WATER POLLUTION CONTROL RESEARCH
Draft Second Report
on Waste Profiles
of the Paper Industry
ENVIRONMENTAL PROTECTION AGENCY WATER QUALITY OFFICE
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DRAFT SECOND REPORT
ON WASTE PROFILES
OF THE PAPER INDUSTRY
BY
WAPORA, Inc.
1725 DeSales St., N.W.
Washington, D. C.
for the
Office of Water Quality
Environmental Protection Agency
Covering
Contract #68-01-0012
Contract #68-01-0022
April 13, 1971
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TABLE OF CONTENTS
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
Treatment-General
S ewer ing
Screening
Neutralization
Clarification
BOD Reduction
Storage Oxidation
Activated Sludge Treatment
Aerated Stabilization Basins
Biological Treatment Summary
Irrigation and Land Disposal
Combined Treatment
Mill Size & Location
Classification of Mills
Mills Considering Discharge
to Public Facilities
Treatment Received & Costs
Allocation
Sludge Thickening, Dewatering
and Disposal
Introduction
Gravity Thickening Tank
Conical Thickening Tank
Mechanical Thickener
Thickener Installations
Vacuum Filters
Centrifuge
Pressing
Incineration
Summary
Groundwood Pulping
Kraft Mills
Acid & Neutral Sulfite Pulping
Deinking Mills
Waste Paperboard Mills
Building Products
Treatment Table Key
Code Table Key
PAGE
1
1
1
2
2
8
8
13
16
21
23
26
26
26
26
27
32
32
33
33
34
34
34
41
42
42
42
46
49
54
62
64
66
68
69
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LIST QF TABLES
PAGE
I. Mills Now Discharging
to Public Facilities -
Major Locations & Number 28
II. Mills Now Discharging to
Public Facilities -
Distribution by Size
and Type 29
III. Mills Studying Discharge
to Public Facilities -
Distribtuion by Size,
Number, and Type
IV. Mill Installations 36
IV.A Thickener Loading
Parameters 36
V. Continuous Vacuum
Filtration 38
VI. Mechanical Pressing
of Sludge Cake 43
VII. Linerboard Mills 70
VIII. Newspring Mills -
Kraft 72
IX. Inegrated Kraft
Mills 74
X. Bleached Kraft Mills 76
XI. Acid Sulfite Pulp Mills 78
XII. NSSC Mill 80
XIII. Deinking Papermills 82
XIV. Waste Paperboard Mills 84
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LIST OF FIGURES
PAGE
1. Percent Total Suspended
Solids Reduction by Settling 4
2. BOD Rates of Suspended &
Dissolved Organic Matter 5
3. BOD5 Reduction by Settling 6
4. Effect of Storage Time on
BOD Reduction 10
5. Effect of Temperature on
BOD Reduction in Aerated
Stabilization Basins 17
6. Thickening Curves for
Various Sludges 35
7. Effect of Activated Sludge
of Dewatering Boardmill
Sludge 39
8. Sludge Cake Conditions
Required to Support
Combustion 44
9. Multi-Path Diagram
of Mechanical Thickening,
Dewatering and Disposal
of Sludges 45
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TREATMENT - GENERAL
Sewering
In most modern pulp mills sewer segregation is common to the extent that
wastes low in suspended solids and those that are high in them are
sewered separately (1). If bleaching is practiced, a separate acid proof
sewer generally of polyvinyl chloride or fiber glass construction
is provided to carry the chlorination effluent so that it can be neutralized
before joining the common effluent stream. This is good practice because
direct mixing of this bleaching wash water with that from alkaline
extraction can cause a serious foaming problem. Bleaching waste is often
low in suspended solids and BOD,- and is sometimes by-passed around the
clarification system.
Some mills are equipped with a waste holding basin to which the sewer
carrying pulping wastes, tank overflows, and apron and floor drains can
be diverted when liquor losses are high for one reason or another. The
basin contents are then metered into the overall discharge at a suitable
controlled rate when the effluent strength is normal. Some of these
systems are equipped with conductivity recorders x^hich activate diversion
valves automatically when losses are high.
Where small volumes of strong wastes are involved, such as the exploded
wood hardboard process, this is segregated for separate handling such as
land disposal and incineration. In general, however, all dilute wastes
from most mills are combined for external treatment.
Screening
In addition to the screening procedures used in wood preparation previously
described in this report, it is standard practice to screen total mill
effluents through bar racks having one-half inch openings (2). It is
well to protect these units from large objects such as logs, tools, etc.,
which get into sewers from time to time. This is done by placing a
manually cleaned bar rack with openings of two inches or more in the
channel ahead of the fine screen. The latter in large mills are mechanically
operated and screenings are taken to a dump or incinerated since they contain
mainly combustible matter such as paper, bark and wood chips or slivers.
It is extremely important that the screening operation be efficiently
carried out since the nature of the materials removed is such that they can
cause serious trouble in succeeding treatment equipment.
Ordinarily grit chambers are not employed nor do they appear to be necessary
since little coarse detritus matter normally finds its way into the
process sewers. In the case of waste paper mills such materials are
removed in the process itself and dumped with the trash removed from hydro-
pulpers.
In larger mills, flow measuring flumes are frequently installed in the
channels following the screening operation and small mills usually employ
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weirs for flow measurement (3). In some cases the flow of the final
effluent is measured rather than the treatment plant influent.
Neutralization
In the case of effluents from acid sulfite pulping, acid sulfite liquor
recovery systems and the acid stages of bleaching neutralization are
required unless these are mixed with other wastes containing sufficient
alkalinity to accomplish neutralization. Neutralization is achieved, in
practice, by either adding caustic soda, lime, or limestone in controlled
dosage or passing the waste through a limestone column or bed. This
treatment is discussed by Lott (4) who developed a mathmatical model
for the design of these devices.
Clarification
While sedimentation, flotation, and filtration are all used to remove
fiber and other suspended matter from mill process waters internally (5),
external clarification is almost universally achieved by sedimentation (6).
This is accomplished in mechanical clarifiers, alternating basins or, in
case of very large storage oxidation installations, in the inlet section
of the large impoundment areas used for this purpose. The trend in the
industry is strongly toward the mechanical clarifier(7). These have
been found to be effective in removing over 95 percent of the settleable
suspended solids from all the effluents produced if properly designed
and installed. They are generally equipped with a skimmer and, for
effluents containing entrained air, a de-aerating device. Clarifier
design has been discussed by Knapp et al (8) and the application of
mathmatical models to such treatment by Korean (9), and Edde (10), and
an NCASI survey (11) of practice at southern mills cover the performance
of settling for treating these wastes. The literature is also replete
with descriptions and performance data for the various specific types
of wastes and individual installation, examples being those by Nemerow (12),
Palladino (13), Fuller, Williams, and Moultar (14), and Linsey, Sullins
and Fluharty (15). Presently more than seventy-five of the one hundred
and eighteen Kraft pulp mills in the United States are equipped with
mechanical clarifiers and twenty-one with settling basins. The waste from
15 of the 38 acid sulfite mills and 25 of the 39 neutral sulfite mills are
treated in clarifiers. While most waste paperboard mills discharge into
public sewers, at least thirty of these are equipped with their own clari-
fiers as are five of the six large deinking operations; the remaining employ
alternating settling basins. Most large groundwood operations are associated
with kraft and sulfite pulping and newspring manufacture and the effluent
is combined for treatment with the effluent from all operations. The sewers
are for the most part served by mechanical clarifiers.
A clear distinction must be made between total suspended solids and
settleable solids. The total suspended solids are all the solids suspended
in an effluent. In laboratory tests, practically all of these are removed
by filtration through a gooch crucible or fine filter paper, both of
which are used to measure them. The settleable fraction of these is
that which separates from the liquid on one hour's quiescent settling
in a laboratory vessel. Hence, the true measure of performance of a
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settling device is the percentage of the settleable fraction that
the device will remove, since it cannot be expected to separate those
which will not settle under the most favorable conditions.
The performance of clarfiers in terms of removal of total suspended
solids reduction is presented in Figure // 1 . These data were obtained
from a detailed industry survey of practice and performance (10) and are
representative of results obtained in actual installations. It will
be noted that removals averaged greater than 80 percent for all except
deinking mill effluent which averaged just under 70 per cent. This
is due to the relatively large percentage of inorganic fines in the
form of fillers and ink that are highly dispersed in the waste due to
peptizing agents employed in the deinking process.
Despite the high percentage reduction obtained on settling, wastes con-
taining pigments and fillers are inclined to be quite turbid after the
bulk of the suspended matter is settled out. Such materials as titaniun
dioxide, carbon black, ink, iron oxides, and other highly optically active
materials are responsible for this. Decoating wastes behave in much
the same manner with some inorganic materials remaining in dispersion
due to the peptizing action of starches used in the coating process.
Since at least a portion of the settleable solids present in pulp and
papermill effluents is biodegradeable, clarification results in some
reduction in the BOD value. The magnitude of this reduction is high
in the case of effluents containing mainly suspended organics and
small quantities of dissolved organic matter. For example, some
specialty board effluents contain little but fiber fines, hence their
removal produces a BOD reduction exceeding 90 percent. Conversely,
waste paperboard mill effluents contain a considerable quantity of
organic materials dissolved from the old papers. Hence, even when
clarified to crystal clarity, they can retain as much as a third of
their original BOD value. This is also true of effluents containing
pulping and bleaching solubles.
Another factor involved is the fact that the oxygen uptake rate of
fiber is slower than that of dissolved materials, since it must first
be liquified by microbical decomposition before oxidation can take
place. This effect is illustrated in Figure // 2 which compares
the BOD rate curves of dissolved materials with that of fiber. It
will be noted that the oxygen demand of the solubles was largely
satisfied in 5 days, while the fiber continued to consume oxygen over
the 20-day period of incubation. Thus, the mere fact that the BOD
is a 5 day test stresses, in the results obtained with settlingjthe
presence of dissolved oxygen consuming materials and limits the demand
figure assigned to the settleable organics.
Results obtained on tabulation of BOD data for a number of mills producing
various products is presented in Figure ^ It is obvious from these
results that effluents from tissue and fine paper mills, which were low
in dissolved organic matter, showed high BOD reductions on settlings.
Pulp mill and waste paper operation yielded low BOD reduction since
they contain appreciable organic matter in solution.
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Percent Total Suspended Solids Reduction bv Settling
01
o
0
o
-j
o
00
o
o
o
"II 1
Deinking Mills
Bleached Kraft Mills
Linerboard Mills
Waste Paperboard Mills
Fine Paper Mills
Insulating Board Mills
1
Tissue Mills
Newsprint Mills
Wrapping Paper Mills
Specialty Board Mills
Figure # 1
Total Suspended Solids Reduction by Settling
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Figure #2
BOD Rates of Suspended
and Dissolved Organic Tatter
100
80
60
I
I
f
Dissolved
Solic's
40
Suspended
Solids
20
10
15
20
Time in Days
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Percent BOD5 Reduction
to
o
Ci
o
oo
o
o
o
Liner
News
Bl. Kraft
Waste Paperboard
s r.ills
Integrated ::ills
i'/hite Paper "lills
Insulating Board
Tissue Mills
Wrapping Paper r.'ills
Specialty Board '.'.ills
Figure £ 3
BOD5 Reduction by Settling
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BIBLIOGRAPHY
(1) Gehm, H.W., Paper presented Tappi Eng. Conf. (1949).
(2) Vickerman, J.L., "Effluent System of a N.A. Kraft Mill," Water &
Sew. Wks. llr, 503 (1967).
(3) McKeown, J.J., "Procedures for Conducting Effluent Surveys," NCASI
Tech. Bull. #183 (1965).
(4) Lott, R.R., "Neutralization of Acid Bleach Effluents," NCASI Tech.
Bull. #186 (1965).
(5) Lardieri, N.J., "Recovery of Useable Solids," Pulp & Paper Mag.
of Canada, T-186 (March 1960).
(6) Gehm, H.W. , "Removal, Thickening and Dewatering of Waste Solids,"
Pulp & Paper Mag. of Canada, T-189 (March 1960).
(7) Gehm, H.W., "Practice in the Treatment of Kraft Mill Effluents
in the U.S.," Appita 22-106 (1969).
(8) Knapp, C.A., Coughlan, F. P. and Baffa, J. J., "Sedimentation Practices
for Paper Industry Wastes," Jour. San. Eng., Div. A.S.C.E.
90 (SA6):41 (1964).
(9) Morean, D. H., "Math, Models of Pulp and Paper Waste Disp. System,"
NCASI, Ind. Bull. #206 (1967).
(10) Edde, H., "Settleable Solids Removal Practices in the Pulp and Paper
Ind.," NCASI Tech. Bull. #178 (1964).
(11) Brown, H., "Survey of Solids Removal Practices in Southern Kraft
and Newsprint Mills," NCASI Tech. Bull. #120 (1959).
(12) Nemerow, N., "Sedimentation and Coagulation of Rag, Rope and Jute
Wastes," NCASI Tech. Bull. #46 (1952).
(13*5 Palladino, A. J., "Design and Operation Criteria for Primary
Treatment of Deinking Waste," NCASI Tech. Bull. #63 (1953).
(14) Fuller, H. E., Williams, R. & Moultar, F.W., "New Developments
in Design and Operation of Primary Clarification and Sludge
Dewatering Facilities at Five West Coast Mills," NCASI Tech.
Bull. #211 (1967).
(15) Linsey, A.M., Sullins, J. K. and Fluharty, J.R., "Progress in
Primary Treatment and Sludge Disposal at Three Integrated
South Eastern Paper Mills," NCASI Tech. Bull. #209 (1967).
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BOD REDUCTION
Biochemical oxygen demanding materials can be precipitated from most
pulp and papermill wastes by the use of coagulating chemicals. However,
the percentage reduction obtained in this manner is small as compared
to that obtainable by biological treatment. Hence, the latter method
is the most widely practiced. It also affords a flexibility in the
degree of BOD reduction obtained since systems can be tailored to
receiving streams' requirements relative to dissolved oxygen resources
and consumption rate.
All pulp and papermill wastes can be oxidized biologically. Some need
to be diluted and/or neutralized and most, being low in nitrogen and
phosphorus, require addition of these nutrients when higher rate processes
are applied. Their amenability to such treatment is evidenced in the
references presented in the annual reviews of the literature published
by the WPCF, in the bibliography of biological treatment of pulp and
papermill effluents,and in a manual on the subject published by the
NCASI (1),(18) .
