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

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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)

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 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

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             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

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                       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

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 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

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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

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 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

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 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

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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

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                                            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

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                                                                       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

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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

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  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

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                            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

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                     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

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                            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

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                         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

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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

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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

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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

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                                                        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
943
GW: Groundrfood
BK: BleachGd K
L'.K: L-.blcached


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( 570)

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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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30
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 60
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               AVERAGE ANNUAL  RAW  WASTE BOD
                       Kg/KKg (LB/TON)
                        FIGURE  31
              BOD VS NUMBER  OF MACHINES
                BLEACHED KRAFT SEGMENT
                          97

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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

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 §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

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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

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 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

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                                                                                 FIGURC 33

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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

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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

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o
C3
                                                                                 K I T
                                                                                 IN A
                                                                                   A C + F vs BODS

                                                                                   FIGURE 34
                                                              iC.OO
                                                                                 i?.co   '  i7.ro

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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

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                        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

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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

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                                             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

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                                                   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

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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

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         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

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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

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 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

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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

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                                             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

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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

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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

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                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)

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 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

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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

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                          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

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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

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                           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

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    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
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-------
                                         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

-------
                                                           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

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                                                                  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

-------
                           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

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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

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 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

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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

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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.
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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

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 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.

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 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

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 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

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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

-------
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

-------
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

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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

-------
                       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

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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

-------
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

-------
                     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

-------
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

-------
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

-------
 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

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 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

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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

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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

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                                                          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*

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 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

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 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

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                             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

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                            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

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               "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
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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

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 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

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                                                   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

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    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

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   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

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        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

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    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

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 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

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                                      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

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 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




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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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-------
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

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                                                          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

-------
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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

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                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

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 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

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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

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 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

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   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

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                                  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

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                                                             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

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                              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

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    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

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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

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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

-------