first
stage of bleaching, followed by the oxygen stage and a third
stage using chlorine dioxide. It produces an 88 brightness 4ulp
from brown stock cooked to a K-No. of 15. The total bleach plant
effluent color is 42.5 kg/kkg (85 Ib/ton) (23). This bleach
plant is illustrated in Figure 18 in Section III.
Results from operations at the Cellulose d'Aquitaine mill in
France are based on the OCEDE/HD sequence. There is no reuse of
the oxygen stage filtrate through the brown stock washing system
and consequently there is not much reduction in effluent color
from the bleach plant. The oxygen bleaching stage includes the
use of 0.2% MQSO4 to protect the cellulose from caustic attack.
Caustic is used in order to maintain the required pH. The
present color in the bleach plant effluent when operating at a
production rate of 408.2 kkg (450 tons)/day is 40.8 kkg (45
tons)/day of color. This is expected to be reduced to 22.7 kkg
(25 tons)/day of color when filtrate from oxygen stage is used on
the brown stock washers and the color subsequently destroyed in
the recovery furnace.
Laboratory studies at Cellulose d'Aquitaine compared OCEDED and
ODED to the CEDED bleaching sequence. In the OCEDED process the
oxygen stage treated pulp at 25 percent consistency and 0.5
percent magnesium sulfate and 1.8 percent sodium hydroxide were
added. Retention time was thirty minutes at 100-105°C (212-
221°F). These laboratory results showed a 77 percent reduction
in color from the bleach stage along with a 52 percent reduction
in BOD. When using the ODED sequence, color was reduced by 90
percent and BOD by 77 percent (260). Table 77 is a summary of
their results. These results assume that all of the oxygen stage
filtrate can be processed through the pulp mill.
During these tests it was also realized that there is a linear
relationship between Kappa number and color.
Laboratory tests conducted by the National Council for Air and
Stream Improvement at North Carolina State University are shown
278
-------
Table 74
INDIVIDUAL FLOW OF EFFLUENT DURING BLEACHING [102]
—i
10
Acid
Treatment
Cnlorine Caustic Chlorine
—Oxygen Dioxide Fvt^rtnVn n-;™^
Normal Wattle/Eucalyptus Pulp, Kappa No 13 14
PH
COD /ppm
OAjjrpm
Dissolved
Solids, ppm
S04,ppm
Cl,ppm
Na,ppm
Ca,ppm
Color, ppm
3.0
416
78
2465
1050
120
215
61
260
9-7 3.5 10.5 7 0
5396 448 544 224
492 130 58 41
8370 1365 3415 660
332 71 83 33
170 300 150 190
!j°0 95 180 100
] 9 qg i , .,
-_ 3000 Combined 100
-------
Table 75
INDIVIDUAL FLOW OF EFFLUENT DURING BLFACKING [102]
1X3
co
o
pH
COD, ppm
w"^ > r* r
OA,ppm
Dissolved
Solids ,ppm
SO A , ppm
Cl ,ppm
Na .ppm
Ca,ppm
Color , ppm
Ac ic1.
Treatment
High Kappa No.
2.7
184
49
2080
974
150
228
59
50
Oxygen
, Pine Pulp,
9.2
10300
2200
16100
550
115
2625
33
60
11000
Chlorine
Dioxide
rat^a No. 35
6.6
600
207
1700
50
115
192
17
45
Caustic
Extraction..
ll.O
432
68
1306
143
155
237
15
240
Chlorine
Dioxjde
3.3
357
03
1018
42
200
216
38
30
-------
Table 75
EFFLUENT LOADING OF PINE .CRAFT, KAPPA NO 35
(Assumes all oxygen stage filtrate is recycled and reclaimed.)
oo
A Od Total ADED
Oxygen system
Dissolved Solids
Ib/ton 20 280 87
OA Ib/ton 2 65 1?
COD Ib/ton 3.4 190 29
Color Ib/ton 0.7 120 2 8
BODa (5 day)
Ib/ton
C B H D E D Total
Chlori ie Svsteni
50 129 130 Combined 7° ^88
9 f\ / Q £ r\
32 73 23 CorMned i; 142
-1-6 3S6 7 Coi'iTn rr>ri 1 /•''n
24 50
a) Bottle method Canadian Standards H2P (1967)
The oxygen filtrate was reused as indicated in Tappi, Vol 54
No. 6, June 1971, PP 966. '
-------
Table 77
COMPARISON OF CEDED SEQUENCE WITH AND WITHOUT D£ STAGE
AND REPLACING CE STAGES V1TH 02 STAGE [245]
oo
Kappa No.
Sequence
Color, Kg Pt/ton
7, Red.
COD, kg 02/tp
% Red.
BOD. kg 02/tp
% Red.
Unbleached Kraft
18.0
CEDED
43
32
10 . 2
Pulp After Ox
9.7
CEDED
10.0
77%
18.0
LL7,
5.3
52%
ygen Bleaching
DED
i.5
90%
15.2
53%
2.4
77%
-------
in Table 78. Their tests also showed that the effluent from the
oxyqen bleaching stage was more readily biodegradable by standard
aeration methods than conventional bleach plant effluent (261) .
As shown in Table 78, effluent from the oxygen stage must be
recycled in order to reduce color in the effluent.
Tables 79, 80, and 81 present laboratory results comparing CEH
with OCE bleaching sequences, the CEDED with the OCED bleaching
sequence, and the CE with the OC bleaching sequences.
Table 82 points out the importance of recycling the oxygen stage
effluent. An 80 to 85 percent washing efficiency should be
attained by most mills. Assuming an 80 percent washing
efficiency this would result in approximately 70 percent effluent
color reduction from the bleach plant (262) .
External_Methods_of_Color_Reduction
M§§sive_Lime_Treatment
The development of the lime color reduction process has been
traced by several authors (5) (263) (26H) (59). A brief review of
this history is in order. In the early 1950' s, the results of a
laboratory program in which several coagulants were tested for
their effectiveness in reducing the color of kraft pulping and
bleaching effluents (246) were reported. This investigation
measured the effectiveness of alum, ferric sulfate, lime,
sulfunc acid, char, clay, activated carbon, activated silica,
ferric chloride, chlorinated copperas, phosphoric acid, waste
pickle liquor, and a barium alumina silicate compound. in
general, it was found that good color reduction could be obtained
with several of the agents. it was concluded, however, that th«
cost of chemical treatment was prohibitive with the exception of
lime treatment which afforded the possibility of lime recovery by
utilizing existing mill equipment. in addition to *h«
prohibitive costs of chemical treatment, large volumes "of
difficult to dewater gelatinous sludge formed in the chemical
treatment processes.
Based on the results of this early work, research continued
towards development of a lime precipitation process. Th«
overriding problem in this work continued to be the difficulty of
dewater ing the lime-organic sludge. Specific studies w-re
conducted for resolving the sludge problem with limited success
(265) (266) . These studies led to investigation of the surface
reaction process (267) (268) (269). This process, wherein effluent
was filtered through a precoat of hydrated lime, had good success
in the laboratory. However, severe operational problems with the
pilot plant scale system forced this process to be abandoned.
Continuing efforts to improve the dewatering of the lim^ sludge
led to consideration of using large dosages of lime for color
reduction. It was believed that a large quantity of rapidly
draining materials would reduce the effect of the organic master
283
-------
Table 78
COMPARISON OF CE1IDED W/OCEDED
(% REDUCTION ASSUMES 100% RECYCLE & COKSUIITTIOi: OF 02 FILTRATE) [247]
r-o
CO
Color
BODs
Chloride
COD
CEEDED
A64
43
139
335
OCEDED
413
70
43
473
CCEDED
U stage
recycle
58
10
A2
79
% Reduction
87
77
70
76
-------
Tnbl.-> 79
co:;:v.;i£o.f o><- cr:: w/ucr
CF.Ii
Color 290
BOU 23
COD 136
Chloride 11 i
CEDLJJ
Color 166
BOD 28
COD 112
CVloridG 58
CE
Color 107
BOD 16
COD 90
Chloride 51
Sof tvood
OCI<
OC1: 0 RocycUd
213 24
3^ 3 . 6
271 53
30 26
Table 8(
cciib.p.ico:: OF c;> :,r,D
Hardv^od
OCI;D OCED
0 RecvrO^d
1^.4 8
37 5
157 /,.->
48 /,3
Table 81
COHPA1-ISCIT OF CE
Hardwood
00
OC 0 Recycled
95 10
31 3
1A2 10
21 19
— —
7, Rc?duct'.on
91
85
57
76
3
w/OCTD f?^7]
% Keouction
95
82
72
26
w/OC [2471
% Reduction
90
81
88
62
% RcducLJon assumes 100"; recycle and consumption of 02 filtrate,
285
-------
Tabla 82
EFFECT OF RECYCLE ON OVERALL PERCENT RFDUCTIOi'lS
OF EFFLUENT CHARACTERISTICS BY USE OF AN
ALTERNATE ALKALI-OXYGEN STAGE [247]
ANALYTE
Color
BOD
COD
Chloride
SOFTWOOD*
100% - Recycle -
87
77
76
70
80%
68
41
25
64
100%
95
82
72
26
HARDWOOD*
- Recycle - 80%
77
47
41
24
*Percentages Recycle refer to Oxygen Stage Effluent.
286
-------
on dewatering. This thinking led to the development and
patenting of the "massive lime" process by the National Council
for Air and Stream Improvement (218). In this process, the
mill's total process lime is slaked and reacted with a highly
colored effluent stream, usually the caustic extraction <=>fflu~nt
The lime sludge is then settled, dewatered, and used "for
causticizing green liquor. During the causticizing process, +-he
color bodies are dissolved in the white liquor and eventually
burned in the recovery furnace. A flow diagram of the patented
process is shown in Figure 52. Although the massive lime process
had been demonstrated as an effective color removal system, i-he
process was not taken beyond the pilot stage for several years.
International Paper Company, Springhill, Louisiana
The first installation of the NCASI's massive lime color removal
system was operated at the International Paper Company's mill in
Springhill, Louisiana. The demonstration plant was sized ^o
treat an effluent flow of 2006 1pm (530 gpm). Sources of
effluent used in the EPA sponsored demonstration project were the
bleach plant caustic extraction and the unbleached stock decker
These effluents were selected for their relative contribution to
the color of the total mill effluent (60 to 75 percent).
In this project, part of the selected effluents were first used
to slake the lime in an agitated reaction tank providing fiv^
minutes detention. The lime slurry was then fed to the effluent
at a dosage of 20,000 mg/1. The lime sludge was then settled out
in a clarifier. Overflow from the clarifier was to a carbonator
clarifier where lime kiln flue gas was reacted with the effluent
to precipitate the dissolved calcium as the carbonate. This
carbonator clarifier had a 20-minute retention center well and
was covered to minimize the escape of foam.
Sludge from the primary clarifier was pumped to a storage tank at
18 Jo 22 percent solids. A two-hour capacity was provided.
Sludge from this tank was dewatered on a precoat vacuum filter to
approximately 50 percent solids. This sludge was then discharged
to the pulp mill green liquor slaker. After processing through
the cooking liquor causticizing system, (shown in Figure 53) *he
lime mud was burned in the kiln, recovering the lime for reus^ in
the color removal system. Makeup lime was added as required.
The color bodies removed in the effluent treatment system w-re
dissolved in the cooking liquor, eventually being burned in th<=<
recovery boiler.
The demonstration plant at Springhill was first tested using 100
percent bleach plant caustic extraction effluent. Various
amounts of unbleached decker effluent were then added until 100
percent decker effluent was treated. Color removal ranged from
yo to 97 percent with an average of 9U to 95 percent (232)
Organic carbon removal ranged from 55 to 75 percent and generally
increased with higher colored effluent. The values reported are
shown in Table 83. BOD removals of 25 to 45 percent
were
287
-------
Figure 52
Massive Lizr,e Process [232]
Lima
rv>
CO
Colored
Effluent
k Steam
I—*. Dregs
Reactiot
/
Sludgo
Tank
Filter !
r
C02
i
I
Primary Clarifier r v
1
Ciarifisr
i i
_i
Sludge Storage j
t j
Decolored Effluent
-------
Figure 53
Causticizing Process for a Kraft Pulp Mill [232]
CO
1C
Green Liquor
Fuel
Lime and/or Sludge from Massive Lime Process
r
Whi'e Liquor
(for cooking)
CaCO3 I jo Recovery-
Mud Washer
-------
Table 83'
COLOR AND ORGANIC CARBON REMOVAL
r\5
to
o
Composition of
Treated Effluent
Bleach Caustic Kraft
Extraction Decker
Stage Effluent, Effluent,
Effluent Color
(APHA Color Units) Color
Before A'ter Removal,
Treatment Trcotment %
Organic Carbon
Content (ppm) Organic Cc.rbon
Be'ore After Removnt.
Treatment Treatment %
100
67
60
50
33
20
0
0
0
33
40
50
67
80
1091
1C02
21,543
14,325
12,125
10,043
6G12
&ceo
KV.Q1
9002
1 265
745
524
4>51
331
293
1401
2342
94.2
9«.8
95.1
95.5
S5.0
93.6
91.51
74 .02
1416
1016
905
798
563
^-o
270 l
2682
373
253
243
245
183
173
1201
12G2
71.2
75.1
72.6
63.3
67.3
&"..•'.
55 F1
53.02
Very little paper mill white water reuse m decker pulp washing and make-up water.
Practically all water used in decker system was white wator from paper mill.
-------
The most serious problems encountered during operation of the
demonstration plant were foaming and carryover of solids in the
primary clarifier. As a result, it was recommended that
equipment throughout the system be designed to prevent air
entrainment to eliminate or control foaming. Sludge settling
rates and filter rates varied inversely with the concentration of
organics for effluents of over 5000 APHA color units. The system
causes dilution of the cooking liquor by about 15 percent, there-
fore, increasing the required capacity of most of the chemical
preparation and recovery equipment. Additionally, organic
^?™d%/a5ried int° the ii^r caused foaming problems; No
adverse effects on pulp bleachability or quality were found.
In an analysis of the impact of the massive lime system on a
cSculat1^^7;."^^1000^0^^^ ble*ched kraft mm? i? was
calculated that the volume of effluent that could be treated with
ST/H^^inf"011^ °f lime ret?uired fcy such a mill would be 15.14
kkl/d (4 MGD). The untreated color loads contributed by the
individual process areas are shown in Table 59.
extraction effluent and 4.73 kkl/d (1.25 MGD)
4 500 p . Cker effluent< "ith a combined color of
14,500 APHA units, could be treated, with a 95 percent color
reduction the treated effluent would theoretically have ^
characteristics shown in Table 84.
The net effect of the treatment would be a 72 percent color
reduction. Based on water and material balances, thl following
Increased Capacity
. Green liquor slaker or mixing tank 17.7
. Causticizers and associated equipment 17*7
. White liquor clarifier, storage, and
associated equipment 17 7
. Mud washers, storages, and associated equipment 15"8
. Mud filter 6"
. Lime kiln 6"
. Pulp washing accessories 5*8
. Evaporators and accessories 5*8
. Recovery boilers and accessories l[q
Mi ni mum_Li m e_T r ea t men t
The massive lime process, as developed, relied on hi ah
concentrations of lime (on the order of 20,000 mg/1). Because of
lt\h°nly a relatlvely small effluent stream could be
with the quantity of lime used for causticizing green
291
-------
Table 84
CONTRIBUTION OF EFFLUENT SOURCES TO TOTAL MILL EFFLUENT
COLOR WITH TIASSIVE LIME TREATMENT OF BLEACH
EXTRACTION STAG IS AN7D DECKER EFFLUENTS [7.32]
Contribution to
Combined 3Lfluent
Color Lor.d Cclcr
Source of Effluent (Ib color/bl ton.) JAFFA Color Units)
Pulp mill-general 12
Paper mill 5
Bleach c'niorination stage 111 46~
Bleach caustic extraction stage 23 ?'3
Rcniainder of bleaching process __2_7_ J i3
Total 178 742
-------
Additionally, the use of this process required modifications to
the recovery system. These restrictions and the need for color
removal from total unbleached kraft mill effluents led to the
independent development of three lime precipitation processes
employing a "minimum" lime dosage for decolorization followed by
various methods of sludge disposal or recovery. Two of these
systems have been in full-scale operation on the total mill
effluent from unbleached kraft production and a kraft/NSSC
operation (270) (271). Lime dosages at both mills have been about
1000 mg/1. At the kraft mill, the lime sludge is not recovered.
The kraft/NSSC mills, however, dewaters the lime sludge by
centrifuge and recovers the lime in the process lime kiln.
In the third "minimum" lime treatment system caustic extraction
stage effluent from a bleached kraft mill is treated with 2000
mg/1 of lime (272). The resulting lime sludge is then mixed with
prefiltered lime mud; the mixture then is dewatered on a belt
filter and burned in the lime kiln.
Interstate Paper Corporation, Riceboro, Georgia
The first full scale color removal facility in the pulp and paper
industry was put in operation at Interstate Paper Corp.,
Riceboro, Georgia in March of 1968. The mill effluent is
discharged to Riceboro Creek, a dead-end estuary where, at times,
the mill effluent occupies the entire cross-section. Because of
the nature of the receiving water and the shrimp and sport
fishing in the adjacent waters, the mill was required to meet the
following state effluent criteria:
Effluent Discharge 37.85 kkl/d
(10 MGD)
Biochemical Oxygen Demand 362.9 kg/day
(800 Ib/day)
Suspended Solids 10 mg/1
Color (APHA cobalt units) 30 mg/1
The mill was designed to produce 362.9 kkg (400 tons) per day of
unbleached kraft linerboard with a process water requirement of
52.15 kkl/ kkg (12,500 gal/ton) exclusive of cooling water. As
of March 15, 1970, production had increased to 510.8 kkg (563
tons)/day; process water requirements were 40.89 kkl/kkg (9800
gal/ton); and BOD to the effluent treatment system was 10 kg/kkg
(20 Ib/ton). y M
The color removal system was designed from laboratory bench test
data without pilot scale testing. The original design provided
for a 190.5 kkg (210 ton) capacity lime silo which is filled from
the process kiln. Lime is slaked in a 58.97 kkg (65 ton)/day
slaker and stored in an agitated 2.84 kl (750 gal) slurry tank at
293
-------
about 15 percent solids. Lime is metered into the total plant
efficient proportional to flow and was originally mixed with the
effluent using an in-line mixer. The mixer has since been
removed with no apparent loss in process efficiency. From this
point, the effluent is pumped to a 13.72-m (45-ft) diameter,
10.05-m (33-ft) high flocculation tank which provides a retention
time of about 35 minutes. The effluent then flows to a 60.96-m
(200-ft) diameter clarifier which provides six hour retention at
the maximum flow of 37.85 kkl/d (10 MGD). Sludge is withdrawn
from the clarifier and pumped to a sludge lagoon of 20.61
hect-ire-m (167 acre-ft) capacity. Lime is not recovered.
The effluent from the clarifier is saturated with calcium
hydroxide at a pH of about 12. Overflow is to a 263.16 hectare
(650 acre) natural stabilization pond. In the first 40.49
hectares (100 acres) of the lake, carbon dioxide is absorbed from
the atmosphere, precipitating the calcium as the carbonate. The
effluent undergoes natural biochemical oxidation in the remaining
area of the pond and is mechanically aerated to raise the
dissolved oxygen to saturation prior to discharge to the creek.
The stabilization pond provides 180 days retention of the average
flow of 18.93 kkl/d (5 MGD). The process flow diagram for this
system is shown in Figure 54.
The Interstate system produces a relatively constant effluent
color of 125 ppm APHA color units at lime dosages of 1000 mg/1
(270). Untreated effluent color is reported as 1200 mg/1 (+200
mg/1). The system performance was found to be related to control
of lime feed.
Separate analysis of samples shipped to the Institute of Paper
Chemistry showed the treatment process to be 86 percent efficient
in removing color (248). Additionally, a 57 percent reduction in
TOG was reported. The analysis further showed that color bodies
with a molecular weight of less than 400 were not removed by lime
treatment and that those with a molecular weight over 5000 were
completely removed.
several conclusions can be drawn regarding the operation of this
color removal system (270). First, experience showed that flash
mixing of the lime slurry with the effluent has no effect on
color reduction. The presence of solids, such as fiber, aid
clarification which would allow a conservative clarifier rise
rate of 20.37 Ipm/sq m (0.5 gpm/sq ft) for similar installations.
The process conditions the effluent allowing rapid biochemical
degradation and foaming problems are said to be eliminated.
Ninety percent of the maintenance costs of the system was for
lime handling. The inference is taken that attention should be
given to the lime handling system in any future design to
minimize operating and maintenance costs.
The Interstate system has several design features that may not
have industry-wide application. First, lime is not recovered.
Make-up lime at the mill is in the form of lime rock, a
relatively inexpensive source of lime. With a different source,
294
-------
10
on
L!»6 STORAGE TANK
VARIABLE SPEED
SCREW CONVEYOR
(10 VGO WAX)
5 MGD
NOOO* BOD/DAN
"^R«.
v
1
1
iy-BO«y;S*
[
1
jm&*eu
»
V
. ,,...J ...
1 J
I
i
| EPFLUENT RETU'N !
L,
?IOChEM!C*L TREATMENT LAX
j 0:0 ACRES - 930
uo
SLUICE GATE
-800» BOD/DAY
LIFT FUMPS
3f • GP« 50' fOH
HOLDING LA .OOK 48 MG
Figure 54
RICEBCRO CPEEK
Effluent Treatment Flow Diagram
Interstate Paper Company [253]
-------
the chemical costs could increase. Second, this lime treatment
system is followed by a large natural stabilization pond. In the
first 40.5-56.7 hectares (100-1UO acres) of the pond, natural
carbonation of the effluent occurs and the dissolved calcium is
precipitated as carbonate. This also reduces the pH and allows
biological activity to proceed normally throughout the rest of
the pond. For installations not having the benefit of large
amounts of land, recarbonation of the effluent might be needed to
the extent required to adjust pH for efficient biological
oxidation in addition to improved lime economy. Third, the
method of sludge disposal is in holding lagoons where some
dewatering occurs. Again, lime is not reclaimed. Although two
sludge lagoons were constructed, one of these has been designated
as an emergency lagoon which is used whenever the clarifier is
by-passed. The dikes on the one sludge lagoon have been raised
0 91-m (3 ft) to provide additional storage capacity and a new
sludge lagoon is needed. Again, the availability of land at this
mill site makes this method of sludge removal practicable, but
other installations may be required to consider alternate
methods.
in
Finally, the lime treated effluent shows a dramatic increase
color as it proceeds through the natural stabilization basin.
This color change is attributed to leaching of natural color from
the soil in the bottom of the pond. The color change at various
points through the pond is shown in Figure 55 which also shows
the reduction in BOD through the pond. The sodium content of the
treated effluent appears to have an effect on the magnitude of
the color increase in the pond (250).
The observation has been made that the color bodies which are not
removed by lime in this system are of low molecular weight and
addition of multi-valent cations could be used to achieve over 99
percent color removal. Another recommendation also concerns the
color bodies not removed by lime treatment. If biological
oxidation of the wastes before lime treatment were practiced, it
could reduce the negative effect, if any, of the low molecular
weiqht color bodies on color removal. These points need
laboratory investigation as does the effect of varying degrees of
pulping on molecular weight of color bodies and the subsequent
treatment efficiency.
Continental Can Company, Inc., Hodge, Louisiana
The second full scale color removal facility put in operation on
an unbleached kraft mill effluent was at Continental Can's Hodg-,
Louisiana mill. The mill is rated at 562.5 kkg (620 tons)/day of
unbleached kraft linerboard and 181.H kkg (200 tons)/day of NSSC
corrugating medium. An expansion program is underway which will
increase the unbleached kraft production to about 1360.8 kkg
(1500 ton)/day. Treated effluent is discharged to a small creek,
which in the summer months, has little or no flow.
296
-------
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AVERAGE BIOCHEMICAL oxvcn-N1 DEMAND-PPmBODc
-------
During research leading to the development of the color removal
system at Hodge (273), consideration of the massive lime system
was dismissed because of the large volume of effluent to be
treated. Mill personnel concluded that the mechanism of color
removal by lime precipitation was accomplished by absorption of
color bodies on solid calcium hydroxide. This led to
experimentation with other solid-phase substances together with
moderate amounts of lime. Experimentation using ferric
hydroxide, calcium carbonate, starches, polyelectrolytes, and
r<*causticizing sludge produced marginal results. It was found,
however, that the presence of fiber fines in the paper mill
effluent enhanced the removal of color with lime additions well
below the solubility of calcium hydroxide (1000 to 1500 mg/1.)
Further experimentation and pilot plant work led to the
development design criteria for a full-scale installation. The
experimentation concentrated on three goals:
1. To establish predictability of the process
2. To provide for disposal of the precipitated color bodies
3. To recover the substantial amounts of lime used
The system consists of a grit chamber followed by a revolving
disc trash screen for the removal of large and heavy solids
(264) The pffluent is then pumped to a flocculator-clarifier.
Experimental work concluded that settling rates of the lime
treated effluent were greater than untreated effluent.
Clarifiers were designed on the basis of a 40.74 Ipm/sq m (1.0
gpm/sq ft) rise rate. The primary clarifier is 41.15 m (135 ft)
in diameter with a 4.57-m (15-ft) side water depth. The
flocculation zone is 2.19 m (40 ft) in diameter. The clarifier
mechanism has a continuous torque rating of l65';^ m-kg
(1,2000,000 ft-lb) with a peak load of 248,940 m-kg (1,800,000
ft-lb). Clarifier overflow is through submerged orifices to a
peripheral launder.
Lime is drawn from the mill causticizing system and slaked in a
renovated slaker. The slaker overflows to a 3.66-m (12-tt)
diam-t-r, 3.05-m (10-ft) deep slurry tank. Water is added to the
tank to maintain constant level. Lime pumps operate continuously
at designed capacity. Lime is added to the raw effluent in the
lift station.
Overflow from the primary clarifier flows by gravity to a
carbonation tank, 9.14-m (30-ft) in diameter and 3.6b-m (12-tt)
deep Entrance to the tank is submerged. The tank is equipped
with four, 29.83-kw (40-hp) agitators. Lime kiln stack gas
(source of carbon dioxide) is discharged to the carbonator tank
through four specially designed outlets below the agitators for
contact with the effluent. The reaction of the stack gas with
the effluent forms a calcium carbonate precipitate which is
s-ttl-d in the following carbonation clarifier. The design of
this clarifier is identical to the primary clarifier. Foam
aenerated in the carbonation tank is spread over th^ surface of
the primary clarifier where it breaks down.
298
-------
were desiSn-S * ?h K • ari*ier, slu^e P™PS a^ centrifugal and
were designed on the basis of a 10 percent consistency sludge
Sludge consistencies from both clarifiers have been higher r^n
design expectancies, however, and the initial pumps have been
replaced with pumps having larger suction openings, sludge
consistencies have been 15 to 20 percent. Primary lime-omnic
cP±?f, 1%PUmJed ^ an a^itated ^rage tank and JhSn^a
wort tSfJo ?K dewatefln^ A considerable amount of experimental
T?2» r? 6 selectlon of centrifuges over vacuum filtration
( , ';. It^ 1S stated that a high »G" force is required in <-h<=>
selection of a centrifuge for this purpose. " '
Underflow from the carbonation clarifier is pumped to the
" o, the
The dewatered primary lime sludge and the dewatered lime mud are
combined and fed to the lime kiln. The kiln was designed ?or ?he
IJttTSJ C2™\ rfm°va\ slud>
This value was reported at a lime dosage of 1100 mg/1. with '> me
dosages resulting in a dissolved calcium concentration of ahout
<*00 mg/1, color removal averaged 85 to 93 percent it wac,
reported that when NSSC effluents contributed more than"half of
tne color, efficiency of color removal was reduced bv abow 1
-------
Figure 56
Flow Sheet for Plant Design Continental Can Corporation [249]
CO
o
o
-------
^^JSHS^3?^i?Sn!?Sss
,« o * - o
be required tS prot^he Mo^™:!"1 hOldln
-------
reused in the woodroom first. This supplies a necessary source
of fiber which aids in the settling and dewatering of the lime
sludge. in the patented process description, the addition of 20
to 200 mg/1 of cellulosic fiber is called for to aid in settling
and dewatering of the sludge solids.
As developed, the process calls for the addition of 1500 to 2000
mg/1 of slaked lime to the caustic extraction effluent ahead of a
solids-contact clarifier. Polyelectrolytes are also added to aid
settling. Overflow from the clarifier is mixed with other
effluents prior to discharge. The sludge underflow is pumped at
10 *o'l5 percent solids to a mixing tank. In the mixing tank,
filtered lime mud is added, raising the solids concentration to
23 percent. The sludge is dewatered on a conventional belt
fil-er ?o about 50 percent solids and then burned in the lime
filter
kiln.
The flow diagram for this process is shown in ^re 57. Certain
of the design criteria used at Woodland are presented in Table
85.
The Woodland, Maine color removal facility reP°rt*d ^hieving 90
percent reduction in color when treating the bleach plant caustic
extraction effluent (275) (276) . When the caustic extraction was
reused^ the woodroom prior to color removal, a 94 percent color
reduction 'was obtained. Lime dosages for the above reductions
werT20oS and 1500 mg/1, respectively. The caustic extraction
effluent color went from 12,000 to 1300. Additionally, a 47 to
55 percent BOD reduction was reported. Lime recovery efficiency
was 75-80 percent with a 6.80 kkg (7.5 ton)/ day lost.
The woodland color removal facility has not been operated for the
past year and one-half for two different reasons (277) :
1 Rivr flow has been high and, thus, adequate dilution
of the colored effluent has been naturally attainable.
2. The green liquor causticizing clarifier has been in the
process of being rebuilt.
For the above reasons, no additional data are available.
Inclusions drawn indicate that the key to successful operation
of th° system is a well designed solids contact clarifier
discharging sludge at 10-15 percent solids (276). It is also
report! SUt high sodium levels in the effluent adversely affect
color removal.
The characteristics of the reburned lime are essent ially ^e same
as conventional calcined lime except for a tan color. No Adverse
effects on +he kiln operation were observed. Color removal added
ll Ql kkg (23 tonsi/day to the normal 362.9 kkg (UOO ton) /day
kiln loading.
considerable foaming was incurred at the cl «"i«- £
This was corrected by installing a ring of water sprays
302
-------
Figure 57
Georgia Pacific Line Process for Color Removal [261]
MUDFP.CM '///
GO
O
co
C.IAK1FIE.Z
-------
Table 85
STATISTICAL DATA
Equipment Description
Color Clary,c 70-ft Dorr-Ohi er Ri*e rat>: gal.jt*/aa\ Retention time, hr
"low 2001 jjai/min 750 29
flow 3000 gal/min 1120 19
Sludgepumps .Moyno (two): 0-300 -nl/min at 200-h head
Slakcr—Uorr-Oliicr .\n 6 65ton'da>
Filter-Eimcu Belt 10 ft X 12 ft—effective area 37G ft2
I.imc Feed, T> pieal Uatj
Lime flurry. 10% as CaO
Dosage. 2500 ppm-42 Ib min-10 ton/day
Lime recovery efficiencx. 75-S07c
Lime lo^t to sewer, 7.5 ton day
Color Removal Sluci'.e, T\pical Data
At 2500 ppm lime dosesludpe flo\\ is 36 sal /mm a; it)7c solids.ind of ))ref ''u-n.-d lime mud adck d at
rni.x tank.
Thicl-.ened thidgc to belt filter. 45 gal/min at sp «r i 73
Kiln Opor.ition, T>pical Djtj —2)011 lime doi.ipo
Color removal system has added an additional 23 ton day to the i.jrmal 400 ton/du Ic'trv
basis) lime mud load to the kiln.
Filtration Hate Data
Leaf filter fcsf.t on i>% ?o/ia'< sludge
Vacuum 25 in
Form time 20 sec
Drying time 20 sec
Cake thickness v, jn_
Cake v,t. o d. 5g p
\Vet cake solids 577,,
Filter rate 1121b/lt2hr"
Calcining
Incineration ot abose cake \ield- oS^i is;nited s.r>lids c-nntainum 1 ,V;'f Midium and 0 TTr -il'i '. n-
biO2 llii-sciiiiifjartMuththi-.^O'V soluL-, jtid 1 !''.(.v-duini knehn (lit- original lime i:iuu
No chan«e in silica or other property ob-er\i-d other than .slight tan coloiation ot rebi'rnt
lime.
"It slud»eMilid-<
-------
Georgia Pacific Corporation, Crossett, Arkansas
Operation of the original Crossett color removal facility was
sporadic, the reason being that color removal was undertaken only
when the flow in receiving stream reached a critical low rate.
The initial treatment system employed the use of a converted
water treatment clarifier. The hydraulic capacity of this unit
was less than the flow rate from the bleach plant. As a result,
new facilities of proper design are currently under construction.
Design criteria used at the new Crossett removal facility are
essentially the same as those used at Woodland. Operationally
the water to be treated (caustic extract) will come directly from
the bleach plant and will not go through the woodroom first as it
does at the Woodland facility. Start-up of the new facility was
scheduled for mid-July 1974.
£;ifflf_Mud_Treatment
An indepth review of minimum and massive lime treatment
techniques has been presented above. However, one scheme -- the
lime mud process -was not included. This is a modification of
the minimum and massive lime processes. A minimum guantity of
slaked lime and the total mill lime mud production are mixed
together and reacted with the effluent. The lime-organic sludge
is dewatered and burned in the lime kiln. This process has the
advantage that the organics are not introduced into the white
liguor since the lime mud-color body sludge goes directly to the
kiln and in no way comes in contact with either green or white
liguor. A flow diagram of the lim mud process is presented in
Figure 58.
International Paper's Springhill, Louisiana, bleached kraft mill
operated their color removal facility on the lime mud process
after the completion of their EPA massive lime demonstration
project in 1971. A number of studies, each of two- to three-week
duration, were conducted at the 1892.5 1/min (500 gpm) facility
Unbleached decker effluent, when treated with approximately 900
o2XL reburned lime and 12,000-15,000 mg/1 lime mud, yielded an
85-90 percent reduction in color. Treatment of a 1:1 mixture of
o™r, «1?J first s-tage caustic extract effluents reguired a
J,000-4,000 mg/1 dose of reburned lime plus 12,000-15,000 mg/1 of
lime mud to reduce the color by 80-85 percent. Treatment of
straight caustic extract reguired reburned lime concentrations
approaching those used in the massive lime process. NO
operational problems were encountered except when straight
caustic extract effluent was treated. However, an extremely
voluminous, non-consolidating sludge was produced. Because of
comparative analyses of the lime mud study results with those of
other treatment schemes, further development and evaluation were
discontinued (278). No published data are available for IP's
trial studies on the lime mud process.
305
-------
Figure 58
NCAST. Line Mud Process
for Color Removal [289]
NEW EXISTING
MUC FILTER MUD FILTER
MUD F£>OM_
! WASHER ~~]
nL
'. ft i rcLAIi 1° I
am ACHE PY .rJ-J
IJrLUiNT
MIX TANK
CLAQIFIEB
{
LIME
306
-------
The coagulation of pulp and paper waste waters by numerous
chemicals has been evaluated by many researchers starting with
the early work discussed previously which led to the development
of the lime process (254) . of all other chemicals investigated,
alum seemed to yield the most promise as a color removing
coagulant.
The effect of pH on coagulation of biologically treated kraft
mill effluent with alum has recently been studied (279) . The
concentration of Al in the treated effluent and the effect of pH
at which coagulation was carried out on residual effluent color
were examined. The minimum concentration of Al was observed at a
pH of 5.9 to 6.3 and the optimum pH for a minimum effluent color
of 50 PCU and minimum residual Al content was said to be 5.5 to
5.8.
Organic polyelectrolytes used with alum or ferric chloride ^
color and solids removal from both bleached and unbleached kraft
pulp and paper mill aerated basin effluents have produced better
than 85 percent color removal, low turbidity, and eventually zero
BOD at an optimum pH of 4.5 to 5.5 (280). Chemical sludge
recycle increased the effectiveness of alum up to 270 percent.
Laboratory tests of the effects of alum and ferric chloride for
the removal of color from kraft mill effluents have been run on
both hard and soft woods (281) . The optimum dosage of alum on
hard wood wastes was found to be 150 mg/1. A color reduction of
89 percent was achieved from an initial color of 710 units. Soft
wood kraft effluent was found to require a dosage of 30 mg/1.
Ferric chloride coagulation of soft wood waste required an
optimum dosage of 286 mg/1 and produced 87 percent removals.
A laboratory investigation of alum and six organic
polyelectrolytes for the removal of color from kraft mill waste
water found little difference in the performance of the six
polyelectrolytes (282). Alum produced good results, but resulted
in approximately three times the volume of sludge. Color
removals averaged 95 percent.
A 287.7-kkl/day (76 MGD) tertiary waste treatment facility of a
Baikal, U.S.S.R. pulp mill treats the wastes from the production
of 273.1 kkg/ day (301 ton/day) of tire cord cellulose and 29.94
kkg/day (33 tons/day) of kraft pulp (283). Treatment consists of
neutralization, nutrient addition, equalization, activated sludge
treatment, alum coagulation, sedimentation, sand filtration,
polishing lagoon, reaeration, and discharge to Lake Baikal. in
the coagulation stage, alum is used at a rate of 30 mg/1 as A1203
and polyacrylamide flocculant is fed at a rate of 1 mg/l7
Detention time in the chemical precipitation clarifiers is six
hours. Color of the raw waste water averaged 1000 units and th<=>
treated water color averages 101 units. Thus, the system yields
an overall removal approaching 90 percent.
At Gulf States Paper, Tuscaloosa, Alabama (284), a 45. 42-kkl/day
(12-MGD) treatment facility is in final construction which is to
307
-------
be capable of reducing the final effluent color to less than 50
APHA units. Raw waste water color from the unbleached kratt mill
is in th* range of 800-1200 APHA units. Treatment is to consist
of primary clarification, bio-oxidation using high purity oxygen,
secondary sedimentation, and finally, alum coagulation and
sedimentation before discharge. Primary clarifier sludge, excess
biological solids, and the alum sludge are to be blended,
thickened, pressure filtered, and burned in a multiple hearth
furnace. The residue from the incineration process, which will
be high in A1203, will be reacted with sulfuric acid to recover
the aluminum as aluminum sulfate. Projected recovery of alum is
94 percent. Final effluent from the treatment plant should be of
a auality suitable for reuse and it is planned to recycle 50
percent of this flow 22.71 kkl/day (6-MGD) . Startup date is
scheduled for early August 1974.
Hyperfiltration (Reverse Osmosis)
At present there are essentially three types of reverse osmosis
systems available on the commercial market:
1. Spirally wound sheet modules
2. Capillary fiber modules
3. Hollow core tube modules
The life of the membranes used in all of these modules are
areatlv influenced by the pH and temperature of the waste waters
being treated. In general, a pH less than 7 and a temperature
less than 38°C (100°F) are reguired to minimize unnecessary
deterioration of the membrane. In addition, membrane fouling due
to "buildup of materials on the membrane surface causes a marked
decrease in permeate yield rate. Fouling is inherent in all
existing systems but may be minimized by pretreatment of tne
waste waters to remove particulate and colloidal materials and/or
pressure pulsing and cleaning of the membranes. In addition,
fouling of tubular modules is further decreased by maintaining a
water velocity over the membrane surface of approximately 0.91
m/sec (3 ft/sec) .
B-cause of the wide spectrum in size of dissolved and particulate
materials found in pulping and papermaking waste waters, the
spirally wound and capillary fiber modules have been found to be
more prone to irreversible fouling problems than tubular modules.
The following average results were obtained with tubular type
module reverse osmosis treatment of various pulping waste waters
(208) :
1. ca-base acid sulfite pulp wash water
water intake - 166.54 kl/day (44,000 gpd)
Permeate yield - 84 percent
Flux rate - 244.46 Ipd/sq m (96 gpd/sg ft)
308
-------
Color removal - 99 percent
2. NSSC white water
Water intake - 200.61 kl/d (53,000 gpd)
Permeate yield - 82 percent
Flux rate - 285.2 Ipd sq m (7 gpd/sq ft)
Color removal - 99 percent
3. NH3-base sulfite liquor
Water intake - 158.97 kl/d (42,000 gpd)
Permeate yield - 65 percent
Flux rate - 285.2 Ipd/sq m (7 gpd/sq ft)
Color removal - 98 percent
4. Caustic extraction effluent (kraft mill)
Water intake - 5.68 kl/d (1500 gpd)
Permeate yield -
Flux rate - 285.2 Ipd/sq m (7 gpd/sq ft)
Color removal - 99 percent
Pretreatment of the wastes was necessary and included filtration
through a^UO-mesh screen, pH adjustment, and cooling to less than
Operating at a flux rate of 285.2 Ipd/sq m (7 gpd/sq ft), the
Green Bay Packaging, Inc. reverse osmosis treatment system
obtained 90 percent permeate yield and 99 percent color reduction
(207).
Ultrafiltration (Macromolecular Filtration)
Because of the relatively high molecular weights of color bodies
in pulp mill effluents, Ultrafiltration has been proposed as a
method of color reduction. Laboratory scale studies achieved a
color reduction of 98.6 percent, from 12,750 to 180 color units
for pine pulp caustic extraction effluent (210). The membrane
used which had a molecule weight "cut-off" of 1000 was
fj^surj-z^ to 90 Psi
-------
various effluents tested during the six-month study are presented
in Table 86.
A method of tubular ultrafiltration for removing contaminants
with molecular weights greater than 500-1000 has recently been
announced (286). In laboratory tests, secondary effluent samples
from sulfite and unbleached kraft mills were subjected to this
mode of treatment and 85-95 percent color removal from the
untreated water was realized. In addition, 95-98 percent
permeate yield was obtained. Operation of the system was said to
be independent of pH (1-14) as well as temperatures up to about
93°C (200°F). Flux rate through the coated graphitic carbon
medium was reported to be 4074.3-6111.4 1/day/sq m (100-150
gpd/sq ft) at a pressure of 7.03 kg/sq cm (100 psig).
P2iX?S§£iS_Adsorbent_and_Ion_Exchange_Treatment
Polymeric Adsorbents
Pilot plant work has been performed on the effectiveness of a
synthetic polymeric adsorbent for decolorization of kraft bleach
plant effluents (287). Since 85 percent of the bleach plant's
total color output was contained in the chlorination and first
stage caustic extract effluents, major efforts were placed on
treating these combined flows. The average color of the waste
water was 2203 APHA units and ranged from 779 to 2923 APHA units.
Average pH of the waste was 2.2.
The efficiency of the polymeric adsorbent used was found to be
very pH dependent. At a pH of U.5, 40 percent decolorization was
realized while at a pH of 2.0, 90 percent decolorization was
obtained. The adsorption system is defined as working on the
principal of Van der Waals attractive forces and not on the
phenonenon of ion exchange.
The system included prefiltration of the chlorination and first
stage caustic extract effluents for suspended solids removal.
The filter was made with 20- to 50-mesh sand and reduced the
total suspended solids of the filtrate to an average of 36 mg/1.
By passing the wastes through the adsorption columns at a rate of
12 bed volumes per hour, about 23 bed volumes could be treated
before regeneration of the adsorbent was required. Volume of
adsorbent in the column was 0.0142 cu m (0.5 cu ft). Therefore,
flow rate through the column was approximately 2.84 1/min (0.75
gpm). Regeneration was most advantageously accomplished by using
white liquor at a rate of 1.1 bed volumes per regeneration. The
concentrated waste water resulting from the regeneration of the
resin is returned to the pulping loop where it is concentrated in
the evaporators and eventually burned in the recovery boiler. In
addition to the above mentioned color removal, 33 percent BOD
removal and 43 percent COD removal from the treated waste stream
was realized.
Ion Exchange
310
-------
Table 86
COLOR REMOVAL EFFICIENCY [270]
Influent
Pine caustic extraction
filtrate
Pine Decker effluent
Hardwood Decker effluent
Initial
Color, m;>/l*
19,000
4,000
8,000
% Water
Recovery
98.5-99
98.5-99
98.5-99
% Solids in
Concentrate
15-20
5-8
5-8
% Color
Removal
90-92
95-97
95-97
* pH of feed adjusted to 6.5 - 6.9, filtered, and color measured at 465 mu.
-------
Ion exchange systems have been used for many years for the
softening and demineralization of water. Until recently, this
unit operation has received little attention as a waste treatment
technique because of a number of technical and operational
problems. Some of these and pretreatment requirements to
minimize pending inefficiencies of the systems are as follows
(245):
Constitutent Problem Pretreatment Required
Suspended Solids Blinding of columns Coagulation and/or fil-
tration
Organics Fouling of strong Carbon adsorption or use
base resins of weak base resins
Oxidants Oxidation of resin Oxidant reduction
functional groups
Fe and Mn Coating of resin Aeration
With the advent of new resins and more advantageous pretreatment
techniques, ion exchange treatment of waste waters is becoming
more technically and economically feasible.
A full-scale ion exchange system treating the first stage caustic
extraction effluent from a 272.16 kg (300 tons)/day bleached
kraft mill using the CEHDED bleaching sequence has been in
operation nearly a year (288). This waste stream averaged 100 cu
m/hr (3531.32 cu ft/hr) in flow, 14,000 PCU in concentration, and
95 percent reduction of the color from the entire bleach plant
31.8 out of 33.6 kkg (35 out of 37 tons)/day of color.
After prefiltration to remove fibers, the waste was passed
through the ion exchange columns at a rate of five bed volumes
per hour. Sixteen bed volumes of the waste could be treated to
an average 90 percent color removal before regeneration of the
resin was necessary. The concentrated waste resulting from
regeneration of the columns is sent to the evaporators and is
then burned in the recovery boiler. At this level of treatment,
total bleach plant effluent color reduction was 86 percent.
Schematic diagrams of the actual system and additional data are
presented in Figures 59 and 60.
In addition to the full scale ion exchange operation, this type
of treatment has been applied on a laboratory scale to waste
waters from a four stage bleach kraft plant (CEHD bleaching
sequence) which had been pretreated by massive lime precipitation
(287). The twenty resins investigated were generally
unacceptable for decolorizing the wastes from the chlorination,
hypochlorite, and/or chlorine dioxide stages because of the
aggressiveness of these waters on the resin functional groups.
Desalination of the pretreated bleach plant waste water (85 per-
312
-------
\
13
BL'-'acii Piasit -.r-d Ion L>:chnriKc- Sysucn [274]
(Ccuircesy of T/PP1")
Cuiier L -
tdnk
- .,, -» -\ J
vv ;i t
r-\ H v
Fiho. f S i
trap i- .'•! '{
LLfin^S ^
Drain
or H-iji
Fjguro 60
c Color Rpir. vai :'vstcn
(Coi:rfi'py of ', A'T'I)
313
-------
cent chlorination and 15 percent caustic extract effluents) with
a strong acid cation weak base anion exchange system yielded
effluents comparable to those obtained with massive lime-
activated carbon treatment.