Through the years, all forms of biological treatment have been explored
extensively. Of these, three have become established and widely applied.
These are storage oxidation, aerated stabilization, and activated sludge.
There are also modifications such as contact stabilization and extended
aeration. Very expensive investigation of trickling filters has not
led to their adoption except for special purposes. There is only one
large unit in operation and it is a pre-treatment device. These filters
have the ability to remove a fraction of the 6005 from a large volume
of waste, but if a high percentage reduction is required filter size
becomes disproportionatelylarge, and, therefore, costly (2). Small plastic
media filters are sometimes used in pre-cooling towers and as such remove
some BOD as pointed out by Burns and Eckenfelder (3) and (4). They have
also been applied to in-mill cooling and treatment of kraft mill condensates
on an experimental basis by Estridge (5). In this capacity they act
not only as biological treatment units, but stripping devices as well
since the constituents of the condensates responsible for the BOD are
volatile organics such as methanol. The use of log and chip piles as
biological filters has been a subject of investigation (6), (7), (8),
although adoption of this technique is most unlikely since it disrupts
the raw material flow of the mill.
Storage Oxidation
Storage oxidation was the first type of biological treatment adopted in
the industry. This was first used by and is still most prevalent in
the southern kraft industry where a number of mills were able to procure
large areas of land having suitable topography remote from dwellings
for this purpose. The high ambient temperatures of the south allow
maximum oxidation rates to be realized throughout the entire dry season
in most cases. Berger (9) summarized results obtained at a number
of these mills. Heustis (10) (11), Bodenheimer (12), and Webster (13),
8
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and Chapman (14) report on results obtained with shallow storage basins.
BOD loadings for which these basins are designed are from 50 to 60
pounds per acre of surface area per day. Rp.ductions obtained in
relation to time are presented in Figure // _4 .
It is imperative that settleable solids be effectively removed ahead
of such basins since if deposited therein will liquify on decomposition
adding more BOD than that contained in the waste water itself. Under
these conditions the effluent can deteriorate to a point where its
BOD is higher than the influent. Nutrients do not accelerate the slow
oxidation occurring under these conditions so are not employed. Retention
time ranges from 20 to over 300 days producing BOD reductions from
about 50 to in excess of 95 percent.
This method of treatment enjoys the advantage of being capable of handling
accidental discharges of strong waste with out upset and perform well
on a continuous basis since no mechanical devices are involved which
can get out of order. Twenty-one large kraft mills in the U.S. employ
this type of treatment, as pointed out by Gehm and Gove (15), as does
one large deinking mill described by Ross (16). A number of very small
mills also use these basins although use of this method is limited
to weak wastes because of odor problems. Forges (17), in a survey of
the application of storage oxidation in industry }lists most of these
installations and their design is discussed by Hermann and Gloyna (18),
Blosser (19), and Edde (20). Results obtained in terms of BOD^ and
total suspended solids reduction by storage oxidation at individual mills
will be found in treatment tables in the latter part of this report.
In some cases these basins are also used for discharge regulation
when mills are located below peak load hydro-power stations, in semi-
arid regions, or where stream flows reach extremely low levels.
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FIGURE #4
EFFECT OF STORAGE TIME ON BOD REDUCTION
100
a
o
H
P
O
3
O
O
p
o
^
o
80
60
40
*
f
20
10 20 30
Storage Time - Days
40
50
10
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Bibliography
(1) Gehm, H. W., "Bibliography of Biological Oxidation as Applied to Pulp
and Papermill Effluent," NCASI Tech. Bull. #161 (1963).
(2) Cawley, W. A. and Minch, V. A., "The Treatment of Pulp and Papermill
Wastes," Ind. Water and Wastes, 8, 12 (1963).
(3) Burns, 0. B., Jr., and Eckenfelder, W. W., Jr., "Aeration Improvement
and Adaptation of a Cooling Tower to an Activated Sludge Plant,"
Tappi, 48, 11, 96A (1965).
(4) Burns, 0. B., Jr., and Eckenfelder, W. W. , Jr., ''Pilot Plant Evaluation
of Plastic Trickling Filters Series With Activated Sludge," Tappi
48, 1 (1965).
(5) Estridge, R. B. et al. , "Treatment of Selected Kraft Mill Wastes in a
Cooling Tower," Tappi Air and Water Conf. (1970).
(6) Middlebrooks, E. S. et al., "Spraying of Stored Pulpwood with Waste
Water," Tappi 51, 930A (1968).
(7) FWPCA Res. Report., "Dilute Spent Kraft Liquor Filtration Through
Wood Chips," Water Poll. Control Services, 12040 E22 04/70 (1970).
(8)
(9) Berger, H.F., "BOD Reduction of Industrial Effluents by Use of
Stabilization Basins and Natural Hydrographic Feature
Pulp and Paper Mag. of Canada," T-231,(March 1960).
(10) Heustis, C. S., "Oxidation Lagoon Treatment of Bleached Kraft Mill
Effluent ," Tappi Eng. Sec. Meeting (1962).
(11) Heustis, C. S., "Design and Construction of High Degree Effluent
Treatment Works ," NCASI Tech. Bull. #139 (1961).
(12) Bodenheimer, V. B., "Factors to Consider in Waste Treatment Systems
Evaluation", Southern Pulp & Paper , 30, 76 (Feb. 1967).
(13)
(14) Webster, W. T., "Reduction of Oxygen Demand of Draft Mill Wastes
by Natural Purification Facilities ," NCASI Tech. Bull. #76,
28, (1955).
(15) Gehm, H.W. and Gove, G., "Kraft Mill Waste Treatment in the U.S./'
NCASI Tech. Bull. #221 (1968).
(16) Ross, A. M., "Newton Falls Gives Details of Stream Imp. Plan ,"
Paper Trd. Jour., 150, 44 ( Dec. 1966).
11
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(17) Forges, R., "Ind. Waste Stabilization Ponds in theU.S.," WPCF
Meeting, Toronto, Canada, (1962).
(18) Hermann, E. R., and Gloyna, E. F. "Waste Stabilization Ponds, III ,"
Sew. and Ind. Wastes, 30, 963, (1958).
(19) Blosser, R. 0., "Oxidation Lagoons" Paper Presented, Tappi Eng. Conf.
Pittsburgh, Pa. (Oct. 1959).
(20) Edde, H., "A Manual of Practice for Biological Waste Treatment in the
Pulp and Paper Ind." NCASI Tech. Bull. #214, (1968).
12
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Activated Sludge Treatment
As a result of experimental work started in 1950 (1), the activated
sludge process was adapted to treating pulp and paper mill wastes.
Early experiments were followed by pilot plant investigation by
Palladino (2), Gehm (3), Bishop (4), and Kniskern (5). Trials on modi-
fications of the process were later carried on by Weston and Rice (6),
and its adaptation to other specific wastes by Nylander and Rennerfelt
(7), Shindler (8), Sullins (9), and Waldmeyer (10).
Design and operation of the first large plant to be built was described
by Moore and Kass ( *) and its operation by Pearman and Burns (* ). This
plant, treating waste from a bleached kraft and limerboard mill, was
followed by others treating kraft pulpmill, newsprint, and fine paper
waste waters as well as waste paperboard effluent in this country and
similar wastes in Europe.
This process operates successfully at over ten mills in this country. It
has been found capable of removing in excess of 80 percent of the BOD,- from
effluents to which nutrients have been added. Because of the nature and
temperature of these wastes high oxidation rates are possible so that loading
in excess of 100 pounds of BOD^ per 1000 cu. ft. of aeration capacity are
obtainable, allowing the use of relatively small aeration tanks. Mechanical
surface aerators are most commonly employed although diffused air has been
used at two plants. The major difficulty relative to their operation is the
dewatering and disposal of the waste activated sludge. This material is
extremely slimy and must be mixed with more free materials to be successfully
dewatered, primary sludge, barks, and fly ash being examples of these. In
one instance it has been disposed of on plowed land. Experimental work
employing centrifugal thickening and heat treatment is now underway in the
hope of finding a solution to this problem.
Three mills employ modifications of the activated sludge process, one using
contact stabilization and two extended aeration plants, and one treating
strong wastes from a magnesium base bleached sulfite pulp mill.
Design and operation of a number of these plants are described in NCASI
Technical Bulletin #220 (* ) and #214 (* ) and others by Coughlan (* ).
Billings and Narum (* ), and Butler (* ) .
Performance data for individual mills is presented in treatment tables
of this report.
* Complete bibliographies will be supplied in the final report.
13
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Bibliography
(1) Moggio, W.A., "Kraft Mill Waste Research," NCASI Tech. Bull. #38
pt. 3 (1951).
(2) Palladina, A.J., "Final Report on Deinking Waste Demonstration Plant,"
NCASI Tech. Bull. #58 (1953).
(3) Gehm, H. W., "Final Report on the Corporative Waste Treatment Pilot
Plant," NCASI Res. Report (1952).
(4) Bishop, F. W. and Wilson, J.W., "Integrated Mill Waste Treatment and
Disposal," Sew., and Ind. Wastes, 26, 1485 (1954).
(5) Kniskern, J.M. , "Reduction of Oxygen Demand of Kraft Mill Wastes by
Application of the Accelerated Aeration Process,"NCASI, Tec.
Bull.#76 p. 31 (1955).
(6) Weston, R. R. and Rice, W.D., "Control Stabilization Activated Sludge
Treatment for Pulp and Paper Mill Waste," Tappi, 45, 223, (1962),
(7) Nylander, G. and Rennerfelt, J., "Investigations on Bio-Oxidation
of Different Types of Pulp Mill Wastes," Congress of Pure and
Applied Science, Munich (1959).
(8) Shindler, I.S., "Bioaeration of a Highly Recirculated Board Mill
Effluent," NCASI, South Cent. Reg. Meeting (1957).
(9) Sullines, J. K., "The Activated Sludge Process as Applied to Pulp
and Paper Mill EFfluents," Pulp and Paper Mag. of Canada,
218 (1960).
(10) Waldraeyer, T., Purification of Paper Mill Effluents by Activated
Sludge,"Proc. Brit. Paper Board Makers Assoc. 39, 425 (1958).
(11) Moore, T.L. and Kass, E.A., "Design of Waste Treatment Plants for
the Pulp and Paper Industry," Biological Treatment of Sewage
and Ind. Wastes," Reinhold Pub. Co. N. Y. (1955).
(12) Pearman, B.V- and Burns, O.B., Jr., "Activated Sludge Treatment of
Wastes from a Kraft and Neutral Sulfite Mill," Purdue Univ.
Ind. Wastes Conf. XII, 480 (1957).
(13) Rennerfelt, J. , "Bio-Oxidation of Pulp Mill Wastes in Sweden,"Conf.
on Biological Waste Treatment, Manhattan College (1960).
(14) Gancaarczyk, J. and Duda, K. , "Activated Sludge Tr. in Poland,"
Przgl, Papier 25, 49 (Poland) (1969).
(15) Potapenko, A.P., "Biological Purification of Effluents at the
Zhidacher Combine," Bumazhn. Prom-(USSR) 4, 15 (1965).
(16) Bailey, B.L., "Water Supply and Effluent Treatment at Kamloops
Pulp and Paper Co.," Pulp and Paper Mag. of Canada 67,
85 (July 1966).
14
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(17) Morgan, 0., "Biological Treatment Case Histories in the Pulp
and Paper Ind.," NCASI, Tech. Bull. #220 (1968).
(18) Edde, H., "A Manual of Practice for Biological Treatment in the
Pulp and Paper Industry," NCASI Tech. Bull. #214 (1968).
(19) Coughlan, F.P., Jr., "Design and Operation of an Activated Sludge
Plant for Scott Paper Co.," Tappi, 46, 191A (1963).
(20) Billings, R.M., and Narum, Q.A., "Design Criterin and Operation of
a Liquid Effluent Treatment Plant," Tappi, 49, 70A (1966).
(21) Butler, J., "A Case History and Evaluation of Waste Treatment
Problems at the D.M. Bare Co.," Tappi, 47, 82A (1964).
15
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Aerated Stabilization Basins
The long period of time required to produce a relatively high degree
of BOD reduction on storage is due to the low rate of natural reaeration.
This time can be reduced substantially by induced aeration as pointed
out by Amberg (1), Eckenfelder (2), and a number of others (3),(4).(5).
(6) (7). In order for the potential of this method of treatment to
be fully realized it is necessary to add mutrients since most pulp
and paper effluents are deficient in these elements. These additions
are usually made in the form of ammonia and phosphoric acid. The
optimum BOD,--N-P ratio is approximately 100-5-2, but this can sometimes
be reduced because of the presence of some nitrogen and phosphorus in
the wastes due to sanitary sewage, boiler blow-down containing
phosphates or detergents, and/or dispersing agents and adhesives used
in the mill. The effect of nutrients on the oxidation rate of pulp
and paper wastes is discussed by Nowacki (8) and (9) and Tracy in
detail (10).
Aeration is generally induced by mechanical surface aerators which are
capable of dissolving on the order of 50 pounds of oxygen per horse-
power day (11), (12), (13). Diffused air can be employed but is less
efficient. Recently a downflow bubble aerator has been developed for
use in deep basins (14).
Eckenfelder (15) and Edde (16) discuss the design of these basins in-
cluding configuration, power requirement, and aerator placement.
These basins are generally designed for about five days detention time
since this provides a sufficient period to produce a BODc reduction on
the order of more than 80 percent and allows stabilization of the bio-
mass by means of autogenous respiration as well as dispersion of most
of the resulting debris. Some sludge accumulates in the bottom of
these basins but is relatively inert and readily removed periodically.
If BOD5 removal in excess of 90 percent is required, the retention
period is increased to about ten days. At some mills a settling
basin follows the aeration unit in order to improve effluent clarity.
Gellman (17) (18) and Gehm and Gellman (19) discussed the performance
of aerated basins treating various types of pulping and paper making
wastes finding them all responsive to this treatment.
Vamvakias et al (20) investigated the effect of temperature on the
efficiency of the process under carefully controlled laboratory con-
ditions and Weston and Rive (21) did likewide in the field. They
found that while efficiency decreased with the temperature, this effect
was not as severe as anticipated and that good BODr reductions were
obtained in 5 days at 2°C. The adverse effect of low temperatures
is minimized with increased retention time as shown in Figure // 5
Bailey (22) reporting on basin performance at sub-freezing ambient
temperatures indicated that operation under these conditions was
satisfactory.
