United States
Environmental Protection
Agency
Office of Pollution Prevention
and Toxics (TS-779)
Washington, DC 20460
EPA-744R-93-002
February 1993
Proceedings
INTERNATIONAL SYMPOSIUM ON
POLLUTION PREVENTION IN THE
MANUFACTURE OF PULP AND PAPER
- OPPORTUNITIES & BARRIERS -
August 18-20,1992 • Washington, D.C.
Organized by the
Office of Pollution Prevention and Toxics
for the
U.S. Environmental Protection Agency
Pulp and Paper Cluster
Recycled/Recyclable
Primed with Soy/Canola Ink on paper that
contains at least 50% recycled fiber
-------
Proceedings
INTERNATIONAL SYMPOSIUM ON
POLLUTION PREVENTION IN THE
MANUFACTURE OF PULP AND PAPER
- OPPORTUNITIES & BARRIERS ~
August 18-20,1992 • Washington, D.C.
Organized by the
Office of Pollution Prevention and Toxics
for the
U.S. Environmental Protection Agency
Pulp and Paper Cluster
-------
Prepared by JT&A, inc. and Abt Associates Inc. under contract 68-D2-0175 for the Office of
Pollution Prevention and Toxics, U.S. Environmental Protection Agency. Publication does not
signify that the contents necessarily reflect the views and policies of the Environmental
Protection Agency or of any other organization represented in this document. Mention of
trade names and commercial products does not constitute endorsement of their use.
Conference Planning Committee
Susan Krueger, Lisa Harris/ and jean (Libby) Parker
Economics, Exposure, and Technology Division
Office of Pollution Prevention.and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-779)
Washington, DC 20460
with special thanks to Cluster Staff
Mark Luttner, Office of Water
Jocelyn Woodman, Office of Pollution Prevention and Toxics
Mahesh Podar, Office of Policy, Planning and Evaluation
-------
Foreword
These proceedings document the presentations at the International Symposium on Pollution
Prevention in the Manufacture of Pulp and Paper — Opportunities and Barriers. This sym-
posium, held August 18-20, 1992, in Washington, D.C., was sponsored by the U.S. Environ-
mental Protection Agency's (EPA's) Pulp and Paper Cluster. Comprised of high-level EPA personnel,
the cluster is working to identify areas of concern in the pulp and paper industry and to coordinate
Agency efforts to reduce pollution associated with the industry.
This symposium provided an opportunity for the international community to share information
on factors affecting the adoption of pollution prevention practices in the pulp and paper industry.
The broad range of perspectives of the panelists resulted in exciting and informative discussions
regarding alternative pulping and bleaching technologies; trade-offs associated with the use of al-
ternative technologies, including emissions, paper performance, and cost; government activities re-
lated to pulping and bleaching technologies; and industry activities related to evolving product
performance specifications and customer demand for environmentally sound paper. Further details
about these issues can be found in these proceedings.
The enthusiasm and personal experiences of the panelists and participants were a key to the
symposium's success. Participants included pulp and paper manufacturers, paper converters, non-
profit organizations, government agencies, publishers, printers, and other wholesale and retail
paper consumers. It is EPA's hope that this symposium was the first of many forums that will lead to
more effective pollution prevention policies and programs within the pulp and paper industry.
These proceedings contain the text of the presentations, transcriptions of the question and
answer sessions, the names and addresses of registered participants, and indices of the presenters
and writers. The index of presenters includes brief biographical profiles of each. We hope that these
proceedings will be a valuable reference tool.
U.S. EPA Pulp and Paper Cluster
Martha Prothro Office of Water
Mark Greenwood Office of Pollution Prevention and Toxics
John Seitz Office of Air and Radiation
Jeff Denit Office of Solid Waste
Peter Preuss Office of Research and Development
Paul Guthrie Office of Regional Operations and State/Local Relations
Maryann Ffoehl ich Office of Policy, Planning and Evaluation
Kathy Summerlee Office of Enforcement
Susan Lepow Office of General Counsel
Tudor Davies Office of Science and Technology
in
-------
Contents
OVERVIEW OF EXISTING AND EMERGING TECHNOLOGIES
Welcoming Remarks 2
Mark Greenwood, U.S. Environmental Protection Agency
Compliance is a Good Start, Prevention is the Next Step 3
Linda Fisher, U.S. Environmental Protection Agency
A Brief Introduction of the Pulp and Paper Industry Cluster 5
Martha Prothro, U.S. Environmental Protection Agency
A Profile of the U.S. Pulp, Paper, and Paperboard Industry 7
Richard E. Storat, American Paper Institute
PANEL ±: Pollution Prevention and Life Cycle Analysis
Pollution Prevention and Life Cycle Assessment 12
Frank J. Consoli, Scott Paper Company
The Pulp and Paper Industry's Long-time Commitment to Environmental Quality 18
Richard). Diforio,Jr., Champion International Corporation
Corporate Versus Societal Perspectives on Pollution Prevention Benefits
and Total Cost Assessment 21
Monica M. Becker, Tellus Institute
Meeting the Challenge of "No Effect" Pulping and Bleaching 27
Dick Erickson, Weyerhaeuser Company
Question and Answer Session 33
PANEL 2: Overview of Technologies of Paper Manufacturing
The ABCs of Conventional Technologies Related to Pulping and Bleaching 35
Thomas]. McDonough, The Institute of Paper Science and Technology
Chemicals Used in the Pulp and Paper Industry 41
Russell E. Kross, The Mead Corporation
Conventional Pulp Bleaching at Westvaco 44
Harold L. Hintz, Westvaco Corporation
Question and Answer Session 48
Luncheon Speaker
Worldwide Sales Opportunities for Environmentally Responsible Products 49
David Mager, Green Seal
PANEL 3: Alternative and Emerging Technologies — Pulping
Low Kappa Continuous Pulping 54
C. Bert// Stromberg, Kamyr, Inc.
The Development of Chlorine-free Manufacturing and Bleached Kraft Pulp 61
Lars-Ake Lindstr&m, Sunds Defibrator Industries AB
Recovery Boiler Capability to Accommodate Alternative Kraft Mill Processes 66
John L. Clement, Babcock & Wilcox Company
-------
Alternative and Emerging Nonkraft Pulping Technologies 76
Bruce I. Fleming, Boise Cascade
Question and Answer Session 81
PANEL 4: Alternative and Emerging Technologies — Bleaching
Bleaching of Kraft Pulp — A Research Perspective 84
Peter Axegard, Swedish Pulp and Paper Research Institute
The Emerging Technology of Chlorine Dioxide Delignification 96
Douglas W. Reeve, University of Toronto
Bleaching Papermaking Pulps with Oxygen and Ozone in a Commercial Installation 100
William H. Trice, Union Camp Corporation
Saving Bleaching Chemicals and Minimizing Pollution with Xylanase 105
Lubomirjurasek, Pulp and Paper Research Institute of Canada
Question and Answer Session 108
TRADE-OFFS, PERFORMANCE, AND GOVERNMENT ACTIVITIES
PANEL 1: Trade-off Issues
The Properties of Pulp Bleached in Low-Chlorine or Nonchlorine Sequences 112
Norman Liebergott, DuPont Canada, Inc.
Trade-Off Issues — The Input of Pollution Prevention Techniques on Paper Products 120
Gerald P. Closset, Champion International Corporation
Unbleached Coated Kraft for Beverage Cartons 126
Rune Anderson, Frovifors Bruk AB
Question and Answer Session 131
PANEL 2: Technical Perspectives — Specifications
Paper Specifications and Pollution Prevention — An Industry View 134
Virgil K. Morton, Jr., American Paper Institute
Opportunities and Barriers for Using Chlorine-free Paper in North America 138
Howard Sproull III, ECO Paper Source
The Original U.S. Chlorine-free Paper Producer Looks Ahead 140
Archie Beaton, Lyons Falls Pulp & Paper
Issues and Needs Affecting Paper Purchasing Decisions — An End User's View 143
David J. Refkin, Time Inc.
Apple Computer's Project Jordache — The Switch to Kraft Packaging 145
Erin Craig, Apple Computer, Inc.
Question and Answer Session 149
PANEL 3: Technical Perspectives — Performance and Cost
The Right Balance — Environmental Responsibility and the Competitive Edge 155
Clifford T. Howlett, Jr., Georgia-Pacific Corporation
A Chlorine-free Paper Economy — Europe on the Verge 161
Margaret Rainey, Greenpeace Paper Campaign
Performance and Cost Considerations in Pollution Prevention Practices 166
Richard N. Congreve, Potlatch Corporation
Question and Answer Session 168
VI
-------
Costs and Benefits of Various Pollution Prevention Technologies in the Kraft Pulp Industry 172
Neil McCubbin, N. McCubbin Consultants, Inc.
Bleaching Cost and Environmental Results at a Modern Kraft Market Pulp Mill 185
Luigi Terziotti, Parsons & Whittemore
Challenges in the Development of Totally Chlorine-free Kraft Pulp Bleaching Technology 190
C. Roger Cook, E.B. Eddy Forest Products Ltd.
The Effects of Alternative Pulping and Bleaching Processes on Product Performance —
Economic and Environmental Concerns 194
Richard B. Phillips, International Paper
Question and Answer Session 206
PANEL 4: Government Activities
A Consultant's View of European Government Activities 209
Jens Folke, European Environmental Research Croup
Environmental Regulation of the United States Pulp and Paper Industry 216
Kathleen M. Bennett, James River Corporation
U.S. Regional Pollution Prevention Activities 220
Michael D. Witt, Wisconsin Department of Natural Resources
An Update on Washington State's Hazardous Waste Reduction Act 222
Dee Williams, Washington State Department of Ecology
British Columbia Regulations to Eliminate Adsorbable Organic Halogens
from Pulp Mill Effluents 225
Ann Hillyer, West Coast Environmental Law Association
Question and /Answer Session 229
PANEL 5: EPA Activities
The Pulp and Paper Cluster's Mission 231
Martha Prothro, U.S. Environmental Protection Agency
The Pulp and Paper Sludge Rule 233
Mark Greenwood, U.S. Environmental Protection Agency
The Maximum Achievable Control Technology Rule 235
John S. Seitz, U.S. Environmental Protection Agency
Solid Waste Office Update 237
Jeffery Denit, U.S. Environmental Protection Agency
Question & Answer Session 238
PRODUCT PERFORMANCE SPECIFICATIONS AND CUSTOMER DEMAND
The Market for Chlorine-free Paper 240
David Assmann, Conservatree Paper Company
PANEL 1: Direct Customers
Life in a Medium-sized Paper Company 244
John F. Church, Jr., The Cincinnati Cordage and Paper Company
Pollution Prevention — How Customers View the Issues 246
Donald C. Monefeldt, Xerox Corporation
The Nation's Number One Paper Purchaser Looks at Recycled Content, Chlorine Processing 248
Barbara Belasco, General Services Administration, Region 2
VII
-------
Pollution Prevention in the Envelope Industry 250
Michael J. Cousin, Georgia-Pacific Corporation
Creating Demand for Environmentally Preferable Paper 257
Lauren Blum, Environmental Defense Fund
Question and Answer Session 266
PANEL 2: Publishers and Printers
The Environment Is Good for Business — A Publishing Company's View 272
Kit Taylor, Times Mirror Magazines
Alternatively Bleached Papers and Other Impossibilities 274
Roger Telschow, Ecoprint
Evolving Paper Product Specifications and Market Demand — A Publisher's Viewpoint 277
Donald W. Hopkins, Hearst Enterprises Division, The Hearst Corporation
Printing the IKEA Catalog Entirely on Totally Chlorine-free Paper 279
Michael J. O'Rourke, IKEA U.S., Inc
Question and /Answer Session 281
Luncheon Speaker
The Implications of Sustainable Development for the Forest Product Industry 284
Peter E. Wrist, Pulp and Paper Research Institute of Canada
PANEL 3: Market Pulp
Market Pulp and Environment Issues in Perspective 291
Dean W. DeCrease, Weyerhaeuser Company
Market Barriers for Aspen Bleached Chemithermomechanical Pulp Products
in the United States 298
Patricia]. Dollar, Slave Lake Pulp Corporation
One Company's Experience with Chlorine-free Bleached Pulp (a Cautionary Tale) 301
Ladd T. Seton, Eraser Paper, Limited
Market and Technical Aspects of Totally Chlorine-free Bleached Kraft Pulp in Europe 304
Steve Moldenius, Sodra Cell
Question and Answer Session 306
Closing Remarks 309
Mary Ellen Weber, U.S. Environmental Protection Agency
Attendee List 311
Index of Presenters 325
Index of Authors 337
Conference Note 339
VIII
-------
Tuesday, August 18,1992
OVERVIEW OF
EXISTING AND EMERGING TECHNOLOGIES
OPENING REMARKS
INTRODUCTION: Profile of the Pulp and Paper Industry
PANEL ±: Pollution Prevention and Life Cycle
Analysis
PANEL 2: Overview of Technologies of Paper
Manufacturing
LUNCHEON SPEAKER: Worldwide Sales Opportunities
for Environmentally Responsible Products
PANEL 3: Alternative and Emerging Technologies —
Pulping
PANEL 4: Alternative and Emerging Technologies —
Bleaching
-------
Welcoming Remarks
Mark Greenwood
Director, Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C.
I would like to welcome everyone to the Interna-
tional Symposium on Pollution Prevention in the
Manufacture of Pulp and Paper: Opportunities
and Barriers. A summer meeting in Washington,
D.C., guarantees that there will be no "sunshine
patriots" here, but only people with interest in and
great expertise on the topics to be presented.
Those of us from the U.S. Environmental
Protection Agency (EPA) look forward to this sym-
posium, because it provides an opportunity to hear
from a wide range of experts who are seldom
gathered together. There have been many technical
conferences held by and for the international pulp
and paper industry, but to 'my knowledge few have
focused on the issues that relate to pollution
prevention, and fewer still have given equal weight
to considering the technological and institutional
issues involved.
A conference like this one is particularly impor-
tant because so few other industries face as much
controversy when environmental performance is
discussed. It is difficult to make a fair assessment of
what is going on in the pulp and paper industry,
and what manufacturers are capable of doing, be-
cause the industry is often faced with a barrage of
conflicting information and opinions from all sides
of the spectrum. This is clearly an area in which
much useful information remains to be shared. In-
formation is nobody's enemy.
Our hope for this symposium is that it will form
a strong basis for common ground among industry,
environmentalists, and government. Another con-
ference goal is to focus on pollution prevention op-
portunities, without dwelling too much on the issue
of risk.
It is my pleasure to introduce the first speakers.
The first speaker, Linda Fisher, is the assistant ad-
ministrator for the Office of Prevention, Pesticides,
and Toxic Substances. She has served in that posi-
tion for three years, and has brought many changes
to her program area. She has been very much a
leader in forging the link between the concept of
pollution prevention and the management of toxic
chemicals.
Our second speaker, Martha Prothro, is also a
leader in the pollution prevention area. She has
served for many years in EPA's Office of Water, and
she is well-known for her thorough understanding
of this industry. She is also known for her strong
leadership on the regulatory issues that face the in-
dustry. It is no surprise that she chairs the Pulp and
Paper Cluster, the interagency workgroup that
coordinates EPA policy for the industry.
-------
Compliance Is a Good Start,
Prevention Is the Next Step
Linda Fisher
Assistant Administrator
Office of Prevention, Pesticides, and Toxic Substances
U.S. Environmental Protection Agency
Washington, D.C.
When we originally planned this sym-
posium, peace and peace talks were
breaking out all over. Even Palestine
Liberation Organization leader Yasser Arafat had
agreed to meet his lifelong adversaries at the
negotiating table. So it seemed like a good idea,
perhaps even a challenge, to bring industry, en-
vironmentalists, community leaders, and different
levels of government together to talk about oppor-
tunities for and barriers to pollution prevention in
the pulp and paper industry.
To add to the challenge that we were setting,
we decided to hold the conference in August in
Washington during the Republican National Con-
vention. I think only a pro-choice plank in the
Republican platform would have been more dif-
ficult to pull off. As symposium participants, you
are to be commended for your willingness to be
here, and I assure you those of us on the planning
committee appreciate your efforts.
U.S. Environmental Protection
Changes Tack
Historically, environmental protection in the
United States has relied on pollution control as its
cornerstone. The major U.S. environmental regula-
tions, the Clean Air Act, the Clean Water Act, the
Resource Conservation and Recovery Act, and the
creation of the Superfund to clean up toxic waste
areas clearly reflect this emphasis. A great deal has
been accomplished under these pollution-control
and cleanup statutes, but much more needs to be
done if we are to continue to make strides to
protect our environment. We cannot achieve our
environmental goals relying solely on complex, un-
wieldy, single-medium statutes to combat the
problems of the future.
In the early 1990s, the environmental protec-
tion philosophy began to take on a new focus. New
ways to prevent pollution received more emphasis,
and we began to figure out new environmental
solutions to our problems. New rules are now
emerging for both industry and government in the
environmental protection area.
When I became the assistant administrator in
1989, industry and government were often per-
ceived as adversaries. Since that time, however,
much has changed, including the name of my of-
fice — to reflect a more prevention-oriented way of
doing business. Business and government leaders
have identified some areas where our goals meet.
The environment and the economy can work in
harmony, and pollution prevention is the tool to
successful accomplishments in both areas.
Pollution prevention is a good framework for
defining the solutions that this symposium is seek-
ing. We seek opportunities to lessen the worldwide
pulp and paper industry's adverse impact on the
environment and to improve economic efficiency
at the same time. Over the last decade, U.S. con-
sumers have begun to demand that environmental
concerns be addressed in the manufacturing stage
of a number of products.
For the pulp and paper industry, consumers are
calling for cleaner products with better environ-
mental performance and facilities with much less
impact on neighboring communities. New proces-
ses and technologies are continually being
developed to meet these demands. During this
-------
symposium, we hope to identify appropriate
emerging technologies for U.S. facilities and reach
consensus on the major issues facing the pulp and
paper industry as it struggles to meet its environ-
mental challenges.
We have structured this conference to reach as
broad an audience as possible among industry,
consumers, environmentalists, and government
regulators. We want to expand our understanding
of potential solutions and identify and work
through barriers to their implementation. The pol-
lution prevention philosophy is resisted by some
manufacturers because it entails added respon-
sibilities, and by some in the environmental com-
munity because of the philosophy's inherent
uncertainty.
Corporations Can Approach
Pollution Proactively
In the past, corporate environmental managers
were primarily concerned to be in compliance with
existing environmental laws. Compliance was less
daunting and far safer than attempting to forge new
trails in pollution prevention. But this attitude has
begun to change, especially with the creation of the
Toxic Release Inventory (TRI) and greater involve-
ment by the public, both as consumers and neigh-
bors.
Today corporate managers are looking beyond
compliance to see what their facilities are actually
doing to their communities. Environmentalists are
beginning to realize that costly prescriptive regula-
tions do not always yield the cleanest environment
over the long-term. Pollution prevention requires
initiative, creativity, and trust. It can require addi-
tional investment for the short- and long-term. But
many interested parties are beginning to realize
that the investment can bring substantial returns —
rewards that encompass far more than increased ef-
ficiency and monetary paybacks. The rewards in-
clude environmental benefits and higher customer
satisfaction. Though environmental returns may be
difficult to measure, we are confident that they are
long-lasting.
Conclusion
Pulp and paper production has been a major in-
dustry in this country for many decades, and its
manufacturing methods have at times been con-
troversial. Government, industry, and groups of
citizens have waged explosive debates over per-
ceived actual and potential harm to the environ-
ment, over how much control should be in place,
and over what costs are necessary or reasonable.
During this meeting and other related gatherings,
representatives from corporations, environmental
groups, and government agencies can engage in an
honest exchange of ideas. The government can
serve a valuable role as facilitator and as a
promoter of many pollution prevention efforts.
EPA has had substantial success in these efforts.
Initiatives like the 33/50 program in which com-
panies voluntarily reduce their TRI discharges by
33 and 50 percent and the Green Lights program,
in which EPA and industry collaborate to change to
new lighting technology, are excellent examples of
the benefits of collaborative efforts between
government, industry, and the public. EPA has been
building rapidly on this record of success. Design
for the Environment — one of our newest programs
— has the potential to change the way chemicals
are developed and used.
Design for the Environment (DFE) promotes the
design, development, and applications of chemi-
cals, processes, and better technologies within in-
dustry through a dynamic process of changing
behavior. By building environmental concerns into
the design stages of products, we can achieve pol-
lution prevention results that will benefit everyone.
This symposium emphasizes the necessity of
thinking proactively rather than reactively. The
company that is able to anticipate problems and
tackle them before they grow to be major obstacles
to corporate success is the industry leader of the fu-
ture. We have great hopes for this symposium. It of-
fers the possibility that pollution prevention is not a
buzzword but an accepted method of doing busi-
ness in the pulp and paper industry, now and in the
future, for the betterment of the environment and
for the economic viability of the industry world-
wide.
-------
A Brief Introduction of the
Pulp and Paper Industry Cluster
Martha Prothro
Deputy Assistant Administrator, Office of Water
U.S. Environmental Protection Agency
Washington, D.C.
welcome you today in my capacity as the chair
of the U.S. Environmental Protection Agency's
(EPA's) Pulp and Paper Cluster. This cluster is not
a new high-fiber candy bar but a group of agency
managers committed to the notion that we can
coordinate and, to a great degree, integrate agency
actions that affect the pulp and paper industry. The
cluster group's members are listed on the back of
your program. I am very proud to work with such a
distinguished group — all of whom are participat-
ing in one capacity or another in this conference.
Given the history of environmental law and
regulation in this country, and the medium-specific
laws and regulations that we have to deal with, we
at EPA think the cluster group presents both an ex-
citing challenge and a promising precedent for
other programs. I believe this marks the first time
the EPA has integrated its regulatory activities in so
many different media (air, water, and soil) areas.
We are proud of our accomplishments, though
sometimes, like Pogo, we do feel as though we are
confronting insurmountable opportunities.
According to the industry's own Toxic Release
Inventory (TRI), the pulp and paper industry is the
fourth largest industrial source of pollutants in the
United States. More than 600 pulp and paper mills
located in this country discharge about 370 million
pounds of TRI pollutants — about 55 percent to the
air, and 34 percent to receiving waters. As most of
you know, in the late 1980s, the industry and EPA
worked together on a study now known as the 104
Mill Study. We found that virtually all bleaching
mills in the industry had dioxins and furans in their
effluent and wastewater treatment sludges.
Since then, the industry has made a great deal
of progress. Some mills have made significant im-
provements in pollution prevention, and some in
their control technology. But most of us here agree
that more work needs to be done.
On the other hand, we need to keep in mind
the economic importance of this industry to our na-
tion. Pulp and paper manufacturers employ almost
200,000 people at more than 500 facilities located
in almost every State. The entire industrial category,
including companies that convert pulp and paper
into finished products, employs another 600,000
Americans at 6,200 facilities. The payroll is more
than $27 billion annually.
Paper industry spending for new plants and
equipment from 1991 through 1992 is an estimated
$14 billion. Spending for environmental protection
is projected at $1.9 billion during that same period
(or about 15 percent of the industry's total capital
expenditures). In the March 1992 edition of For-
tune magazine, George Adler of Smith Barney
states that the paper industry is to the United States
what oil is to Saudi Arabia. So we must address the
question of how to further the goals of environmen-
tal protection and economic strength. This duality
is at the heart of the pollution control controversy
in our pulp and paper mills. Change means move-
ment, movement means friction, friction means
heat, and heat means controversy. But, as Bertrand
Russell once said, the most savage controversies
are usually about matters for which there's no good
evidence either way.
This conference provides an opportunity to
review the evidence and to move from controversy
to consensus. In the long run, as President Bush has
said, successful environmental protection is a pre-
requisite to solid sustainable economic growth.
That is EPA's belief vis a vis this industry.
-------
Later in the symposium, you will have an op-
portunity to hear more about the Pulp and Paper
Cluster and our coordinated approach to develop-
ing new technology requirements for air and water
pollution. Because the Cluster's goal is to promote
pollution prevention, we have supported this sym-
posium financially and many Cluster members
have worked hard on this effort. We hope you will
find the information about the Cluster and the
Cluster itself useful. We think its success will mean
a greater appreciation and knowledge of the oppor-
tunities for pollution prevention in this industry.
It has been said of some government officials
that even if they attended a conference on creation,
they would remain loyal to chaos. I assure you,
however, that we at EPA have not approached this
symposium from that point of view. We are here to
listen and learn as I know you are.
-------
A Profile of the U.S. Pulp,
Paper, and Paperboard Industry
Richard E. Storat
Vice President, Economic and Financial Services
American Paper Institute
New York, New York
The primary raw material for the myriad of
products that we produce and you use in your
daily lives is largely fiber or cellulose derived
from trees — a renewable resource. The industry
formerly obtained its fiber from another recyclable
and renewable resource, namely cotton, in the
form of rags. When demand outstripped that source
of cellulose, we discovered how to obtain cellulose
from trees. The renewability of this resource is un-
derscored by the fact that nearly 3 billion seedlings
are planted each year, with forest growth exceeding
harvests and losses to natural causes; in fact, the
United States has 20 percent more trees today than
we had just 20 years ago.
Pulping and bleaching processes separate the
cellulose in trees from other constituents such as
lignin w'rth as little damage to the natural cellulose
fibers as possible. The kind and extent of pulping
depends on the end-use characteristics needed for
particular products; the greater the cellulose con-
tent, for example, the greater the strength, bright-
ness, longevity, softness, and absorptive capacity.
Finally, paper and paperboard mills in turn use the
pulp to make a range of commercial and consumer
products: printing and writing papers, newspapers,
packaging, sanitary and personal care products,
and corrugated containers.
Pulp and Paper in Perspective
With only 5 percent of the world's population, the
United States has 12 percent of the world's paper
and paperboard mills and 16 percent of the world's
oulp mills. The United States manufactures 30 per-
cent of the world's paper and paperboard and 35
percent of the world's pulp. Last year, 544 mills lo-
cated in 42 states produced 79.4 million tons of
paper and paperboard products and 9 million tons
of market pulp. In 1991, the paper and allied
products industries employed nearly 700,000
people with a payroll topping $28 billion and
generated sales of $122 billion. U.S. mill produc-
tion amounts to 5 percent of the total value of U.S.
manufacturing output, placing pulp, paper, and
paperboard among the nation's top 10 manufactur-
ing industries.
As the world's top producer, U.S. paper and
paperboard mill output is greater than the com-
bined total output of the next four countries —
Japan, Canada, Germany, and China. Of the world
paper and paperboard market, the United States
has 30 percent, Japan, about 12 percent; Canada, 8
percent; Germany, 6 percent; and China, 5 percent.