Activated_Carbon_Treatment
Activated carbon is a material characterized by extremely large
surface area to unit weight ratios, typically 450-1800 sq m/gram
(2,362,8299,451,317.1 sq ft/lb). The large surface area
available results in substantial adsorptive capacity. The rate
of adsorption is a function of carbon particle size, powdered
carbon having a faster rate than granular carbon. Ultimate
adsorptive capacity, however, is essentially in the same for both
(234).
Activated carbon has been used in combination with other
treatment processes on a pilot scale for the treatment of
unbleached kraft mill effluent (234). The treatment sequences
were:
1. Primary clarification; activated carbon
2. Lime treatment; clarification; activated carbon
3. Clarification; biological oxidation; activated carbon
The flow diagram of the pilot system is shown in Figure 61. Two
carbon systems were evaluated. The first used four standard
down-flow columns for series or parallel operation. The second
system is called the FACET (Fine Activated Carbon Effluent
Treatment). Use of a trade name does not constitute endorsement
of the product system and is a multistage stage countercurrent,
agitated system with continuous countercurrent transfer of both
carbon and liquid from stage to stage. It uses a carbon size
between standard granular and powdered classifications. The
system is the subject of a patent application.
In the lime-carbon system, lime dosages were from 318 to 980 mg/1
CaO. This system is referred to as "micro" lime treatment as
compared to the "minimum" lime treatment used by others
(247) (270) (271). With these dosages, recarbonation of the
effluent was unnecessary for reuse of the treated effluent. It
should be noted that the intent of this investigation was to
treat the effluent to a degree allowing reuse in the mill. A
combination of systems capable of producing an effluent suitable
for discharge was not necessarily being sought.
The efficiency of activated carbon absorption preceded by massive
lime treatment and carbonation both with and without extended
aeration has been investigated in a batch treatment pilot plant
(232).
Similar studies were undertaken on a pilot scale (219) to
investigate the effects of massive lime treatment, biological
oxidation, and absorption in granular carbon columns. Others
314
-------
CO
en
Figure 6'l
Activated Carbon Effluent Treatment Pilot Plant [219]
LIVE—. [! r
•it li >V
LiME TREATER CARBONATCR p.H
FILTER ACTIVATED CARBON COuUMNS
STORAGE
-ANK
CLARIFICATION
NO. 2 MILL EQUILIBRATION OR
EFFLUENT BIO-OXIDATION BASIN
U-MM
<
9
Cy
^
/
/
/
* s
! /
|i /
Cl'i-
PI r
>Y
IA.^/
ACTIVATED CARSON
0!
! I
SPENT
CARBON
FACET
1 /
i /
i /
i i
i,./
-fy lii
Mil
CONTACTORS
FILTER STORAGr
TANK
-------
investigated the effect of activated carbon as a polishing step
following biological oxidation and lime treatment (280). This
process was tested on total kraft mill effluent on a semi-pilot
plant scale and was also run without the lime treatment step to
test the effectiveness of carbon in reducing the effluent color.
The biological-carbon treatment sequence utilizing four columns
in series reduced color of total kraft effluent to 212 units
which was too high for reuse in some areas of the mill. This is
shown in Table 87. It is estimated that an additional three
columns would be required to produce the goal of 100 color units
(234).
The primary clarification-carbon system also used four columns.
Color was reduced to 185-202 units. This is shown in Table 88.
As with the biological-carbon system, it was estimated that an
additional three columns would be required to reach 100 color
units.
The clarification-lime-carbon system produced the best results of
the three systems. Color removal increased from 70 percent at a
dissolved Ca concentration of 80 mq/1 to 86 percent of a Ca
concentration of 400 mg/1. Lime dosages ranged from 318 to 980
mg/1. Color reduction is shown graphically in Figure 62. Color
removal in the carbon columns (2 columns in series) was also
found to be dependent on Ca concentration. Color in the effluent
remained at about 60 units at calcium concentrations above 40
mg/1. Color removal through the carbon columns in the soluble
calcium range of 69-83 mg/1 averaged an additional 21 percent, to
give an overall reduction of 90 percent. This is shown in Table
89. Water of this quality was considered suitable for reuse.
Operation of the FACET* system following lime treatment produced
similar results to the two carbon columns after filtration. This
is shown in Table 90.
A four-stage (lime-carbonation-oxidation-carbon) system achieved
a total color removal of 99.5 percent (232). In a three-stage
system (no oxidation) the total removal was again 99.5 percent.
This is shown in Table 91.
The color of unbleached kraft effluent was reduced to 10 and 15
units in two separate pilot runs using the massive lime-
biological-carbon system (289) . Raw effluent color was 4800 and
3000 units respectively. This is shown in Tables 92 and 93.
A final color of 40 units was readily achievable by a biological
oxidation-lime-carbon treatment system (290).
It was concluded that the use of a sand filter ahead of the
carbon system did not provide enough benefit to warrant
consideration in a fullscale installation (234). concentrated
bio-activity was noted in the top one or two foot layer of the
first column in series which caused plugging. Backwashinq was
316
-------
oo
Table 87
COLOR REMOVAL IN BIOLOGICAL OXIDATION
CARBON ADSORPTION SEQUENCE AT 15 GPM (2.13 GPM/FT2)[219]
Ran?e. Average
Feed to bio-oxidation, APHA CU ^n 9,nn
Feed to carbon, APHA CU ,£n~™ 110°
Product from carbon, APHA CU A?~lnn ?4°
Removal by bio-oxidation plus filter % ^JfUU 212
Removal by carbon, % of feed to carbon' - 33
Total removal % of feed to bio-oxidation - 71
Rate of removal by carbon, CU/g hr 0 5l_± QQ 81
Note: Color measured at PH 7.6 after 0.8 micron Mlllipore filtration
-------
Table 88
COLOR REMOVAL BY PRIMARY CLARIFICATION
CARBON ADSORPTION SEQUENCE [219]
Range •'verage
Flow rate, gpm 10 5
bJ Flow rate, gpm/ft2 1.42 0.71
00 Feed to carbon, APHA CU 925 1160
Product from carbon, APHA CU 135 2C2
Removal by carbon. % 80 83
Rate of removal by carbon, CU/g hr 0.69 0.64
Note: Color measured at pK 7.6 after 0.8 micron Millipore filtration
-------
CO
><
i
Ix
»-.
C*i
'*
j
6
u
uu
0
gc
o
s
^
.LUU
90
80
70
60
5 0
40
30
20
10
0
—
^ rxO"~
9PO-oo^""^"^"'""
0 ^DO- C 0
"O ^x
u X o
„ / o
/o
o
—
—
—
1 1 1 ! 1 1 .!. 1 1
120 200
2°
o
360
0 80 ISO 240 320 400
SOLUBLE CALCIUM FROM LfME TREATER, MG/l
Figure 62
Color Removal ±r\ Lime Treatment as a
Function of Soluble Ca In Water [219]
319
-------
ro
o
Table 89
COLOR REMOVAL BY LIME TREATMENT - CARBON ADSORPTION
SEQUENCE AT SOLUBLE CALCIUM RANGE OF 69 -83 rag/I [219]
lime dosage, CaO, rag/1 523
pH of feed to carbon adsorption 11.3
in
flow rate to carbon adsorption, gpm -1-1-'
No. of carbon columns ^
Color, TOC,
Concentrations: APHA pH 7.6 iag/1.
to lime treatment 852 2,2
to carbon columns 252 I//
from carbon columns 76 100
% removals from feed to lime treatment:
in lime treatment 70 -"
in carbon adsorption 21 28
total * 91 63
-------
Table 90
^ REMOVAL OF COLOR AND TOC BY
FACET CARBON ADSORPTION FOLLOWING LIME TREATMENT FOR 12-DAY PERIOD
10/20 THROUGH 11/6 [219]
CO
Conditions:
Water feed rate
Carbon feed rate
Carbon in system
Carbon slurry density
Stages
10 grm
2.7 ib/hr = 4/5 lb/1000 gal
605 Ib
14.3 g/100 ml slurry
Removals:
Feed
Product
Percent removal
Removed, mg/g carbon
Removal rate, mg/g x hr
Color, C.U.
APHA pH 7.6
157
73
54
214
0.71
*Use of a trade name does not constitute endorsement of the product.
-------
£'65
CZ
CT
S'96
£1
01
ST
ooz
„ -^ < -
£1
83
£31
CI
OS1?
OvZ
£6
C6
CCC'I
ooz's
COO'I
coo'zi
scooo-d c/S33S-^
ZOT
69
COC -XYG-S
oil
"u~-:
C\J
CO
-------
00
Table 92
RZSOVATSP VATEP. ANALYSIS
CKED KEATT LIXER30AI3 TOT/L >r.LL E«LU2KT
PILOT PLAINT P.VN :,'0. 1 50 GALLOi; LATCH OPERATION
"On.:> t^. fj^n u
"..-•-,• •-• «.
Color, units
K.-.rdr.c3s, ppm CaCOj
Dissolved solids, pna
Chloride, pp.,
COD, pp=
t?O"> _
Ka, err*
T) ,•»(, -'._._ J "Drt*-!!-*/!
5-25
0-50
6.5-7.7
5-200
50-500
10-150
0-12
0-5
T c c} .,__*.
£.i.li"or.t
4COO
3.7
107
3330
110
O T O
1^03
""^ ^' • S"
140
11.5
7.1
2510
140
—
£60
1130
_ •*• * . r'
3io ^f
200
9M
55
2650
35
201
S
1500 (d)
-. t,^'. u — _ .* U
CcrbcrA0''
10
8.7
61
2500
35
1
1400
.valcnt to
Cb) Sx;er.d=d aeration for 10 days. Or.c gallon fertile lake veto- added as «c-'
na.cr,a... ^011, :^03 and K3?CA added a= nutrient. H2S04 added to n-.utralisft.
(d) Possible Nil," interference.
-------
Table 93
R2XOVATED WATER A>7.L,YSIS_[7041
U> Turbidity, ppa
[S Colcr, units
:.r-:r.css, p?= CaC03
Dissolved Solids, p?n
BLEACHED KRAPT L
.07 PLANT RVX NO.
D^i i**ed FkCrirc
5-25
0-30
6.5-7.7
5-200
5Q-500
10-130
G-12
0-5
IXu^OAIO TOTAL
2 50 GALLCX S
Effluent
_ ,
3000
7.5
4190
ISO
I'OO
320
HILL EFFLUENT
ATC11 0?E?-'\TIOX
Obtaircc
Lir.e(a)
„
100
12.1
2610
2CO
7^0
23C
ov Trc.-tr.sr
Bio^> C
-
S.2
1CCO
3070
130
(135) W)
230
it
:arbon^c:
-
8.5
865
2 SCO
130
(80) W
Notes: (a) 2.87 Ib3. reburncd liae slaked and adde:. to raw effluent (equivalent to 75.0 p
(K) z^^dcd aeration for 5 days. One gallon fertile lake vater added cs sc.d
Material. !L\03, H3r04 added as nutrient. H2SOi accca to r.eutra.i.c.
f^ C,_s0, ^!,.-,,3 containing 12x^0 ccsh activated carbon furnished by Pittsburgh.
"C Carbcn."contact" t-L~c in°carbon bed was 1.6 aiautcs.
(d) Estimate, incubator problems.
-------
the elimination of
remove the calcium. Higher
prior to reuseTf the S
Produced a sludge that
Lime treatment to higher diol V«H
followed by carbonation anJ carlon
color reductions.
The possibilities of the FAPFT*
enthusiasm. A rate of TOC removal T of
removal in columns has been observed "Inr.
removal was the same as in the ™?,,mnf K f
amount of carbon. More wSrk is planned. "
w is
carbonate the effluent to
° re
-------
har o- JET-
pd ar -
of ?emSving both color and BOD from the first stage caustic
™g effluent of a kraft bleach plant (228) The char was
'
(100 Ib) of
Wez« Wuu«x»~ "when'the selected~^s;eawater was treated with 20
grams/liter (.166 Ib/gal) of the activated char.
Extraneous_Treatment_Technigues
Ozonation
mill secondary treatment plant effluent has been subjected
^ "piTot plan? Satment by ozonation (294). The mi 11 Produced
U53.6 kkg (500 tons)/day of fully bleached pulp »nd b^.J ^g
f600 tons)/day of fine papers. Color of the was.e water
.ublec-2 to treatment ranged from about 400 to 900 color units.
removal was found to be primarily a f™^™ of the applied
concentration, but was also influenced by initial color,
anS Suspended solids concentrations The amount of color
removal obtained from the 18.93 1/min (5 gpm) pilot plant
operation is shown in Table 9U .
Enzymatic Pretreatment
Thp removal of dyes from the effluent of a fine paper mill has
been rSSr-ed (156). The waste water was intially subjected to
of the starch sizing in the waste water. By
- .ss
o e which cw not be rectified »|xt an enzyme
was introduced to destroy the dispersing power of
clarifier and
•t-hPre was adequate cnioriri« ieaj-i-K-iaj- - _„_,• «/^ wa<5
overall suspended solids removal_for^a three-month period
treated.
326
-------
TABLE 94
COLOR REMOVALS FOR VARIOUS APPLIED OZONE DOSES [279]
Ozone_A££liedJL_E£m
/* Color Removal
10
20 32
30 56
40 67
-------
Precipitation With Seawater
clarifier underflow.
Extraction
m
expensive amine.
ADVANCED_WASTE_TREATMENT
discussed as they apply to:
1 Removal of turbidity and colloidal and suspended solids
2 Removal of dissolved salts and dissolved solxds
3. Removal of refractory orqanics
4. Removal of nutrients
Each technology is Ascribed -d its efficiencies and operational
considerations are discussed. " wl"°ai£ A^ systems has h^en
subcateqor ies .
328
-------
u^_ for
subject subcategories unless"otherwis^noted!
The
o
-~
Bemoval_of_TurbiditY_and_Colloidal_and_SusEended_sglids
settling-
Filtration
concept'0" Mechanicaftrationo- Pr°CeSS is ^ « new
back to 1883 I? wJs noJ wf? i Primary settled sewage dates
methods became popular b'ut faJY "+** ** biolo<3ical treatment
because of the^ve * COnsidered i" the 1930- s
ecause of thevelomt ofr™ s
include: 1) remoiai of MoloaSTf,10"^ ln waste>«"--« treatment
2) removal IT prec?pita?es ??i S S"1 S9conia^ effluent.
'
of
been practiced in
329
-------
conventional downflow gravity method, although some pressure
filters are being used. Information on the use of filtration in
waste treatment is summarized in Table 95 (196).
Many tests have been conducted on both pilot plant and plant
scale operations to determine the effectiveness of filtration for
suspended solids and BOD removal and to develop design criteria.
Gravity downflow filtration has been found to be a cost-effective
m-ans of reducing suspended solids in the effluent of wastewater
treatment facilities. Both conventional and special design
filter beds have been tested. The effectiveness of chemical
addition to improve filterability of secondary effluents from
pulp and paper mill wastes has been established in an NCASI
Technical Bulletin, No. 266 (213).
This report gave details of a study to evaluate the effectiveness
of various filtration systems for the removal of suspended solids
and BOD from three separate and different mills. Comparisons
were made between removal efficiencies for filtration without the
use of chemical additives and filtration with the use of chemical
additives. The conclusion of this study was that chemical
addition, either alum or polymers, would improve greatly the
filterability of these wastes as compared to their tilteraoniry
without chemical addition.
Treatment Efficiencies
Tchobanoglous (199) evaluated the performance of various filter
configurations including conventional and special bed designs and
the effects of chemical" addition. His conclusions were: 1)
filtration efficiency without chemical addition is a function of
filter bed grain size, 2) in most dual-media filters as presently
designed the sand underbed contributes little to overall
suspended solids removal, and 3) polyelectrolytes can be used to
aid in removal of suspended solids. At a filtration rate of
209.82 ipm/sq.m 5.15 gpm/sq ft) and with polyelectrolyte
addition, an average influent suspended solids concentration ot
23.5 mg/1 was reduced to 1 to 3 mg/1. Run lengths were between 4
and 5 hours. Removals ranged from 87 to 96 percent,
Tchobanoglous and Eliassen (200) investigated filtration of
activated sludge effluent in a pilot plant study. They developed
a generalized rate equation based on size of filter medium, rate
of filtration, influent characteristics, and the amount of
material removed within the filter. Using 0.188 mm sand,
suspended solids were reduced from 6.3 mg/1 to 2 mg/1, a 68
percent removal. Filtration rate was 236.30 lP»^-»- (5.8
gpm/sq ft) and run length was 6.25 hours. The top 0.025ft (1
inch) of the filter captured 75 percent of the suspended solids,
and no solids were retained below a depth of 6 inches.
Gulp and Hansen (201) found that up to 98 percent of the
suspended solids found in an extended aeration P1^ effluent
with 24-hour aeration of domestic sewage could be removed by
330
-------
Table 95
SUMMARY OF AVAILABLE INFORIIATION ON FILTRATION IN WASTE TREATMENT [190]
Source
.^ir-'°n .,
Dr. Hohr In
C*rrr^".y F^pH
(fr;- ZscV"7,
15J7)
Atls-.ta,
rep TS"d by
A. ?;tt,r
(frr- Z,;-,*7,
l-u?Fortal pt-
lot filter
(frr, S:rc3n-
d-r", 1940)
Vastc-
Vfiter
Charact.
M
Chcm.
tre«»l
prl-iry
effluent
Prl-.iry
lettled
Influent
Type. Site . SS (pptr) BOD (aig/1)
Filter e-Hf,, frfc^ fo, *nn M Ryn 5
(nn) fl V ' length j — —= - ,
Sand ~ ' ~~ ' ' —
1*^7 4.1 fl
Sand
2~3 0.32 4.1 J5
Anthracite 2 1 , •. „ ,
E'S-.<;-^ 5 12 "~" 79 tvice ., .,ny b.cVv^tn,, „,»!«
for Influent of 57 pp^ ag for
3.5 1 •» 19 PPQ SS
5 3,~,5 79 ^'
Sand
3 — 4 73
zs 40-50 low efflcienc.
Sa->d Ul °f "''S^'
2~3 12 0.75-;. 5 3.9 zo'~?i Reductl=- 1? t
Sand
28 0.75-1.5
«°~'°
"uppertal full
»cal» plj"t
26' 3" x 123'
(fr« Strean-
PrLsary
settled
effluent
Sand
1-2
28
0.83
4.25
Reducti=" 12 to :1X of
oxy^er. cons-, rrt IJ^ .
Prior to the
advent of high
velocity wash
fcchanlcal r^kcs
and lov velocity
!•-• Vvash or air
agitation frl.oweJ
Reduction In 0 Co-.s -*•
20- for 1.5 £ r/ft2
25-30-. for 1.1 Sp=/ft
35r. for 0.75 gpr'ft
dtjtr^bated throu<;i^t
the bod
Air wash, aupplled Lov reaoved by SS vaj JL4
by ceatrlfuEil to the Inability to
blower - 2.4 tf1/ thorouihly re;»ove the
rln/ft . Tne rate retained s»!lds fr the
of bick-.«h ir a .and bed. B3cV-.3rd "r.t'e
-------
Table 95 - Cont'd.
Source
Infor-tf tIon
ScJth ^l»er
pli-.l. N. J.
(fror Strean-
H.X. SS (ppm) lODj'.cs I)
W«te- Type. SUe terminal Run . __ .
s::.r.«. '"sr1' Du"
_ nj cln
I°t«l vashir.g ti».'d«>
. 120 air..
Reduction in EOi '-s
not proportional to
reduction of 55
Aucor Sewage
Wrrks, pilot
j>l«it, Sovth
Africa (froa
T 93
Secondary Sand
-ttled 0.5 ~ 1.7
effluent
29
10
6-18
24.3 0.7 ,7
bacswash
Pilot plant
•t Luton,
E-ijUnd
1949-1950
(free. Pettet,
Ccllett rf.d-
dlr-eton7",
1952)
Sand
0.85-1.7
24
Anthracite 24
1~2
S«nd
0.85-2
24
62
2.34-
2.34-
3.42
•"•
24
,,
.O
0.7 96
, 4 86 26 10 61.5 2-37. of treated No appreciable 1:! iere-.ce
water, 13.3 In held '.oss fcr SJ-i
gpm/ft2 rate filters iitK 2 ft a-d
3 ft 6 in depth, resper-
, , 57 26 9 65.5 2-3J. of treated tively. A'.3= llf.'.e i .'-
voter, 10 gpW ferer.ce In tffue-.ts .roa
ftz r«te twj fllteri at ratsi be-
low 2.92 gr=,'ft2, fcJt at
1,,3 0.9 95 23.8 7.2 70 W<£"}'Ue^f'V -i"
23.8 6.3 74
•uperlor.
-------
Table 95 - Cont'd.
GO
CO
CO
Source
Vaste- Type, Size
va'er Filter rod
Full ,cale sind
filter at Luton,
Evans'7, 1937).
Pretoria Sewage- Secondary Sand
._
Z'5
SS
terminal Run
head length » ;
(ft_v««) Chr, inf.. EH1. Ke^oved Infl. Effl. RCM'ucd i^l'tion
3.33 8-9
«««,,-„
73 13-° 6'7 49 By SIr-srour, 1. DuMp, sto--, '1^ -.- h-^
2-5'. »f lo^^S, bar•<•.«>! c cr/'
trestcd vster 12 ^rs.
2. iP-.or DO In filter cCfij'.n.s.
3. Cyldatiop. of ar-^cnia rar^e
frco 35 t3 b?'..
4. Cost per It- of SS resovtd
- 4.25 er,t pla:it effluent f.C. 1.6
(p-cl Irlnary
tests)(fro=
La.-etty «•!.
1961).
water .:sed
12'7 46 9'8 4-8 51 .uton.tclc
-------
Table 95- Cont'd.
Max.
terminal Run
SS (ppr.) BODj(»«/l>
Waste- Type, Sir-
«ter Filter fcdla Depth Rate". head
Source rv Lt (m) (in) (fcpn'fO (ft»i<:^/ » _ir___. . '
Inform! ion Charac^ (^ LJ—1? Filter closed easily
' l u 16.0 8 50 28.3 17 40 ^ ^ ,^
Lab stud> at M?v «t« ' a lev hours
Pe = r!a Ss-ltar/ a:ti'.ated
Dittvict Treat- sludge
ctr.l VsrVs '. froc effluent
Fall i Kr*.!S21
196i). 7 71 j 56 24.2 5=.» No tit v>sh j cl"£Sci^f^
R«carcf. .t T*nutlri8 £^0.55 24 4 6-25 6.25 18.5 &.0 «•* ^.^ ^-^ ^^ for 10 D,n. propc-rly
ie'i't at?xlot" final U.C2.1& 6
pla-t vis lo- effluent
cat'..: at f:*s
Sf-a^t troat-
ecr.t p.'/"'-.
Phlln^th Xu- r««ded rlxed- go AutoMtle R«-e pKc.ph.t. by
nlclpat se-.a2e aeration Mdia 59 4 93 Zf control, «="«£ chemical
tr^at-.^r.t effluent JQ j Ko >lr vash
plant, Ore£-n
oo (f«- C'i?. f .
CO Ra-iscr' , 1967; » * \ \ AJ up-ricv iin-i.
.g. 4 „ 12.8 7.5 41 5.3 i.i •"• produced « better
Gravity sand final Sand 36 ' effluent.
filter and ,1- settled 0.85-1.
lot uo-f'.w /do---i-flov-\
fiHer^.t^uton. Vfull scale/ ^ ^ ^^ ^ ^^ j^ „
tCans. ?'id Dun- Vpi^t plantj 0.85-1.7
• c^V.1"', 1W7)
^"Ui rkr iff^r1" 77 ». t.«u., «...r/« ^
•u..^^, n;«^,,<- fdcvr.-flcw) Sar.d - j 20-iO 77 only be s-cces^.^.- *
V 0.85-1.7 24 2.5 > the tnfiu(.-t vis u^-ll
(u?-flov) Ssnd 24 20-40 oxldlicii
0.85-1-7 24 2.5 z_ Effluent poorer at
hliher rat*
-------
Table 95- Cont'd.
CO
— — "J^z. —
land, 13-3
'f": \z-i.
J
l'--.-.:,:-
~"J--C, t-..-Urd
1566 - 1 .„;
'frj= Ir.esdaJc
and 5! 7 1 1^-^91
1 . i •
Lewi-.:- 3;ict
' - r-~ H-:r, -j
-eit pia-t
?*>.:- Ch:-.a?,p
>•»!•:•«'•> ~-a-
c -- ~5 ' ' A:
frn- U-a-'.'
i'.ttit, j
fr'. _ L-.ri-,
~ .
c""ct. F'4;,rL D,7? , T» ^tMl £u — -P--r — —'
— i!^_Ji!T^lUll^^(^.) Infl. Eft,. Ro«vcd Inn. Eta. Rer-L- ?"f*:""
flnsl Sand 60 13 ~
effluent 1-2 ' 5 W.3 1.; 95.7 57 7 3 , ,. .
of trick- Sand 60 ,„ . Alrsc-ur 1 - Sharr f, • 1 ^ ," . c i-r
Iln8 f'l- 1-2 J"" 3 37.3 3.7 90.1 53 i 6 ,i , 'h" b'1C'" for ' '^ 5- • -f - tna- '
te- Sand 60 ,A V"^ Vith un- »,=-'ft2
(up-flow) l-2 "-16 5 55.5 7_, 8?-I 42 ..^ gs^ Create' e/liu- 2. Little or no r-url^-a
Send ^Q en • c c ~r'P2tJe'1'''' •"---••
-; 5" 5 »•' - »., K, i,7 5,5 «- P:«, .: ::.-:,!:
-"««- '~2 6° 4'4 ».« e, so i,2 90
wtcd sludge ' -° " 'ir scour Ff f l,,r: t 're-- '.i • - ,-
(up-Jlcv) then V3iScd lr,fc-,or at >- 1 4 -"
by u[r. ^ rd flow rHt--s ''^6 ' -- ^
to abo-.t 11.7 "'
6* trej-cd
"C-i-ated 51 water j = .-d
s!u-3c •'!•- E.S. 0.75 \ 20 5 ,o , 3~6
-'. efflu- L-.c. l 5 J ,„ 28.3 5-25 1. rate of 1. Ef'i-jc-,- - ,',,, •
en; --itl dual--£Jia ' 1.5-3 IS-TO^ o.; JU." ^"' ' '"ss "-'
Pd/.loc- 14" coal ] . g-.c,ft- 2. 1^,1 Cost 5.7:--.--v- -,-
trnyte E.S. 0.75, „ , 2- bs = '^«'-. 33. of . ..I.,;";
'2- 5 eg'?) U.C. 1.5 \ 10 28-3 2.5-4 water U3ed P^2r a-d cne-,/-'s"'
a-i'or alup 6" 3and ( 6-6~- (for
f12 -g/() E.S. 0.75 2'5 hr run)
U.C. 1.6 J 11" (for
1.5 hr -up)
of treated
water
final Sand 12
effluent E.s.0.51 4~3 „
of acti- UC.1.62 8S travcHr.s t. Efficiency of tertierv
•'ated backvash f-n,. . j .
c.e«tr-j-.: dere-..- on c-e
80 el.icit- -,-y of seco-.carv
tre't-ent.
2. /,Joi:iOT"l sol-ds re^:.3
Pr-v <*f' S- - T-I- r
^ «i^'.^ Dy ^^^ JUtlCr.
with a;lc- ,,'^s =o'.>rer
waj not sufficics: tc-
wjrra-it ir-clusu-a vith
tlety t reJtT...-",t desi^r..
-------
Table 95 - Cont'd.
CT>
-. —
V^ste- Type, Sire
Source va'.rr filter redia Depth
tnfcrr.iticm C'-^r-ct. (rO (tn>
>|
Trickling
eocru sand
1.2-2-4 24
filter
fitvl /
effluent
?ilot scale
«ni filter
It D-rtf,
Fn4l«-.' (fron < ^
CrI?;!W, 1959;
Jos'. In
i, Gree-. . 1970;
Trickling
co1"^.'. said
1.2-2.4 36
L.B. said
1.2-1.68 24
Three-layer
filter
A-.tlir^clte
8"-2.4~1.5
Sand
filter V
ef flue-it
Hl2h ilzte fil-
tration of Mill
y.tll Seal- ' scale
^ova-,fV
/ Carrt.;t
8"-0.85~0.7
4°-l ~2
Gravel
, 2'-2"
(up- flow)
f
Antiiractte
5.1 "
Sand
( 2-3 84
Anthr-icltc
4--5.1
Sa:.d
3 ' -2 . 3
Rate
(jo./ft1)
2.5
3.33
5.0
3.33
5.0
2.5
3.33
2.5
3.33
5.0
3.33
5.0
a
16
23
30
8
16
23
30
8
16
21
30
Kax.
ternin* 1
head
(ft water)
12
12
12
12
12
12
12
12
12
12
12
12
15
15
15
15
15
15
15
15
15
15
15
15
~~ SS (pp.) BODs<*g/l)
Run r— ' X Bac'o.as'1
'hr£r Infi. Effl. Recced Infl . Effl. Removed Infor^tlon *'--•>•'< |
U-17 59-60 23-38
20 57-6C. 50-64
17-18 47-58 32-37
19 65 67
14-17 60 43-46
10-12 59-60 54
H-15 52-6'. 53-65
. , (.4 69
13 "u
'13-17 5'-'° 59'71
12-H 53-65 3*-«
25-26 »'"> 6°-6'
12-17 47*58 48"5°
46 150 11 92.5
38 150 36 76
33 150 93 45
23 150 85 43 Air scour for the catlonlc polyelcct r • './te
'5 mtn. at 8 produced the best res-itts.
cfn/sf then TV cost of feoii-.;. r'i.--
20 150 2 99 I flush wx-h electrolyte i-^s le:,5 th'i
9.5 150 4 98 water at '0 SI. 00 per cLilion g.ill?-s
3.5 150 7 95 10 nln.
28 150 3 98
20.5 130 3 98
12 150 10 93
8.5 150 9 94 ^
-------
Sir
quality without
Process Iffluent_TSS
High-rate trickling filter
Two-stage trickling filter
Contact stabilization
Conventional activated sludge
Activated sludge with load
factor less than 0.15
°f
10-20 mo/l
6-15
5-15
3-10
•
1-5 mg/1
::
suspended solids
effuent
" ^
-s
rather thar-
337
-------
carbon adsorption. Suspended solids removals of 99 percent are
obtained.
Most filtration rates reported in the literature vary from a low
of 40 74" to a high of about 307.42 Ipm/sq.m. (1 to 10 gpm/sq
ft). in optimization studies, the rate has been established at
'clev land
rs nd o
tne range of rates 325.93 to 1303.74 Ipm/sq. m. (8 to 32 gpm/sq
ft* u"Sgin ?he studies. The investigation also revealed that
for influent concentrations of less than 30 mg/1, the filter
efflueS generally remained in the range of 1 to 12 mg/1 with or
withou?" poljmer or coagulant and polymer, but for influent
concentrations above 60 mg/1, filtration with coagulant and
polymer addition produced a higher quality effluent.
Operational Considerations
-
can be
and depths) is such that nearly any effluent
achieved."
Tertiar-y filtration has been applied successfully to many types
of industrial wastes. Industries that are .either employing
filtration or have successfully tested and are installing f^ers
includ- steel manufacturing, petroleum refining, brewing, corn
we* milling, wine processing, and food processing.
sand or multi-media filters.
338
-------
Table 96
Effluent Quality from Conventional
Filtration of Various Biologically Treated Wastewaters
Influent
Source
Filter
Type
Filt|r_lnfluent_lm3/l) Filter Effluent (mg/l)
BOD TCO •nn.'Z. •*=•*——*-
Activated Sludge Gravity 15-20
mixed media
Activated Sludge multi-media 11-50
7-36
Extended
Aeration plus
settling
Trickling
Filter
pressure,
multi-media
Gravity,
Sand
15-130
TSS
10-25
28-126
30-2180
8-75
BOD
4-10
3-8
1-U
2-714
TSS
2-5
1-17
1-20
1-27
Activated Sludge multi-media
with Clarifier
Contact
Stabilization
(raw waste
includes
cannery)
Miscellaneous
Trickling
Filter with
Nitrification
mixed-media
sand
(slow and
rapid)
sand
aorbe b
absorbed by
10-50
18
(AVE)
15-75
2-4
2-6
9-28
*hese fluctations cab
backwash frequency. This point is
p
h
that
°*, f iltration is one which is unusual
will never, if properly designed
f inf erior ^lity of effluent? In
filter can provide the desired
or~ under normal conditions, upsets in
pretreatment processes will provide shorter filter
JhSo an^,not significantly poorer effluent quality.
Thus, if under normal conditions the effluent SS
are running at 18 mg/l and suddenly increase ?o a
level of 30 or ftO mg/l. the principal effect will
2-14
(AVE)
2-8
3-10
3-7
339
-------
Table 97
CAPTURE PER FOOT OF HEAD LOSS INCREASE
F^TRATION OF SECONDARY EFFLUENT [197]
OJ
-^
O
Secondary Filtration
Effluent Rate
Type 6P^' **^
T.F.* 3-33
» 3
" 2
it 4
» 6
ii 2
ii 4
ii 6
" 7
A.S.* 16
11 24
" 32
" 16.0
" 22.2
" 27. f
A.S. 2 to 5
A.S. 5.1
A.S. 5.1
Mode
of
Operation
C**
c
v_*
r
v>
r
V^
r
V*
r
VJ
C
D**
r\
LS
D
C
r
\*
C
Top
Media Size, Solids capture,
10% Finer, ,
urn Ib/ft2/ft of head loss
increase
0.85
0.85
0.59
1.84
1.84
1 . 84
0.42
0.42
0.42
0.92
1.78
1.78
1.78
1.78
1.78
Up flow
1.08
1.45
0.052
0.074
0.035
0.064
0.070
0.079
0.065
0.070
0.073
0.078
0.35
0.093
0.093
0.23
0.21
0.12
0.26
0 2;
0.34
*T F. - Trickling filter plant final effluent.
*A.S. = Activated sludLa plant final effluent.
**C = Constant rate.
D » Declining rate.
-------
be a significant decrease in run lenath bu*
relatively lesser increase in efflSent Ss?«
Reverse_Osmosis
ana Tbe
2* q- an cooing waters
^. NSSC white water
i>. Cold soda pulping wash water
.. J- an imPortant
Removal." e been Clted Previously under "Color
^'
bv
continuously OT the Mm fee^ ™? ff Ji^ltaneously and
— --aaj s
available:0 tyP6S °f reV6rSe °Sm°sis -e^rane surfaces are
341
-------
1. capillary fiber
2. Sheet membrane (spiral round)
3. Tubular
systems (206) (209) .
. «ea
for certain uses.
If color removal only is necessary, then ultraf iltr *tion, which
Sti ^nf 2S£? St ^e^^ir.
satisfactory (209) .
Treatment Efficiencies
(208) .
below aO°C (10U°F) (208) .
ss^f
(207) :
solids
_
color-optical Comparator - ^
M3 ~ "
Color-Spectrophotometer - 99.8%+
Experience there had indicated loss levels of ..986 k,
SSSKJS. rU,.°-plUe le ^ei o, 3 .
BOD/pulp kkg (ton) and 0.454 kg (1.0 ID)
342
-------
solids/machine kkg (ton) are expected when an upse^ control
system is in operation (214). p ' c'onT:ro-L
Table 98
SUMMARY OF RESULTS OF TREATMENT BY REVERSE OSMOSIS (208)
B§P2£ted_ReJection - %
Total
Waste_Flow solids BOD COD Base Color___Rec!ve
Calcium Sulfite 87-98 69-89 87-95 95-99Ca 99 80-90
,SSC . 96~98 87-95 96-98 82-95Na 99+ 79-99
Ammonium Sulfite 93-96 77-94 92-97 92-98NH3 99 \l
Kraft Bleach 91-99 85-97 97-99 83-95™' 99+ --
Operational Considerations
fouir°? 5 ^^"^V'-^^-^ •^j.^^cSS*
isLrJEE?.^
surfaces. Self-cleaning, high velocities of flow were
^.tbLSn.iikeiL!!!???.?f --Dining high flux rales ._„,..
high performance, tight
__ t-^j."j. j.*.« uj-wii uj.u noT: appear to ser-
attect performance at operating pressures below 54.43 atm"
psigj,
Kii,,°Lth!w??frf^ional and maintenance problems at the NSSC
increased soluble solids in the white
Present commercial hyperfiltration membranes cannot be operated
at temperatures much above ambient and cooling of mlny pulnina
considered satisfactory. Research is being carried ou? to
P ^Pr°ved ^^^n with ultrafiltration because ?t has
flux rates than hyperfiltration and the advantages ol
343
-------
to wase treaproblems lies in the --^causes o sor
life expectancy of the membrane system. It is felt that memcran_
manufacturers should be encouraged to pursue the goal of a
and temperature and high flux rates (208) .
After three years of reverse osmosis pilot plant work at Pomona,
memtean? fouling was identified as the most important operation
problem (215). Physical cleaning methods such as water or air-
water flushing were only partially successful.
(208) (209) (216) .
Removal_of_Dissolved_Salts_and_pissolved_Solids
nature, should be less than 150 mg/1.
Reverse_Osmosis
reference to lower pressure reverse osmosxs systems.
Treatment Efficiencies
reverse osmosis work at the above mentioned NSSC mill (207)
reverse ws, e/o.»;,«, -—-^o-t-ions of 99-1- percent, with
are described above.
99 (208) .
344
-------
Chloride and TDS concentrations of caustic extraction stage
ettluent achieved by reverse osmosis are shown in Tables 100 and
101 (210) .
The reported data from pilot and laboratory work shows that
reverse osmosis is very effective in removing TDS and chlorides
from selected pulp and paper industry flows as presented herein.
The ultimate concentration of each element, however, will be
dependent on the initial concentrations and the recovery and
treatment processes preceding reverse osmosis.
Ion exchange has been a well-known method for softening and
deionizing water, but application to waste water treatment has
been negligible primarily because high molecular weight organic
compounds present in waste water have a deleterious effect on
most anion exchange materials and disposal of regenerates is a
ma^or problem. New types of resins have been developed, however
that are less affected by organics. in addition, separation
technigues using ion exchange demineralization are known, but
their application to waste treatment is not generally practiced
nor is there sufficient information on such a system to predict
performance (217) . FJ-^UJ.^
-------
Table 99
TOTAL SOLIDS REMOVAL (210)
REVERSE OSMOSIS
Calcium Sulfite
NSSC
Ammonium Sulfite
18.47-11.05
10.75-5.72
10.31-50.48
87-98
96-98
94-97
2.04 - 0.37
0.68 - 0.32
6.44 - 0.66
Table 100
REVERSE OSMOSIS OF RAW AND PARTIALLY RENOVATED HARDWOOD PULP
CAUSTIC EXTRACTION EFFLUENT AT 600 psiqf 21-22°C, pH 5.2
Reverse Osmosis Of
PH
Color, units
COD, mq/1
BOD, mq/1
TDS, mq/1
C1-, mq/1
Product recovery as
% of feed volume
Avq. Flux,(qal/ft2)/day
AVQ. Flux/water flux
Mass.
lime
plus
Raw
11.7
2800
1460
523
4240
787
_ _
__
Massive
Massive act.
405
702
324
3890
751
__
__
—
5
173
105
3500
751
_ _
—
—
Mass.
lime
plus
act.
Raw
5
42
41
152
56
92
13.1
0.52
lime
5
36
27
192
51
93
12.8
0.48
car bo
5
42
22
256
111
92
22.8
0.82
346
-------
Table 101 (210)
2™SIS °F RAW AND PARTIALLY RENOVATED PINE PULP
CAUSTIC EXTRACTION EFFLUENT AT 600 psig, 23-26<>c, pH 5.2
Feed
Color, units
COD, mg/1
BOD, mg/1
TDS, mg/1
C1-, mg/1
Product recovery as % of
feed volume
Avg. flux, (gal/ft2)/day
Avg. flux/water flux
Raw
Waste
5
106
220
106
86
15.7
0.58
Massive
lime
EEQduct
5
96
276
137
86
13.8
0.37
UM-2*
product
5
92
320
29.8
0.75
Mass.
lime
plus
act.
carbon
product
5
72
324
240
85
29.9
0.77
efectrolv?^3 ^H a deionizati°n technique based upon two
electrolyte ion exchange resins (218). The advantages Of
his process over conventional ion exchange process a?e claimed
.00
300-o^^so^
of
re sicantes's "° am°Unti theref°~- -generation costs
3.
High degree of utilization of theoretical capacity.
process uses three beds of weak ion exchange resins
process. The first bed is a •---- ---- • "sims
second bed, a de-alkalization
be regenerated with ammonia and sulfuric acid, respecively
exhaustion, the third unit is in the bicarbonate
e
347
-------
ion exchange studies have been conducted on sewage effluent from
an activated sludge plant (217) . The waste was pretreated prior
to ion exchange with a system that consisted of lime
clarification, dual media filtration, and granular activated
carbon filtration to reduce the total phosphate, suspended
solids, and total organic carbon of the waste water prior to ion
exchange. The investigations included the performance of the
following resins:
1. weak base anion exchange - bicarbonate form
2. Strong acid cation exchange - hydrogen form
3. Weak base anion exchange - free base form
4. Weak acid cation exchange - hydrogen form
5. weak acid : strong acid cation exchange - hydrogen forms
It was concluded that the ion exchange process with the weak base
anion exchange resin - bicarbonate form was not sufficiently
established to use on domestic sewage containing less than 500
mg/1 of dissolved solids. The work did show, however, that a
system using a strong acid cation exchange resin and a weak base
anion exchange resin can be used without difficulty for a waste
water containing as much as 500 mg/1 of total dissolved solids.
In addition, a weak acid cation exchange resin can be ve;y
efficient as the first resin to demineralize certain waste
waters.
Treatment Efficiencies
in laboratory and pilot studies on the DESAL* process (219) ,
pariiall? renovated pulp and papermaking effluents were used
The efflvUr^s were a bleached kraft mill total effluent and
caustic sSae extract. Both effluents were clarified and then
causic sage ex.
preheated with lime and activated carbon to produce samples ^hat
were virtually free of all color, BOD, and turbidity, but which
wire not acceptable for reuse because of the dissolved solids
content. Table 102 shows the results of this work (219) .
AS can be s-en from Table 101, only the pH of the caustic extract
did not achieve the desired range. The low pH was attributed to
laboratory operating conditions and it is felt the system can
produce a pH near 7.0 with a commercial system.
Other work (220) showed that a cation-anion exchange system was
very erfective in the removal of major ions fr ?? a.8f ^P
effluent. The results of this work are shown in Table 103 (220) .
Operational considerations
ion exchange is considered technically feasible by some for ^he
d°ionization of partially renovated domestic and pulp and paper
mill washes (218) . In order to successfully use ion exchange
Processes the majority of orqanics and suspended solids must be
removed from the waste stream. In one laboratory undertaking the
348
-------
effluent from a well-operated domestic activated sludge plant was
used without any additional treatment (221). In other work (219)
which consisted of laboratory sized columns and equipment, the
selected kraft mill waste stream was clarified and treated with
lime and activated carbon prior to ion exchange; domestic waste
used in another project (217) was similarly treated.
If the waste streams are not properly pretreated prior +0 ion
exchange, severe operational problems due to clogging will be
encountered. with biological treatment, the waste stream
probably would require a minimum of mixed media filtration for
suspended solids removal as pretreatment. Depending on the
organic nature of the secondary effluent, it may have to be
pretreated with activated carbon, or reverse osmosis, if the
total dissolved solids of the waste stream exceeds 3000 mg/1,
pretreatment with reverse osmosis may be necessary to keep cost
of ion exchange within reason.
Table 102
WATER QUALITY FROM "DESAL"* ION EXCHANGE PROCESS (219)
Desired Range DESAL_PRgDUCT
Bleached Mill From ~ From~Total~Mill~
Parameter Feed Caustic_Extract Iffluent_lBleachedl
Color 0-5 5 5
PH 6.8-7.3 3.7 7 2
Cl, mg/1 10-150 120 150
Hardness, CaCo3 mg/1 5-100 25
Dissolved Solids mg/1 50-250 250 180
BOD, mg/1 0-2 0 0
Turbidity, JTU 0-5 0 0
COD 0-8
*Use of a trade name does not constitute endorsement
of a product.
Proper disposal of waste regenerates associated with the use of
ion exchange treatment of waste waters must be fully recognized.
Effective regeneration requires regenerate volumes in excess of
stoichiometric quantities. Strong resins require large excesses
while weak resins require small excesses only. In order to
greatly reduce the regenerate volume to be treated, the ion
exchange process should consider fractionation of the total
effluent during regeneration and use (217). Acid wastes are
easily neutralized, but precipitated sludges and neutral brines
must be satisfactorily disposed of. Waste regenerant ammonia
349
-------
TABLE 103
BEHAVIOR OF MAJOR CHEMICAL CONSTITUENTS IN RENOVATION SYSTEM [205]
OJ
on
O
Ca-H- as CaC03 (mg/1)
Na+ (mg/1)
Cl- (mg/1)
S04- (ing/1)
Alkalinity as
(rag/D
COD (mg/1)
Solids
Total (mg/1)
Fixed (mg/1)
Volatile (%)
Turbidity (JTU)
PH
CONCEMTRATION OR VALUE
Before
Coagu-
62
49
53
145
175
131
431
312
27.6
16
7.3
After
Settling
205
44
48
130
260
102
377
257
31.8
1.5
11.4
After
Rer ar-
bonation
62
44
42
127
139
336
237
29.7
2.3
7.6
After
After Carbon
Sand Absorption
— — —
61
254
172
32.3
4.1
. u
16
233
170
27.0
0.23
0 Q
After
Cation
Exchange
0
0.7
12.5
68
42
"8.2
0.25
3.0
After
Anion
Excha -.ge
2.5
o
5.9
10.8
24
15
37.5
0.23
4.8
-------
the ion
Remgval_of_Trace_RefractorY_Qrganics
tr^.aSnCe? WaSte treatment ^sterns studied for the removal of
trace refractory organics, those not removed through a s-condarv
treatment system, include the following: 1) activated cfrbon 5|
chlorination, and 3) ozonation. The activated carbon procS' ha s
demonstrated its applicability to the treatment of mSniSioJl
waste water at full plant scale. In addition, i^po^entS for
SJntlnLdPU!Ph an? pape™akin
remove organics that caused taste and odor problems in Pdr?nking
th^nh !UPP^' . Also' the u^ of activated carbon as a s^p ?n
add ^ysical-chemical treatment process for waste waters or an an
add-on to existing biological treatment systems is w-11
ac?ivJ?eS cai?bo9) * M«y ."searchers have studiS the use of
and Snl ^?n \a te^tiary Process for the treatment of pulp
and paper mill wastes (230) (231) (232) (233) (234) (235) it has
CODn SSn tha Vctiva^ carbon is caplble of reducing color"
DD
One of the highest concentrations of BOD in a kraft pulp mill
waste discharge is contained in the evaporator condensate (230^
Most of the BOD and COD of the condensate waste is Ixerted by
dissolved organic material. one project demonstrated that 75
percent of the BOD, COD, and TOC could be remove^ from th-
condensates by activated carbon adsorption. removea trom ths
practical aCtilVate
-------
Constituent
Organics
TaMe 104
PRETREATliEXT REQUIRE!C^.'TS
FOR ION EXCHANGE [207]
Probl e^n
Pretrcatr?.?nt Required
Solids Blinds resia particles Coagulation and f jitration
Large molecules (e.g., Carbon adsorption or use of
human acids) foul strong weak base resins only
basic resins
Oxidants Slowly oxidizes resins Avoid prechlcrination
Iron and Manganese Coats resin particles Aeration
352
-------
Activated carbon is characterized by an extremely large surfar«
area (450-1800 sq m/g) (234) which is one of its features which
results in its large adsorption capacity. Activated carbon can
arannSarat™ ^° tw° *eneral classifications: powdered and
granular. The ultimate adsorption capacities of both powdered
and granular carbons are essentially equal (234) ; however
S^M ^v^r fa!t9r adsorPtion rates\han granular carb^
(2J4) (236) . while there are numerous carbon manufacturers and
particular specifications, the selection of a specific carbon
cannot be made without first testing the carbon under consider-
ation with the particular effluent to be treated (237).