16
-------
c
o
H
-p
o
o
0)
Q
g
C
0>
o
!H
0
O.
90
80
70
60
50
Tl
o
30
20
10
J_
2.5 5.0 7.5
Aeration Time (Days)
10.0
Figure # 5 Effect of Temperature on
BOD Reduction in Aeratef
Stabilization Basins
17
-------
Operation of a number of these basins at large kraft mills are reported
in the literature for example those appearing in papers by Bailey (23),
White (24) , and Ebersole (25). Canadian operations are reviewed by
Voege and Stanley (26).
Some forty installations of this kind have been made at kraft pulp
mills in the U. S. They provide a high degree of BOD reduction without
very extensive land use and at capital and operating costs lower than
those for highly accelerated oxidation processes. The advantage of this
method is that it does not produce a slimey waste sludge, difficult
to dewater and dispose of. Effluents produced at reasonably high BOD
reductions are not conducive to slime production in receiving waters.
Performance data for many of these installations are presented in treatment
tables in a subsequent part of this report.
18
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Bibliography
(1) Amberg, H.R., "Factors Affecting the Lagooning of White Water,"
NCASI Tech. Bull. #55 (1952).
(2) Eckenfelder, W., "Design and Performance of Aerated Lagoons for
Pulp and Papermill Waste Treatment," Purdue Univ. Ind. Waste
Conf. XVI. 115 (1961).
(3) Betts, C.N., et al, "An Approach to Design of Biological Oxidation
Treatment Facilities for Paper Machine Waste Waters," Purdue
Univ. Ind. Waste Conf. XI 73 (1956).
(4) Gehm, H. W., "The Application of Stabilization Basins in the Purification
of Pulp and Papermill Wastes," Paper Presented 35th Annual Meeting,
WPCF, Toronto, Canada (1962)
(5) Gehm, H. W., "New and Basic Res. Approaches to Pulp and Papermill
Liquid Effluent Treatment," NCASI Tech. Bull. #104 (1958).
(6) Techenberg, P.E. et al., "Aerated Basin Planning for Purification
-of Pulp Mill Effluents," Paperi Pun 50 (12) 741 (Finland)
(Dec. 1968) Chem. Abs., 70 (12) (50263d).
(7) O'Connor, D. and Eckenfelder, W. W. Jr., "Treatment of Organic
Wastes in Aerated Lagoons," Jour. WPCF, 32, 365 (1960).
(8) Nowacki, J;, "Nutrient Salt Reduction in the Biological Purification
of Kraft Mill Effluents," Fortachr Wassechem ihrer Grenggeb,
#11, 135 (1969).
(9) Nowacki, J., "Influence of Addition of Phosphorus and Nitrogen to
Pulp Mill Effluents," Pregeglad Papier, 25, (6) 211 (Poland)
(June 1969).
(10) Trach, J. C., "Secondary Waste Treatment Nutrient and Aeration
Studies," Southern Pulp and Paper Mfg. 33. 46 (Feb. 10, 1970).
(11) Laws, R. and Burns, 0. B., "Oxygen Transfer and Power Cost with
Turbine Type Equipment," Purdue Univ. Ind. Waste Conf. XIV,
633 (1960) .
(12) Dreier, D. E., "Theory and Development of Aeration Equipment,"
Biological Treatment of Sewage and Ind. Wastes, Vol. I
Reinhold Put- Co. N.Y. (1956).
(13) Gloppen, R.C. and Roeber, J.A., "Rating and Application of Surface
Aerators," Tappi, 48, 103A (1965).
(14) McKeown, J. J., "Results of a Cooperative Field Study of a Down-
flow Bubble Contactor and a Conventional Surface Aerator,"
NCASI Tech. Bull. #237 (1970).
19
-------
(15) Eckenfelder, W. W., Jr., "Ind. Waste Water Control," McGraw Hill
Book Co. New York (1966).
(16) Edde, H., "Field Res. Studies of Hydraulic Mixing Patterns in
Mechanically Aerated Stabilization Basins," Int. Cong, on
Ind. Waste Water, Stockholm, Sweden (1970).
(17) Gellman, I., "Practice and Research in Biological Oxidation of
Pulp and Paper Mill Wastes," NCASI Tech. Bull. #162 (1963).
(18) Gellman, I., "Aerated Stabilization Treatment of Mill Effluents,"
Tappi, 48, 106A (1965).
(19) Gehm, H. W., and Gellman, I., "Practice Research Development in
Biological Oxidation of Pulp and Papermill Effluents," Jour.
WPCF, 37, 1392 (1965).
(20) Vamvakias, J. et al., "Temperature Relationships in Aerobic
Treatment and Disposal of Pulp and Paper Wastes," NCASI Tech.
Bull. #191 (1966).
(21) Weston, R. F. and Rice, W.D., "Contact Stabilization Activated
Sludge Treatment for Pulp and Paper Mill Waste." Tappi, 45,
223 (1962).
(22) Bailey, B. L., "Water Supply and Effluent Treatment at Kamloops
Pulp and Paper Co., " Pulp and Paper Mag. of Canada, 67,85
(July 1966).
(23) Bailey, G.S., "Weyerhaeusers's Treatment of Pulp and Paper Wastes
at Plymouth, N.C.,"Purdae Univ. Ind. Waste Conf. XXIV, 128A
(1965).
(24) White, M.T., "Surface Aeration as a Secondary Treatment System,"
Tappi, 4F, 128A (1965).
(25) Ebersole, W.M., "Effluent Treatment System at Alabama Kraft Company,"
NCASI Tech. Bull. #208 (1967).
(26) Voege, F. A. and Stanley, D. R., "Industrial Waste Stabilization
Ponds in Canada," JWPCF, 35, 109 (1963).
20
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BIOLOGICAL TREATMENT SUMMARY
It can be concluded that biological treatment in its several forms is
now extensively employed in the pulp and paper industry for reducing
the BOD of spent process waters. When properly pre-conditioned, all
of the weak wastes of the industry are responsive to such treatment,
with the degree of reduction depending upon the extensiveness of the
facilities provided. The selection of the specific method at a
particular mill frequently depends upon land availability since the
methods requiring a considerable area are the least expensive and often
the most reliable. Within limits, the level of BOD reduction can be
adjusted by design and operation to meet local requirements. Natural
performance limits have been established by statistical analysis of the
performance of such plants over long periods of time by Burns (1) and
Weston (2).
Added benefits obtainable from biological treatment are the destruction
of toxicity to aquatic life (3), reduction in foaming tendencies (4),
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 (5) .
The shortcomings of biological treatment are its failture to remove color
to a high degree and the production by high rate processes of a waste
sludge of an extremely slimey nature (6). Color bodies are not oxidized
(7) and at best only a fraction of them adsorbed into the bio-mass. The
use of these processes will be limited until better solutions than those
presently available are found Lo solve the sludge disposal problem.
21
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Bibliography
(1) Burns, O.B., Jr., "A Statistical Study of Five Years' Operation
of the West Virginia Pulp & Paper Co.'s Waste Treatment Plant,"
Purdue Univ. Ind. Waste Conf. XVIII, 108 (1963).
(2) Weston, R.F. and Rice, W.D., "Contact Stabilization Activated Sludge
Treatment of Pulp & Paper Mill Waste, Tappi, 45, 223 (1962).
(3) Warren, C. E., "Biology of Water Pollution Control," W. B. Jounders,
Philadelphia, Pa. (1971).
(4) Carpenter, W. L., "Foaming Characteristics of Pulping Wastes During
Biological Treatment," NCASI Tech. Bull. #195 (1966).
(5) "A Critical Review of the Literature on Slime Infestations," NCASI
Tech. Bull. #232 (1969).
(6) Caren, A. L., and Mazzola, C. A., "The Effect of Waste Activated
Sludge Addition on Vacuum Filtration of Primary Clarifier
Sludges," Purdue Univ. Ind. Waste Conf. XXIV, 850 (1969).
(7) Lawrence, W. A. & Fukui, H. N., "Calcium Lignosulfonate Oxidation
Sew. and Ind. Wastes, 28, 1484 (1956).
22
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IRRIGATION AND LAND DISPOSAL
Irrigation
Although extensive field studies of the disposal of mill effluents has
been made by large kraft producers (1), (2), (3), (4), actual use of
this technique has been made only by small papermills. This is because
of the limited amount of effluent that can be applied per acre in
relation to the volume mill dishcarge. It had been hoped that irrigation
of southern woodlands would lead to an increase in wood yield that would
justify the extensive irrigating systems required. Experiments proved
that the increased yields realized would not justify the cost (5), (6),
hence no large scale project of this kind was developed. However, rice,
vegetables, peanuts, and fodder crops were all successfully grown at high
yields using kraft mill effluents as irrigation water.
A number of small mills employ irrigation as both a means of secondary
treatment and as a seasonal supplement to secondary treatment. There
are descriptions of some of these applications in the literature (7),
(8), (9), (10), (11), (12). Wastes from fine paper, tissue, corrugated
board, waste paperboard, and hardboard production are all treated in
this fashion, mainly by small mills utilizing streams having very low
seasonal flow.
Extensive investigations conducted by NCASI and reported in several
technical bulletins (13) , (14) , (15) and by Gellman (16) have established
the parameters and good practice requirements for this form of treatment.
Percolation through the soil is extremely effective and, during dry
weather, color bodies present in pulping wastes are inclined to leach
out when the soil is washed with rain water. From ten to twenty gallons
per acre per day of weak waste waters can be successfully disposed of
in this manner. With stronger wastes the BOD or organic solids determine
the allowable application rate. Blosser and Caron (8) recommend that BOD
loadings be held to less than 200# per acre per day. Parsons (9) reports
that total solids application of as high as 500 pounds per acre per day
have been applied in irrigating with fiberboard waste water having a solid
content of 2 percent.
While spray disposal started as a summer dry weather procedure it has been
used at some locations recently the year around with a measure of success
(12).
Land Disposal
Soil percolation is employed for the disposal of spent acid and neutral
sulfite liquors at small mills. Experience with this method of disposal
has been reported by Billings (17) , Guerri (18) , and Wisniewski et al (19).
One mill recently reported on disposing of 200,000 gal. of NSSC liquor
containing 10% solids from a 250 ton dry mill. One sixteenth of an inch
per day is applied, 3/8" to 7/16" being sprayed on in a day and a 6-day
resting period allowed. The liquor solids are adsorbed and decomposed
in the soil and do not reach adjacent surface water or wells. This method
is applicable only at small mills having especially suitable land which is
not in the proximity of dwellings.
23
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Bibliography
(1) McCormick, L.L. et al., "Paper Mill Waste Water for Crops Irrigation
and its Effect on the Soil," Bull. 604 Louisiana State Univ.
Agric. Expt. Sta. (Dec. 1965).
(2) Bishop, F.W. & Wilson, J.W., "Southland Paper Mills Waste Treatment
& Disposal," Sew. & Ind. Wastes 26, 1485 (1954).
(3) Crawford, J. C., "Spray Irrigation of Certain Pulp Mill Wastes,"
Sew. & Ind. Wastes 30, 1266 (1958).
(4) McCormick, L. L., "Effects of Papermill Waste Water on Cattle, Crops
& Soil," La. Agr. Experiment Station Bull. 529 (1959).
(5) Jorgensen, J. R., "Irrigation of Slash Pine with Paper Mill Effluents,"
Louisiana State University Div. Eng. Res. Bull. 80: 90 (1965).
(6) Barrett, J.P-, "The Effects of Paper Mill Effluents on Slash Pine
Seedlings," Prog. AL-14 Southern Forest Exp. Station.
(7) Voights, D., "Lagooning and Spring Disp. of NSSC Pulp Mill Liquors,"
Purdue Univ. Ind. Waste Conf., X 497 (1955).
(8) Westenhouse, R., "Irrigation Disposal of Wastes," Tappi, 46, 8, 160A
(1963).
(9) Parsons, W.C., "Spray Irrigation of Wastes from the Manufacture of
Hardboard," Purdue Univ. Ind. Waste Conf., 602 (1967).
(10) Blosser, R.O., and Caron, A. L., "Recent Progress in Land Disposal
of Mill Effluents," Tappi, 48, 5,43A (1965).
(11) Slaby, F., Riegel Paper NCASI Monthly Bull. II (4): 2 (1964).
(12) Flower, W. A., "Spray Irrigation: A Positive Approach to a Perplexing
Problem,"Purdue Univ. Ind. Waste Conf. 679112 (1965).
(13) Blosser, R. 0., "Pulp & Papermill Waste Disposal by Irrigation,"
NCASI Bulletin #124 (1963).
(14) Blosser, R. 0., "Disp. of Pulping Effluents by Land Disp. &
Irrigation," NCASI Tech. Bull #164 (1963).
(15) Blosser, R. 0., & Caron, A. L., "Recent Progress in Land Disp.
of Mill Effluents,"NCASI Tech. Bull. #185 Pt. IV (1965).
(16) Gellman, I., "BOD Red. of Paper, Paperboard, and Weak Pulping
Wastes by Irrigation," Pulp & Paper Mag. of Canada 37, T-221
(1959).
(17) Billings, R.M., "Stream Improvement Through Land Disp. & Soil Cond.,"
Pulp & Paper Mag. of Canada 37, T-226 (1959).
24
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(18) Guerri, E. A., "Land Disposal of NSSC Liquor at the Terra Haute,
Ind. Mill of Weston Mfg. Co.," NCASI Bulletin (1971).
(19) Wisniewski, T.W., et al., "Ponding and Soil Filtration for Disposal
of Spent Sulfite Liquor in Wise.," Tappi 39, 65 (1956).