In world market shares of wood pulp, the United
States has 35 percent; Canada, 16 percent; Japan, 9
percent; the former Soviet Union, 7 percent; and
Sweden, 7 percent, according to a United Nations
Capacity Survey (U.N. Food Agric. Ass.. 1992).
Continuing a long-term trend, total U.S. paper
industry exports rose in 1991 to record heights, up
11 percent to 21.4 million tons, valued at $9.7 bil-
lion, in spite of slower world economic growth and
global overcapacity in several paper industry
products. This strong export performance can be at-
tributed to several factors:
• relatively better demand in foreign markets;
• fundamentally sound exchange rates;
• greater global market focus by U.S.
producers; and
• a very competitive U.S. cost structure.
Perhaps the most significant of these factors is the
competive cost structure.
-------
Labor, Capital, and Capacity Costs
Comparative unit labor costs are a key measure of
competitiveness because they summarize the com-
bined influences of productivity, compensation,
and exchange rates. Partly as a result of favorable
exchange rates but mainly as a benefit from
productivity advances, U.S. paper industry unit
labor costs have held flat since 1982, outperform-
ing other major paper-producing industries around
the globe (see Fig. 1).
A Fortune cover story, called "How American
Industry Stacks Up," analyzed the competitiveness
of 13 key U.S. industries relative to japan and
Europe. On its "report card," the U.S. paper in-
dustry was one of only two industries awarded an
"A," which implied "a dominant position in the
world, one not likely to erode significantly in the
1990s." Fortune also noted that "the United States
leads not just because it has a lot of trees. American
companies also have relative lower labor and ener-
gy costs, and they have invested more than $100
billion since 1980 to raise productivity and under-
write expansion into new products and markets."
The pulp and paper industry requires enormous
amounts of capital — $16.7 billion in 1990. Even
Index 1982=100
200
after the sharpest spending cutback in recent his-
tory, investments in 1991 neared $12 billion and
will top $10 billion again this year. From 1980 until
the end of 1991, a new capacity of almost 21 mil-
lion tons was added to U.S. mills. As the rate of
capacity expansion slows, 2 million additional tons
of capacity are still expected to come on-line in
1992.
During the 1980s, the portion of industry
capacity in paper mills larger than 500,000 tons per
year almost doubled — from 18 percent to more
than 32 percent. Pulp mills followed a similar
trend. Almost 60 percent of the industry's capacity
exists in machines that were either newly installed
or extensively rebuilt during the past 10 years. This
newest segment of the U.S. paper industry is larger
than any other nation's entire industry — more than
1.5 times the size of the entire Japanese paper in-
dustry.
Industry capital spending also translates into
exceptional productivity gains. During the 1980s,
productivity rose 37 percent, providing the basis for
paper industry unit labor costs that are among the
lowest in the world, measured in dollars.
Changing to meet new customer demands has
required significant capital resources. The growing
180
160
140
120
100
80
60
Sweden
I
I
I
i
I
I
I
I
I
I
I
200
180
160
140
120
100
80
89 90 91
1980 81 82 83 84 85 86 87
Source: Bureau of Labor Statistics
Figure 1.—Unit labor costs trends in the paper industry. Source: Bur. Labor Stat. (1991); Am. Paper Inst. (1991).
8
60
-------
R.E. STORAT
demand for paper -products containing recycled
fiber is one example. As a result of a multibillion
dollar investment program, fiber consumption from
recovered paper is growing more than twice as fast
as overall fiber consumption, and this trend is
projected to continue to 1995 and beyond. The rate
at which the U.S. industry uses recovered fiber
jumped to 29 percent in 1991 from less than 24
percent only six years ago.
Last year, 31 million tons of paper and paper-
board were recovered in the United States — in-
cluding half the newspapers and close to 60
percent of corrugated boxes. With last year's
recovery rate at over 35 percent, the industry is on
track to achieve its voluntary 1995 goal to recover
40 percent of all paper Americans use for domestic
recycling and export. By 1995, more paper will be
recovered for recycling than will be discarded to
landfills.
Primarily by using its own waste by-products,
the U.S. paper industry generates more than 56 per-
cent of its energy needs. Over the past two decades,
oil consumption has been reduced by nearly 66
~ percent; natural gas consumption by 10 percent;
and fossil fuel and energy consumption per ton of
paper by 46 percent — while production grew by
60 percent. In addition, over 50 percent of the
industry's energy is more efficiently cogenerated,
saving the energy content of nearly 24 million bar-
rels of oil annually.
Capital Intensity
In part, how much an industry has invested per
employee defines its capital structure. Currently, on
average, each employee in our industry is backed
up by more than $100,000 of plant and equipment.
This level is more than twice the average of domes-
tic manufacturing industries and, excluding petro-
leum, is matched only by the chemical industry.
When capital investment is measured as a percent
of paper industry sales, its intensity has been grow-
ing at an average rate of 2.7 percent per year for
over two decades. Contrast that to U.S. manufac-
turing in general, which has traced a much slower
growth path.
The paper industry is the most capital intensive
industry in the United States. In the last decade, it
was twice as capital intensive as the all-manufac-
turing average, twice as capital intensive as the
chemical industry, and significantly above the
primary metals industry. This feature, more than
any other, distinguishes the paper industry's capital
structure from that of other basic manufacturing in-
dustries (see Fig. 2).
The industry's capital intensity is extremely
high. During the 1980s, on average, 10.7 cents of
every sales dollar went for capital spending. Until
recently, most of the industry's capital spending
was provided for by cash flow, allowing for some
shortfalls during the early 1980s. From 1989 to
1992, however, cash flow fell far short of capital
spending requirements. By doing so, the industry
positioned itself well for world-class competitive-
ness during the 1990s. But it also shouldered a
huge debt along the way.
The industry has peaked in its cyclical pattern
and must now get "end of cycle" returns on these
large investments to retain the long-term financial
strength that will enable it to remain globally com-
petitive.
Being capital intensive also means having to
sustain a larger asset base relative to sales and
having higher operating rates — in the case of the
paper and pulp industry, the highest of any in U.S.
industry, averaging 92 percent over the long-term,
compared to an 82 percent manufacturing mean
and a 75 percent rate in some industries like
transportation.
To maintain and improve existing mills and to
increase capacity to keep pace with anticipated
demand in domestic markets alone, the U.S. paper
industry will need to spend some $100 billion and
add about 19 million tons of new capacity in the
1990s.
Pollution Abatement Spending
During the 1970s, environmental control expendi-
tures comprised 23.5 percent of capital spending.
While remaining in the $400 million per year range
during the 1980s, such costs averaged only 8.1 per-
cent of industry investment (see Fig. 3). Capital out-
lays for environmental compliance, having risen
dramatically over the past few years, now exceed
$1 billion per year. As a result, the paper manufac-
turing process today uses 60 percent less water per
ton of product produced than it did 23 years ago.
Biological oxygen demand of industry wastewaters
has been reduced by 70 percent since the first
phase of implementation of the Clean Water Act,
even though paper production has increased by 50
percent since then.
While this recently stepped-up spending does
include the industry's response to dioxin-related
concerns, none of the multibillion dollar invest-
ments in recycling facilities, none of the billion dol-
lar-plus investments that will be required to comply
with the recently enacted Clean Air Act, and none
of the associated operating and maintenance costs
are reflected in these data.
Extrapolating from recent trends and using the
pollution spending projections developed by Data
Resources, Inc., we estimate that environmental
-------
Percent
16
14
12
10
8
6
4
Paper S Allied Products
All Manufacturing
i
i
i
i
i i i i
J I
J I
J I
16
14
12
10
8
6
4
74 76 78 80 82
Source: IRS. Bureau of Census. API
84 86
88
90
92
Figure 2.—Comparative capital intensity (capital expenditures as a percent of sales). Source: Intern. Rev. Serv. (1991);
Am. Paper. InsL (1991).
spending may claim about 20 percent of industry
capital during the 1990s. That's the capacity
equivalent of 18 world-class paper machines each
capable of producing 500 tons per day.
The costs of future environmental regulations
are especially high for a business as capital inten-
sive as paper.
Large capital investments relative to sales are
required for the industry to remain globally com-
petitive. In turn, the industry's global competitive-
ness enables it to run at the 90-plus percent
operating rates that translate into low unit costs.
Low-cost operations relative to other global com-
petitors generate the cash flow that provides the in-
vestment capital to sustain the industry's position,
closing the loop. If any one link is broken, the sys-
tem fails. Since committed capital is neither easily
nor inexpensively redirected, one needs to con-
sider carefully the impact of policy prescriptions for
the paper industry that may be proved wrong in the
long-term .
References
Data Resources, Inc. 1991. Review of U.S. Economy, 10-year
Projections. McGraw-Hill. Lexington, MA.
Fortune Magazine. 1992. How American industry stacks up.
March 9: 30-38.
United Nations Food and Agriculture Association of the United
Nations. 1992. U.N. Capacity Survey: Pulp and Paper
Capacities 1991-1996. United Nations Press. New York,
NY.
10
-------
R.E. STORAT
Billion Dollars
3
2.5
1.5
0.5
- 23.5%
1970'S
Percent of Total
Capital Spending
\
8.1%
1980's
17.9%
21.4%
2.5
1.5
0.5
1990's
Trend DRI Proj.
Figure 3.—Pollution abatement expenditures for U.S. paper, paperboard, and wood pulp mills. Source: Natl. Counc.
Paper Indus. Air Stream Improve. (1990); Am. Paper Inst. (1991); DRI/McGraw Hill (1991).
11
-------
Pollution Prevention and Life Cycle
Assessment
Frank J. Consoli
Manager of Packaging Technology
Scott Paper Company
Philadelphia, Pennsylvania
I am here to talk about the science, practice, and
application of life cycle assessments or analyses
(LCAs), and how we may improve this tool and
use it to pull together a methodology that may help
us make better environmental decisions. Ultimate-
ly, our environmental decisions are crucial, and I
want to help us make those decisions better. So let
me begin this presentation on the background and
use of LCAs with a textbook definition.
LCAs are a three-part process: an inventory of
a system's inputs and outputs; an impact assess-
ment; and an improvement analysis. The first part
is an inventory in which one models a system and
evaluates all inputs and outputs across its boun-
daries. As the entire system is included in the in-
ventory, a great deal of data is collected in this step,
which is also the only step in the LCA process that
is truly well developed at this point.
The second part of an LCA is the "impact as-
sessment." What do these materials and energy
releases do to the environment? This part of the
LCA process is still in conceptual development.
The third part of the LCA encompasses an improve-
ment analysis. The purpose of making the inven-
tory, the impact assessment, and the improvement
analysis is proactive: LCAs should reduce the en-
vironmental burden and resource consumption as-
sociated with products, packaging, processes, or
activities. I borrowed these words from the LCA
advisory board of the Society of Environmental
Toxicology and Chemistry (SETAC), but the impor-
tant consideration is that LCAs be used to make
overall improvements.
Figure 1 is the famous SETAC triangle drawing
of the LCA concept. Life cycle assessments help us
look beyond our traditional company boundaries
to see the effects of our processes upstream and
downstream. In fact, the various decisions that we
make affect both sides of the equation. LCAs are a
way to visualize the effects of our decisions on all
stakeholders, our internal and external customers.
Impact
Analysis
Improvement
Analysis
SETAC. 1990
Inventory
Figure 1 .—Triangular Model of Life Cycle Assessment
Components.
In addition, LCAs carry us to another degree of
detail; they take into account multiple issues. I am
sure all of us have our favorite issues that need to
be included in an LCA. But I think we would also
all agree that within the scope of this process rages
a great debate. Really, what LCAs do is help us
deal with this debate — not to make our environ-
mental decisions for us, but to help us deal with
them more effectively.
Single-issue Charlie
To give you an example of my experience with this
debate, let me tell you about a friend of mine,
Single-issue-Charlie, and his efforts to create better
packaging for the environment. Consider, for a mo-
ment, the issue that Charlie is dealing with when he
takes on this task. He is committed to better pack-
aging, and he has been told to do it, so the will to
act is not an issue here. All Charlie has to do is
12
-------
F.I. CONSOLI
jump into the fray. "The obvious thing to do," he
says, "is to make this package biodegradable."
I don't think any of us now, unless we are inter-
ested in composting, would talk about bio-
degradable products as a solution to municipal
solid waste. Single-issue-Charlie, though, is up on
the facts and knows that packages should contain
recycled content and be recyclable. In addition,
Charlie also wants to make his packaging recycl-
able. But he has also heard some stuff about source
reduction and now his troubles start; he knows that
there are trade-offs between source reduction,
recycling, and recyclability, but he doesn't really
know what to do to balance them.
To make matters worse, Charlie also wants to
put a label on his packaging, and when he thinks
about this label, he realizes that a variety of label-
ing regulations exist across this land. Notwith-
standing that the Federal Trade Commission (FTC)
has helped us here, Charlie still has questions on
this score. Finally, he may discover that various
regions want it one way; other regions require
something different. New Jersey may want it one
way, and his friends from Oregon may want it
another way entirely. The net effect is confusing;
what is poor Charlie to do? His dilemma is
portrayed by the cartoon in Figure 2.
Charlie may, however, turn away from single-
issue viewpoints to LCAs as a way of helping him
sort out the issues.
The Status of LCA Development
Life cycle assessments are really not very magical.
LCA methodologies were here in the early 1970s,
when they were really nothing more than an
input/output diagram or model. The LCA frame-
work is an engineer's dream: good stuff with lots of
numbers and systems to analyze. SETAC is one of
the groups working on this development. Its ad-
visory board has focused on trying to develop this
concept and methodology into a global vision. The
U.S. Environmental Protection Agency (EPA) is also
taking a very active role in the development of this
methodology, along with several other groups, in-
cluding the pulp and paper industry. I will con-
centrate my remarks on SETAC's contributions in
this area.
SETAC is trying to advance the science and
practice of this methodology overall, in a way that
makes sense and uses good science. To do that, it
serves as the focal point for issues and develop-
ment, and it facilitates and coordinates the overall
experiments with this methodology. SETAC's LCA
advisory board, or steering committee, of which I
Don't Forget
Source
duction
Put a
abel on I
New Jersey
Yes,
But Also
ecyclabl
Wants It
It Has
to Be
Recycled
But,
Oregon Wants
It Different
Make It
iodegrade!
Figure 2.—What should Charlie do?
13
-------
Pollution Prevention and Life Cycle Analysis
am a member has worldwide and multisector rep-
resentation; it also tries to operate on consensus.
What we are trying to do now is form commit-
tees to help with the overall development of the
methodology. Now being a group that is excited
about triangles, we revisited our original LCA
model and decided that it needed to be more
detailed. In fact, a life cycle assessment is really
only as good as the goal definition and the scope of
the study. It is very important to spend time defin-
ing your system and understanding the inter-
relationships among its various parts. The revised
LCA triangle and these interrelationships are shown
in Figures 3 and 4, respectively.
The first step is to define the goal and purpose
of the study and to characterize the system that you
are analyzing. Then you can begin the inventory.
Details of an inventory assessment are shown in
Figure 5. In essence, what you are doing is
categorizing your inputs and outputs all the way
Impact
Analysis
Goal
Definition
and
Scoping
Improvement
Analysis
Inventory
Figure 3.—Refining the LCA concept.
SETAC, 1992
back to Dino the dinosaur, if you can find him. The
inventory details the system's life cycles, from raw
material acquisition through waste management.
These inclusive cycles have been termed "cradle to
grave," "earth to earth," "dust to dust," but the bot-
tom line is to achieve an understanding for all
potential inventory items and potential impacts that
are associated with a particular industrial system.
Defining Systems
A life cycle assessment doesn't analyze products; it
analyzes systems. Systems make products, but the
first thing to do is make sure that your system is well
defined. This step takes you into very simple en-
gineering, but it can be an engineering nightmare
to define your system. If you walked into one of
our paper plants and asked to see the system in-
volved in a particular paper-making process, I think
you would be faced with a confusing albeit inter-
esting collection of pipes and valves and systems
that are linked together through many subsystems.
You will need to spend more than a little time
breaking your system down to its various com-
ponents.
Figure 6 shows the types of inputs and outputs
that are of interest from a life cycle perspective.
This process has been well documented by SETAC,
and EPA will soon publish a guidance manual on
how to do an inventory. Therefore, instead of
describing the inventory process, I will consider an
example of its applicability to the pulp and paper
industry.
s
c
o
p
I
N
G
GOAL
DEFWmON
. .INVENTORY
1 "ANALYSIS
IMPACT
ANALYSIS
I
MA
P N
R A
OL
V Y
E S
M I
E S
N
SETAC. 1992
Figure 4.—Interrelationships among the major LCA components.
14
-------
FJ. CONSOLI
Inputs
Energy
Raw
Materials
Raw Materials Acquisition
]
>
Manufacturing, Processing,
and Formulation
i
r
Distribution and Transportation
i
r
Use/Re-Use/Maintenance
'
•
Recycle
!
r
Waste Management
Outputs
Water Effluents
Airborne Emissions
Solid Wastes
Other Environmental
Releases
Usable Products
System Boundary
Figure 5.—A sample LCA inventory.
SETAC, 1990
Inputs
Raw Materials
Energy —
System
Outputs
Solid Waste
Emissions to Air
Releases to Water
Other Environmental Releases
Usable Products
System Boundary
Figure 6.—Inputs and outputs of interest in LCA assessments.
Suppose that I am interested in analyzing the
environmental effects of bathroom tissue, and that I
am looking at recycling. I might at first consider
closed-loop recycling. Figure 7 is a simple closed-
loop recycling system. In essence, what we have
are the production processes of bathroom tissue on
the bottom, and a recycling loop in square number
four, a closed-loop system. Unless some of you
know something that I don't know about bathroom
tissue, it hardly lends itself to a closed-loop recy-
cling process, so this simple diagram doesn't apply.
Indeed, recycling wastepaper into bathroom tissue
is an open-loop process.
When you look at open-loop recycling in the
context of a life cycle assessment, you need to look
at the true original processes. Assume, for ex-
ample, that the recycled fibers source for the bath-
SETAC, 1990
room tissue comes from office paper. In this con-
text, which is illustrated in Figure 8, systems one
through three are the individual processes related
to the production of office paper. The bottom sys-
tems, four through six, are the ones related to
bathroom tissue, and system seven links the two
procedures. To make a life cycle assessment of this
recycling process, I have to look at both of these
systems and do an entire analysis, looking at the
impacts of various factors, for example, the energy
savings in recycling.
Figure 9 is a hypothetical graph of energy
savings as a function of recycling. In this case, if
our purpose is to maximize recycling, and we are
not concerned with energy consumption, then
clearly we want to be over to the 100 percent recy-
cling line.
15
-------
Pollution Prevention and Life Cycle Analysis
F(1-f)m
B
m
Figure 7.—A simple recycling system.
m.
m.
fm 1 ..^ _
m2- fm1
m2- fm1 m.
m, (1-f)
fm
m
m.
m,
Baustead, 1992
Figure 8.—An open-loop recycling system.
On the other hand, the logic of any industrial
system is that the more "stuff," it picks up to
recycle, the more energy it will require to gather
and reprocess these materials appropriately. There-
fore, what we probably should do is seek to
balance energy and recycling. If this is our goal, we
may be better off dealing with Ti. But if we want to
maximize energy and recycling at minimum ener-
gy, we may even consider T2 as our goal.
European Eco-labeling
Another example that I want to discuss con-
cerns the European Eco-labeling program, because
it is based, in fact, on a life cycle concept. In es-
sence, the Europeans are considering the labeling
of products that meet certain hurdles and barriers.
Energy
Saving
0%
T2 Ti
Reclaimed Fraction
100%
Baustead, 1992
Figure 9. — Hypothetical graph of energy saving as a
function of reclaimed fraction.
16
-------
F.I. CONSOLI
To accomplish this task, they are looking at emis-
sions from four systems based on LCA perspectives.
They award load points on the basis of good to
worse within the category. Then they go through a
weight factor analysis of potential improvement
within the industry versus the level of concern and
assign points against that.
Finally, they add these figures together to
produce a rating. If your product is among the 25
percent best in the industry against these factors,
then you could be awarded an Eco-label. This is
not to say that you need an LCA to do Eco-labeling.
On the other hand, if you did perform life cycle as-
sessments on your processes, clearly it would help
you in terms of addressing Eco-labeling schemes.
I want to leave you with three interrelated ideas
regarding LCAs:
• You need to be very careful with how you
use life cycle assessments.
• They are extremely valuable as internal
guidance tools to companies.
• They can be very dangerous in the public
context unless they are appropriately framed
and unless you put forth all the assumptions
that go with them.
Their value is largely related to the possibility of in-
cluding different perspectives in each analysis and
in evaluating multiple issues simultaneously. Their
danger relates to the fact that the methodology is
still emerging.
I think LCAs — like the principles of total
quality management — are a very effective tool.
They are the tool of the future because they can
help us consider pollution prevention and other en-
vironmental issues in a different light. I am ab-
solutely convinced that if we work hard on this
technique and really focus on pollution prevention,
the pulp and paper industry has much to gain from
the effort.
References
I. Boustead. 1992. The Relevance of Reuse and Recycling Ac-
tivities for the LCA Profile of Products. Open Univ., East
Grinstead, United Kingdom.
J. Fava et al. eds. 1990. A Technical Framework for Life Cycle
Assessment. Workshop Rep. Setae Found. Environ. Educ.,
Pensacola, FL.
J. Fava et al. eds. 1992. Conceptual Framework for Life Cycle
Impact Analysis. Setae Found. Environ. Educ., Pensacola,
FL.
17
-------
The Pulp and Paper Industry's
Long-time Commitment to
Environmental Quality
Richard J. Diforio, Jr.
Vice President, Environment, Health, and Safety
Champion International Corporation
Stamford, Connecticut
Because the pulp and paper industry operates
in a worldwide marketplace, it has been
quick to recognize the importance of having
a proactive approach to environmental quality.
In 1943, the industry formed the National
Council for Stream Improvement and, in the 1960s,
expanded it focus and name to the National Coun-
cil for Air and Stream Improvement (NCASI). Today,
NCASI operates a cooperative research program to
identify and solve pollution problems and to
monitor the industry's progress. This national pro-
gram includes a high degree of technical coopera-
tion with existing regulatory agencies.
Four regional NCASI centers address all aspects
of the industry's activities in conjunction with two
aquatic biology research centers and two forestry
wildlife habitat research centers. These NCASI ac-
tivities drive many of the pollution prevention ef-
forts within the industry.
A good example is the aquatic ecological study
that has been under way for more than 15 years
and has provided valuable insights into the effects
of industry discharges on the aquatic environment.
The study results form the basis for judgments on
how best to optimize our successes. Other long-
term NCASI research led to the widespread use of
secondary-waste treatment in U.S. papermaking.
The recently approved environmental health
and safety (EHS) principles and forest management
principles are testimony to management's commit-
ment to pollution prevention. Adherence to EHS
principles is a condition of membership in the
American Paper Institute (API). This commitment il-
lustrates the industry's willingness to continue its
history of voluntary efforts to maintain environmen-
tal quality and preserve our natural resources.
The pulp and paper industry operates on a
natural resource base that is unique and renewable.
We devote our energies to protecting and enhanc-
ing that uniqueness.
Other indicators also show that the idea of pol-
lution prevention is alive and well. U.S. Environ-
mental Protection Agency Administrator William
Reilly's industrial toxics program has been
embraced by Champion International Corporation
(CIC) and others in the industry. While only a
limited number of the 17 chemicals in the program
have implications for our industry, we moved swift-
ly to line up behind the idea. The 33/50 goals will
be met as agreed.
The dioxin issue was also part of the industrial
toxics program. The industry's voluntary program
had the participation of all affected companies, and
the results bear repeating as a prime example of
voluntary pollution prevention action.
When trace amounts of dioxin were discovered
in emissions and determined to be an unwanted
by-product of the papermaking process, the in-
dustry, with the help of NCASI, mobilized its
resources. The result of the industry's voluntary ef-
fort is that today's 105 U.S. paper and pulp bleach-
ing mills annually produce less than 1 percent of all
dioxins in this country. Dioxin is no longer detec-
table in most kraft pulp mill effluents, even though
more capacity exists in mills today than in 1985;
and detection limits are also significantly lower and
more accurate than they used to be.
The industry's anti-dioxin efforts were source
reduction in the truest sense. A substance was
voluntarily reduced through efforts that included
process modifications, substitution of raw
materials, improvements in housekeeping, and
18
-------
R.J. DIFORIO, JR.
training. The industry is proud of this record and
agrees with Mr. Reilly that it exemplifies the efforts
that his agency seeks to encourage.
In addition to reducing the unwanted formation
of dioxin, CIC and other companies have increased
their capability to analyze for the presence of
minute amounts of compounds. CIC has invested
more than $1 million to build and equip an
ultratrace lab that can quickly and accurately track
its dioxin reduction program. Our in-house labs are
as sophisticated as commercial laboratories. This
capability is a major asset in our scientific research
and product development programs.
The kraft process has evolved as the principal
papermaking process primarily because of its in-
herent pollution prevention opportunities. The
process allows for the in-process recycling of waste
streams leading to the destruction and recovery of
chemicals for reuse. It provides for treatment of by-
products for recycling and it allows for treatment
prior to disposal. Over the years, the process has
lent itself to development, which has resulted in
greater efficiencies and reduced environmental im-
pacts. Energy generation optimization is one of the
most significant attributes of the process.
At CIC, as at other mills, more than 50 percent
of all energy needs are supplied by recycling
process streams, bark, hog fuel, and sludge. In
some locations, we act as a local recycler, using tire
chips as a substitute for coal. This recycling method
provides significant benefits to the surrounding
countryside — the life cycle of the ubiquitous dis-
carded tire ain't what it used to be.
Conservation, recycling, reuse, and reduction
principles are continuously applied by CIC person-
nel who plan and operate kraft pulping and bleach-
ing facilities. Recycling also takes place outside of
our processes. CIC has successfully developed a
waste product from a nonintegrated paper mill into
a raw material for use in the manufacture of ce-
ment.
At CIC's Hamilton, Ohio, plant, primary sludge
is put through a drying and deodorizing process
and shipped for use as a mineral source after it has
passed through a cement kiln. This process avoids
disposing of material in a landfill, conserves natural
resources that would otherwise be required for
manufacturing cement, and has a positive effect on
our long-term capital spending requirements.