^ocess has various configurations which
r n • granular or Powered carbon, contact in a column
or slurry, fixed or moving beds, upflow or downflow of influent
series or parallel arrangement, and continuous or periodic
wasting and regeneration of spent carbon. Treatability of a
particular waste by activated carbon is described by various
analytical adsorption isotherm equations which are covered in
?S£ V" t litera^re. Th* Freundlich equation is probably +-he
most frequently used to determine adsorption isotherms. However,
poor correlation between isotherm results and column tests have
?fnnrffrted; ™^ ±S Partia11* *™ to the fact that absorption
is not the only mechanism attributed to the removals throuah
cofumn^ T™, ^ functions Ascribe the operation of carbon
columns (238): adsorption, biological degradation, and
ion .
Treatment Efficiencies
Most of the researchers studying activated carbon treatm^n- of
pulp and paper wastes have made one common assumption: ^ha^' the
effluent from the carbon system should be of a sufficient "quality
to permit reuse as process water. suaxxr.y
Pilot plant tests have shown that renovated waste wat«r sui+abl-
for reuse can be obtained without a biological oxidation step
Son^o^L'U116 renovation P^ess star?s with a mSderaTl
^o? ? 200-300 mq/1 (232). Color of a satisfactory low
concentration can also be obtained by such treatment. Tabl- 105
presents th* pilot plant results. -laoi^ iub
with changes in temperature is not well defined.
o
materials are biodegradable and would not be pres-rr ?r
appreciable quantities in a well bio-oxidized secondary -fflu-n-
turh Ai^-x % carbon columns do a relatively poor job of removira
turbidity and associated organic matter (237) .
353
-------
Table 105
RESULTS OF GRANULAR ACTIVATED CARBON COLUMN
PILOT PLANT TREATING UNBLEACHED KRAFT MILL WASTE
oo
en
303, r.g/1
COD, -g/1
SS, Kg/1
Turbidity, J.U.
Color, Units
Odor
pH
T.S. r.g/1
Preceded by Line j
Precipitation and
Biological Oxidncion
Influent
48
"~*~
—
"•"
365
—
23
*"""*
13
—
52%
96%
—
102
185
TTf ft..pn~
3,
23
—
Colutnns*
Preceded by Line
Precipitation
Removal |! Tntlucnt
69%
88%
320
35
23
1 11.9
1285
Effluent
11
209
74
35
0
10.5
12C5
Removal
35%
33 r
36?
C/
100%
12%
6%
*Colums loaded at 3.6 - 4.0 gpn/ft2
-------
?o , ' Sn9 P™1 activated
2* v?^^Urrent a^itated tank adsorption
^. Flotation adsorption
3. Diffusion adsorption
j». Packed bed columnar adsorption
3. Upflow column adsorption
1.
^secondary effluent aia not have to be filtered prior to con-
3. Maintenance costs were low.
*- Design and operation were simple.
5. The system was truly continuous.
6- COD removals to approximately 5 mg/1 could be achieved.
effluent?1131 6X1Sted for treating primary treatment plant
8.
were
carbon
--™™
make the us
the P°Wd-ed carbon
eoaan (230,
with U56 mq/1 of caon t was al?o J C,matter co^ld be removed
contact time (over l hri sho5iS • de^erm^ned ^hat an extended
removal. Howeve?, even aftlr s?x V?dinsifllf icant additional COD
effect on the removal of ?ox?cJt5 wSrh f COntact. the^ was an
various constituents. The rSSlta o? JS^ W9S 5ttributed to other
findings of other researches ?h?t ^".^f* conflict with the
s t .
effective in removi ow molecular wiTah? CarbOn ±S nOt
-------
fine
Pilot plant tests on the effluent from two ^-i^rate ine
paper mills determined that the necessary carbon dosage, based on
a flow of approximately 56.78 kkl/d (15 MGD) , amounts to 192 mg/1
of carbon?Por 2.1 times that needed for settled domestic sewage
Preliminary design of a full scale treatment plant called for 12
carbon columns (ten active) ^ be preceded by f locculat, on and
sedimentation. Each column would be 6.10 m (20 ft) in diameter
a U.72m (15.5 ft) depth of carbon.
w . . a32
*rranaed for parallel operation and would be loaded at J2b.y4
Ipm/sq m V gpm sq ?ft) with a 15 minute contact time at peak
hourly flow. Maximum operating pressure was to be 3.40 atms (50
psi). Table 106 presents data from the pilot plant operation as
well as the design criteria that was used.
plant tests were undertaken for treating
Extensive
processes as follows:
1. clarification followed by downflow granular carbon columns
2. Lime treatment and clarification followed by granular carbon
columns
3. Biological oxidation and clarification followed by granular
carbon columns
a Lime treatment and clarification followed by FACET* (Fine
Activated Carbon Effluent Treatment). (Subject of a patent
application)
of all treatment processes was to obtain a
ale
ch . b oe
t?eatm^t achieved the desired effluent criteria and was
300 mg/1 of carbon.
356
-------
en
^~i
Table 106
RESULTS OF GRANULAR ACTIVATED CARBON COLUMN
PILCT PLANTS AM) DESIGN CRITERIA [216]
Hydraulic
Load
Contact Tiae
20D ng/1
COD Eg/1
Xass. (37)
DGn:rm Data
j-nf. Eff. RPT-IV--
8 gpn/ft2
1
15
35-40 5-7
80+%
•" — — i M
Fitchbt
KS.SS .
Pilot P]
Inf. v-f
0.3.
5.£
13.2
53.4
5 gpm
;
7.6
29.2
"••• " ii.
r-g
(37)
-ant
42%
45%
Fitchburg
Mass. (37)
Pilot Plc--*-
Inf .
0.3
1
7.6
29.2
Lrr .
5 gpn
3.0
2.6
11.9
66%
59%
Fitchburg
0.35
22
2.6
11.9
.9
1.7
6 3
35%
43%
-------
K was found that non;a^orp*ive
siqnificant amount of color and TOC remo were not due to
SfSo.^rW Cation 2&JU.SE ^"^or^n
carbon columns. Rather it was ™lnf ace> The color
" '
both powdered and granular carbon w^^ decreased
apPc i isted in Ta.les
and 109.
Operational Considerations
The use of granular activated carbon for the ^"^
refractory organics is technically sound. f™ ' the
degree of treatment is °btaln^:.^ie ^powdered activated
effluent for process water £ ^s£^e ofP^rfIcult handling
carbon has not been wld^ypU^^Z^c^ery and regeneration (236)
"
h
of the
advantageous to the operation o e ^J lans for
approximately 6.7.
in utilizing a carbon slurry to treat .unici
,~.K™.
operation and pressure dr ops became pro ii ^
tried but tn COD
operation an pr ^
upflow contact process was tried but tn t
stabilized and serious ^anneling occurred resuii g
removal efficiencies. Po lyelect ~^« ^c^t powdered carbon.
be the most economical method ^recover sp GSncentration of
^O^mg/i^or'rre^^'be ^mSntafneS in the carbon slurry to
assure flocculation efficiency.
358
-------
107
RESULTS OF ACTIVATED CARBON PILO~ PLANTS
TREATING UNBLEACiZD KXAFT MILL EFFLUEN
00
en
Description Of
Carbou Process
Hydraulic
Load, gpa/ft
Carbon
Contact Tise, Kin.
BOD, cg/1
TOC, ag/1
Turbidity, J,U.-
Color, Units
Fresh Carbon
Dosage
lb. carbon/
1COO gal.
?H
i ••••-••••^••^a
_
Columns
Preceded By
Biological
Oxidation &
Clarification
(
- '
orar
iuAa,r
140
148
740
57
212
p
•^•^H^M.
__
61%
712
i .
" —
Colun.is
Preceded By
Primary
Clarification
Int. Erf. i Re^.ival "~
1.42
t
i
Granular
220
925
83
185
2C
~n i
1.5
62%
802
i
s
i
*1M1 f-01-a^
Columns
Preceded By
Prin^ary
Clarification
1
0.71
i Granular
310"
1160
121
202
8
i ner-.cvai
612
83%
— 1
Colcrr.r.s
Preceded 2y
Lir.e Treatment
& Clarification
Inf.
Erf.
/ o
s.i
Granular
10P
26% Re:
177
252
-oval
100
5-15
76
2.5
11.3
• im HIM i in.
•^— ••••••-.•^ i
Rc...oval
44%
70Z
^«~«««— MM«
r.^c"^ c,,-. ,
if.' — . iy^t^=
2i r . i Ri~ov° 1
K.A.
— ter=
158
157
Ct" "e
101
1
73*
3.9
•^™^™^™^^
362
541
1
— — "'
-------
Tab lei 08
PHYS!CAL-CHEiVil"A'_ 1 KiAi IYICIM i ru/Aiiio
. p
SiTE ;
;
]. Cc-'.'ar.d M Y.
' 2 Ci€'.'.lr.nd Westerly,
| ' C-o
j 4. Gar'ard, Texjs
i
5. L-KoY. NI.-W York
' ~, N,:. ira f- Is. N.Y.
7. O.vosso. Vic ' S~n
3. P.os-jrncunt, Minn.
3. Rocky R.v«.r. Ohio
i
i .
STATUS
1373
Des'gn
Construction
Design
Design
DESIGN |
ENGINEER
Stearns & VVneler
Engineering-Science
Crmp Dresser
UP.S Forest &
Cotton
Lozter Engineers
^•-.,.,r^ Pro' r .1 \/ ; t V
McKec -•
Ayrcs, Lewis,
Morns & May
6
B;n'Ster, Short, i 0-6
Elliot, Hordnckson,
and Associates
., I .. , ,1 C,.^">i
& Assoc.
Kaiser Engineers
J —
10
! Uptlow
Packed
Upflow
Downflow
pressure
L A'P.T.OW
i Pressure
13 j Upflow
i ^^
——~~
NO. OF
CONTACTORS
IN SERIES
1 or 2
1
n
2
2
1
CONTACT
TIME111
(WIN )
30
35
35
30
27
20
1
!
2 1 ic
3
(max.)
1
1
— — ^^— ^— — —
uw
65
(max.)
26
26
- 1 ' '-"•
HYDRAULIC
LOADING
GPM/SQ FT.)
- • '— —
4.3
3.7
3.3
2.5
7.3
3.3
6.2
4.2
4.3
4.6
_«_«~ — —~ — ~—
TOTAL
CARBON
DEPTH
(FT.)
17
17
15.5
10
26.8
9
30
36
(max.!
15
16
~ *
CARBON
SIZE
__ ^ ^^~—
8 x 30
8 x 30
8 x 30
8 x 30
12 x 40
8 x 30
12 x 40
12 x 40
8 x 30
12 x 40
— - ••-' •"
EFFLUENT
REQUIREMENTS121
(OXYGEN DEMAND)
TOD ^ 35 mo/i
BOD < 15mg/t
BOD < 10rng/l
BOD < 10mg/l
BOD < IOmg/1
COD <112mg/l
BOD < 7m9/.l
BOD < 10mg/1
BOD < ISmj/l
BOD < 45mg/l
(90% of time)
1) Er-.ry bed !su:-e-! c.,.1) copt=ct fme io' i.ver2Se plant flow
(2! I"02 3 oc'K-^.crl oxygen de~iond
COD: Chemical oxygen demapci
TOO: Total oxygen di.-r.and
(3) 90 mgd ultimate capacity
-------
Table 109
TERTIARY TREATMENT PLANTS
CO
CTl
SITE
1. Arlington, Vi-glnia
2. Colorado Sp-',ngs, Cclo.
3. Dallas, Texas
1
4. Fairfax County, Va.
5. Los Angeles, Calif.
6. Montgomery County,
Vd.
7. Occocuan. Va.
i
STATUS
1973
Design
Operat'ng
Dec. '70 to Present
Dei'gn
Design
Oes.gn
Design
Design
8. Orange County, Calif. Construction
9. Pi:cat;way, V!d.
!
10. St. Charles, Missouri
i
11. South Lake Tchoe,
Call'
12 Wndhoek. South
Afr.ca
Operating
f»".v '73 to Present
Construction
Opcrafng
\"ar. 'C3 to Present
Oreratirrj
Oc: '03 to Present
DESIGN
ENGINEER
Alexander Potter
Assoc.
Arthu- 3. Cha'et
& Assoc.
URS Forest
2< Cotton
Alcxonder Potter
Assoc.
City of Los Angeles
Cri2f,'/Mlll
CH2M/HHI
Orjnge County
Water District
Roy F. VVeston
Moran ond Cooke
CH2M/Hill
National Institute
for 'W^ter Research
P'uton,., So. Africa
AVERAGE
PLANT
CAPACITY
(WGD)
30
3
100
36
5<3)
60
18
15
5
5.5
7 5
I
1.3
CONTACTOR
TYPE
Downflow
G'avitv
Oovvnf'ow
Pack* 1
Down f'ow
Gravity
Downflovv
Up* low
Packed
Up Mow
Packed
pj-v-d
Downflow !
Pressure
Dowr flow
Gravity
Ur\ " r \*r
p < . c w
Oownf'ow
Pressure
NO. OF
CONTACTORS
IN SERttS
1
2
CONTACT
WIN.} •
op
•JfJ
30
1
1
2
1
1
1
I
2
' |
T
2
for pvrr,-,. „:-, >,-.?. ' co"ts" time (3) 50 mgd ultimate capacity
3S
50
30
30
30
37
30
17
30
HYDRAULIC
LOADING
( GPM/SQ FT.
2 9
5
8
3
4
6.5
5.8
5.8
6.5
3.7
62
38
TOTAL
CARBON
DEPTH
15
20
10
15
„
26
24
2-1
32
15
14
15
J
CARBON
S!ZE
8 x 30
Sx 30
8 x 30
8x30
8 x30
8 x 30
8x30
o x 30
8 x 30
8 x30
w x 30
12x40
L
EFFLUENT
(OXYGEN DE'/AND)
BOD < 3 mg/l
BOD < 2 ' 3/1
BOD
-------
a breakthrough of
- within
problecasea by -biological activity
the columns.
u.dB -
discussed above (231) a"°*J ._.„,_,, flou for the backwashing
ncom.n °»
discusse aov ._.„,_,, flou for the backwashing
approximately 12 P«cent of the incom.ng £°»hf e££luent from the
SS^Si-i «S5 ^SSpl^ of oxygen and wouia re^u.re
aeration.
— -
Chlorination
means or
effluents.
a well-documented Process Costs «£££» £or removai of
competitive with actlv^!d^Cjf°SD rom muncipal wastes (222) .
relatively large W^^l*0*™^ f|^r the Lmoval of very
It may, however, offer £ alternative for ^^ remQved by
362
-------
Treatment Efficiencies
process treatig t
chlorination caused a substantial ,-J? ^ determined that
average of 31.5 percent fjaii ,, reduction in the BOD'S, an
12 to
suspended solids
was theorizezed
"precipitated"
and TOD werp no
*AV^ _ v _^^ »*_i, i. J.VrtHi '—-Ly Cl
has revealed that chlorine will
improved. The
the chlorine. Th«- r^-r
chlorination. A study
elimination
oxidation process
effective than
of
chlorine
ov«r*ll
°f absorbed radiant
alS° established lhat
The
the
color and
organic oxidation for a specific
energy than do higher intensities
the chlorine consumption is
of radiant energy absorbed,
effectiveness of treatment
achieved by the ultraviolet
of treatment efficiencies WIT
concentrations was not reported.
?:r™ "K:"s,;; s;s?M°',.,sr" »»•"- «•-«»..
ff^&Jsr^fg-S&S&s
(10-MGD)
mg/1 using light-catalyzed 7 hi or L it i on ^^ ™* COD frOm 25 '° 10
Operational Considerations
^
-a-
s?-
363
-------
Figure
63
PROCESS FLOWSHEET FOR TERTIARY TREATMENT BY LIGHT-CATALYZED CHLORINE,
CAPACITY 10 MOD
CO
WASTC -".'I* "f _j~^
~\ ,4&0
J
-.
1
j- i i i
o 0 o o I o
0 0 ° 0 1 o
o ° o ! o
•" i !
!"• : . ° : -
01. ° ' 0
4 0 ' 0
j ° 1 0 ' 0
° i o ° : o
"" 1
i
r- O
0 0
0
e«us'ic s'o»»i; '»•"' 73"o~
I!.COO CAitCTt C*^»CITV
-------
~r—--™ ,,,ay uc at cunDient p« values without -t-he addition of
caustic for pH control. addition ot
Chlorine concentrations above 5 mg/1 produced no sionif i
ae " "6- '
concen^aSon
Ozgnation
ozone for color removal was previously discussed in detail
Residual ozone decomposes very rapidlv T-I- hac: a h^i* i • c
drinking water of abSut 20 minSes t2H3\ I half-f
\' ph1^9150^10 discharge in air or oxygen
2. Photochemical conversion of air or oxygen
3. Electrolysis of sulfuric acid
nere
Treatment Efficiencies
;g^-
reeved. No living
365
-------
mq/1. Ozone concentrations from 11 mg/1 to 48 mg/1 as oxygen
proved equally effective (243).
Rates of COD and TOC removal were very dependent on agitation
ra-«s. Removals were increased approximately twofold using hign-
sh-ar contacting rather than low-shear countercurrent contacting.
Cocurrent contacting, mixing effluent and ozone in an ^ect^'
proved more desirable than the use of a turbine agitator. For
effective ozonation, good agitation must be considered the prime
ob-jpctive in contactor design (243) . Low pH resulted in lower
reaction rates, but higher ozone utilization efficiencies.
Ozone oxidizes many compounds which resist biological oxidation.
Sowever* the most reldily biooxidizable organics also consume
ozone the most efficiently (243). Chemical clarification prior
°o ozonation will remove a portion of the TOC that is resistant
to oxidation by ozone resulting in lower final TOC level and less
ozone consumption. Ozonation efficiency was high "$en C°° a"^
TOC concentrations were high. However, the effluent had an
unaccpp-ably high COD and TOC content. It was concluded that
ernuents having high organic content (COD above 40 mg/1^ are
more economically treated by a combination of chemical
clarification and ozonation. Effluents with a low organic
content require only ozonation.
The tests showed that, because of the short life of °*on* *^he
slow r-eaction of ozone with many organics, the best treatment
would Se achieved with multi-stage, high-shear, gas-liquid
contacting. It was also determined that a residence time of ten
minutes per stage was reasonable. One hour was needed for a COD
reaction from 35-40 mg/1 to 14 mg/1; therefore, «« ^aqes were
necessary. With the required amount of ozone being added to each
S?aae as it was needed, an overall ozone efficiency as high as 90
percenf was obtained. Figures 64 and 65 show schematically a
3?!85-l/d (10-MGD) ozonation system designed to reduce COD from
35 mg/1 to 15 mg/1.
In other feasibilty studies ozonation, catalyzed with activated
RanevNickel removed 85 percent of the COD and 60 percent of the
TOC Yrrom secondary treatment effluents in two hours under
favorable conditions (244) .
Operational considerations
treatment with ozone appears to have ^potential of an
trouble-free operation with low main.enanc-.
it was thought ?that the ammonia in the waste would
react with the ozone, but this was not the case (24J) .
rrsL .
enhanced by higher pH. Lime dosage resulted in high pH, while
alum-acid Coagulants gave the lowest PH. A PH ^om 6 0 to 7 . 0
spemed *o b- optimum for multi-stage, cocurrent ozonation.
366
-------
Figure 64
OZONE TREATMENT PLANT [228]
CO
CT>
-vl
OXYGEN
PURGE
CATALYTIC rS
OZC.\'E-~'
CECO.VR ^
Dt'AFRATOR
—ypQl^GCdj^ir^
. LIQUID
EXIT
C IU 72 T
STAGtD COfJTACTOR
ruow RATES FOR 10 MGD PLANT
© EFrL'J£;jT= 6.940 GP.V
©OXYGt'N MAKEi.'? = 6,340 h 'd;y
@CCO\£ GAS- 7.0 -J SJFV
GAG FEED TO CV.GES
12
13
-------
FOR O/;OL\;;
^PRl'ShN'l'ATION OF A KM LCD PLANT
TREATHJ<;;;T or SECONDARY: EFFLUENT
"r' ~r"'x
63*
rjfCTOrt ANO_
L153CLVEI! '
TUCES
A
A
\
-O
r-O
-O
-.-O
o
EJECTCT? PUMP_
STAGES
GAS RECYCLE " .'
GAS EJCCTCR
V/ATER LE\'EL —"^
OISSOLVCR TUOG —
HCLO-UP T/iNKO
-o-
•K>*
-o-
=0"
-•O
PROCESSED
LiTLL'EHT
OUT
LIQU;O
i
™
^7.
~~~~
—
~:
i—
GAS
IN
J,
LIQUID
IN
1
r.'E
\~.
—
i
—
_ .
—
__
GAS
IN
.J
— •-
_ .
STAGE STAGE
LIOU;D
IN
Crf
U
i
~—-\
—~-\
—
— -
—
LICU 10
IN
GAS
IN
J>
LICUiD
IN
,_1 1. ) I
i
—
—
STAGC
— -
_.
~ ' --,
—
—
—
--
,~."
STAGE
Z"
.- —
—
:L:~.
"T.
GAS
IN
-A.
~~~.
—
—
— -
— -
STAGE
s
LIQUiO »
j
—
GAS I
Jl
— •
--
STAGE
-_~
1
I
ie
368
-------
Removal_gf_Nutrients
these element
vegetation which can result from
~»
PaPe™aking operations are very !ow in
of SI."
added in this
clarifier by the
**
Mount
pri~ry
ssr -%
and ion Lchange -- ?ollow"PP ^ nitrif lcation-^nitrif ication,
l2Q_Exchange
°f
seiective for
ions
"hi°h is
ammonia can be destroyed by eeolvsis of
results in the production7 Sf chloSJI tha
ammonia to produce nitroaen aas r5?af a *
97 percent have been reposed (22Ji . ' Amm°nia
which
with the
of 93 to
An average ammonia removal
demonstration studies on ?hr~ee
content of about 20 mq/1
removal to less then 0 5
only »ith shorter -
^
perfent was obtained in
wastes havi"g an NH3-N
stated tha* ammonia
clarification of the
In
to
.concentrations may require
369
-------
clarification by plain filtration to prevent fouling of the
zeolite beds (222).
Ammonia removal by selective i°n.^Jha^e }
en may* bue ine armecaes at a lower
cost, but at a somewhat lower efficiency.
Nitrification-Denitrificatign
nitrates to nitrogen gas.
.he region of nitrate proceeds too slowly ^ b.
influent.
temperatures greater than 1» °C ^nd four « stable
temperatures greater than 8-10 c have pr resuitg be
remova? to a practical value of about 90 percent.
Se /Ser^tre^lapljg ^jgS»
1f Ls not been
widely published
neavy
370
-------
process can be used with industrial wastes, therefore careful
testing must be conducted under realistic conditions? careful
n?trir?catton; ^ f°llowing considerations will influence
1. Dissolved oxygen level should be about 1.0 mg/1.
2* of 7?5a8?5Tated Sludge syste™ should be in the range
The growth rate of the nitrifiers is temperature re-
lated. Nitrification below 5<>c is mining whiL
optimum temperature is about 32°C.
The growth rate of nitrifiers is reduced by chlorates
cyanides, alkaloids, mercaptans, urethanes?
methylamine, and nitrourea.
Overflow and waste sludge rates must be
-
Ammonia_striBging
Stripping pr°cess can be generally summarized, as
1. raising the pH of the water to 10.5-11.5;
2* fS5m^ti°1n' and reformation of water droplets (can
be easily accomplished in a stripping tower) ;
3. circulation of large quantities of air
371
-------
average lower limit of the process will be in the range of 50-60
percent ammonia removal.
The limitations of the use of ammonia stripping towers was first
realized with the winter operations at Lake Tahoe. These
limitations are outlined as follows (267):
1. When the air temperatures are at 0°C, or below, freezing
problems can occur which will restrict air flow.
2. Ammonia solubility increases at the lower temperatures,
which results in higher treatment costs.
2. A calcium carbonate scale formation results on the tower
because the lime treated wastes are saturated with CaCOl. The
scale could be flushed from the Lake Tahoe Tower, but at .he
EPA's Blue Plains Pilot Plant it was hard and adhered to tne
tower fill.
Based on the current status of ammonia stripping towers, they
probably will only be used in warm climates. In addition, the
hard scale problems will have to be solved.
372
-------
SECTION VIII
COSTS, ENERGY, NON-WATER QUALITY ASPECTS
£ationale_for_peveloBment_of_Costs
costs of internal and
-«• r
scale installations are few or nonexis?enf Pf°oesses- ""ere fuU
are largely based on exo-rienn. wfih •?',. * e cost estimates
estimates from and -l^^iS^18 "* °n
fro uthe
production facilities aid ^ ? ign and °Pera*ion of the
^
a
effluent treatment costs rented bS^^'T-
from one installation to JnSher Sn2 3 • lndustry varV greatly
procedures. The estimates of effluenf ^i UP°n ^ookkeeping
^^^
effluent treatmnt
ori.
subcategory in order t 2fct ?he °f m11S in each
ucategory in order t fct he snfo mS n
upon the costs of implementing the Lchnolo^™* °f ^ °f
Ten he
t hatthe t ~ •
next approximated 3:1. ThJ selected ^ t? °f.°ne Size tO the
subcategory are shown in Table 110 ?« Si ^ S1Z6! for each
are presented only for the laraer %-i 2 K 3Se °f NSPS' costs
unlikely, for economic re Jsons^hat ^small nT^6 At iS mOSt
mxU8 will be built in the foreseeable Iu?ure. ^ Sma11" neW
-pressed in terms of June
1974
eSch obcHf ^^ usi^ aerated
nor ech obc
using activated sludge in place of LB £? 5°rie? and the costs
158. with the exception of NS?s <£S n ln Tables 129 to
the costs of BATE£ incluL ?he'capitSiaJn/UmUl^iVe' That is'
shown in BPCTCA and the costs "fSr Sra?J ?^?SS2a\HO8t8 already
shown for pretreatment. Figures 6 fi fin th°Se alrea'3y
pretreatment, BPCTCA, BATEA and N?PQ ? arS C°St curves for
achieving the above le^ls^f ?lh i 9nd relate the c°sts of
each subcategory! ?hl inter nal^V0 ^ S±Ze °f mills f°*
internal treatment costs for NSPS in
373
-------
Table 110
MILL SIZES SELECTED FOR COSTING
kkg/day (tons/day)
Subcategory
Sulfite
Dissolving Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Groundwood Chemi-Mech.
Groundwood Thermo-Mech.
Groundwood C-M-N
Groundwood Fine
Soda
Non-Integrated Fine
Non-Integrated Tissue
Non-Integrated Tissue (FWP)
Very
Small
14(15)
FWP) 14(15)
Small
145(160)
73(80)
227(250)
227(250)
91(100)
91(100)
68(75)
272(300)
27(30)
32(35)
32(35)
Medium
480(530)
499(550)
209(230)
544(600)
318(350)
608(670)
608(670)
272(300)
272(300)
136(150)
635(700)
272(300)
91(100)
100(110)
100(110)
Sulfite
Dissolving Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Groundwood Chemi-Mech.
Groundwood Thermo-Mech.
Groundwood C-M-N
Groundwood Fine
Soda
Non-Int.egraced Fine
Non-Integrated Tissue
Non-Integrated Tissue (FTP)
NO. OF PAPER MCHINES USED IN COSTING
3
3
7
3
454(500)
907(1000)
635(700)
1179(1300)
1179(1300)
544(600)
544(600)
454(500)
635(700)
254(280)
408(450)
408(450)
2 Tissue
2
2
1
5
2
2
2
3
2
3
3
Board
3 Tissue
2 Board
5
3
3
2
4
2
2
3
3
4 Tissue
3 Board
9
4
4
3
6
5
5
5
5
374
-------
takPn in? +h a Same aS f°r BATEA' and no credit has been
th^o J equipment or systems that would be installed if
there were no effluent limitation requirements. Table 159
££™ \ "*nternal Effl*ent Treatment Costs for NSPS", takes into
account the equipment or system that would be installed. This
P?ared usin^ order of magnitude estimates for
- or
in this report, and will be revised for the final
INTERNAL_TECHNOLOGY_CgSTS
The
111 1pSaiTHoe5h?010^ Sy*tems identified are listed on Table
111, titled "Identification of Internal Technology items" A
Si^ descriPtion of each of these 29 systems will be found on
the following pages, and schematic drawings of the internal
controls are shown in Figure 65A. internal
It is assumed that operation and maintenance costs are recovered
by the mill in the forms of material and/or energy savings for
the internal technologies at all levels. Therefore, the annual
operating costs for the internal technologies is the depreciation
chla^? h03"8;, ^ d*Preci^°n c°s?s are the account
charges which reflect the deterioration of the capital assets
as™LPeri°d ?f yearS' Stra^ht ^ne depreciation has S
assumed in all annual cost calculations. The interest is the
financial charges on the capital expenditures fo? potion
reduction. Depreciation and interest together are assumed ?o be
15 percent of the investment costs. s»s»umea _o oe
sulfite li^or incineration and/or recovery is not
SSS.lJ1'.^
" in°luded at the *>°^Om of each table for
The number of paper machines in the paper mills bv -ach
subcategory will be found in Table 110. A very brief description
nClUded ^ ^^ °f the 29 inte
Is a
1^ — Bep.lace_Flume_with_Mechanical_ConveYors __
ii1 K°r ^hiS ^stimate Processes 1200 cords per day of a
trrk Th P^lpwood hardwood and softwood, received by ?ail
* K I flUme' Wlth C0arse and fines removal system, is
- "
conveyors over the flume structure. Unloading docks or
" ^^ °" On3 SdS °f the C0nv e^0" " "educe
ar'frevLsIbfe.
375
-------
Table 111
IDENTIFICATION OF INTERNAL TECHNOLOGY _ITEMS
ITEM NO. DESCRIPTION
I Replace Flume with mechanical conveyor.
2 Use of steam in drum barkers.
3 KnotL- collection and disposal.
4 Fourth stage brown stock washer.
5 Decker filtrate for brown stock washer showers.
6 Close-up screen room.
7 Pulp mill spill collection from washers.
8 Pulp mill spill collection from tanks, equipment
and drains.
9 Jump stage countercurrent washing.
]_0 Evaporator surface condenser.
•Q Steam stripping condensates and reuse.
12 Evaporator boilout tank.
13 Black liquor storage tank spill collection.
j_4 Green liquor dregs filtering.
15 Causticizing area spill collection system.
16 Evaporator condensate for causticizing makeup.
Yl Lime mud storage pond.
2_8 Alarms on chemica1 tanks.
19 Prehydrolysate disposal by burning.
20 MgO recovery system.
2i Paper machine vacuum saveall.
22 Paper machine flotation saveall.
23 Paper machine high pressure c.lowers.
24 Paper machine white water showers.
25 Cyliner former white water showers.
26 Cooling water segregation and reuse.
27 Felt hair removal.
28 Vacuum pumps seal x<7ater reuse.
29 Paper mill stock spill collection system.
376
-------
Table 112
-JlJECHNOLOCTES_USED_IN COSTING
Sulfite Subcategory
Data are percentages of total item cost. X = 100%
.Pre BPCTCA
1
2.
3.
4-
5.
6.
7.
8.
9.
.10.
11.
12.
13.
14.
15.
16
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
50
50
50
50
25
33
33
75
33
50
33
ij*-\ i i-,/-\
X
x x
X
x x
X
X
X
x x
x x
x x
x x
x x
x x
x x
X
x x
x x
X
JNb
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
377
-------
Table 113
INTEUKAL TECHNOLOGIES USED TN COSTING
Sulfi.c Dissolving Subcategory
Data are percentages of total item cost. X = 100%
Item Pre BPCTCA BATEA NSPS
1.
2.
3. 50
4.
50
•J *
6.
7.
8.
9. 50
10. 50
11.
12. 25
13. 33
14.
15.
16.
li:
20.' 50
21.
22.
23.
24.
25. 50
26.
27. 50
28.
29.
X
x x
x
x x
X
X
X
X X
x x
x x
X X
x x
x x
X X
X
x x
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
378
-------
Table 114
INTERNAL TECHNOLOGIES USLD IN_COSTINft
Deink Subcauegory
Data are percentages of total item cost. X = 100%
— ^£ BPCTCA BATFA NSPS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18' 33 x
19. x X
20.
21. 75
22.
23. 40
24.
25.
22. X X x
24. X X x
26.
27. X X
28. 50 v
29. X X
x X
379
-------
TAble 115
INTERNAL TECHNOLOGIES USED TN COSTING
Bleached Kraft Dissolving Subcategory
Data are percentages of total item cost. X = 100%
Item Pre BPCYCA -.A.TEA NSPS
1.
2.
3.
4.
5.
6.
7.
»
8.
\J •
9.
y •
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
90
33
75
50
33
33
33
33
67
50
33
X
X X
X
X X
X
X
X
X X
X X
X X
X X
X X
X
X
X
X X
X X
X X
X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
380
-------
Table lib
:™'-.™™^^
Marvel: Kraj t Subcategory
Data are perccat^es of total item cost. X - 100%
BPCTCA BATEA
1.
2.
3. 90
4.
5. 33
6.
7.
8.
9. 75
10. 50
11.
12. 33
13. 33
14. 33
15.
16.
17.
18. 33
19.
20.
21.
22.
23.
24.
25. 50
26.
27. 40
28.
29.
~~
X
x x
X
x x
X
X
X
x x
x x
x x
x x
x x
X
X
X
x x
x x
X
x x
_«a
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
381
-------
Table 117
INTERNAL TECHNOLOGIES USED IN COSTING
BCT Kraft Subcategory
Data are percentages of total item cost. X = "00%
Item Pre BPCTC MTEA NSPS
3.
2.
3.
,
5.
.
7.
8.
Q
7 •
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
90
33
75
50
33
33
33
33
90
20
20
33
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
x-
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
382
-------
Table 118
INTERNAL TECWrOJ.OGTES USED TN COSTINC,
Fine Kraft Subcategory
Data are percentages of total item cost. X = 100%
£££ BPCTCA BATEA NSPS
1.
2.
3. 90
4.
5- 33
6.
7.
8.
9. X
10. 75
11.
12. 50
13. 50
14. 33
15.
16.
17.
18. 33
19.
20.
21.
22. X
23. X
24.
25.
26.
27. 40
28. 50
29.
X
x x
X
x x
X
X
X
x x
'I X
x x
x x
x x
X
X
X
x x
x x
x x
X
x x
x x
X
JX«J
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
383
-------
Table 1 19
INTERNAL TECHNOLOGIES IIS"D IN_COST1NG
Groundwood Chemi/Mec'.i. Subcatcgory
Data are percentages of total item cost. X = 100%
Item Pre BPCTCA BATEA NSPS_
\.
4.
• 5.
6 X X
o. v y
7. X X
8.
9.
10.
11.
12.
13.
14.
15.
16.
S: 25 x x x
19.
20.
21. 40 X X X
": 25 x x x
24.
25.
X X
26.
27. 25 X X X
28. X X
29.
384
-------
Table 120
INTERNAL TECHNOLOGIES USED IN COSTING
Goundwood Thermo /Mech. Subcategory
Data are percentages of total item cost. X = 100%
Pre BPCTCA B/.TEA NSPS
1.
2.
3. X x
4.
5.
6.
7. X X
8. X X
9.
-10.
11.
12.
13.
14.
15.
16.
17.
18- " x Y
19. X X
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
40
25
25
x x
x x
X
x x
X
X
X
X
X
X
385
-------
Table 121
^r^q^
Goundwood C-M-N Subcategory
Data are percentages of total item cost. X = 100%
Item Pre BPCTCA 3AIEA
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18. /D
19.
20.
21. 4°
22. 25
23. "
24.
25.
26.
27' 25
28.
29.
x x
x x
x x
x x x
x x x
x x x
x x
x x x
x x
386
-------
Table 122
INTERNAL TECHNOLOKTESJJSED IN COSTING
Groimdwood Fine Subcategory
Data are percentages of total Item cost. X =
— BPCrCA
.JA-JEA
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18. 25
19.
20.
21. 75
22.
23. 25
24.
25.
26.
27.
28. 25
29.
X X
x x
x x
x x x
x x x
x x x
x x
x x x
x x
387
-------
Table 123
INTERNAL TECHNOLOGIES USED IN COSTING
Item BPCTC NSPS
2
o 90 X X X
L XX
5. X X
, x
;•
'• xx
x
X
Soda Subcategory
iata are percentages of total item
Pre BPCTCA
90 X
33 X
75 X
50 X
33 X
33 X
33 X
33 X
XY
*\.
50 X
50 X
50 X
cost. X
BATEA
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
' X
X
X
x
15.
X
16- X X
»;
19,
20.
21. x XXX
22. X X
2A.
25.
X
27 X
28 50 X X X
•^B- x x
29.
388
-------
Non-l7.tegratcd FinL- Subcatr.gory
Data a.e percentages of total item cost. * - 100%
Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Pre
25
75
33
33
33
BPCTCA
x
x
•"•
x
x
BATEA
x
Y
X
X
X
X
X
NSPS-
X
X
X
X
385
-------
Table 125
INTERNAL TECHNOLOGIES USED T.N COSTING
Non-Infagratcd Tissue Subcategory
Di*ta are percentages of total item cost. X = 100%
Item Pre BPCTCA BATEA
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
S: »
19.
20.
»
22.
S: 25 x x x
25.
X X
26.
27. 33 X X X
28. 33 X X
29.
390
-------
Table 126
Non- Integrated Tissue (£*»>) Subcategory
Data are percentages of total itcn cost. X - 100%
Item
BATEA KSPS
1.
2.
3.
A.
5.
6.
7.
8.
9.
10.
11.
12.
13.
I*.-
15.
16.
17.
18- 25 x v
19. X X
20.
21> 50 x x
22. X X
23.
24' 2S X x
25. X x
26. y
27. X x
28. 33 x
29. J x
x X
391
-------
Table 127
EXTERNAL UNIT PROCESS USED IN COSTING
Unit Process
1. .Preliminary
*
2. Pump Station
3. Primary Clarifier
4. Sludge Lagoon
5. Aerators
A. AS3 Basin
7. Vacuum Filters
8. Press
9. Monitor
10. Outfall
il. Biffuser
12. Foan
13. Neutralization
14. Eiacfc Liqucr Lagoon
15. Mixed Media
16. Air Flotation
17. Secondary Clarifier
IS. Mini-Lime
Sulfite
73 77 33 NS
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X
X X X X
X
X
X
X
X X
X
X
X
X
X
Diss.
Sulfite
73 77 83 NS
X
X
X
X
X
X
X
X
x -x x
X
X
X
X
x x
X
X X
X
X
X
X
X
*!.
X
X
X
X
X
X
X
DeinU
73 77 83 NS
X
X
X
X
X
X
X
X
x x
X
X
X
X
X
X X X X
x x
x x
XX X
X
X
X
Diss.
Kraft
73 77 83 NS
X
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X
X X X X
x x
x x
x x
XX X
X
X
X
X
Market
Kraft
73 77 83 NS
X
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X
X X X X
x x
x x
x x
XX X
X
X
X
X
-------
Table 127 cont'd
EXTERNAL WIT PROCESS USED IN COSTING
BCT
Kraf t
ynit_Erocess 73 77 g3 NS
1. Preliminary x X
2. Pump Station x XX
3. Primary Clarifier x X
4. Sludge Lagoon x X
5. Aerators X X
6. ASB Basin y v
A A
to
10 7 . Vo cuuni v v
CO AX
8. Press X X
9. Monitor X X X X
10. Outfall x X
11. Di^fuser v y
A A
12. Foam X x
13. Neutralization
14. Black Liquor Lagoon XX X
15. Mixed Media X
16. Air Flotation X
17. Secondary Clarifier x
13. M_ni-Li'ue ^
Fine
Kraft
73 77 83 NS
X X
X XX
X X
X X
X X
X X
X X
X X
X X X X
X X
x x
x x
XX X
X
X
X
X
Soda
73.27 83 NS
X X
X XX
X X
X X
x x
x x
X X
x x
X X X X
X X
x x
X X
X X
XX X
X
X
X
X
Groundwood
Chemi/Mech
73 77 81 NS
X X
X XX
X X
X X
X X
X X
X X
x x
X X X X
x x
x x
x x
XX X
X
X
X
Groundwood
Thermo /Mech
73 77 8"* M
-------
Table 127 cont'd
EXTERNAL UNIT PROCESS 1
Groundwood Groundwood
Fine CMN
___Jjnit^roces±____^lJl_MJiS 73J7_83JiS
1. ^Preliminary x X
Y Y X XXX
2. Pump Station A A A
X X
3. Primary Clarifier X
Y X X X
4. Sludgt Lagoon
XX XX
5. Aerators A
Y X X X
6. AS3 Basin x
. Y X X X
. 7. Vacuum Filters *•
XX XX
8. Press *
YYYX XXXX
9. Monitor X X A A
v X X X
1.0. Outfall x A
Y X X X
11. Diffuser *
12. Foam
13. Neutralization
Y Y X XX X
14. Black Liquor Lagoon A a.
Y X
15. Mixed Media
X x
16. Air Flotation
Y X
17. Secondary Clarifier *
18. Mini-Lime
[JSED IN UUMJ.JNI* NI
.TT MI Tissue
NX
F-inp Tissue FWP
_. J1^ „ „ 77 «. NS 73 77 83_NS_
— ^.^. i — — -
ir V
xx xx xx
xxx xxx xxx
xx xx xx
Y XX XX
X A •"•
v x XX XX
^i. -A.
xx xx xx
xx xx xx
xxx xxx xxx
v V
xx xx xx
TT V
xx xx xx
xx xx xx
x x x
x x x
x x
-------
Table ]^o
Dat.a in kl/kkg (legal/ton) For 7-luv
And kg/kkg (Ib/ton) For All Others
PARAMETER PRETR I1A TMFNT
Q-- J __ — — • ' - • i • i
oocta
09 BOD 55 (110)
09 TSS 150 (300)
Flow 208 (50)
79 BOD 46.75 (93.5)
79 TSS 33 (66)
GW-Chemi-Mechanical
09 BOD 60 (120.0)
°9 TSS 32.5 (65.0)
Flow 99.84 (24)
79 BOD 42 (84)
79 TSS 7.5 (13)
GW-Fine Papers
09 BOD 21.0 (42.0)
09 TSS 65 (130)
Flow 108.16 (26)
79 BOD5 14.7 (29.4)
79 TSS 13 (26)
Groundv/ood - CMN Papers
09 2CD 22.0 (44.0)
09 TSS 80 (160)
Flow 120.64 (29)
79 BOD 15.4 (3o.8)
79 TSS 16 (32)
Thermo Mechanical
09 BOD
09 TSS
Flow
79 BOD
79 TSS
BPCTCA
42.5 (85.0)
105 (210)
122.7 (29.5)
3.45 (6.9)
5.15 (10.3)
50.5 (101)
28 (97.0)
83.2 (20)
2.1 (4.2)
3 .65 (7.3)
17.0 (34.0)
52 (104)
90.69 (21.8)
2.25 (4.5)
4.0 (".0)
17.5 (35.0)
70 (140)
99 (23.8)
2.5 (5.0)
4.35 (8.7)
28.0 (56.0)
25.0 (97.0)
62.4 (15)
1.55 (3.1)
2.75 (5.5)
BAT FA
J.Jf\. i L, t\
30 (60)
65 (130)
95.7 (23)
1.45 (2.9)
0.95 (1.9)
45 (90.0)
22.5 (45.0)
74.88 (18)
0.75 (1.5)
0.75 (1.5)
16.0 (32.0)
45.0 (90.0)
74.88 (18)
1.0 (2.0)
0.75 (1.5)
16.0 (32.0)
48.0 (96.0)
79.04 (19)
1.05 (2.1)
0.8 (1.6)
26.5 (53.0)
25.0 (50.0)
41.6 (10)
0.65 (1.3)
0.4 (0.8)
NSPS
30 (60)
65 (.1 '>(})
95.7 (23)
1.45 (2.«
1.9 (3.C-
45 (90.0)
22.5 (45.0)
74.88 (18)
0.75 (1.5)
1.5 (3.0)
16.0 (32.0)
45.0 (90.0)
74.88 (18)
.1.0 (2.0)
1.5 (3.0)
1C.O (32.0)
48.0 (9^.0)
79.04 (19)
1.05 (2.1)
1.6 (3.2)
28.0 (56.0)
25.0 (50.0)
62.4 (15)
1.55 (3.1)
1.25 (2.5)
395
-------
Table 128 cont'd
BATEA.