25
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COMBINED TREATMENT
Sewage treatment plants encounter no problem in treating pulp and paper-
making wastes if they are adequately designed to handle the load imposed
as pointed out by Pirnie and Quirk (1), Gehm (2). Falukender (3), Opferkuch
(4), Quirk (5), and others. In some cases pretreatment is required ae
discussed by Swets et al,(6). This is particularly the case where
suspended solids loads are high. In any event it is advisable for connected
mills to practice efficient film recovery. The smaller the percentage
of the total load contributed by the mills the more readily it is
handled by the treatment works, since variations in process losses have
less impact on the overall waste strength received at the plant at any
given time. Therefore, few pulp mills are involved in public projects
largely because of their generally large size although this trend may be
changing as consideration is being given to joint treatment of all wastes
in heavy industrial areas such as Green Bay, Wisconsin; Macon, Georgia,
and Erie, Pennsylvania. However, for many years many waste paperboard
mills in or close to large communities have been discharging their waste
to these systems for treatment with satisfactory results. The National
Council for Stream Improvement reports on this practice as follows:
It can be concluded that the trend toward treatment of the effluent from
small mills in community sewage treatment works will continue and both
small and large mills in metropolitan areas will probably join with the
municipality and industries in joint treatment. However, the large
outlying pulp mill will continue to provide its own waste handling
facilities.
Mill Size and Location
The study data, summarized in Table I showed that of 753 separate pulp
and paper manufacturing locations, 123 or 16 percent now dishcarge their
process effluents to publicly-owned treatment facilities. These mills
account for approximately 5.5 million tons per year of paper production
capacity, or 11 percent of the industry total. This suggests that they
tend to be smaller mills, and this is borne out by the results. The
mills are concentrated in a number of local areas such as Los Angeles
County, Northern Metropolitan New Jersey, Philadelphia, Neenah-Menasha,
Kalamazoo, Cincinnati and Chicago, which together account for 58 mills,
or 47 percent of those discharging to public systems.
Classification of Mills
The mills tend to produce those grades most closely associated with location
in, and adjacent to, major urban centers. Study data, summarized in
Table II, showed that coarse paper grades account for most of the
remainder (divided evenly between fine papers, specialties and tissues).
Only four mills are characterized as integrated pulp and paper units.
Thwenty-five percent are smaller than 50 TPD, and the median size is
only 100 TPD. Only twelve mills, or 10 percent, are larger than 300 TPD.
Mills Considering Discharge to Public Facilities
(a) Number of Mills - This broad category covers mills known to have
recently completed arrangement for public treatment, those where
feasibility and rate schedule studies are still in progress, and some
where such studies have lead to a decision to proceed with independent
26
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treatment. The survey data presented in Table showed that the entire
group includes 91 mills, or 12 percent of those now operating. Their
annual capacity totals 5.5 million tons, or 11 percent of the total
for the industry. Taking both groups together, we find that use of public
treatment facilities is more than an academic question for 28 percent
of the industry's mills, accounting for 22 percent of its production
capacity.
(b) Mill Location - The largest concentrations of mills now considering
public treatment are located in three states: New York, Massachusetts
and Maine, accounting for 55 mills or 60 percent of the total. These
are states where effluent treatment has only recently gathered momentum
after extended periods of stream classification and abatement program
development for both municipalities and industries, and where planning
funds have been allocated by the legislatures to assist such regional
treatment feasibility studies.
(c) Mill Classification and Size Distribution - The size distribution
profile of these mills is similar to that for mills already in public
systems. Nearly 25 percent are smaller than 50 TPD, and the median size
is 100 TPD. The coarse paper grades account for a lesser fraction of
the mils, being equalled in number by those producing fine grades.
We also see a significant increase in the number of integrated pulp and
paper mills involved in such studies. This is particularly true in
Maine and New York. Most of the feasibility and rate studies are
not far enough along to permit an analysis as to projected costs or
financing'procedures. The bulk, hox^ever, are predicated on providing
secondary treatment in line with actual needs or regulatory policy.
Treatment Received and Costs Allocation
Of the total, 59, or slightly less than half, receive primary treatment,
treatment charges are reported as 20C and 65C respectively for primary
and secondary treatment for the waste paperboard mills, and 30c amd
80c for all the mills surveyed respectively. Three methods for computing
sewer service charges enjoy approximately equal use. These are ad
valorem property taxation, and rates based on flow alone, or flow
plus effluent strength. Specially negotiated contracts account for
only 7 percent of the rates, while each of the more prevalent systems
are in use at approximately 30 percent of the mills.
27
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TABLE I
MILLS NOW DISCHARGING TO PUBLIC FACILITIES
NUMBER OF MILLS
CAPACITY, 106 TPA
MAJOR LOCATIONS
LOS ANGELES COUNTY
NORTHERN METROPOLITAN NEW
PHILADELPHIA
NEENAH-MENASKA
KALAMAZOO
CINCINNATI
CHICAGO
123 of 753, or
5.5 of 50, or
AND NUMBER
13
JERSEY 19
6
6
5
5
b
16%
life
58 of 123, or
28
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TABLE II
MILLS NOW DISCHARGING TO PUBLIC FACILITIES
DISTRIBUTION
TPD
0 - 100
101 - 200
201 - 500
^500
BY SIZE
NUMBER
62
35
23
3
DISTRIBUTION BY TYPE
COARSE PAPER GRADES
WASTE PAPERBOARD
ROOFING FELT
FINE PAPER GRADES
INTEGRATED PULP & PAPER
80
64
16
39
4
MEDIAN SIZE 100 TPD
29
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TABLE III
MILLS STUDYING DISCHARGE TO PUBLIC FACILITIES
DISTRIBUTION BY SIZE NUMBER DISTRIBUTION BY TYPE
0
101
201
TPD
- 100
- 200
- 500
S»* 500
44 COARSE PAPER GRADES 38
19 WASTE PAPERBOARD 32
23 ROOFING FELT 6
-5. Firm PAPRR r.RAnire ^R
MEDIAN SIZE 100 TPD
INTEGRATED PULP & PAPER 15
30
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Bibliography
(1) Pirnie M., Jr., and Quirk, T.P., "Design and Cost Considerations
for Treatment of Deinking Wastes," Paper Trd. Jour., 146,
30 (July 1962).
(2) Gehm, H.W., "Effects of Papermill Wastes on Sewage Treatment Plant
Operation," Sew. Wks. Jour., 17, 510 (1945).
(3) Faulkender, C. R., et al., "Green Bay, Wise., Joint Treatment of
Pulp Mill and Municipal Wastes,"Jour. WPCF, 42, 361 (1970).
(4) Opferkuch, R. I., "Combined Treatment of Sanitary Sewage and Semi-
Chemical Pulp Mill Waste,"NCASI, Tech. Bull. #42 (1951).
(5) Quirk, T.P-, "Combined Waste Treatment Design," Jour. WPCF, 31,
1288 (1959).
(6) Swets, D. H. et al., "Combined Treatment at Kalamazoo," Jour. WPCF,
39, 204 (1967).
31
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SLUDGE THICKENING. DEWATERING. AND DISPOSAL
Introduction
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 fact,
the problem is of greater magnitude than ever, not only because of
increased production but also because an increasingly larger percentage
of this material, formerly discharged to surface waters, is now removed
from the effluents. The great progress made during the last 30 years
in water recirculation and fiber and filler recovery began to make
it appear as though the immemorial dream of the completely closed
paper machine system would eventually come true. However, these
practices were found to reach a critical level and had to be curtailed
beyond a certain point at which a number of operational problems
made themselves immediately apparent. Among them are:
1. Foaming in stock system
2. Sheet formation troubles
3. Slowing of the stock
4. Dirt in the sheet
5. Decreased felt life
6. Accentuated slime control problems
7. Difficulties with water clarification systems
The causes of these troubles were found to be primarily the accumulation
of dissolved and colloidal substances entering the system with the
furnish, or produced during the mechanical processing or chemical treatment
of the fibers. The use of the many new paper additives, as well as
the high quality and cleanliness standards required at the present time,
have not improved this situation. Many mills operating with close
to the maximum of water recirculation have found it necessary to reduce
this practice somewhat, since one" way or another the concentration of
tne offending substances must be kept below a tolerable level within
the machine system. Hence, it can be reasonably concluded that some
water will have to leave the system to carry the undesirable materials
off, and with them is bound to come some fiber sizing, filler, and other
additive materials.
As improved effluent quality was required, it was believed that filtration,
sedimentation, or flotation devices would alone suffice to remove
suspended solids, if properly designed and with the aid of coagulant
addition. Indeed, in some instances where process water was in short
supply or costly, it was believed that the expanded use of the clearer
recirculated water would justify the added cost of clarification. This
conclusion was based on the assumption that the reclaimed material could
be used back in the system quite as readily as that returned from a simple
saveall arrangement, despite the finer division of fiber. This is where
real difficulties arose and where the returned slurry gained the name
of sludge rather than furnish.
The cnaracteristics of such material changed altogether in that it was no
longer free-draining but gelatinous in nature. More remarkable was the
fact that on addition of a small proportion to a relatively free furnish.
32
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it was able to transmit its water holding capacity to the entire fiber
mass of the furnish to a very appreciable degree. Careful examination
of the fibers revealed that the fines, frequently aided by coagulants,
paper additives, and in the case of waste paper furnishes, adhesive
materials, plated out on the long fibers changing their physical
characteristics.
The National Council for Stream Improvement has published extensively
regarding the various type sludges. Reports have been made on sludges
varying from 95-98% volative solids (groundwood) to deinking and roofing
mill sludges with ash contents varying from 40 to 70%. Between these
extremes runs the whole gamut of kraft, sulfite, groundwood papers,
and various specialties, so that it is almost impossible to generalize
the type sludge to be encountered. Gehm (1) has given a summary of the
complex nature of paper industry sludges. Activated sludge produced
from the treatment of pulp and papermill wastes, is of similar hydrous
nature to that of activated sludge derived from sanitary sewage.
While that obtained from treating paper wastes high in inerts dewaters
more readily, that from treating pulping and boardmill wastes
has very much the same properties.
The handling of all types of sludges produced by treatment of pulp
and papermill wastes are described in detail in the NCASI Manual of
Practice (_2) and a variety of installations in NCASI Tech. Bull. #209 (J3) .
Gravity Thickening
There is probably no one single factor which affects the feasibility and
end results of sludge dewatering, regardless of the method chosen, more
than the degree of preconcentration of the sludge. With rare exception,
it can be said that the higher the feed sludge solids content, the
more efficient the dewatering operation, from the performance, operation ,
and economic standpoints.
Pulp and papermill sludge can be thickened in the primary clarifier.
However, in some cases, particularly when clarifier capacity is limited,
the sludge cannot be thickened to a desirable consistency without creating
problems in the primary clarifier. When this is true, the sludge
is removed from the primary clarifier and thickened in a gravity thickener,
two types of which are in common use. These are the conical tank and
the "picket fence" mechanical unit.
Conical Thickening Tank
The conical tank has generally been replaced bv the picket fence thickener.
However, it still has application, particularly for small installations.
The conical thickener is frequently a fill and draw, or batch operation,
but can be designed for continuous operation. Side slope of these units
should exceed 60° so that sludge accumulation on the sides does not occur.
In batch operation the tank is filled with sludge over a period of time
and the sludge is allowed to settle for several hours. The liquid
above the sludge (supernatant) is drawn off with a swing tube. The
thickened sludge is then withdrawn. The tank is then refilled to start
33
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another cycle. For continuous operation, this type of thickener is
equipped with a feed well and overflow weir similar to that of a clarifier.
Mechanical Thickener
The mechanical, or picket fence, thickener is a continuous feed operation.
Sludge is fed continuously and thickened sludge removed from the unit
continuously. The tank, rake mechanism, and other appurtenances are
similar to those used in clarifiers, the difference being that a
series of vertical vanes resembling a picket fence are attahced to
the rake mechanism. These serve to accelerate separation of water
from the solids.
Figure # 6 shows gravity thickening curves from three different types
of papermill sludges. It can be seen that these sludges approach their
ultimate compaction in 4 to 6 hours. However, at the end of a thickening
period of 12 hours, widely divergent solids contents of 2.6% in the
groundwood sludge, 4.2% in the boardmill sludge, and 9.4% in the deinking
sludge exist. This is due to variation in the degree of hydration and
inorganic content, as illustrated in Table IV.
Thickener Installations
There are not many thickener installations within the industry due to
the fact that sludges are generally thickened in the primary clarifier.
They are most frequently found at large mills having activated sludae
treatment. Table IV-A shows data obtained from some of those in use. It
appears from these data and laboratory studies that detention times of
4 to 6 hours with solid loadings of 200-800 sq.ft./ton/day and hydraulic
loadings of 400-900 gpd/sq.ft. will give good results. As can be seen
from the wide loading ranges given, laboratory thickeneing tests must
be made with maiy samples of the sludge to obtain the best design
parameters for a given installation.
Both dissolved air flotation and vertical disc type centrifuges have
been applied to dewatering hydrous sludges by individual mills. The
first of these methods is described by Katz (4) and in a NCASI research
report (5). Woodruff et al (6), Gehm (7), and Barton et al (8) discuss
the centrifuge application. Both of these methods are confined to use of
very slimy sludges such as those high in groundwood fines or biological
in origin. Dissolved air flotation produces overflows up to 4.5 percent
concentration while the centrifuge cake ranges from 7 to 12 percent
depending upon the feed rate and initial consistency.
Vacuum Filters
The continuous rotary vacuum filter is widely used for dewatering sludge-
This unit is similar to drum filter that are used as pulp washers. The
rotary vacuum filter consists of a drum covered with filter cloth, wire
mesh, or a series of endless coil springs and is arranged to rotate
partially submerged in a vat of slurry. The periphery of the drum is
divided into a number of compartments which are underdrained beneath
the filter media and individually piped to a rotating valve located
at one end of the drum. Hence each compartment is an individual filter,
34
-------
%7
CO
§
o
?£2i*pax. ^etic^JS- W£Kbu3QM» _*
DEINKING SLUDGE
BOARDMIL.L SLUDGE
GROUNDWOOD SLUDGE
____J!____L^
0 2 4 (
TIME
FIGURE 6
THICICENING CURVES FOR VARIOUS SLUDGES
8 10
HOUR
C
12
35
-------
OJ
CTS
TABLE J-V
MILL INSTALLATIONS
Type Waste
Deinking
Gl as sine
Biological Waste
Seed Sludge
Papermill
(low ash)
Papermill
(high ash)
Thickened
Feed Consistency Loading Detention Sludge
Consistency
% gpd/ft2 Sq ft/ton/day Hr. %
1 360 910 5.6 3-5
0.5 50 1000 48 3-4
1.6 480 150 4 3-4
TABLE JV-A
THICKENER LOADING PARAMETERS
600-800 1-3
400-600 5-9
Bo ardmi11
(waste paper)
Activated Sludge
Primary Sanitary Sewage
300-450
100-250
85-200
3-5
1-2
3-7
-------
being sealed from its neighbor by division strips and functioning through
its own drainage system as controlled by the filter valve. As the drum
rotates individual filter segments become submerged in the slurry at
which point the valve connects this segment to the evaluation source.