Another example of CIC's recycling efforts is
the use of boiler ash in potting soils. We also
recycle bark for use in landscaping practices —
this, of course, is the bark we don't use as a fuel
source. We're conducting research in using filter
cake as an ingredient in nonfood packaging
materials and as an absorbent material with an em-
phasis on groundwood operations. These efforts to
reduce inevitable waste have a high profile among
our employees. They see the environmental
benefits. At Champion, we also have a team
marketing tall oil and turpentine, two other kraft
pulping by-products. This team is always on the
lookout for recycling opportunities to minimize the
waste burden.
Each of CIC's mills is part of a program to cut
waste. We call it Conserving Our Resources Every-
where (CORE). CORE gives everyone an added in-
centive to develop ideas to reduced waste and
improve our handling of waste materials.
CORE and other programs involving our
employees focus on what they can contribute to
environmental conservation. Command and con-
trol will only take us so far. The rest of our progress
will be attained by personal commitment to doing
the right thing. If you think about what you do
today and what you did yesterday, I'll bet you can
measure a contribution.
A discussion of pollution prevention in our in-
dustry is not complete without recognition of our
commitment to recycle 40 percent of production
tonnage. At CIC, we are considering an $85 million
facility to process 500 tons per day of newsprint
and magazines to be collected in Houston, Texas,
using relatively new technology and a brand new
collection and separation program that has been
developed from scratch. Our other mills are also in
the voluntary recycling business, using magazines,
newspapers, office waste, and even milk cartons.
We are part of the solution and we intend to keep it
that way, balancing our cost, quality, and
worldwide competitive position objectives along
with our environmental objectives.
Every new major capital project in the industry
includes plans to minimize detrimental environ-
mental effects. Other objectives include customer-
driven quality requirements, cost considerations,
and competitive conditions. Environmental condi-
tions drive projects from the standpoint of how
much we spend and when we spend it. The effect
of environmental conditions on the timing of capi-
tal spending is often overlooked — partly because
environmental considerations are not necessarily
dictated by regulatory requirements. We cannot,
therefore, always give a simple answer when asked
how much of what we spend is for pollution
prevention.
Looking at capital expenditure another way,
obsolescence is not only a physical consideration,
it is a subjective decision made sometimes from
concern for environmental impact.
CIC is presently constructing its fourth installa-
tion of oxygen delignification and expanded
19
-------
Pollution Prevention and Life Cycle Analysis
chlorine dioxide substitution equipment. Looking
back on our first dioxide installation in 1985, it was
purely for pollution prevention. In fact, it was a
classic instance of a trade-off between an in-
process change versus an end-of-pipe treatment.
We chose in-process, not because it was cheaper,
but because it minimized the environmental im-
pact. CIC's move to chlorine dioxide substitution in
excess of 50 percent has been driven by subjective
judgments and by the desire to minimize potential
environmental burden. We're in compliance with-
out it, but we're also at a point in our modern-
ization and expansion programs where it makes
sound business sense to do it.
The chlorine dioxide substitution meets the
criteria for cost, quality, competitiveness, and en-
vironmental integrity.
Research is focusing more today on process
control and the ability to minimize process varia-
tions that cause environmental upsets. So, in addi-
tion to installing new technology, we need to give
credit to the pollution prevention that comes from
the most stable modern processes. Control rooms
are testimony to the industry's commitment to con-
trol the potential sources of pollution. In respect to
process control technology, today's mill employees
are better trained than ever before. They under-
stand the environmental, health, and safety conse-
quences of what they do. They — and we —
understand more because of developments in
scientific research. The changes we have made
have been driven by good science. Further changes
must be made from the same solid scientific base if
we are to avoid the pitfalls associated with percep-
tion-driven decisions.
Pollution prevention is no longer just an en-
vironmental consideration. It is a competitive issue
— competitive not only from a manufacturing
standpoint, but also from our customers and
consumers' viewpoints. In addition, regulators and
legislators are involved. The involvement of
everyone is laudable; it also has risk. If there is no
common set of facts, the possibility exists for sub-
jective perceptions and manipulations. These,
however, must be avoided. I strongly urge, and I
think the industry strongly urges, that the
worldwide competitive marketplace be allowed to
function without interference.
20
-------
Corporate Versus Societal Perspectives
on Pollution Prevention Benefits and
Total Cost Assessment
Monica M. Becker
Research Associate
Allen L. White
Director, Risk Analysis Group
Tellus Institute
Boston, Massachusetts
Today, numerous forces are encouraging com-
panies to shift from pollution control to
prevention-oriented strategies. Prominent
among these are liability under the Federal Super-
fund Act, public concerns with environmental
degradation, increasingly stringent pollution dis-
closure requirements, and widely publicized in-
dustrial accidents in the United States and abroad.
Despite these and other pressures, most firms have
been slow to move away from traditional end-of-
pipe strategies toward more prevention-oriented
practices.
If, as many argue, pollution prevention pays,
what accounts for this slow pace of change? If
prevention investments are, in fact, in the self-inter-
est of the firm, what accounts for the continuing
reluctance to move aggressively toward a more
preventative mode? And why, in light of the
publicized benefits of pollution prevention, do
firms, even large sophisticated ones, continue to be
surprised when prevention-oriented projects pro-
duce attractive financial rewards to the firm?
Barriers to Pollution Prevention
Within the Firm
The explanation for this apparent contradiction
seems to be twofold. First, the organizational struc-
ture and behavior of firms inhibit pollution preven-
tion projects from entering the capital budgeting
process from the outset, thereby precluding al-
together these .alternatives from consideration by
the firm. Second, once prevention investments are
included in the capital budgeting process, they may
still fail to compete successfully with other projects
for limited capital dollars owing to inadequacies in
standard profitability analysis techniques. Both fac-
tors contribute to a sluggish pace of investment in
industrial pollution prevention. The focus of this
presentation is the second factor, barriers within the
capital budgeting process.
Capital budgeting is the development of a plan
for capital spending over a defined period of time.
The capital budgeting process includes the follow-
ing activities: a search for profitable investment
proposals, investigating engineering and marketing
aspects of proposals to predict the outcome of the
investment, and economic analyses to determine
the profitability of the proposals. The size of a capi-
tal budget is generally based on estimates of future
sales, costs, production, research and development
(R&D) needs, and the availability of capital.
What are the special features of prevention
projects that defy conventional profitability
analysis procedures? When "environmental costs
and savings" (e.g., waste management, regulatory
compliance, future liability costs) are introduced
into project analysis, certain limitations in tradition-
al methods immediately surface. The source of
these limitations lies in the uncertainties of environ-
mental costs themselves, namely: What are they?
How large are they? When will they occur?
For all of these questions, the degree of uncer-
tainty can be high owing to two conditions: the
21
-------
Pollution Prevention and Life Cycle Analysis
complexity of assessing risks associated with the
use, transport, and exposure to hazardous substan-
ces; and rapidly changing regulations and shifts in
judicial decisions that define and continually alter
costs. Traditional project profitability analysis is not
well equipped to handle the high degree of uncer-
tainty and flux these two conditions create.
Total Cost Assessment
Total Cost Assessment (TCA) is an alternative ap-
proach to profitability analysis of prevention invest-
ments. TCA differs from conventional project
analysis in several key ways. It uses expanded cost
and savings inventories, a longtime horizon, long-
term profitability indicators, and it properly allo-
cates environmental costs to processes or product
lines within the company's cost accounting system.
Expanded Cost and Savings Inventory
Conventional cost analysis practices generally in-
clude only the capital costs directly associated with
the investment, and any obvious operations costs
and savings such as waste disposal and labor. TCA
considers a broader range of costs and savings.
Typically, it includes direct costs such as capital
expenditures — buildings equipment, utility con-
nections, and equipment installation project en-
gineering; and operation and maintenance
expenses/revenues — raw materials, labor, waste
disposal, utilities (energy, water, sewerage), and
value of recovered material. Indirect or hidden
costs, which include compliance costs — permit-
ting, reporting, monitoring, and manifesting in-
surance; on-site waste management; and operation
of on-site pollution control equipment. These costs
are indirect or hidden in the sense that they are
either allocated to overhead (rather than their
source in the production process or product), or
they are omitted altogether from the project's finan-
cial analysis. Liability costs, including penalties
and fines, personal injury and property damage,
and natural resource damages, must be considered.
Liability costs stem from penalties and fines for
noncompliance, and legal claims, awards, settle-
ments for remedial action, personal injury and
property damage due to routine or accidental haz-
ardous releases under the Comprehensive Emer-
gency Response Compensation and Liability Act of
1980 (also called Superfund). This program holds
companies financially responsible for environmen-
tal damage caused by previous waste disposal and
management practices.
• The Effects of Pollution Prevention on Liability
Costs. A pollution prevention project by definition
reduces or eliminates potential liability costs by
reducing or eliminating the source of the hazard
from the production process. One method
described in the next section provides a procedure
for estimating these potential costs, the year in
which they will occur, and a method of incorporat-
ing them into financial calculations. In this way,
liability is treated in the same way as conventional
capital and operating costs. However, liability costs
are by nature difficult to estimate and to locate in
the life cycle of a project. By including estimates of
future liability directly into a financial evaluation,
the analyst introduces considerable uncertainty
that top management may be unaccustomed, or
unwilling, to accept as part of a project justifica-
tion.
Firms currently use several approaches to con-
sidering liability costs in project analysis. For ex-
ample, in the narrative accompanying a profit-
ability calculation, a firm may include a calculated
estimate of liability reduction, cite a penalty or set-
tlement that may be avoided (based on a claim
against a similar company using a similar process),
or qualitatively indicate without attaching dollar
value the reduced liability risk associated with the
pollution prevention project. Some firms have
chosen to loosen the financial performance re-
quirements (e.g., raising the required payback
period from three to four years, or lowering the re-
quired internal rate of return from 15 to 10 percent)
of the project to account for liability reduction (U.S.
Environ. Prot. Agency, 1988).
For publicly traded companies, liability estima-
tion is controversial because the Securities and Ex-
change Commission requires firms to report
liabilities to stockholders and accrue assets to cover
these future costs. Also, a liability estimate may be
damaging to a firm if it is made public in a legal
proceeding. For all these reasons, if a firm con-
siders liability costs in any form in project analysis,
it normally exercises substantial caution in assign-
ing a quantitative estimate of liability to a specific
investment. Less tangible benefits of TCA are in-
creased revenue from enhanced product quality
and company image, reduced health maintenance
costs from improved employee health, and in-
creased productivity from improved employee rela-
tions.
These benefits, like liability, are difficult to
predict and estimate. A TCA analyst may find a
qualitative analysis more appropriate and saleable
to management.
Expanded Time Horizon
A second feature of a TCA evaluation is its longer
time horizon, usually 10 or more years, to capture
certain costs and savings from pollution prevention
22
-------
M.M. BECKER &A.L WHITE
that take many years to materialize. Conventional
project cost analysis, on the other hand, often con-
fines costs and savings to a five- to ten-year period
— a time horizon unlikely to capture the very cost
and benefits that TCA is designed to track. The will-
ingness of firms to extend the time horizon varies
with their size, structure, capital, and competition
from other investments.
Long-term Financial Indicators
To consistently provide corporate decisionmakers
with accurate and comparable project financial as-
sessments for capital budgeting, the financial in-
dicators must meet at least two criteria: they must
consider all cash flows (positive and negative) over
the life of the project; and they must consider the
time value of money. The Net Present Value (NPV),
Internal Rate of Return (IRR), and Profitability In-
dicator (PI) methods meet both these criteria. The
NPV method is preferred when projects are com-
peting against each other for limited resources be-
cause there are certain conditions under which the
IRR or PI methods fail to identify the most ad-
vantageous project. The payback method, com-
monly used by small companies, meets neither
criteria.
The Cost Accounting System
A firm's cost accounting system is used to track and
allocate production costs to a product or process
line, principally for operational budgeting and pric-
ing. When costs for waste management, regulatory
compliance, and pollution control are properly al-
located to processes or product lines, the cost ac-
counting system provides a rich source of data for
TCA. For purposes of investment analysis, the op-
timal cost accounting system should allocate all
costs to the process responsible for their creation.
Waste disposal costs, for example, often appear in
overhead accounts, while a process or product al-
location would assign such costs to an activity or
component of the manufacturing process.
Costs should be allocated to reflect how costs
are actually incurred. For example, waste disposal
costs in some companies are allocated across
operating centers — administrative, research and
development, and manufacturing — on the basis of
floor space rather than on the quantity and type of
waste generated by each. This impedes a rigorous
estimation of the financial benefits of reduced
waste generation. Thus, effective cost accounting is
critical to directing management attention to the
sources of waste generation and the benefits of
changing current waste management practices.
Case Studies of Total Cost
Assessment in the Pulp and
Paper Industry
A major source of industrial pollution, the pulp and
paper sector provides a context for examining the
usefulness of TCA. Historically, environmental
regulation of the industry has focused on reduction
of biological oxygen demand (BOD) and total
suspended solids (TSS) in water effluent, and par-
ticulates, sulfur dioxide, and organic sulfur com-
pounds in air. Reductions of these pollutants have
been achieved principally through end-of-pipe
controls.
Nonetheless, pollution prevention is by no
means a new concept to pulp and paper firms. In-
plant recovery and reuse of pulping chemicals are
integral parts of the kraft pulping process. Other
preventative measures include in-plant fiber and
water recovery and reuse in the paper mill,
countercurrent washing in the pulp mill, and dry
wood debarking. These technologies have been
widely implemented to reduce pollution genera-
tion and to reduce raw material and energy costs.
Current environmental regulation of toxic air and
water pollutants, toxic constituents in mill sludge,
and pulp mill effluent standards for foam, odor, and
color are posing new challenges to pulp and paper
firms. Meeting many of these regulations will re-
quire materials and process changes rather than
traditional end-of-pipe controls.
In a compliance context, a mill's choice be-
tween an end-of-pipe or a prevention strategy will
depend heavily on the comparative economics of
these options. This is true even when the firm ex-
pects a net loss on its investment. Unlike most end-
of-pipe technologies, pollution prevention projects
tend to reduce operating costs by reducing waste
generation and avoiding compliance requirements
and pollution-related liabilities. In addition, invest-
ments in pollution prevention may increase
revenue by improving product or corporate image.
Including these indirect and less tangible savings in
the financial analysis of projects may enhance the
estimated profitability (or reduce the estimated
cost) of the prevention strategy and may be decisive
in selecting a prevention versus an end-of-pipe op-
tion. It is at this decision point that TCA can play a
role in improving the financial picture of a pollu-
tion prevention investment and enhance its com-
petitiveness with pollution control projects. TCA
techniques also can improve the projected finan-
cial performance of discretionary pollution preven-
tion projects, thereby increasing their ability to
compete for limited capital resources.
23
-------
Pollution Prevention and Life Cycle Analysis
To assess how TCA works in practice, we
worked in close collaboration with the staff of two
mills to analyze the profitability of two pollution
prevention projects (U.S. Environ. Prot. Agency,
1991). The first is a conversion from solvent/heavy
metal paper coating to aqueous/heavy metal-free
coating at a paper coating mill. This investment
would substantially reduce solvent and heavy
metal usage, volatile organic compounds (VOC)
emissions, and hazardous waste generation. The
second is a white water and fiber recovery and
reuse project at a coated fine paper mill. This in-
vestment would permit fiber, filler, and water reuse
on two paper machines at all times, thereby con-
serving raw materials and reducing water use,
wastewater generation, and energy use for fresh
Table 1.—Overview of Total Cost Assessment case
studies.
COATING CONVERSION PROJECT
Paper Coating Mill
Current Conditions:
• Pigmented base coatings contain:
• Solvents
• Heavy metals — lead, chromium, cadmium
Problems:
• Volatile organic compounds (VOC) emissions
• Hazardous wastes generated containing solvent and
heavy metals
• Heavy metals in product
Proposed Project:
• Convert to aqueous, heavy metal-free base coating
Benefits:
1. Reduce/eliminate solvent and heavy metal use
2. Reduce VOC emissions
3. Reduce hazardouse waste generation
WATER AND FIBER RECOVERY PROJECT
Coated Fine Paper Mill, 200 TONS PER DAY
Current Conditions:
• Two paper machines share one white water system
• One machine has a dedicated saveall
• Machines produce a variety of grades (acid, neutral,
alkaline)
Problems:
• White water from two machines often incompatible;
therefore, Whitewater must be sewered — loss of
fiber, filler, water
Proposed Solution:
1. Separate white water systems, and
2. Install dedicated saveall for second machine
Benefits:
1. Recovery and reuse of fiber and filler
2. Recovery and reuse of water:
• Reduced freshwater pumping and heating
• Reduced wastewater pumping and treatment
and wastewater pumping and freshwater heating.
Table 1 provides an overview of these projects.
For both projects, we compared the company's
financial analysis to TCA analyses of the same
project, in which a full accounting was made for
less tangible, longer term, and indirect costs and
savings. In the case of the coating conversion
project, the paper coating firm omitted all nondis-
posal waste management costs, utilities (energy,
water, and sewerage), solvent recovery, and
regulatory compliance costs from its analyses of the
aqueous conversion project. The firm also omitted
several costs associated with the storage needs and
shorter shelf life of aqueous coatings, namely a
steam heating system for the coating storage shed,
lost raw material value, and the cost to dispose of
spoiled coating (see Table 2).
According to our collaborator at the second
mill, a financial analysis of the white water/fiber
recovery project would not include energy savings
associated with reduced fresh and wastewater
pumping and treatment and freshwater heating.
These energy savings, which are included in the
TCA, represent a substantial benefit of the project.
Their omission in a conventional financial analysis
would have dramatically underestimated the
profitability of the investment.
In these case studies we focused on two
general forms of future liability costs: liability from
personal injury or property damage (e.g., Super-
fund liability stemming from a leaking landfill) and
penalties and fines for violation of environmental
regulations. The paper coating mill did not include
an estimate of avoided future liability costs from
reduced hazardous waste disposal in its financial
analyses. It did, however, allude to this benefit in a
qualitative way in an appropriations request: ". . .
major reductions in levels of fugitive emissions,
and amounts of solid hazardous waste going to
landfill, are very positive from a regulatory and
community standpoint." The TCA developed for
this project includes an estimate of avoided future
liability made using a methodology contained in
General Electric's Financial Analysis of Waste
Management Alternatives (1987). The mill sends its
coating waste to an incinerator, so this risk-based
methodology produces a relatively low estimate of
$35,000 in total avoided liability for the project.
Since Project 1 does not involve hazardous
materials or waste, neither the company analysis
nor the TCA contains a future liability estimate.
Neither the company analyses nor TCAs con-
tain estimates of less tangible benefits. In the case of
the coating conversion project, the coated paper
product is sold domestically on the basis of cost,
visual appearance, and performance durability to
book publishers and other intermediate product
24
-------
M.M. BECKER & A.L. WHITE
Table 2.—Overview of cost Inclusion by company and Total Cost Assessment
COATING CONVERSION
COMPANY
TCA
WATER/FIBER RECOVERY
COMPANY
TCA
CAPITAL COSTS
Purchased equipment
Materials (e.g., pipe, electricity)
Utility systems
Site preparation
Installation
Engineering/contractor
Start-up/training
Contingency
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
OPERATING COSTS
Direct Costs?
Raw materials/supplies
Waste disposal
Labor
P
P
X
X
X
X
X
X
X
X
Indirect Costs*
Waste Management
Hauling X
Storage
Handling
Waste-end fees/taxes
Utilities
Energy
Water
Sewerage (publicly owned treatment
works)
Pollution control/solvent recovery
Regulatory compliance
Future liability
X
X
X
X
X P
X
X X
X
X
X
X
X
X = cost(s) included; P = cost(s) partially included.
* The term "direct costs" means costs that are typically allocated to a product or process (i.e., not charged to an overhead account) and that
are typically included in financial statements. In this table, "indirect costs" mean costs that are typically charged to an overhead account and
typically not included in the project financial analysis.
manufacturers. Although the company expects
some quality improvements using aqueous coating,
it does not anticipate an increase in market value.
Therefore, it expects no increase in domestic sales
as a result of the conversion to the aqueous/heavy
metal-free coating. The company hopes to improve
its competitive advantage in the European market if
the European Community implements lead-free
packaging standards as expected; however, it
would not speculate on the potential revenue ef-
fects associated with increased European market
share, though clearly they could be very substan-
tial.
The coated/fine paper mill does not expect an
increase in market share or product value from its
white water/fiber reuse project. Both mills are
manufacturers of intermediate, rather than con-
sumer, products and cannot, directly market their
products on the basis of environmental perfor-
mance in the way that a consumer products com-
pany can and does.
The comparative analyses for each project
yield substantially different results (see Tables 3 and
4>. Impressive results are produced for the aqueous
conversion investment. The net present value for
this $0.6 million capital expenditure shifts from
$0.1 million to $0.2 million in the company versus
TCA analyses, respectively; the internal rate of
return shifts from 16 percent to 27 percent; and
simple payback drops from 5.3 to 3.0 years.
Similarly, for the fiber/water recovery investment,
the net present value for this $1.7 million capital
expenditure increases from minus $0.6 million in
the company analysis to $1.8 million using a TCA
approach; the internal rate of return increases from
6 percent to 36 percent; and the simple payback of
11.4 years decreases to 2.0 years.
Analysis of a limited sample of two projects
does not suggest that more comprehensive treat-
ment of project costs and savings necessarily yields
higher projected profitability for prevention invest-
ments. Much depends on the project's original
capital cost, the completeness of the company
analysis, and indirect and less tangible benefits'
magnitude and timing. TCA is equally likely to turn
up additional costs as additional savings, potential-
ly diminishing the appeal of prevention invest-
ments. Moreover, the effort expended in preparing
25
-------
Pollution Prevention and Life Cycle Analysis
Table 3.—Summary of financial data for coating con-
version project.
Total capital costs
Annual savings (BIT)*
COMPANY
ANALYSIS
$623,809
$118,112
TOTAL COST
ASSESSMENT
$653,809
$216,874
Financial Indicators:
Net present value (years
1-15) $13,932 $428,040
Internal rate of return
(years 1-15) 16% 27%
Simple payback (years) 5.3 3.0
* Annual operating cash flow before interest and taxes.
Table 4.—Summary of financial data for white water
and fiber recovery project.
COMPANY
ANALYSIS
TOTAL COST
ASSESSMENT
Total capital costs
Annual savings (BIT)*
Financial Indicators:
Net present value (years
1-15)
Internal rate of return
(years 1-15)
Simple payback (years)
$1,329,000 $1,329,820
$ 116,245
($587,346)
6%
11.4
$ 658,415
$1,808,384
36%
2.0
* Annual operating cash flow before interest and taxes.
the TCA analysis, though partially attributable to
startup costs of any new management practice, is
substantial enough to make even large firms wary
of adopting such an approach for all projects com-
peting for capital resources.
Within the limitations of our study, however, it
is clear that TCA can serve as a valuable tool for
translating discretionary judgments into concrete
dollar values during the capital budgeting process.
Insofar as pollution prevention projects produce
less tangible and indirect costs and benefits, TCA
equips managers to develop a more precise estima-
tion of the real financial returns. Though TCA does
not ensure an attractive profitability level for pre-
vention projects, the cost characteristics of such
projects suggest that their financial performance in
general will be enhanced by TCA. This is especially
true for industrial prevention projects that are
materials and process-focused, that is, well up-
stream in the production process. Over the longer
term, TCA can serve as a substantial force in recast-
ing the "must-do" and "inherent loser" image of en-
vironmental projects into a more positive, profit-
adding, and market-expanding image.
As a final note, what is financially optimal for
the firm, of course, is not necessarily optimal from a
social cost standpoint. In this sense, TCA is no sub-
stitute for life cycle analysis (LCA), in which the
choice of a material input or the manufacture of a
product is assessed for its full societal costs,
whether such costs fall within or outside the pur-
view of the firm.
References
General Electric Company. 1987. Financial Analysis of Waste
Management Alternatives. Corporate Environ. Prog., NY.
Tellus Institute. 1991. Total Cost Assessment: Accelerating In-
dustrial Pollution Prevention Through Innovative Project
Financial Analysis, With Applications to the Pulp and
Paper Industry. Off. Pollu. Prev. Toxics. U.S. Environ. Prot.
Agency, Washington, DC.
U.S. Environmental Protection Agency. 1988. Page 22 in Waste
Minimization Opportunity Assessment Manual. EPA/625/
788/003. Haz. Waste Eng. Res. Lab., Cincinnati, OH.
26
-------
Meeting the Challenge of
"No Effect" Pulping and Bleaching
Dick Erickson
Vice President
Environment and Technology
Weyerhaeuser Company
Tacoma, Washington
FDunded in 1900, Weyerhaeuser is one of the
aldest and largest forest products companies
in North America. The company has four
main sectors — Pulp and Paper, Solid Wood, Tim-
berlands, and Real Estate. I am part of the Pulp and
Paper sector, which has several operating divisions
— Market Pulp and Recycled Fibers, Fine Paper,
Newsprint and Bleached Board, and Container-
board Packaging.
The Weyerhaeuser Company is the world's
largest producer of softwood lumber and one of
North America's largest exporters in the pulp and
paper industry. Overall the Weyerhaeuser Com-
pany has
• 5.6 million acres of timberlands,
• 12 primary pulp and paper facilities in the
United States and Canada, and
• 8 facilities that produce bleached pulp and
paper products.
Weyerhaeuser's production capacity has reached 6
million tons per year of pulp and paper, and we
manage 1.8 million tons per year of recycled fiber.
Weyerhaeuser also has a long history of en-
vironmental accomplishments. In 1941, we dedi-
cated America's first tree farm, and in 1967, we
appointed our first Director of Environmental Af-
fairs. In the last three decades, the company has
marked the following milestones:
• 1971 — adopted formal, companywide
environmental policy
• 1974 — began recycling program
• 1979 — completed installation of
secondary waste treatment systems at all
primary facilities
• 1986 — planted our 2 billionth seedling on
company land
• 1987 — launched companywide ongoing
environmental auditing program
• 1991 — participation in EPA pollution
prevention effort (33/50 program)
• 1992 — joined the Global Environmental
Management Initiative (GEMI)
The goal of "no effect" pulping and bleaching
involves more than media-specific pollution pre-
vention. We must ensure that the total pulping and
bleaching process prevents pollution, and we must
balance our emissions to air, water, and land to
minimize their overall environmental impact. We
must practice waste minimization and make con-
tinuous improvements in health and safety
methods.
The pulping and bleaching processes are part
of an interconnected system. Changes in one
process often affect the performance of other
processes. Enormous resource commitments of
time and capital are essential for most changes.
The "No Effect" Vision
Our goal is to eliminate environmental impacts
while maintaining or improving quality, produc-
tivity, and economic competitiveness.