NSPS
PARAjlET_K!._ __
BCT - Ur~i (:
09 BOD
09 TSS
Flow
79 BOD
79 TSS
Fine Kraf •'
09 BOD
09 TSS
Flow
79 BOD
79 TSS
Sulfite
09 BOD
09 TSS
Flow
79 BOD
79 TSS
Dissolving
09 BOD
09 TSS
Flow
79 BOD
79 TSS
Deink
09 BOD
09 TSS
Flow
79 BOD
79 TSS
Dissolving
09 BOD
09 TSS
Flow
79 BOD
79 TSS
PRF/TPVY.Y. -NT
42. 5 (85. 0)
55,0 (1.1.0.0)
208 (50)
3?.. 9 3 (77.85)
18.59 (37.18)
40. 0 (80.0)
90.0 (180.0)
166.4 (40)
36.64 (73.28)
30.42 (60.84)
600 (1200)
100 (200)
332.8 (80)
468 (936)
15 (30)
Sulfite
650 (1300)
100 (200)
416 (100)
507 (1014)
15 (30)
92.5 (185)
300 (600)
124.8 (30)
55.5 (111)
45 (90)
Kraft
80 (160)
200 (400)
332.8 (80)
73.28 (146.6)
67.6 (135.2)
u) iiiwi
33.5 (67.0)
51.5 (103)
151.84 (36.5)
3.8 (7.6)
6.4 (12.8)
30.0 (60.0)
84 (168)
108.16 (26)
2.8 (5.6)
4.55 (9.1)
115.5 (231)
82.0 (164)
208 (50)
9.1 (18.2)
13.15 (26.3)
132 (264)
92.5 (185)
271.23 (65.2)
13.6 (27.2)
16.3 (32.6)
68.5 (137)
204 (408)
94.02 (22.6)
4.2 (8.4)
7.85 (15.7)
55 (110)
150 (300)
241.28 (58)
7.75 (15.5)
9. 65. (19. 3)
26.0 (52.0)
46.5 (93)
112.32 (27)
1.7 (3.4)
1.15 (2.3)
23.5 (47.0)
46.5 (93.0)
95.68 (23)
1.15 (2.3)
0.95 (1.9)
68.5 (137)
75.0 (150)
176.8 (42.5)
3.85 (7.7)
1 95 (3.9)
125 (250)
85 (170)
249.6 (60)
5.0 (10.0)
2.5 (5.0)
68.5 (137)
204 (408)
74.88 (18)
1.5 (3.0)
1.5 (3.0)
37.5 (75.0)
85 (170)
216.32 (52)
3.25 (6.5)
2.15 (4.3)
26.0 (52.0)
46.5 (93.0)
112.32 (27)
1.7 (3.4)
2.25 (4.5)
23.5 (47.0)
46.5 (93.0)
95.68 (23)
1.15 (2.3)
1.9 (3.8)
91 (182)
73.5 (147)
112.32 (27)
2.45 (4.9)
2.45 (4.9)
125 (250)
85 (170)
249.6 (60)
5.0 (10.0)
5.0 (10.0)
68.5 (137)
204 (408)
74.88 (1.8)
2.25 (4.5)
2.25 (4.5)
37.5 (75.0)
85 (170)
216.32 (52)
3.25 (6.5)
4.35 (8.7)
396
-------
PR ETRFAT; jr. r
Table 128 cont'd
BPCTCA
Market Kraft
09 BOD
09 TSS
Flow
79 BOD
72 TSS
NI Tint P
09 BOD
09 TSS
Flow
79 BOD
79 TSS
NI Tissue
09 BOD
09 TSS
Flow
79 BOD
79 TSS
NI Tissue
09 BOD
09 TSS
Flow
79 BOD
79 TSS
60 (120)
80 (160)
332.8 (80)
54.96 0^9.92)
27.04 (54.08)
'ipers
17.5 (35.0)
75 (150)
108.16 (26)
17.5 (35.0)
75 (150)
17.5 (35.0)
62.5 (125)
141.44 (?'0
17.5 (35.0)
62.5 (125)
(PWP)
20.0 (40.0)
75 (150)
141.44 (34)
20.0 (40.0)
75 (150)
41 (82.0)
70 (140)
176.8 (42.5)
4.25 (8.5)
6.4 (12.8)
10.75 (21.5)
31.0 (62.0)
62.4 (15)
2.5 (5.0)
2-55 (5.3)
11.5 (23.0)
34.0 (68.0)
95.68 (23)
2.8 (5.6'.
2.9 (5.8)
14.5 (29.0)
40.0 (80.0)
95.68 (23)
2.8 (5.6)
2.9 (5.8)
BATEA
26.5 (53.0)
65 (130)
141.44 (34)
2.0 (4.0)
1.4 (2.8)
10.0 (20.0)
28.0 (56.0)
60.32 (14.5)
1.2 (2.4)
0.6 (1.2)
13.5 (27.0)
35.0 (70.0)
60.32 (14.5)
1.2 (2.4)
0.6 (1.2)
27.5 (55.0)
65 (130)
79.04 (19)
1.1 (2.Z)
1.6 (3.2)
9.5 (19.0)
30.0 (60.0)
38.27 (9.2)
0.75 (1.5)
0.4 (0.8)
9.5 (19.0)
30.0 (60.0)
38.27 (9.2)
0.75 (1.5)
0.75 (1.5)
10.0 (20.0)
28.0 (56.0)
60.32 CU.S'!
1.2 (2.4)
1.2 (2.4)
13.5 (27.0)
35.0 (70.0)
60.32 (14.5)
1.2 (2.4)
1.2 (2.4)
397
-------
Table .29
AERATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Sulfite Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 160 TPB
1983
NSPS
1.
2.
3.
4.
Int.
600
90
90
1973
Ext.
2875
315
195
120
Total
3475
405
285
120
1.
2.
3.
4.
Int.
1000
150
150
iy / /
Ext.
7550
1453
895
555
Total
8550
1600
1045
555
1.
2.
3.
4.
Int.
2035
3C5
8730
1810
1070
740
Total
10765
2115
1375
740
Int.
2. ^305
3. 30:,
4.
Ext .
7540
1690
1145
545
Total
95"5
1995
1'50
•H5
CO
IO
03
Mill Size: 530 TPD
1983
NSPS
1.
2.
3.
4.
int.
1430
215
215
1973
Ext.
6390
625
415
210
Total
7820
840
630
210
1.
2.
3.
4.
Int.
2310
345
345
iy//
Ext.
1580D
3135
18Z5
1310
Total
18110
3480
2170
1310
1.
2.
3.
4.
T-rtt-
in u .
4500
675
675
18335
3840
2185
1655
Total
22835
4515
286^
1555
1.
2.
3.
4.
Int.
4500
675
'75
Ext.
15320
3600
2300
1300
Total
19820
4275
2975
1300
Int: Internal Cost
2. Total Operating Cost
Ext: External Cost
3. Depreciation & Interest
1. Total InvesUEient Cost
4. Operation & Maintenance
NOTE: MgO Recovery System not included.
Capital Cost: 160 TPD - $11,300
530 TPD - $34,000
-------
CO
Table 130
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Sulfite Subcategory
Costs in Thousands of Dollars)
HiJ-1 Size: 160 T?D
Int.
1. 600
2. 90
3. 90
4.
Int.
1. 1,430
2. 215
3. 215
4.
1973
Ext.
2,875
315
195
120
1973
Ext.
6,390
625
415
210
Total
3,475
405
285
120
Total
7,820
840
630
210
TnT
1UL .
1. 1,000
2. 150
3. 150
4.
Int.
1. 2,310
2. 345
3. 345
4.
1977
Ext.
8,980
1,820
1,110
710
Mill
_1977
Ext. T
19;630 21
3r995 4
2.400 2
1.595 1
Total
9,980
1,970
1,260
710
Size:
otal
-
,940
,340
,745
,595
—
Irrt.
1. 2,035
2. 350
3. 350
4.
530 TPD
1. 4,500
2. 675
3. 675
4.
1983
Ext.
10,160
2,180
1,285
895
1983
E::t.
22,165
4,700
2,760
1,940
Total
12,195
2,530
1,635
895
Total
26,665
5,375
3,435
1,940
_Int.
1. 2,035
2. 350
3. -"so
4.
jnt.
1. 4,500
2. 675
3. 675
4.
NSPS
Ext.
6,5/0
1,620
980
640
NSPS
13,610
3,565
2,0^5
1,520
Total
8,555
1,970
J,330
640
.Total
18,110
2 '7:0
Int: Internal Cost
2. Total Operating Cost
NOTE: £0 Recovery Syste, not included.
Capital Cost: i60 TPD _ $11>300
530 TPD - $34,000
Ext: External Cost
3- Depreciation & Interest
1. Total Investment Cost
4- Operation & Maintenance
-------
o
o
Table T1
AERATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Sulfite Dissolving Subcategory
(All Costs in Thousands of Dollars;
Mill Size: 550 TPD
1977
1.
4.
InTT"
415
60
60
iy/j
6880
1320
1080
240
Total
7295
1380
1140
240
Int. Ext..
1. 870 16695
2. 130 3925
3> 130 2570
4. - 1355
Tot al
17565
4055
2700
1355
Mill Size:
Int.
1973
Ext.
Total
1977
Int. Ext.
1.
2.
3.
4.
Total
1.
2.
3.
4,
Int: Internal Cost
2. Total Operating Cost
Ext: External Cost
3. Depreciation & Interest
Int.
1. 2940
2. 440
3. 440
4. -
TPD
Int.
1.
2.
3.
4.
Interest
1983
Ext.
19980
4940
3065
1875
1983
Ext.
1.
4.
Total IBJL-
22920 1. ?9 VO
5380 2. 440
3505 3. <-' +0
1875 4 .
NSPS
Ext.. Total
195«'0 22900
4955 5395
2980 3420
1975 1975
KSPS
Total int. *XL. ±u±±z.
1.
2.
3.
4.
Total Investment Cost
Operation & Maintenance
NOTE- MgO Recovery System not included.
Capital Cost: $35,000
-------
1973
Int.
1. 415
2. 60
3. 60
4.
Int.
1.
2.
3.
4.
Ext.
6880
1320
1080
240
1973
Ext.
Total
7295
1380
1140
240
Total
Int: Internal Cost
2. Total Operating Cost
Table 132
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Dissolving Sulfite Subcategory
(.All Costs in Thousands of Dollars)
Mill Size: 550 TPD
1977
int.
1. 870
2. 130
3. 130
4.
Int.
1.
2.
3.
4.
— '
20,775
4,860
3,165
1,695
Mill
1977
Ext.
l£^i ^-- s Tim ^FT
21,645 1. 2940 24,060 27,000 l 9o,0
,90 2. 440 5,875 6,315 \\ ^ 0
l'695 f '4° 3'660 4,100 3. 44L
1,695 4. - 2,215 2,215 4. -
Size: TPD
Total Trt: ^r— -
. i ^rvt. Ext. Total Tnt
i. ~
, 2.
/ 3-
4.
NSPS
—
Ext.
18,740
4,840
2,810
2,030
NSPS
Ext.
— —
21,680
5,280
?,250
2,030
To-al
~
NOTE: Mg0_Recovery Syste, not included.
Capxtal Cost: $35,000
Ext: External Cost
3. Depreciation & Interest
1- Total Investment Cost
4. Operation & Maintenance
-------
Table 133
AERATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Deink Subcategory
(All Costs in Thousands of Dollars;
Mill Size: 80
— ' —
j, Ti L *
- , 400
"; 60
3. 60
o
rvr-v ^t
1. 535
!. SO
3 . 80
— -*•
Int.
1. 965
2. 145
3. 145
7 „
1973
_E:ct_._
1225
255
190
65
1973
2350
445
360
85
1973
4,050
720
610
110
Total.
1625
315
250
65
Total
2885
525
440
85
To Ceil
5,015
865
755
110
1977
T 600 3555
2' 90 855
90 550
4*. - 3°5
Mill
T Q "7 "7
1. 835 6405
2. 125 1530
3, 125 965
4. - 565
Mill
1977
Int. Ext..
1 1,485 10,135
2. 225 2,500
3 225 1,530
4. - 97°
3
, - •
~r> *- ^ i Tnt •
\ r\r f\ 1 -LIU- •
4155 I.'745
945 2. H°
640 3. 11°
305 4. ~
size: 230 TPD
Total" l.nt-
^240 1. I110
1655 2. 165
1090 3. 165
565 4.
Size: 500 TPD
Toral Int.
11,620 1. 1,930
2,725 2. 290
1,755 3. 290
970 4.
QQ1
.yo -j
3905
980
605
375
1983
Ext
7140
1670
1075
595
1983
Total int.
4650 i.
1090 2.
715 3.
375 4.
T^Vfal Int .
8250 1. 111°
1835 2. 165
1240 3. I65
595 4.
~~ rri i_~1 Tnf .
Ext . lULaJ- .'
11,405 13,335 1.1,930
2,915 3,205 2. 290
1,715 2,005 3. 290
1,200 1,200 4.
NSPS
Ext.
NSPS
Ext.
7670
1795
1150
645
NSPS
Ext.
11,795
2,750
1,770
980
Total
_. . - • —
Tr.t- al
8780
1960
1315
645
Total
13,725
3,040
2,060
980
Int.: Internal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 134
WASTE ACTIVATED SLUDGZ
EFFLUENT TREATMENT COSTS
Deink Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 80 TPD
Int.
1. 400
2. 60
3. 60
4. -
int.
1. 535
2. 80
3 . 80
4, -
0
GO
Int^
1. 965
2. 145
3. 145
4. -
1973
Ext.
1,225
225
190
65
1973
Ext^
2,350
445
360
85
1973
Ext .
4,050
720
610
110
Total
1,625
315
250
65
Total
2,885
525
440
85
To tal
5,015
865
755
110
1.
2.
3.
4.
1.
2.
3.
4.
1.
2.
3.
4.
Int.
600
90
90
Int._
835
125
125
Int.
1,485
225
225
1977
Ext.
4,115
1,010
625
385
Mill
1977
Ex_t_._
7,405
1,835
1,120
715
Mill
1977
Ext .
11,985
2,820
1,635
1,185
Total
4,715
1,100
715
385
Size: 230
JTotajl
8,240
1,960
1,245
715
Size: 500
Total
13,470
3,045
1,860
1,185
1.
2.
3.
4.
Int.
745
110
110
1983
Ext.
4,465
1,135
680
455
Total
5,210
1,245
790
455
Int.
1.
2.
3.
4.
NSPS
Ext.
Total
TPD
2
3.
4.
Int^
1,110
165
165
1983
Ext_.
8,140
2,070
1,230
840
Total
9,250
2,235
1,395
840
Int.
}' 1,110
' 165
i' 165
H •
NSPS
_Ext .
6,675
1,780
1,005
775
Total
7,785
1,945
1,170
775
TPD
2.
3.
4.
int .
1,930
290
290
1983
Ext.
13,255
3,235
1,820
1,415
Tc -.cil
15,185
3,525
2,110
1,415
Int.
1" 1,930
2* 290
3- 290
4,
NSPS
Ext.
10,755
2,870
1,615
1,255
T~ <- ~ "
12,685
3,160
1,90.5
1,255
Int.: Internal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation i Maintenance
-------
Table 135
AERATED STABILIZATION BASIN
EFFLUENT TRIwYlMi-.in: COSTS
Bleached Kraft Dissolving Subcategory
(All Costs in Thousands of Dollars;
Fill Size: 600 T?D
1973 1977 - - , ~ ^f- ToTaT Int. Ext. Total
1. 525 5,640 6,
2 80 1,030 1,
3" 80 845
4; - iss
1973
Int. Ext. •£
, 740 8,055 8
2 HO I,470 !
* no i,2ic i
4. - 26°
Int: Internal Cost
tal
165
110
925
185
•i
,795
,580
,320
260
Int.
1. 1,040
2. 155
3. 155
4.
Int.
I 1,460
2. 22°
3. 22°
4.
E?! t . T-
14,475 1
3,310
2,170
1,140
Mill
1977
20.. 135
3 'P020
1,735
.5,515 1.
3,465 2.
2,325 3.
1,140 4.
size:1000
21,595 i.
4,975 2.
l',735 4!
3,725
560
560
TPD
5,210
780
780
Ext: External Cost
< r,t--t<-.Ti ^. Tn1
merest
18,865 22,590 1.
/ ~) o c <^ O Q ^ O
4 , / Z _) .3 , A. O _; Z. *
2,830 3,390 3-
V<;T>C
1983 ^±i T— -
26,210 31,420 i. 5,210 22'/'/^ 2^'?~o
6785 7,565 2. 780 5,^40 b.^0
3,930 4,710 3. 780 S.nlS ,1^
2,855 2,855 4. - 2'125 *"1"
1. Total Inves'—.ert Cost
4. Operation & Kainuv r.-.r.ce
2. Total Operating Cost
-------
Table 136
i
Bleached Kraft Dissolving Subcategory
(All costs i, Thousands of Dollars)7
will Si^e: 600
1973
4
o
en
1.
^» *
3.
4.
. 525
SO
. 80
Int.
740
110
110
5,640
1,030
845
185
19-3
I>:t.
8,055
1,470
1,210
260
Total
6,165
1,110
9^5
185
Tor. =1
8,795
l,5iO
1,3-J
260
Int.
1. 1,040
2. 155
3. 155
4.
TnTT~
1. 1,460
2. 220
3. 220
4.
1977
Ext.
18,585
4,255
2,785
1,470
Mil
1977
Ext.
25,750
5,975
3,865
2,110 .
Total
19,625
4,410
2,940
1,470
1 Size:
Tor it
27,210
6,195
4,085
2,110
Tii t-
JLUC »
1. 3,725
2. 560
3. 560
4.
1000 XPD
jnt.
1. 5,210
2. 78''
3. 780
4.
1983
Ext.
22,975
5,670
3,445
2,225
1933
Ext,
31,825
8,000
4,775
3,225
Total IntT
26,700 l.
6,230 2!
4,005 3
2,225 4'
X • ^ 9 £-1. U
8>780 2. 780
5,555 3 780
3,225 4. „
NSPS
Ext^.
MCPC
Ext.
22,415
5,615
3,365
2,250
Total
Total
27,625
6,395
4,145
2,250
Int: Internal Cost
2. Total Operating Cost
Ext: Exteraal Cost
3- Depreciation & Interest
Total Investment Cost
Operation & Maintenance
-------
Table 137
AERATED STABILIZATION BASIN
EF11AJENT TREATMENT COSTS
Market Kraft Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 350 TPD
Int.
1. 360
2. 55
3. 55
4. -
1.
2.
3.
4.
Int.
565
85
85
1973
Ext.
3,430
645
515
130
1973
Ext_.
5,610
1,045
845
200
Total
3,790
700
570
130
Total
6,175
1,130
930
200
Int.
1. 705
2. 105
3. 105
4. -
Int.
1. 1>115
2 165
3; 165
4.
1977
Ext. Total int.
8 745 9,450 1. 2,570
1,880 1,985 2. 385
1,315 1,420 3. 385
565 565 4,
Mill Size: 700 TPD
1977
13,630
3,000
"2,050
950
Totaj^
14,745
3,165
2,215
950
Int.
1. 3,980
2. 595
4,
1933
E_xt_.
11,210
2,660
1,690
970
1983
Ext.
17,265
4,850
2,600
2,250
Total
13,780
3,045
2,075
970
TotaJ.
•••
21,245
5,445
3,195
2,250
Int .
1.
2.
3.
4.
Int.
1. 3,980
2. 595
3. 595
4.
Ext . Total
NSPS
Ext.
11,560
2,790
1,735
1,055
Total
15,540
3,385
2,330
1,055
Int: Internal Cost
2. Total Operating Cost
Ext: External Cost
3. Depreciation & Interest
1. Total Investrcer-r. Cost
4. Operation & Maintenance
-------
Table 138
WASTE ACTIVATED SLUD
f A 1 •? CD^"''*- j
(All Costs In Thousands of Dollars)
Mill Size: 350 TPD
.977
J-.l I. .
36C
J_^
55
£.'.'.*" .
3,430
645
515
130
Tct M 'f — " —
3,790 1 -Q5
7C3 2. 105
^70 3. 105
130 4. -
__ *
n ^~=zi. *
10,865
2,330
1,635
695
Total
11,570
1,740
695
1.
2.
3.
A
.,_
Int.
2,570
335
~
1 Q - o
Ext
13,330
3,110
2,010
1,100
— ™.
Total
15,900
3,495
2,395
1,100
NSPS
l££. Ext. Total
1.
2.
3.
4.
Mill Size: 700 TPD
1977
-•• • — . x^jij
.'.• 5£ i5;S? f'^o5 j- i-iis ".i-''° "" "' """
43' 85 •« «o° • J« 23-"o
4. - 2oo 2CO ,J- i65 2'575
uu A« ~ 1,235
Int: Internal Cost
£:
-------
AERATED*STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
BTC Kraft Subcategory
(All Costs in Tnou^-rv-o %IOLX
Mill Size: 250 ^
Int.,
I 885
2". 135
3. 135
4. ~
""
Int .
1. 1,800
2. 270
3 . 270
4.
-p>
CO
1.
2.
3.
4.
-
— — — — • •
Int.
3,030
455
455
-
1973
1977
_Ex_t .. Total
2,185 3,070
425 560
330 A65
95 95
1973
Ext. Total
3,950 5,750
740 1,010
595 865
145
1973
Ext.
6,320
1,175
950
225
143
Total
9,350
1,630
1,405
225
Int. t-xt. j-uL^i.
le 1,335 6,115 7,459 ;
9 DO 92G 1,^-^'J
3- 2UU 375 375
4-
Mill Size: 67°
1Q77
Int.
1. 2,645
2 395
3*. 395
.
•
Int.
1. 4,365
2. 655
3. 655
4.
Ext.
10,860
2,360
1,630
730
Mill
1971, __
Ext.
16,795
3,790
2,520
1,270
JTotal
13,505
2,755
2,025
730
Size: "00
- •
21,160
4,445
3,175
1,270
1983 -
f^T~ E;:t. Total I
1 3,C20
2. A55
3 455
a ,
TPD
__ ~...M ""-
Int.
1 5,715
2 860
3'_ 860
4.
TPD
Int.
1. 9,050
2. 1,360
3. 1,360
4.
7,595
1,750
1,140
610
1983_____
14,010
3,340
2,105
1,235
1983
Ext.
21,485
5,215
3,225
1,990
10,615 j_
2,205 ?'
1. 595 -^
610 4]
Total
19,725 i.
4,200 2.
2.965 3.
1,235 4.
Total
30,535 L
6,575 2.
4,585 3.
1,990 4.
TC .
5,715
860
860
Int.
9,050
1,360
1,360
J.> - :.
FSPS
"xt .
12,590
2,895
1,890
1,005
NSPS
Er.t .
18,505
4,455
2,775
1,680
--"—'--
18.205
3,755
2,750
1,005
pp _ *- 0 "1
i O L S- -L
27,555
5,815
4,135
1,680
Int.: Internal Cost
2. Total Operating Cost
Ext,: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 140
WASTE ACTIVATED SLUDGE
EFiLUENT TREATMENT COSTS
BTC Kraft
Costs in Thousands of Dollars)
Mil] SIzo: 2,Q TPD
jnt.
1. 885
2. 135
3. 135
4, "
• — -•• ' — —
I 1,800
2 270
3\ 270
4 . ~
o
IQ
— — — • .
1. 3,030
2 455
3. 455
1973
_Ext.
2,185
425
330
95
1973
— - —
3,950
740
595
145
1973
_ __
6,320
1,175
950
225
Total
3,070
560
465
95
— ' — .
Total
5,750
1,010
865
145
i .i-—
Total
9,350
1,630
1,405
225
Int.
!. 1,335
2.' 200
3! 20°
4.
Int.
I 2,645
2. 395
3. 395
4.
1977
•"• ' 1 — — - - - _
Ext.
7,475
1.645
1,125
52.0
Mil]
1977
Ert^
13,870
3,050
2,085
975
Mill
1977
_Int^ Ext.
1. 4,365
2 655
3! 655
4.
21,715
4,875
3,260
1,615
To f- - 1
8,810
l,Si5
1,525
520
Si?G: 67C
-"•.».— ,._
Totajl
16,515
3,445
9 •' ^ O
S- , H- -J J
9^5
Si.e: "00
— - — — • — .
Total
26,080
5,530
7 O" c;
~} ^ _,- j J
I,6i5
1030
^r ±^- , KSPS
J-^L. ixt. Total i^f- "F:^
3. 3,020 8,955 11,975 .
2. 455 2, ICO 2,555 *'
3. 4:)J J-,J45 1,300 -
4. - 755 7S5 ;'
4 .
1 TPD
lnt^_ £Kt. Total 7nt. F^ ~
I. 5,715 17,010 22,733 5,715 n 2r70
2. 85° 4,040 4,9Cn ^ 8GO oV;"
3. 35° 2,500 3,^20 „' y50 j';.v;'0
4. l,40lj i,430 /(> _ 1,110
TPD
1933 I;C:T,S
— ^ih^. i9_ri_ lnt_._ ::-t.
1. 9,050 26,402 35,452 9,050 17,225
5- i;31S :L°5° M5? - i>™ ^
,^ „ " 3 . J- , -^ D V /,.}>_">
To t a 1
Tot il
16,975
2,550
1,110
j,^f-a-
26.275
5^525
3 , 9 '• 5
Int.: Internal Cost
2. Total Operating Cost
Ext,: External Cost
3. Deprecistion & Interest
^-'JJ 4.
Total Investnent Cost
Operation & Maintenance
:,'-'n
-------
Table 141
AERATED STABILrVTION BASIN
EFFLUENT TREATMENT COSTS
Fin 3 Kraft Subcategory_
(All Coses in Thousand'
_C&W-J
of Dollars)
Mill Si;
250 -
NSPS
1
J
1.
2.
3,
'"T •
1.
2,
3 .
4.
o
1.
2.
3.
1,030
155
155
1,970
295
295
int.
3,200
480
430
1973
Ext^
1,930
385
290
95
ly / ->
Ext.
4,425
795
655
130
_973
Ext.
5,845
1,065
875
190
1977
Total
2,960
540
445
95
Total
6,395
1,090
960
130
Total
9,045
1,545
1,355
190
Int.
1.1,235
2. 125
3. 135
4.
—
int.
1.2,365
2. 355
n r- f-
3. 3:>5
4. ~
Int.
j.3,820
2 575
3'. 575
4.
Ext.
5,470
1,200
820
380
Mill
1977
Ext,
10,690
2,385
1,605
780
Mill
1977
Ext .
15,140
3,575
2,270
1,305
— . „ -
6,705 1-2,920
1,235 2. 440
1,035 3. 440
330 A.
Size: 670 TPD
Total iBli.
13,055 1.5,410
2.740 2. 810
1,9^0 3. 8iO
780 *. -
Size: 1300 TPD
18,960 15,505
4,150 21,275
2,845 31,275
1,305 4. -
Ext.
7,040
1,660
1,060
600
1983
hxt -
13,510
3,225
2,030
1,225
1983
Kxt .
19,455
5,OC3
2,920
2,080
"r^l Int. Ext. Tct-il
9,960 1"
2,100 2.
1,500 3.
600 4>
XSPS
Tot-^1 J.nt . i:,,\!- . ' ,.^.-'.-^
18,920 1- 5,410 11,565 16,975
4,065 2- 010 236CO 3r-,C
2,840 3- MO 1,735 2,5-5
1.225 l'-- - 925 ?•:
1\?I''S
27,960 1 8,505 17,160 25,665
6,275 2. 1,2}5 4,135 %^r
4,195 3, 1,275 :,5''5 3,-: I
2,080 4- - 1,560 1,5 .;
Int.: Internal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation £ MaLnLen;.r,ce
-------
I able K2
WASTE ACTIVATED SLUDGE
EFFLUENT YREATNLNT COSTS
Fine Kraft
(All Costs Ir Thousands of Dollars)
Mill Size: 250 TPD
~ r- *•
1. 1,030
2. 155
3. 155
T- -
I. 1,270
2. 295
3 . 295
•v • *"•
— '
T ••. f
1. 3,203
2. 480
3. 480
4.
___. .
-~^L. ^-tS45 9,045
1.065 1,545
875 1,355
190 190
Int.
1. 1,235
2. 185
3. 185
4.
Int.
1. 2,365
2. 355
3. 355
4.
1977
Ext.
6,750
1,570
1,015
555
Mill
1977
Ext.
13,140
2,950
1,975
975
Mill
Total
7,985
1,755
1,200
555
Size: 670
Total
15,505
3,305
2,330
975
Size: 1300
Tn f-
1. 2,920
2. 440
3. 440
.
TPD
*~'" —
1. 5,410
2. 810
3. 810
4.
TPD
1977
1. 3,820
2. 575
3. 575
4.
19,100
4,510
2,865
1,645
lofal
22,920
5,085
3,440
1,645
Int^
1. 8,505
2. 1,275
3. 1,275
4.
1 QR T
—~—~ — — — _^_
___. C t .
8,320
2,030
1,255
775
198J
— - — —
15,960
3,820
2,400
1,420
1983
23,415
5,890
3,515
2,375
••' ii i i . _
•i'otal Int.
11,240 i
2,470 {
1,695 3'
775 4.
— ".I _
_Total int.
21,370. i. 5,410
4,630 2. 810
3,210 3. 810
1,420 4.
l°tal Int_._
31,920 i. 8,505
7,165 2. 1,275
4,790 3. 1,275
2,375 4. -
NSPS
_Ext_._
NSPS
Ext .
10,305
2,555
1,545
1,010
NSPS
Ext_._
15,985
4,070
2,400
1,670
Total
Total^
15,715
3,365
2,355
1,010
_Total
24,490
5,345
3,675
1,670
Ir.r. : Inccrnal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
1973
Int.
1. "0
7 25
V 25
~J *
/ —
T •
1
Int.
1. 275
2. 40
3 . 40
/
ro
..._.
1. 455
9. 70
3. 70
Exc.
845
190
130
60
1973
-i — •"
Ext .
1690
340
255
85
1973
Ext.
2735
515
410
105
Total
1005
215
1.35
bJ
^otal.
1965
380
295
85
Total
3200
585
480
105
'iAbie 143
AF.n.ATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Groundwood Chem/Mech. Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 100 TPD
1977
1.
2.
3.
4.
Int.
435
65
65
3040
645
460
185
Total
3475
710
525
185
1.
2.
Int.
930
140
140
4."
1983
•J!xt._
3460
785
520
265
Total,
4390
925
660
265
Mill Size: 300 TPD
1977
1983
Int.
1. 745
2. 110
3. 110
4. -
Ext.
5655
1230
855
375
_Total
6410
13M)
965
375
Int.
1-1725
2. 260
3. 260
4. -
Ext.
6570
1510
990
520
Total
8295
1770
1250
520
Mill Size: 600 TPD
1.
2.
3.
455
70
70
197 J
Ext.
2735
515
410
105
Total
3200
585
480
105
3.
4.
Int.
1245
185
185
1977
Ext.
8755
1940
1315
625
Tocal
10000
2125
1500
625
Int.
1.2735
2. 410
3. 410
4. -
lycj
Ext.
10260
2395
1540
855
rprt f- ^1
12995
2805
1950
855
Int.
1.2735
2. 410
3. 410
4.
Ext.
10305
2300
1545
755
Tota.
13040
2710
1955
755
.
.
.
4.
1.
2.
3.
4.
1
2
3
4
Int.,
930
140
140
Int.
1725
260
260
™~
Int.
.2735
410
410
[
NSPS
Ext._
3625
780
545
235
NSPS
Ext.
6930
1510
1045
465
NSPS
Ext.
10305
2300
1545
755
Total
4555
920
685
235
Total
8655
1770
1305
S65
Total
13040
2710
1955
755
int. : Intel.ial Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table i44
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Groundwood Chem/Hech. Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 100 TPD
i 160
2. 25
3. 25
4. -
Int.
•» n "7 ^
2. 40
3 . 40
4. -
CO
.
1. 465
2. 70
3. 70
4. -
1973
_ Ext .
84.3
190
130
60
1973
1,590
335
255
80
1973
Ex ti «
~
2,755
510
410
100
Total
1,005
215
155
60
T1- *- « 1
1,965
375
295
80
• " _
•
3,200
580
480
100
Int.
1 . 435
2. 65
3. 65
4.
Int._
1. 745
2. 110
3. 110
4.
f t-
!. 1,245
2. 185
3. 185
4. -
3977
'"
Ext.
3,430
810
520
290
Mill
1977
-!££L
6,585
1,535
990
545
Mill
1977
l-Xt .
10,315
2,415
1,550
865
— — -
Total
35365
875
585
290
Size: 300
JTo^al
7,330
1,645
1,100
545
Size: 600
Total
II c: ,c •-)
J--A. . _/ W ^
2,600
1,735
865
T
J_ .
2.
3-
4.
TPD
Int .
930
140
140
ilLE_L
1. 1,725
2. 260
3. 260
4.
TPD
1. 2
2.
3.
4.
Int.
,735
410
410
1983
EKt.
3,850
950
585
365
1983
— •- — - — «_
7,490
1,815
1,125
685
1983
Ext.
11,820
2,870
1,775
1,095
Total
4,780
1,090
725
365
Total
9,215
2,075
1,385
685
Total
14,555
3,280
2,185
1,095
Int.
1. 930
2. 140
3. 140
4.
Int.
1. 1,725
2. 260
3. 260
4. -
Ire
1. 2,735
2. 410
3. 410
4. -
KSPS
F-.-i-
3,165
775
475
300
KSPS
Ext.
6,080
1,485
915
570
V -. r- *-
9,255
2r280
1,390
890
m ~
4,095
915
615
300
Total
7,805
1,745
1,175
570
j-Qtal
11,990
2..690
1,800
890
1-it. : Inter-al Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
2.
3.
25
25
275
40
40
1. 465
2. 70
3- 70
4. -
_197_1L_
Ext.
1973
Total
160
25
25
275
40
40
Table 145
AERMiED STABILIZATION BASIN
FFf'LU'-NT TREATMENT COSTS
Groundwood Thermo/Mech. Subcategory
in Thousands of Dollars)
LI Size: 1"0 TPD
(All Cost
465
70
70
Int.: Internal Cost
2. Total Operating Cost
i
i
^_ •
3.
4.
1.
2.
3.
4.
1
^
t.
•\
4
i
Int.
430
65
65
Int.
745
110
110
Int.
. 1245
. 185
. ' 185
•
977
E-t.
O o AA
£- ~j '-^vj
500
345
155
Mill
1977
Ext.
4270
925
640
285
Mill
1977
Ext_._
6275
1395
945
450
Total
2730
565
410
155
Sizai
Total
5015
1035
750
285
Size:
Int.,
1. 925
2. 1^0
3. 140
4. -
300 TPD
•Int.
1.1725
2. 26u
3. 26°
4. -
500 Ir-D
Total inc-
7520
1580
1130
450
1.2735
2. 410
3. 410
4. -
1983
Ext_._
2585
505
390
215
1983
Ext .
4875
1120
730
390
1933
Ext.
7255
1700
3095
605
To t a !_
3510
745
530
215
Tr^r fll
6600
1380
990
390
lO L.B.-L
9990
2110
1505
605
1.
2.
3.
4.
1.
9
o
.2 •
.
i
2
3
4
Int._
925
140
140
Int.
1725
260
260
Int .
. 2735
410
. 410
NSPS
Ext.
—
2300
500
345
155
NSPS
Ext.
4270
925
640
285
NSPS
Ext .
6275
1395
945
450
Total
3225
640
485
155
Total
5995
1185
900
285
Total
9010
1805
1355
450
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
1.
*• .
3.
4.
1.
2.
3 .
4.
-pi
en
Int.
160
25
25
Int.
275
40
40
—
Int^
1- 465
2- 70
3- 70
4. _
Int.
•' Inter
1973
_Ext._ To tail
160
25
25
1973
Ext^_ Total
275
40
40
1973
Ext_._ Total
465
70
70
•nal Cost
2. Total Operating Cost
TAble 146
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Groundwocd Thermo/Mech Subcategory
(All Costs in Thousands of Dollars)
Mill Size
100 TPD
1
2
3
4
1.
2.
3.
4.
1.
2.
3.
4.
Tnf
• 430
• 65
• 65
— i
745
110
110
Int^
1245
185
185
1977
hxt .
2730
655
410
245
Hill
1977
— •• ,.— — .
5050
1165
760
405
Mill
1977
Ext^
7700
1770
1155
615
Total
3160
720
475
245
Size: 30o
5795
1275
870
405
Size: 600
Tojtal
8945
1955
1340
615
1- 925
2- 140
3- 140
4. _
TPD
1- 1725
2- 260
3- 260
4. —
TPD
I- 2735
2. 410
3. 410
4. __
1983
Ext.
3015
760
455
305
1983
Ext^
5655
1360
850
510
1983
• — — — —
8680
2075
1305
770
Total
3940
900
595
305
Total
73SO
1620
1110
510
" -!.•.— ___
Total_
11,415
2,485
1,715
770
Int.
1. 925
2-140
3.14C
4. _
Irvt,._
1.1725
2- 260
3- 260
4. _
Int._
1-2735
2. 41Q
3. 410
4. —
NS^S
2730
655
410
245
NSPS
5050
1165
760
405
NSPS
7700
1770
1155
615
Total
3655
795
550
245
Total
6775
1425
1020
405
Total
10,435
2,180
1,565
615
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 147
AfRATrD STABILIZATION BASIN
. I L,, K , „, ,-,
EI-ILUEKT
Ground woo:
(•'.11 Costs in
Mill S
1077
'-- --;- ---,-T-f i?r. Sxt;,
li 03 "-• 4iC 26^5
'^i — ,/, ~Y,Q 2. 60 575
:, T/'0 u-0 3. 60 400
r ~co &-j 4- - l75
Hill
1977
— ' — i"7~- " ' r " "i in;:. :..-.-•.—•.
.-:.::- —
, -,-- i;--o 1-4J" 37A)
- :;= ^r,0 ^303 2. 70 805
' ;c 905 230 3. 70 550
• _ "-5 75 4. - 245
^ Kill
1C_ 1577
-_-.-. ::>•-•:. ii_-.^i _J-^:—
., -,-^ 99'-;o 33/0 1-1025 742o
V%5 555 610 2. 155 .610
f 1, -.so 505 3. 155 1115
•?' r 105 105 - - 493
TR'ZAll-^T COSTS
i C-M-1^ Subcategory
Thojsar-ds of Dollars:
,i2e: 75 TPD
— ' '
Total Int.
3055 !• 830
635 :' 125
460 ?' 125
175 H" -
Size: 150 TPI)
— •
Tv,t- •- 1 int .
4220 i' 1125
8/5 2- 170
630 3' 170
245 4. _
Size: 500 TPD
_- -••—
Trifl >nt.
r,,,, i 2350
o-tjO
1765 2' 350
1270 3- 350
495 4- -
)
3000
695
455
4325
995
650
345
_1983
Ext .
K755
2015
1-315
700
Total
3830
820
580
240
To*~al
5450
1165
820
345
local
11,115
2,365
1,665
700
_ — "—
Int.
1- 830
1' 125
;• 125
4 .
~Int.
1. 1125
2" 170
3' 170
4.
_ . - " * •
Int.
1.2360
2- 350
*: 3!°
NSPS
Ext .
3130
700
470
230
NSPS
Ext.
4400
950
660
290
KS ir* S
8565
1960
1285
675
Total
3960
825
595
230
Total
5525
1120
830
290
Toca.
-
10,925
2,310
1,635
675
:ernal Cost
Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 148
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Groundvood C-M-N Subcategory
(All Costs in Thousands of Dollars)
Kill Size: 75 TPD
-,
i 150
i. C
:; 20
4. ~
- 175
'"/ ±.J
3\ 2j
4 . ~
±
T -s *-
o' ~55
3. 55
4 -
-L J t J
O ,- ! A ,-, r -^
^_ ^' \J ^/
1^0 160
60 60
H73
i-.-t. local
l-~5 1530
205 230
75 75
1973
^^—^ i^'t. —
2£90 3370
- -' -J Oil)
450 505
105 105
1977
J-HC . tXt .
1. 4 j 2990
2. 60 690
3. 60 450
4. - 240
Hill
1977
—— — ^ — !^I_
1. 4?3 4370
2. 70 9'JO
3. 70 655
4. - 335
Mill
1977
Int. Ext.
1-1025 8395
f~.
Z' 155 1955
3- 155 1335
4' - 620
Total
3400
750
510
240
Size: 150
.Total
A850
1060
725
335
Size: 500
Total
9920
2110
1490
620
Int.
1. 830
2. 125
3. 125
4. _
TPD
Int .
1-3125
2- 170
3- 170
4. _
TPD
Int._
^-•2360
3* 35°
. 350
4 .
1983
Ext.
3345
815
505
310
1983
Ext.
4960
1180
745
435
3983
Ext^
10,225
2,365
.1,535
830
Total
4175
940
630
310
Total
6085
1350
915
435
Total
12,585
2,715
1,885
830
Int.
1. 830
2'125
3 -125
4.
Int.
i;1m
I: _170
Int^
1.2360
3' 35°
4] 35°
NSPS
Ext .
2505
605
375
230
NSPS
Ext .
3735
885
565
320
NSPS
JExt.
7445
1760
1115',
645
Total
3335
730
500
230
Total
4860
1055
735
320
Total
9805
2110
1465
645
-.--t.: ^r.tarr.c.i Cost
2. Total Operating Cost
Ext.: Excarnal Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
1973
Int.
, 403
^' 60
-; 60
II'.^
i . 535
o. 90
3\ 90
4. -
CO
Int.
! 930
;' 140
r 140
3 .
4. ~
Ext.
1230
255
185
70
1973
Ext.
19-3
380
/95
85
1973
"rXC.
29-55
545
440
105
Total
1630
315
245
70
Total
2530
470
385
85
Total
3365
685
580
105
Table 149
AERATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Groundwood Fine Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 150 TPD
1 Q77
Int. Ext.
l 6iO
2 90
3'. 90
4. ~
Int.
1. 880
2.130
3.130
4. -
Inc.
T 13C5
9] 210
4. ~
3435
745
525
220
Mill
1977
Ext.
5110
1105
770
335
Mill
1977
Ext.
7375
1585
1105
480
Tgtal_
4095
835
615
220
Size: 300
Total
5990
1235
900
335
Size: 550
Total
8760
1755
1315
480
Int.
! 1244
2* 19°
3; 190
4.
TPD
1. 1860
2. 280
3. 280
4.
TPD
1.
2.
3.
4.
Int.
2790
420
1983
4060
930
610
320
1983
Ext .
6020
1395
910
485
1983
Ext.
&755
2005
1315
690
Total
5315
1120
800
320
7880
1675
1190
485
Total
11,545
2,425
1,735
690
Int.
1. 1255
2. 190
3. 190
4. '
Tnt
1. 1860
2. 280
3. 280
4. -
Tn f
1. 2790
2. 420
3. 420
4. ~
NSPS
_Ext_._
4290
940
645
295
NSPS
Ext .
6295
1370
945
425
NSPS
8925
1985
1340
645
j •"» *• a 1
5545
1130
835
295
Total
8155
1650
1225
425
Total
11,715
2,405
1,760
645
Int.: Internal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation S. Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table J50
WASTE ACTIVATED SLULGE
EFFLUENT TREATMENT COSTS
Groundwood Fine Subcategory
(All Costs in Thousand of Dollars)
Kill Size: 150 TPD
1.
2.
3.
4.
1.
2.
3 .
4..
£
1.
2.
3.
4.
Int.
400
60
60
-DJEj.
585
90
90
••
Int^
930
140
140
1973
Ext.
1230
255
285
70
1973
"" —
jfft'.
1,945
380
295
85
1973
Ext.
2,935
545
440
105
Tr»1~ -a 1
345
70
i ... _
Total
2,530
470
385
85
Total
3,865
685
580
105
Int.,
1977
Ext_._
1. 610 4005
2. 90 1000
3. 90 705
4. - 295
Int.
1. 880
2. 130
3. 130
4.
Int.
1. 1,385
2. 210
3. 210
4.
Mill
1977
Ext.
6,010
1,325
905
420
Mill
1977
__
Ext .
8,705
1,900
1,305
595
Total
4615
1090
795
295
Size: 300
,. _
— — *_
6,890
1,455
1,035
420
Size: 550
— ii
Total
10,090
2,110
1,515
595
Int.
1. 1,244
2. 190
3. 190
4. -
T?D
~— i i ...
Tn t~
1. 1,860
2, 280
3, 260
4.
TPD
- -
T-nt-
1- 2,790
2. 420
3. 420
4.
1983
Ext._
4580
1185
790
395
iy83
Ext .
6,920
1,605
1,040
565
1983
— . . „. _
Ext_._
10,085
2,320
1,515
805
Total
5824
1375
980
395
•"'• ' - —
Total
8,780
1,885
1,320
565
•—
T taJL
12,875
2,740
1,935
805
I rit . Ey.r.
1. 1,255 2S65
2. i:0 835
3. 190 530
4. ~ 305
NSPS
T**it" "i~1-"*-
1. 1,860 5,3-0
2. 280 1,275
3. 280 800
4. - 475
NSPS
7 • 2,790 7,635
2- 420 1,825
3- 420 1,155
4- - 670
To t a 1
^190
1025
/20
3C5
- O L- H 2.
1,555
1,OSO
475
.Total
10,475
2,245
1,575
670
Int.: Internal Cost
2. Total Operating Cost
Ext.: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Mair.ter.ance
-------
TAble 151
AERATED STABILIZATION BASIN
EFfLUENT TREATllZNT COSTS
Soda Subcategory
(All Costs in Thousands c-f Dollars)
Mil Sine: 300 Tl'D
Int.
1 825
? 125
k- . -*-'--'
o 125
.}. ••-*•-'
4. ~
1973
Ext.
3,150
585
470
115
Total
3,975
710
595
115
Int.
1. 1,195
2. 180
3. 180
4.
1977
Ext.
7,525
1,685
1,125
560
Total
8,720
1,865
1,305
560
Mill Size:
ro
0
Int.
1 1,705
,* 255
, 255
3.
4.
1973
Ext.
5,615
1,020
845
175
Total
7,320
1,275
1,100
175
Int.
1 2,355
2. 355
3 355
4.
197"'
Ext.
12,640
2,935
1,900
1,035
Total
14,995
3,290
2,255
1,035
1.
2.
3.
4.
700
1.
2.
3.
4.
nt.
3,070
460
460
TPD
nt .
5,500
825
825
-
9,200
2,170
1,3SO
790
1983
15,295
3,745
2,300
1,445
T^ *- *1 1
^ i »_--i.
12,270
2,630
1,840
790
TV-*"- 1
20,795
4,570
3,121)
1,445
1- 3,070
2. i-6P
3. 460
4.
Tr t~
1. 5,500
2. 825
3. 8L5
4.