A cake of wet solids is then formed on the surface of the media as
filtrate is removed through the underdrain system to the valve which
in turn directs it to a receiving tank. The segment remains under vacuum
after emerging from the slurry and until it reaches the top point of
the drum's rotation where the vacuum is cut off by the rotating valve.
During this stage air displaces more water from the cake.
As the segment no longer under vacuum descends in its rotation toward
the vat the cake is removed in one of several ways. Compressed air
can be admitted to each segment in turn just above the discharge point
to loosen the cake from the media or the cake can be scraped from the
drum with a doctor blade.
In the spring discharge type, continuous strings run .around the drum
and over the media at intervals of about 3/4 an inch. These are lifted
from the drum above the discharge point passing over an external guide
roll carrying the cake with them and discharging it as the strings
pass around the guide roll. The strings return to the cloth on drum
to begin another cycle.
In the most advanced filters, the entire media (cloth, wire mesh, or
coil spring) is lifted from the drum, unloaded, and washed by a high
pressure shower and returned to the drum through a guide roll system.
This type has been used on all recent installations in the pulp and
paper industry for sludge dewatering.
Operation data and results obtained in dewatering a variety of sludges
is shown in Table V . It will be noted that the loading range varies
widely for most of these sludges, the percentage of fiber present in
them at any particular time being the determinant; the higher the fiber
content the higher the loading.
It will also be observed that the filtrates, produced varied in suspended
solids content but that these were largely settleable. Since filtrates
are returned to the system ahead of the clarifier these solids are
recaptured.
This addition of activated sludge to clarifier underflows has a decidedly
adverse affect on dewatering. This is shown in Figure // 7 . The
effect of other additives such as fiber and fly ash and coal was studied(9)
and none of these with the exception of.fiber showed much promise of
improving vacuum dewatering. Some sludges respond to conditioning with
chemicals such as lime, ferris chloride, alum, or polymers. However,
the response of a particular sludge is unpredictable. Precoating of
filters with fly ash was tested with some success on hydrous sludges
but the quality of ash was found to vary widely in respect to usefulness
for this purpose. Recently, interest has developed in heat conditioning
and partial wet air oxidation as methods of sludge conditioning.
37
-------
TABLE V
CONTINUOUS VACUUM FILTRATION
Sludge Type
Feed Solids %
1
% Ash
Drun Speed
MFR
White Water
1.33-4.70
15.0-42.0
1.66-8.25
Decoating
& W.W.
5.85-10.02
49-58.3
1.23-6.66
Rag Pulp
Mill
3.98-11.25
_
1.53-3.08
Boardmill
0.87-2.36
- - _
1.22-3.33
Deinking
& W.W.
5.89-7.15
45.6-51.9
1.50-5.00
W.W.
2.21-8.26
34.5-58.1 ,
1.33-2.62
Felt
Mill
5.20-
5.27
1.5-
w Filter Cake
00 & Solids
Loading Rate
#/ft2/hr.
Ave. Filtrate
Suspended
Solids #AOOO
gal.
23.3-33.0 34.6-42.9 26.2-39.9 26.1-30.7 31.4-36.4 28.3-4.14
1.7-13.4
2.13-10.95 2.83-8.88 1.22-5.75 3.09-10.00 8.13-19.2
3.99
% Settleable
Solida in filtrate 86.9
Filter Media
70 X 56 mesh
fourdrinier
wire
26.1 62.7
95.6
70.56 Stainless
fourdrinier steel
4.68
86.6
22.5
94.1
6.34
89.4
3.08
21.4-
25.8
3.71-
5.92
Fourdrinier Stainless Fourdrinier Stainless
wire steel wire steel
-------
K
M
CSl
EH
I
o
K
W
a
FIGURE 7
EFFECT OF ACTIVATED SLUDGE OF
DEWATERING BOAHDMILL SLUDGE
4.5
4.0
3.5
3.0
2.5
10
iii- '-^ra^a.-jrEi :.~xi
20
30
% ACTIVATED SLUDGE
39
-------
Bibliography
(1) Gehm, H.W., "Removal, Thickening and Dewatering of Waste Solids,"
Pulp & Paper Mag. of Canada. Vol. 37, T189 (1959).
(2) Follett, R. and Gehm, H.W., "Manual of Practice for Sludge Handling
in the Pulp & Paper Industry," NCASI Tech. Bull #190 (1966).
(3) Lindsey, A. M., Sullins, J. K., and Fluharty, J. R., "Progress in
Primary and Secondary Sludge Disposal at Three Integrated
Southeastern Papermills," NCASI Tech. Bull. #209 (1967).
(4) Katz, W. J., "Solids Separation Using Dissolved Air Flotation,"
Purdue Univ. Ind. Wastes Conf XII, 163 (1957).
(5) "Flotation Thickening^ of Activated Sludge," Res. Rept. NCASI (1964).
(6) Woodruff, P.H., et al., "Dewatering Activated Sludge by Two Stage
Centrifuging," San. Eng. Conf., Vanderbilt Univ., (1967).
(7) Gehm, H. W., "Removal, Thickening and Dewatering of Waste Solids,"
Pulp & Paper Mag. of Canada 37, T189 (1959).
(8) Barton, C. A. et al., "A Total Systems Approach to Pollution Control
at a Pulp & Papermill," Jour. WPCF, 40, 1471 (1968);
(9) Carpenter, W. L., "Effect of Fiber on Dewatering Papermill Sludges
by Vacuum Filtration," NCASI Tech. Bull. #168 (1963).
(10) Beck, A., "Dehydration of Hydrogels," NCASI Tech. Bull #74 (1954).
(11) Bing, K. E., "Selected Papers on Industry Experience in the Disposal
of Waste Treatment Sludges," NCASI Tech. Bull #238, pt. IV (1970).
(12) Fuller, H. E., "New Developments in Design and Operation of Clarification
and Sludge Dewatering Facilities at Five West Coast Mills,"
NCASI, Tech. Bull. #211, Pt. Ill, (1967).
(13) Coogan, F. J. and Stovall, J. H., "Incineration of Kraft Pulp Mill
Effluents," Tappi 48, 94A (1965).
(14) Stovall, J. H. and Berry, D. A., "Pressing and Incineration of Kraft
Mill Clarifier Sludge," Tappi, Air and Water Conference 23-1
(1969).
40
-------
Centrifuge
The critical review of literature on the dewatering of hydrogels con-
ducted by Beck (10) at the University of Syracuse in 1954 indicated
that centrifuging offered one of the best possibilities for mechanical
dewatering hydrous slurries obtained from the clarification of some white
waters. This lead to the evaluation of two bench-scale units and the
experience and data obtained from them indicated that large-scale units
and the experience and data obtained from them indicated that large-scale
equipment of both types should be tested on various paper industry
primary underflows. Field work conducted in cooperation with mills
and equipment manufacturers, resulted in the development of a suitable
type of centrifuge for this job - a horizontal conveyor type machine.
A horizontal conveyor type centrifuge is essentially a settling device
which induces an increased force of gravity. Dewatering is a function
of the gravitational force applied and the detention time in the unit.
The slurry is introduced into the bowl by means of a feed tube located
in the hollow center shift. It is acted upon by centrifugal force,
the solids being deposited against the wall of the bowl. The liquid
having a lower specific gravity, forms a concentric inner layer in
the bowl. Inside the rotating bowl is a helical screw conveyor which
rotates in the same direction, but at a slightly different speed than
that of the bowl. This conveyor is pitched so that the solids, which
are deposited against the bowl wall, are conveyed to one end of the
bowl where they are discharged from suitably located discharge posts.
As in gravity settling, the liquid near the surface of the liquid
layer has the greatest clarity. This clarified liquid continuously
overflows adjustable weirs at the liquid discharge end of the bowl.
Suitable partition in the machine case form compartments for receiving
discharge effluent and solids guilding them into their respective hoppers.
Results of these tests indicated that the horizontal conveyor machine
appeared capable of producing a cake of 25 to 35% solids at recoveries in
excess of 85 percent.
Subsequent to these investigations the dewatering of sludges by
centrifugation has become a common practice. Installations have provided
the opportunity to evaluate this form of dewatering and establish some
of the factors which affect solids content of the cake and solids recovery.
Feed consistency, rate of application, and slurry character all effect
performance of these machines. Solids recovery efficiency must be
maintained at a high level or fines build up in the clarifier to which
the centrate is returned. This was studied by Sullins (3) who concluded
that this problem did not occur when recovery efficiency exceeded 85 percent,
Description and performance data appear in NCASI Technical Bulletin #235
covering a number of recent installations.
41
-------
Pressing
After experiments had shown that additional water could be removed
from vacuum filter and centrifuge sludge cakes by pressing, development
work proceeded with commercial presses of different types in order to
allow the application of this technique. Data, such as that presented
in Table VI, indicated that cakes approaching 50 percent solids could
be obtained. However, a wide variation in sludges and press performance
was observed and a considerable amount of press development work was
involved in applying them.
Their application to vacuum filter cake from pulp mill sludges is
described by Bing (11) , Fullter (12), Coogan and Stovalo (13), and
Linsey (3).
In pressing sludges consisting primarily of fibrous organics, Bing,
Fuller^ and Coogan report operations producing press cake in excess of
40 percent dry solids. Linsey, however, handling a slurry containing
variable quantities of lime, other inorganics, and some non-fiberous
organics obtained very erratic and frequently unsatisfactory results.
Recently, pressing has been successfully applied to pressing charifier
underflows containing substantially fiber by Stovall and Barry (14).
Problems could develop with this procedure due to fines which pass
the press accumulating in the clarifier, hence it must be applied
with care.
Incineration
Three types of incineration are practiced for disposing of papermill
sludges. These are burning in an incinerator designed specifically to
handle sludge as described by Coogan and Stovall (13) and in a bark
boiler as indicated by Stovall and Berry (14), and others (11)- The
third method is incineration in a power boiler burnine fossil fuel.
All these methods are successful. However, the high costs involved
relative to land disposal at most mill sites has limited its use.
Incineration is also limited to low ash sludges not only because of
their low fuel value but due to technical problems with incinerators.
Figure 8 is a curve showing the relation between moisture and organic
content of sludge necessary to support combustion.
Summary
A number of other types of combustion have been tried including multiple
hearth and kiln type units as well as wet air oxidation anl the fluidized
bed. Of these only the fluidized bed system appears promising of
considerable application.
Figure #9 is a multi-path flow diagram covering the common mechanical
methods of sludge thickening, dewatering, and disposal of clarifier
underflows obtained from treatment of pulp and papermill effluents.
Which pieces of equipment are chosen for a particular installation and
how they are arranged depends on the character of the particular sludge
handled. The response of the sludge to these unit processes varies
from day to day as pointed out by Linsey (3). Hence, careful pilot
studies generally precede design of these systems.
42
-------
TABLE VI
MECHANICAL PRESSING OF SLUDGE CAKE
Grams of r?ater
Applied
Pressures
psi
Removed per
Final
Solids
Pressed Cake
Consistency
Kilogram of sludsqe
Pressing time, min.
1
5
10
Board Mill Filter
100
500
500
700
900
100
300
500
700
900
65
75
81
84
97
85
103
108
135
150
123 191
180
191
207
246
Delink in
190
231
265
285
300
234
268
270
293
K Filter
235
280
310
335
344
Pressing time, min.
1
Cake
27.5
28.5
29.1
29.4
30.7
Cake
38.5
40.0
40.6
43.3
45.0
5
33.3
39.0
40.1
41.7
45.6
49.0
53.2
56.4
58.5
60.0
10
40.1
44.4
47.8
48.0
50.3
53.3
58.0
61.0
63.0
64.3
43
-------
FIGURE 8
SLUDGE CAKE CONDITIONS
REQUIRED TO SUPPORT COMBUSTION
80
65
OT
P
O
CO
£50
O
w
a
o
3 35
w
20
SLUDGE CAKE
PERCENT ORGANIC
44
-------
CLARIFIER
UNDERFLOW
FIGURE 9
MULTI-PATH DIAGRAM OF MECHANICAL
THICKENING,, DEWATERING AND DISPOSAL OF SLUDGES
Scroll
Centrifuge
CENTRATE
Ln
Gravity, DAF
or Centrifugal
Thickener
Vacuum
Filter
Press
Press Water
FILTRATE
Incinerator
Bark
Boiler
Power
Boiler
Land
Disposal
Sludge
Cake
Ash
Return
-------
_GROUNDWOOD PULPING
The bulk of groundwood pulp is manufactured at mills producing chemical
pulp and newsprint, although some manufacture this material for tissues
and groundwood specialties at papermills. Some fifty-eight mills having
a daily capacity of about 14,000 short tons are in operation in the
U. S. at present. However, better than 50 percent is made in sixteen
large mills.
The large integrated mills,as well as papermills, treat the groundwood effluent
in combination with the total discharge. Thirty-eight mills which
manufacture 9750 tons daily provide treatment. Of these twelve, representing
a daily production of 5,000 tons of groundwood, provide secondary
treatment. Storage oxidation basins, aerated lagoons?and activated
sludge are all employed. While groundwood pulp, when treated alone by
accelerated biological methods offers some resistance to high degree
treatment, it responds without difficulty when combined with pulping
effluents.
46
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GROUNDWOOD PULP MILLS in the UNITED STATES
Alabama
Arizona
Arkansas
California
Georgia
Louisiana
Maine
Michigan
Minnesota
Missouri
New York
Oregon
South Carolina
Tennessee
International Paper Co. Mobile
Kimberly Clark Coosa Pines
National Gypsum Co. Mobile
Ponderosa Paper Prod. Corp. FlagstaJff
Southwest Forest Industries Inc. Snowflake
International Paper Co. Pine Bluff
Kimberly Clark Corp. Anderson
Cox Newsprint, Augusta
Boise Southern Corporation, De Ridder
St. Francisville Paper Co. Francisville, La.