The evolution toward "no effect" pulping and
bleaching systems is constrained by customer
quality demands, regulatory expectations, tech-
nological evolution, high capital costs, and in-
dustry competitiveness. We will review each of
these constraints in more detail.
27
-------
Pollution Prevention and Life Cycle Analysis
Customers always want the best quality
products at the lowest possible price and with the
best possible service. They want value. The cus-
tomer, not the producer, defines quality and we
must never forget that demand drives supply.
A pulp and paper mill must deal with customer
expectations and regulatory expectations. A multi-
tude of increasing regulatory expectations affects
every facility today.
Figure 1 looks at the range of issues that need to
be addressed as we move toward "no effect" mill
operations. Unless regulatory programs are proper-
ly focused and entaligned, they will actually divert
our resources from achieving the final vision.
Overview of Prevention Technologies
Pollution prevention is not new to kraft pulping or
our industry. Advances in technology began in the
1940s and led to cleaner and tighter operations.
Two advances in the 1940s were the introduction
of chlorine dioxide substitution in multistage
bleaching and continuous digesters; the 1970s
gave us low-odor boilers, Rapson-Reeve bleach
plant effluent recycling, oxygen delignification
(bleaching), extraction-stage oxygen, and displace-
ment bleaching. High-efficiency washers and ex-
tended delignification were implemented in the
1980s; and finally, in the 1990s, ozone bleaching is
being pursued.
Weyerhaeuser has been a leader in developing
many pollution prevention technologies. Table 1
lists a selection of Weyerhaeuser patents or proce-
dures in chronological order. Note that most of
these technologies were brought to full-scale im-
plementation.
Significant advances in pulping and washing
technologies have allowed for more efficient lignin
removal in the digester system, resulting in a greatly
reduced need for bleaching and bleaching chemi-
cals. In addition, there have been significant chang-
es in bleaching technologies through time. The
evolution of state-of-the-art bleaching processes
has had a dramatic impact on the amount of adsor-
bable organic halogens (AOX) found in bleach
plant effluents (see Fig. 2).
AOX is a gross measure of chlorinated organics
and one measure of general loading to the environ-
ment. To date, we have found no correlation be-
tween AOX and toxicity. We need to be cautious
about drawing broader conclusions than the meas-
urement technique warrants.
Bleaching is a multiple-step operation, not
simply the use of chlorine or oxygen. Multiple
stages are used to improve pulp quality as well as
reduce the total chemical usage.
Ingemar Croon of Croon Consult in Stockholm,
Sweden, has developed a model of worldwide
bleaching chemical use (see Fig. 3) based on the
evolution of technologies in the pulp and paper in-
dustry. Weyerhaeuser's bleaching chemical use
reflects similar trends, and is also customer- and
technology-driven (see Fig. 4).
Target
Pulp Mill
2010
>r
Nutrients .Xwater Use
Aesthetics (foarrO^Xco mm unity Concerns
Color
Groundwater ^^ "Pollution Prevention" Expanded
_ Odor Control
Stormwater Permits
Target Pulp Mill Vision
No color
No odor
No toxicity
Minimum effluents
Excellent aesthetics
New Effluent Guidelines
Stream Mixing Zones ^X**Air Permits
Pollution Prevention ^X^Sedlment Criteria
Recycling Legislation
Chronic
Toxicity
AOX
Clean Water Act Reauthorization
Air Toxics
CRA Reauthorization
1992
Figure 1.—Regulatory expectations.
2010
28
-------
D. ERICKSON
Table 1.—Weyerhaeuser patents or procedures.
YEAR
1946
1954
1962
1968
1970
1972
1973
1974
1981
1991
TECHNOLOGY
Developed magnesium-based sulfite process
Developed vaposphere to reduce odor
Black liquor oxidation to reduce TRS
Acetic acid recovery from sulfite condensate
Red liquor stripping to remove SOz
Caustic scrubbing of chlorination washer vent gas
Kraft condensate stripping
Soda-oxygen pulping
Vapor phase bleaching
Rapson-Reeve beach plant effluent recovery
Dry scrubber for hog fuel boilers
Displacement bleaching
Large-scale ozone bleaching pilot plant
Artificial marsh
PATENTED
X
X
X
X
X
X
X
TRIAL/PILOT FULLY
PROGRAM IMPLEMENTED
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Technologies take time to develop and imple-
ment. As an example, oxygen bleaching lab experi-
ments were done in the early 1950s and the first
pilot plant was in 1967 — long before the current
cry for chlorine-free processes and products. The
evolution of oxygen bleaching technology clearly
illustrates that extended periods of time are needed
to develop, prove, and implement technologies on
a large scale. In 1973, Weyerhaeuser was one of
the first to install an oxygen system. It was not until
the advent of medium consistency oxygen bleach-
ing, 10 years after the first commercial installations,
that the technology gained universal acceptance
(see Fig. 5). Weyerhaeuser has three oxygen
bleaching systems in place at this time and three
more will be coming on line in the near future.
Weyerhaeuser is planning major modern-
izations at several of its pulp and paper facilities. As
a result of these modernizations and because of
customer requirements, the availability of proven
technologies, and their alignment with the goal of
closed-loop systems, Weyerhaeuser expects to
reduce the use of elemental chlorine for bleaching
by over 95 percent by 1996 (see Fig. 6). Although
high environmental standards are already being
met by well-run bleached kraft mills with secon-
dary treatment, modernized operations will make
our overall environmental performance even bet-
ter.
In addition, Weyerhaeuser is committed to the
development of new and better technologies that
can continue to move us toward the optimal goal of
AOX (kg/ton of pulp, in effluent)
8
CEDED
State-of-the-art kraft mill
OC/DE0DED
OD/CE0D£pD
pre-ODEopDED
Pre-OZOD?
C Chlorine
E Caustic Extraction
D Chlorine Dioxide
O Oxygen
P Peroxide
Z Ozone
pre- Extended
Delignification
1965 1975 1985 1990
Note: AOX does not correlate with toxicity
Figure 2.—Reducing bleaching effluent.
1995
29
-------
Pollution Prevention and Life Cycle Analysis
Relative
Amounts
of Bleaching
Chemicals
Chlorine
\ Chlorine Dioxide
\
\
^.^P—Oxygen
s ^^ Peroxide
^^ Hypochlorite
1 3.1TI Ozone
1930 40 50
Source: Croon Consult, Stockholm,Sweden 1991
Figure 3.—Bleaching chemical use — a worldwide perspective.
70 80 90 2000 10
Relative
Amounts
of Bleaching
Chemicals
Chlorine
Chlorine Dioxide
Oxygen
Peroxide
1935 40 45 50 55 60 65 70 75 80 85 90 95
Figure 4.—Weyerhaeuser bleaching chemical usage.
Hypochlorite
a "no effect" mill. Weyerhaeuser has already
reduced dioxin formation by more than 97 percent
since 1987-88, when trace quantities were first
detected in pulp mill effluents. Dioxin is currently
nondetectable in all of our bleached pulp mill ef-
fluents. Our concern now is contamination from
external sources rather than generation of dioxin
within our processes.
As we move toward "no effect" mills, all ef-
fluents will be reduced dramatically. Weyer-
haeuser's data illustrate the accomplishments
achieved to date and also suggest trends for the fu-
ture (see Fig. 7). It should be noted that most of our
early efforts were directed to reducing convention-
al pollutants. One key assumption is that elemental
chlorine must be removed from the bleaching
process so that we can close up the process streams
and recycle them to the recovery boiler. This
process will allow us to eliminate the small quan-
tities of organic material currently going to treat-
ment facilities and to recover additional pulping
chemicals. Elemental chlorine in the process forms
chloride ions, which cause corrosion and de-
creased boiler efficiency when recycled.
High Capital Costs
A major constraint to upgrading facilities is the stag-
gering cost of pulp and papermaking equipment.
The paper industry is the most capital-intensive in-
dustry in North America, more than metals, chemi-
cals, or petroleum. As a percent of sales, the paper
industry spends twice the average of all U.S. in-
dustry on new plants and equipment. A process
change that on the surface sounds simple, such as
incorporating oxygen bleaching, can cost in the
30
-------
D. ERICKSON
ADt/d (Thousands)
100
80
60
40
20
0
Medium Consistency
High Consistency
First Lab Experiments
I First Pilot Plant
nnnn
1952 1967 72 74 76 78 80
Figure 5.—Worldwide oxygen delignification.
82 84
86 88 90 92
Source: Jaakko Poyry, 1991
Elemental Chlorine Used for Bleaching
100
90
Change QQ
Since 79
1988 6Q
50
40
30
20
10
0
49%
Current
, Reduction
98%
Planned
Reduction
1988 89 90 91 92 93 94 95
96
Figure 6.—Chlorine bleaching at Weyerhaeuser.
range of $30 million and take up to three years
from concept, approval, and design to installation
and start-up. In addition, costly or negative side ef-
fects, such as additional loading to the recovery
boiler, must be taken into account. Customer reac-
tion to changes in pulp and paper quality is another
important consideration.
Limited capital must be allocated between
competing priorities. Is it better to expand recycling
capacity or modify bleaching processes? In the
pulp and paper industry, it appears, companies
must do both. This competition for capital forces
many companies to set priorities among conflicting
stakeholder needs. Weyerhaeuser is more than
doubling its recycled fiber usage every five years.
We strongly support the industry recovery goal of
40 percent by 1995. In fact, with three active
projects coming on line in the near future, and
other projects being considered, Weyerhaeuser will
play a strong role in helping the industry achieve its
overall objective (see Fig. 8).
Conclusion
Since no two plants are the same, mandatory in-
flexible standards can siphon scarce capital away
from achieving environmental goals. Piecemeal
and conflicting regulations can sidetrack or delay
31
-------
Pollution Prevention and Life Cycle Analysis
Relative
Effluent
•M • • • V* vr I 1 %
Levels/
Ton of
Product
100
75
50
IHH
-
•"""
TSS + BOO are actual amounts
AOX + water are estimated amounts
based on modern facilities
Water
25
1940 50 60
Figure 7.—Weyerhaeuser effluent reduction.
Tons/Year (Millions)
3
70 80 90 2000 10
0
iZ_3 Projects currently under study
O Approved projects
2.2
2.35
1.9
1.5
1.25
0.52
0.68
0.86
1.0
0.03
•SSSSy
Equivalent to
8 Kraft Mills
Each Producing
800 Tons/Day
1974 1989 91 92 93
Figure 8.—Weyerhaeuser recycled fiber usage.
94 95 96 97 98
investments in line with the "no effect" vision.
Government can do the following to facilitate pol-
lution prevention and the "no effect" vision:
• Keep regulations simple — complexity in-
creases errors.
• Coordinate regulatory initiatives to assure
wise capital investment in the long run.
• Maintain regulatory flexibility — the industry
needs the ability to use a variety of process
and treatment options to meet environmental
requirements.
• Be aware of the global market — competi-
tion is worldwide.
• Support sound science and economics to en-
sure rational investments addressing real
priorities.
Pulping and bleaching are a part of a cycle in
the manufacturing of forest products. Our goaJ is to
advance the whole cycle, focusing research, tech-
nology, and capital at the right time and in the right
places to derive the optimum environmental
benefit overall. "No effect" is the ultimate goal of
the forest products industry. It should include sus-
tainable forestry providing fiber and energy from
pulpwood trees, sawdust, and forest residuals;
energy self-sufficiency in pulp and paper produc-
tion; closed cycle mills; the recycling of usable
recovered fiber; the clean conversion of unusable
recovered fiber to other uses, energy, or compost;
and the return of ash and compost to the land.
Weyerhaeuser's goal is nothing less.
32
-------
Panel 1:
Pollution
Lifecycle Analysis
and
Question and Answer Session
• Gayle Coyer, National Wildlife Federation: I
think that some of the points that Monica Becker il-
lustrates are very important and I would like to get
reactions from Dick Diforio and Dick Erickson.
How much do your companies consider pollution
prevention versus pollution control? When you
present us with statistics and figures on capital in-
vestment in pollution abatement, can you break
those statistics down into how much goes into not
creating or generating pollution in the first place
versus pollution control once it has been created?
• Dick Erickson, Weyerhaeuser Company: At this
point, very little of our capital investment goes for
end-of-pipe treatment. Nearly all capital is for pol-
lution prevention. The problem is that when you
are looking at capital investments on three major
modernizations from 1940s technology, you're ex-
pecting quality, cost, and productivity benefits as
well as pollution prevention, so we can't just look
at one item. The toughest thing for us is looking at
the liability side; five years ago, the liabilities
people are facing now were unimaginable. What
are the liabilities that we will face five /ears from
now? So liability costs are the toughest ones to
predict. But certainly we use pollution prevention
calculations to estimate future operating costs and
most of the money is for pollution prevention
projects rather than pollution control.
• Richard Diforio, Champion International Cor-
poration: I would concur with Dick Erickson. In our
case, we are involved in one major modernization,
one major expansion, and we are about to embark
on some other internal process changes. All of
these have been driven by in-process considera-
tions, not end-of-pipe considerations. If there is an
end-of-pipe consideration in any of our invest-
ments, it could only be that we haven't found any
reasonable way to take care of the problem within
the process as we now perceive it. I suppose we
could break it out in dollars and cents, or have that
done internally. But I assure you that every engineer
has as his or her principal objective to clean up the
process as opposed to controlling pollution at the
end. And I don't say that boastfully as far as Cham-
pion is concerned; I think this attitude is typical of
the industry.
• Ray Chalk, World Bank: I deal entirely in the
developing world. I have just come back from
China, where we made a major pollution improve-
ment by installing a recovery boiler. I am very im-
pressed with what Mr. Erickson had to say about
the year 2010, and I would like to ask him and
others how can we move faster in the developing
world? What is it that moves your company? Is it
regulation, cost savings, or the opportunity to be a
good corporate citizen?
• Dick Erickson: All of the above.
• Ray Chalk: Is there a priority among them?
• Dick Erickson: No, as I mentioned before we are
making three major modernizations — at a huge
sum for us. We are really looking at quality. First in
mind comes the customer. If we don't have a cus-
tomer, we don't exist. We have to ensure that the
customer is taken care of. The quality of the
product is second. It comes from an internal
process control or process management. Cost
33
-------
Pollution Prevention and Life Cycle Analysis
savings are the third major incentive; basically our
modernizations are replacing 1940s technologies.
So energy, chemicals, and our people resources
must be used properly.
We have five pulp mills in one facility — we're
going to one. So, of course, we want the in-process
changes to reduce the environmental impacts — in
air, water, and solid wastes. The key is technology
management, and the technology that was
developed in the 1950s and 1960s is now commer-
cially available to us at the same end-cost. To mod-
ernize just casually is very difficult. If a mill
modernized 10 years ago, it will have a difficult
time to legitimize the huge investment necessary to
make what is now only an incremental gain. For
Weyerhaeuser, the gains are quite large.
• Richard Dlforlo: There's no Silver bullet, and no
one way to do it. I think you have to look at a site-
specific situation, whether it's a country or a par-
ticular mill or process within the mill, then make
your judgments about the best approach for that
particular situation.
• Unidentified Speaker: Give us an example. You
said it is difficult or dangerous for an outsider to the
company to use the results of lifecycle analysis.
What did you mean by that statement?
• Frank Consoll, Scoff Paper Company: If I have an
internal lifecycle assessment done at Scott and then
I publish it to a client or other external user — or
perhaps the Environmental Protection Agency
(EPA) or someone else wanted to use it — it would
be very difficult for these users to get the full em-
bodiment of the study. Literally, when you do a
lifecycle assessment, you end up with a desk full of
numbers. And not only do you end up with a desk
full of numbers, but behind each number is a data
quality path that contains numerous assumptions
and bits of information that went into developing
the number. We just went on a month-long trek, for
example, to find one number. This is very complex
stuff, so to do it in a way that everyone can under-
stand is tricky at best.
The second difficulty is that the impact assess-
ment area is in its infancy. Inventory data alone are
meaningless. I need to provide a framework of
what the impacts are, and we are still in the process
of trying to develop those kinds of methodologies.
My point — and I know my view is shared by some
people at EPA and the attorneys general — is that
we are not quite sure yet whether lifecycle assess-
ments are ready for prime time. That doesn't mean
you can't use them. But in terms of saying this
product is better than that product, or that from an
environmental perspective this technology is supe-
rior to others; I have got to tell you, we are not yet
ready for that and may never be.
34
-------
The ABCs of Conventional
Technologies Related to Pulping
and Bleaching
Thomas J. Me Do no ugh
Professor of Engineering and Group Leader, Pulping and Bleaching
The Institute of Paper Science and Technology
Atlanta, Georgia
The purpose of this paper is to provide a brief
overview of "conventional" pulping and
bleaching technologies, with two objectives.
First, I would like those who are not very familiar
with the industry to gain an appreciation of the
diversity and technical complexity of the various
pulping and bleaching processes used by the in-
dustry. Second, I hope that this paper will set the
stage for discussions of the new and modified tech-
nologies that subsequent authors will introduce.
Pulping Technologies
The manufacture of unbleached pulp begins with a
raw material that has a complex microscopic struc-
ture. Figure 1 is a close-up view of a little block of
pinewood showing one annual growth ring and
part of another. The top surface is similar to what
we would see if we looked at the end of a log with a
powerful magnifier. The wood is made up of many
hollow cells, each about a thousandth of an inch in
diameter. The cells are elongated and arranged in
parallel fashion. They are also quite rigid because
they are impregnated with lignin, which is a rigid
substance. In addition to imparting rigidity, lignin
serves to cement the fibers together.
With regard to the chemical composition of
wood, all we have to know for our present pur-
poses is that it is made up of three substances, oc-
curring in roughly equal proportions: cellulose,
hemicellulose, and lignin. Cellulose consists of
long, chainlike molecules that possess extremely
high tensile strength. Cellulose is resistant, but not
immune, to chemical attack and can be dissolved
only with difficulty. Hemicellulose is somewhat
similar in structure to cellulose but is more easily
Figure 1.-Microscopic view of the comer of a block of
pinewood.
dissolved and not as strong. Lignin, as noted
above, is the rigid, brittle, water-insoluble material
that impregnates the cells and cements them
together.
Mechanical Pulping
Pulping may be defined as the separation of the
wood cells from one another, after which they are
referred to as fibers. Two of the many ways of
doing this are mechanical pulping and chemical
pulping. In mechanical pulping, the fibers are
separated by simply tearing them apart — that is,
by grinding up the wood. In chemical pulping, on
the other hand, chemicals are used to dissolve the
lignin; then the fibers are easily separated.
35
-------
Overview of Technologies of Paper Manufacturing
A major advantage of mechanical pulping is
the high yield of fiber. Nearly all the wood is con-
verted into product. The off-setting disadvantages
are the substantial damage suffered by the fibers
and the undesirable properties imparted to them by
the remaining lignin. The result is relatively weak
paper that easily turns yellow. You've seen that
happen if you have ever left a newspaper out in the
sun for more than a few minutes. As shown in Fig-
ure 2, mechanical pulps consist of straight, rigid,
and inflexible fibers that have been damaged
during separation. Separation is also incomplete,
resulting in the occurrence of small broken bundles
of unseparated cells.
Figure 2. -Microscopic view of mechanical pulp fibers.
There are many different mechanical pulping
processes that are often referred to by their
acronyms (Table 1). The first two on the list, SGW
and PGW, use cylindrical grindstones to pulp logs;
the others use disk refiners to pulp wood chips. In
the case of thermomechanical pulp (TMP), the
refiner is operated at high temperature and pressure
to soften the lignin. TMP is now the dominant
mechanical pulping process used in the United
States. Note also that some of these processes use
chemicals to soften the lignin. These chemither-
momechanical pulp (CTMP) processes are part of a
whole spectrum of processes bounded on the high-
yield end by pure mechanical pulping and on the
low-yield end by pure chemical pulping.
Chemical pulping avoids the disadvantages of
mechanical pulping by removing most of the lignin
Table 1.-Some mechanical pulping processes and
their acronyms.
SGW-Stone Groundwood Pulping
PGW - Pressurized Groundwood Pulping
RMP - Refiner Mechanical Pulping
CMP - Chemimechanical Pulping
TMP - Thermomechanical Pulping
CTMP-Chemithermomechanical Pulping
APMP. BCTMP. TCMP. etc.
before attempting to separate the fibers. As a result,
the fibers suffer very little damage — they remain
strong and intact. Subsequent bleaching to remove
the residual lignin that remains after pulping gives
lignin-free fibers that bond together to form very
strong paper. A noticeable disadvantage is the low
yield of pulp per ton of wood. This disadvantage,
however, is largely offset by recovering the dis-
solved wood and using it to generate energy. If you
look at a chemical pulp through a microscope (Fig.
3), you will readily see that the fibers are un-
damaged. Their bent and twisted configuration in-
dicates that they are flexible and conformable.
These last two properties enable the fibers to con-
tact and bond to one another efficiently.
Figure 3.-Microscoplc view of krsft pulp fibers.
A variety of chemical pulping processes are
available, but kraft pulping is dominant in the
United States and Canada. Kraft pulping was, how-
ever, preceded by the sulfite process, which used
an acidic solution to dissolve the lignin. The most
commonly used form of the sulfite process
generated spent pulping liquor that could not be
easily recovered; it was discharged instead to the
receiving water. Replacing sulfite pulping with the
kraft process ended this environmentally unsound
practice because spent pulping liquor recycling is
an intrinsic part of the kraft system. Other points
worth noting here are that sulfite pulping produces
weaker fibers that are easier to bleach than kraft
fibers, and the kraft process is sometimes called the
sulfate process and confused with the sulfite
process. Because of the dominance of the kraft
process in North America, I will restrict my remarks
to this process for the balance of this presentation.
Bleaching Technologies
Bleaching is the chemical treatment of pulp fibers
for one or several different purposes: (1) to increase
the pulps' whiteness or brightness; (2) to improve
36
-------
T.I. McDONOUGH
cleanliness by disintegrating or decolorizing con-
taminating particles, such as pieces of bark or un-
pulped fiber bundles; (3) to improve brightness
stability by reducing the tendency of the bleached
pulp to turn yellow; (4) to remove residual hemi-
cellulose or resinous contaminants that are also
known as extractives; and — not the least impor-
tant — (5) to alter the physical properties of the
pulp in ways required to achieve a particular use.
Most of these objectives are achieved by
oxidizing and removing residual lignin from the
fiber. Brightness, for example, is adversely affected
only by residual lignin because cellulose and
hemicellulose are virtually colorless. Since lignin
removal is its major objective, bleaching can be
considered an extension of the pulping process.
Lignin, which comprises about one-quarter of the
original wood, is largely removed in the pulping
step, as shown in Figure 4. However, trying to
remove all of the lignin in the pulping step would
produce weak pulp because the pulping chemicals
are not perfectly selective. They attack car-
bohydrates as well as lignin, and the extent of car-
bohydrate attack increases as the content of
residual lignin decreases. The residual lignin, al-
though it is only a small fraction of the total amount
of lignin present in the original wood, must be
removed by bleaching with chemicals that are
more selective than the pulping chemicals.
—Hemicellulose
and
Cellulose
Concerns Related to the
Bleaching Process
Although it is similar in nature to pulping, bleach-
ing is different in several important ways. One of
these differences is the property of selectivity that I
have already referred to. Another is the fate of the
effluents from these processes, illustrated by Figure
5. The pulping effluent contains the organic
materials removed from the wood during pulping.
It is recycled to the kraft recovery system where it is
evaporated and burned to generate large amounts
of energy and to regenerate the pulping chemicals
for recycling to the process. The bleaching effluent
on the other hand, because it contains chlorides,
cannot be recycled to the recovery system. Instead,
it must pass to an effluent treatment system that will
satisfy its biochemical oxygen demand and
detoxify it before discharging it.
Several different chemicals may be used to
bleach kraft pulp. The important ones are listed in
Table 2. With one exception, all are oxidizing agents
and work by breaking down the lignin structure and
making it soluble in alkali. The exception is sodium
hydroxide, the alkali used to dissolve the oxidized lig-
nin. It is important to realize that these chemicals are
not freely interchangeable. Each has its own set of
properties that dictates how and where it is best used
in the bleaching process. These properties include a
chemical's chlorine equivalent, efficiency, reactivity,
selectivity, bleaching ability, and environmental con-
cern quotient.
Bleaching
Chemicals
Pulping Bleaching
Figure 4.-Sankey diagram showing relative magnitudes of material flows in kraft pulping and bleaching.
37
-------
Overview of Technologies of Paper Manufacturing
wood
r energy
to
process
recovery
system
'chemicals
water
multistage
bleach
plant
A white
-y pulp
effluent
treatment
Figure S.-Pulping and bleaching effluent fates.
Table 2.- Important bleaching chemicals and their
formulas and symbols.
NAME
Chlorine
Chlorine Dioxide
Oxygen
Hydrogen Peroxide
Sodium Hypochlorite
Ozone
Sodium Hydroxide
FORMULA
CI2
ClOa
02
H2O2
NaOCI
03
NaOH
SYMBOL
C
D
O
P
H
Z
E
Table 3.- Chlorine equivalent and efficiency ratings
of important bleaching chemicals.
CHEMICAL
CI2
CIO2
02
H202
NaOCI
03
* Delignifying Efficiency,
EQUIVALENT CI2
1.0
2.6
4.4
2.1
0.9
4.4
L = Low, M = Medium,
EFFICIENCY*
H
H
L
L
M
M
H = High
Comparing Bleaching Agents
Two important properties of bleaching chemicals
are chlorine equivalent and efficiency. Table 3 is a
qualitative comparison of bleaching chemicals
with respect to these properties. The chlorine
equivalent is the number of pounds of chlorine that
would theoretically be required to accomplish the
same amount of oxidation as one pound of the par-
ticular chemical. Another way of saying this is that
the number of pounds of chlorine that can theoreti-
cally be replaced by one pound of this chemical is
the chemical's chlorine equivalent.
In general, however, this replacement is not
possible in practice because the replacement
chemical will perform inadequately in terms of ef-
ficiency or some other property included on our list
of six. An exception to this statement is that
chlorine can usually be completely replaced by
chlorine dioxide.
The second property, efficiency, is an indicator
of the chemical's ability to oxidize lignin and to
realize the potential represented by its equivalent
chlorine value. Oxygen, for example, has low
efficiency so it is capable of replacing much less
than the theoretical 4.4 Ibs. of chlorine indicated
for oxygen in the equivalent chlorine column of
Table 3.