7,555
1,715
1,135
580
rs?s
12,395
2,910
1,860
1,C50
-c<. ,',-•
10,o25
2,175
1,595
580
T,-, -T
17,895
3,735
2,5£5
1,050
Int: Internal Cost
2. Total Operating Cost
Ext: Zxtemal Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table "I [32
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Soda Subcategory
(All Costs, in Thousands of Dollars)
Mill Size: 300 TPD
1. 825
•7 125
3.' 125
4 . ~
"int
1. 1,705
2 , 21,5
5. 155
i V . J
3,150
585
470
115
JFt7~~
5,G15
1,010
S45
175
r- , -
3,975
7.10
5S5
115
Tct.il
7 320
1,275
1,100
175
1°77
lr i~ -"-. t-
1. M95 8,985 10,180
2. 180 2,060 2,240
3. 180 1,345 1,525
4. - 715 715
Mill Size:
1977
j-^*-. i^xt.
1. 2,355 15,170
2- 355 3,545
3- 355 2,280
4- ~ 1,265
iULaj.
17,525
3,900
2,635
1.-65
1.
2.
3.
4.
700
1.
2.
3.
4.
Int.
3,070
460
460
TPD
Int.
5,500
825
825
1983
Ext. Total
10,660 13,730
2,545 3,005
1,600 2,060
945 945
1S83
j-xt. Total
17,825 23,325
4,355 5,180
2,680 3,505
1,675 1,675
1.
2.
3.
4.
1.
2.
3.
4.
Int.
3,070
460
460
Int.
5,500
825
825
NSPS
Ext.
6,690
1,645
1,005
640
NSPS
Ejct,.
10,695
2,610
1,605
1,005
Total
9,760
2,105
1,465
640
Total
16,195
3,435
2,430
1,005
E:;c: External Cosi
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
ro
ro
Table 153
AH'ATFD STP.L-ILILKT'.OM BASIN
I-!• FLUENT TREAifl£Nr COSTS
Foil-Integrated Fine Subcategory
(All Costi in Thousands or Doxlars;
Kill Sisa: -0 T?0
lr>7'
i r 7 7
~7TT int Ji- c- Total
i^ , 300 675 975
25 ^' 45 l&O 225
7s V 45 105 150
t ~ 75 75
Kill Sise: 100
',;•' L. Lr.-L. i.. ... _r^..xi^.
230 1. 415 1,1 SO 1,605
--s 2. 60 290 2bO
:; 3. 60 1&0 2^0
I 4. - HO HO
Mill Size: 2.iO
"'• - * I" ' '•' • -11'' -_-A
=;••, , 9J5 2,C50 2,995
"".', ~7' -i/0 470 610
SO -;' 140 310 ^50
_ ,.' - 160 160
Int.
1. 400
?' 60
3! 60
4. -
TPD
Tnt.
1. 575
2. 85
3- 85
4. -
TBiJ
Iut._
J*. 'l85
3'. 185
4.
1983
Er.t .
1,010
290
155
135
198"
l'.\t.
1,825
460
275
185
198:;
L::^.
3,275
795
495
300
Total Int^
1,410 i.
350 2.
215 3.
135 4.
Total Int.
2,400 1. 575
545 2. 70
360 3. 70
185 4. -
Total Int.
4,520 L 1,245
980 2 185
680 3*. 185
300 4]
NSPS
Ext.
NSPS
Ext.
2,210
515
335
180
NSPS
3,740
835
560
lotai
Total
2,785
585
405
180
To^al
4,985
1,020
745
275
}-vt.i i-'xternal Cost
3. Eonrcciauion ^ Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
•£>
ro
OJ
2'°
35
—-•' c *
80
Internal Ccst
Operating Ccsc
Table 154
[.ViSTS; ACTIVATED SLUDGE
i:;'FLU;:hr T^AT^INT COSTS
^Non-Integrated Fine Subcategory
''All Coses in Thousands of Dollars)
Mill Si?,-:: 30 TPD
1 T ' .
300
45
^.5
2.-
.3-5
60
GO
19
-~-: — L.
J;Q
-- - ___
675 975 l. 400
ISO 225 2. 60
llJ5 150 3. 60
75 75 4. -
Hill Sij.c: ICO TPD
« 7 7
U-C'O 1,605 1. 575
2«;0 350 2. 85
IMG 240 3. 85
110 110 4.
Mill Size: 280 TPD
— . -,
__xxi.
2,060 2,995 im 1,245
470 610 o 185
320 450 3.' 185
160 160 4.
1953
Ext.
1,150
325
180
145
1983
Ext^
2,200
555
335
220
1983
£_.<(;.
4,215
950
635
345
Total
1,550
385
240
145
Total
2,775
640
420
220
Tojtal
5,460
1,165
820
345
Int.
1.
2.
3.
4.
Int^
1. 575
2. 70
3- 70
4. _
Int.
1. 1,245
2. 185
3. 185
4.
NSPS
Ext.
NSPS
Ext .
1,910
430
290
190
NSPS
Ext.
3,310
795
500
295
Total
Total
2,485
550
360
190
Total
4,555
980
685
295
Ext.: "xtarnel Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
1.
2.
3.
4.
1973
Int
190
30
30
Ext.
Totc.1
190
30
30
Table 155
AERATED STABILIZATION BASIN
EFFLUENT TREATMENT COSTS
Non-Integrated Tissue Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 15 TPD
1977
1.
2.
3.
4.
Ijit_.
410
60
60
-
Ext.
560
150
85
65
Total
970
210
145
65
1983
Int.
1. 490
2. 75
3. 75
4. -
Ext. Total
NSPS
Int.
Ext.
Total
1.
2.
3.
4.
ro
Kill Size: 35
i
Jt. •
2.
3.
A.
Ir-c.
290
45
45
_
1973
Ext.
_
-
-
-
Total
290
45
45
—
lat: Internal Cost
2. Total Oparatins Cost
1.
2.
3.
4.
Int.
620
95
95
197?
Ext.
835
210
125
85
Total
1,455
305
220
85
1.
2.
3.
4.
Int .
720
110
110
1983
Ext.
1,155
315
175
140
,
Total
1,875
425
285
140
Ext: External Cost
3. Depreciation & Interest
NSPS
Int. Ext. Total
1.
2.
3.
4.
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 155
AERATED STABILIZATION BASIN
,. EFFLUENT TRTATKENT COSTS
Non-lntegroted Tissue Subcategory (Concinued)
(Ail Co,t.5 Jn Thousands of Dollars)
Mill Size: HO TPi)
- ±-LL± ___ l Q 7 7
I- E . E^t •£->--•' ~ — ~ — ----— .
1 335 TO,;
•> so \l !• 720 1,495
;?: f° -
-------
ro
i able 156
WASTE ACTIVATED SLUDGE
EITL'JENT TIIKATMENT COSTS
Non-Integrated Tissue Subcategory
(All Coses in Thousands ot uoiiars)
Mill Size: 15 TPD
1973
Int. E:-:t.
," 30
I: 30
4. ~
Int[ 1*1-
. 290
— * / - _
9 "*
3* 45
190
30
30
_.
Total
290
45
45
Int. .
1. '-10
2. 60
3. 60
4. -
Int.
l' 695
2 .
3. 95
4. ~
1977
Ext.. Total
560 970
150 210
85 145
65 65
Mill Size:
•* A TJ
L* 1 1
Ext.
835
210
125
85
1,455
305
220
P5
Int.
1. 490
2. 75
3. 75
4. -
35 TPD
In_t.
1. 720
2. 110
3. 110
4. -
1983
Ext_.
910
260
135
125
1S83
Ext.
1,440
390
220
170
KSPS
"YTal IF*"- Exc. Total
1,400 I-
335 2>
210 3-
125 A-
NSPS
Total Int. E^iL- iut -
2,160 1.
500 2.
330 3.
170 4.
4.
Int: Internal Cost
2. Total Operating Coct
Ext: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
156 cont'd
WASTE ACTIVATED SLUDGE
EFFJIENT TREATMENT COSTS
kon-Intergrat:ed Tissue Subcatetory Con't
(All Costi in Thousands of Dollars)
MJ11 Size:
TPD
l-
T-t,c
50
Ext. Total
335
50
50
1.
2.
3.
4.
'
720
110
110
±".i / 1
£..•__.
1,495
350
225
125
Tot al
2,215
335
125
1.
2.
O
-> .
4.
int.
890
135
135
1983
Ext.
2,870
695
430
265
Total
3,760
830
565
265
2.
3.
4.
Int.
890
135
135
MCpC
Ext.
2,265
535
340
195
Total
3,155
670
475
195
rv>
Kill Size: 450 TPD
3.
1 0 n
13°
;- . '_£.-» ..",
130
.30
Tr — 230
3.' 280
4.
Ex t .
3,350
755
505
250
— — — ~
fotal
5,210
1,035
785
250
2
3.
4.
2:275
340
340
IS 83
Fxt.
6,910
1,575
1,040
535
Total
9,185
1,915
1,380
535
1.
2.
3.
4.
Int.
2,275
340
340
MCpq
Ext.
5,220
1,190
785
405
Total
7,495
1,530
1,125
405
~-t;: Intern:;i C:>sc
2. Tctai Operating Coct
l Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
CO
1973
190
?'-'
30
A3
45
Table 157
AERATED STABILIZATION BASIN
KFFJAJIINT TRF,-\TMENT COSTS
Non-Integrated Tissue (fwp) Subcategory
(All Costs in Thousands of Dollars)
Mill Size: 15 TPD
^
o
4.
ff
*j
L.
Lire .
410
60
60
— ~
f '-v ,~S
CZ.U
95
95
_
1977
Ex t .
810
2C5
125
80
•^
1977
T ,225
2'JO
i ^5
105
Total
1,220
265
185
80
fill Size:
•fr £ p "!
1,045
3-S5
280
1A5
1.
?,.
3.
4.
35
i.
2.
3.
4.
Int.
430
75
75
TPD
Int. .
720
110
110
-
19£.3
Ext.
920
255
l-iO
115
19 a 3
E::t .
1,425
370
215
155
Total
1,410
330
215
115
Total
2,145
480
325
155
NSPS
In_t. Ext.
1.
2.
3.
4.
NSPS
Int. Ext.
1.
2.
3.
4.
Total
Total
Total Investment Cost
Operation & Maintenance
-------
Table 157 cont'd
AERATun STASILIZATIOM BASIN
' " rR>-ATXLr
i i - r -, - *-
3:0
50
50
— ,.-
330
50
50
1
2.
'!
4.
j.nt .
720
110
110
1977
Er.t ,
2,230
515
345
170
Total
3,000
625
455
170
1.
2.
3.
4.
Int.
890
135
135
1983
Ext.
2,710
660
410
250
Tota^
3,600
795
545
250
1.
2.
3.
4.
Int.
890
135
135
NSPS
Ext.
2,870
635
430
205
Total
3,760
770
565
205
10
ot
Mill Size.: 450 TPD
^ ,«. ^
R c c
o_O
130
1JO
v,.;. ' r~— r
130
130
1.
2.
3.
4.
•Lr.L .
1,860
280
280
.'--• ,' !
Ent.
5,370
1,180
805
375
— . ____.
Total
7,230
1.46C
1,085
T75
1.2
3,
4.
Int.
,275
340
340
1983
Hxt.
S.510
1,525
975
550
Total
8,785
1,865
1,315
550
1.
2.
3.
4.
Int.
2,275
340
340
NSPS
Ext.
"
6,585
1,475
990
485
Total
n ••-
8,860
1,815
1,330
485
mai Ccsc
arati.-;:. Cost
Ext: External Cost
3. Dapraciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
CO
o
Table 158
WASTE ACTIVATED SLUDGE
EFFLUENT TREATMENT COSTS
Non-Integrated Tissue (fwp) Subcate^ry
(All Costs in Thousands of Collars;
Mill Size: 15 TPD
Int.
1 19G
2; 30
3. 30
4. ~
3 290
o 45
Z.
3 .
1973
"Ext. Total,
190
30
30
1973
I::t. 1V--cl_
290
45
45
Int..
1. /-10
2. 60
3. 60
4. -
.±i~*
•( 620
2! 95
3. 95
4. "
•t Cl"7 "7
iy / /
— .—, •— — ™
E>'t.
1,070
280
160
120
Mi
1977
1,615
395
245
150
i —
Total
1,430
340
220
120
11 Size:
Total
—
2,235
490
340
1C0
Int.
1. 490
2. 75
3. 75
4. -
35 TPD
Int.
1. 720
2. 110
3. 110
4. -
1983
Ext.
1,180
330
175
155
1983
Ext.
1,315
475
275
200
Total
1,670
405
250
155
Total
2,535
585
385
200
_NSPS
Ext. Total
NSPS
Total
lat: Incetr.al Cost
2, Total Cperctins Cost
Ext: Ex~era".l Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
CO
3.
4.
3.
4.
Int
50
1 855
A *
2. 13°
130
.HI!
Ext;
1973
330
50
50
855
130
130
Int: Internal Cost
2. Total Operating Cost
Table 153 cont'd
WASTE ACTIVATED SLUDGE
EFFLUENT Tr-ATI-ENT COSTS
Mil Size: 110
X.
2.
3.
4.
Int.
720
110
110
1977
E::-;.
3,150
710
475
235
Mill
— 2±_£Ji
3,870
"20
585
235
Size:
1977
J 7\ ti . •-? rr r rp ^ j 1
1.
2.
3.
4.
1,860
280
280
7>230 9,090
1.560 1,840
i.685 l,36i
475 475
Int.
1. 890
2. 135
3. 135
4. -
450 TPD
Inu .
1. 2,275
340
3. 340
4.
.1 3 O ~>
"• . —
— -
3,580
855
540
315
1933
E_xt_.
8,370
1,905
1,255
650
Tptr.1
4,470
990
675
315
Total
10,645
2,245
1,595
650
Int.
!• 890
2- 135
3- 135
4.
Int_.
1. 2,275
2. 340
3. 340
A
NSPS
Ext .
2,540
645
410
235
Y^pq
Ext.
5,935
1,415
890
525
Total
3,430
780
545
235
Total
8,210
1,755
1,230
525
Ext: External Cost
3. Depreciation & Interest
1. Total Investment Cost
4. Operation & Maintenance
-------
Table 159
INTERNAL EFFLUENT TREATMENT COSTS FOR NSPS
(Costs in Thousands of Dollars)
Subcategory
Sulfite
Dissolving Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Goundvoocl Chcmi/Mech
Goundwood Therno/Mach
Goundvood C-M-N
Goundvcod l-'ine
Soda
\on-Intcgrated Fine
No n-Tn^ grated Tissue
Non-Integrated Tissue
(i'wp)
Size of Mill
Tons/day
160
530
550
80
230
500
600
1000
350
700
250
670
1300
250
670
1300
100
300
600
100
300
500
75
150
500
150
300
550
300
700
30
ion
280
15
35
110
45C
15
35
110
450
Capital
Cost
1165
2565
1385
555
825
1450
1935
2640
1330
1990
17 \5
3250
5075
1730
3110
4790
595
1135
1815
590
1130
1810
525
720
1555
820
1235
1865
1780
3140
295
435
940
370
540
675
1735
365
540
675
1735
Depreciation
and Interest
175
385
210
85
125
220
290
395
200
300
260
485
760
260
465
720
90
170
270
90
170
270
80
110
235
125
185
280
265
470
45
65
140
55
80
100
250
55
80
100
2fO
432
-------
It is assumed that the existing conveyor receiving wood from the
flume will receive the wood from the new log conveyors. Some
modification to the existing transfer section is included.
Debris (rocks, etc.) which were removed in the flume by a rock
pit and grit chamber systems will be carried into the barking
drums. Some removal takes place through the bark slots in the
barking drums. A rock drop out station is included in the
woodroom conveyor system, before the chippers, to remove large
rocks.
The bark burned for fuel will have a higher concentration of non-
combustible material using mechanical yard conveyors.
2i. ys§_2f_Steam_in_Drum_Barkers
This cost estimate is based on processing 1200 cords per day of
rough H to 8 foot pulpwood, softwood and hardwood, in three
barking drums.
In converting from use of hot water to steam in the barking
drums, the bark conveyors under the drums were replaced. The
bark press is modified to handle bark during the sap period.
It is assumed that the wood handling system preceeding and
following the barking drums is the same whether steam or water is
used in debarking.
A steam header, from an existing steam main in the woodroom, is
run in front of the inlet to each drum. Small branch lines
inject steam into the drums. The drumming rate using steam will
be slightly lower than with the use of hot water. Cutting bark
slots in a solid inlet section is included.
3^ 2Q2ts_Collectign_and_Diseosal
Most mills have a knot handling system and return the knots to
the digester. The mills that cannot recycle the knots dispose of
them through incineration with bark or haul to landfill. This
estimate was based on conveying the knotter rejects to a
vibrating screen with showers to recover loose fibers and liquor
then to a container for disposal by landfill. '
i-. Iourth_Stage_Brown_Stock_Washer
Essentially all kraft mills with recovery have an equivalence of
three stages of brown stock drum washing. The amount of liquoT-
held in the pulp after brown stock washing increases as
bottlenecks are eliminated and production is pushed beyond design
capacity. The liquor carried over is subsequently washed out of
the pulp and sewered with the brown stock screen rejects and
decker filtrate. The addition of a fourth stage of washing may
be necessary to reduce the liquor lost to the sewer to an
acceptable level. A vacuum filter washer was used in the
estimate, and the system includes a submerged repulper, filtrate
433
a
-------
Figure 65A
FLUME REPLACED BY MECHANICAL CONVEYOR
WOODROOM
CONVEYOR
UNLOADING DECK
GO
-------
Figure 65A (Cont'd)
USE OF STEAM IN DRUM BARKERS
BARK COLLECTING
CONVEYOR
-Pa
OO
cn
BARK CONVEYOR
UNDER DRUM
INLET END
EXISTING
NEW
-------
Figure 65A (Cont'd)
KNOTS COLLECTING AND DISPOSAL
FROM BLOW TANK
KNOTTER
H
i
j
STOCK TO BROWN STOCK WASHERS
WWBL FROM 3rd STAGE BROWN STOCK WASHER FILTRATE TANK
—J
TO INTERSTAGE REPULPER BETWEEN 2nd AND 3rd STAGE BROWN ,
STOCK WASHERS
a
CONVEYOR
LEGEND
NEW
EXISTING
TO DISPOSAL
436
-------
^
Pecker_Piltrate.for_Brown_Stock.Washer_Showers _
'"
Jib£e «< caustn the decker
existing decker filrattank and LIST' * PU|?P is added to the
the brown stock washers A Lw L=f ? pump decker filtrate to
estimate. "asners. A new heat exchanger is included in the
£i. — £iose-u2_Screen_Rgom_
pressure screens. The
screen rejects and rtn thm
included. The new screens are Io?at
the existing building. A new
included also.
* replaced with
th reflne/he secondary
a „ SecondarY sc^en is
« ^zzanine inside
screens supply pump is
1^— Pulp_Mill_sEill_collection_frgm_Washers
r0
washers and pipe the vriows ?o a
pump is installed at the collection
a controlled rate back into thJ system
diagram; one tank is used for
brown stock decker and washers.
as the spills from the bleach washes
brown stock for fear of gettina
recovery system. The system is desd
sequence. Vat overflows a?e *~^ *
production flows. The collect iSn de^lgned
retention of production at'rf consis^ncy"
bleach plant
COliection P°int. A
^^ the Spills at
h°Wn °n the flow
?***** ^ °ne for
ar6 re{Jui^ed
• f PUt back into the
J the black li*uor
X a CEDED bleach
to handle 10058 of
10
sell SSI.
^
*****
the system at a conroed at
are returned to the suc?ion of t
tion pump as shown on ?he flow
the floor drains are screened and
which has fresh water made UD ?or
go to a trash tank for SullnS -
spill occur, it is pumped^to^
???
Sp±lls back into
the
area
collecte(3 from
dlrty Water tank
Cntro1- The solids
437
-------
Figure 65A (Cont'd)
DECKER FILTRATE FOR BROWN
STOCK WASHERS SHOWERS
EXISTING F.W. SHOWER WATER
DECKER
BROWN STOCK
\ WASHER
v HEAT
& EXCHANGER
HOT WATER
ACCUMULATOR
TANK
DECKER
FILTRATE
STORAGE
TANK
433
LEGEND
NEW
EXI
-------
Figure 65A (Cont'd)
SCREEN ROOM CLOSE-UP
SECONDARY] TERTIARY
EXISTING
PRIMARY i 4
---CTS , I
TANK
-------
Figure 65A (Cort'd)
BLEACHED KRAFT MlLL
SPILL COLLECTION AND REUSE
BLEACH
WASHERS
VAT
--8
BLEACH
STOCK
COLLECTION
TANK
VAT
DRAIN
VERFLOW
BROWN STOCK
WASHERS
BROWN
STOCK
COLLECTION
TANK
440
-------
Figure 65A (Ccnt'd)
SULFI TE PULP
COLLECTION
Ml LL SPILL
AND REUSE
BLEACH
WASHERS
HYPO
VAT
DRAIN
VAT
DRAIN
OVERFLOW
CAUSTIC
CHLORINE
BROWN
STOCK
WASHERS
OVERFLOW
BLEACH
STOCK
COLLECTION
CHEST
DECKER
BROWN
STOCK
COLLECTION
CHEST
441
-------
Figure 65A (Cent'd)
GROUNDWOOD PULP MILL SPILL
COLLECTION AND REUSE
FROM SCREENS
DECKERS
442
LEGEND
NEW
EXISTING
-------
Figure 65A (Cont'd)
PULP MILL SPILL COLLECTION SYSTEMS
SEAL TANK PUMP
TANK PUMP
FROM WASHER
SEAL TANKS
FROM TANK AND
_r A
-&
-------
g ___ jumE_S±age_Countercurrent_Washing —
CEDED The filtrate from the second chlorine dioxide washer is
cSstfc and cnlorination seal boxes overflowing to the
4. • ^f i o -t-n i i
-------
JUMP STAGE COUNTERCURRENT
WASHING IN BLEACH PLANT
-P.
-e»
en
<• WHITE WATER
S-
FRESH WATER
OECKER
CHLORINE
STEAM
9 f... "*°" 9
O Y ^
o
1
^—
El
_
E
\
L
tt
i
CIO
Dl
2
J
\
y
i
E2
_
E.
I
>
I
IT
|
°2
v
cio.
-------
MILL PROCESS WATER MAIN
Co
cz
a
m
01
m
-33
I
• TO ATMOSPHERE ON START-UP
-------
Figure 65A (Cont'd)
STEAM STRIPPING AND REUSE
OF BLOW STEAM AND
EVAPORATORS CONDENSATE
( DIGESTER BLOW
CONDENSATE
EVAPORATOR
CONDENSATE
FRC \-if-
CONTAMINATED
CONDENSATE
STORAGE
TANK
( HOT WATER
<
,
* .WARM WATER
-^v
CONDENSER
NON
CON DEN SABLES ,
TO rOMRIISTinN
.'/ .'/ .'1 ITC
Tr wrf l lv-
STRIPPING
COLUMN
\
i
/' /'
r\
v_
HEAT
EXCHANGER
1
1
1
. j
1
l
t
l
l
1
STRIPPED CONDENSATE
// / FRC
STEAM
447
-------
During evaporator boil out in the basic kraft and soda mills the
liquor was returned to the weak black liquor storage tank until
the concentration got down to about 8% or l°Be, with the
remaining liquor discharged to the sewer. This system was
designed to collect the weak black liquor from about 10% down to
approximately 2%, with the remainder below 2% going to sewer.
During normal operation, the liquor is slowly metered back to the
weak black liquor ahead of the evaporators.
13^ Black_Liguor_Storage_Tank_Sp_ill_Collection
This system is to run all of the black liguor storage tank
overflows to the evaporator bailout tank included in another
estimate. The piping is arranged so that the weak liquor in the
boilout tank would overflow to the sewer first.
Iiii__Green_Liguor_pregs_Filtering
The basic mill takes the dregs from the green liquor clarifier,
dilutes the dregs in a dregs mixer and reconcentrates the dregs
in the dregs washer. The dregs from the washer are severed and
the dilute liguor sent to weak wash storage. This system
includes a vacuum dregs filter, with vacuum pump. The solids are
collected in a container for disposal by land fill. The diluted
green liguor goes to weak wash storage.
15^ Causticizing_Area_SBill_Cgllection_SYstem
The causticizing area liquor spill collection system includes a
tank sized to hold the liquor from any clarifier or storage tank
in the causticizing area. A transfer pump is used to pump to and
from green liquor storage, white liquor storage, weak wash
storage, green liquor clarifier, white liguor clarifier, and mud
washer, as shown on the flow diagram.
16._ Evap_oratgr_Condensate_for_Causticizing_Makeug
Evaporator condensate from the second, third, and fourth effects
are pumped to a holding tank for use in the causticizing and lime
recovery area. Evaporator condensate is used at the kiln
scrubber, lime mud dilution from storage, mud filter shower,
dregs filter showers, and mud washer dilution. A conductivity
probe is used to detect liquor carry over so that black liquor is
kept out of the causticizing and lime recovery system. The
holding tank uses fresh water for low level control.
!?._ Lime_Mud_Storage_Pgnd
A concrete lime mud holding tank is located 800 feet from the
lime kiln. The tank is 55' x 130' x 10' high for a bleached
kraft pump mill producing 670 TPD. With a 12' free board, the
tank holds U80,000 gallons.
448
-------
Figure 65A (Cont'd)
EVAPORATORS BOIL OUT TANK
LEGEND
NEW
EXISTING
WEAK BLACK
LIQUOR STORAGE
I TANK
i
EVAPORATORS
NO i
T
TO STRONG BLACK
LIQUOR STORAGE
h.
V
r
EVAPORATORS
NO 2
449
-------
Figure 65A (Cont'd)
BLACK LIQUOR STORAGE TANK
SPILL COLLECTION AND REUSE
WEAK BLACK
LIQUOR TANK
OVERFLOW
WEAK BLACK
LIQUOR TANK
OVERFLOW
STRONG BLACK
LIQUOR TANK
EVAP
BO I LOUT
TANK
LEGEND
NEW
EXISTING
450
-------
en
Figure 65A (Cbnt'd)
GREEN LIQUOR DREGS FILTER
DREGS
k_ULEJD
NEW
EXISTING
-------
Figure 65A (Oont'd)
CAUSTICIZING AREA SPILL COLLECTION SYSTEM
GREEN t
LIQUOR I
STORAGE i
GREEN
LIQUOR
CLARIFIER
HXh
HXJ-!
CAUSTICIZING
SAVE-ALL
TANK
1
; WHITE !
LIQUOR 1
CLARIFIER
! HX-
WHITE
LIQUOR
STORAGE
-r^sl.
MUD
U WASHER
,
I
1
i . , 1
1 WEAK
LIQUOR
STORAGE
t
•CXhl
I
LEGEND
EXISTING
NEW
452
-------
Figure 65A (Cort'd)
EVAPORATOR CONDENSATE USED FOR CAUSTICIZING MAKE-UP
n n n n n n n
I I ' I ' I I ' '
TO LIME MUD
STORAGE PUMP
TO MUD
WASHER
TO SLAKER
CLASSIFlER
453
LEGEND
EXISTING
NEW
-------
The lime mud pond provides storage when the kiln is down and the
mill continues tb run on purchased lime. The mud is reclaimed
with a floating "Mud-Cat".
18i__Alarms_for_Chemical_Tanks
High level alarms are installed on all pulp mill and paper mill
cnemical tanks so that the operator is alerted as soon as a tank
is ready to overflow to the sewer, so that the duration of the
spill is kept as short as possible. The small bleached kraft
soda and sulfite mills required 20 alarms and each paper machine
required three.
19^ prehYdrolYsate_Di§Egsal_bY_Burning
Each system is unique and includes proprietary information.
Therefore, the system used to arrive at the cost estimates will
not be described.
20..__Ma3nesium_Bisulfite_Liguor_Recovery_SYStem
The magnesium bisulfite liquor recovery estimate includes brown
stock drum washing, evaporators, incineration Wlt* c*~m1^
recovery and liquor reconstitution, to include make-up sulfur and
magnesium oxide systems,
21.. Pap.er_Machine_Vacuum_Saveall
To properly cover all of the segments with some accuracy,
estimates were prepared for the installation of vacuum disc
filters on tissue machines, newsprint machines, and board
machines. To establish an exponential factor to vary the cost
from small to large machines, two tissue machine saveall
estimates were prepared. Some of the smaller machines may
install deckers since the cost would be considerably less and
there may not be room for a vacuum saveall; however, all ot -he
estimate^ are based on disc filters. It was also estimated that
the smallest installation would cost in the range of $150,000.
22.. Pa2er_Machine_Flotation_Saveall
Most of the savealls being installed today a^.J^uum disc
filters. It was noted that more than half of the savealls on
fine paper machines in the mill surveyed were flotation savealls.
At least a partial reuse of white water is practiced on most fine
paper machines without savealls because of the relatively
expensive additives and fillers used in the manufacture of many
grades or fine papers. The cost of addition flotation savealls
to fine paper machines was estimated on this basis.
23., pap_er_Machine_High_Pressure_Showers
The fresh water used for headbox shower, fourdrinier section
cleaning and sheet knock off, and in the P^* se^ion '^J
significantly reduced by the installation of high pressure
454
-------
Figure 65A (ContV)
LIME MUD STORAGE POND
en
en
TO MUD
MIXER
LIME MUD
STORAGE
TO MUD FILTER
LEGEND
• EXISTING
NEW
-CXK-
TO DUMP TANK
CONCRETE LIME MUD
HOLDING TANK
FROM CONTAMINATED
CONDENSATE-HIGH
PRESSURE
-------
Figure 65A (Cont'd)
PAPER MACHINE
VACUUM SAVEALL
ALTERNATE I
LEGEND
01
DISC SAVEALL
. NEW
. EXISTING
-------
?igure 65A (Cont'd)
PAPER MACHJNE
VACUUM SAVEALL
ALTERNATE I I
DISC SAVEALL
END ^
-------
Figure 65A (ContY)
PAPER MACHINE
VACUUM SAVEALL
ALTERNATE I I I
DISC SAVEALL
L E G END
en
oo
NEW
EXISTING
I I
| BLEND |
CHEST
-------
car
GO
$
VO
3:
C_)
d
oc
LU
Q.
el
Q-
LOW PRESSURE W.W.
HIGH PRESSURE W
459
-------
oora
Each system includesa stand-by high pressure
2«._ Pager _Machine_m!Jte_water_showers
~
1««
additives and fillers, jell cieaniiy shower water volume
installed. On tissue -jchxnes JJe h^ra^ter tine. resulting
will help to work in new felts «J ^m ft single white
wateTbacK-up on supply header low
pressure control.
25 ...Cylinder Former_White_Wash_Shower
filtered white water showers.
26 . _Cooiing_Wat er _Segr egat i on.and_Reus e
^rJdlrect cooling water collected i..
condenser, air compressor <***™1' l°^lw through steam
dryer drainage c°n?en?"JerCO°^de?nbrake cooling, and stream
ne iater
rtons and from non-
integrated mills are included.
Felt_Hair Removal ..
clean water can be recycled.
28.._ Vacuum_PumES_Seal_Water_Reuse
^"es^ates are included for reuse o^vacuum
For large inte9ratfd N11^', ^ JJh a covered trench. The system
ech
»ater storage.
460
-------
Figura 65A (Cont'd)
HIGH PRESSURE FRESH WATER
CLEANING SHOWERS FOR PAPER MACHINES
NO. 1 P.M
NO. 2 P.M.
300 PSI
NO. 3 P.M.
TO FOURDRINIER.COUCH
ROLL AND VENTA NIP SHOWERS
500 PSI
1
«i
LEGEND
300 PSI SHOWERS
',50 PSI
500 PSI SHOWERS
EXISTING
HILL WATER
-------
Figure 65A (Cont'd)
PAPER MACHINE WHITE WATER SHOWERS
LEGEND
NEW
EXISTING
TOP FELT SHOWERS
BOTTOM FELT
SHOWERS
FOURDRINIER
SHOWERS
CLARIFIED
WHITE
WATER
CHEST
462
-------
Figure 65A (Cont'd)
FELT HAIR REMOVAL FROM PRESS
SECTION VAC PUMP SEAL WATER
FROM 2nd PRESS
VACUUM PUMP
SIDE HILL
SAVEALL
VACUUM
PUMP SEAL
WATER CHEST
FROM 1st PRESS
VACUUM PUMP
LEGEND
NEW
EXISTING
463
-------
Fi jure 65A (Cont'c)
VACUUM PUMPS
SEAL WATER REUSE
FROM 2nd PRESS
'OR PRESSURE ROLL
VACUUM PUMP
cr>
-p-
VACUUM PUMP
SEAL WATER
CHEST
FROM FLAT BOXES
i.OR BREAST ROLL]
VACUUM PUMP
FROM COUCH ROLL AND
1st PRESS VACUUM PUMP
-------
-52
quality paper. The stock is thickened fo stoge on
static screens, which also separates some of the sand from the
;.
EXTERNAL_EFFLUENT_TREATMENT
The following is a brief description of the external
systems used to prepare external construction coltsf
?t ^nniTSnanCe K°St!' chemical c°sts, and power requiements
It should be remembered, however, that actual external treatment
cT?^7 rrY 8i9n«icantly ^on, "HI to mill depending upon ?he
climate, topography, soils conditions, unit location!, and thj
Each9Sr±o??era^°n10f the Particular ^8te treatment facilitiy?
Each production facility or waste treatment facility has som^
uniqueness which may be of importance in assessing th*
^^ pr°blems and the associated cost^of
Raw and final waste characteristics associated with M^h
technology level have been developed for eich of the ?5
subcategories. The data presented in this repor? represents
caS°X"o Jhe^^'-r:"^8' "^ may n0t be r^able in every
case to the limitations and standards shown in other section^
because of the different methodologies utilized In ordSr ?o
determine the impact of the limitations on the profitability of a
"Sr " " been Lveloped'for Sen
conructone
characteristics, unit construction costs a^d operational
practices. Detailed design for each unit, procesfand mlchaniSal
layout, is beyond the scope and time limitations of ?his repor??
The construction costs presented are those defined as the cani+ai
?ncl±r^S^reqUired t0 imPle^nt the control technology1
Included in these costs are the traditional expenditures for «mn
items as mechanical and electrical equipmJn?
*
an ' uon s
and grading, equipment installation and testinq and
ItemS SUCh aS el^rical. instrumentation* process
^ti0n'-.a?d en^ineeri^ are included aS a
S
465
-------
Figure 65A (Ccnt'd)
PAPER MILL STOCK SPILL COLLECTION SYSTEM
TO BLEND
CHEST
-CX1 1
ROM STOCK CHESTS
FROM STOCK CHESTS
STOCK
COLLECTION
CHEST
tz
FLOOR DRAINS
FLOOR DRAINS
466
-------
ies, as follows:
Total Operating Cos^-s
Depreciation and Interest
Operation and Maintenance
for the
are subdivided into three
. p
depreciation has been assumed
interest is the financial charges
the pollution control facilities
depreciation plus interest
initial capital expense?
years. straight
?°St cai™^™
l expenditures for
Prposes of this report
tO be 15 P«cent of
1.
2.
3.
**•
are subdivided as follows
Operator Labor
Maintenance Labor
Energy Requirements
Chemicals
treatment facility. These
etafp operaio"-" -^-a to
control, monitoring, etc for ?h! « Sr administration, quality
The maintenance cos?s arf the annuf?1" tjeatme'* facility!
prevent ative maintenance tasks such al "anhours required for
inspection, minor parts replacement nlubjicati°n. equipment
assumed that major equipment ^^ ^ ' Xt was
ba
based on the
attributable to the
-quired to meet
°peratio» of the
requirements
.
requirements, and chemicals"
ar9 th.
' maintenance labor,
Ambient temperatures can
performance of biological
an aerated stabiliza?ion
tend to approach ambien"
operational and treatmen
impact on the
In COld climates
detention times will
can
467
-------
necessary, therefore ^.^^Syto year
use of an activated sludge system J^16* d on the above
round basis their eff Jwn* ^S^S* 'f or Soth activated sludge
comments, this report Presents costs tor DO risons of
and aerated «*ablli«tion^e^to allow cos^^ ^ cold
each system. In addition to incre desire
weather, it is antl^*^edth;iudgrsystem because of limited
for o^of9 anY aerated stabilization
basin.
Preliminary__Treatment
a was? =.; '
bark, wet strength Wef ' ..^'^ar on the process equipment.
treatment processes or incwase wear ™ * removed from
Consequently, it is nece^sa^p^n^ ^ mechanically cleaned bar
the mill sewers prior to treatment. «ID and paper mills for
screen is generally utilized by most ^ ^J^^s flow into
°
te m «ID and paper m
screen is generally utilized by most ^ ^J^^s flow into
preliminary treatment. . J^Q ^f sew°r s bypassing it. The bar
?his facility, with the low s°Jld? *^e" °*? is a mechanically
screen used for purposes of *" ^ w±th a bar spacing
reen
, s a
screen used for purposes of J*" ^^ w±th a bar spacing
operated, self -cleaning travelling bar "creen^^ ^ B ^
of 1-2 inches. A °yV***.cn™ allow for screening during
incorporated into the facility to allow tor ^^^^ R
, the
^
periods of . maint enance «, the Sment of the removed
'•dumpster11 unit is utilized
solids.
It is advantageous to monitor and sample
treatment process. Thjf f^ef eaSd monitoring and sampling
includes the necessary ^^s^urement and sampling. The
fi<
ur
equipment for co"PL***fi .... n-Hlized for this
tSe treatment facility. The P^P^facility ^ilized^^ ^^
report assumed a wet well and dry well. ine m &t maximum
in?o the wet well ^if^JaSle speed pumps are located in a dry
daily flow), while the variable spee P Ptruction costs prepared
well adjacent to the wet weij.. .-,,. include excavation,
for the mill effluent P™P»£ aMe speed controls, ancillary
backfill. concrete, pumps, variable speeu
ptping and equipment, and superstructure.
Primary__Clarification
468
-------
acct
justification. Therefore! external f?L he degree of economic
not been considered in the treatment n recover* for reuse has
sewers containing suspend solids' aS cSS?eS5 d^ign' A11 mil1
clarification, ^with total reo C°mblned prior to Primary
caon, with total removl , o Prmary
mechanical clarification. Primal r?i . *ein? accomplished by
percent of the total suspSSS^soSSaS*10? rem°VeS 15~85
for this report is a heav-duS Clifier selected
. -
primary clarifier at an anticioate^ S^ Y pumPln9 from the
to either a sludge iJgooS or f SSi •°°?tent °f 3^ Percent
suge igoo or • cen
Scum collected in the cUri?fer dischJr^"^ dewateri^ Device.
where it is then pumped for dewatS™ ^ st°rage tank
prepared for primary clarification fn^ J g' The caPit^l costs
concrete, mechanical, elect rica? ^lud\excavationr backfill,
scum facilities, wast4 sludgj pu^s an^^T^^^ e^iP^nt
unit construction. P^mps, and yard piping related to
Lagoon
sgeo
allowed to settle, the decanS ™+ * n he Waste solids
treatment system. In addmSn a sluL^1** back to the
Slude lao
. n a su
emergency solids disoosal ^^ Sludge lagoon may serve as an
facilities are down due S mechanical" *?? mechanic^ dewatering
coste
mecanca
costed in this report provides suf^^^' The la^oo«
years' detention of 20 percenl sofidJ J? nt . caPacity for five
the required earthwork ^o'cSnstJScfs' C°St
Deration
ynegir
r'Td^d^
based on the use of^ecEanica! su?f Le aS ^ " tMS rep°rt are
eguxpment is sized to p?ovidf «uff?2 rators« The aeration
redu 6nt °
ze to povid «uff on
reduction and to ensure p?ope? m?»f 6nt °Xygen for fiOD5
particular biological t?ea?m2n? nro™9* ?ePending on the
requirements will differ? Process selected, oxygenation
by the
Standard design criteria^ for aeration of » b^Ztl°n Basin
-------
characteristics of the system (temperature, basin configuration,
biological characteristics, alpha and beta).
The activated sludge system with its
cos?
for an ASB.
Aerated_Stablization_Basin
treatment by aerated
are
minimal decreases
deficient in the
to
baS?ns
The basins chosen for Preparation of
liner is not included.
The sizin, of the -rated stabilisation basins were^evaluate^^n
^e^eSrnnaetenriortimears.iraafsrjhi=K.ss?rd 13 davs o,
aeration' with one da y °f ^^^/Ssti lUes ob?ainlo fo? the
iS^lit^^lS^-r^ rd-orSnir^oadin, «ere compared to
Se?ermine which criteria was the governing value.
The capital costs
include excavation, dike
an
protection and
associa?ed with the
basin size.
Activated_Sludge_Basin
^"activated sludge . P--SS /as
detention times, ?^njc loading^ ^o^yfsncommOnly referred to
selected for consideration in this repor 6 t 8 hours
-ss-s-a
470
-------
susceptible to upsets due to shock loadings. it is recommended
that an equalization basin be included with this system to even
out hydraulic and organic loads to the system.
As stated previously, pulp and paper wastes are deficient in
nutrients (nitrogen and phosphorus) . The nutrients are added in
proportion to the organic (BOD5) loading to the facility A
°f 10°:5:1 iS utilized for cost analysis in this
Final clarifiers are required with the activated sludge basin to
allow separation of the biological mass and treated stream. A
large portion of these solids are recycled back to the activated
sludge basin to maintain the biological mass in the aeration
basin. This biological mass is necessary to achieve high removal
efficiencies. The high rate activated sludge system also
generates large quantities of biological solids which are not
oxidized as in ASB systems. it is necessary, therefore, to
continuously remove excess biological solids. These excess
solids (waste activated sludge) can be extremely gelatinous with
9 *u°i ! concentration of approximately 0.5-1.0 percent. The
methods for disposal of these excess solids are presented in a
subsequent section of this report.
Since the activated sludge process has high horsepower
requirements, an earthen basin would be susceptible to erosion
Consequently, the costs prepared for the activated sludge basin
are based on a two-cell concrete tank. The cells would be
operated in parallel to provide operational flexibility. The
clarifiers associated with the activated sludge process are
described in a subsequent process item.
hL ^ tK64.»,A?B system' Sizin9 of the activated sludge system is
based on both detention time and organic loading. The detention
time is eight (8) hours (excluding recycle) while the organic
loading rate is 50# BOD/1000 Cu.Ft. of aeration volume. The
governing value was selected for cost analysis in this report.
The capital costs prepared for the activated sludge basins
(presented as a function of the basin capacity) includel
excavation, tank construction, concrete, nutrient feed systems.
vard P1?1^? electrical and instrumentation costs associated with
the basin size.
!aualization_Basin
rec*uired <*uite often to minimize upsets
ze upses
vari,tn Si On in ?H valuations- and hydraulic and organic
variations. This is particularly true of the activated sludge
process. The equalization basin utlized for cost analysis
!^deS * i2:hour detention time for equalization of process
wi?h control d£aultc Peaks« The basin utli^d is a concrete tank
with control facilities to equalize the flow. The capital costs
y£rd i !r*cavation' tanks construction, concrete, backfill, and
471
-------
Vacuum_Filtration
V Cli 1OU.53 Ull-L f ._ i_ ,-.. ~-.-I m 0 -VtT 33 Tl^ *-i (-"I LIllVAfcl J_r •-••«-»-»- — / -
for sludge dewatering Cboth primary and —— J industry is
method which has gained the widest acceptance ^ ^^ ^^
vacuum filtration. A vacuum f^e^or°ngprings which is partially
covered with a wire "Jes» rotary drum is divided into a
submerged in the waste solids. ™e ror y vacuum when
series of compartments which are P^^ ^ates so that when a
submerged in the waste soiias. vacuum is released.
compartment reaches the top ot tne cir fl it descends
A filter cake is built up on the ^1^"^' ?he filter media
waste solids.
The efficiency of vacuum filtration operation is ^^ Dexny
by the consistency and ProPJ^f_n°ris more efficient and
dewatered. The Jj^atering operat^ ^ ^ filter are in a
economical when the waste ^^^y, often times it is
range of 3 to 5 P6^6?^' waste sludge solids prior to
advantageous to Pr^5f nparticularly true when dewatering
a biological system.
The waste sludge (primary excess biological solid, ^
from an ASB clari-floccula tor) obtained fro
?equ?res ^etaSr'air to actual design of
dewatering facilties.
Waste sl«dge o ainea
solids. Ths ie rate
to
cake of 20 to 30 percent solids.
As described Previously the waste ^logical
from an activated sludge ^^ul^oDdewater because of its
This type of sludge is ^^"^"Sor to vacuum filtration.
consistency and requires,^h^^^gs^uds can be combined with
Once thickened, the waste ^^J^^f °when thickened waste
primary waste solids for vacuum ^ra)rjo£' solids, filter rates
biological solids are combined with primary , addition of
solids removal by clarification following an ASB is no^a cojjan
-movaf ^^^f^^S^l, l^ arrSrem-y
se?tSlf afd S^rt^r^^ntl,. it is anticipated
472
-------
dded at
efficient^ dawater
The hours per week which tho ,, nsiere, as outlined above
P of -
s oage a SO
equipment and 'appropriate anclll™ pumpln^' building, mechanical
electrical, insLum^ation? an? a SSnSh^' Pr°CeSS pipin^'
h ™
i ' •*•"»•> vj_ umc:ui_ciT:ion. and a o+-3vi^K ,-. ir—c--~"~it
The operation and maintenance cost? ^nrfnL^"11111 fllter Unit«
solids to a landfill site. include disposal of the
Sludge_Press
priorto -lids
particularly if the solids arfVS i K "Inmate disposal,
achieved by use of a V-Sess TV Sr ??d< ThiS is no^Hy
solids concentration £ Is to JS WlU normally raise the
conveyor feeds solids in?o a aao 1L percent solids. A screw
wheels. These wheels caJrvtL be:-y?en tW° revolving press
"Pinch point" is reaped. Atythfl Sn?^0^- tU1 a S°-^*
exerted on the solids. The presald sol ?5J maximum Pressure is
the wheels gradually diverge A sorL ^ are then rel^ased as
the solids into a rlcei^na ^ co"veyor then discharges
Pressing operation is tSen reSycJef baSk^o ^ filtra^ from ?he
The capital costs for pressing Sf ««?f ?-J treatment system.
filtration include mechaSIca? ^Ipment and ancf?}10"1^
electrical and instrumentation, "S
^I°t at i on_T hie ke n i ng
of the vacuum fne is re^Tv0""111/11?^1011' the opacity
selected as the thickening process fo/th^^ /ir flota^°n wal
requires addition of a floc?£lan?%n?h ^y> Air flotation
473
-------
s -
influent.
udrh
f^a^^iir^ease^hrsecon-dar? ££f ISSi fol 45
pe?clnt Solids. T£S filtrate and scum from the air flotation is
ESS"- ^SS n
oo
vary dependinon the solids loading The follo.ii.,
of application were assumed:
SecondarY_§olids_z_*/paY Hours/Week
0-5,000
5,000-20,000
20,000-60,000
system! electrLaU instrumentation, and ancillary equxpment.