Statler Tissue Corp. Augusta
Hearst Corp. Brunswick
St. Regis Paper Corp. Bucksport
Great Northern Paper Co. E. Millinocket
International Paper Co. Jay
International Paper Co. Livermore Falls
Kennebec River Paper & Pulp Co. Madison
Great Northern Paper Co. Millinocket
Oxford Paper Co. Rumford
Keyes Fiber Co. Shawmut
Escambia Paper Co. Escanaba
Manistique Pulp & Paper Co. Mimistique
Scott Papei- Co. Menominee
Blandin Paper Co. Grand Rapids
Boise Cascade Corp. Int. Falls
Henepin Paper Co. Little Falls
St. Regis Paper Co. Sartell
Packaging Corp. N. K.C.
J. P. Lewis Co., Beaver Falls
International Paper Co., Corinth
St. Regis Paper Co., Deferiet
Stevens & Thompson Co., Greenwich
Kimberly Clark Corp, . Niagara Falls
Publisher Paper Co., Oregon City
Crown Zellerbach Corporation, Wanna
Crown Zellerbach Corporation, West Lynn
Bowaters Carolina Corp., Catawba.
Catauba Newsprint Co., Catawba
Bowateis Southern Corp. Calhoun
47
-------
Texas Southland Paper Incorporated, Lufkin
Southland Paper Incorporated, Houston
United States Plywood Champion Papers, Pasadena
Vermont Standard Package Corp., Sheldon Springs
Washington Crown Zellerbach Corp., Camas
Inland Empire Paper Co., Millwood
Crown Zellerbach Corp0, Port Angelis
i FiiTierboard Corp., Port Angelis
Keyes Fiber Co., Wenatchee Chelan
Boise Cascade Corp., West Tacoma
Wisconsin Charmin Paper Product Co., Green Bay
Combined Paper Mills Incorpoated, Combined Locks
St. Regis Paper Co., Cornell
B*segling Paper & Pulp Co., Ban Claire
American Can Co., Green Bay
JPog'fe Howard Paper Co., Green Bay
Kimberly Clark Corporation, Kimberly
11 OlJHOTTln Paper Product Corpoation, Little Rapids
Kimberly Clark Corporation, Niagara
Consolidated Papers Incorpoated, Stevens Point
Consolidated Papers, Wisconsin Rapids
48
-------
KRAFT MILLS
Mills manufacturing kraft pulp have been divided into four classes:
those which produce only linerboard, corregating board, and associated
products; the newsprint mill which produces semi-bleached kraft pulp
and groundwood pulp for this product: the bleached pulp mill producing
market pulp or paper products not involving extensive additives or
coating; and those mills integrated with other pulping processes and/or
complex papermaking operation. An excess of kraft pulp is generally
produced in the newsprint mill which is made into paper, board or
lapped market pulp at the mill. Some such mills also produce small
linterboard.
There are at present a.21 kraft pulp mills in the U.S., two of which have
not yet started operations. Of these, 109 apply primary treatment to their
effluents, 86 using mechanical clarifiers and the remainder earthen basins.
Four others employ ocean outfalls. Seventy nine employ BOD reduction
techniques, 44 having aerated lagoons, 21 storage oxidation basins, 9
activated sludge, 2 trickling filters, and 3 chemical treatment to remove
both BOD and color.
Tabulations presented in Tables in a subsequent section present
performance data for themills having BOD reduction installations.
49
-------
KRAFT MILLS IN THE U.S. - MAY 1971
Alabama
MacMillan-B. United, Pine Hill
Container Corp., Erewton
Kimberly Clark Corp., Coosa Pines
Gulf States Paper Co., Tuscaloosa
Gulf States Paper Co., Demopolos
Allied Paper Co., Jackson
International Paper Co., Mobile
Scott Paper Co., Mobile
American Can Co., Naheola
Union Camp Corp., Prattville
Hammermill Paper Co., Selqa
Alabama Kraft Corp., Mahrt
Arizona
S.W. Forest Ind.f Snowflake
Arkansas
International Paper Co., Pine Bluff
International Paper Co., Camden
Arkansas Kraft Co., Morrilton
Nekoosa EL wards, Ashdown
Georgia. Pacific Corp., Crossett
California
Crown Simpson P. Co., Fairhaven
Fiberboard Prod. Co., Antioch
Georgia Pacific Corp., Samoa
Kimberly-Clark Corp., Anderson
Florida
Georgia
St. Joe Paper Co,, Port St. Joe
International Paper Co., Panama City
Hudson Pulp & Paper Co., Palatka
Container Corp., Fernandina
St. Regis Paper Co., Jacksonville
St. Regis Paper Co., Pensacola
Alton Box Bd. Co., Jacksonville
Buckeye Cellulose Corp., Foley
Rayonier Inc., Jesup
Owens-Illinois, Voldosta
Brunswick Pulp & Paper Co., Brunswick
Continental Can Co., Augusta
Continental Can Co., Port Wentworth
Union Camp. Corp., Savannah
Great Northern, Cedar Sp.
Georgia Kraft Corp., Macon
Georgia Kraft Corp., Rome
Interstate Paper Corp., Riceboro
St. Mary's Kraft, St. Mary's
Idaho
Potlatch Forests, Lewiston
50
-------
Indiana
Kentucky
La.
(2)
Westcore, Hawescille
Westvaco, Vickliffe
Boise-Southern, DeRitter
Pinevllle Kraft Co., Pineville
International Paper Co., Bastrop
Crown-Zellerbach Corp., St. Frncisville
Crown-Zellerbach Corp., Bogalusa
Calcasueu P. Co., Elizabeth
Olin Kraft Corp., W. Monroe
Georgia Pacific, Port Hudson
Continental Can Co., Hodge
Maine
International PC., Jay
Scbtt Paper Co., Cumberland
Oxford Paper Co., Rumford
Standard Pkg,, Lincoln
Penohscot Co., Old Town
Georgia-Pac. Corp., Woodland
Maryland
Michigan
Westvaco, Luke
S. D. Warren/Scott, Muskgon
Packaging Corp., Filer City
Mead Corp., Escanaba
Minnesota
M 0 Paper Co., Int. Falls
Northwest Potlatch, Cloquet
Mississippi
International Paper Co., Moss Point
International Paper Co., Vicksburg
International Paper Co., Hatches
St. Regis Paper Co.,' Montocello
Montana
Ho erner-Wald., Mis soula
New Hampshire
New York
Brown Co., Berlin
International P. Co., Ticondercga
North Carolina
U.S.P. Champion, Canton
Riegel Paper Co., Riegelwood
Weyerhauser Co., Plymouth
Weyerhauser Co., New Bern
Hoorner Waldrf Paper Co. Roanoke Rpds.
51
-------
Ohio
Mead Papers,Chillicothe
Oklahoma
Weyerhauser Co., Valliant
Oregon
Weyerhaeuser Co., Springfield
American Can Co., Hals.ey
Georgia Pacific Co., Toledo
Boise Cascade Corp., St. Helens
International Papaer Co., Gardiner
Western Kraft Corp., Albany
Crown Zellerbach Corp., Wanna
Pennsylvania
Westvaco Corp., Tyrone
Westvaco Corp., Williamsburg
P. H. Glatfelter Co., Spring Grove
D. M. Bare Paper Co., Roaring Springs
N.Y.-Penna, Co., Johnsonburg
South Carolina
International Paper Co., Georgetown
Westvaco, Charleston
S. C. Industries, Florence
Bowaters S. Corp., Catanba
Weyerhauser, New Born
Tenn.
Tenn River P.M., Counce
Bowaters S. Corp., Calhoun
USP Champion, Cortland
Texas
Eastex Corp., Eradale
Southland Papers, Lufkin
Southland Papers, Houston
U.S.P. Champion, Passadina
Owens-Illinois, Orange
International Paper Co., Texasakana
Virginia
Westvaco, Corington
Union-Camp. Corp., Franklin
Contc Can Co., Hopewell
Chesapeake Corp., V/est Point
Washington
Crown Zellerbach Corp., Camas
Crown Zellerbach Corp., Pt. Towsend
Weyerhaeuser Co., Everett
Weyerhaeuser Co., Longview
Longview Fiber Co., Longview
St. Regis Corp., Tacoma
Simpson Lee Corp., Everett
Boise Cascade Corp., Wallula
52
-------
Wisconsin Nekoosa-Mwards, Nekoosa
Consolidated Papers, Wise.,Rapids
Thilmanyl Hammermill, Kaukauna
Mosinee Paper Hills, Mosinee
53
-------
ACID & NEUTRAL SULFITE PULPING
At the present time the United States has the capacity for producing
about 20,000 short tons daily of acid and neutral sulfite pulps. While
manufacture of the former has been declining in recent years the latter
has steadily increased and presently the capacity for producing neutral
sulfite semi-chemical pulp exceeds that for acid sulfite by approximately
1,500 short tons daily. Projections indicate that acid sulfite capacity
will probably remain quite stable while that for neutral sulfite will
continue to increase in the next several years.
Obviously, the major water pollution load emanating from these processes
has been centered in the spent cooking liquors. These were discharged
for many years because, unlike Kraft pulping, recovery was both
economically unsound and technically difficult. However, elimination
of the discharge of these liquors is now well underway in the United
States, and,with the possible exception of a few mills manufacturing
by-products or having ocean outfalls, will be eliminated altogether within
the next few years.
In the case of acid sulfite, this is coming about through switching to
kraft pulping, changing the chemical pulping base and burning the
liquor (with or without chemical recovery), production of by-products,
and the dismantling of small, high production cost mills. At present;,
fifteen of the thirty-four operating mills burn the liquor, long con-
tinued operation of several others is doubtful, and most of the remainder
are definitely committed to burning in the near future. The tonnage
equivalent of the fifteen mills now burning liquor is about half of
the total.
Examination of this table reveals that in regard to bases other than
calcium, magnesium is the most favored, with about the same tonnage
of this type being manufactured as of calcium base pulp. Smaller mills
appear to favor ammonia while little effort has been made in the use of
soda base for pulping. This is evident since the one mill employing it,
constructed about ten years ago, was not eminently successful and the many
sodium base recovery systems proposed (Collins (1)) have, for one reason
op another, not been sufficiently attractive to xrarrant their application.
However, new developments in pulping indicate that this situation could
change in the future.
A total of eight mills manufacture by-products ranging from simple evaporate
used for road binder and cattle food additive to some fairly sophisticated
formulations and intermediates. Four mills produce the latter which are
used in adhesives, dispersants, tanning agents, drilling mud additives, etc.
Two mills make fermentation products, ethanol and torula yeast. All of
these products account for about ten percent of the liquor solids produced.
These operations are described in detail by Pearl (2) and in a Chemical
and Engineering News staff report (3). By-products manufacture does not
in all cases represent a complete or a permanent solution to the liquor
problem.
Liquor disposal from neutral sulfite semi-chemical pulp mills is further
advanced than that of the acid mills largely because of the integration
of many of them with kraft recovery systems. This is because the pulp
54
-------
produced is moved in the same markets as much of the kraft pulp, and
the wood species situation at many mills favors the combination of
the two processes. Twenty-eight of the thirty-six
NSSC mills burn the spent liquor, eighteen of them through cross
recovery with kraft. Pulp tonnage equivalent of the total liquor
burned is about eighty percent, forty-one percent being through
cross recovery. Actually the liquor from all but four mills is disposed
of in one manner or another, and at one of those not disposing of it,
tremendous dilution is provided by the receiving stream the year round.
Actually the liquor from thirty-four of the thirty-six NSSC mills representing
about ninty-five percent of the total manufacturing capacity is disposed
of satisfactorily, at least for the present.
Only three NSSC mills employ chemical recovery, all of these using
the Institute of Paper Chemistry soda base process. Fluidized bed burning
of soda base liquor is practiced by 3 others and an equal number cook
with ammonia base liquor and burn it together with bark. It can be
safely predicted that before long all NSSC liquor will be satisfactorily
handled in the States. Unbalance which has existed in cross recovery
systems from time to time will become at thing of the past.
Only two NSSC mills manufacture by-products. One of these separates
acetdc and formic acids from spent liquor by a solvent extraction process
and supplies it to a kraft mill for use as make-up. The second mill
evaporates the liquor by submerged combustion producing road binder (5).
Despite much initial interest in wet combustion and the atomized suspension
burning technique, neither of these processes were carried beyond the
pilot plant for handling spent pulping liquors in the State.
It was demonstrated by Opferkuch (6) in a laboratory pilot plant a number
of years ago that NSSC liquor could be treated biologically together with
sanitary sewage. This has been proven to be the case by three mills
which discharge into public treatment facilities.
Under ideal soil and drainage conditions, land disposal of the spent
liquor can be employed. While this may not prove to be a permanent
solution, it is presently used to handle the liquor from the NSSC mills.
Unfortunately, disposal of the cooking liquor does not eliminate the
pollution load discharged by either type of sulfite mill. Decker seal
pit water from the wet room, condensates from digester and evaporators
as well as bleachery wastes constitute the major sources of the residual
load. Bleachery waste is almost entirely a problem of the acid mill since
the bleaching of NSSC in the United Staes is now defunct. This effluent
has become an increasing problem for the mills pulping with ammonia base
liquor because of the heavier pollution load produced in brightening
this pulp. Contributing in varying degrees to the continuous load are
floor drains, tank overflows and aprons, and the acid plant.
The major individual factor causing pollution problems is, in the case
of both waste streams, their oxygen demand. In regard to suspended
solids NSSC pulping is by far the worst offender because of the relatively
large amount of fines washed from the pulp. Also to be considered are
solids contained in wood preparation effluents and accessory pulp lapping
or papermaking operations.
55
-------
While the problem of pollution cannot always be solved entirely through
in-mill control, this procedure can reduce it appreciably and is
mandatory if high degree treatment must be afforded in order to keep the
treatment system of reasonable size and performing uniformly.
Obviously the first step toward this end is to provide adequate washing
and evaporator capacity for the pulp tonnage produced. The second is
to provide sumps for collecting periodic strong liquor losses due to
process upset, leaks, and accidents from which these can be returned
to process at appropriate locations and at suitable rates.
The third step is to provide retention basins to which the effluent can
be diverted during periods of mill upset or wash-up. The contents
of these can then be pumped to the treatment works at controlled rates
during period of normal operation. Proper treatment plant design
provides sufficient capacity over that of the normal waste load to handle
the basin contents.
Excellent descriptions of such control measures are presented by Barton,
Byrd et al (7) (8). These measures were proved at the most recent
acid sulfite mill to be built in the States which was put in operation
in 1968. Because of stringent water pollution regulations set as a result
of the high quality and usage level of the receiving stream, activated
sludge treatment was provided. To maintain this treatment at required
performance levels, good internal control was mandatory. Those employed
are described by Barton et al (7).