Next on the list of properties are reactivity and
selectivity as shown in Table 4. Reactivity is a
measure of the chemical's ability to react rapidly
and completely with the lignin in the pulp. Reac-
tivity is very high for chlorine and ozone and quite
low for oxygen and hydrogen peroxide. For this
and other reasons, neither oxygen nor peroxide is
capable of completely substituting for chlorine.
Selectivity characterizes the chemical's ability to
38
-------
T.J. McDONOUCH
Table 4.- Reactivity and selectivity ratings of impor-
tant bleaching chemicals.
CHEMICAL
CI2
CIOz
Oa
H202
NaOCI
03
REACTIVfTY
H
M
L
L
M
H
SELECTTVrTY*
H
H
M
H
M
L
Table 5.- Particle bleaching ability and environmen-
tal concern ratings of important bleaching
chemicals.
* L = Low, M = Medium, H = High
remove lignin without damaging cellulose. The
selectivity of chlorine and chlorine dioxide are very
high; ozone, on the other hand, has low selectivity.
The last two criteria for comparing bleaching
chemicals are their particle bleaching abilities and
their environmental concern quotient. Table 5
compares bleaching agents with respect to these
properties. Particle bleaching ability represents the
power of the chemical to disintegrate and
decolorize particles that would otherwise show up
as dark specks on the paper. The chlorine-contain-
ing compounds excel in this ability; ozone has the
least.
The final criterion for judging a bleaching
chemical is the amount of environmental concern
its use engenders among the general public. Such
concern may or may not reflect the chemical's ac-
tual effects on the environment. Environmental
concern is highest for chlorine and lowest for non-
chlorine-containing bleaching agents.
The Bleaching Sequence
An important consideration in designing processes
to bleach kraft pulp is that none of these chemicals
PARTICLE BLEACHING
CHEMICAL ABILJTY*
CI2
CIO2
02
H202
NaOCI
Oa
H
H
M
L
H
L
ENVIRONMENTAL
CONCERN
H
M
L
L
H
L
' L = Low, M = Medium, H = High
can be used alone. It is always necessary to use
combinations of at least two of them. Another con-
sideration is that it is always more efficient to use
two oxidizing treatments separated by an alkaline
treatment than to use a single oxidizing treatment.
These principals dictate the use of multistage
bleaching sequences. An example is the CEDED
sequence, illustrated in Figure 6, which consists of
sucessive treatments with chlorine, alkali, chlorine
dioxide, alkali, and chlorine dioxide. This se-
quence was standard in the 1970s and early 1980s.
In this and similar sequences, the bulk of the
residual lignin is removed in the first two stages.
Therefore these stages have the greatest potential
for environmental effect. For example, dioxins are
formed exclusively in the first stage and most are
liberated from the pulp in the second stage. Con-
cern over the generation of chlorinated organics,
measured as adsorbable organic halogens (AOX),
has initiated a trend toward progressively greater
use of chlorine dioxide to replace chlorine in the
first stage. It has, in addition, become common to
use oxygen in the first alkaline extraction stage,
converting it from an E-stage to an EO-stage.
w = wash
brown _x
pulp n
V
Figure 6.-The CEDED sequence.
white
39
-------
Overview of Technologies of Paper Manufacturing
O
D
To Evaporation
and Combustion
Figure 7.-The ODEOD sequence.
Oxygen is also used as a first bleaching stage to
remove part of the residual lignin, usually about 40
percent. This removal decreases the amount of
chemicals needed in the subsequent stages. If the
next stage is a chlorine or chlorine dioxide stage, it
results in a corresponding reduction in the genera-
tion of chlorinated organic compounds, total dis-
solved organics, and color. An attractive feature of
such a system is that the effluent from the oxygen
stage contains no chlorides and can be easily
recycled and burned. An example of a sequence
that uses oxygen as the first stage together with
complete replacement of chlorine by chlorine
dioxide and oxygen reinforcement of the alkaline
extraction stage is shown in Figure 7. This
OD(EO)D sequence is capable of limiting
chlorinated organic material production to ex-
tremely low levels.
Concluding Remarks
The preceding discussion may be briefly sum-
marized as follows: pulping, or fiber separation,
can be accomplished by a variety of chemical and
mechanical processes. Bleached chemical pulps
are superior to mechanical pulps in strength,
brightness, and permanence. Bleaching is done for
a variety of reasons, not just to increase brightness;
and bleaching chemicals differ from one another
with respect to a variety of criteria including selec-
E
O
tivity, efficiency, reactivity, and actual bleaching
ability or particle removal. Oxygen bleaching can
reduce the amount of AOX in the bleaching ef-
fluents as much as 50 percent.
This simple list of facts has a number of im-
plications vis-a-vis pollution prevention: (1) The
choice of pulping process can itself be a means of
pollution prevention: the currently dominant kraft
pulping process, by virtue of the closed-cycle na-
ture of its recovery system is environmentally supe-
rior to some of its predecessors; on the other hand,
mechanical pulping cannot generally be sub-
stituted for kraft pulping for the sole purpose of
achieving environmental benefits, because of large
differences in the pulps' properties. (2) Bleaching
agents cannot be freely substituted for one another
to improve effluent properties because of (a) in-
herent differences in their behaviors and (b) the
resulting effects on the pulps' properties. (3) In spite
of constraints on the interchangeability of bleach-
ing agents, the quality of bleaching effluents can be
improved by means of a growing list of tech-
nologies, such as the use of oxygen to furnish part
of the necessary oxidizing power, and the substitu-
tion of chlorine dioxide for chlorine. Continued
evolution of such technologies may be expected, in
response to demonstrably real environmental
needs.
40
-------
Chemicals Used in the Pulp and
Paper Industry
Russell E. Kross
Vice President, Human and Environmental Protection
The Mead Corporation
Dayton, Ohio
Pulping and bleaching technologies are not
the only source of chemical use in the pulp
and paper manufacturing industries. Other
chemicals are used, and some of these are sources
of exposure to our employees, our neighbors, and
the environment. When you think about the
various pulping processes, the different wood
species that we use, and the many products that we
make available worldwide, you know that we are
talking about many different chemicals.
The chemical inventory of the Mead Corpora-
tion, for example, contains over 2,000 chemicals
that can be used at different times in the many
processes that convert wood to paper. The industry
also puts many coatings on paper products. These
coatings are chemicals. We may also put a variety
of raw materials into our products, sometimes with
unwanted or unintended by-products being gen-
erated in the process. The end result equals lots of
different chemicals.
Monitoring Chemical Uses
What do we know about these chemicals, or what
can we find out? It takes a large number of com-
prehensive surveys to understand the chemical ex-
posures in our industries. One snapshot taken at
one point in time is insufficient to record potential
sources of chemical exposure in our line of work.
The government has done some surveys and has
some records for some companies. In the 1980s,
for example, the U.S. Department of Health and
Human Services and the U.S. Environmental
Protection Agency (EPA) documented employee
exposures to chemicals in our industry. And in my
company, since the mid-1970s, we have been
doing annual, comprehensive industrial hygiene
surveys.
To accomplish this task, we go into our plants
and monitor different chemicals through the collec-
tion of area samples. Another method that we use
to monitor chemical exposures, directly involves
the workers. That is, we attach small portable
samplers to individuals in the plant. This sampler is
usually at waist-level, but the intake port for the
sample is on the lapel — close to the worker's
breathing zone. These samples are collected for
two hours, six hours, and eight hours, depending
on the chemical being monitored. Such an exten-
sive program identifies many of the exposures that
are present in the work place.
My list of these chemicals (see Table 1) does
not include the chemicals that are typically used in
the pulping and bleaching processes that we have
focused on at this meeting or that we are going to
focus on in the next couple of days. However, it
does contain examples of different chemical ex-
posures that are found in our industry. We can
break the industry down into pulping, bleaching,
power, and recovery chemical uses, and have
categories left over for other basic processes. We
can fine tune our lists even further. My point is that
this list from Mead is only a portion of a much
broader list.
I should also say that when we do this monitor-
ing — and I believe all companies who do it — also
share this information with all employees as part of
our employee's right-to-know programs. In addi-
tion, it is very clear that communities have a right to
know what chemicals they may be exposed to. We
have programs that address community rights as
well.
41
-------
Overview of Technologies of Paper Manufacturing
Table 1.—Chemicals evaluated through comprehensive industrial hygiene monitoring programs in pulp and
paper mills 1970-1990.
PULPING
BLEACHING
POWER & RECOVERY
PAPERMAKING
(COATING, FINISHING,
CONVERTING)
Ammonia
Anthraquinone
Asbestos
Benzene
Calcuim Oxide
Calcuim Carbonate
Carbon Black
Carbon Monoxide
Chlorine
Chlorine Dioxide
Chloroform
Coal Dust
Epichlorohydrin
Formaldehyde
Hydrogen Suit Ide
Metals (Flyash)
Metals (Pigments)
Metals (Welding)
Methanol
Methyl Mercaptan
Methylene Chloride
Naphtha-VM&P
Oil Mist
Particulates-
Respirable
Wood Dust
Total
Petroleum Distillates
Sodium Hydroxide
Sulfur Dioxide
Sulfuric Acid
Quartz, Respirable Silica
Welding Fumes
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X
X X
X X
X X
X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Pollution Prevention
Technologies
So that's what has happened over the last 15 or 20
years in terms of chemical types and exposures. As
a result of knowing more about potential exposures
and what effects they may have on humans and the
environment, we try to make sure that our efforts
meet or exceed the Occupational Safety and
Health Administration (OSHA) and EPA require-
ments or standards.
One way that significant change is made is
through pollution prevention, which is source
reduction, the effort to discontinue use of these
chemicals entirely or substantially through process
changes and substitutions. I have here a list of
chemicals (see Table 2) that have been essentially
eliminated from our company; another company's
list might be quite different. Nevertheless, the
move to more environmentally desirable chemicals
is the type of thing every company is doing to mini-
Table 2.—Chemicals essentially eliminated in Mead
as product raw materials or as by-products.
Asbestos
Benzene
Lead Pigments
Mercury and Mercury compounds
PCB's
Penthachlorophenols
Trichlorophenoll
42
-------
R.E. KROSS
mize the risk to company employees and neighbors
from harmful chemical exposures.
I will not go into examples of conventional air
and water emissions, their kind of exposures, and
what has happened in this area, except to say that
we all know that significant reductions have been
made over the last 20 years. One comment that I
would like to make about some of those end-of-
pipe treatments and reductions, however does con-
cerns the solid waste issue. Taking wastes out of
the water or air has sometimes meant putting it on
the land in landfills.
Here, also, much change has taken place in our
industry. If you look at our industry over the last 15
to 20 years, we don't use nearly as many landfills as
before. Sludge from our waste treatment plants is
not hazardous, and there are large volumes of it.
Our disposal methods are clearly undergoing
change. Old landfills are being closed with water-
tight caps and other kinds of environmental protec-
tion, and new landfills are being lined before they
are used. Landfills will clearly be used for disposal
in the future; it is a method we will always need.
If you look at our industry as it appeared in
1979, 86 percent of wastewater treatment plant
sludge went to landfills. Ten years later, this figure
has been reduced to 70 percent. So, the trend is
moving in the right direction. The recovery of ener-
gy from sludge has also grown in the last decade.
In the late 1970s, 11 percent of paper industry
sludge was burned. In the late 1980s, over 21 per-
cent was being managed for energy recovery.
Again, the trend is in the right direction.
This sludge also has physical and chemical
properties that can benefit agriculture and mining
interests when applied to fields or abandoned strip
mines. Land application of sludge has also grown
from roughly 2 percent in the late 1970s to over 8
percent in the late 1980s.
The Mead Company, for example, is very much
involved in reclaiming abandoned coal strip mines
in the state of Ohio. Ohio has over 200,000 acres
of abandoned strip mines that are considered very
serious or critically in need of reclamation. During
the nonwinter months in our operation in Ohio, al-
most 100 percent of our treated sludge goes to
reclaiming these abandoned strip mines. That
amounts to more than 200 tons of dry material each
day, and as noted previously, there are still many
strip mines that need to be reclaimed.
Accomplishments
Let me switch gears a minute to speak briefly about
the Superfund Amendments and Reauthorization
Act of 1986 (the SARA emissions) and the Toxic
Release Inventory (TRI). Over the last several years,
our industry and others have significantly reduced
these emissions on a voluntary basis. Many pulp
and paper companies joined Administrator William
Riley's voluntary commitment program — the
33/50 program — that identified 17 different
chemicals to be given high priority from EPA's
standpoint.
The Mead Corporation participates in this pro-
gram. Seven of those chemicals were present in
emissions at one or more of our 40 manufacturing
locations in the United States; however, most of
these seven were not in the pulping and bleaching
area but in the emissions from other operations. In
our case, we use 1987 as the base year, and we have
already exceeded the 33 percent reduction target.
For six of the seven, we have, in fact, already ex-
ceeded the 50 percent reduction target, and the ac-
complishment has raised our sights. In July of last
year, we committed to 75 percent reductions by
1995. We are well on our way to that target.
Another related issue: in April 1992, Ad-
ministrator Reilly announced that our packaging
division, which is headquartered in Atlanta, Geor-
gia, was one of the national winners of the pres-
tigious Administrator's Award for Pollution
Prevention. This award was for reducing toxic air
emissions by substituting water-based inks for the
formerly solvent-based inks used in our printing
processes. It took a major effort lasting many years
for us to accomplish this substitution. It is truly a
pollution prevention technology and resulted in
reducing the volatile organic compounds (VOCs) in
these emissions by more than 85 percent. We are
obviously very proud of our efforts and we are also
proud of the recognition from the EPA.
Facing the Future
We recognize that our industry uses a large number
of chemicals in a wide range of processes including
pulping and bleaching. We also recognize how
important it is to protect our employees, our neigh-
bors, and the environment and to operate with an
adequate margin of safety. Mead's programs are
clearly designed to do that, and we will continue to
make sure that we follow those efforts. However,
we also recognize that the very stringent technol-
ogy-based provisions of the 1990 Clean Air Act and
the expected wastewater effluent guidelines that
are now being revised may require further sig-
nificant reductions for many of these emissions that
we believe could go way beyond what is necessary
to protect human health and the environment.
These regulatory issues will be discussed in greater
detail later in the symposium.
-------
Conventional Pulp Bleaching
at Westvaco
Harold L. Hintz
Technical Assistant to the Vice President and Corporate Research Director
Westvaco Corporation
New York, New York
To reduce the formation of chlorinated or-
ganics in conventional pulp bleaching
processes, Westvaco has developed a novel
chlorination stage technology that splits the applied
chlorine into three doses. This technology was im-
plemented voluntarily in 1989 to control dioxin
formation in Westvaco's bleaching operations. In
combination with chlorination stage pH control
and some chemical adjustments, the formation of
key chlorinated dioxins and furans was reduced
more than 96 percent to nondetectable levels in ef-
fluents and products. The formation of other
chlorinated organics has decreased 25 to 50 per-
cent.
Conventional Pulp Bleaching
The chlorination stage is a key stage in convention-
al pulp bleaching. The overall performance of pulp
bleaching sequences depends on this critical first
stage, whether or not the chlorination stage is
preceded by an oxygen stage or whether it is a
modified stage in which chlorine dioxide is applied
before, after, or simultaneously with the chlorine.
The success of the pulp bleaching process in
terms of bleached pulp quality parameters —
brightness, strength properties, viscosity, and dirt
level — combined with the efficiency of chemical
use depends on getting the right chemical reactions
to occur in the chlorination stage. These reactions
alter the residual lignin macromolecule so that the
lignin can dissolve in the chlorination stage or be
extracted in the subsequent caustic extraction
stage.
Some chlorine reactions with lignin result in at-
tachment of chlorine to the lignin. Most of the
chlorinated organics generated in pulp bleaching
are formed in reactions with chlorine, although
small amounts result from reactions with chlorine
dioxide. These chlorinated organic compounds are
known collectively as adsorbable organic halogens
(AOX). Trace amounts of chlorinated dioxins and
furans can be formed in the chlorination stage. It is
possible, with the modifications we have
developed in our labs and implemented at our
mills, to reduce the generation of dioxin to non-
detectable levels in effluents and bleached pulps
and simultaneously to reduce AOX levels in con-
ventional pulp bleaching systems.
Chlorine Dioxide Substitution
Most modern chlorination stages use some chlorine
dioxide with the chlorine. The amount is usually
expressed as the chlorine dioxide substitution. The
percent of substitution is calculated from this equa-
tion in which the amounts of both chlorine and
chlorine dioxide are given in chemical oxidation
equivalents or active chlorine:
CIO2
% substitution -
CI2+CIO2
Many different methods for chlorine dioxide
substitution have been developed because chlorine
and chlorine dioxide are compatible chemicals and
can be used together or in sequences. Certain of
these approaches offer technical advantages for
achieving the best lignin removal or pulp quality.
The combined amount of chlorine and chlorine
dioxide applied to a pulp in a chlorination stage is
often expressed as a kappa factor.
%Cl2 + CIO2
Kappa Number
44
-------
H.L HINTZ
This term takes into account the normal need to
adjust the chemical charges when the amount of
lignin to be removed, that is, the kappa number,
changes. In a similar way, the chlorine applied rela-
tive to the kappa number is known as the chlorine
factor:
Chlorine Factor -
Kappa Number
Westvaco's Program in Review
After trace amounts of dioxin were identified in
paper industry matrices in 1987, Westvaco began a
testing program at its three mills producing
bleached pulp. We also began a research program
to understand the cause of dioxin generation and to
develop preventive actions. The U.S. Environmen-
tal Protection Agency (EPA) and Paper Industry 104
Mill Study confirmed the general levels found in
our earlier screen ing tests (NCASI, 1989,1990).
Our working hypothesis was that the formation
of a minor reaction product, such as dioxin, could
be affected by the concentration of molecular
chlorine in the reaction system. When a given
amount of chlorine is applied to a pulp, it is pos-
sible to vary the chlorine concentration in several
ways, and by splitting it into three charges, a dif-
ferent profile of concentration versus time results.
The upper part of the graph in Figure 1 shows a
typical chlorine versus time curve for a single
charge. The bottom curve shows a profile when
three charges were used. The high initial con-
centrations observed with one charge are avoided
by using three additions (Hise, 1989). High
chlorine concentrations are also avoided by
chlorinating at low pulp consistencies, but lowered
consistency has limited practicality. Good chemi-
cal mixing will avoid local high chlorine con-
centrations.
Chlorine concentration
Splitting Chlorine Additions and
Adjusting pH
In Westvaco's initial laboratory work, the chlorine
charge was divided into two or three additions and
compared to a control experiment with a single ad-
dition (see Fig. 2). The results show reductions in
the 2378-tetrachlorinated isomer of dibenzodioxin
(TCDD) of 41 percent for two additions and 53 per-
cent for the three additions. The results for the
2378-tetrachlorinated isomer of dibenzofuran
(TCDF) show slightly greater percentage reduc-
tions. This work was done on a softwood pulp
using a relatively high chlorine factor of 0.21 and a
10 percent substitution of chlorine dioxide. The
pulp was not washed between chlorine additions in
order to simulate a more practical process for com-
mercial bleaching.
Addition Method
One charge
TAvo charges
Three charges
Chlorine factor, 0.21
10% CIO, substitution
2378-TCDD
(ppt)
2378-TCDF
(ppt)
Base Case
-41% -45%
-53% -70%
Reaction time
Figure 1.—Consumption of chlorine vs. time (one vs.
three chemical additions).
Figure 2.—Effect of splitting chlorine addition on 2378-
TCDD/F in C-stage pulp.
Studies in Canada and at North Carolina State
University have also shown the potential for vary-
ing the reaction products of chlorination by chang-
ing the way chlorine is added. They found a clear
decrease in the amounts of chlorophenols formed
when the chlorine was added continuously as com-
pared to the amounts formed after a single large ad-
dition of chlorine (Liebergott, 1984; Marwah et al.
1992).
In addition to splitting the chlorine charge, the
concentration of the chlorine molecule in solution
can be affected by adjusting the pH. The hydrolysis
of chlorine to form hypochlorous acid and
hydrochloric acid is an important reaction in pulp
chlorination. The chlorine molecule concentration
can be controlled by shifting the hydrolysis equi-
librium toward hypochlorous acid. Decreasing the
total active chlorine concentration forces the equi-
librium toward HOCI + H+ + Cl". This effect can be
achieved by lowering the chlorination stage consis-
tency or by splitting chlorine additions. The
chlorine molecule concentration can also be kept
low by reducing the concentrations of hydrogen
and chloride ions, for example, by avoiding
45
-------
Overview of Technologies of Paper Manufacturing
chlorination filtrate recycle. Controlling the pH
level by alkali addition is also effective.
Figure 3 shows how the distribution of chlorine
species changes as pH is adjusted. Many commer-
cial chlorinations finish in a low (1 to 2) pH range
in which the chlorine molecule is the predominant
species of active chlorine. As the pH increases, so
does the active chlorine present as hypochlorous
acid.
100%
Chlorine species distribution
60%
40%
20%
0%
0
pH
8
10
— Chlorine — Hypochlorous acid — Hypochlorite
Figure 3.—Chlorine species at varying pH (total active
chlorine = 0.1 M).
The effects of pH were tested in laboratory ex-
periments using a single addition of chlorine. The
formation of TCDF is clearly reduced when the pH
measured at the end of the reaction is increased
(see Fig. 4). Similar results have also been reported
by researchers at the Pulp and Paper Research In-
stitute of Canada (PAPRICAN) (Berry et al. 1989).
Higher amounts of hypochlorous acid and less
molecular chlorine at the high pH levels reduce
TCDF formation. The nature of the delignification
reactions also shifts with pH since hypochlorous
acid is known to react with lignin through oxida-
tion reactions. Molecular chlorine will also react
through oxidation, but substitution reactions are
favored.
2378-TCDF, ppt
300 -
200 -
100 -
30 kappa softwood pulp
0.21 chlorine factor, 10% ClOa
Figure 4.—Effects of C-stage pH on chlorinated pulp
TCDF.
A potential result of increased chlorination pH
is chemical attack by hypochlorous acid on the
pulp carbohydrates and loss of pulp viscosity and
strength. Our experiments with a single charge of
chemicals showed this possibility. Other experi-
ments and our commercial experience show that
this problem can be avoided.
Controlling the Chlorine Factor and
Contaminants
The amount of chlorine applied is naturally an im-
portant variable controlling dioxin formation.
Swedish researchers first showed a link between
the amount of dioxin formed and the chlorine used
(Kringstad, 1988; AxegSrd, 1989). Chlorine use was
expressed in terms of a chlorine factor.
AxegSrd's data (see Fig. 5) suggest a rapidly in-
creasing level of dioxin above certain chlorine ap-
plications. Dioxin approached nondetectable
levels as the chlorine factor decreased to about
0.15. Chlorine factors below 0.20 were obtained in
these experiments by increasing the chlorine
dioxide substitution for chlorine.
100
2378-TCDD,ppt
75
50
25
0.05 0.1 0.15 0.2 0.25
Chlorine Factor
0.3
o LabSW -MfflSW ALabSW02 AMillSWO2
Figure 5.—Bleached pulp TCDD and chlorine factor
(Axegard, 1989).
These and other data suggest reducing dioxin
formation by reducing the amount of chlorine used.
Many process changes have been proposed to
reduce chlorine use. In a few mills, the chlorine
factor can simply be reduced and adjustments
made in the later stages of bleaching to compensate
for the reduced delignification in the first stage.
Chlorine dioxide substitution can be used to reduce
the chlorine factor while maintaining normal levels
of first stage delignification.
Chlorine use can also be reduced by processes
that leave less lignin in the unbleached pulp. Oxy-
gen bleaching or extended delignification can
reduce the requirements for chlorine by 40 percent.
These processes require major capital investments
to implement. Also, even when bleaching pulps
46
-------
H.L. HINTZ
with lower lignin content, it is still important to
control the chlorine factor to avoid dioxin forma-
tion.
Contaminants, particularly unchlorinated
dibenzodioxin and dibenzofuran, are now well-
established contributors to dioxin formation (Allen,
1988; Berry, 1989; Hise, 1990). Laboratory experi-
ments and mill experiences show the importance of
washing the unbleached pulps before chlorination.
Because the defoamers used in brown stock wash-
ing can be a source of dioxin precursors, it is impor-
tant to use only good quality products at minimum
dosages. Good washing will reduce precursor con-
centrations and allow bleaching with less chlorine.
Thus, incremental improvements in brown stock
washing and defoamer control were parts of our
program (Hise, 1992).
Conclusion
The results from these changes in Westvaco's
bleaching operations have been excellent. Dioxin
formation has decreased more than 96 percent
from the levels measured in 1987. Currently, our
dioxin testing program, using the most modern in-
strumentation available, indicates that our effluents
and products are at nondetectable levels for TCDD.
All regulatory standards are being met at levels ap-
proved by EPA.
Note that these results are from the convention-
al bleaching technology except for the addition of
Westvaco's approach to splitting the chlorine addi-
tions and controlling pH.
The significance of other chlorinated organics
(AOX) as an environmental measurement has been
widely debated. A review of available data indi-
cates no effect when AOX in the effluent is less than
2 kg per metric ton of bleached pulp. A target of 1.5
kg per tonne has often been discussed as a
regulatory target.
The process changes implemented to control
dioxin formation have resulted in decreases in the
AOX levels in the effluents from Westvaco treat-
ment plants. AOX levels generated in the process
have been reduced 25 to 50 percent, and with a 30
to 50 percent decrease in the biological treatment
process, the levels in our effluents are well below
1.5 kg per ton.
The technology discussed in this paper has
been in use at Westvaco mills for over three years
— all of the company's bleaching lines are now
using it. The equipment for split chlorine additions
was purchased and installed in a year or less, and
capital requirements were moderate compared to
other alternatives. Adjustments in the chemical ap-
plications and operating strategies were rapidly im-
plemented and control of the process has been
excellent.
References
Allen, L.H. et al. 1988. Evidence that oil-based additives are an
indirect source of the TCDD and TCDF produced in kraft
bleaching plants. Pres. 8th Int. Symp. Chlorinated Dioxins.
VC Instruments. Umea, Sweden.
AxegSrd, P. 1989. Improvements of bleach plant effluent by cut-
ting back on Cb. Pulp Paper Can. 90(5):T183.
Berry, R.H. el al. 1989. Toward preventing the formation of
dioxins during chemical pulp bleaching. Pulp Paper Can.
90(8):T279.
Hise, R.C. 1989. Split addition of chlorine and pH control for
reducing formation of dioxins. Tappi J. 72(12):121.
Hise, R.C. and H.L. Hinlz. 1990. The effect of brownstock
washing on the formation of chlorinated dioxins and
furans during bleaching. Tappi J. 73(1):185.