Secondary._Clarification
"-'
separation
474
-------
The design overflow rate for the clarifiers, excluding
flocculation area, is 500 gpd/sq.ft. The drive mechanism would
be rated for a torgue of 10(D)2.
In a waste activated sludge system, most of the biological solids
settled in the secondary clarifiers are recycled to the aeration
basin to maintain an active biological mass in the aeration
basin. Pumping capacity is provided for a maximum recycle rate
of 75 percent of the average daily flow with an average recycle
rate of 40 percent of the average daily flow.
The capital costs presented for secondary clarification include
excavation, backfill, concrete, recycle pumps, mechanical
equipment, electrical, instrumentation, yard piping, and
ancillary equipment for proper operation.
Mixed_Media_Filtration
a
Mixed media filtration is presented in this report as *
"polishing process" following secondary treatment for
supplemental suspended solids removal. The units evaluated are
single-stage, parallel pressure filters with provision for
operation of two units in series for two stage filtration. A
clear well for storage of the backwash water is provided for
backwash of the captured solids. A surface wash is also provided
for scouring the media and minimizing slime growth. The backwash
water with its high solids concentration is pumped to a storage
tank where the solids can settle, with the decanted water being
conveyed back into the treatment system. The settled solids are
transported to the solids dewaterinq equipment. The design rate
for the filters is 5 gpm/sq.ft. A standby unit is provided for
periods of breakdown or maintenance on one of the other filters.
The capital costs for mixed media filtration include buildinq,
process equipment, equalization basin, piping, electrical,
instrumentation, and ancillary equipment.
Pulping processes significantly change the pH of a wastewater
Such variations in pH can affect the waste treatment process"
therefore, it is necessary to add chemicals (acid and/or caustic)*
and flash mix the wastewater for neutralization.
The capital cost for pH adjustment includes excavation, backfill,
concrete, mixer, chemical feed system, etc. The flash mix -f-ank
provides one minute detention time at peak flow with mixing
capacity of 1 Hp/ 1000 gal. capacity of mix tank.
Ii2S?_Monitoring_Structure
In order to monitor the unit processes and overall efficiency of
the treatment process, it requires installation of flow
monitoring structures throughout the process. The flow
475
-------
monitoring structure considered in this study includes a Parshall
flume and automatic sampling equipment.
Foam_Contrgl
K5K SSIT.'SJ.SS: S"??-?-? •»";•«;«. 2333
capacity.
Outfall_Sewgr
connections
Diffuser
Discharge from the outfall sewer is . Ine
laying and jointing of the diffuser pipe.
Minimum Lime_Treatment
ronhla r s
iUlr^he ^^U"!^1!.11^.' "ISrth.. . thicKened by
^^^^^^t^^«s^
*
and a clarifier for settling of the lime
476
-------
r
UD
(U
3
01
•r—
477
-------
00
-------
'.o
^^—J—j_j,_
-------
0817
CO
-------
• '• t d I H L N' T
HARKfT KHAFT SUBCATEGORY
C 0 S I
•I- ^ J>>
00
s~
I
Figure 70
-------
I,
OJ
CO
-------
HK'E KDF!
-Pi
00
r
r
Figure 72
-------
f f F
•; F M T T P c A T !''• E N T !
' GRO'UN'GIOOO CHEHI riCH SUBCAT:CQSY
J E T
00
Figure 73
-------
it.. ,.•-:-;• T CCS
GROCSDH303 Tntfi.VO VECK SUBCATEGOR1
-_i -. ..
-Pi
00
CJ1
Figure 74
-------
VD
CO
-------
L '• ' I - F A ' V f >, r r r. - T
G?CIWOOD FINE SL'BQATEGORY
-p.
oo
Figure 76
-------
03
CO
-
t-
c
r~
Figure 77
-------
-j
j
00
-------
r F L (j t ;< T ^ t t T M E N T 1 0 S T
NON-INTEGRATED TISSUF SUBCATEGORV
Figure 79
-------
08
i
i !
01
-------
Retrof it_cgsts
on the following criteria.
,. "profit costs-
. a
using P°ny for
treatmen but mills using P°^no£iy primary treatment for
mills re qui re y Por that were
exception in that ^ese mis re ubcategory
1" costs- incite mills with only
primary treatment facilities.
mill and the average of the a^a^im^tions for the subcategory.
used to establish the f^^Sl BOD and TSS removal
use
This difference ^P^fnt^e^nua? average wastewater volume and
The groundwood segment Deludes
os
»e o
qualified for a6^11"^""11 °fciSl system, have no treatment
16U
492
-------
TABLE 160
Mill
Code
003
002A
004A
051
052
150
152
Tons/
Day
542
217
71
296
101
300
600
Treatment
Train
Flow
M.G.D.
Groundwood
C-TF-C
C-A
SB-SB-SB
C-ASB
C-ASB
C-TF
C-ASB
13.8
4.9
2.1
Sulfite
16.6
4.1
Soda
Blecjj
140
108
120
110A
136
134
104A
116
118
132
103
107A
112
121A
138
113A
109A
100
501
122A
111A
102 A
320
1000
1160
1132
1650
T45
1342
1150
192
'4 17
425
31.0
6X 0
1351
936
1177
1119
1027
1305
598
772
1020
SB- ASB
C-ASB
ASB
ASB
ASB
ASB
ASB
A
*
ASB
A O T)
A . j li
ASB
/SB
A
t\
ASB
ASB
AS R '
AS 3
12.0
17.0
Kraft
BOD
6,179
586
277
240
537
19,000
11,000
TSS
3,848
1,259
I.C.
503
I.C.
24,000
24,000
6.0
55
36.1
27.8
47.4
21.0
70.2
36.1
5f-*
. 0
8.1
18.4
9.4
16.9
48 . L
33.0
39.8
43.8
37.1
66. L
17.3
? r> . 0
34.7
2,300
6,800
580
906
3,300
8,978
13,554
13,685
1,133
3,294
7,055
i.e.
I.C.
T r -7 n
•1. , J t O
4 ,'9°' 3
""> 1 ') ' O
' J- , 3v>2
O 1 ~< ' r-
/ J. , / '4 5
J i _y
12,030
3 6, '.103
1,200
4,000
19,952
3,736
33,655
37,044
27,511
N.'A. J
i.e.
T..C.
3,689
13,394
0 , u ,
'• . 733
N.A.
?-•'., 1 70
I.C.
' ' r" o 1 r~
-.5, '6 08
772
8,976
1 • C-* = in
N.A. = No;
ipn.incfi
PlU-ablt
493
o-n
-------
TABLE 1_60
(continued)
#/r>av To Be Removed.
Mill
Code
210
205A
284
257A
252
303
308A
318
333
337
259A
312
313
330
208A
302
329
T C.
N.A.
Tons/
Day
320
100
375
187
49
45
160
125
163
36
194
15
37
20
104
226
74
- In Ccmpl
Treatment Flow
Train M.G.D.
Deink
SB-PS
C-ASB
Fine
C-ASB-C
C-A
Tissue
C-PS
FI
C
C
C
C
C-F1
C-ASB-PS
C-PS
C
C
C-PS
C
lance
6.2
1.9
2.3
1.9
0.6
2.8
4.4
4.2
5.2
4.5
3.4
0.7
0.2
0 4
1.5
2.8
? 7
BOD
6,003
245
262
430
54
239
560
188
652
508
446
N.A.
644
352
707
2.26
488
TSS
_ •
i.e.
N.A.
i.e.
N.A.
i.e.
N.A.
304
438
N.A.
72
T , C .
590
N.A.
N.A.
62
N.A.
96
"• ••- —— — . — — —-••--
= Noc Applicable
494
-------
-
.
determination of etrofit costs ^n^f*9^ ^ *>alified fir
to a municipal sewer. Save no Thf_«JainJn9 mills discharged
treatment or are in compliant w?th t£ ^n haVG °nly Primary
- "
164 represents the total
§2da_SubcategorY
S3 mills tha^qua'urf f^ XSlloiS0 J°Vhe S°da ^category are
this subcategory. The cost^Ji P n ,°f "retr°fit costs" fo?
facilities for these two mills if „* ^he^wastewater treatment
in Table 164. The design criteria on Cw^f^ C°StS" are shown
is described in Table 161 ireria on whlch these costs are based
2§ink_Subcategory.
ct .^^; S.gi- Category qualified for
this subcategory discharged to a mun?^' remaining mills in
treatment, have primary treatment on1v Pal 8Ysten«r have no
the effluent limitations! ?he "re?rof^r are/n C™W™* with
these four mills therefo^e ™f^J\H 8tS devel°Ped for
subcategory which are shown L Tab?e i ?a thlcosts fo^ the entire
whach these costs are baseS S SSriJeS'in"1^1* °n
Fine_Paeer_Subcatec[orv_INon-inte3ratedI
termningretrf cSstBV^isTt3 ^S «>*
mills m this subcategory discharged t n f Sub?a^e
-------
TABLE
ASIS mi RF.TUOliT COST DFTi:iOli:iATIOi:
exlstinc primary and
I™,
13.0 6200
5.0 600
,r^a, r._.
600
300
=
200
100
Ground wood_ S ejip,f-n c_
> J
/nnn
^ °
fhfnical fefid only
None
500 none
,;oiia
spj-A.^ASjr^-ri.t-
17.0 11000
12.0 1"000
s
3.0 10CO
2.0 300
Aerators + 6 .
Aerators + 8 days r-t-nn
Dein k_ ^epH1.2!^
, 3000
= : f r. =
.
Aerators c..*>
Aerators only
Chr-nical feed + sludge
f«d
3000
OQ
Chsnical fe'd only
='"' '"' ""
Chcnical feed
chstnical feed
i
375 2.5 270 Aerators only
,
200 2.0 A50 Aerators only
In com- None.
^^
2000 Chemical feed
496
-------
unsurveyed
were derived usinq the *»«
Surveyed Mills
all
surveyed mlUs sectio e re^rol??"" ^ Table 168 <"><>«
treatment levels required are shoS in ?SblS "Iff f°r the
Un surveyed Mills
are . ir^ treatment faciliti,s
fnd "vo? mil1: The aver-^ Si size is'lOQf ^Wafew^er volume
and volume is 113.4 MLD (30 MCD?- Jh i 92 kk9/day (1200 T/D)
developed for the surveyed mills l^ ref°re' the retrofit costL
T/D) and 121 MLD (32 M?D) iere uSjd ^oT?^ 91° kkg/da^ WO
there ?;f rSUrV6yed mills- "^ng^fble 162* ^ retrof^ costs
addiJ^ i €n survey^ mills requiring fl^ I °an be seen that
addxtional retention time in %-hf* q Om two to ten davs
the unsurveyed mills. TheSlore tL fxp;crte'3 to be required by
rVed ml 0 °t'S d
"
*
B
S« ten.surveyed mills. The results nf ^ Was exPerienced by
shown m Table 168. The ?o?a? ™5 J^ese calculations are
segment is also shown in th?s tab?e retr°flt c°*** for the
S"^S^^TS^^V5 --"-h^eeSrele^
497
-------
TABLE 162
BASIS FOR RETROFIT COST DETERMINATION
/LL ASB TREATMENT FACILITIES
# OF
Mills
1
1
4
3
2
2
2
1
Tons/
Day
320
1000
1000
1000
1000
1000
1000
1GOG
MGD
6.0
55.0
32.0
32.0
32.0
32.0
32.0
32.0
BOD
#/Day
2400
6800
1000
3000
3000
13000
22000
3GGGG
TSS
Added Treatment Required #/Day
Aerators only lj-00
Aerators + 3 days retention 4000
Aerators only ™00
Aerators + 2 days retention 28000
Aerators + 4 days retention 19000
Aerators + 6 days racantion 50000
Aerators + 8 days retention 13000
Aeracois +10 days retention ?OuO
Added Treatment Required
None
Chemical feed only
Chemical feed only
Chemical feed + sludge ham
Chemical feed + sludge hanc
Chenical feed + sludge hanc
+ Clarifier for 16 MGD
Chenical feed + sludr.? han;
Chemical £e«d -r aluuso haut
250
1230
7.0 1000
57,0 10000
ALL ACTIVATED.SLUDGE TREATMENT FACILITIES
Aeration
Provide Activated Slu.dg£
plant for 20 MGD
Chemical
Chemical fs-d for 57 KG
<-or "••iids per day of additional ^^
are co be made for the MGD's shovn.
498
-------
TABLE J_63
BASIS FOR RETROFIT COST DETERMINATION
^resents the additional removal requirements to be achieved by
secondary treatment facilities in the clsaue segment? *
TISSUE FROM 60% PURCHASED PULP OR MORE
AVG. // OF AVG. BOD TSS
T/D MILLS MGD ,/DAY ,/DAy ADDED TREATMENT REQUIRED
2'6 27° 2?° Chemical feed + full primary system
for 1.3 MGD. Use clariflers
•1-60 4 4.3 460 Sflfi
Chemical feed -f full primary system
for 1.0 MGD. Uu> clarificrs
3 2<3 4?5 8° Chanical feed + full primary svstam
for 0.5 MGD. U-, - «•'---»cj "
-^- *--^C*JL J.X .1-^.i tf
TISSUE (£wp-9Q% W.iSTE PAPER OR MORE)
2^ 3 0.4 500 T3r>
330 Aoratora -!- 4 day, retention for 0.4 M,
•*• siudgo handling facilitiss.
N01T.: Mted aerators, che-nicsl feed, &
-------
Table 164
RETROFIT
EFFLUENT TREATMENT COSTS
(All Costs In Thousands Of Dollars)
Mill Size
Retrofit Costs
Tens/Day
560
220
75
en
o
o
3 CO
100
600
SCO
400
320
_ _
BODr
MGD #/Day
13.0 6200
5.0 600
2.0 300
17.0 300
4.0 600
17.0 115OOC
12.0 19,000
7.0 8200
6.0 60CO
o n i nnn
TSSr
#/Day
4000
None
None
500
None
24,000
24,000
2700
None
30CO
Additional
Investment Cost
Groundwood Segment
1540
50
30
Sulfite Segment
25
45
Soda Segment
3870
4430
Deink Segment
1820
1430
125
Additional ueprecxcti-xuii a
Operating Cost Interest
450 230
15 10
10 5
10 5
10 5
1040 580
1130 665
435 275
285 215
55 20
Wp t--*. CL t_ J_t*
Maintena
220
5
5
5
5
460
465
160
70
35
-------
Table 165
RETROFIT
EFFLUENT TREATMENT COSTS
(All Costs In Thousands Of Dollars)
en
o
Tons/Day
Mill Size
BODr
M'-D ///Day
TSSr
///Day
Retrofit Costs
Additional Additional
Investment Cost Operating Cost
Depreciation &
Interest
Operating &
Maintenance
Bleached Kraft Segment
320
ICOO
10CO
1
1
1 1000
ICOO
1000
1000
1000
— 250
1230
6
55
32
32
32
32
32
32
7
57
2AQO
68CO
1000
3000
tooo
13,000
22,000
36,000
1000
10,000
1200
4000
7000
2800
1900
50,000
13,000
9000
3000
26,000
150
2980
125
3115
3930
6570
5410
6250
Bleached Kraft Segment
Waste Activated Sludge
110
6885
40
1130
345
1050
1170
1730
1470
1630
95
2270
25
445
20
470
590
985
810
940
20
1035
15
685
325
580
580
745
660
740
75
1235
-------
Table 166
RETROFIT
EFFLUENT TREATMENT COSTb
(All Costs in Thousands Of Dollars)
Tons /Day
375
200
tn
o
ro
43
160
135
Mill Size
BODr
2.5 270
2.0 "0
2.6 270
4.3 460
2.3 475
TSSr
#/Day
None
2000
270
500
80
25
0.4
5-0
330
Retrofit Costs
Additional
Investment Cost
Additional
Operating Cost
Fine Segment
25
85
Tissue Segments
630
600
405
Tissue (fwp)
520
10
40
175
165
125
105
Depreciation &
Interest
5
15
95
90
60
80
Operating &
Maintenance
5
25
80
75
65
25
-------
Table 167
MGD
179
173
149
177
167
ISO
171
161
174
187
Average 1?QO
30.0
503
-------
Table 168
RETROFIT COSTS FOR THE bLEAdlED KRAFT SEGMENT
Surveyed Mill s
_ ,. -a _ M-Mi Total Cost
Nunber $LOOO_
' --
of Mills.
150 15°
4 3 5 9,345
3 3,115 7>86Q
2 3.930 Q
2
2 0 6,250
2 6'gO 220
6,885 ^,770
Unsurve.yed Mills
Total Cost
-
2 3,930 I-2 ',R
1-2 15,768
s'.uo
1 6>250 I-2
TOTAL COST PER SEGMENT 121,933
504
-------
Table 169
RETROFIT COSTS FOR THE TISSUE SEQUENT
Surveyed Mills
Number
of Mil.Is
3
4
3
3
A-erage
T/D
43
160
135
25
Unsurveyed Mills
Mill
Code
607
609
335
344
339
338
336
348
329
327
612
Average
_.. T/D
10
20
30
30
30
35
/\ s
JO
40
50
75
210
Cost Per Mill
Jl,_000_
630
600
405
520
Cost Per Mill
$].000
630
630
630
630
630
630
630
630
630
630
600
Factor
1
1
1
1
Factor
10/43
20/43
30/43
30/43
30/43
35/43
•> /- / / /•»
JO/ 4j
40/43
50/43
75/43
210/160
TOTAL COST PER SEGMENT
Total Cost
. $1,000
1,890
2,400
1,215
1,560
Total Cost
$1,000
147
293
440
440
440
513
527
586
735
1,099
788
13,073
505
-------
SSTf.rSr-.-Fm^ «£«££ -Jfcont costs
derived using the procedures described
Surveyed Mills
below.
The surveyed .ills e
require various i^ovements^n existing TSS removals shown
order to achieve the additional « u derived by grouping the
design criteria shown in Table 163 we ±nantly virgin pulp or
are shown in Table 166. The^n^°Sand a total for each level of
of mills to which they apply and a f treatment
treatment is obtained for each of ^^ arfshown in Table 169
•reauired. These final re^roLxt.
under Si surveyed mills sectxon.
Unsurveyed Mills
additional irreatinent
The eleven unsurveyed mills that require Qf developing
facilities are listed in Table 169. For P g d for the
retrofit costs for these mills, the cost 3g>1 kkg/day
surveyed mills for the group of mills tn f±rst ten
T/D) in size, see ^le 166, was «sed ^ ed miii
- e
or the entire tissue segment
also" shown in this table
DeveloEment_gf_Cgsts
following pages.
506
-------
SAMPLE CALCULATION
FOR: BCT Kraft Subcategory
MILL SIZE: 670 Tons per day
A. Internal Costs (All Costs in $1 000) Caoital_Cost
Subtotal Total
1- To Achieve Pretreatment:
90% of Item 3. 0 9 x 62
55.8
33% of item 5. 0.33x103
75% of item 9. 0.75 x 135
50% of Item 10. 0.5 x 530
33% of Item 12. 0.33 x 23.5
33% of Item 13. 0.33 x 11.7
33% of item 14. 0.33 x 93
31.0
33% of Item 18.
Pulp Mill
13.3
Paper Mill (Three alarms per machine)
6.5
0.33 x 19.8
90% of Item 21. (AH disc savealls)
Two Board Machines, 220 TPD ea. 574 Q
Three tissue machines, 75 TPD ea. 780 0
0,9 x 1354
1219.0
20% of Item 23. (For Board Machines)
0.2 x 124
30% of Item 24. (For Tissue Machines)
0.2 x 108
33% of Item 28. 0.33 x 83
27.7
TOTAL CAPITAL COST
507
-------
2. To achieve BPCTCA
Item Cost
3 62.0
5 103.0
9 135.0
10 530.0
12 23.5
13 . H ' '-
TOTAL CAPITAL COST
INT. & DEP. AT 15%
3. To achieve BATEA
Item Cost
2 145.0
4 560.0
6 730.0
7 288.0
8 245.0
SUBTOTAL
PLUS BPCTCA
TOTAL CAPITAL COST
INT. & DEP. AT 15%
4. For NSPS
Cost same as BATEA
TOTAL CAPITAL COST
INT. & DEP. AT 15%
Item Cost
14 93.0
18 19.8
21 1354.0
23 124.0
24 108.0
78 83.0 _
$2,647,000
$ 397,060
Item Cost
!5 147.0
16 95.0
17 237.0
26 430.0
29 193.0
$3,070,000
$2JL647j_000_
$5,717,000
$ 857,560
$5,717,000
$ 857,560
508
-------
Internal Power Requirements
I- Power Required To Achieve Pretreatment
90% of Item 3.
33% of Item 5.
75% of Item 9.
50% of Item 10.
33% of Item 12.
33% of Item 13.
33% of Item 14.
33% of Item 18.
90% of Item 21.
440 x 21. (Board)
665
22.5 x 56.2 (Tissue)
665
0.9 x 32.9
20% of Item 23. (For Board Machines)
440 x 15.2 = lo.l
665
0.2 x 10.1
20% of Item 24 (For Tlssue Machines)
225 x 11.5 = 3.9
665
33% of Item 28
0-2 x 3.9
TOTAL
13.89
19.01
KW-HR/T
0.27
0.50
5.54
0.06
0.01
0.00
0.07
0.00
29.61
2.02
0.78
0.76^
39.62 KW-HR/TON
509
-------
2. Power required to achieve BPCTCA
Item
3
5
9
10
12
13
KW-HR/T
0.30
1.51
7.38
0.11
0.03
o.oo
Item
14
18
21
23
24
28
KW-HR/T
0.22
0.00
32.90
10.10
3.90
— - —
58.72 KW-HR/T
TOTAL
3. Power required to achieve BATEA
Item KW-HR/T
2 - 1'30
4 10.80
6 56.50
7 2.43
8 -A^L
SUBTOTAL
PLUS BPCTCA
154.85 KW-HR/T
TOTA.L
4. Power Required for NSPS
Requirements same as BATEA
154.85 KW-HR/T
TOTAL CONNECTED
Item
15
16
17
26
29
KW-HR/T
1.73
0.57
3.70
17.16
.A^o
96.13
58.72
510
-------
C. External Cost
1. To Achieve the Pretreatment Level
Design Flow 50 K gal/T x 670 TPD x 1.5/1.3 = 38.7 MGD
Clarifier Flow 38.7 MGD x 47% = 18.2 MGD
Solids 48,819 #/D Dry Solids
53 Million Gal. @ 5 Years 20%
Black Liquor Spill Lagoon 2500 Gal. - D/T x 670 TPD = 1.67 MG
25% of the Cost
Unit Process:
Capital Depreciation and
Preliminary Treatment
Mill Effluent Pumping
Primary Clarification
Sludge Lagoon
Flow Monitoring
Outfall
Diffuser
Foam Control
Black Liquor Spill Lagoon
—""-••-' i •--. - -r, _
170
850
1500
540
36
504
240
85
25
J-I1UCJ. COL \?±\J\J\JJ
25
127
225
81
5
76
36
13
4
Operation and
Maintenance ($1000)
12
70
24
39
$592,000
TOTAL COST: $3,950,000
To Achieve BPCTA Treatment Level
Design Flow 36.5 K gal/T x 670 TPD x 1.5/1.3 = 28.2 MGD
$145,000
Solids
BOD
BOD
72% Removed x 103 #/T x 670 TPD x 92% of TSS to
Clarifier = 45,712 # Dry Solid/D
8.4% Removed Through Primary Clarifier
Influent to ASB 91.6% x 67 #/T x 670 TPD =
41,119 #/D
511
-------
BOD
BODr
Effluent 7.6 #/T x 670 TPD = 5902 #/D
= 35,217 #/D
• i - -^ 917 #/D = 704 Ac-Ft. = 230 MG
ASB - Biological = 3_5.,21/ tf/jj.
50 #/Ac-ft./D
ASB - Detention 28.2 MGD x 14 Days = 395 MG
Detention Controls
Aerators 1.25 #02/BODr x 35,217 |BODr/D x 1.6 = 70,434 #02/D
= 2934 #02/Hr.
H P. Required = 2934_J02/Hr^ = 1676 H.P.
-
Black Liquor Spill Lagoon 75% of the Cost
Unit Process^
Aerators
ASB
Vacuum Filter
Press
Flow Monitoring
Capital Cost
($10001
Depreciation and
Interest ($1000]
Operation
And Maintenance
$1000}
1700
4000
900
200
32
Black Liquor Spill Lagoon —75.
TOTAL COST: $6,907,000 $1,036,000
3. To Achieve BATEA Treatment Level
Design Flow 27 K gal/T x 670 TPD x 1.5/1.3 = 20.9 MGD
Caustic Flow 20.9 MGD (0.2) =4.2 MGD
225
600
135
30
5
11
200
151
205
28
$584,000
512
-------
Unit Process:
Mixed Media Filtration
Flow Monitoring
Mini Lime
Mill Effluent Pumping
Capital Cost
'$1000)
Depreciation and
_lnterest__($ip0pj
1700
28
840
580
255
4
126
87
Operation
And Maintenance
_($1000)_
300
154
$472,000
TOTAL COST: $3,148,000
To Achieve NSPS Treatment Level:
The calculations for NSPS are the same as those for the previous
treatment levels.
$499,000
UnitPrpcess:
" ' - —
Preliminary Treatment
Mill Effluent Pumping
Primary Clarification
Sludge Lagoon
Aerators
ASB
Vacuum Filtration
Press
Flow Monitoring
Outfall
Diffuser
Foam Control
Air Flotation
Secondary Clarification
(With Recycle)
Black Liquor Spill Lagoon
Capital Cost
($1000)
Depreciation and
130
580
1000
480
1400
3500
1500
200
28
371
100
65
440
2700
20
87
150
72
210
525
225
30
4
56
15
10
66
405
95
TOTAL COST:
$12,589,000
513
$1,889,000
Operation
And Maintenance
($1000)
8
45
20
155
133
244
31
35
42
290
$1,003,000
-------
D. External Power Requirements
1. Power Required for Systems Added to Achieve the Pretreatment Level.
Unit Process: KW-Hr/Ton
Preliminary Treatment 0.20
Mill Effluent Pumping 10.42
Primary Clarification 0-61
TOTAL: 11.21 KW-Hr/Ton
2. Power Required for Systems Added to Achieve the BPCTCA Treatment Level.
Unit Process: KW-Hr/Ton
Aerators 40.89
Vacuum Filtration 1.23
Press _0•41
SUBTOTAL: 42.53
Pretreatment 11.21
TOTAL: 53.74 KW-Hr/Ton
3. Power Required for Systems Added to Achieve the BATEA Treatment Level.
Unit Process; KW-Hr/Ton:
Mill Effluent Pumping 5.72
Minimum Lime 10-22
SUBTOTAL: 15.94
To Achieve BPCTCA: 53.74
TOTAL: 69.68
4. Power Required for System to Achieve the NSPS Treatment Level.
Unit Process KW-Hr/Ton
Preliminary Treatment 0.20
Mill Effluent Pumping 5.52
514
-------
Primary Clarification 0.41
Aeration 31.69
Vacuum Filtration 1.23
Press 0.20
Air Flotation 0.41
Secondary Clarification 3.27
TOTAL: 42.93 KW-Hr/Ton
515
-------
The costs discussed above
trical energy are shown in Table i/ui activated sludge
industry-wide basis.
"" "" ' '
ss.
in a place of ASB. require-
For approximate comparison Purposes j ^e^ernal treatment) are
utilizing these data,
"p^ceSs fn
^
Air_Pollution_Potential ^
BSS---SST- .
the subcategories. ^ biological
iru ssi str,-' <-« P,oblems.
516
-------
Tabie 170
AERATED STABILIZATION BASIN
ELECTRIC POWER COST
C1000 Per Year
Mill Size
Sulf it-
Dissolving Salfite
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Gr oundwood Chern :. /Mech
Grcurriwood Thermo /Nach
Groundwood C-H-M
Ground wood Fine
Soda
Non-Integrated Fine
Non-Integrated Tissue
I?.-n-Integrated Tissue (fwp)
530
557
230
600
7PO
670
670
300
300
150
300
300
100
110
110
Pretre-itfTient
164
115
44
113
129
248
245
35
23
21
49
95
13
26
25
RPOTCA
712
585
167
443
424
550
451
188
140
66
128
237
29
62
75
BATEA
918
985
178
981
1000
1098
990
353
302
149
293
477
37
70
80
NSPS
742
983
178
853
803
1017
946
346
298
153
293
441
39
71
80
517
-------
Table 171
WASTE ACTIVATED SLUDGE
ELECTRIC POWER COST
$1000 Per Year
Subcategor^r
Sulfite
Dissolving Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Groundwood Chcni/Mech
Groundwood Thermo/Mech
Groundwood C-M-N
Groundwood Fine
Soda
Non-Integrated fine
Non-Integrated Tissue
Non-Integrated Tissue (fwp)
Mil: Size
i'on/Day_
530
550
230
600
700
670
670
300
300
150
300
300
100
110
110
Pretreatment
164
115
44
113
129
248
245
35
23
21
49
95
13
26
25
BPCTCA
641
520
174
448
406
540
458
184
139
72
129
235
29
62
78
BATEA
846
919
185
986
982
1088
996
350
301
155
294
475
38
74
83
NSPS
665
808
173
806
743
992
907
329
297
145
281
419
37
69
76
518
-------
Table 172
AERATED Sr/UULIZATION
EK:,;c,f
u-:,..
jju_bcatpf;ory
Sulfite
n;- Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Groundwood Chemi/Mech
Groundwood Thermo/Mech
Groundwood C-M-N
Groundwood Fine
Soda
Non-Integrated Fine
Non-Integrated Tissue
Non-Integrated Tissue (fwp)
550
80
230
500
600
1000
350
700
250
670
1300
250
670
1300
100
300
600
100
300
600
75
150
500
150
300
550
300
700
30
100
280
15
35
110
450
15
35
110
450
-47.1
42.4
28.6
27.7
26.2
25.7
/-5.8
25.2
25.6
25.2
53.0
50.8
49.7
50.6
50.1
49.6
18.9
16.2
15.7
10.7
10.7
10.7
21.6
18.9
17.0
23.6
?? 2
22.0
43.3
42.2
18.0
18.0
18.0
31.8
31.8
31.8
31.8
31.7
31.7
31.7
31.7
CT
EPCTCA
BATF.A
NSPS
196.4
184.0
145.8
115.6
99.4
96.2
101.1
101.6
83.4
83.0
115.4
112.4
112.4
92.5
92.2
91.8
90.9
•'5.9
85.0
69.0
64.0
62.8
64.4
59.9
58.1
58.9
58. 1
56.3
108.2
107.7
41.4
40.2
39.8
80.4
78.5
77.4
76.7
97.0
94.3
93.9
92.8
249.4
237.2
245.4
120.1
105.8
10^.3
224.0
222.9
198.0
195.6
223.6
224..'.
221.6
204.0
702.3
200.6
165.9
161.4
160.5
142.7
138.1
136.9
140.4
135.8
133.7
134.8
134.0
131.8
217.6
215.8
51.0
50.6
49.9
90.1
87.9
86.7
85.9
103.1
100.3
99.9
98.6
JOS. 2
191.7
244.9
105.9
105.2
194.7
157.2
208.0
204.6
J03.5
1M.3
159.1
157.8
I55.
-------
Table 173
WASTE ACTIVATED SLUDGE
ELECTRICAL ENERGY REQUIREMENTS FOR THCATMENT
kwh/ton
Subcategory
Sulfite
Dissolving Sulfite
Deink
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Groundwood Cherai/Mech
Groun<" rood Thenno/Mech
Groundwood C-M-N
Groundwood Fine
Soda
Non-Integrated Fine
Non-Integrated Tissue
Non-Integrated Tissue (fwp)
Mill Size
Ton/Day
160
530
550
80
230
500
600
1000
350
700
250
670
1300
250
670
1300
100
300
600
100
300
600
75
150
500
150
300
550
300
700
30
100
280
15
35
110
450
15
35
110
450
Pretreatment
47.1
42.4
28.6
27.7
26.3
25.7
25.8
25.1
25.7
25.3
53.0
50.8
49.7
50.6
50.1
W.6
18.9
16.2
15.7
10.7
10.7
10.7
21.6
18.9
17.0
23.6
22.2
22.0
43.3
42.2
18.0
18.0
18.0
31.8
31.8
31.8
31.8
BPCTCA
BATEA
NSPS
31,
31
31
31.7
175.0
165.7
129.4
107.1
103.7
101.4
102.2
97.0
82.4
79.5
115.4
110.4
109.3
97.4
93.6
93.2
92.3
84.1
82.2
71.8
63.5
62.6
73.5
65.3
59.9
61.7
58.9
57.3
107.3
104.6
41.4
40.2
39.8
80.4
78.5
77.4
76.7
107.9
101.6
97.1
93.4
228.1
218.6
^8.9
111.6
uo.i
107.5
225.1
218.3
196.9
192.1
223.7
227.5
218.6
208.9
203.7
202.0
167.3
159.6
157.7
145.5
137.6
136.7
149.5
141 .7
135.5
137.6
134.4
132.8
216.7
212.7
59.2
55.0
52.2
92.3
96.4
91.9
89.2
114.0
107.5
103.1
99.2
179.1
172.0
201.3
102.9
100.3
184.0
145.4
702.9
199.5
185.5
182.8
153.6
150.4
148.8
144.1
135.8
134.9
140.4
137.1
127.1
131.2
128.5
127.1
191.2
185.4
50.8
48.1
85.6
82.9
94.5
93.6
520
-------
Table 174
Total Mm Energy Requirements-
en
ro
•<- ''HI. BiU/tnn
Pasergrade Sulfite 23
Dissolving Sulfite 23
Deink
11
Dissolving Kraft 24
Market Kraft 23
£CT Kraft
Fine Kraft
Grojpd/.ood
-te-i-Hech. ]?
SrcLjrid. oo;'
G • • ' ^
°';,"M"''-J°
15
o-ounc-.\c>od Fine •,
lo
;od-
24
•an-IPt-rated Fi-.. g
•-'• "'..>. -o re t^d Tissi:- 7
1 i t> ^ ^ 0 ( .^ iV. j o
^'-l ''J : -t ^ V° fl^CV--,., .
-••iv^ t.,gv.ny i"p,,, vv,,,. ,-i^
• ,,, '
^•"H/tOll
1250
1600
500
1050
1000
1300
1400
1700
1800
1800
1900
1300
700
425
425
iota!
KWH/ton pre
7985 r2
7735 ,9
3720 26
8075 26
7735 ,5
8325 51
8425 j0
6680 16
6485 n
6190 ,9
6290 22
8325 43
3335 -IQ
2475 32
2765 32
' i\jyt
184
146
99
101
83
112
92
86
64
60
59
108
40
77
77
'LiUfldl KWH/1
_BATEA_
237
245
106
224
196
225
202
161
138
136
J34
218
51
82
86
at
_NSPS_
192
245
106
195
157
208
194
158
136
140
134
201
5?
00
GO
85
^f!ts
-------
and returning
s-
in their immediate environs.
pffluent treatment
e
requirements in most insta™;es. appliances or are
-ol from
incinerators are negligible.
^U centre!. *i* e«ef a
losses, such as savealls, r^cj^2t recovery process, are not
removal of dregs and grits in the kr a« "cov^y^^ reco v ?f
producers of air P^f^; proSess, which, in addition to its
cooking chemicals in the kraft P^oc^ • materials and
atmosphere, they become ^^^"'o control them are described
mill. These emissions and measures o>Qr agency entitled
nrePePae Sessions in tL Wood Pulpin, -—
(125).
Noise_Pgtential
" no
.
from the operation o£ effluen- tre a jm ^^ Qf many year's of
SSSS"- °«i- Ho" 4 ireTe^SIT Jfi°.
complaints engendered by such noise are ^^ of most large
- t
ten in sorieneoo, t
JT ESS' Spfoy^lortl^-nf islenerauy lo»er than that
of some manufacturing machinery.
The sources of noise are for the most part Jj^^r^rocfsseS!
mechanical surface *e*^u *Hnvolved in sludge ^watering, and
vacuum pumps and centrif^!^rg with the exception of su^fac^
110""'^^^.!, operated in bu.ia.ngs
serve to muffle their noise.
SmaU surface aerators are genera! ly
f
522
-------
s2lid_Wastes_and_Their_piseosal
to the
solid
-
°*
in
practiced on a iiii.s preSs-S Slt'ia Dr^L,^ ^ ±S Sti11
vary with wet/dry weather etr' ?„ »J!-£? C6d ln amounts which
and trimmings in a paper mill
or burned.
" T
1S alS° true of broke
are ret«rned to the process
filters or scrubbers
devices such as bag
523
-------
and dreqs from the causticizing system of kraft and soda
rypSnts, inorganic solids, are generally water-carried to
a land disposal site.
Tntermittent washing of the reaction towers in calcium base
sulfit^ mills "every two months or so) produces a small amount of
grits!" ThesS are easily dewatered for land disposal or can be
sent to ash ponds.
n^inkina mills do not produce the large quantities of trash
aJnerSed in waste paperboard mills because of better quality raw
materials In 197 1? deinking accounted for only one percent of
the SduSiry-S solid wastes while the use of waste paper in other
processes contributed nine percent (303) .
from bark- and coal-fired boilers, screening rejects, in some
-
accessory ^pe^ _^ ^ d±sposal by contractOrs engaged
business.
=ss--ra
preparation of fresh cooking liquor.
recovery plant for its chemical or heat value.
Many kraft mills recover two byproducts from the P"^ Process
sras
these substances are pulped.
524
-------
and other
^^t^^!s^«^"I1^«ll^s?:1!
conaensates' or! in
525
-------
which
1-i.i.j.j. r~ I^^n ™i are> forecast. For exampi«, on^-u^-
recovery efficiencies (168)
- tine -s
prateran
reduces the recovery of tall oil J"a ^".j ^^ wastes,
^S^SSd.'iS'^.S: cSip Storage are other adverse factors
(163).
the next decade.
BY- Product s_of_Sulfite_PulEing
Table 175
1) those which use the whole liquor itselt, 2) proa b
lil: a
evaporator condensate (179) .
The first class .of liquor
\ o
to produce
526
-------
Table 175
MILLS MANUFACTURING SPENT SULFITE LIQUOR BYPRODUCTS
Mill Code Products
070 Ethanol
Lignin Products
051 Torul* Yea'-t
061 Lignin Products
402 Lignin Products
063 Evaporate
052 Lignin Products
056 Evaporate
066 Evaporate
527
-------
vanillin and other saleable materials (175] 1(172) such as
dispersing and emulsifying agents, some of which are used in
dyeing.
Fermentation products include ethanol and torula yeast which is
been steam stripped and returned to the acid plant.
The only ma-jor waste produced in the manufacture of spent sulfite
liquor evaporate are the condensates which amount to about 6260 1
e raw
carbohydrates -ponsible for a
percent of this parameter.
528
-------
IMPLEMENTATION_RE2UIREMENTS
sars
529
-------
tn
oo
o
Figure 8-1
Total Water Pollution Control Expenditures
-------
en
co
9CO
SCO
YEAR
1<5 SO
Figure Q2
Waste Water Treatment Equipment Sales
-------
The data in Figures 66 and 67 related to industrial
pollution expenditures include only those costs external to the
industrial activity. Internal process changes made to accomplish
water pollution control are not included.
Recent market studies have projected the total available
production capacity for water and waste water treatment
equipment. Mosfof them have indicated that the level of sales
S currently only 30-UO percent of the total available plant
capacity. several major manufacturers were contacted to verify
?hese figures and indications are that they are still Accurate
A partial reason for this overcapacity is that the demand for
equipment has been lower than anticipated. Produc^n,£ap^s'
has increased assuming Federal expenditures in accord with funds
authorized by Congress and conformance to compliance schedules.
For the immediate future, increased demands for waste water
treatment equipment can be absorbed by the existing overcapacity
Long term requirements will probably necessitate expansion of
production capacity in various product lines where the demand is
expected to increase dramatically — specifically, advanced
treatment systems and waste solids handling equipment.
It should also be noted that the capacity to produce waste water
treatment equipment could be expanded significantly through the
use of independent metal fabricators as subcontractors. Even at
-he present time independent fabricators are used by some
equipment manufacturers when work loads are heavy and excessive
shipping costs make it desirable to use a fabricator close to the
delivery site.
There appear to be no substantial geographical limitations to the
disteibStion of waste water treatment equipment to industry. In
various areas, certain suppliers may be more successful than
others- however, this seems to be related more to the
effSivenSss of the sales activities than to geographical
limiSion The use of independent metal fabricators as
^contractors to manufacture certain pieces of equipment further
reduced geographical limitations.
Equipment delivery schedules may vary substantially depending
upon the manufacturer, the current demand, and the specific
equipment in question. Obviously, the greater the demand or the
more specialized the equipment, the greater the delivery time.
Availability._of_Construction_Man20wer
After consultation with the Associated General Contractors of
facilities.
sa-srss?
532
-------
topr B of Labor statistios
Qonstruction_Cgst_index
The most detailed study and careful analysis of cost trends in
prior years still leave much to be desired in predicting
construction costs through the next ten years. Predicting
During the years 1955 through 1965 there was a very consist^nt
price rise. The Engineering News Record (ENR, Construction Cost
a
viations rom a
, costs rose at a steady rate to an index of 988 in
*• ?TiS rePresented an increased colt of 53 J
over an 11 year period of approximately five percent per
°f 1966 Saw an inc^ase of 6.6 percent th-n
f 6 2 oern ™ly t0-riSe Sharply a^ain in ^67 a? a rate
of 6.2 percent, then increasing to 9.4 percent in 1968.
The increase in costs continued to rise at about
^0"11 19?1' '
rates"'7 PTOent ^"^ «ue to larger
ncsdoPP8
f the Same rat€ durin^ ^e first six months of 197?
193 ?eX ^^ b€gan t0 leVel °ff durin^ th* lattL part of
1973 resulting in an increase of 6.8 percent for the
bewildering period in a quarter'c^tu^" 1S ^^^ the m°St
— material as well as labor".
capacity as well as actual incead
have caused ENR to revise its predictions
^
Building cost index and *7.5* for Construction Cost ?ndex
on June 20, 1974, further revised 1974 predic?ed Buildina
index increase to 10.3« and Construction Cost Indlx to 10 Ql
533
-------
• -ss? ^s
In spite of the sKyrocK eting cos, Ceases d
quarter of 1974, theKlon? "?9to^n araual increase of 8 percent,
?ndex would seem to be closer to an an nual^ Developments in the
the bases on which /^ur® °° "a down from the projected
industry may require ad justment s up or down cular year.
cost index for current program COSTS in y
Land_Reguirements
^r «« of exf rna!
evaluated and are shown in ^ £ dewaterea sludge has
Ssunmed?eThrM°Luaf,eSirgoacnsPbe used on-.it.. adrenal
land would be required.
TimeReguired.to.ConstrucS.Treaasent.Iacilitiei
" equired to cons, --Primary and se^ndary^f fluent
rereiiT, pj-wj^v-- ur-n ^ to 20 MGD,
•~«c, owainated were under 5 MGIJ, -> , £~.~
m^~ plant sizes evaluatea w~ ibilities evaluated were for
over 50 MGD. The contract P°8?"^;^ te or On a turnkey
engineering and construction to be separ
basis.
small mill with relatively small effluent ^£UJ®C5S^
TAX ^rvii 1 ft Vl3.V6 1 "t S P^ lIHai y «•* *_.-—j-»v\^i-»^1pi<^ OT1 c*. w •—— -
70) COUJ.Q nave .u fl if the contract was handiea un &
operation in 2.5 years " £" . treatment facilities hanax —
basis The majority of the etriue tion contracts, plus the
with separate engineering and cons turnk basiSf would be
medium and large mills handled
completed in 2.5 to 4.5 years.
534
-------
en
GO
en
x
LLJ
CD
i^
CJ
CD
CJ
3400
3000
2600
2200
IfcOC
1430
1000
1955
1960
1965
19t3
JUL
19177
510
LY 1963
~3-.20
1970
1973 1975 1977
1930
1963
YEAR
Figure 83
-------
MINIMUM f'RLA -RfOUl l-Lll FOR
WASTEvJAiLR TRLA H.LIi I
*SLUO'E IS LANDFILLED
0,000
4,000
3,000
2,000
900
BOO
TOO
SCO
500
400
SOO
UJ
CJ
60
50
40
N&TURAl
STABILIZATION
v* AERATED
STABILIZATION
A
ACTIVATED
SLUDGE
^
v PRIMARY
^ CLARIFICATION
..-
X'
X
/
X
XI..I-L
X
iu
j 4 68789 10
zo JO 40 BO 80 SO 100
nw - nnn «__
FIGURE 4
536
-------
537
-------
SECTION IX
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE (BPCTCA)
INTRODUCTION
The effluent limitations which must be achieved by July 1 1977
specify the degree of effluent reduction attainable through the
application of the BPCTCA, which is generally based upon the
average of the best existing performance by plants of various
sizes, ages, and unit processes within the industrial subcatecrorv
as discussed in detail below. m addition to the factors
mentioned above, consideration was given to:
a. the total cost of application of technology in relation
to the effluent reduction benefits to be achieved from
such application, including energy requirements.
b. the engineering aspects of the application of various
types of control techniques;
c. process changes;
d. non-water quality environmental impact.
Best Practicable Control Technology Currently Available
emphasizes treatment facilities at the end of a manufacturing
^C?!SrKbut *n°^UdeS the c°ntrol technologies within the process
itself when the latter are considered to be normal practice
within an industry.
on^rth^ consideration is the degree of economic feasibility and
engineering reliability which must be established for ?he
technology to be "currently available." As a result of
demonstration projects, pilot plants, and general use, there must
prac^icabil^or £ T" J^9 ±n the e^ineering and economic
practicability of the technology at the time of commencement of
construction or installation of the control facilities.
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF BPCTCA
Based upon the information available to the Agency
J haS Kbe!n made that the point source discharge
aions for each identified pollutant as shown in Table 176
can be attained through the application of the Best Practicable
Pollution Control Technology Currently Available.