Lowe (9) reported on mill tests conducted to determine the effect of
recycling white water within a NSSC corrugating board mill through which
he was able to ascertain the minimum fresh process water requirement
necessary before problems arising from this practice became intolerable.
The difficulties observed as a result of closing the system were as
follows:
(1) Variable paper quality
(2) Decreased wet felt life
(3) Increased slime deposits
(4) Higher maintenance
(5) Increased scaling
(6) Greater chemical additive demands
(7) Build up of contaminants from waste paper
It was found that these problems could be minimized at an effluent
discharge of only 2,000 gallons per ton of product, but the troubles
experienced were severe at the 1,000 gallon level. This is very much
lower than the water usage of most systems of this type. The author claims
that this practice both reduced the overall pollution load of the' mill
and provided a more uniform distribution of it to the aerated stabilization
basin in which the effluent is finally treated.
Primary treatment for the removal of settleable solids is provided by
over half of the sulfite mills. Table shows the situation in respect
to this practice which is expected to become almost universal before long,
if the State regulations approved by the Federal Government are to be met.
56
-------
In most instances circular, mechanically cleaned clarifiers are employed
for handling the combined dilute wastes from the mills. Where a
kraft mill is operated at the same site, the waste water from attending
NSSC operations is combined with it for treatment. However, when wet
barking is practiced, the effluent from this operation is frequently
treated separately because its peculiar properties can upset clarifier
operation.
The second most important undesirable characteristic of the dilute wastes
is generally their biochemical ]_ oxygen demand. For sulfite mills this is,
as a rule, much higher than that of kraft mill. In the case of acid
sulfite, this is due to the high acetic acid content of the condensates
and, for NSSC, the difficulty experienced in washing the pulp well allows
relatively high concentrations of sodium acetate to appear in the seal
pit water. Then,too,some of the older mills are not provided
with modern washing systems so that a considerable amount of liquor
solids appear in the machine white water. High degree bleaching of
acid sulfite pulp produces effluents high in oxygen demand.
To date,biological treatment is the solid method being applied for treating
these wastes to reduce their BOD. Effluent from two acid sulfite mills
and twelve NSSC mills receive this treatment. Methods employed include
the activated sludge process, aerated stabilization, storage oxidation, as
well as irrigation and soil percolation. In all, fourteen mills treat by
these methods.
Because of the generally smaller size, greater age, and the high costs
attendant to providing liquor handling facilities, the sulfite mills in the
States are not as far advanced as the kraft mills relative to providing
secondary treatment of dilute effluents. The fact that a number of the
larger ones discharge into very large bodies of water has also been a
limiting factor. The effluent requirements fo the future will exert
a strong restraining influence on growth of acid sulfite pulping as it
is presently practiced in the States.
Another consideration is the inability of biological treatment to remove
appreciable amounts of lignin compounds as well as color from the
effluents irrespective of the degree of BOD reduction achieved. Approaches
to this problem will be discussed later in this presentation since it
might be well to first review the present application of the biological
oxidation processes as they are not practiced.
One example is that provided by an acid sulfite mill in Pennsylvania
(7) Decker seal pit water together with the condensates, bleachery
effluent, and return flowage from a detention basin which holds by-passed
wastes, are neutralized to pH 6.5 with lime and nutrients added. At
the entrance to the aerators, the stream, which contains up to 35,000 pounds
of BOD 5 daily at a concentration averaging 24,000 m/1 is mixed with
sufficient return activated sludge to maintain -a mixed liquor of suspended
solids level of around 5,000 m/1. Two one million gallon capacity aeration
basins equipped with three 150 HP mechanical aerators each are employed
with aerator loading runs as high as 120 pounds of BOD per thousand
cubic feet of capacity. Effluents from the aeration basins pass to an
80 foot diameter Clar±flocculator and thence to the receiving stream.
During periods of sub-normal operation, the effluent, or a portion
there of, can be diverted to a holding basin for return to the head end
57
-------
of the treatment plant at a controlled rate. Underflow from the
clari-flocculator is returned partially to the process and the remainder
wasted. This latter portion has presented the most difficult problem
with regard to operation of the process because of its resistance to
de-watering, despite the provision of a two-stage centrifuge system to
accommodate this .
The first machine is a disc-nozzle centrifuge. The slurry discharged from
this unit, after the addition of a polymer, is fitted to a solid bowl
centrifuge, the cake from which is disposed of by land fill. A serious
nozzle problem was encountered in operating the thickener but this has
since been overcome. It was found that the thickened sludge responds to
heat treatment at 480°F., producing a granular cake readily dewatering on
a vacuum filter. Application of this process is now under consideration.
This process has reduced the BOD of the waste in excess of 85 percent.
Together with the suspended solids removal system of the papermill, an
efflunt of very high clarity is produced.
The other activated sludge plant treat a mixture of condensates from
the pulping and magnesium base recovery system together with caustic
extraction effluent from the bleachery. This flowage amounts to around
1.65 MGD and carries a BOD load ranging from 30 to 120 thousand pounds
daily because of the variety of pulp grades manufactured. Extended
aeration-activated sludge treatment was chosen to oxidize this waste.
Because of the wide swings in load two aeration basins were constructed
and the piping arranged so that they can be oprated either in paralleld
or in series. Each is equipped with eight 75 H.P- surface aerators and
has a capacity of 5.5 million gallons. This provides a nominal detention
period of five days.
Premixing of the wastes provides a netural stream to which nutrients
are added. While influent temperature ranges from 68 to 146 degrees
Fahrenheit, it has not proven to be a problem since blending and cooling
due to turbulence in the aeration basins cool it to below 100 degrees.
A fifty foot diameter clarifier follows the aeration basins. The under -
f lo -j frorr. this unit can be returned to the influent or diverted to a
land fill area for disposal. Generally one hundred percent recycle is
practiced so that when sludge is removed from the system it is well
stabilized .
c reduction efficiency has ranged from 83 to 95 percent with the lower
values corresponding with aerator failures. After correction of these
difficulties an average reduction of 88 percent was recorded with the
influent BOD5 averaging 4,000 mgm/1 or 55,000 pounds per day. Installation
of this process has sllowed the mill to more than meet effluent quality
requirements and is considered a success by both management and the
regulatory agencies.
58
-------
Dilute NSSC wastes are treated in aerated stabilization basins at six
mills in combination with unbleached and bleached kraft effluents.
Another employs the activated sludge process to handle the combination
(11) with only one mill treating it alone by aerated stabilization (9).
No difficulties have arisen in oxidizing these wastes biologically either
alone or in combination with others since both the rates and degrees
of oxidation observed are normal when they ar neutralized and nutrients
added. The only effect it has had on treatment systems in general is to
increase the quantity of primary sludge collected and decrease dewater-
ability. This is due to the high suspended solids loss in the form of
fines attendant to the manufacture of this pulp.
Irrigation disposal of weak NSSC wastes, which is practiced by two
mills, can be successful if properly installed and managed (12) (13).
Fodder crops are grown on the disposal area and this is a particularly
economical and effective system for small mills discharging into
streams having a low summer flow. However, a large area of suitable
land is required (14).
Extensive research and development work on other than the present
methods for reducing the pollution load after recovery is underway
in the States. Since a substantial portion of the BOD load from an acid
sulfite mill is contained in the condensates \n the form of acetic
acid, Clark, Lang and De Haas (15) (16) worked out a method for reacting
it with caustic soda and making acetic acid and sodium sulfite of acceptable
quality. ^Application for this process is dependent upon the quantity
that can be made at a single location as well as the markets for it.
Considerable attention has been given to the use of activated carbon
for treating dilute pulp mill wastes since this material can adsorb
most of the color and a part of the BOD (17)- Regeneration is a basic
requirement for the application of carbon adsorption which can now
be efficiently accomplished with some carbons (18). Its application
to sulfite waste waters is likely to be limited because of its relatively
low capacity for adsorbing materials responsible for the BOD in relation
to its high affinity for color bodies.
An extensive research and development program on the use of reverse
osmosis for concentrating the dissolved solids present in weak sulfite
wastes and reclaiming process water was conducted by the former Pulp
Manufacturer's Research League. This study, which included tests
employing a portable reverse osmosis plant which was moved from mill to mill,
was partially financed by the Federal Water Quality Administration. After
extensive laboratory work with the process, this unit was assembled and
operated at several mills of different types including acid and NSSC
plants. In addition to concentrating solids for introduction into recovery
or incineration systems and reclaiming water, the separation of acetic
acid and sugars having unique properties was attempted.
While the reports covering these investigations have not as yet been
published, it has been pointed out by the participants (19) that flux
rates obtained were undesirably low and that membrane life fell short
of that required for commercial practicability. These observations
were confirmed by other investigators (20). Very extensive effort is
being expended by membrane manufacturers and others supplying hardware
for these systems and it is anticipated that these shortcomings will be
overcome to some degree in the not too distant future.
59
-------
As an outgrowth of these studies, the Green Bay Packaging Company, which
manufactures NSSC pulp and corrugating medium, has agreed to join in a
project with EPA-OWQ to conduct comparative pilot plant tests of various
proprietory reverse osmosis systems for concentrating weak pulping wastes
to a degree that they can be introduced into the existing fluidized bed
burner handling the spent liquor. If results obtained with the most
efficient unit tested appear favorable, plans call for the installation
of a demonstration unit at the mill. The company is attracted to the
process because it removes both BOD and color and could possibly lead
to a closed system.
It is envisioned by some, that the bleaching effluent problem which is
becoming increasingly acute, may be eliminated or drastically reduced
by developments such as those proposed by Rapson (21) or by oxygen
bleaching (22). Both of these processes return a relative concentrated
liquor low in chloride ion to the recovery system. The success of these
schemes await further development.
60
-------
Bibliography for
Acid & Neutral Sulfite Pulping
to be supplied.
61
-------
DEINKING MILLS
Five white papermills which employ deinking of old papers treat their
wastes for the reduction of BOD. Four have aerated stabilization
basins, one being supplemented by spray disposal on the land. The
fourth uses storage oxidation which is accomplished in two large
basins. Treatability of this waste was first determined on a demonstration
scale by Palladino (1) using the activated sludge process. Limitations
of this process led Blosser (2) to experiment with aerated stabilization
basin treatment. This led to the successful applications described by"
Laing (3), Haynes.(4), and Quirk and Matusky (5). Flower (6) described
land disposal following partial aerated basin treatment at the storage
oxidation installation.
62
-------
Bibliography
(1) Palladino, A.J., "Final Report Aeration Development Studies,"
NCASI Tech. Bull #12 (1959).
(2) Blosser, R. 0., "Oxidation Pond Study for Treatment of Deinking
Wastes,"Purdue Univ. Ind. Waste Conf. 87 (1962).
(3) Laing, W. M., "New Secondary Aerated Stabilization Basins at
the Moraine Division of Kimberly Clark Corp.," Purdue Ind.
Waste Conf. XXIII 484 (1969).
(4) Haynes, F. D., "Three Years Operation of Aerated Stabilization Basins
for Paperboard Mill Effluent," Purdue Univ. Ind. Wastes Conf.
(1968).
(5) Quirk, T. P. and Matusky. R. E., "Aerated Stabilization Basin
Treatment of White Water," Purdue Univ- Ind. Waste Conf.
XXIV, 789 (1969).
(6) Flower, W. A., "Spray Irrigation for the Disposal of Effluents
Containing Deinking Waste," Tappi, 1267 (1969).
(7) Ross, A.M., "Newton Falls Gives Details of Stream Imp. Plan,"
Paper Trd. Jour., 150, 44 (Dec.. 1966).
63
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Waste Paperboard Mills
As pointed out previously in the section on treatment in public facilites,
most waste paperboard mills dispose of their effluents to sewage treatment
systems. Here the effluents are treated by either primary or secondary
treatment, and, since their constituents respond well to these forms
of treatment, they exert no deleterious effect on the effluent of the
treatment plant if it is designed to handle the loading they represent (1).
Some mills treat the waste in clarifiers or alternating basins to remove
suspended solids. Where a high degree of clarity is necessary coagulants
such as alum or polymers are employed. These latter have but little effect
on the BOD since much of it is in the dissolved state and most of the
suspended matter is settleable.
BOD removal is practiced to a high degree by a number of mills. These
employ aerated lagoons or activated sludge since few mills of this type
have sufficient storage area available to employ storage oxidation.
Some experiments with thelatter indicated that this treatment was not
applicable because of abundant hydrogen sulfide formation by reduction
of sulfates present in the water naturally and from the use of alum in
papermaking.
Examples of the results obtained on biological oxidation of waste paper-
board effluent at a number of mills is shown in subsequent tables.
(Note: This segment will be referenced in final report. See bibliography.)
64
-------
Bibliography
(1) Amberg, H. R., "Aerated Stabilization of Boardmill White Water,"
Purdue University Ind. Wastes Conf. XX, 525 (1965).
(2) Haynes, F.D., "Three Years Operation of Aerated Stabilization
Basins for Paper Board Mill Effluent,"
Purdue Univ. Ind. Wastes Conf. XVIII, 361 (1968).
(3) Betts, C. N. and Weston, R.F. "An Approach to Design of Biological
Oxidation Treatment Facilities for Paper Machine Waste Waters,"
Purdue Univ. Ind. Waste Conf. 73 (1956).
(4) Gellman, I., "Aerated Stabilization Treatment of Mill Effluents,"
Tappi, 48, 106A (1965).
(5) Amberg, H. R. et.al., "Supplemental Aeration of Oxidation Lagoons
with Surface Aerators," Tappi, 47, 27A (1964).
(6) Edde, H., "A Manual of Practice for Biological Waste Treatment in
the Pulp and Paper Industry," NCASI Tech. Bull. #214 (1968)
(7) Gehm, H. W., "Effects of Papermill Wastes on Sewage Treatment Plant
Operation," Sew. Wks. Jour. 17, 510 (1945).
(8) Betts, C.N. et. al., "Construction and Early Operation of a One MOD
Bio-Oxidation Pilot Plant," Sunoco Prod. Co.,
Hartsville, S. C. (1954).
(9) Klinger, L. L., "whippany Completes Final Link in Tri. Mill Waste
Treatment System," Paper Trd. Jour, page 36 (May 1962).