Hise, R.C., R.C. Striesel, and A.M. Bills. 1992. The effect of
brownstock washing, split addition of chlorine, and pH
control in the C stage on formation of AOX and chloro-
phenols during bleaching. Tappi J. 75(2):57.
Kringstad, K.P. el al. 1988. Bleaching and the Environment.
Pres. Addendum. Int. Pulp Bleaching Conf., Orlando, FL.
Liebergoll, N. 1984. Chlorinalionof pulp — the effect of mixing
intensity, chlorine concentration, and reaction tempera-
ture. Pages 359-68 in Proc. Pulping Conf. TAPPI Press. At-
lanta, CA.
Marwah, N., T.W. Joyce, C.-L Chen, and J.S. Gratzl. 1992.
Laboratory reduction of chloro-organics during bleaching
of kraft pulps by continuous addition of chlorine and
chlorine dioxide. Tappi J. 75(6):167.
National Council for Air and Stream Improvement. 1989. U.S.
Environmenlal Protection Agency/Paper Industry Coopera-
tive Dioxin Screening Study. Tech. Bull. No. 545. New
York, NY.
. 1990. U.S. Environmenlal Protection Agency/Paper In-
dustry Cooperative Dioxin Study: The 104-Mill Study.
Tech. Bull. No. 590. New York, NY.
Voss, R.H. el al. 1989. Some new insights into ihe origins of
dioxins formed during chemical pulp bleaching. Pulp
Paper Can. 89(12):151.
47
-------
Panel 2:
Overview of Technologies of
Paper Manufacturing
Question and Answer Session
m Valerie Harris, Midwest Research Institute: My
question is for Tom McDonough and Harold Hintz.
We talked about two very different approaches to
reducing dioxins and furans in the effluent. Earlier
this morning, we also talked about a multimedia
approach to pollution prevention. So my question
is, what are the multimedia impacts, for example,
in oxygen delignification? There will bean increase
of solids to the recovery cycle. Are there disad-
vantages or advantages to that? What are its various
cost impacts? And the same questions are as-
sociated with pH control and stage chlorine control
for the conventional chlorine bleaching.
• Tom McDonough, The Institute of Paper Science
and Technology: I can address the specific part of
your question. There are certainly many costs and
disincentives associated with installing oxygen
delignification in the system — you mentioned one
or two of them. An increase of solids in the
recovery cycle means that an already overloaded
recovery system may become even more over-
loaded. If so, there's a high capital cost as well. In
general it's not an investment that can be justified
on the basis of chemical cost savings alone. The en-
vironmental benefits play a big role in the justifica-
tion of the decision to install oxygen deligni-
fication.
48
-------
Worldwide Sales Opportunities for
Environmentally Responsible Products
David Mager
Director, Environmental Standards
Green Seal
Washington, D.C.
According to the American Paper Institute, 13
million tons of paper products were exported
from the United States in 1991. Yet with only
750 million pulp and paper products customers in
a world population of 6 billion, that leaves 5.25 bil-
lion people who are not customers. Today the op-
portunities for the sale of environmentally respon-
sible products is tremendous. In searching for a
win/win situation, Green Seal can help manufac-
turers not only take advantage of those unreached
markets but work with them to enourage mutually
beneficial solutions to common energy and en-
vironmental problems and move toward a healthy
environment.
A healthy environment creates monetary
wealth via an annuity income from our global capi-
tal assets. These assets are then available for the
world's population to enjoy through sustainable
development and growth. When we plunder the
environment, when we spend our rich global capi-
tal assets, we damage the planet's ability to provide
for its inhabitants. To make a better environment re-
quires that corporate planners, government regu-
lators, and environmental designers have the right
tools to help them select the best targets for their ac-
tions.
Green Seal's History
Green Seal was formed to respond to consumers'
needs to identify environmentally superior
products. Four out of five people say they want to
buy Green products, 49 percent say they would
even pay more for environmentally superior
products. In 1991, 13 percent of all new product
introductions were Green. J. Oilman's new book,
Green Marketing: Challenges and Opportunities for
the New Marketing Age (1992), contains survey
results indicating that 23 percent of all consumers
are putting their money where their mouth is and
actually making environmentally responsible pur-
chases. A whopping 61 percent of Americans go
out of their way to buy products labeled as environ-
mentally sound and 35 percent boycott companies
that are careless toward the environment.
Consumers want to buy Green products, but
they are often confused by what a Green product is.
Most consumers disbelieve environmental claims
that manufacturers make about their own products.
Similarly they are distrustful of government labels
attesting some products as environmentally supe-
rior; such labels could represent the lowest com-
mon denominator or be the product of a special
interest group that succeeded in getting the
government's ear.
In a 1991 Gallup poll, 34 percent said they
would be influenced to buy products endorsed by
an independent "Green Seal," with Denis Hayes
heading the Green Seal organization. Hayes served
as International Chair of Earth Day 1990 and writes
a weekly column on environmental concerns for
USA Weekend, which reaches 35 million readers.
Green Seal is a nonprofit organization that sets
standards for environmentally superior products
and tests products for compliance with standards.
Green Seal receives support from foundations and
individuals but does not accept contributions from
corporations. Green Seal is a member of the
American Society for Testing and Materials (ASTM)
49
-------
Worldwide Sales Opportunities .. .
and the American National Standards Institute
(ANSI). We use both groups' open, public process
in setting our standards (see Table 1).
Table 1.—Green Seal inputs to standards.
• Basic research
• Manufacturers
• Trade associations
• Public interest and environmental groups
• International environmental standards organizations
• Federal, State, and regulatory agencies
• Standards organizations
• Independent experts
• Consumers and users
Green Seal works closely with other interna-
tional standard-setting organizations, particularly
with the Environmental Choice Program in Canada
to ensure that standards do not become barriers for
international trade and that manufacturers don't
have to make 65 different products to accom-
modate 65 different standard-setting organizations.
Green Seal also has a strategic alliance with
Underwriters Laboratories (UL), Inc., which serves
as Green Seal's primary testing and compliance
monitoring laboratory. UL has a field staff of more
than 500 people in 73 countries.
Green Seal's board of directors is comprised of
leaders of industry, government, and the environ-
mental community. Green Seal has become a
bridge between these three groups.
Benefits of Green Seal Certification
The benefits of Green Seal certification, according
to the manufacturers who have responded to Green
Seal so far, include the following:
• Increased Sales and Market Share. Over 80
percent of consumers want environmentally
superior products, yet they distrust manu-
facturers' claims and are dubious about a
governmental labeling program. However,
these same consumers respond positively to
an independent Green Seal Certification
Mark on a product. Green Seal has received
several substantial grants to promote the
Green Seal Certification Mark and certified
products through use of TV, radio, and
printed public service announcements and
toll-free telephone response lines. In addi-
tion, the Green Seal has received positive
media attention.
• Reduced Costs of Goods. Environmental
regulations are forcing manufacturers to
redesign products and manufacturing pro-
cesses to make them more environmentally
responsible. Designing products to comply
with standards for environmentally superior
products can reduce costs through the "Rule
of Tens": if it costs $10 to create a design
criteria, it costs $100 to change the design,
$1,000 to change the prototype, $10,000 to
make a change in preproduction, $100,000
to make a change in production, and $1 mil-
lion to recall a product from the field.
Many paper companies, instead of be-
coming "victims" of regulation, have in-
stalled environmentally responsible manu-
facturing equipment, processes, and prac-
tices. I have visited plants in which sludge,
which used to be carted off to landfills, is
now sold as a landfill sealer — creating in-
come from a former expense. Some plants
have installed new water treatment facilities,
thereby saving huge amounts of money.
Other plants allow waste haulers to bring in
paper wastes, which are subsequently
recycled and sold as paper products. During
this conference, we have learned about tech-
niques that use chlorine for bleaching in
small doses at intervals, instead of one large
dose. This practice significantly reduces the
amount of chlorine required and saves
money.
Prevent Government Product/Process Regu-
lations. When products and processes are
designed and built for environmental excel-
lence and when industry acts in a proactive,
environmentally responsible manner, gov-
ernment regulation is no longer needed.
Regulatory compliance adds significantly to
costs.
New Federal regulations state that in the
presence of an existing voluntary standard,
regulations need not follow. The voluntary
standard can be the basis for government
procurement decisions. And as Raymond
Coates, winner of the 1991 Nobel Prize in
economics, points out, when companies ful-
fill their "social contract" with consumers, no
one needs regulations. Government regula-
tions are created when industry fails to main-
tain this contract.
Regulatory Compliance. On July 28, 1992,
the Federal Trade Commission (FTC) issued
new Guides for the Use of Environmental
Marketing Claims in response to a prolifera-
tion of meaningless and misleading environ-
mental advertising and product claims. The
50
-------
D. MAGER
Guides say environmental claims need to be
substantiated by "competent and reliable
scientific evidence" and "conducted in an
objective manner by persons qualified to do
so, using procedures generally accepted in
the profession." Green Seal Certification
provides such substantiation.
increased Corporate Stock Values. Com-
panies with poor environmental perfor-
mance records (as indicated by the Toxic
Release Inventory reports) have low earnings
ratios and poor stock values, regardless of
their profitability. Stock analysts carefully
review public companies' environmental
records as part of the basis for making stock-
buying recommendations.
Improved Employee Morale. Employees love
to be on the side of the "good guys." Worker
productivity is high in companies that are
proactive environmentally. Conversely, em-
ployee morale suffers when workers feel
guilty about their involvement in in environ-
mentally damaging company actions and
policies. In the extreme, unhappy employees
can become whistleblowers causing a very
expensive and damaging experience for
companies.
Recognition For Environmental Achieve-
ment. Corporations seek compliance with
published environmental standards to gain
recognition for their service to the planet.
The Green Seal announces their accomplish-
ment to workers, customers, suppliers, the
local community, and the world at large.
Better Community Relations. Environmen-
tally responsible manufacturing reassures
residents who live near a plant. It addresses
their concerns about the community right-to-
know laws, and it fosters more cooperative
company/community relations.
Improved Relations with Peers, Friends, and
Family. Environmentally responsible pro-
ducts, processes, and services turn workers,
product designers, and decisionmakers into
heroes in the eyes of their colleagues,
friends, and family. Decisionmakers at com-
panies with bad environmental performance
are shunned and ostracized in social circles
and by their families.
The tuna boycott in the late 1980s,
protesting the killing of dolphins during tuna
fishing, was successful not because it did
economic damage to tuna producers, but be-
cause a granddaughter wouldn't sit on the
lap of the company chairman because his
company was killing dolphins. A revealing
article in The New York Times disclosed that
chromium platers were cleaning up their
operations not because regulatory com-
pliance made business unprofitable, but be-
cause their neighbors wouldn't talk to them
anymore.
Voluntary Environmental Standards
Versus Life Cycle Analysis
Green Seal is one of only 50 invited worldwide par-
ticipants in the Society for Environmental Toxicol-
ogists and Chemists (SETAC) workshop and the U.S.
Environmental Protection Agency (EPA) peer
review group on life cycle analysis. Although we
now have an accepted methodology for measuring
the environmental effects of a product throughout
its life cycle, it is not yet possible to discover the
sum of these impacts. That is, no useful number is
produced when we add the total tonnage of pulp
used, the kilowatt hours that go into transforming
pulp into paper, the weight of the chlorine used for
bleaching, the weight of chlorinated organic ef-
fluents, the carbon dioxide, monoxide, nitrogen
oxides, and sulfur compounds that are emitted, the
millions of gallons of water discharged at elevated
temperatures, and the tons of packaging and paper
discarded after use.
This is why SETAC, the EPA, and the States' at-
torneys general all agree that life cycle analysis
should not be used as the basis for product labeling
or public policy. Nevertheless, life cycle analysis
technologies and methodologies are pushing the
envelope in environmental matters — just like the
Apollo space program stimulated developments in
electronics and computers. New and improved
ways of making environmental evaluations of
products can result from life cycle analysis, which
already influences the way Green Seal sets its en-
vironmental standards.
Green Seal's voluntary standards are set at the
level of environmentally superior products, in con-
trast to mandatory government regulations that are
generally set at minimum performance levels (see
Fig. 1). Standards are set at Green Seal using a life
cycle approach. We look at all aspects of a
product's impact on the environment, from
preproduction to manufacturing, packaging, dis-
tribution, use, and ultimate disposal. The energy
and materials that are used, the emissions to air and
water, solid waste considerations, and toxicologi-
cal and ecological implications are considered.
Green Seal standards address a product's environ-
mental performance, its packaging, its general per-
51
-------
Worldwide Sales Opportunities . ..
formance, and its labeling requirements. For
general performance criteria, Green Seal's stand-
ards defer to ASTM, ANSI, the Technological As-
sociation of the Pulp and Paper Industry (TAPPI), or
other industry-accepted performance criteria.
After doing basic research for each standard,
we solicit input from every group that has an inter-
est in the product — manufacturers, trade associa-
tions, public-interest and environmental groups,
UL, Federal, State and regional regulatory agencies,
other standards organizations, and consumers.
Green Seal builds a consensus on the issues and
then sets a proposed standard at a level reflecting
environmentally superior products.
The proposed standard then undergoes a
"purification by fire": a public review process. The
proposed standard and its rationale, along with
documented and technical references, is dis-
tributed to all manufacturers of the product and any
person or organization who requests it. Comments
received are researched and all get responses.
Green Seal standards have been set for facial
tissue, toilet tissue, printing and writing paper, re-
refined engine oil, showers, sinks, toilets, and ener-
gy-efficient lighting. Proposed standards have been
released for household cleaners, paper towels, and
paper napkins (see Fig. 2). Proposed standards are
being finalized for newsprint and newspapers,
paint, thermal windows, major household applian-
ces, insulation, and reusable shopping bags. We
are also working on an amendment to our printing
and writing paper standard to include coated
paper.
As an example, Green Seal's standard for toilet
tissue addresses recovered paper and post-
consumer material, ASTM performance specifica-
tions, no inks or dyes, certain chemicals that
cannot be used in deinking, restrictions on the ad-
sorbable halogen content (AOX), restrictions of
toxics and packaging (including minimum size re-
quirements), and a requirement that all products
must comply with existing environmental law.
After a standard is set, the Green Seal process
provides for a manufacturer to apply to Green Seal
to have the product tested against the standard. If a
test product meets the requirements, it is awarded
certification with the provision that the manufac-
turer agrees to ongoing compliance monitoring, in-
cluding unannounced site visits and product
testing.
Green Seal has a proposed standard for paper
towels and paper napkins. I invite you to review
this and other Green Seal proposed standards and
provide your comments. Your participation in this
process will ensure that the standards reflect your
knowledge and experience and point the way
toward a new paradigm of solving our world's en-
vironmental problems.
Category
Selection
Standard
Setting
Application
Product
Evaluation
Figure 1.—The Green Seal process.
Certification
Compliance
Monitoring
52
-------
PAINT
WINDOWS
HOUSEHOLD
CLEANERS
LAUNDRY
DETERGENTS
PAPER TOWELS
AND NAPKINS
BATTERIES
D. MACER
DAILY TIMES
NEWSPRINT
MAJOR
APPLIANCES
Figure 2.—Standards under development.
53
-------
Low Kappa
Pulping
C. Bertil Stromberg
Director, Research and Development Laboratory
Kamyr, Inc.
Glens Falls, New York
M
uch research has been performed in the
pulp and paper industry over the last few
years to minimize the environmental im-
pact of chlorine and chlorine dioxide bleaching by
reducing the need for these chemicals. The solution
has been to reduce the lignin content in the pulp
going into the chlorine and chlorine dioxide
bleaching stages. A combination of cooking,
oxygen delignification, and nonchlorine com-
pound (hydrogen peroxide and ozone) bleaching
have been used in this process.
One drawback to oxygen and peroxide is their
limited ability to remove and brighten lignin.
Ozone is effective in removing lignin, but as it also
attacks cellulose, its use is limited to about 1 per-
cent on pulp (Liebergott et al. 1992). One way to
improve the lignin removal efficiency is to chelate
for metals removal before the peroxide, oxygen,
and ozone stages, thereby reducing the breakdown
of the reagents and the cellulose and achieving a
brighter, stronger pulp at the same chemical
charge. There are still limits to what these chemi-
cals can do, as shown by work done at the Pulp and
Paper Industry of Canada (PAPRICAN) (see Fig. 1).
When laboratory kraft pulps at different kappa
numbers were subjected to peroxide bleaching
after a chelating stage, the dependence of final
brightness on the incoming kappa number is clear
(Anderson, 1992).
Another way to reduce the bleach chemical
demand is xylanase enzyme treatment of the pulp
prior to bleaching, which makes the pulp appear as
if the kappa number is 10 to 30 percent lower, by
increasing the accessibility of the lignin in the fiber
structure (Farrell, 1992; Munk, 1992; Senior et al.
1992; Senior and Hamilton, 1992).
To lower the kappa number below that
achieved today by conventional oxygen delig-
nification, the kappa number in the cooked pulp
has to be decreased substantially. In the last 10 to
15 years, many improvements have been made in
the ability to lower the kappa number from both
batch and continuous cooking systems. This paper
examines the status of low kappa pulping in
modified and extended modified continuous cook-
ing techniques.
£76
16 20
K«pp» Number Batora Q-P Stages
Figure 1.—Peroxide stage brightness versus incoming
kappa kraft pulps. Source: Pulp and Paper Research In-
stitute of Canada (In press).
Principles of Modified
Continuous Cooking
The basis for kraft extended delignification was
developed at the Swedish Pulp and Paper Research
Institute (STFI) and the Royal Institute of Technol-
ogy in Sweden (Johansson et al. 1984). Research in-
dicates that the selectivity of the kraft cook could be
increased by the following process parameters:
• the alkali concentration should be low and
even throughout the entire cook;
• the concentration of sulfide ion should be
high, particularly at the beginning of the
cook; and
• the concentration of dissolved lignin should
be low, particularly at the end of the cook.
54
-------
C.B. STROMBERG
In addition, it is known that the selectivity of
the kraft cook is also improved when the cooking
temperature is kept as low as possible.
These principles were applied to a Kamyr
digester, by adding a circulation loop below the
normal extraction screens, and diverting about 20
percent of the total white liquor charge to this cir-
culation, which is heated to full cooking tempera-
ture. The latter part of the cook is thus carried out
by bringing the cooking liquor countercurrently to
the chips. Full-scale 1983 trials in Finland con-
firmed the lab findings (Kortelainen and Backlund,
1985). All new digesters for bleachable pulp sold
since 1985 have been either prepared for, or fully
equipped for, MCC7* operation. Figure 2 shows a
flowsheet for a two-vessel hydraulic digester
equipped with MCC®.
Both lab and mill MCC pulps permit about a
10 percent reduction in bleaching chemicals as
compared to a conventionally cooked pulp of the
same kappa number bleached to the same bright-
ness. This reduction is mostly the result of the alkali
concentration at the end of the cook being higher
in the MCC® procedure than in conventional cook-
ing (Kortelainen and Backlund, 1985; Whitley et al.
1990).
The brightness levels that can be achieved with
a given bleach sequence are also consistently
higher for MCC pulps. Figure 3 shows lab data for
bleach chemical consumption versus brightness for
Canadian hardwood chips cooked in the lab to the
same kappa number using MCC® and conventional
procedures. Figure 4 shows operating data from a
U.S. softwood line, before and after conversion to
MCC® (Whitley et al. 1990).
30
35 40 45 SO
Total Consumption of act Cl.kg/ADMT bl.
Figure 3.—Bleaching response of conventional and
MCC9 pulps.
Work by Kamyr, Inc., shows that extending the
time in the countercurrent part of the cook further
enhances selectivity; the kappa number can now
be reduced by 30 to 35 percent over the conven-
tional cooking procedure, with the same bleaching
response as for MCC® pulps. These findings led to
the introduction of a white liquor addition point to
the wash circulation and the ability to bring this cir-
culation up to full cooking temperature, which in-
creases the countercurrent cooking time by two to
four hours, as compared to the normal one hour.
This process, called the Extended Modified Con-
tinuous Cook (EMCC®), has been adopted by many
mills, some of which were already equipped with
Figure 2.—Two-vessel hydraulic digester with MCC9 and two-stage diffuser.
-------
A/ternaf/ve and Emerging Technologies — Pulping
18
20
22 24 26
K-NUMBER (40 ml)
30
MCC CONVENTIONAL
A —- Q—-
Figure 4.—Cfe consumption versus K-NO. (Conventional and MCC* operation.)
MCC® and others that were not originally equipped
for countercurrent cooking.
Figure 5 shows the impact on unbleached pulp
viscosity of going from a conventional lab cook to
an MCC® and an EMCC® cook. A kappa reduction
of about 4 units is possible with an EMCC® cook at
the same viscosity, as compared to an MCC® cook.
The successful application of EMCC® has been
confirmed in several mills (Jiang et al. 1992a;
Munro, 1991).
Screened Pulp Kappa Number
Figure 5.—Pulp viscosity versus kappa number. (Con-
ventional, MCC®, and EMCC9 pulps.)
Figure 6 shows a two-vessel hydraulic digester
equipped with EMCC®. The addition of white liq-
uor to the wash circulation can also be incor-
porated on digesters that do not have the MCC®
circulation between the wash circulation and the
extraction screens.
Currently, about 30 mills in the United States
and Canada and about 10 mills in the rest of the
world practice some form of MCC or EMCC®.
These numbers correspond to about 25 percent of
the total production of bleached chemical pulp in
the United States and Canada and about 10 percent
in the rest of the world. As new systems are sold,
and older ones are converted, these numbers in-
crease very rapidly.
For these mills, kappa targets are generally 20
to 25 on softwood and 12 to 15 on hardwood. In-
dividual conditions and product requirements in
some mills cause them to operate above or below
these ranges periodically or all the time, and equip-
ment configurations or capacity limitations some-
times make it difficult or impossible to convert to
MCC® or EMCC® using existing digester vessels.
EMCC® is also practiced in continuous sulfite
digesters in North America, but there the process is
used mainly for operational advantage as it does
not improve the kappa number-pulp viscosity
relationship (Stromberg, 1991).
56
-------
C.B. STROMBERC
WWIEUQUOR
Figure 6.—Two-vessel hydraulic digester with EMCC® and two-stage diffuser.
Low Kappa Continuous Cooking
Challenges
With the proven capability of bringing the softwood
kappa number down to the low 20s and the
hardwood kappa number to the low teens, the next
step in the process of reducing the chlorine in
bleached pulp is to find the low practical limit. This
step has focused on softwood because the environ-
mental impact is more intense for higher kappa
pulp and because there are concerns about
softwood's ability to retain its strength properties.
Pulp yield and chemical and energy requirements
are also of interest to determine capacity limitations
and operating cost.
Yield
By removing more lignin from the fibers before
bleaching, more chemicals are consumed in the
cooking or oxygen delignification processes, and
more cellulose and hemicellulose are dissolved
from the fibers.
The yield loss for the cooking accelerates
below kappa 18 for softwood, as shown in lab data
^ig. 7), and for Southern pine as indicated in mill
data (Jiang et al. 1992b; Elliott and Walley, 1991).
Figure 8 shows the impact on yield by oxygen
delignification and final bleaching of four different
EMCCr lab produced pulps from Southern pine
(Jiang et al. 1992b). The yield loss in oxygen delig-
nification accelerates when the degree of delig-
nification exceeds 50 percent. The final bleached
yield is essentially unchanged for a digester kappa
41
a
m
g
*«•
2
o
0.44
3
20 30
Screened Pulp Kappa Number
Figure 7.—Laboratory pulp yield versus kappa number.
(Conventional, MCC*. and EMCC* pulps.)
TS
8 45
f «
0.
Kappa Number
Figure 8.—Laboratory pulp yield versus kappa number.
(Combinations of EMCC* and oxygen delignification.)
57
-------
Alternative and Emerging Technologies — Pulping
above 18, as long as the oxygen delignification is
limited to a 50 percent kappa reduction. If we com-
pare the pulps cooked to kappa 12 versus kappa
18, the yield loss after bleaching corresponds to an
increase in wood consumption of about 5 percent.
Mill MCC® and EMCC® pulps have higher total
yield than lab pulps produced from the same chips
because the measured hemicellulose content is
higher in the mill pulps (Jiang et al. 1992b; Teder
and Sandstrom, 1985; Teder and Janson, 1986).
Mill MCC® and EMCC® pulps generally also have
much lower amounts of rejects compared to con-
ventional pulps produced in the same digester
(Whitleyetal. 1990). The effect of this reduction on
total pulp yield varies between different mills,
depending on how the rejects are treated. The yield
impacts of hemicellulose and rejects are the same
at kappa 12 and 18, so the difference in yield be-
tween the two kappa levels is about 2 percent on
wood.
Our laboratory data show that a softwood
kappa level of 10 after oxygen delignification can
be produced without an appreciable total yield
loss, although the load on the recovery system will
increase considerably, compared to operation at
higher kappa levels (Jiang et al. 1992b). The impact
of pulp yield will also vary considerably between
different mills because of the operating limits of
various equipment.
Processes that produce a higher pulp yield are
clearly preferred. Lab studies conducted by Kamyr,
Inc., show that polysulfide additions also increase
the pulp yield for EMCC® pulps (Jiang, 1992). The
yield improvement is up to 3 percent on wood at 3
percent polysulfide addition. Figure 9 shows the
yield data for the cooked pulps, of which two have
been conventionally bleached using a D-Eop-D-nD
sequence. The yield improvement from the
polysulfide addition is maintained after bleaching.
The data also show that the relative yield difference
between kappa 12 and kappa 18 discussed pre-
viously does not change with the polysulfide addi-
tion. Interestingly, the low kappa EMCC® pulps did
not show the typical decrease in tear-tensile
strength that normally accompanies polysulfide
treatment for conventional pulps at higher kappa
numbers (Fig. 10).
I-
8 1BO
CONV KAPPA 2S.O
EMCC KAPPA 16.7
OKPS
EUCC KAPPA 1Z5
EMCC KAPPA 17J
2%P8
EMCC KAPPA 17.0
40 46
Klppa Numliw
Figure 9.—Effect of polysulfide addition on pulp yield.
(Conventional and EMCC* pulps.)
U 9 U 10 105 11 11.5
Breaking Length (km)
Figure 10.—Effect of polysulfide on EMCC* pulp
strength. (Tear factor versus breaking length.)
One obstacle associated with polysulfide pulp-
ing is the very high sulfur to sodium ratio in the
recovery boiler that is needed to keep white liquor
sulfidity to a level that will not affect the cooking
selectivity. The recent development of the Black
Liquor Heat Treatment process could offer a solu-
tion to this problem (Ryham and Nikkanen, 1992).