IhL!r?a9e of .dailv values for any 30 consective days should not
exceed the maximum 30 day average limitations shown. The value
for one day should not exceed the daily maximum limitations shown
in this table. The limitations shown are in kilograms of
pollutant per metric ton of production (pounds of pollutant per
539
-------
Table 176
BPCTCA
Effluent Limitations in ka/kka/lbs/ton)
Sub category
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Papergrade Sulfito
Dissol v my Si 'f i te
GW-Chemi -Mechanical
GW-Thermo-Hechani cal
GW-CHN Papers
GW-Fine Papers
Soda
Deink
NI Fine Papers
H! Tissue Papers
NI Tissue (FWP)
pH for all subcategories shall
Subcategory
GW:Chemi -mechanical
GU:Thermo-mechanical
GW:CMN Papers
GW:Fine Papers
Maximum Jl"l n,iv Avpraoc
~BOU5" " ~T5S
1?. 95(25. 9) 15.55(31.1)
7.1 (14.2) 10.3 (20.6)
6. 35(1?. 7) 10.3 (20.6)
4.7 ( 9.4) 7.35(14.7)
15.2 (30.4) 21.15(42.3)
22.7 (45.4) "5.25(52.5)
3.5 ( 7.0) 5.9 (11.8)
2.6 ( 5.2) 4.45( 8.9)
4.2 ( 8.4) 7.0 (14.0)
3.75( 7.5) 6.45(12.9)
5.75(11.5) 8.3 (16.6)
7.0 (14.0) 12.65(25.3)
4.2 ( 8.4) 4.25( 8.5)
4.7 ( 9.4) <1.£5( 9.3)
4.7 ( 9.4) 4.65( 9.3)
not exceed 6.0 to 9.0
Zinc
Maximum 30 Dav Average
kg/kkg(lbs7ton)
0.125 (0.25)
0.095 (0.19)
0.150 (0.30)
0.135 (0.27)
Ma xi ir.1 m Day
BOU5 TSS
21.95(43.9) 34.05(68.1)
12.05(24.1) 22.6 (45.2)
10.75(21.5) 22.6 (45.2)
7.9 (15.8) 16.05(32.1)
25.75(51.5) 46.4 (92.6)
38.5 (77.0) 57.55(115.1)
5.95(11.9) 12.9 (25.8)
4.4 (8.8) 9.7 (19.4)
7.1 (14.2) 15.35(30.7)
6.75(12.7) 14.1 (28.2)
9.75(19.5) 18.2 (36.4)
11.9 (23.8) 27.7 (55.4)
7.1 (14.2) 9.35(18.7)
7.9 (15.3) TO. 25(^0. bj
7.9 (15.8) 10.25(20.5)
Maximum Day
kq/kkg(lbs/ton)
0.25 (0.50)
0.19 (0.38)
0.30 (0.60)
0.27 (0.54)
540
-------
ton of production). Effluents should always be within th« pH
range of 6.0 to 9.0.
Production in kkg (tons) is defined as annual tonnage produced
from pulp dryers (in the case of market pulp) and paper machines
(for paper/board) divided by the number of production days in the
12-month period. Pulp production is to be corrected, if
necessary, to the "air dry" moisture basis. No such correction
is necessary for paper/board production.
Allowance for Wet Woody_ard Operations
Irrespective of the wood pulping subcategories the allowanc^ for
BOD5 and TSS shown below can be added to the above effluent
limitations for mills with wet woodyard operations. Application
of the additional allowance only shall be made for that portion
of the total mills production attributable to the use of logs
specifically excluding any allowance for the portion of total
production attributable to purchased chips, purchased pulp, or
purchased waste paper.
The woodyard operations which qualify for this allowance are the
following:
1. Log ponds used for defreezing logs prior to
processing.
2. Log transport and defreeze flumes.
3. Log washing.
4. Wet debarking operations.
For mills using the above operations, the additional allowances
for BOD5 and TSS are shown below:
Max 30 day Max daily
Average Average
kg/kkg_llbs/ton)
~ ~
BOD5 0.5 (1.0) ~0.9~ (1.8)
TSS 0.75 (1.5) 1.6 (3.2)
IDENTIFICATION OF BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
Best Practicable Control Technology Currently Available varies
among the subcategories. Internal technologies are shown in
Tables 112 through 126 of Section VIII, and the external
technologies are shown in Table 127. The selected external
technology suggested as BPCTCA and the internal technologies
employed by the mills in each subcategory are discussed in detail
in Section VTI and VIII.
541
-------
It is emphasized here that these technologies are not of
themselves required. Due to economic, space, or other factors,
many mills may choose to use alternative technologies.
Conversely, some mills may choose technologies in addition to
those shown. For example, biological treatment is not included
for mills in the non-integrated tissue subcategory. The reason
is that many of these mills with only primary treatment have
achieved egual or better results than some others which also use
biological treatment. A specific mill within these subcategories
may, howeven, choose biological treatment as the most effective
method of meeting the limitations.
RATIONALE FOR THE SELECTION OF BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE
Age_and_Size_of_Eguip.ment_and_Facilities
There is a wide range, in both size and age, among mills in the
subcategories studied. However, internal operations of most
older mills have been upgraded, and most of these mills currently
operate very efficiently. The technology for upgrading of older
mills is well known within a given subcategory. Studies have
also shown that waste treatment plant performance does not relate
to mill size. There is no significant variation in either the
waste water characteristics or in the waste water loading rates,
in kg/kkg (Ib/ton), among mills of varying sizes.
Processes_Employed
All mills within each subcategory studied utilize the same_basic
production processes. Although there are deviations in equipment
and production procedures, these deviations do not significantly
alter the characteristics of the wastewater generated.
Treatability of all these wastes is similar.
Application of best practicable control technology currently
available does not require major changes in existing industrial
processes for the subcategories studied. incorporation of
additional systems, treatment processes, and control measures can
be accomplished in most cases through changes in piping, and
through modifications of existing equipment. Such alterations
can be carried out at all mills within a given subcategory.
The technology to achieve these effluent limitations is practiced
wi?hin ?he subcategories under study. The concepts are proven,
available for implementation, and applicable to the wastes in
question. The waste treatment techniques are also broadly
applied within many other industries. The technology required
will necessitate improved monitoring of waste discharges and ot
waste treatment components on the part of many mills, and may
recruire more extensive training of personnel in the operation and
maintenance of waste treatment facilities However, these
procedures are currently practiced in many mills and are common
practice in many other industries.
542
-------
N2nrWater_QualitY_Environmental_lmgact
The technology cited will not create any significant increase in
odors, or in noise levels beyond those observed in well-designed
municipal waste water treatment systems which currently are being
approved by the federal government for construction in populated
areas. Further, no hazardous chemicals are required as part of
this technology.
Cost of Application in Relation to Affluent Redaction Benefits
- - -
The total project costs of BPCTCA reflect an increase of
production expenses as shown in Tables 129 through 158 of Section
VIII. These increases reflect both all internal mill and
external waste treatment improvements. They are based on 360
days of production per year. it should be emphasized, however,
that most mills have already carried out many of these
improvements. Consequently, their increased costs would be l<=»ss
than those shown. The energy requirements associated with the
application of pollution control technologies are described in
Section VIII.
RATIONALE FOR SELECTION OF EFFLUENT LIMITATIONS
The rationale used in developing the effluent limitations for
BOD, TSS, zinc (groundwood subcategories only), and pH is
discussed below for each of the subcategories. Specifically
identified are the methods used to select the limitations for the
maximum 30 consective day average and the daily maximum value for
BOD and TSS. TO the extent possible, the effluent limitations
for both parameters are based on twelve months of data obtained
from nearly 200 mills during this study. The procedure for
selecting the mills in each subcategory whose external pollution
control facilities demonstrate a high level of performance is
also described in this section.
The development of the effluent limitations for each subcategory
are discussed in detail in the following paragraphs. The basic
approach used in determining the effluent limitations involved
(1) the establishment of raw waste loads for each subcategory
(see section V), (2) determination of external treatment
capabilities within each of the subcategories, and (3)
establishment of the effluent limitations using the raw waste
loads and external treatment capabilities. Specifically the
average effluent flow volume as determined for each subcategory
in Section V was used with the average of the BODS and TSS
concentrations presently being achieved by mills with well
designed and operated secondary treatment systems. The effluent
flow indicates the extent of inplant control measures in use at
mills within the subcategories, and use of the average flow per
subcategory in developing the effluent limitations inherently
543
-------
reflects a level of in plant waste water
which are commonly practiced. The use of the final effluent
average BODS and TSS concentrations from mills with adquately
designed and operated secondary treatment systems reflects basic
sanitary engineering concepts. By using the average ^ *£
each subcategory, mills using a normal level of in plant control
measures and well designed and operated external treatment should
be able to achieve the effluent limitations through use of BPCTCA
external treatment. It should be pointed out that the BODS and
TSS raw waste loads that were developed in Section V were used in
the development of the costs in Section VIII along with the
effluent flow values.
The selection of the BODS and TSS concentrations used in
determining the effluent' limitations involved thorough
evaluations of the external treatment systems at mills within
each of the subcategories. In several cases, mills achieved high
quality BODS concentrations in their effluents while the TSS
concentrations were very poor. In nearly every case, the poor
performance on TSS can be related directly to poor design and
Deration of the facilities (i.e. the design was based solely on
BODS removal without regard to TSS removal; for example, ASBs
with short detention times and adequate aeration horsepower
demonstrate low BCOSs and high TSS).
The effluent limitations were developed on an annual average
basis and ?hen multiplied by the variability factors developed in
section VII to determine the 30 consecutive day and maximum day
limitations. The flow values developed in Section V were based
upon 12 or more months of daily data when available. In
addition the final effluent concentrations represent averages ot
?2 mon?hs or'more of daily data. It should again be emphasized
that mill sampling, flow measurement, and laboratory analytical
techniques were thoroughly evaluated to assure that the mill data
used in the development of the effluent limitations was valid
Because of this, some mill data was eliminated from consideration
due to various deficiencies. For instance, a number of mills
measure TSS by non-standard methods using a paper filter rather
than by the standard procedure of using a glass fiber filter.
The twoanalytical procedures yield widely different results and
no correlation exists between the two tests. TSS data as
measured by non-standard methods was thereby not used in
determining effluent limitations.
Bleached_Kraft_Segment
Extensive effluent data were available for 28 bleached kraft
millS that have biological treatment facilities. Of the 28 mills
with treatment, 20 were determined to have biological treatment
systems capable of achieving high quality effluents. Three of
Se STmmS. however, were not achieving high quality TSS levels
due to apparent deficiencies in the design of their treatment
systems.
544
-------
177 h fnaeffentDS^an^TsT^lu? SUbcat^ory - Table
kg/kkg (Ibs/ton) and concentration/ ? Vre Sh°Wn in both
TSS data measured by non-standard ii^h',, discussed previously,
table. The most commonljp^cticef f± ^SK?X?luded fron> ***
practiced by these mills L abated 5?X-?* biological treatment
which is used by eleven millJ ao«ab^zatiOn basins (ASB)
(PS) ponds are used by eight ^iins AS^f°Howed by post storagl
treatment system is used by Sv« mills % ac*ivated ^ludge (A)
ASBs followed by clarification "r "s follSwed^ ^ millS USe
ar,
Also, shown in the tatte are* tnT^f^T in Table 178:
treatment system, and the final *ff?i* Subcate^oriesr the
Figure 71 presents a graphic disSlav of ^ ,TSS COnc^tration.
Table 177. The ob?ioSsbrtS Joint . fn* Prese"ted in
above which the slope of the curve K£ at 4° mg/1
-------
Table 177
Bleached Kraft Segment
Final Effluent Characteristics
FINAL EFFLJENT
Kill
V.;R;
-------
Table 177 cont'd
Bleached Kraft Segment
Final Effluent Characteristics
Continued
Hill
Size
Flow
FINAL EFFLUENT
r
1
1
i
f
1
F7\'F DflDFOC
r i me. rMr CJO
116
118
134
en
112
135
104
FINE & MARKET
103
105
101
T r\~i
107
no
120
Kkg/day( tons/day^
1043
174
857
522
580
1497
1217
385
473
517
281
1027
1052
(1150)
(192)
(945)
(575)
(640)
(1650)
(1342)
(425)
(522)
(570)
: (310)
(1132)
(1160)
kl/kkq(kqal/ton)
149.7
107.2
94.2
97.2
117.6
124.3
218.1
181.0
161.4
150.9
126.4
102.6
129.7
(35.9)
(25.7)
(22.6)
(23.3)
(28.2)
(29.8)
(52.3)
(43.4)
(38.7)
(36.2)
(30.3)
(24.6)
(31.1)
i reagent
C-ASB
C-A
C-ASB-C
C-A
C-ASB-C
C-A
C-A
C-ASB-PS
'C-ASB-PS
C-ASB-PS
C-A-PS
C-ASB-C
C-A
BODb
kg/kkgQbs/ton")
8.7 (17.5)
5.7 (11.5)
7.5 (15.1)
1.1 ( 2.2)
1.4 ( 2.9)
3.8 ( 7.6)
7.8 (15.7)
11.7 (23.5)
3.4 ( 6.9)
1.5 ( 3.0)
2-7 ( 5.4)
3.7 ( 7.4)
3.5 ( 7.1)
E3/1
58
54
80
11
12
31
36
65
21
10
21
36
27
TSS
. kg/kkgHba/ton) me/
40.9
24.1
3.2
29.9
4.7
3.f
22.5
6.7
13.8
(81.8)
(48.3)
( 5.5)
(59.8)
I \
v - ;
( 9.5)
( 7.8)
(45 )
\ -* /
(13.5)
(27.6)
273
255
33
240
~
26
24
15
.66
105
-------
TABLE 178
BLEACHED KRAFT SEGMENT
FINAl EFFLUENT BODS & TSS CONCENTRATIONS
BODS
Mill lybcat_ec^orj/ Treatment m_q/l
101 Fine & Market C-ASB-PS 10
130 Market SB-ASB 11
119 Fine C-A 11
112 Fine C-ASB-C 12
117 BCT & Market C-ASB 14 25
105 BCT C-ASB-PS 16
114 Market C-ASB 17 22
106 Fine & Market C-ASB-PS 21 24
111 BCT C-ASB 21 50
107 Fine & Market C-A-PS 21
127 Dissolving C-ASB 24 35
12^ BCT C-ASB-PS 27 29
120 Fine & Market C-A 27 106*
136 Fine C-A 31 240*
138 BCT & Market C-ASB 33 62
113 BCT & Market C-ASB 35
109 BCT C-ASB 36 104*
110 Fine & Market C-ASB-C 36 66
104 Fine & Tissue C-A 36
108 Dissolving C-ASB 40 47
Ave. 23.9 36.1
118 Fine C-A 54
116 Fine C-ASB 58 273
501 BCT & Market C-ASB 60 80
103 Fine & Market C-ASB-PS 65 26
134 Fine C-ASB-C 80 256
100 BCT & Market C-ASB-PS 94
140 Market C-ASB 98 103
122 BCT & Market C-ASB-PS 116 160
Ave.(all mills) 39.5 84.8
*only included in average for all mills
548
-------
Figure 86
BLFACIO KiiAFT SfGMfNl
SECONDARY .RJVTMENT Lf-l-LUENT BOD;, CONCENTRATIONS
o
CM
o
o
I
Note: Each data point ,-epre. ants
the final effluent 60D5
concentration from a single
bleached kraft mill's secondary
+>"eatrnent system.
o
OC)
in
a
O
CO
o
UD
-------
data is too limited to base any conclusions upon other than that
hiqh quality TSS concentrations can be achieved by ASB and A
treatment systems.
The final effluent BOD5 and TSS concentrations for the top 20
mills are separated into subcategories and presented in Table
180. The average concentrations are, in most cases, those used
in developing the effluent limitations and are described below.
Dissolving Kraft
Table 176 presents the BODS and TSS concentrations used with the
subcategory average effluent flow to determine the effluent
limitations on an annual average basis. As mentioned earilier in
Section IX, these values were then multiplied by the variability
factors developed in Section VII to determine the maximum 30
consecutive days and maximum day effluent limitations. The
factors used are shown in Table 182 and were used for all
subcategories.
As shown in Table 183, the BOD5 and TSS concentrations used as
the basis of the effluent limitations were 32 mg/1 and^40 mg/1
respectively, which were the averages of mill 127 and mill 108
(See Table 180) .
Market Kraft
The average BODS and TSS concentration for mills 114 and 130 were
14.0 mg/1 and 23.5 mg/1 respectively, as shown in Table 183.
Since these average values were near the best achieved by all
bleached kraft mills (See Table 180), the effluent limitations
were based upon 24 mg/1 and 36 mg/1 which were the average BOD5
and TSS concentrations, respectively, for the top 19 mills
(excluding mill 112) in the bleached kraft segment.
BCT Papers
The average BOD5 concentration used to determine the effluent
limitations was 25 mg/1 which is shown in Table 183 and developed
in Table 180 from mills in the BCT Papers Subcategory. The TSS
concentration used to determine the effluent limitations was 42
mg/1 which is an average of mills 111, 121, 117, and 138, the
latter two manufacturing both BCT papers and market pulp. Since
TSS data was available for only two mills in the BCT Paper and
the average TSS increased only slightly, the four mills were used
as the basis.
Fine Papers
As shown in Table 183, the average BODS and TSS concentrations
used in determining the effluent limitations were 26 mg/1 and 42
mg/1, respectively. The BODS value of 26 mg/1 was an average of
three mills in the fine papers subcategory. It should be noted
that the average for fine papers and fine and market
subcategories was 24 mg/1. The TSS value of 42 mg/1 is the same
550
-------
Table 179
External Treatment Facilities
Bleached Kraft Segment
Mill
• C
k1pd/m2(gpd/ft2)
100
101
102
103
1C4
105
105
107
103
109
en
^ no
m
112
113
114
116
117
27.70
14.26
10.96
18.33
32.39
'io.30
37.89
24.44
15.15
25.34
19.15
10.72
NA
19.64
14.26
87.30
20.37
•(680)
(350)
(269)
(450)
(795)
(400)
(930)
(600)
(372)
(622)
(470)
(263)
( NA)
(482)
(350)
(2155)
(500)
hrs
1785
440
ASB
days
4
20
4
20
-
14
10
5.5
16
6
13
8
3.75
15
10,5
2
14
1185
850
750
300
-
750
400
60
3225
1500
1020
1650
600
1990
1400
1170
480
C
klpd/m2(qpd/ft2
-
-
-
-
48.89 (1200)
-
-
16.30 (400)
-
-
19.96 (490)
-
25.99 (638).
-
-
-
_
PS
days
7
15
16.5
12.5
10-12
58
-------
m 1 1
118
119
-|20
en .„,
en i£l
ro
122
125
127
130
13i
136
138
501
lclpd/m2(<3Dd/ft2)
NA ( NA)
31.00 (751)
28.52 (700)
21.59 (530)
24.44 (600)
24.44 (600)
9.94 (244)
NA ( NA)
39.07 (959)
25.56 (652)
18.62 (457)
6.51 (162)
Table 179 cont'd
External "reatment Facilities
Bleached Kraft Segment
Continued
hrs hp
4.6 NA
7 NA
NA 2000
6.6 2500
ASB
days
3.6
12
10
8.5
7
6.5
14.5
6
f
1660
900
1300
1920
1030
1250
1950
1700
L
klpd/m2(gpd/ft2)
19.31
NA
(474)
( NA)
31.78
(780)
PS
days
7
197
24.5
-------
TABLE 180
BLEACHED KRAFT SEGMENT
BEST MILLS: FINAL EFFLUENT BOD5 & TSS
Mill
Market Pulp
114
130
AVJ.
BCT Papers
105
109
111
121
Ave.
BCT & Market
117
IT *}
13
138
Ave.
Ave. (BCT
Dissolving Pulp
127
108
Ave.
Fine Papers
119
136
104
Ave.
Fine & Market
106
101
107
110
120
Ave.
Ave. (Fine
Treatment
C-ASB
SB-ASB
C-ASB-PS
C-AS3
C-ASB
C-ASB-PS
C-ASB
C-ASB
C-ASB
, BCT & MKT)
C-ASB
C-ASB
C-A
C-A
C-A
C-ASB-PS
C-ASB-PS
C-A-PS
C-ASB-C
C-A
, Fine & Market)
BODS
M/l
17
11
14
16
36
21
27
25
14
35
w w
33
27
26
24
40
32
11
31
36
26
21
10
21
i— I
36
27
23
24
TSS
mcj/1
22
25
23.5
104*
50
29
39.5
25
62
43.5
41.5
34
47
40.5
33
240*
33
24
15
66
106*
35
34.5
*Not included in averages (see text)
553
-------
TABLE 181
BLEACHED KRAFT SEGMENT
TYPE TREATMENT VS BODS & TSS
BOD5(mg/1) TSS(mg/l)
Treatment j Mills Av£ RanSi * Mills Ave Rancje
ASB 9 26 11-4C 7 38 22-62
ASB-PS 4 19 10-27 3 23 15-29
A 4 26 11-36 1 33 33
ASB-C, A-PS 3 23 12-36 1 66 66
554
-------
Table 182
BPCTCA Variability Factors
555
TSS 1-61 3.53
-------
en
01
en
Table 183
Basis for BPCTCA Effluent LinntatTons
0 Summary
subcateqory.
BK: Dissolving
Kraft
BK: Market Kraft
BK: BCT Papers
BK: Fine Papers
Soda
GVl: Chemi-
Kechanical
GV(: Thermo-
Kechani cal
GV!: Fine Papers
GW: CMM Papers
Papergrade Sulfite
D-iisolviig Sulfite
Dei nk
M Fine Papers
;.I Tissue Papers
!-,T Tissue Papers
(FWP)
95.9 (23.0)
29
30
Annual Average
Flow
Itl/kkqtkgal/tonl
241.9 (58.0)
177.2 (42.5)
152.2 (36.5)
108.4 (26.0)
123.0 (29.5)
83.4 (20.0)
62.6 (15.0)
90.9 (21.8)
99.2 (23.8)
e 208.5 (50.0)
,e 271.9 (65.2)
94.2 (22.6)
62.6 (15.0)
95.9 (23.0)
BODS
Bfl/T
32
24
25
26
28
25
25
25
25
40
50
41
40
29
TSS
40
36
42
42
42
44
44
44
44
58
60
77
42
30
BOD5.
kq/kkqi'1bs/ton)_
7.75 (15.5)
4.25 ( 8.5)
3.8 ( 7.6)
2.8 (5.6)
3.45 ( 6.9)
2.1 ( 4-2)
1.55 ( 3.1)
2.25 ( 4.5)
2.5 ( 5.0)
9.1 (13.2)
13.6 (27.2)
4.2 ( 8.4)
2.5 ( 5.0)
2.8 ( 5.6)
L^H
-------
Groundwood_seament
summarized in T^Tss^ **"** **• The **•£ PaSeter^a^e
n _
)05 S JJ|(5«, lOez^8, J'J" 0.009(0.018,
>13 Na 461 SOft 94.7(22.7 J'^ 0.^4(0.887)
08 Zn ?flJJftifJ 85.5(20.5 n"H« 0-037(0.074)
10 No^ Io4 997 112(26.8,' J'J" 0.010(0.020)
14 Na gSi/n??* 179(42.9, °-®J2 0.099(0.197,
11 Na Sim i 97.6(23.4, °'°" 0.016(0.032
101(111) 48.8(11.7) «',3^ 0.034(0.068)
iree mills for which fla^a 0.010(0.019)
'
mills
557
-------
tn
m
CO
Table
GROUNDWOOD SEGM^IrnTCTTrc
FINAL EFFLUENT CHARAC I ERISTICS
onn TSS
BODr , ,, ,,,wn,nMh<
Mill
001
003
005
002
Size
kk£/d^tons/dayj_
85
492
505
194
( 94)
(542)
(557)
(214)
kl/kka(
91.
106.
98.
8
3
0
97.2
now
kgaj/tonl
(22.0)
(25.5)
(23.5)
(23.3)
SB-AS5-C
C-TF-C
SB-ASB
C-A
kSAk£ilPJ/tpni
n 1 1 ft ~\ \
2.1 ( 4- 1 )
8.0 (15.9)
o 1 I 4 T)
)
-3 3 ( 6.5)
«3»O \ w • w /
J-litLL
75
21
33
3.2
7.9
2.2
7.3
( 6.4)
(15.7)
( 4.4)
(14.6)
35
74
22
75
-------
Mill
001
OC2
003
005
klpd/m2(qpd/ft2)
NA ( NA)
18.09 (444)
37.81 (928)
NA ( NA)
hirs
Table 185
External Treatment Facilities
Gro'jndwood Segment
ASB
12 240
8 '320
TF
8 600
klpd/m2(qpd/ft2)
18.09
28.40
444
697
PS
jays
en
en
-------
effluent values
i *. u
maximum day limi*a^ respectively , which reflect
o,
treatment systems.
Sulfite Seqment
fluent data for the six .ills in the Sulfite
biol^cal ««hrensev2rfie??emf shoSw?" noted when evalua
noted on the table, several items these mil^s_ Mill
o «.nc
the »aste water from both the |alfi-e an ^ bioloqlcal
han
0?3 is a relatively new W^gt^ip^lil wastes and the paper
rss in;\ r S -ss^f iU"^
a portion of the was-c« *<* , . fine papers, and tne
BPCTCA internal
Lch'^rii^s "eat^t svste. !rrallvenshortithast
f I
presently achieving f"*^KSy. ixamination of some of the
e of 7.b aayt,
snow i_»«*^- .
detention time of 7.b
560
-------
en
Table 186
SULFIiF SEGMENT
FINAL EFFLUENT CHARACTERISTICS
Size
kkg/da,y(tons/day)
****
006*
007*
051
052
053***
501****
463
517
281
92
_
(510)
(570)
(310)
(101)
**
* includes groundwood puling
** Tv*a^£i ff*f+vt*\4-
IN 1 f I\I\\J \
79.6
95.9
193
169
121
effluents
i\ya I/ LUFiy
(19.1)
(23.0)
(46.2)
(40.6)
(29.0)
(\
- )
C-ASB
C-ASB
C-ASB
C-ASB
C-A, OAF
ASB-C
'
to
kg/kkgpbs/ton) me,/I
4.6 ( 9.1)
5.0 ( 9.9)
13.2 (26.4)
16.3 (32.5)
2.9 ( 5.8)
57
51
68
96
24
83
TSS
kg/kkg(lbs/ton) mg/1
- ( - ) -
8.6 (17.1) 44
7.5 (15.0) 61
-------
en
CT>
ro
Table 187
External Treatment Facilities
Sulfite Segment
. PS
C A
Xl11 jdpd/m2(gpd/ft2) hrs. JtE.
51
52
53
OC6
007
401
20.78
NA
NA
17.52
22.33
-
(510)
( NA) - -
( NA) 24 NA
(430)
(548) - -
~
ASB
days
7.5
10
12.6
6
7-8
HE
1600
374
1200
1100
3200
u
k^pd/m2(gpd/ft2)
"
19.56 430
-
-------
adequate design (i.e. 11 days, see Section VIII). m addition
operation of the treatment system has an effect upon effluent
K Th?, relatively high BOD5 concentrations being
by mill 051 can be attributed to both design and
rnonth™38 tW° °r three aerators are shut down during winter
effectiveness? Certainly has an effect "P™ the treatment
As discussed above, the treatment systems in use by sulfite mills
B?c?CAnorin,f T5^^^ high qUal±ty *fflue»ts representative of
BPCTCA primarily because of the design and operation of +he
^ha«m!S • ^^Kf' High <*ualitv effluents are presently being
achieved in the bleached kraft segment of the pulp and paper
industry by 20 mills for which effluent data from Seir
biological treatment systems were available. As graphically
displayed in Figure 75, BOD5 concentrations from blelched kraf?
mill treatment systems vary from 10 mg/1 to 116 mg/1 with a
data^nl th** **'?>*"*" ** "° "^ *™™™^™ of ?he e^fluen?
data and the treatment system design and operating parameters
above UO ma/rSn? ^ *** "^ treatment systems which Jchilvl
?herebv 1? In * ,, The "nge of hi<>h quality effluents was
avP™S oJ ^ x? Wlth an avera^e of 24 mg/1 BOD5 and a TSS
average of 36 mg/1. Because the treatment systems in use by
Pfifi«% mt *+ !re ^enerally not representative of BPCTCA, the
effluent limitations were based upon adequate design and
Saff iSla ftfeatrnJ facilities a* demonstrated by bleached
kraft mills. Adequate design and operation of the sulfite mill
treatment facilities should result in at least a final effluent
and" ^Ce?^ati?Vf.U° mg/1 {t°P end of Beached kraft rangeT?
based upoS aJU^/ilimrtHi0nS f°r V**^*te s««ite were theLby
??x^ uponcj0 m9/:L and the average subcategory flow of 208 5
kl/kkg (50.0 kgal/ton). The dissolving sulfite effluent
limitations were based upon 50 mg/1 which is conservative^ sine.
only one dissolving sulfite mill has any experience with
treatme and since the dissolving sulfite flow and
B05 rw n
BOD5 raw waste loads are higher than the papergrade sulfite
subcategory The TSS effluent limitations were baled upon 58
mg/1 for the papergrade sulfite subcategory and 60 mg/1 for *he
dissolving sulfite subcategory. The averagj TSS concentration
presently achieved by mill 051 is UU mg/1 which is relativelv
" -°thebleach9d ^t TSS average of 36 mg/1? "J^ve?
mill s h ve
Si aflS?Jin i J ^hieving high quality BOD5 concentrations and
the additional treatment required to achieve 40 mg/1 may generate
additional TSS in the form of biological organisms. Y AsSumJng
in theVtrL^ ? *** additional biological organisms are remSvel
in the treatment process (a very conservative assumption) and
applying the general rule-of-thumb of 0.227 kg (0.5 Ibs) of TSS
created per 0.454 kg (1.0 Ibs, of BODS destroyed yields 1*
level10nof 1Jam9/1,?f ^^ ^ f±nal e"lue^ above the presen?
if^J*. ^ mZ/l- Thus' the Papergrade sulfite effluent
ef?lnf i°n?-Wer.baSed UP°n 58 mg/1- The Dissolving su"
effluent limitations were based upon a conservative 60
ofCSpera?LthJ ^lari^ in waste wa?er char act erisXcIand c
of operating data from dissolving sulfite mills operating systems
representative of BPCTCA. The basis for the effluent SSitaSonl
563
-------
for the sulf ite subcategories are su.marized
maximum 30 ^"^tlriaSl^Y factors In Table 182 which
determined using the variability i*
developed in Section VII.
were
Two of the three mills in
treatment facilities and the
o( the treatment facilities
an, the design parameters
are
summarized in Table 189
mill 152 achieved 28 ^.f?0!/^/ mii£s 150 and 152 are not
treatment facilities utilized by mills indicated by the
considered to be rePresentati^?*s The BODS concentr
d TSS ~«*at "
effluent BOD5 and TSS
mill 152 are high
Sdicate a deficiency
facilities. The mill
consists of a clarifier
ASB. The ASB appears
The BODS concentrations of
. %he "TSS concentrations
• ± f the treatment
^displayed in Figure U2A
six days detention time
SIK Y
v . sx
by a SIK aeation capacity for
to a much less than normal
seSlon
level of TSS in the final effluent.
have an effect upon the
The effluent limitation^ .were based upon f m,/!
h
kraft segment. The soda
the blealhed Kraft
thereby the raw waste
Section III) and
treatability are
waste waters and
thsdaubcategory are
Table 183
The maximum 30
determined by '""-"^r^"^"^^
variability factors in Table
Deink_segment
564
-------
Mill
en
o»
Size
Table 188
CTM« SODA
FINAL EFFLUENT CHARACTERISTICS
Flow
150
152
262
548
(289)
(604)
158
110
KfliVton^
(37.9)
(26.3)
C-TF-C
C-ASB
35.2
3.1
BUU5
(70.3)
( 6.1)
222
28
23.7 (47.3) 150
11-7 (23.4) 107
-------
Mi 17
- TafaTs 739
txcernal Treatment Facilities
Soda * 6S
ASB
38'70
(1061)
6'f 60C
TF
35.44 870
en
-------
suen data for £. «« aeif .ills
facilities are shown JJ ^abie iv v- presented in Figure U2A
treatment facilities a* ^e*® "^^S ?able 191. The treatment
and the design Paramet?^ areshow aerated stabilization basins,
systems used by these ^llsV^e Activated sludge - aerated
activated sludge, and « modhJil 300 is located in the Southwest
stabilization basin sY^em. Mi JJ *™ ^ to achieve total recycle
and uses an ASB followed by £litr_u" with only 1.4 Says
ofwaste waters, *p18f ^fepower. The final effluent BOD5
detention time and 18 0 horsepo w er^ ^ ±g much ^ter
concentration from mill 204 was 108 mg ^5 by 7.2 days
than mill 203 which achieved on£Y 5 ^sed an ASB with six
detention time and 735 horsepower Mill 20^^^ ^ ^
days detention time and 180 horsepower tionSr these mill
AS indicated by their final j"{:utpcTCA as the detention times
treatment systems do not rePj?^nasB^presentative of BPCTCA (See
are less than that considered as ^PJ;^ ills 206 and 216 are
Section VIII) . The ef fluent Dualities from mill Evaluation f
significantly better than all of the othe ghQws t ^
eatment sem dg P adeuate
sgn
the mill treatment s?^em d|^g^16 Pare of relatively adequate
1
T
ma/1, respectively. i^ r^TT^ IOVP! of TSS in the tinai
mills 216 and 206 even though the ^c^ds°£hat normally achieved
effluent (110 mg/1) from mill 206 jxceeds ^ ^ natur Qf
by biological treatment. T^s P0^1^ yremove the impurities from
the manufacturing process which is to rem roduct. This
the waste paper in order to produ ce ^ ^^ ^ effect upon
St^dSlSng upon the types of waste paper
utilized.
The e«luen, libations were
ae, or is
Table 183.
30 consecutive
Non-integrated Fine Papers subcateqory
Effluent aa,a -rnon-in^ra-a fine paper .ill^is su»arf ea
two mills, 257 and 28U utilize biologica^^ concentrations
which data was available. Tne tin*
568
-------
en
cri
10
Table 190
DEINK bUBCATEGORY
FINAL EFFLUENT CHARACTERISTICS
Mi]1 -- ,, §?ze .. , Flow
Treatment B^DS TSS
203
204
206
205
216
349
181
673
89
72
(385)
(200)
(743)
( 98)
( 79)
75.
55.
102.
80.
79.
1
5
2
9
2
r\yu i / LUII i
(18.0)
(13.3)
(24.5)
(19.4)
(19.0)
C-ASB
C-ASB
C-ASB-C
C-ASB
C-A
Kg/K
14.
6.
3.
5.
4.
:xgi
8
0
2
4
2
Ibs/ton)
(29.6)
(11.9)
( 6.3)
(10.8)
( 8.3)
mg/1
197
108
31
67
52
kg/kkg(lbs/ton) mq/
10.6 (21.2) 141
( - )
11.3 (22.5) 110
( - ) -
3.6 ( 7.?) 4R
-------
Table |yi
External Treatment Facilities
D;ink Ssgment
ASB c PS
"111 klpd/.2(gpd/ft2) hrV da^ M ^M/^^l^ d^s.
. . 7.2 735 - -
1 4 IPO - -
_ _ 6 180 -
5 1400 19.31 (474)
5.3 NA - - 41-80 (1026>
203
204
205
2C5
215
30.56
9.93
13.85
11.41
21.35
(750)
(245)
(340)
(230)
(524)
en
o
-------
Tn »*Xi}« II £00 28a W6re 86 mg/1 and 110 m cases, removal of the
TSS also removes a large amount of the raw waste BODS. Three
forms of primary treatment are used by NI tissue mills- m
SSXofeS' (2>- DiSS°ird alr flot^i°n, and (3) Settling basins
anf ^ i^ aj^apajle °f achieving high quality levels of BOD5
Irt aSL S fluents from NI tissue mills. At times, chemical
are added as a coagulant to aid in BODS and TSS removal
Examination of the BODS and TSS levels achieved by mills in^ach
of the three groups results in the following conclusions?
Ji&STi1? e"^uents can *>* achieved with primary
treatment by mills using 100% purchased pulp or by mills
using varying proportions of waste paper and purchase!
(2) ciiiotUS^?- 10°%- T16 Paper and P^i^ry treatment
cannot achieve similar quality effluents as mills usina
purchased pulp with similar treatment systems? This ±1
571
-------
Table 192
NI FINE PAPERS SUBCATEGORY
FINAL EFFLUENT CHARACTERISTICS
Mill Size Flow Treatment BODS TSS
kl/kkg(kgal/ton) kg/kkg(1bs/ton) i,:g/l kg/kkg(lbs/con) mg/
266
261
257
255
250
281
275*
265
284
277
279
274
217
100
180
57
84
330
373
415
339
573
561
18
y w — • i — • / — —*^/ /
(239)
(no)
(199)
( 63)
( 93)
(364)
(411)
(458)
(374)
(632)
(618)
( 20)
49.2
26.3
40.0
37.9
53.8
73.0
90.5
69.2
25.8
80.5
37.5
138
(11.8)
( 6.3)
( 9.6)
( 9.D
(12.9)
(17.5)
(21.7)
(16.6)
( 6.2)
(19.3)
( 9.0)
(33.0)
C
C
C-A
C
SB
SB
C
C
C-ASB-C
C
SB
SB
4.4
1.7
3.5
-
4.8
2.6
14.7
5.6
2.9
10.6
8.7
4.6
( 8.7)
( 3.3)
( 6.9)
( - )
( 9.")
( 5.2)
(29.3)
(11.2)
( 5.7)
(21.1)
(17.3)
( 9.1)
88
63
86
-
90
36
162
81
no
131
230
33
1.3
-
-
6.3
0.8
1.7
11.7
-
2.7
-
7.4
2.0
( 2.6)
( - )
( - )
(12.5)
( 1.5)
( 3.4)
(23.4)
( - )
( 5.3)
( - )
(14. ?)
( 4.0)
26
-
-
1C5
14
22
125
-
102
-
196
V
* 20% Deink
-------
r . Table 193
L ?a! 'reatment Facilities
Kill Non-Inteorated Fine Segment
en
^j
Co
hrs AS8
"0 -- 1- days ho C
8-80 (216) ~^~ -B- LIed/m2(cipd/ft2) Ps
251 - ( ) " " 9 NA - L
257 „ " 90 30
253 32'63 ^) 22150 . - -
10-06 (247) " 32.63 801
3.5 60
-------
TABLE 194
NI TISSUE SEGMENT
FINAL EFFLUENT CHARACTERISTICS
Mill
Group 1*
3C3
325
313
315
3C6
252
319
Group 2*
208
329
302
310
334
309
333
259
326
Group 3*
330
312
Size
kkg/-day(tons/day)
FLOW
k1/kkg(kcia1/ton)
141.5 (156)
110.7 (122)
113.4 (125)
926.0 (1021)
85.3 (94)
44.4 (49)
20.0 (22)
94.3 (104)
67.1 (74)
205.0 (226)
41.7 (46)
229.5 (253)
18.1 (20)
147.8 (163)
176.0 (194)
59.0 (65)
115.5 (27.7)
130.9 (31.4)
140.5 (33.7)
66.3 (15.9)
43.4 (10.4)
48.0 (11.5)
120.1 (28.8)
Average (Group 1 )
61.3 (14.7)
153.9 (36.9)
50.9 (12.2)
96.7 (23.2)
94.7 (22.7)
69.6 (16.7)
133.4 (32.0)
73.8 (17.7)
72.6 (17.4)
Average (Group 2)
Average (Group 1 & 2)
18.1
33.6
(20)
(37)
79.2
27.9
(19.0)
(6.7)
Treatment
C
DAF
C
DAF
DAF
C-PS
SB
C
C
C-PS
C
SB
C
C
C,
C
BODC
kg/kkci(lbs/ton) mg/L
DAF
c-;.
4.5
17.5
3.5
4.4
1.0
3.4
2.5
3.3
6.2
6.1
3.3
2.7
1.4
1.9
4.8
3.9
2.4
3.5
3.5
11.6
11.5
(9.1)
(35.1)
(7.1)
(8.9)
(2.0)
(5.9)
(5.0)
(6.5)
(12.4)
(12.2)
(6.6)
(5.5)
(2-8)
(3.8)
(9.6)
(7.9)
(4.9)
(7.3)
(7.0)
(23.2)
(23.0)
39
134**
25
67
23
72
21
41
101
40
65
28
15
27
36
54
34
44
43
146
411
TSS
kg/kkg(lbs/ton) mg/L
3.8 (7.7)
4.6 (9.3)
1 1 (2.2)
- ( - )
3.2 (6.4)
3.2 (5.4)
3.5 (7.1)
- ( - )
3.0 (6.0)
1.5 (3.0)
1.9 (3.9)
- ( - )
2.6 (5.?.)
2.8 (5.7)
33
33
23
30
52
23
31
15
26
30
30
Average (Group 3) 53.4 (12.8)
11.5 (23.1)
278
*Group 1 mills use 100" purchased pulp;
Group 2 n.-:ils use purchased pulp and waste paper in varying proportions;
Grcup 3 mills use 100" v:aste paper.
**;;ot included in averages.
-------
(3)
TSS
mg/1
334 ,,-
319 if 16
306 Ot
309 |5 33
310 ,0
326 32* 31
333 i,
308 OQ
329 «« 33
259 II 23
302 ^c 26
315 |f
252 75
208 -,«, 23
-. ~». J-U J. c; o
325 -, -,,, 52
29 mg/1
was <9 mg/i. ThJTSS e^ - J^,?00^ , forage for alj'ie
The basis for the efflu^r,^ i7 -f f° a11 mills was 30 ma/1
BOD5 and 30 mg/1 for TSS with a f^ ^ thereby 29 mg/J foi
kgal/ton) (See Section V) TH^ m. °f 95-9 *l/kkg (23 0
maximum day limitations were det^^1^ 3° c°nsecutive days and
' 3lUeS by the ^mimultiPlying the InnSa
shou H the iabismultiPlying the
should be pointed out that- -i-ho ^Ln s ln Table 182
either the S Tissue Papers ^ l^^ limitations for mi
subcategory are idlntSS T?e H 5? NI tiSSUe P^ers (fWp
facilities included S BPCTCA lfferences ^ in the treatment
respectively. ln BPC?CA, primary VS. secondary
575
-------
SECTION X
BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE^BATEA)
INTRODUCTION
B-t e Ec Acb?^^- of the
be achieved not later than July ? 19^ ^ (BATEA) are to
upon an average of the be
-------
SubcatojoO'
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Papergrade Sulfite
Dissolving Sulfite
GW-Chcmi-Kechanical
GW-Thermo-Mechani cal
GW-CI-1N Papers
GH-Fine Papers
Soda
Deink
Nl Fine Papers
HI Tissue Papers
Ml Tissue
Table VJ5
BAT LA
ns in kg/kkg(1bs/ton)
til 1 UCI1L L
Maximiiii1 30_
BODV
5.45(10.9)
3.35( 6.7)
2.85( 5.7)
1.9 ( 3.8)
6.45(12.9)
8 35U6 71
1.25( 2.5)
1.1 ( 2.2)
1.75( 3.5)
1.65( 3.3)
2.4 ( 4.8)
2.5 ( 5.0)
1.25( 2.5)
2.0 ( 4.0)
2.0 ( 4.0)
HtUtClUIUJU ''' ' » y / p * " iJ \ ' ~
Dav Av< (vfP
"TSS
3.45( 6.9)
2.25( 4.5)
1.85( 3.7)
1.55( 3.1)
3.15( 6.3)
4.05( 8.1)
1.2 ( 2.0
0.65( 1.3)
1.3 ( 2.6)
1.2 ( 2.4)
1.55( 3.1)
2.4 ( 4.8)
0.65( 1.3)
0.95( 1.9)
0.95( 1.9)
Maxjnuini.
.
11.25(22.5)
6.9 (13.8)
5.9 (11.8)
4.0 ( 8.0)
13.3 (26.6)
17.3 (34.6)
2.6 ( 5.2)
2.25( 4.5)
3.65( 7.3)
3.45( 6.9)
5.0 (10.0)
5.2 (10.4)
2.6 ( 5.2)
4.15( 8.3)
4. .5( 8.3)
Day
TSS
~ • •
.7.6 (15.2)
4.95(.9.9)
4.05( 8.1)
3.35( 6.7)
6.9 (13.8)
8.85(17.7)
2.65( 5.3)
1.4 ( 2.8)
2.8 ( 5.6)
1.0 ( 2.0)
3.35( 6.7)
5.3 (10.6)
1.4 ( 2.8)
2.1 ( 4.2)
2.1 ( 4.2)
pH for all subcategories shall not exceed 6.0 to 9.0
Color
Subcategory
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Soda
Maximum 30 Day Average
125 (250)
95.0 (190)
65.0 (130)
65.0 (130)
65.0 (130)
Maximum Day
250
190 (380)
130 (260)
130 (260)
130 (260)
Zinc
Subcategory
GVJiCneini-inccnanical
GW:Therroo-mechanica1
GU:CMN Papers
GW:Fine Papers
Maximum 30 Dav Average
0.115 (0.23)
0.065 (0.13)
0.120 (0.24)
0.115 (0.23)
Maximum Day
0.23 (0.46)
0.13 (0.26)
0.24 (0.48)
0.23 (0.40)
578
-------
. a
- — 6I§I MBttMLB TECHNOLOGY |SONOHICteLY
579
-------
It is emphasized here that these technologies are jot of
themselves required. Due to economic, space, or other factors,
manv mills may choose to use alternative technologies.
ConversSy, some mills may choose technologies other than those
indicated above.
RATIONALE FOR THE SELECTION OF THE BEST AVAILABLE TECHNOLOGY
ECgNOMICALLY~ACHIEyABLE
Aa§_and_Size_of_EguiEment_and_Facilities
There is a wide range, in both size and age, among mills in the
subcategories studies. However, internal operations of most
Side? mi?ls have been upgraded, and most of these mills currently
SS^T^US^
SSif ^SecSons* £~ 5JT3S' is^i™* b Sis^
Se-uS^or SyVSe wal^ "^^^^M
within a subcategory.
Proc ess es Employed
All mills within each subcategory studied utilize the same basic
pioduciion processes. Although there are deviations in ^P"f J*
and production procedures, these deviations do not significantly
alter the characteristics of the waste water generated. The
treatability of these wastes, is similar.
p
».l systes treats "t Proc-ses and
SS cic.s e
i o
equipmlnt? Such alterations can be carried out by mills within
given subcategory.
Engineej-ing_AsEects_qf_th^^
Much of the technology to achieve these effluent limitations is
practiced wi?hin the pulp and paper industry by /fr^^rk'nas
in a given subcategory. Sufficient research and pilo * ^ J"
been carried out on color Removal to demonstrate the feasibility
of achieving the recommended effluent limitations after
completion of additional demonstration studies. The technology
?2qui?ed ror all best available treatment and control systems
will necessitate sophisticated monitoring, sampling, and control
programs, as well as properly trained personnel.