(10) Shaw, R. F., "Activated Sludge Treatment at the Whippany Mill,"
NCASI Tech. Bull. £220, p24, (1968).
(11) Peters, J.C. & MacNeal J. A. "Comp. Waste Treatment for a Paperboard Co.,'
Pub. Wks. 94, 99 (1963).
(12) Yaeck, D., "Waste Treatment Plant at Depaco," Depaco Diary, p.3
(June 1962).
(13) Haynes, F.D., "Aerated Lagoons," Paper Presented NCASI Cont.-Lake
States Meeting, (Sept. 1969).
(14) "Nat. Gypsum Describes Milton Mill Facilities" NCASI Tech. Rev. P9
(Dec. 2 1970) Private Communication, Federal Paperboard Corp. Bogota,N.J.
(15) Klinger, L.L., "Whippany Expands Tri. Mill Waste Treatment Complex,"
Water Wks. & Wastes Eng. 1, 60 (1964).
65
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BUILDING PRODUCTS
Felts
Most of the mills manufacturing building felts are small, producing
less than 100 tons of product daily. The waste produced is low in
Volume because these mills can recirculate to a high degree since the
furnish is generally high in temperature and the forming machines used are
simple in design and operation. Effluent volumes as low as 2000 gallons
per ton or product are common. Since waste paper is the major constituent
the waste has characteristics similar to that of concentrated waste paper-
board mill effluent. It has been demonstrated that these wastes can be
treated by biological oxidation, both alone and in municipal systems (1)
(2) (3). No plants for treating this effluent have been reported and most
of the waste water from mills producing building felts is treated in public
sewage facilities.
Insulating Board
Insulating board mill waste can be clarified to a relatively high degree
by sedimentation as previously pointed out and demonstrated by Fields
and Lewis (4). Quirk (5) and others (6) (7) (8) have demonstrated that
this waste can be treated biologically for BOD reduction after the addition of
nutrients. It can also be treated together with municipal sewage as
indicated" by Husmann (7). Other than clarification, wastes from the
production of insulating board mills receive no in-mill treatment at the
present time.
Hardboards
Hardboards are manufactured by two processes as previously pointed out in
this report. One process is similar to that used in producing insulating
board and produces a similar effluent. The other, the "explosion" or
Masonite process ,produces effluents for which treatment has been the
subject of considerable research, development,and demonstration plant
work. One of the two wastes produced is a liquor high in BOD which
at one mill has been evaporated and burned (10) and at another disposed
of on the land (11). The weaker wastes, including wash and machine waters,
are high in fines and contain considerable BOD. Parsons and Woodruff (12)
have proposed a system for treating these which involves neutralization,
clarification, and activated sludge together with sludge dewatering.
66
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Bibliography
(1) Research Reports, NCASI (1956).
(2) "Evaluation of Bio-Oxidation Pilot Plant Studies of Pulp and Paper-
mills," NCASI, Tech. Bull. #90 (1957).
(3) Gehm, H.W. & Gellman, I., "Practice, Research & Development in
Biological Oxidation of Pulp and Papermill Effluents," JWPCF
37, 1392 (1965).
(4) Fields, W.F. and Lewis, T.W., "Primary Treatment for an Insulation
Fiberboard Plant," Tappi, 46 178A (1963).
(5) Quirk, T.P., "Bio-Oxidation of Concentrated Board Machine Effluents,"
Proc. Purdue Univ. Ind. Waste Conf. XIX 655 (1967).
(6) Bachanek, S., "Determination of Technological Parameters for Activated
Sludge Purification of Effluents from the Mfg. of Fiberboards,"
Prgeglad Papier, 23, 292 (1967) (Poland).
(7) Gafiteaneu,M. and Godeanu, S., "Investigations on the Treatment of
Waste Waters from the Manufacture of Fibre Building Boards,"
Inst. Hydrotech Res. Science Session Sec. 4, 29 (1964) (Romania).
(8) Nepper, M., "Biological Treatment of Strong Ind. Wastes from a
Fiberboard Factory," Purdue Univ. Ind. Waste Conf. XXIV,
884, (1968).
(9) Husmann, W., "Combined Treatment of Waste Water from Fiberboard Mills
and Municipal Sewage," Int. Congress on Ind. Waste Water,
Stockholm, Nov. 1970.
(10)
(11) Parsons, W.C., "Spray Irrigation of Wastes from the Manufacture
of Hardboard," Purdue Univ. Ind. Waste Conference, XXIII 112,
(1967).
67
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Treatment Table Key
Internal
Fiber Recovery
Pretreatment
Susp. Solid Reduction
Intermediate Treatment
BOD Reduction
Third Stage Treatment
Sludge Thickening
Sludge Dewatering
Sludge Disposal
Discharge Control
S-Settling
DAF-Dissolved Air Floatation
F-Filtration
N-Neutralization
K-Nutrient Addition
SC-Screening
E-Equalization
Q-Cooling Tower
C-Mechanical Clarifier
AB-Alternating Basins
SB-Set in Storage Basin
CC.-Chem. Coagulation
T.F.-Trickling Filter
H.L.-Holding Lagoon
A.L.-Aerated Lagoon
A.S.-Activated Sludge
E.A.-Extended Aeration
I-Irrigation Disposal
P.L.-Polishing Laggon
A.-Aeration
T.G.-Gravity Thickener
T.C.-Centrifugal Thickener
B-Drying Beds
VF.-Vacuum Filter
CE-Centrifuge
P-Pressing
LF-Land Fill
INC-Incineration
P-Return to Process
PS-To Public Sewer
H-Hauled Away
BP-By-Product Mfg.
DIF.-Diffusser
Do C. -Flow Control
68
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CODE TABLE KEY
Source of Data
A. Personal visits or files
B. Questionnaires
C. Literature
D. Estimate
Type of Data Sampling
L. Grab (single sample)
M. Composite
N. Period sampling (average of grab samples)
0. Unknown
Quality of Data
X. Reasonable reliable
Y. Acceptable
Z. Questionable
69
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TABLE VII
LINERBOARD MILLS
1fc
M
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
M
W *
CQ U
FM 3
F
F
F
F
F
F
F
F
F
DAF
F
F
F
DAF
PRSTREAT.MErO1
K
K
K
K
K
E
K
-
c.c
K
-
-
K
K
K
K
SUSP. SOLIDS
RED.
C
C
C
C
C
C
AB
C
C
AB
C
C
C
C
Q
W
K
Q
O
M
AL
AL
TF/
AL
AL
AL
AL
HL
HL
HL
HL
AL
AL
AL
AL
W FH
O ^
W H
gw
K
M EH
HL
-
-
-
HL
-
-
A
-
PL
PL
-
-
-
SLUDGE
HANDLING
P
M
f'\
u
M
EH
-
-
-
-
-
-
-
-
-
-
-
-
-
P
K
W
G
P
-
CE
-
CE
P
-
-
-
-
-
-
-
-
DISPOSAL
L.F.
L.F..
L.F.
L.F.
L.F.
Inc .
L.F.
L.F.
L.F.
L.F.
L.F.
L.F.
L.F.
L.F.
EFFLUENT FLOW
JIGD
26
10
19
3
12
30
15
6
12
27
12
10
16
9
BODr
#/ton
Prod .
INFLUENT
42
22
38
35
33
90
18
30
26
41
27
101
33
34
FH
W
W
14
4
10
11
3
6
5
2
7
5
6
28
21
2
TSS
#/ton
Prori .
w
M
30
40
12
19
25
23
69
12
30
53
55
139
-
27
FH
W
;TJ
W
11
4
6
20
1
5
7
0.4
3
4
4
7
-
3
-------
TABLE VII-A
LINERBOARD
MILL SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
IB MX
2 A MX
3 B MX
4 C MX
5 B MX
6 B MX
7 B MX
8 A MX
9 B MX
10 B MX
11 A MX
12 B MX
13 B MX
14 B MX
71
-------
TABLE VIII
NEWSPRINT MILLS - KRAFT
1-0
1t
>J
iJ
hH
"R
1
2
3
4
5
6
DS
W
ca u
S 2
DAF
F
F
F
F
F
&
H
,--
PPETREAT
K
K
-
-
-
-
OT
Q
_1
0
C/1
t
Oi
W O
S3 W
i/l C4
C
C
C
C
C
AB
O
w
K
§
«
AS
AS
HL
HL
AL
AL
W H
0 X.
£g
W H
-------
TABLE JVI_I1>A
NEWSPRINT MILLS - KRAFT
MILL SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
IB M X
2 A M X
3 A M X
4 A M X
5 A M X
6 A M X
73
-------
TABLE IX
INTEGRATED KRAFT MILLS
J
O
C£
ft
CO Q
W 2
c
c
c
c
c
AB
C
AB
C
C
Q
W
K
Q
8
AS
AS
AS
AS
AS
HL
AS
AL
AL
AS
W E-"
0 ^.
3RD STA
TREATiME
-
AL
-
-
-
-
-
HP
SLUDGE
HANDLING
O
Y,
HICKENI
H |
-
-
GT
GT
GT
-
-
-
-
GT
o
X,
1 1
K
W
F-H
<,
W
Q
D
VF
VF
VF
VF
-
-
VF
-
VF
ISPOSAL
w
LF
LF
LF
LF
LF
LF
LF
INC
LF
LF
H
EFFLUEN-
MC-D
14.5
10.3
26.1
25.1
63.0
28.0
4.2
40.0
3.0
38.0
DOD5
#/ton
Prod .
NFLUENT
M
56
121
33
73
91
63
41
39
35
67
FFLUENT
M
9
19
9
11
10
25
1
13
11
9
TSS
ff/ton
Prod .
NFLUENT
M
196
39
211
158
96
87
49
49
189
75
FFLUENT
W
14
7
57
18
17
2
19
10
21
27
-------
TABLE _IX-A
INTEGRATED KRAFT MILLS
MILL SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
1 A M X
2 B M X
3AM X
4AM X
5AM X
6 B M X
7AM X
8 L M X
9 L M X
10 L M X
75
-------
TABLE X
BLEACHED KRAFT MILLS
It
J
v»
s
1
2
3
4
5
6
7
8
9
Qfl
W
CQ CJ
PM 2
F
F
F
F
F
F
F
F
F
ft
£
H
W
ort
CU
N/K
K
E"/N
K
K
K
-
K
E/K
en
Q
O
c/i
A
t/D O
D W
CO K
C
C
C
C
C
AB
C
AB
C
.
Q
W
K
Q
O
W
AL
AL
AL
AL
AL
HL
AL
HL
AL
W f-i
o ,r<
29
Sw
Crf
co E-"
-
PL
""
-
HP
-
-
PL
PL
SLUDGE
HANDLI'NG
O
Xi
n
H
o
HH
H
-
-
~"
-
-
-
-
-
-
O
'S~,
s
w
w
Q
-
-
K
-
-
-
VF
-
-
-------
TABLE X-A
BLEACHED KRAFT MILLS
MILL SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
IB MX
2 B MX
3 A MX
4 B MX
5 A MX
6 A MX
7 B MX
8 B MX
9 B MX
77
-------
TABLE XI
ACID SULFITE PULP MILLS
oo
11;
I
1
2
erf
w
CQ O
CM 3
DAG
-
H
w
M'
KN
HB
K
SUSP. SOLIDS
RED.
C
AB
Q
W
Q
O
W
AS
AL
W FH
O -X.'
co En
HB
-
SLUDGE
HANDLING
THICKEia.XG
K
-
a
l-H
ci
w
Q
K
-
DISPOSAL
LF
-
EFFLUENT FLOW
MGD
4.0
BOD5
#/ton
Prod .
INFLUENT
235
160
FH
H
CM
CM
W
35
28
TSS
#/ton
Prod.
INFLUENT
-
FH
W
fM
CM
tt
30
Volatile
21 121
-------
TABLE XI-A
ACID SULFITE MILLS
MILLS SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
1 A MX
2 L MX
3 L MX
79
-------
TABLE XII
NSSC - Mill
oo
o
^t
^
J
t!
1
fl*
w
03 o
F 3
T£. (j^
F
g
H
<^
w
OS
H
£
Pk
K
w
Q
O
(X
w n
D W
W K
Int.
only
,
Q
W
C£
Q
O
CQ
AL
W F-i
0 X.
f- ) -
W H
Sw
te
CO [-H
SLUDGE
HANDLING
O
|^(
M
i< <
a
u
M
H
O
X,
i i
Cti
w
FH
W
Q
h>l
-------
TABLE XII-A
NEUTRAL SULFITE
Mill SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
IB G Y
81
-------
TABLE XIII
DEINKING - PAPERMILLS
oo
NJ
-------
TABLE XIII-A
DEINKING MILLS
MILLS SOURCE OF DATA TYPE DATA QUALITY OF DATA
1 A M X
2 A M X
3 ~
4 A M X
83
-------
TABLE XIV
WASTE PAPERBOARD MILLS
oo
1 1
1
2
3
4
5
6
7
8
9
OS
w
CO CJ
I-H W
s
F
S
-
S
-
-
s
s
PRE.TREATME.NT
K
K
K
K
K
K'
K
K
K
SUSP. SOLIDS
RED.
AB
C
AB
C
C
C
AB
C
C
Q
W
K
Q
O
W
AL
AL
AL
AL
AS
AL
AL
AS
AS
3RD STAGE
TREATMENT
I
-
A
-
AS
-
-
-
-
SLUDGE
HANDLING
P
t-H
U
H
-
TC
-
-
TC
-
-
-
-
p
I-H
W
FH
W
Q
B
B
B
-
-
B
B
B
B
DISPOSAL
LF
LF
LF
PS
R
H
LF
LF
LF
LF
EFFLUENT FLOW
MGD
0.7
2.0
2.7
2.0
3.3
0.3
0.3
2.7
0.6
BODr
ff/ton
Prod .
INFLUENT
45
26
23
30
15
8
15
14
19
EFFLUENT
4
3
2
7
0.2
1
2
0.7
2
TSS
ff/ton
Prod .
1
KH i
46
51
81
87
7
56
60
56
73
EH
W
2
4
9
8
0.5
3
4
2
6
-------
TABLE XIV-A
WASTE PAPERBOARD MILLS
MILLS SOURCE OF DATA TYPE OF SAMPLING QUALITY OF DATA
1 A M X
2 A M X
3 A M X
4 A M X
5 A M X
6 B L Y
7 B L Y
8 A M X
9 A L Y
85
-------
|