This process removes about half of the sulfur in the
black liquor as a gas, which bypasses the recovery
boiler. This gas can then be converted to polysul-
fide or other useful forms. One full-scale Black Liq-
uor Heat Treatment System is in operation, and the
sulfurous gas conversion process is being
developed. Anthraquinone also has the same im-
pact on EMCC® pulp yield increases as it does on
conventional pulps (Mayovsky, 1992).
Pulp Strength
Pulp viscosity is frequently used as an indicator of
pulp strength. Most mills have a minimum accept-
able viscosity below which the pulp's physical
strength begins to deteriorate. Viscosity is a good
relative indicator of the selectivity of the lignin-
removing process, showing how well the cellulose
is preserved at a given kappa level for a specific
process. In relation to process changes associated
with MCC® and EMCC , many indications are that
the minimum acceptable viscosity level will
change to a lower number before the physical
properties deteriorate (Elliott and Wai ley, 1991). To
avoid confusion, the discussion that follows will
focus on the pulp's physical strength properties —
mainly its tear and tensile strength.
Pulp strength of lab-cooked EMCC® pulps from
Southern pine is not affected until the kappa num-
58
-------
C.B. STROMBERC
ber from the lab digester is below 18 (Jiang et al.
1992b). Figure 11 shows the tear-tensile relation-
ship for the fully bleached softwood pulps that
were used for the yield determinations in Figure 8.
The tear-tensile curves show no difference for pulps
cooked to kappa numbers above 18 and then
oxygen delignified to kappa numbers above 8. The
kappa 12 pulp that was oxygen delignified to kappa
6.5 shows about a 20 percent reduction in tear at
constant tensile, compared to the other pulps.
220
210
200
s190
IS
£ teo
*~ 170
160
EUCC KAPPA 304
O2 KAPPA 1*2
EUCC KAPPA 214
O2 KAPPA 124
EUCC KAPPA 1BLS
02 KAPPA U
EUCC KAPPA 11J
7 IS a
Breaking Length (km)
Figure 11. — Pulp strength for fully bleached
pulps. (Tear factor versus breaking length.)
To determine the impact on pulp quality and ef-
fluent characteristics of low kappa pulping, trials
lasting several days each were performed at
Longview Fibre on West Coast softwoods (Elliott
and Walley, 1991). The mill data showed no effect
on the tear-tensile strength of the unbleached
MCC® pulp down to about kappa 14, probably a
10 percent reduction in tear-tensile strength at
kappa 1 2 and a definite strength reduction at kappa
8 (Fig. 12). Bleached sack paper produced from
these same pulps showed no reduction in pulp
strength until the unbleached pulp was about
kappa 9. The mill does not normally operate at
such low kappa levels because of the effect of yield
ninuu. *ITMAL
6 I
TENSILE (km)
*1TRUU. »1 TRIAL
"4C? •2S=r
Figure 12.— Low kappa MCC* operation at Longview
Fibre. (Tear-tensile comparison of low and normal
Kappa unbleached pulp.)
loss on production capacity. Laboratory cooks on
the mill chips showed that a 12 kappa pulp had a
tear strength that was about 10 percent lower than
18 to 28 kappa pulps at constant tensile.
The differences in strength retention between
the 12 kappa pulps made from Southern pine in the
lab, West Coast softwoods in the lab, and un-
bleached and bleached West Coast softwoods in
the mill compared to the higher kappa number
pulps can have several explanations. Effects of
species, testing procedures, testing accuracy, and
lab and mill cooking and bleaching procedures are
probably the most important.
Different pulp parameters are of varying impor-
tance to the makers of the vast array of products
made from bleached pulp fibers. One set of process
parameters would not be suitable for all types of
bleached pulp from all types of wood sources. This
difference could affect the optimum operating
point for individual pulp mills.
Conclusion
In the laboratory, Southern pine can be cooked to
kappa 18 using the EMCC® procedure, oxygen
delignified to kappa 9, and bleached without total
yield loss or physical strength loss, compared to
kappa 28 pulps. Unbleached pulps of kappa 14
from West Coast softwoods have been produced in
a mill without physical strength loss compared to
kappa 28 pulps. Lower kappa pulps have been
made with some strength loss and with a yield loss
that is measurable in the mill. Capacity limitations
in a mill resulting from the yield losses associated
with pulping to lower than normal kappa numbers
can have a major economic impact on an in-
dividual mill. Lab work has been performed to
show yield improvements when polysulfide is
added, but this process has had no mill applica-
tions as yet. The yield difference between different
kappa numbers is maintained. MCC® and EMCC®
have become widely accepted procedures for pulp-
ing to low kappa numbers.
References
Anderson, R. 1992. Peroxide delignification and bleaching. In
Proc. Nonchlorine Bleaching Conf., March 2-5,1992, Hil-
ton Head, SC. Morgan Freeman, Inc. San Francisco, CA.
Elliott, R.G. and C.A. Walley. 1991. Low kappa number pulping
trials. In Proc. Int. Pulp Bleaching Conf., Stockholm,
Sweden.
Farrell, R.L. 1992. Status of enzyme bleaching R&D and mill
work. In Proc. Nonchlorine Bleaching Conf., March 2-5,
1992, Hilton Head, SC. Morgan Freeman, Inc. San Francis-
co, CA.
Jiang, J.E. 1992. EMCC* with polysulfide for simultaneous pulp
yield and strength improvements. In Proc. Tech. Ass. Pulp.
Pap. Indus. Alkaline Pulping Conf., Boston, MA.
59
-------
Alternative and Emerging Technologies — Pulping
Jiang, J.E., B.F. Greenwood, J.R. Phillips, and E.S. Becker.
1992a. Extended delignification with a prolonged mild
countercurrent cooking stage. APPITA45(1 ):19.
Jiang, J.E. et al. 1992b. Combining modified continuous cook-
ing with two-stage oxygen bleaching for optimal extended
delignification. In Proc. 4th SPCI Int. Conf., Bologna, Italy.
Johansson, B. et al. 1984. Modified continuous kraft pulping.
Svensk Papperstidning (87)10:30.
Kortelainen, V.A. and E.A. Backlund. 1985. Experience with ex-
tended delignification of hardwood and softwood kraft
pulp in a continuous digester. Tappi J. 69(11):70.
Liebergott, N., B. van Lierop, and A. Skotos. 1992. A survey of
the use of ozone in bleaching pulps. Part 1. Tappi J.
85(1):145.
Mayovsky, J. 1992. Low Kappa Kraft, Kraft SAQ, Polysulfide and
Polysulfide-SAQ Pulping, and Physical Properties Com-
parison. M.S. Thesis. Univ. Washington, Seattle.
Munk, N. 1992. Bleach boosting of eucalyptus kraft pulp. In
Proc. Nonchlorine Bleaching Conf., March 2-5,1992, Hil-
ton Head, SC. Morgan Freeman, Inc. San Francisco, CA.
Munro, F.C. 1991. Wash zone modified continuous cooking:
mill experience on softwood. In Proc. Pacific Paper Expo,
December 1991, Vancouver, B.C., Can.
Ryham, R. and S. Nikkanen. 1992. Liquor heat treatment and its
impact on chemical recovery. In Proc. 4th SPCI Int. Conf.,
Bologna, Italy.
Senior, D.J., J. Hamilton, R.L. Bernier, and J.R. DuManoir. 1992.
Reduction in chlorine use during bleaching of kraft pulp
following xylanase treatment. In Proc. Nonchlorine
Bleaching Conf., March 2-5,1992, Hilton Head, SC. Mor-
gan Freeman, Inc. San Francisco, CA.
Senior, D.J. and J. Hamilton. 1992. Use of xylanases for the
reduction of AOX in kraft pulp bleaching. In Proc. Non-
chlorine Bleaching Conf., March 2-5, 1992, Hilton Head,
SC. Morgan Freeman, Inc. San Francisco, CA.
Stromberg, C.B. 1991. Sulfite Modified Continuous Digesting.
South African Patent No. 90/9259.
Teder, A. and J. Janson. 1986. A contribution to the determina-
tion of pulp yield by chemical analysis. Nordic Pulp Paper
Res. J. 1:43.
Teder, A. and P. Sandstrom. 1985. Pulp yield in continuous kraft
pulping with a modified alkali profile. Tappi J. 68(1): 94.
Whitley, D.L., J.R. Zierdt, and D.J. Lebel. 1990. Mill experience
with conversion of a Kamyr digester to modified con-
tinuous cooking. Tappi J. 73(11:103.
60
-------
The Development of Chlorine-free
Manufacturing of Bleached Kraft Pulp
Kari Kovasin
Sunds Defibrator Pori OY
Pori, Finland
Lars-Ake Lindstrom and Lars Sjodin
Sunds Defibrator Industries AB
Sundsvall, Sweden
With collaborators MoDo and CIL, Sunds
Defibrator Industries pioneered the devel-
opment of oxygen delignification technol-
ogy in the late 1960s and early 1970s. Our basic
approach was to look for processes that increased
delignification and increased recycling of dissolved
lignin (Annergren and Nasman, 1980; Lindstrom et
al. 1987; Nord£n and Simonson, 1984; Hartler et
al. 1983; Nasman and Sjodin, 1984).
Simultaneously, the pulp industry and research
institutions began studying bleach plant effluents,
with particular interest in their chemical composi-
tion and impact on receiving waters. Some effluent
effects can be characterized as short-term and
others as long-term. Short-term or acute effects are
related to the presence of easily biodegradable
material, often represented by the biological
oxygen demand (BOD) value of the effluent. BOD
causes oxygen starvation in the receiving water and
can be acutely toxic, but it can also be handled in
secondary treatment systems.
Long-term effects are not easily handled in
secondary treatment systems because of the persist-
ent character of some effluent components. Highly
chlorinated low molecular mass organic material,
caused by chlorine chemicals in bleaching is not
very biodegradable and interferes with natural
aquatic life processes.
The effluent's dark color, which decreases light
penetration in the receiving water, is not affected by
secondary treatment. These findings convinced us
to develop processes that increase delignification,
allow recycling of dissolved organic material, and
minimize the use of chlorine chemicals.
The following technologies will offer these
benefits:
• Oxygen delignification — More than 50 per-
cent of kraft pulp production is processed in
oxygen delignification stages, thereby de-
creasing the chemical oxygen demand
(COD) in the effluent as much as 50 percent
(Carre etal. 1986; Lindstrom, 1991).
• SuperBatch™ cooking — A recent develop-
ment by Sunds Defibrator that decreases the
lignin content of pulp significantly compared
to conventional cooking. Mill scale trials
have demonstrated that a lignin content cor-
responding to kappa numbers ranging from
10 to 12 can be reached via SuperBatch™
cooking as compared to about 30 for con-
ventional cooking (Kovasin and Tikka, 1992;
Hiljanen and Perala, in press).
• CFree™ — A novel technology by Union
Camp Corporation that applies ozone at high
pulp consistency to produce pulps with very
low lignin contents (Nutt, in press).
• Hydrogen peroxide bleaching of kraft pulp
— A process pioneered by EKA Nobel that in
combination with CFree™ produces fully
bleached pulps without the use of chlorine
chemicals (Andersson et al. 1992; Igerud and
Basta, 1992).
The Conventional Kraft Fiber Line
A kraft pulp mill's target product is a bright pulp,
suitable as raw material for manufacturing white
papers and sanitary products among others. To
61
-------
Alternative and Emerging Technologies — Pulping
achieve maximum brightness, lignin is removed
from the wood in the cooking and bleaching
processes. But the cooking process removes part of
the hemicelluJose arid cellulose-content of the
wood and partly depolymerizes the remaining
pulp. As this effect also occurs in the bleaching
processes, the production of bleached kraft pulp
has to be performed in several delignification and
bleaching stages.
Economical pulp production requires that the
cooking chemicals be recovered from the spent
cooking liquor and recycled. A simplified repre-
sentation of a bleached kraft pulp mill is outlined in
Figure 1. Roughly 50 percent of the wood is dis-
solved in the cooking process. The dissolved wood
substance and spent cooking chemicals are
removed from the pulp in subsequent washing
stages.
Wood
Chips
Recovery
t Air emission
I
M J T
Pulp
Water emission
Figure 1.—Conventional kraft fiber line.
The black liquor obtained in this operation is
concentrated and burned in a recovery boiler,
generating heat and inorganic chemicals for further
conversion to fresh cooking chemicals.
The final brightening of the pulp is performed
in the bleach plant. Elemental chlorine (Cb) and
chlorine dioxide (CIO2) are the main chemicals
used. It has not been possible to recycle and
recover the bleach plant effluents to any significant
degree because of the chlorides in these liquors. If
these liquors were recycled with the black liquor,
severe corrosion would occur, especially in the
recovery boiler. In addition to the material dis-
solved in the bleaching process, the mill bleach ef-
fluent contains dissolved material from the incom-
plete washing of pulp prior to bleaching.
Oxygen Delignification
Oxygen delignification has been around for more
than 20 years. The chemicals used in this process
are oxygen, (02) and sodium hydroxide (NaOH),
which are compatible with recycling. Thus, dis-
solved lignin can be recovered together with black
liquor (see Fig. 2). A lower lignin content of pulp is
thereby obtained (see Fig. 3), and less wood sub-
stance is dissolved in the bleaching process,
decreasing the discharge of organic material by
roughly 50 percent, analyzed as COD.
Wood
Chips
t
> f
overy -
Coofctftg W 0
'
'
_J Air emission
4 J~~
W<0«»
1
1
-------
K. KOVASIN, L-A. LINDSTROM, & L SjODIN
quiring about twice the retention time of the high
consistency system. The simplicity of the medium
consistency system — which doesn't have to con-
trol the carbon monoxide (CO) concentration in the
gas phase — is attractive to the industry.
SuperBatch™ Cooking
The batch kraft cooking process remained virtually
unchanged for about 100 years, until the 1950s,
when continuous cooking technology gained ac-
ceptance. In the 1970s and 1980s, the technology
advanced by stages, starting with a displacement
and cold blow cooking technology at the ASSI
Karlsborg kraft pulp mill, in Sweden. Those changes
were the basis for the SuperBatch™ cooking
process.
Figure 4 is a simplified flowsheet of the cooking
sequence. Conventional cooking has different ini-
tial procedures, and the final displacement and
handling of the spent cooking liquor is also dif-
ferent. The SuperBatch™ technique has led to an
unmatched improvement in the impregnation of
wood with cooking chemicals.
% on wood
Digesters Blowtank
Cooking sequence
Chip filling
Warm black liquor impregnation
Hot black liquor treatment
Cooking liquor charge
Heating
Cooking
Displacement
Digester discharge
Figure 4.—SuperBatch™ cooking sequence.
By using the SuperBatch™ method, a more
homogeneous and selective delignification is pos-
sible. This process results in lower kappa number
variation and increased yield at a given final kappa
number. Strength properties are also improved sig-
nificantly. These benefits make it possible to extend
delignifications beyond the normal practice in kraft
cooking.
Figure 5 shows the effects on lignin content
when conventional cooking is replaced by Super-
Batch™ cooking or a combination of SuperBatch™
and oxygen delignification. Environmental benefits
are shown in Figure 6. The combination of Super-
Batch™ and oxygen delignification has the poten-
tial of decreasing the amount of organic material
dissolved in bleaching by as much as 80 percent.
CFree™
Ozone delignification has been investigated in
laboratory and pilot plant scale for years without
commercial success. After 10 years of extensive re-
100
so
60
40
20
EJCellulose + Hemi E3 Lignin
Kappa No
Softwood Conv Cooking SuperBatch SuperBatch + O2
Figure 5.—Chemical composition.
COD, kg/odt unbl
80% reduction!
Conv Cooking SuperBatch SuperBatch + O2
Figure 6.—Impact of SuperBatch™ and oxygen delig-
nification on effluent-COD from bleaching of softwood
kraft pulps.
search, however, Union Camp Corporation has
recently experienced a technological break-
through. This success resulted in the first commer-
cial installation of a 900 tons per day system at
Union Camp's Franklin Mill. Sunds Defibrator sup-
plied the system, known as CFree™. This process
will result in a dramatic 90 percent decrease of ef-
fluent-COD.
The CFree™ process operates at atmospheric
pressure and at high pulp consistency (see Fig. 7),
which requires dewatering to the desired consisten-
cy in a twin roll press. Oxygen, used as a carrier gas
for the ozone, is recycled to the ozone generation
plant. An ozone stage can be installed to further
decrease the lignin content of pulp prior to bleach-
ing. Pulp with a very low lignin content can be
achieved when SuperBatch™ cooking is combined
with oxygen delignification.
Peroxide Bleaching
In 1989, EKA Nobel developed and introduced
hydrogen peroxide (H2O2) bleaching, now known
as LIGNOX™ bleaching, or oxygen delignified
softwood kraft pulps aiming at brightness levels of
70 to 75 percent ISO. The pulp's end use has main-
ly been for reinforcement of newsprint, super
calendered (SO, and lightweight coated (LWC)
grades of paper. To qualify for woodfree printing
and writing papers and high quality tissue, bright-
63
-------
Alternative and Emerging Technologies — Pulping
CFree reactor
02
O3 generation
Figure 7.—CFree™ delignification system.
ness levels of 85 percent ISO have to be matched.
But, EKA Nobel has demonstrated the potential of
completely replacing chlorine chemicals in the
bleaching of kraft pulps. Their work spurred inten-
sive research efforts all over the world to further
develop this technology.
The basic LIGNOX™ technology has a chelat-
ing stage prior to bleaching at medium pulp consis-
tency with peroxide (see Fig. 8). The chelating stage
and the subsequent washing of the pulp are of key
importance in removing transition metals detrimen-
tal to the bleaching process. The LIGNOX™ tech-
nology can often be used in existing bleach plants
with only minor modifications.
Chelating stage Peroxide stage
Figure 8.—Peroxide bleaching system — medium con-
sistency.
In new installations, bleaching at high consis-
tency should be considered, to improve the ef-
ficiency of peroxide bleaching. High consistency
peroxide bleaching is a standard technology for
bleaching mechanical pulps. It has not proved pos-
sible to recycle the spent liquors from these stages.
One reason is the buildup of transition metals that
occurs in the chelating stage. These metals can be
carried into the peroxide stage and ruin its bleach-
ing efficiency.
Today's challenge is to combine extended
delignification in cooking and oxygen and ozone
delignification with a final hydrogen peroxide
bleaching. The result would be fully bleached
softwood kraft pulps produced without the use of
chlorine chemicals — a product already confirmed
in laboratory delignification and bleaching of mill-
produced SuperBatch™ softwood kraft pulp (see
Fig. 9). In Figure 9, the bottom x-axis refers to
sodium hydroxide (NaOH) in the oxygen stage, the
middle and top x-axis refer to ozone and peroxide,
respectively.
Brightness, % ISO
"0 10 20 30 40 50
Chemical consumption, kg/odt unbl
Figure 9.—Total chlorine-free bleaching of SuperBatch™
kraft pulp, Kappa 10.5.
By the end of 1992, all of these technologies
will be up and running, but not yet combined into
one kraft pulp mill system. What they can achieve
in combination is previewed by two Swedish kraft
pulp mills, currently operating with cooking sys-
tems similar to SuperBatch™ followed by oxygen
delignification. These mills have reached final
kappa numbers as low as 10. Extended mill runs
applying the LIGNOX™ technology have also
achieved brightness levels exceeding 80 percent
ISO.
Concluding Remarks
The environmental benefits of the developments
described in this paper are related to increased
delignification and recycling of spent liquors. Thus,
the resulting pulps will show lower kappa numbers
compared with conventionally produced pulp. As
the kappa number is decreased, a lower amount of
organic material is dissolved in bleaching. A lower
kappa number also makes it possible to decrease
and eventually eliminate the use of chlorine chemi-
cals in bleaching. The importance of reaching the
low kappa numbers in the prevention of pollution
is evident. All effluent parameters — chemical
oxygen demand, biological oxygen demand, color
and adsorbable organic halogens are decreased as
64
-------
K. KOVASIN, L-A. LINDSJROM, & L. SjODIN
the kappa number decreases. However, in the case
of the adsorbable organic halogens, the kappa
number is less important than the reduction of
elemental chlorine in the various stages of the
process (Lindstrom, 1991).
The ultimate goal is to achieve total closure of
the pulping and bleaching system.
References
Andersson, L., J. Basta, and W. Hermannsson. 1992. Lignox™
and complementary combinations. Pres. Nonchlorine
Bleaching Conf. March 2-5, 1992. Hilton Head, SC. Tech.
Ass. Pulp. Pap. Indus. Atlanta, GA.
Annergren, G. and I.E. Nasman. 1980. Medium-consistency
oxygen bleaching — an alternative to the high consistency
process. Tappi J. 68(4):105.
Carre, G., L-A. Lindstrom, K. Takahashi, and H. Yamada. 1986.
Operating experience from medium-consistency oxygen
delignification at Oji Paper, Ebetsu mill. Page 43 in Proc.
Pulping Conf., October 26-30, 1986, Toronto, Onl. Can.
Tech. Ass. Pulp Pap. Indus. Atlanta, GA.
Hauler, N., J. Mjoberg, K. Sjoblom, and L. Sjodin. 1983. New
technique for pulping to low kappa numbers in batch
cooking: results of mill trials. Page 107 in Environ. Conf.,
March 2-4,1983. Tech. Ass. Pulp Pap. Indus. Atlanta, GA.
Hiljanen, S. and J. Perala. In press. SuperBatch™: mature and
field tested cooking concept — practical considerations
and mill scale results of system performance. In Proc.
Pulping Conf., November 2-5, 1992, Boston, MA. Tech.
Ass. Pulp Pap. Indus. Atlanta, GA.
Igerud, L. and J. Basta. 1992. Development of the Lignox™
process. Pres. European Pulp and Paper Week, May 19-22,
1992. Bologna, Italy.
Kovasin, K.K. and P.O. Tikka. 1992. SuperBatch™ cooking
results in super low kappa numbers. Pres. European Pulp
and Paper Week, May 19-22,1992. Bologna, Italy.
Lindstrom, L-A., A. Marklund, and O. Simonson. 1987. The
Prenox® process — experiences from a pilot plant installa-
tion. Tappi J. 70(8):73.
Lindslrom, L-A. 1991. Bleach Plant Operations Short Course.
Page 95. Tech. Ass. Pulp Pap. Indus. TAPPI Press Publica-
tions. Atlanta, GA.
Nasman, L.E. and L. Sjodin. 1984. A new low energy batch
cooking system. Page 112m Proc. SPCI, World Pulp Pap.
Week, April 10-13,1984. Stockholm, Sweden.
Norden, S. and O. Simonson. 1984. Ozone bleaching for sulfite
pulp — a pilot plant study. Page 112 in Proc. SPCI, World
Pulp Pap. Week, April 10-13. Stockholm, Sweden.
Nutt, W.E. In press. Development of an ozone bleaching
process. Int. Pulp Bleaching Conf., November 1-5, 1992,
Boston, MA. Tech. Ass. Pulp Pap. Indus. Atlanta, GA.
65
-------
Recovery Boiler Capability
to Accommodate Alternative
Kraft Mill Processes
John L. Clement
Manager, Pulp and Paper Industry Marketing
The Babcock & Wilcox Company
Barberton, Ohio
The Technical Association of the Pulp and
Paper Industry (TAPPI) sponsored a Paper In-
dustry Research Needs workshop at the State
University of New York, College of Environmental
Science and Forestry in Syracuse, New York, May
26-28, 1992. The Pulping and Bleaching Processes
Panel identified the major need in kraft black liquor
recovery, namely, an affordable, incremental,
chemical recovery capacity increase to remove the
bottleneck in the recovery boiler operation. This
paper will explore kraft mill process factors that
cause a pulp producer to require more capacity.
Approaches to removing the bottleneck and
providing increased black liquor processing
capability include retrofitting the existing recovery
boiler to increase its capacity. Retrofit case histories
were selected from an extensive list of retrofit ex-
perience to represent a spectrum of possible ap-
proaches.
Kraft Process and the
Recovery Boiler
The kraft process diagram (Fig. 1) shows the typical
relationship of the recovery boiler to the overall
pulp mill operation. The primary function of a
recovery boiler is to combust the black liquor
produced in the pulping operation for the purpose
of recovering the .inorganic chemicals in the
reduced form required for recycling to the digester.
The heat content of the black liquor is recovered as
steam for process heat and cogeneration electrical
production. Electrical production is a secondary
function, but an important economic considera-
tion.
The kraft process starts with feeding wood
chips to the digester. Chips are cooked under pres-
sure in a steam heated aqueous solution of sodium
hydroxide (NaOH) and sodium sulfide (Na2S)
known as white liquor, or cooking liquor. Cooking
can take place in continuous or batch digesters.
After cooking, pulp is separated from the residual
liquor in a process known as brown stock washing.
The most common method in use features a
countercurrent series of vacuum drum washers to
displace the liquor with minimum dilution.
Modern continuous digester installations incor-
porate a brown stock washing stage in the lower
part of the digester body. Following washing, the
pulp is screened and cleaned to remove knots and
shives and to produce pulp for use in the final pulp
and paper products. Currently, industry is focused
on maximizing washing efficiency to recover
chemicals, thereby reducing the chemical demand
in the bleach plant.
The black liquor rinsed from the pulp in the
washers is an aqueous solution containing wood
lignins, organic material, and inorganic com-
pounds oxidized during the cooking process. Typi-
cally, the combined organic and inorganic
compounds are present at a 13 to 17 percent con-
centration of solids in weak black liquor. The kraft
cycle processes this black liquor through a series of
operations, including evaporation, combustion of
organic materials, reduction of the spent inorganic
compounds, and reconstitution of the white liquor.
The recovery boiler furnace (Fig. 2) was
developed to combust the black liquor organic
material while reducing the oxidized inorganic
material in a pile, or bed, on the furnace floor. The
66
-------
J.L. CLEMENT
n Chips
Clean
Conden
Digester
*
Blow
Tank
it
Washers
^
Weak
Liquor
sate i
Multiple
Evapc
»..