580
-------
*0»»s aaaste, a,
The total projected costs of BATEA rofi *r.+ .
s;?rj£.rssu.s ssSdi-.s?^"5 F-* "s.1;?1^^
waste improvements In! tSly fie base^on^lo ££r°Vnd eitt«"^
their
H2nzWater_Qualiti-_Environmental_lEEact
signi(icant increase in
S
RATIONALE TOR SELECTION OF EFFLUENT LIMITATIONS
"""ations for
is the rationale for the color iim?Lf • 5 he Subcategories as
and soda subcategories Specif ic^l^ ^\^ ^ bleached kraft
used to establish the limi?ation^ S 1?®ntxfied are the methods
and the daily etO<
a eapou
identified in Section VI ?i? Pollution control technologies
The general approach in detenriinina the pffi»en4. i • -^
given below: «-«u.iiing rne etfluent limitations is
3.
581
-------
U The raw waste load achievable by the best mill or mills
in each subcategory by the use of BATEA was thus
established.
5 The effluent reduction capabilities of the identified
external treatment systems were than used in conjunction
with the established raw waste load per subcategory to
determine the effluent limitations.
The maximum 30 consecutive days and maximum day limitations were
determined by multiplying the annual average values by the
variability factors shown in Table 196. The development of the
variability factors is discussed in Section VII. It should be
pointed out that the variability factors used for the BATEA
limitations are the same or slightly higher than those used for
the BPCTCA limitations.
Table 197 summarizes the BATEA raw waste loads and BOD5 and TSS
concentrations for each subcategory used as the basis for the
BATEA limitations.
Bieached_Kraft_segment
Dissolving Kraft Subcategory
The dissolving kraft raw waste load was based upon mill 127 which
had the following flow, BOD5, and TSS raw waste loads:
Flow: 229.3 kl/kkg (55.0 kgal/ton)
BODS: UO kl/kkg (80 Ibs/ton)
TSsT 87.5 kl/kkg (175 Ibs/ton)
Evaluation of the in plant controls presently in use at mill 127
and the additional controls identified as BATEA in Section VIII
resulted in the following estimates of RWL reduction:
Flow: 12.5 kl/kkg (3.0 kgal/ton)
BOD5: 2.5 kg/kkg (5.0 Ibs/ton)
TSS: 2.5 kg/kkg (5.0 Ibs/ton)
Thus, the BATEA RWL for the dissolving kraft subcategory were the
following:
Flow: 216.8 kl/kkg (52.0 kgal/ton)
BOD5: 37.5 kg/kkg (75.0 Ibs/ton)
TSsT 85.0 kg/kkg (170.0 Ibs/ton)
Mill 127 presently achieves 24 mg/1 BOD5 in the final effluent
from the aerated stabilization basin which is the best quality
effluent of the two mills in the dissolving kraft subcategory
that have biological treatment facilities. This level of BOD5
is, however, higher than that achieved by many other mills in the
bleached kraft segment. Table 198 presents BOD5 and TSS
concentration for the top seven bleached kraft mills which were
derived from Table 180 in Section IX. As shown, the averages for
582
-------
Table 196
BAi'EA Variability Factors
583
-------
Table J97
Ban's for BATEA Effluent Limitations
Annual Averages
S'.bcateqory k
EK:
S'<:
H:
Ul\ I
Dissolving Kraft
Market Kraft
BCT Papers
Fine Papers
Scda
GV,' :
GV,':
GVI :
co GV;:
Par
Cheni -Mechanical
Therno-Xechanical
Fine Papers
C;'-"< Papers
,3rsrade Sulfite
Dissolving Sulfite
Deink
M
v T
•;i
Fire Papers
Tissue Papers
Tissue Papers (FWP)
Flow
L1/kkq(kqal/ton)_
216.3
141.4
112.3
95.7
95.7
74.9
41.7
74.9
79.0
176.8
249.6
74.9
38.4
60.5
60. 1
(52.0)
(34.0)
(27.0)
(23.0)
(23.0)
(18.0)
(10.0)
(18.0)
(19.0)
(42.5)
(60.0)
(18.0)
( 9.2)
(14.5)
(14.5)
me /I
15
14
15
15
15
10
15
13
13
20
20
nf\
20
on
20
20
20
TSS
mg/1
in
i u
i n
1 U
in
i \j
in
I w
i n
1 U
10
1 w
in
1 \J
in
1 U
in
1 \J
in
1 U
in
1 U
70
C,\J
10
1 \s
in
1 U
in
1 U
BODS
kg/kkg(lbs/ton) _.
3.25 (6.5)
2.0
1.7
1.15
1.45
0.75
0.65
1.0
1.05
3.85
5.0
1.5
0.75
1.2
1.2
(4.
(3.
(2.
0
4)
3)
(2.4)
(1.5)
(1-3)
(2.0)
(2
(7
(10
(3
(1
.1)
.7)
.0)
.0)
.5)
(2.4)
(2.4)
TSS
ka/kkq(lbs/ton)
2.
1 .
1.
0.
0.
0.
15
4
15
95
95
75
0.4
,
0
1
1
1
*rr
. /3
.8
.95
.5
.5
0.4
1
1
.2
.2
(4.3)
(2.8)
(2.3)
(1.9)
(1.9)
(1.5)
(0.8)
.
• •*/
(1-6)
(3.9)
(3.0)
(3.0)
(0.8)
(2.4)
(2.4)
-------
en
oo
en
Table 1198
Bleached Kraft Segment
Best Final Effluent BODs & TSS Concentration
Subcategory_ Treatment
101 Fine & Market
130 Market
119 Fine
"2 Fine
117 BCT & Market
105 BCT
114 Market
Average
C-ASB-PS
SB-ASB
C-A
C-ASB-C
C-ASB
C-ASB-PS
C-ASB
ng/1
10
11
n
12
14
16
17
13
mg/1
15
25
33
_
25
_
22
24
-------
BOD5 and TSS for the
treatment system and the dition of etri VIII should allow
reduces TSS to leve Is between 5 ^duciOn approximately 20% of
Is^e.oSef bffStratfon/Ire effiuen? limitations were
upo-n IS^/l BOD5 and 10 mg/1 TSS.
Market Kraft Subcategory
The mar,et Kraft subcateory raw waste load was
limitations were based upon mill 11» "hl^ehj°t|rnai, controls in
"
ern,
kl/kkq (»!.» kqal/ton). Ev ^"^^/^toi reductions of about
e te load hic, , was
.
and mo. Evaluation of .8005 reductions of
-
l.
controls not yet in use by mill 130 and .nat ~d waste
achievable as demonstrated by mill 140. The estima-ce
loads for BATEA were the following:
Flow 141.8 kl/kkg (34.0 kgal/ton)
BoSsi 26.5 kg/kkg (53.0 Ibs/ton)
TSST 65.0 kg/kkg (130 Ibs/ton)
The effluent limitations for BATEA were based upon 10
and 14 mg/1 BOD5 in conduction «^ «j;;° ^hl coagulation and
As discussed previously, the capabilities ot eff^uents of 5 -
filtration systems results in levels or averae of mills
asss
systems of the biological treatment effluents.
Bleached Kraft - BCT Papers Subcategory
^^^
Vlow- 134.7 kl/kkg (32.3 kgal/tpn)
BoS?i 30.8 kg/kkg (61.6 Ibs/ton)
Tssl 51.5 kg/kkg (103 Ibs/ton)
586
-------
TSS:
<5-° *gal/ton)
. kg/kkg (10.0 Ibs/ton)
5.0 kg/kkg (10.0 Ibs/ton)
TSS:
(27'°
26.0 kg/kkg (52.0 Ibs/ton)
46.5 kg/kkg (93.0 Ibs/ton)
fina! eff!uent EOD5 concentraons5
Bleached Kraft - Fine Papers Subcategory
TSS:
(23-3 kgal/ton)
23.4 kg/kkg (46.7 Ibs/ton)
46.5 kg/kkg (92.9 Ibs/ton)
TSS:
(23.0 kgal/ton)
23.5 kg/kkg (47.0 Ibs/ton)
46.5 kg/kkg (93.0 Ibs/ton)
The TSS i«
119 and 112
respect.vely,
of 10
mg/1' respective
by the activated
prcss
587
-------
activat-d sludge - aerated stabilization basin treatment process
T£e Affluent limitation was thereby based upon 12 mg/1.
Color Limitations
The color effluent limitations were based upon the color data
presented in Table 37 in Section V. Analysis of the data in .he
?esnec?lv*?y. It should be pointed out that the data used in
d-ermlnlng ^hese color RWL is the highest of stream 09 or stream
7Q data per mill in Table 37. The dissolving kraft and market
Kra?f RWL were Cased upon mills 127 and 114 re spectively,
whereas the BCT RWL was based upon mills 105, 125, jnd 117^
Mills 101, 110, 106, 116, and 119 were used as the basis for the
fine RWL.
«U,b?f SS« values fothose breams. As ai.oussed in
coreuc
by massive lime process can achieve similar results (247)
colo
ef lensa
72% «32?! SBATEA internal controls such as extensive spill
control and more efficient liquor recovery, it is estimated that
basSdu^n 212.5 kg/*Kq (»« Ibs/ton) which was »
mills manufaoturinq various proportions of BCT
rSelf Tar^f ^ o^cofor^ "Sr J
proportions of fine papers and market pulp.
Sgda_Segment
s-lksssr^ "^•n«1r02.r;ist;ssriig sr.s
JSlls ill and 152. The average flow and EOD5 RWL for .His 151
and 152 are shown below:
FLOW: 105.9 kl/kkg (25.4 kga I/ton)
588
-------
BOD5: 35.7
OD5: 35.7 kg/kkg (n>, ^^
23! &'4JjSV?:,» Je
23!
5
«* *
j \ — — vr J.UO/T torji
ta - "
taions
were the
Chemi^echanical Subcategory
'
589
-------
1 kl/kkq (18.0 kgal/ton)
(90.0 Ibs/ton)
CW.O Ibs/ton,
Durinq
cnsn,
TSS.
GW- Thermo-mechanical Subcategory
001 has achieved an
a trea, «£ ^«
GW- ^ ^
2
few .ills in
(50.0
country fesentlyausing .he
thermo-m
mills in
GW: Fine Papers Subcategory
GW: Fine ap
an/?T, orless than , 3** ^ ly which couia
«
-
iaen
590
-------
=S €« = :SF='5Ks» ss
CMN Papers Subcategory
RWL was 52.9 kl/kka no ,-oa?sr i.e. mill 009 «s flow ^n
Since none of the mi no
previously. was bas^ upon 10 mg/1 Js
Groundwood Subcategorles Zinc Umitations
Papergrade sulfite Subcategory
591
-------
(42.5 kga I/ton)
(137 Ibs/ton,
— -
.
mill 66 sznce TSS flat ^^ ^Q d
1 "
-n
Dlssolvinq sulfite subcategory
aiscussed prev.ousXv-
su
boategory
-
,
.. -
3S32S
•the
mill and "the
the effluent limitations
(250 Ibs/ton)
"
TSS
determination o
sulfite subcategory.
for
592
-------
s
BATEA controls identified in Section
that a flow rate of 75.1 kl/kkg n* 0
BATEA. AS discussed in Section v
TSS are related to thT J?£e of
BATEA BOD5 and TSS raw waste i
costs were the same usefas for
costs were developed for the
VIII. F rne
3nd
«8ulted in estimating
k^al/J°n) was achievable by
1** raW Waste BOD^ and
Pf?er utilized* and the
^J. devel°P^nt of the
\ manner, maximum
systems costed in Section
waste loads .can occur
n
varying
Ngnrintearated_PaEer_Mills_Segment
N.I. Fine Papers Subcategory
the extent of internal contols a each
indxcator of the extent of in plan?
the mills which achieved low"r flSw
of 62.4 ki/kkg (15.0
as shown below:
™ relation to
Sxn°e flow is a"
Paper mills'
Ml11
Flow
kl/kkg (kgal/ton) kg/kkg
37-9
Si
.
an ascending order
BODS
(bs/ton,
- -
75
Ui,
43;6 «67
33.8 (67.6)
kgal/ton).
an .
and above 40.0 kl/kkg (9.6
was 38.3
thoS9 mills
593
-------
in determining the BATE* effluent limi tat ions and in
the costs. The BATEA BOD| raw waste load of ^ presentea
Ibs/ton) was based upon an ^rage than all Qf
above excluding mill 276 whose BUU^ *** f data the BATEA TSS raw
the other values Because of a lack °f waf Jssentially the same
waste load of 30.0 kg/kkg (60.0 lbs£°^ ld be nOted that this
capabilities of the BATEA internal controls.
The BATEA Affluent limitations were based upon 38.3^/KKg^ ^2
kgal/ton) and BOD5 and TSS leve^ ° x h J been shovm to be
respectively. BOD5 level?°* *? /Ireatmen? systems in other
achievable by mills usin^^i°^|^ent^fmitSionI were based upon
r^servaXve H?rmg>l!heTnef SSoniJTfor the TSS level of 10
mg/1 has been discussed previously.
NI Tissue Papers Subcategory
for the NI tissue papers subcategory was
for the NI ti v ypapers subcategory
*« ® lower flow rates
kgal/ton) were
The BATEA raw
developed in a similar
raw waste load. The
"
ibs/ton,
306
252
309A
48. 0 (11.5)
ai:
69.6 (16.7)
( ; ) [ _
I; '" -
29.3)* - (
Ave 60.5 (14.5) 10.0 (20.0)
*Not included in average
were
The BATEA flow was
than the BPCTCA average ;;heab0ve eight mills that
Ibs/ton) was b^ed upon three of th^above^g ^^ ioa
achieving better than the ^"^f^ waste load. The TSS raw
used as the basis for the BATEA BOD^ ^ based UpOn an
^frage'ofmifls 259A, 5fof andSoB whose TSS levels demonstrated
relatively high control of TSS
The BM-E* effluent
"'S
of the
BOO5 and TSS
594
-------
subcaLgory! PreVi°USly "-cussed for the Ni fine papers
NI Tissue Papers (fwp) Subcategory
Section IX. The BODS^nJ^TQ?™ fJ^f^f??*;7 as. Discussed in
r
595
-------
Table i99
NSPS
FfriucrM Limitations in 1 ../
'- '-* fiaxiirui.; Day
Dissolving Kraft
Market Kraft
BCT Kraft
Fine Kraft
Papergrade Sulfite
Dissolving Sulfite
GW-Chemi -Mechanical
GVJ-Thermo-Mechanical
GW-CHN Papers
GW-Fine Papers
Soda
Dei k
NI Tine Papers
NI Tissue Papers
NI Tissue (FWP)
pH for all subcategories
Subcategory
GW: Chemi -mechanical
GVhThermo-mechanical
GW-.CMN Papers
GW:Fine Papers
C()iJ5
5.45(10.9)
1.85( 3.7)
2.85( 5.7)
1.9 ( 3.8)
4.1 ( 8.2)
8.35(16.7)
1.25( 2.5)
2.6 ( 5.2)
1.75( 3.5)
1.65( 3.3)
2.4 ( 4.8)
3.75( 7.5)
1.25( 2.5)
2.0 ( 4.0)
2.0 (4.0)
shall not exceed 6.0 to
0.115 (0.23)
0.095 (0.19)
0.120 (0.24)
0.115 (0.23)
rss
7.0 (14.0)
2.6 ( 5.2)
3.6 ( 7.2)
3.05( 6.1)
3.95( 7.9)
8.05(16.1)
2.4 ( 4.8)
2.0 ( 4.0)
2.6 ( 5.2)
2.4 ( 4.8)
3.05( 6.1)
3.6 ( 7.2)
1.2 ( 2.4)
1.85( 3.7)
1.85( 3.7)
9.0
Zinc
/crage
»).
BODS TSS
11.25(22.5) 15.35(30.7)
3.8 ( 7.6) 5.65(11.3)
5.9 (11.8) 7.95(15.9)
4.0 ( 8.0) 6.7 (13.4)
8.5 (17.0) 8.65(17.3)
17.3 (34.6) 17.65(35.3)
2.6 ( 5.2) 5.3 (10.6)
5.35(10.7) 4.4 ( 8.8)
3.65( 7.3) 5.65(11.3)
3.45( 6.9) 5.3 (10.6)
5,0 (10.0) 6.7 (13.4)
7.8 (15.6) 7.95(15.9)
2.6 ( 5.2) 2.65( 5.3)
4.1?'' 8.3) 4.25( 8.^)
4.15( 8.3) 4.25( 8.5)
Maximum Day
kq/kkgQbs/tonl
0.23 (0.46)
0.13 (0.26)
0.24 (0.48)
0.23 (0.46)
598
-------
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS (NSPS)
INTRODUCTION
This level of technology is to be achieved by new sources. The
term "new source" is defined in the Act to mean "any source, the
construction of which is commenced after the publication of
proposed regulations prescribing a standard of performance."
Such commencement of construction can occur within the near
future, certainly before the 1977 or 1983 compliance dates for
best practicable or best achievable technologies.
The New Source Performance Standards (NSPS) are predicated on the
application of the Best Available Technolgoy Economically Achiev-
able. These standards are thus not based upon an average of the
best performance within a given subcategory under study, but have
been determined by identifying the best demonstrated control and
treatment technology employed by the specific point source within
a given subcategory. Consideration was also given to:
a. The type of process employed and process changes;
b. Operating methods;
c. The engineering aspects of the application of control
technologies;
d. the cost of application in relation to effluent reduction
benefits (including energy requirements);
e. The non-water quality environmental impact;
f. Use of alternative raw materials and mixes of raw materials;
g. Use of dry rather than wet processes (including substitution
of recoverable solvents for water);
h. Recovery of pollutants as byproducts.
EFFLUENT REDUCTIONS ATTAINABLE THROUGH THE APPLICATION OF NEW
SOURCE PERFORMANCE STANDARDj
Based upon the information available to the Agency, the point
source discharge standards for each identified pollutant are
shown in Table 199 and can be attained through the application of
appropriate internal and external control technologies.
The average of daily values for any 30 consecutive days should
not exceed the maximum 30 consecutive days average standards also
shown in Table 199. The value for any one day should not exceed
the daily maximum standards shown in this table. The standards
shown are in kilograms of pollutant per metric ton of production
(pounds of pollutant per ton of production). Effluents should
always be within the pH range of 6.0 to 9.0.
Production in kkg/(tons) is defined as annual tonnage produced
from pulp dryers (in the case of market pulp) and paper machines
597
-------
»°
,. 3
IDENTIFICATION OF TECHNnroov ^
- -ctaol;;T ~ i2 f *" ~-
Si'S,"1^^ ^""-iS-K'^'S"?^- " i-
3ta9e than inS^iSfS^^ " «» ^ti."^^!^.^
599
-------
RATIONALE FOR SELECTION OF TECHNOLOGY FOR NEW SOURCE PERFORMANCE
STANDARDS
It will be mandatory, however, to utilize the well-
S?ag'if sPS a achieved by a new production
and at
•v-v»<=> wa
-------
municipal waste
S"';ectaSS£: '~ "a2«a°u= chemicals are~«^-^ „ parfc
S^J^Hs^T-iS^'is: sjy-.s'V' -
of raw materials a her con<3itions HoSe Demand,
available i-h-*-* i. ^ -ijua ror removal of n-i^-v- ertectivo
a-Lj-aoie through further study. nitrogen does not becom°
i2ryiif^« ^a««M
2a _of
+•«
ro be considered
-uSnts_Si.Bmoducts
2
sss "^-" %* sr^s
^
Th
601
-------
C!SiSeSBS^S£^3rll
Bleached Kraft.Market.PBlE-Subca£eaorir
are
TQ ? kl/kka (19-0 kgal/ton)
Sil 525
TSS
ar r-s!-"? rr ss m»- -
relatively new mill naa
kqal/ton) .
eaor, based upon
for
. /KKq (15-0 ibs/ton,
•Unbleached tonnage
~ - '=
Deink_SubcateggrY ,-oc^ss can be
aelnk
602
-------
a-onstratea tectaol^y *££„*? ™*
"
thermo-mechanical
603
-------
SECTION XII
ACKNOWLEDGEMENTS
" -•
the vrUMli?y of Confucti^ extens
appreciated. ' Efflu^t Guidelines Wvis?onY IrT °yWin and
-"•'-"i, are certainly
-
for '
605
-------
IlliSMillissiSiSi's
•the project.
606
-------
SECTION XIII
REFERENCES
2nd Ed., InterscIence'publishers^ln^T'Nf w^llrk^l960??1"22*'
2nd Edition, McGraw-Hill'Book'corr^New'Yofk 7l969f7~22~'
3. Rvdholm. s. A_ Dni ?->•;>-,,•* n^,, T ,
r Interscience Publishers,
^
5.
6.
Sor™' ?;aW"^-i---r2r—-f--™-—-i"^-2£-^lE-and PaEer Was-e ^rea--
ID±nt, EPA Contract Mo. 68-01-0012, April (1973f7 "~~~~
co.. m
York (1969) .
7. TAPPI Standard Method T235m-60.
8- Ihe_Bleaching_of_PulEr TAPPI Monograph No. 27 (1963).
Ins^itu?JE§n?2§I7t^?r-----B--§e§£i-YA------i^^^' American
0. M±chanical_PulBing_Manual, TAPPI Monograph No. 21 (1960).
Control_of_AtmosEheric_Emissions in
-=i--^_iii;--_i.iii^iriii_.Liiuus2rx, OHEW, NAPCA Contr-act No rPA~~93AQ~TQ
March (1970). v.^..^aui, IMO. ^^A ^-69-18,
?' c'rPulo'w^A ^-D°r^friK',C- P" "Reductive Bleaching of Mechani-
Canada,P59riOa958)ye"' ^i2_and_PaE£r_Magazinf_of
p^:^^!f-_H;; ^^h^l'^t^nyl Groups in
Bleaching and
607
-------
"• ^jfefra-fSS^s'SSr's S.
ZVIChE Symposium Series) .
18.
19. " a"fl KraU ' " " "
20.
w PI- al "Peroxide Bleaching
22. Barter, N.f et ai.,
10 (1960) .
23.
24. "
of the CEHDP Bleach sequence,
25< m,«T>T sh i u.V'01 •
CEDED and DCEDED Se-
on
26" quences," TAPPI
27. Dei; "
Vol iIH_Paeerma3sina_and_PaEerboard
28. E«l2-.aHSri:aH^-^^-?-r::Irr5ook CS.. New York (1970).
29.
PHIn and
•^974.
74.
r, E., ^^^i-^-^r'--^-"'"-5t 3rd Ed"
30.
T«V,« t.7-i 1 OV ST1U OWlli=» v,^..
Inc.,
3, SXatin. B.. "Paper." BooK_ofJ
-------
53E£E_flB3SSiaS_S£_£SHSSs, 69, 62 (1968).
' Barker Bffiuent
nth pacific Northwest
36. Private Communication (1970).
31- SSn&l??*' D8Pt- °f """"• **> «- Paper Mvisory co.ittee
38' g}1fc£fl-aB*' te'-' 1975- combustion Engineering, Inc. .
°f the msi:ra n—- Bleaching Plant,"
41.
""' ~ of
and Paper Industry."T^^^i^13, . ^ ""^ Slates
42.
43.
44.
45. Private Communication, Nov. (1973).
from the Evaporation of Suifit^ ^!f4-C?™position of Condensates
21, 689 (1970). buitxte Spent Liquor," Swenska_Pap.eerstidninc
47. f
' .i-t_.2.£r 9 (1969)
4 8 T n
49.
50.
51.
609
-------
52.
ing
53
a. H. ana -berg H « ^ E«ects of
S: Serial Waste Conf. XXV ,1959).
55.
tions,"
SS: 5-J.3 <->>
56. ^-^^J^gii^^H^fe^^lioS8?^!! -
seSrch1Series 120UODLQ (1971).
"• EPA "ater
C. N., Survex.of_Water_Utilization_and
Waste_Cgntrol_Practices -iS-|rf r??2~~nSvT~of ~North~Car olina ,
———————— Ti^Nc-^o-r-r-n TnST.lv,UT.*2 . \JIlJ-v. >^^-
.
ae Resources Research
Project No. A-036-NC (1970) .
et
D^^HC Q ™^ ^ LO. V^^ ^f ^ \w-* »^—• r
Ses, EPA-R-2-73-16U (1973).
Theory and_Practice, Lockwood
60 • p^iisw^io^/ilSrNls-fSl-i^T:
in the
A Cove G W. "Kra.lt Mll-L vMa»v-c; ^ j. j- <-— - ^ /1Q681
. , , „ w Jr "A Statistical Study of
62. Burns, O. B., and Eckenfelder J- -± ^ia Pulp and Paper Oom-
L±V. Industrial Waste
,m^;ii<— *, ^-^«.**• — w
wGnty "-^ *' ~ ~
Conf. XVIII (1963)
"• Eaae,r l^^'SS^^iSaSSlS!^
* TT HMamial of Practice for Sludge
and Gehm, H. w., luuiuai NCASI Technical_Bulletin
Handling m i_ne Pulp ana f3 —
NO. 190 (1966).
and Incineration of
Water and *--
Conf. (1969).
ana .ce.one in Kra£t
66. ,ilson. 0. ,-. eal,
son. . -.
Streams," TAPPIz._55r 8 (1972).
610
-------
67.
68"
iiD_No.._258 (1972) .
69.
70. O(JUtil. W- II_ _ "Co 1 =>•»-•,•„,., Vmf4- ri->»j. r,j-
Kratt Waste Stream Properties to BOD "
\S IS f
anpf??D E*la«°ns»ips of Raw ana Biologi
Effluents," Scasi_Technioal_Bulletin9
72.
73.
™.
in Water,"
75. "•____ _. .
__^ ^ Fish Food
76.
~ '-
ExPeri^ntal stream Studies of
79. Private Communication, Dissolving Pulp Manufacturers (1971)
30. Private Communication (1973).
n.
2.
Effluents,"
611
-------
84. "Bleaching Effluents with Lime. I. Treatment of Caustic Extraction
Stage Bleaching Effluent," NCASI_Technical_Bulletin_No.._239 (1970) .
85. Ibid, "Part II. Treatment of Chlorination Stage Bleaching Effluent,"
NCASI _Technical_Bull etin_No ._ 2U2 (1970).
86. Gould, M. , "Physical-Chemical Treatment of Pulp Mill Wastes,
woodland, Maine". Purdue_International_Waste_Conference,
1972.
87. Haynes, D. C., "Water Reuse - A Survey of the Pulp and Paper
Industry," TAPPIX_4 9, 9 (1966).
88. "Deinking Report," NCASI_Technical_Bulletin_Noi_5 (1946) .
89. Hodge, W. W. , and Morgan, P. F. , "Characteristics and Methods of
Treatment of Deinking Wastes," Sewage_Works_Journal , 19, 5(194/).
90. Barton, C. A., et al., "Treatment of Sulfite Pulp and Paper Mill
Waste," Journal_WPCF, 45, 1 (1973).
91. Morgan, O. P., "Biological Waste Treatment Histories in the Pulp
and Paper Industry," NCASI_Technical_Bulletin_Noi_220 (1968).
92. Bystedt, M. I., "What is the Future of Thermomechanical Pulp?,"
Pulp__S_Pap.er, Dec. (1973) .
93. Rysberg, G. , "Thermo-mechanical Pulp Advancing Around the World,"
P§p.er_Trade_Journal, Dec. 24 (1973) .
94. Marton, J., and Marton, T. , "Mercury in the Pulp and Paper Mill
Environment -- Appraisal and Perspective," TAPPIA_55r 11, (iy/2).
95 Mayer, C. , "Water Quality Control Program at Publishers Paper Co.,"
Presented at NCASI West Coast Regional meeting, Nov. (1972) .
96. Hrutfiord, B. F., et al. , Steam_StriEEina_Qdorous_Substances_from
Kraft_Effluent_Str earns, EPA-R2-73-196, Apr. (1973).
97. Mattoson, M. J. , et al., "SEKOR II: Steam Stripping of Volatile
Organic Substances from Kraft Pulp Mill Effluent Streams,"
TAPPIX_50, 2 (1967).
98. Maahs, H. C., et al., "SEKOR III: Preliminary Engineering Design
and Cost Estimates for Steam Stripping Kraft Pulp Mill Effluents,"
TAPPIi.SO, 6 (1967) .
99. Bengkvist, S., and Foss, E., "Treatment of Contaminated Conden-
sates in Kraft Pulp Mills," International Congress on Industrial
Waste Water, Stockholm (1970) .
100. Estridge, R. B. , et al. , "Treatment of Selected Kraft Mill Wastes
in a Cooling Tower," TAPPI 7th Water and Air Conf . (1970) .
101. Timpe, W. C., and Evers, W. J. , "The Hydropyrolysis Recovery Pro-
612
-------
cess." TAPPlt_56, 8 (1973} .
102-
---
Recovery
Reuse in - Di8CUB.
in a Kraft
107>
1oe-
109. Carpenter W L
onen, H. , et ai «r,
Chemical Fiberiza?^ °^ygen Bleaching
Journal,
111.
PI- Sr^|-- Sr
wlth
i
Rayonier> ^
613
-------
Florida," Southern_PulE_and_PaEer_Manufaclurer, July 10 (1972)
"»• ^^-^^^^^^
sollas-" «-
The Lean water
sss; a; abSirs sss
(1974) .
,23. Gould, M., and walzer, J.. "Mill waste Treatment by Flotation."
Chem 26/Paper Processing, Nov. (iy/^).
124. Fuller, R. S. , "Screening of Effluents," TAPPI..56, 6 (1973).
125. Warren, C.E., BiologLY_of Jfatgr. Egption.Control,
W.B. Saunders, Philadelphia (1971).
W. L., "Foaming Characteristics of Pulping Wastes Dur
gical Treatment", NCASI_Technical_Bulletin
N0._195 (1966) .
#11, 135 (1969).
"'• ^^ <
Poland, June (1969).
129 Tracy, J. C. . "Secondary Waste Treatment Nutrient and Aerator
Studies," Southern.PulB.and.Paeer.Manufacturer, Feb. (1970).
130. Eckenfelder, W. W. , Jr., I^?trial_Waste_Water_Control, McGraw-
Hill Book Co. , New York (1966) .
(1971) .
r, T 0-t- *1 "The Activated Sludge Process Using High-
133' ?r?o";y ixygen fo? TieaSng Kraft Mill Mastewater," TAPPI.-56,
4 (1973).
134. Ayers, K. C. , and Patton, T. H., Jr., "Biological Treatment Alter-
614
-------
natives for Kraft Effluents," TAPPI 8th Water and Air Conf.
I35' £»££; ?LSept for^coSirr^e" f votating
Board Mill Effluents," TAPPlLt|? 12 (19?3*? °* Xnsulati"
-------
wastes," Purdue Univ. Industrial Waste Conf. XVII (1962)
ssi?
waste Conf. XXIV (1969)
,52. MacAleese, a. E.. "How Hewton Falls Solved a clean water Problem"
PaEer_Trade_Journal, Nov. 14 (1966) .
153. Flower, W. A., "Spray Irrigation for the Disposal of Effluent
Containing Deinking Waste," TAPPIi_52, 1267 (1969).
154 "Wisconsin Tissue Effluent Plant Pioneers European Process Here,"
PaEer_Trade_Journal, March 11 (1970).
Practical Approaches to Utilization
," NCASI_Technical_Bulletin_No.__67
(1964).
no »+- al "Recycling Fine Paper Mill Effluent by
156' Seiner" PressureaFiItra1ion*"?APPI Environmental Conf. (1972).
157. Mdrich, L. C.. and Janes, RL "White "ater Reuse on Fine Paper
Machines," TAPPI Environmental Cont. M
158. "New Approaches to In-Plant Load Control and Monitoring.-
NCAS I_Technical_Bulletin_No.._24 8 (19/1).
Permit.
160. "G-P's -Pipe Organ- Aeration System," Southern_Pul£.and_PaEer
ManufaSiUESEf MaV 10 (1972)•
161. "K-C to Spend $92 Million at Coosa Pines Mill to ^S*0
put and Control Pollution," PaEer_Trade_Journal , May 20
162. Tall_0ii_and_lts_uses, Pulp Chemicals Assn., New York (1965).
163. Ellerbe, R. W. . "Why, Where and How US Mills Recover Tall Oil
Soap," Pa2er_Trade_Journal, June 25 .
16U. "Resource Engineering Associates "St ^e-of-the-Art Review on
Product Recovery," FWPCA Contract No. 14-12-495, Nov. 11*0*1
165. Stengle, W. B., "Crude Tall Oil Manufacture," Southern_PulE_and
PaEer_Manufacturer, Dec. 10 (1971) .
c^afa^
167. Ores, J. ,et al., Sulf ate_TurP.entine_RecoverY, Pulp Chemicals
Assn., New York (1971).
616
-------
r
'"'
Process,. Forest
Wiley A
175-
m.H«,rd.6
'
Patent No.
178. Robeson,
Si
32. Hendrickson
83. Haynes, D
*
industry.., AIChE Sym.
the Pulp and Paper
and Enai
Jan.
1,075.857; 1,069,029;
-cover, from sula,'
....,^
--- (
-ro
Papsr Inaustry „
617
-------
T "Staras of Kamyr Displacement Bleaching Project,''
185. Gullichsen, J. , S^at'ifl1° 3Q (1973).
Pap.er__Trade_ Journal, July J" U^'JJ
„.. r^.rTl.^in, eg*. ~ .. P-rt o£ BaSte* *U Expansion,.
Pap^r Trade_ Journal, Apr. <>9 u^'1*)-
n H "Oxyqen Bleaching Development
187. serafin, J. P., ^f^i menus' to ?ul? Scale Commercial
rns?aila?irrandSrPe?aSrn:» TAPPI Annual Meeting, Jan. 14-16
(1974) .
188. «-.. K. E.. "CheSapea,e punches O»M« Ble.chin,.- BO^
Paper, Oct. (1973) .
189 Private Communication (1974)
-- -
York (1971).
NO.. 253 (1971) .
Jan. (1973).
, a. E. ,
D.C..
Enhanced Turbidity
"
^f filters for Advanced Wastewater Treat
196. Baumann, E. R., "Design of .^^rtment of Civil Engineering,
"
EPecn seninar,
Iowa, June (1973) .
i:
1,8. -.
S4-^e. Ma,
- iues in Tertiary
199. Tchobanoglous , G.,
Treatment, Journaj.
42, April 1970.
613
-------
20°- ; muenViT86'" »- - -ii^o. of
smnmina.|ivS^n^Ef2--§aail
20 ''
Aeration
967. ---s__ ewage
202. Gulp, R. L and
Van Nostrand Reinholl'
203. Vecchiolo, jr. e* al
Middlebrooks E
University, Logan,
, eyr A. j^ ^
209. Johnson, J. s JT- M- *.
2* Direct
ts, EPA
^
619
-------
n c "Process Water
"
APPXt-56' 7 (1973) .
Ter-tiaryTreatment_bx
17020 DHR, Dec. (1970)
wastewater Demineralization_^J2D
--l70,0 EEE, Oec. «»7M .
_f mior from Bleached
System, " NCASI_e
* 3'12°'U6U
laboratory and Pilot Stu-
T T "Trace Element
OTO
222'
nd culp G. L., Advanced_Waste_Treatmentr Van
R. L.» anu CUlp» «• , '-.QrfTT ---
ReinhoW, New York (1971, . rlinoptilo
22
Cincinnati, Ohio,
- era-
<.pwaters-
'"" "'""'"" "
620
-------
Teohnoiogy
Treatment of Kraft
Renovation,,. ^
water
Timpe, w G
Davies D
organi;8,;
Bishop D F
aSBMlja
238 . Vanier c
=~—
°n v carbon Treatment,..
(1967)
«astewater CMorination,. j^ter
Huibers, T. A e-j- =,1
• f c.
62]
-------
TV ml or Removal from_Kra£t
«
.
PulE_&_PaEer,
Tr^Toj.t-a-te Paper corporation (1973)
250 Private Communication, Interstate i-ape
sns
c;
'
sity » Pager r a_ ,
of
"Water
and Recycle in
Reuse and Recycle in
^i^as^:-----
(1973) .
11 (1973) •
o PaEribleach.£alE-llSa£feiaa-ffi2£tl
o--
11 (1971) .
Process for Pollu-
(1973)
622
-------
**-.
. E., ,,BieacMng ^ cro
£«lE-6
262. Carpenter w L M K «E-6_Pafier, Aug. a973)
'
264. Spruili
E
"
^
267. "Development S
268. Berger H F rt
^
2M"
270. Davis C r
273. Spruilir EL
Patsnt
by an
623
-------
277. Private communication, Georgia Pacific Corporation U«»>
278 Private communication, International Paper Company (197-,
- sr: s--j£.'^ -
Chem'. , 44, "561 (1973).
»•• s^^'^-^srsi^s
69 (1973) .
T^^
• ^- mif states Paper, Tuscaloosa, Alabama (1974)
284. Private Communication, Gulf States rape ,
285. Fremont, H. A.. Tate, D. C ,
and Development, EPA, Dec. (1973) .
Private communication. Union Carbide Corp.. 8. CharXeston. «- Va.
(1974) .
• Kfe ^
mental Conf., Apr. 17-19 (1974).
29°
„ r et al "Treatment of Pulp Mill Effluents with
-
tin_No.._267 (1973) .
. M.
a. . . .
e(r972;\E!fc:ssn:!S5ziiii:£Eii::-«,
624
-------
295 .. ea»
, Feb. 25 (1971). ft Effluents," Paj5gr_Trade
296. "Color Removal Process » D,,I ^
297 T . Process. £ulE_aad.PSEer_ Intgrjjat lona 1 , May (1973,
' ^cfcaic^lonffo
Oxyge, Bleaching,- TAPP!
Conf. (I9?a)
Bleach Plant Effluents,-
'
30 1" 'Bii^I^SiJSe8?^^ Uon of
wastes," TAPPI Environmentfr?onf U9?J,?^ PUlP and Paper
or-Second^?LtPLant STb?" ahRot^9 Biological
TAPPI Environmental Conf . (19?J) ? Unbleach^ Kraft Mill Wastes, »
303- L^yL^^rss/^
Waste ManageminT-p^grSrlSbr^ftfff:^' EPA' Office STsolid
304. Tyler, M. A., and Fitzgerald AD ** D
duction Technology in Puln ?Ari D ' Revaew of Colour Re-
at the 58th Annul? nSetSg JSchnJS 5^' Efflusnts'" Presented
Jan. 24-28 (1972). technical Section, CPPA, Montreal,
625
-------
SECTION XIV
GLOSSARY
^
£ Prjj _{AiDl. Ton
content of 10
The protective covering of a tree.
Barking
of bar* from logs in .
point of
of pulp by addition of
Blow
Fjection of the chips from a digester.
Breaker Stack
operations
627
-------
calender St
surface.
Cellulose
"
Chest (or Stock Chest)
Tan~R~usea for storage of wet fiber or furnish
Small pieces of wood used to make pulp.
Color Unit
of color concentration in water using
Consistency .
"" percent of solids in a solids-water mixture used «
wooa, water, and emicals in
constituents.
Cooking Liguor. H^H« in
"."'.i-re of c^icais ana -ater usea to aiSSOlve 1^»
wood chips.
countercurrent Washing
^ rhf -eif^f fro^LTt^L^ sa s sr-,l-~ -
the previous stages.
to remove water or spent cooKin, U,uor
pulP consistency.
vessel used to cook wood chips in the
cooking liquor and heat.
628
-------
Cooking of chips in the above manner.
Dregs
The inert rejeots from the
on Water
Water removed during a pulp manufacturing process.
Felt
and dewater
Fiber
*»**» «* «>e tree used to maKe pulp, paper, and
Fines
Fiber fronts produced by fiber cutting in
Sa£Di§h
The mixture of fibers
Gland "
to
portxon of a vessel such as pump? 9 ft and the stationary
Gland Water
to iubricate a gland. Sometimes
Grade
type of pulp or paper product
629
-------
Headbox
;"h7T,ea of «« Paper macaine fro, ««icn the stoc* flows tnrougn
a sluice onto the wire.
A non-degradable organic compound of wood.
of newspapers
see Gland Water
prehy.drolY§is
cellulosic
fibers after conversion from wood chips.
papermaKing.
Ray Cells.
. epelaHy unbXaaohed operatlons.
Rejects
~~ „»»!««. for Pu1P or pap.r.aKin, which hasb^n
in the manufacturing process.
Save-all
^o r-cov-r papermaking fibers and other
waste ^ater ^process strea,.
Screenings
K~ects separated fro. useab!. pulp by a device such as a scr.en
Side^Hill Screens
630
-------
Steeply sloped, 60-mesh screens.
2E§fit Cooking Liguor
chSiSIl m^ertalsf^ digestio« containing lig
Stock
naceous as well as
«et pulp uith or
S-iiSiion Box
•£==-•=
s- s
s
uction Couch Roll
'
a
-«.
1 __ Steel
Carbon
Manganese
Silicon
oo.posi.ion
i
Remainder iron
Wood PulE
-------
formaldehydes used in
v, =»o nrpa and mej.cuu.ji«= roime*j.uciijr
Chemicals such as urea *"* .. to papers used in w~-
papermaking to impart s^reny-
applications.
White Liguor
mafle by caustici.ing green liquors; cooking liquor.
White Water
Wire
moving bjlt -- i-dn a
window screen, upon
fourdrinier machine.
632
-------
A.
A.
AD Pulp
APHA
API
APS
ASB
atm
AWT
B.
BATEA
BCT
BK
BOD or BOD5
BPCTCA
BTU
C
C
°C
C+F
CMN
CMP
COD
cu m/min
cu. m./kkg
SECTION XV
TERMINOLOGY INDEX
Activated Sludge
When associate, wlth a
Air Dried puip
American Public Health Association
American Paper Institute
anti-pollution sequence
Aerated Stabilization Basin
atmospheres
Advanced Waste Treatment
Board or Paperboard
BeSt *vailable Teohnology
Paperboard, coarse. Tissue
Bleached Kraft
Biochemical Oxygen Demand (five-day,
AvaSilSf 1Cable C°ntro1 Phenology currently
British Thermal Units
Clarifier
Coarse
degrees Centigrade
Clays and Fillers
Coarse, Molded, Newsprint
Chemi-mechanical Pulp
Chemical Oxygen Demand
Cubic meters per minute
Cubic meters per 1000 kilograms
633
-------
D
DAF
Diss.
DO
E. Coli.
ENR
F
FACET
oF
Fwp
gal
gpd/sq. ft.
gpm
GW
ha
hp
IDOD
IJC
in. Hg
JTU
kg
Deink
Dissolved Air Flotation
Dissolving
Dissolved Oyxgen
Escherichia coliform
Engineering News Record
Fine
Fine Activated carbon Effluent Treatment
degrees Fahrenheit
from waste paper
Gravity
gallons
gallons per day per square foot
gallons per minute
Groundwood
hectare, 10.000 meter squared
horsepower
mediate Dissolved Oxygen Demand
mternational Joint commission
inches of Mercury
jackson Turbitity Units
kilogram, 1000 grams
kg BOD/kg
MLVSS/day
kg/ha sur-
face area/
day
kg/sq cm
kilogram of BOD per kilograms of MLVSS per day
Kilograms per 1000 kilograms
kilograms per square centimeter
634
-------
kgal
kkg
kw
L
m.
L/kkg
Liquor
Recovery
Ib
Ib/ac/day
mgd
mg/l
MKT
MLSS
MLVSS
MM
mu
N
N (NSM)
N.A.
NCASI
NI
nm
NOV
1000 gallons
1000 gallons per tOn
1000 kilograms, metric ton
kilowatt
liter
liters per day per square meter
liters per 1000 kilograms
liters per minute
c - Collected
B - By-products
I - Incinerated
pound
pound per acre per day
million gallons per day
miliigrams per liter
market
Mixed Liquor Suspended solids
Mixed Liquor volatile Suspended Solids
Maximum Month
millimicrons
News
non-standard methods when associated with
Not Available
- integrated
nano meters, 10 - 9 meters
Number of Values Reported
635
-------
NPDES
NSPS
NSSC
P
PCB
PCU
PP
ppm
PS
psig
RBS
rpm
RWL
S
SB
Set Si 5s
so
SSL
Std. I
T
TA.PPI
TC
TDS
Temp
TMP
TOC
TOD
-A--*«•*•*- T~IT <3f*ficii~M ^ EJ-ln*-"^
National
System
New source Performance Standards
Neutral Sulfite semi-chemica
Pulp
Polychlorinated biphenyl
Platinum color Units
Purchased Pulp
parts per million
post Storage
pounds per square inch gage
potating Biological Surface
revolutions per minute
Raw waste Load
sulfite
settling Basin
sevtleable Solids
Soda
spent sulfite Liquor
Standard Methods
Tissue
Technical Association of the Pulp
ana Paper Industry
Total Carbon
Total Dissolved Solids
Temperature
Thermo-mechanical Pulp
Total organic Carbon
Oxygen Demand
636
-------
TOM
ton
tpd
Ts
TSS
turbid
TVS
Type
Condenser
UK
Total Organic Matter
1000 pounds (short t0n)
tons per day
Total Solids
Total Suspended Solids
Turbitity
Total volatile Solids
v - Vapor Recompression
| I f^face Condenser
Barometric Condenser
Unbleached Kraft
637
-------
Table 200
00
MULTIPLY (ENGLISH UNITS)
English Unit
acre
acre - feet
British Thermal Unit
British Thermal Unit/pound
cubic feet/rinute
cubic fect/seccnd
cubic feet
cubic feet
cubic inches
degree Fahrenheit
feet
gallon
gallon/minute
horsepower
inches
inches of mercury
pounds
nillion gallons/day
mile
pound/square inch (gauge)
square feet
square inches
tons (short)
yard
Conversion Table
by
Abbreviation Conv-rsion
TO OBTAIN (METRIC UNITS)
ac
ac ft
BTU
BTU/lb
cfm
cfs
cu -ft
cu ft
cu in
°F
ft
gal
apm
bp
in
in Kg
Ib
mgd
mi
psig
sq ft
sq ir,
ton
yd
0.405
1233.5
0.252
0.555
0.028
1.7
0.028
28.32
16.39
0.555(°r-32)*
0.3043
3.785
0.0631
. 0 . 7 A 5 7
2. 54
0.03342
0.454
3785
1.609
(0.06305 psig+D*
0.0929
6.452
0.907
0.9144
Abbreviation
ha
cu m
kg 'cal
kg cal/kg
cu m/min
cu m/min
cu m
I
cu cm
•C
m
1
I/sec
kw
en
a tin
kg
cu m/day
kn
atr
sq m
sq cm
kkg
m
Metric Unit
hectares
cubic meters
kilogram - calorics
kilogram calories/kilccrar.
cubic meters/minute
cubic meters/minute
cubic netcrs
liters
cubic centircters
degree Centigrade
meters
1j ters
liters/second
kilowatts
centimeters
atmospheres
kilograms
cubic meters/day
kilometer
atmospheres 'absolute)
souare meters
scuara cer.tiretors
metric tcr.r (1000 kilogrars)
meters
* Actual conversion, not a multiplier
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