Pulp
— Byproduct ,
* Acid
r
Black
Storage
-
Effect
jrator
/T1
Heavy Black
Liquor Storage
1
White Liquor
Storage
Bleached
Pulp
it
Is Bl^ch
t CIO,
v Chlorine Dioxide
Manufacture
t
NaCIO,
L^ Contaminated
Condensate Strippe
t
k Recovery
w Boiler
r
Gr
i
t
->
Sn
its
r
L
ielt „
White Liquor
Clarifier
j
i
Causticizers
t
Slaker
i
/
Lime
Mud
Lime
i
Noncondensible
v Gases »_
1 Water
Lime Mud
Washer
i
~l
Weak Water
, Storage
Lime Mud
Filter
i
Lime
r
Kiln
Incinerator
<^r SO, Gases
Green Liquor
Storage
t
Green Liquor
Clarifier
t
Dissolving
Tank
^
SO2
Scrubber
^— Water
Dr<
Wa
sher
Dregs
—1
1 w
Weak
Stor
Wash
age
Figure 1.—Kraft process diagram.
molten inorganic chemicals, or smelt, are dis-
charged to a tank in which they are dissolved to
form green liquor. The active chemicals in green
liquor are sodium carbonate (Na2COs) and Na2$.
Green liquor is clarified to remove insoluble
material, then reacted with lime (CaO) in a caus-
ticizing plant to convert Na2COs to active NaOH
in the product white liquor.
Energy is released as the black liquor organic
compounds are combusted, paralleling the reduc-
tion of sulfur compounds to form smelt in the
recovery furnace. This combustion energy
produces steam, which can be introduced to a tur-
bine generator to supply a large portion of the ener-
gy demand of the pulp and paper mill. Steam
extracted from the turbine at low pressure is reused
in the process for cooking wood chips, evapora-
tion, recovery furnace air heating, and drying the
pulp or paper products.
Impact of Alternative
Manufacturing Processes
Alternative kraft mill processes are increasing the
quantity of organic and inorganic material in the
black liquor that must be processed in the recovery
boiler. Therefore, additional incremental capacity
is required to recover the inorganic chemicals. In
many mills, this capability is limited by the installed
equipment.
Values for the increased capacity requirements
are quoted from a 1992 report prepared for the On-
tario Ministry of the Environment, which describes
the impact on the recovery boiler throughput of al-
ternative kraft mill processes (N. McCubbin Con-
sultants, 1992). Several processes have been
developed to extend delignification of the kraft
pulps beyond the conventional levels. This exten-
sion is environmentally desirable in circumstances
in which the pulp will be bleached in subsequent
processes. "Extended delignification" is also known
as "extended cooking." Delignification by oxygen,
extended cooking, and improved brown stock
washing and screening can produce up to 12 per-
cent additional black liquor solids in a mill that has
relatively high losses of black liquor solids in the
sewer. In mills that already have good washing,
defined as sodium losses under 10 kg of sodium
sulfate (Na2SO4) per ton of pulp, the additional
recovery load would be about 6 percent.
If the alternative processes are considered inde-
pendently, oxygen delignification increases the
solid flow to the recovery boiler about 4.4 percent,
which represents a 3.3 percent increase in heat
input. Applying extended cooking would increase
the solids to the recovery boiler approximately 3
percent when the bleached yield of pulp from
wood is maintained. The alternative of combining
both oxygen delignification and digester-extended
delignification, as well as efficient washing, could
result in a drop in the yield of bleached pulp from
wood, with corresponding increases in wood con-
sumption and steam production. The combined
changes to a mill operating with high losses could
67
-------
Alternative and Emerging Technologies — Pulping
Figure 2.—Typical modern recovery boiler.
result in a 15 percent increase in solids to the
recovery boiler and a 16 percent increase in heat
input.
Chlorine dioxide (CIO2) is used increasingly to
replace the traditional chlorine in the first stage of
the bleach plant. ClOa substitution is a simple ap-
proach to reducing organochlorines discharged
from the mill. CIO2 is always manufactured on the
kraft mill's site since it is impractical to transport
significant quantities. The CIO2 plant is linked with
the recovery process since the manufacturing
process produces significant quantities of sodium-
based by-product acid. It is general practice to
blend the effluent acid from the CIO2 generator into
weak black liquor at a rate equivalent to the total
sodium losses in the mill. In a modern mill with low
sodium losses and practicing 100 percent substitu-
tion to produce a molecular chlorine free pulp,
only about 25 percent of the by-product acid can
be used. The excess must be neutralized before
being discharged to the sewer; this effect is general-
ly accomplished with lime.
Recovery Boiler Capacity
There are several ways to increase the recovery
boiler capacity by 6 to 15 percent generally re-
quired by the combined application of oxygen
delignification, extended cooking, efficient wash-
ing, and similar processes. Incremental capacity in-
creases can also be measured in several ways. It
can be an increase in the time between shutdowns
to waterwash the recovery boiler, or, the capability
to burn more black liquor without increasing the
time (run campaign) between outages.
68
-------
J.L. CLEMENT
The most significant limiting factor to increased
recovery capacity is ash buildup on the boiler heat
transfer surfaces (Fig. 3). Low melting point, inor-
ganic ash compounds formed in combustion of
black liquor are borne upward by the gases in the
furnace and stick to the surface of the tubes. As the
black liquor throughput is increased, the increased
temperature and velocity of the combustion gases
increase the propensity of ash to stick and block the
gas passages. Ash is cleaned from tube surfaces
using jets of steam introduced through sootblowers.
Even with sootblowers in constant use to clean
surfaces, the operator has no alternative but to shut
down the boiler periodically and waterwash the
tube surfaces. To accomplish this, the smelt bed
Figure 3.—Recovery boiler ash deposits.
must be totally removed and the boiler cooled.
Total smelt bed removal precludes a possibility of
water contacting molten chemical in the bed and
producing a smelt water reaction. Interruption in
operation for one to two days for waterwash ing
represents a potential loss in pulp production, or al-
ternatively, continuing pulp mill production by
shipping black liquor to an alternate mill site for
burning, and purchasing the lost electrical genera-
tion from the utility. Downtime is an expensive
proposition!
Therefore, the operator requiring additional
capacity to process black liquor solids has two
basic approaches to consider. The first is to add an
additional recovery equipment line to process the
solids. Alternatives to adding
more lines are the focus of
development projects. One al-
ternative, a black liquor gasifica-
tion unit installed at Frovifors in
Sweden, is reported to have
operated commercially for half a
year (Bostrom and Hillstrom,
1992). The purpose of the instal-
lation was to increase the
recovery boiler capacity by 75
to 100 tons of dry solids per day,
corresponding approximately to
an 8 to 10 percent increase in
the capacity of the existing
recovery boiler.
Another solution to adding
more lines is being developed
by MTCI and ThermoChem and
is based on pulse-assisted fluid
bed gasification technology for
indirect gasification of black liq-
uor (Mansour et al. 1992). A
design is reported to be under
way of a 72 to 100 wet ton per
day gasifier for demonstration
testing at a southeastern mill. An
incremental increase in capacity
can be accomplished with a
more traditional approach to
combustion of black liquor by
installing a modular unit similar
to that installed at Millar
Western Pulp Company in
Meadow Lake, Saskatchewan
(see Fig. 4). The boiler is
designed to process 225 tons
per day (or 496,000 Ib per day)
of dry solids.
The second way to achieve
the required increase in black
liquor throughput is the retrofit-
69
-------
Alternative and Emerging Technologies — Pulping
ting of a mill's existing recovery boiler. It is general-
ly possible to retrofit a recovery boiler to increase
capacity; however, in some mills, the boiler is al-
ready operating at its limit.
Retrofit Case Histories
An innovative project to increase recovery boiler
capacity was completed in 1991 by Georgia-
Attemperator
Steam
Drum
Superheater
Downcomer Forced
Draft
Generating
Surface
Secondary
Air Duct
Steam Coil
Air Heater
Composite
Tertiary
?:Air Duct
Tube Line
Soda
Liquor
Burners
a. a_ a_
"I ITf
Guillotine
Damper
-Drain 14
Valves
D Economizer
Gas Burners
and
Secondary
Air Ports
Precipitator
Bypass c
8 0'««***.*
Port Rodder
Smelt
Dissolving
Figure 4.—Effluent recovery boiler.
70
-------
j.L CLEMENT
Pacific at their Cedar Springs, Georgia, mill
(Pedroso and Edwards, 1991). Two 1960-vintage
recovery boilers were replaced with one drum
modern boilers using the existing space, steel, and
foundations to the maximum extent. The new
boiler configuration provided a 22 percent increase
in capacity. Elimination of the direct contact, black
liquor evaporator accomplished a reduction in total
reduced sulfur (TRS) emissions. Using a thoroughly
planned construction approach, a 75-day outage
(black liquor out to liquor in) was achieved for Unit
1, and 65 days for Unit 2. Figure 5 shows the boiler
and equipment configuration before and after the
upgrade.
After Modification
Figure 5.—Georgia-Pacific.
An incremental capacity increase can be
achieved with a more modest approach to a retrofit
program. Capacity improvements are presented as
black liquor solids rate, but, it should be under-
stood that recovery capacity is rated in heat input.
Some of the increases in black liquor solids
throughput may be the result of operating at a
lower heat value than was used in the original
design. Nevertheless, they are indicative of the in-
cremental increases that can be achieved through
various programs.
Case History No. 1
The capacity of the recovery boiler at Stone Con-
tainer Corporation in Florence, South Carolina, was
limited by buildup of ash deposits in the
economizer. Frequent outages were required to
waterwash the economizer. The operator acquired
an increase of 10 percent in liquor solids capacity
and conversion of the recovery unit to low odor by
eliminating the direct contact evaporator. Babcock
and Wilcox provided engineering, material and
construction to modify the boiler to achieve the in-
crease in solids throughput. Modernization in-
cluded
• a state-of-the-art, three-level air system;
• modified liquor firing system;
• additional superheater surface to maintain
the temperature of steam; and
• an extension of the building to accommodate
the new long flow economizer.
For maintenance purposes, the lower furnace and
boiler bank were replaced. The lower furnace was
replaced with modern composite tube construction
and the boiler bank was retubed. In addition, the
larger superheater required a new screen. The con-
figuration before and after modifications is shown
in Figure 6. The boiler was started in 1991, and the
retrofit proved successful.
Case History No. 2
Potlatch Corporation in McGehee, Arkansas, ob-
tained a 63 percent increase in solids processing
capability when Babcock & Wilcox enlarged the
furnace and added a new three-level air system as
shown in Figure 7. The furnace depth was in-
creased five feet for the entire height of the furnace.
The increase in furnace size resulted in a solids in-
crease from 680 tons per day (1.5 million Ib per
day) to 1,111 tons per day (2.45 million Ib per day).
Steam flow increased correspondingly by 54 per-
cent. The steam flow increase resulted in part from
the customer's decision not to modify the super-
heater surface, offset by a lower than rated solids
heating value. The unit operates at a lower steam
temperature, decreased from the initial design
temperature of 440°C (825T) to 392°C (737°F). The
capacity increase was completed in early 1992.
71
-------
Alternative and Emerging Technologies — Pulping
Before Modification
Figure 6.—Stone container.
After Modification
Case History No. 3
Gaylord Container Corporation at Bogalusa,
Louisiana, wanted to increase the time between
six-week waterwash intervals on an overloaded
recovery boiler while also reducing the TRS emis-
sions from the stack. The boiler, rated at 1,043 tons
per day (2.3 million Ib per day) of black liquor
solids, was operating at 1,270 tons per day (2.8 mil-
lion Ib per day). Final air flow modifications com-
pleted in June 1988 resulted in reduced TRS
emissions coinciding with extending the interval
for waterwashing to beyond six weeks. The final air
system modification introduced secondary air from
furnace sidewalls only and tertiary air from the
front and rear walls. Babcock and Wilcox's port
design for interlaced air jets was maintained at both
levels.
The success of this project encouraged addi-
tional modifications to achieve a significant over-
load at 1,451 tons per day (3.2 million Ib per day)
of solids. The upgrade involved changing the su-
perheater and removing every other row of generat-
ing bank tubes (see Fig. 8). The unit proved capable
of operating at a significant overload of 28 percent
over the original heat input rate for six months be-
tween waterwash ings.
Case History No. 4
The retrofitting of the boiler at James River's St.
Francisville, Louisiana, mill was driven by the State
of Louisiana's requirement to bring boiler operation
into compliance with emission standards, neces-
sitating a conversion to a low odor arrangement.
James River also required an additional 23 percent
72
-------
J.L CLEMENT
New
Furnace
Panel
Front Wall
After
Modification
n
- Front Wall
Before
Modification
New
Composite
Lower
Furnace
Before Modification
Figure 7.—Potlatch.
solids processing capacity. The unit was originally
designed to process solids at a rate of 816 tons per
day (1.8 million Ib per day) and routinely operated
at 998 tons per day (2.2 million Ib per day). To
achieve 1,224 tons per day (2.7 million Ib per day)
of dry solids processing capability, the furnace vol-
ume was increased to that required to process the
desired solids by adding seven feet to the furnace
depth and nine feet to the height (Fig. 9). A new
combustion air system with interlaced tertiary air
After Modification
ports supplied with high static ambient air and in-
terlaced secondary air ports was also incorporated.
Other modifications included a new superheater to
restore the original steam temperature; additional
black liquor burners for operating flexibility; and
additional sootblowers arranged to efficiently
remove ash deposits from the heat transfer surfaces.
The odor compliance was achieved by replacing
the direct contact evaporator with a long flow
economizer to cool the gases prior to discharge.
73
-------
Alternative and Emerging Technologies — Pulping
Two years of planning went into the capacity
increase and low odor conversion. A team effort by
James River with Babcock & Wilcox resulted in a
fully integrated project program with detailed en-
gineering governed by feasibility of construction.
The intensive effort resulted in the entire project
being completed in a 49-day outage, seven days
ahead of the forecasted downtime, and within
budget. The retrofit relieved a significant capacity
bottleneck while satisfying emission requirements.
Conclusion
Alternative kraft mill processes are incrementally
increasing the quantity of black liquor solids that
must be processed in the recovery boiler. Although
New
Attemperator
Piping
New Pri. SH
Inlet Header
New Pri. SH
Outlet Header
\
New Screen
Outlet Header
New Roof
Insert Tubes
Mew S.H.
Section
New Boiler Bank
Screen Tubes
Removed & Plugged
Every Other Row
1st Bank Gen. Tubes
New Sidewall
Panel Insert
New Arch
Insert
Tubes
New Screen
Inlet Header
Supply Tubes
New Casing
New 21/2" Screen
Inlet Header-
Drain Line
New Screen
Inlet Header
Figure 8.—Gaylord convection surface modifications.
74
-------
J.L CLEMENT
H—26'6"-
Before Modification
Figure 9.—James River.
After Modification
a number of approaches to increasing a mill's black
liquor processing capability exist, no one solution
fits every situation and each must be studied to as-
certain the most economical approach. The new
technologies should be investigated as an alterna-
tive to processing the increased solids in the exist-
ing recovery boiler or boilers. While the retrofitting
of an existing recovery boiler is an attractive option,
feasibility and cost need to be determined. In many
cases, the retrofitting of a recovery boiler can
achieve a capacity increase exceeding the require-
ments imposed by alternative processes.
References
Bostrom, G. and R. Hillstrom. 1992. Status report from the
Chemrec recovery booster at Frovifors. Page 451 in Proc.
1992 Int. Chem. Recovery Conf. Can. Pulp. Pap. Ass. Tech.
Ass. Pulp. Pap. Indus. Press. Seattle, WA.
Mansour, M.N., K. Dural-Swamy, W.G. Steedman, and R.E.
Kazares. 1992. Chemical and energy recovery from black
liquor by steam reforming. Page 473 in Proc. 1992 Int.
Chem. Recovery Conf. Can. Pulp. Pap. Ass. Tech. Ass.
Pulp. Pap. Indus. Press. Seattle, WA.
N. McCubbin Consultants, Inc. 1992. Best Available Technol-
ogy for the Ontario Pulp and Paper Industry. Rep. PIBS
1847. Ontario Ministry Environ., Water Resour. Branch.
Toronto, Canada.
Pedroso, P.P. and E.I. Edwards. 1991. Replacing 1960 vintage
recovery boilers on an accelerated construction schedule
at Cedar Springs, Georgia. Page 55 in Proc. 1991 Eng.
Conf. Tech. Ass. Pulp. Pap. Indus. Press. Nashville, TN.
75
-------
Alternative and Emerging
Nonkraft Pulping Technologies
Bruce I. Fleming
Senior Research Advisor
Boise Cascade
Portland, Oregon
nvented more than 100 years ago, kraft pulping
has gradually achieved dominance in the pulp
and paper industry as a result of continued
refinements. Since 1950, many processes have
been proposed to replace kraft pulping, but few
have received even a single mill trial, and even so,
it is a big step from a laboratory demonstration to
commercial reality. Most competing processes
have failed to do sufficiently well in pilot trials to
convince investors to go ahead at full scale. Their
failure does not mean that the kraft process will al-
ways be dominant, but it indicates the extreme ef-
fort and cost that is involved in commercializing
any alternative to this established and versatile
pulping technique. New refinements to the kraft
process, such as extended delignification, made it
even more attractive.
This brief review covers the main competitors
to the kraft process for the production of chemical
pulp — the sulfite processes, soda-anthraquinone
(AQ) pulping, and the solvent pulping processes.
The processes selected for discussion are commer-
cially proven, or at least have had extensive plant
trials.
Sulfite Processes
The sulfite processes provide pulps that have in-
ferior strength properties to those of kraft pulp but
which nonetheless are enjoying some success in
the European marketplace because, unlike kraft
pulp, they respond well to bleaching with
hydrogen peroxide. Totally chlorine-free (TCP)
softwood sulfite pulps having an 80 percent ISO
brightness are easily obtainable, and 86 percent
brightness aspen pulps can be produced by
bleached chemithermomechanical pulp (BCTMP)
mills.
Low Yield Sulfite Pulping
No modifications to the pulping process have been
required for the production of TCP pulps in sulfite
mills — it was sufficient only to switch the bleach
plant to peroxide bleaching. Often a single
peroxide stage is sufficient to produce the required
brightness. A significant market for this kind of pulp
exists in Europe; it is currently supplying all the
primary fiber used by the German tissue industry,
according to an article in a May issue of Pulp and
Paper Industry This Week (1992). However, the
TCP pulp market was not strong enough to keep
alive one Canadian mill (Fraser Co., Atholville,
New Brunswick) that was capable of producing
120,000 tons per year of peroxide-bleached sulfite
pulp until it closed in 1991. Many papermakers
cannot accept the lower strength of sulfite pulp —
particularly those making lightweight coated and
super calendared (SO grades. For them, sulfite pulp
is not an alternative.
Bleached Chemithermomechanical Pulp
BCTMP is cheaper to produce than low-yield sulfite
and, in the case of Mi liar-Western's Alkaline
Peroxide Pulping (APP) process, can be obtained at
a high brightness right from the chip refiner. Other
BCTMP installations postbleach CTMP with
hydrogen peroxide. Since BCTMP generally sells at
prices 15 percent below the price of comparable
kraft pulp, papermakers are interested in trying it as
a kraft substitute and BCTMP is moving into coated
wood-free grades and printing and writing papers
in Europe (PPI This Week, 1992). Apart from the
strength deficit of softwood BCTMP compared to
softwood kraft pulp, the main disadvantage of this
pulp is that it contains lignin. The lignin causes
brightness reversion when BCTMP-containing
76
-------
B.I. FLEMING
paper is exposed to light. This reversion is in-
hibited, but not totally eliminated, in coated grades.
Closed-cycle Pulping
The Millar-Western Company recently began
operations at its new closed-cycle BCTMP mill at
Meadow Lake, Saskatchewan, Canada (Evans,
1992). Within three months, the mill reached 95
percent of its target production — a phenomenally
successful start-up. If the mill continues to perform
in this way through the end of 1992, the feasibility
of closed-cycle operation for CTMP mills can be
considered proven.
The profitability of closed-cycle operations is
something else; no cost figures are available for the
Meadow Lake mill, but these are expected to be
somewhat higher than conventional BCTMP using
the same wood furnish because of the elaborate
water treatment plant required. Water use has been
kept very low at Meadow Lake, but 13 cubic meters
of water have to be evaporated for every ton of pulp
produced. This compares with about 10 cubic
meters per ton that evaporated from black liquor in
an average kraft mill. The difference is that a kraft
mill has plenty of steam from the recovery boiler to
drive the evaporation, whereas closed-cycle
BCTMP mills use electric power to operate the
evaporators (or crystal I izers).
• How Far Off Is a Closed-cycle Kraft Mill? To
answer this question, we must first recognize that
we are dealing with two different problems — clos-
ing an existing kraft mill, or building a greenfield
closed-cycle kraft mill. The key factor for closed-
cycle operations is water consumption, which must
be brought to an absolute minimum if the
economics and logistics of running with a closed
loop are to be acceptable. There is little chance that
any of the older pulp mills will be closed — water
consumption is too high (see Table 1). Even many
pulp mills of modern design, such as the Riocell
mill in Brazil, still have effluent flows amounting to
three times the evaporator load at Meadow Lake.
Table 1.—Effluent volumes discharged by pulp mills.
m'/ADMT
BCTMP Mills
Whitecourt, Alberta
Meadow Lake, Saskatchewan
22
12-14*
Kraft Pulp Mills
Older mills 80-300
Alberta Pacific, Alberta -58
Riocell, Brazil 40
Ngodwana Kraft Mill. Republic of South Africa 8-10**
•This effluent is discharged to a holding pond and completely recycled.
**This effluent is used to irrigate grasslands.
ADMT = air-dried metric ton
ADT = air-dried ton
So it appears that with one exception, only
greenfield kraft mills are serious candidates for
closed-cycle operations. The Ngodwana Mill in
South Africa was specially built for low water use
(Coetzee et al. 1985) and represents an example of
the type of kraft mill that could be closed, but it is
unique. Besides controlling water volume, other
steps must be taken before a closed-cycle kraft mill
can be operated; for example, we need to minimize
the chloride ions in the liquor loop. Pitch and non-
process elements also need control.
Note that Meadow Lake has a purge of non-
process elements because it is not presently
recovering its pulping chemicals. That option,
however, is not feasible for a kraft mill.
Hardwood Pulps
Soda-anthraquinone
This pulping process, although an alternative to
kraft pulping, is not exactly emerging; it has
emerged and stalled. First proposed in 1977 (H.H.
Holton's U.S. Patent 4,036,681; see also Holton,
1977), soda-AQ pulping techniques are used in
roughly a dozen hardwood mills around the world.
The process is sulfur-free and works best with short-
fibered hardwoods and annual plants. It is exten-
sively used in India and China in small operations
pulping bagasse, bamboo, and straw.
Practically all the existing soda-AQ mills are
modifications of earlier soda cooking operations.
Anthraquinone brings benefits to a soda mill in
terms of pulp strength, cooking rate, and yield, thus
compensating for the AQ cost. To my knowledge,
none of the current soda-AQ operations were
originally kraft mills. Conversion of a kraft mill to
soda-AQ offers no rate or yield improvements and,
for long-fibered furnishes (softwood and eucalyp-
tus), soda-AQ pulps are definitely weaker than kraft
pulps.
In contrast, for short-fibered hardwoods, soda-
AQ pulping offers a proven sulfur-free alternative to
kraft pulping that does produce an acceptable
product. Conversion of an existing
- kraft mill to soda-AQ would entail
us gai/ADT capital and operating expenditures
to expand the output of the lime
5,300 |
-------
Alternative and Emerging Technologies — Pulping
return on the investment. Since no kraft mills have
made this switch, we can assume that the return on
investment is not high enough. For a greenfield
mill, the size of the recausticizing unit would not be
an issue; however, since no greenfield soda-AQ
mills have been built recently — only kraft mills —
the economics of greenfield soda-AQ mills are evi-
dently not impressive either.
AlcelP Pulping
In this technique, hardwood chips are exposed to
an acidic (pH 4) alcohol-water mixture at 195 °C
(400 pounds per square inch gauge), which
degrades and dissolves lignin and produces
hardwood pulps at about 30 kappa. Much of the
residual lignin can be removed by an alkaline ex-
traction. Oxygen delignification is particularly ef-
fective for that purpose. Alcell® pulp strength is
similar to that of kraft hardwood pulps from the
same species (Petty, 1989), and some charac-
teristics, such as opacity, are often superior. True
solvent processes, like Alcell®, do not use recovery
boilers since there are no inorganic materials to
recycle. After the solvent has been flashed off, lig-
nin precipitates from the aqueous component of
the pulping liquor, leaving a carbohydrate solution.
The carbohydrate solution should be rather
easy to dispose of as a cattle feed supplement, but
the lignin is an important component in the mill's
economics and represents both a challenge and an
opportunity for the true solvent processes. The ab-
sence of a recovery boiler (a big saving in capital
cost) means that the true solvent techniques are
heavy net energy consumers; therefore, the lignin
by-product must be credited with sufficient value to
cover these energy costs. Lignin must be used for
something other than hog fuel. Herein lies the chal-
lenge — to find new uses for lignin, for example, as
a binder or resin extender.
Since true solvent lignins are free of sulfur and
sodium, they are well suited to developing the spe-
cial market niches that would be needed to estab-
lish the first North American solvent mills.
The absence of a recovery boiler means also
that Alcell® units should be economically viable at
a scale of about 300 tons per day, and units
processing 550 tons per day are said to offer the
same return on investment as a world-scale (1,200
tons per day) kraft mill. The small scale should
make Alcell® pulping attractive in situations of
limited wood resources or capital availability.
Another possibility is the addition of solvent pulp-
ing units alongside existing kraft mills, perhaps
providing a hardwood furnish component so that a
softwood pulp mill can become integrated with
papermaking operations. In this case the existing
kraft recovery furnace could possibly be used to
recover the effluent from the oxygen stage in the
solvent pulp bleachery.
Alcell® has practically completed its trials in a
batch pilot plant running at about 15 tons per day.
Larger scale trials are now contemplated in order to
demonstrate improved recovery efficiencies for the
ethanol solvent (Maddern, 1991). As happens with
most new technologies, Alcell is likely to begin
commercial production in a niche market — pro-
ducing special grades of lignin and a bleached
hardwood pulp that may at first be captive.
Whether Alcell becomes a serious competitor to
hardwood kraft mills will depend on controlling
solvent losses and making process refinements, ex-
panding the markets for lignin, and — not least —
the efficacy of refinements still occurring in kraft
pulping.
Softwood Pulps
Alkaline Solvent Processes
The two main alternatives to kraft in this category
are emerging in Germany. No kraft mills were ever
built in former West Germany because of concern
over odor problems and boiler safety. Germany has
an abundance of softwood, and while German sul-
fite mills have thrived on pulping spruce, much
pine wood was exported. Some of this fiber was
later reimported from Scandinavia or Austria in the
form of bleached kraft pulp. As a result, a sizeable
effort has been underway in Germany for many
years to develop a process for converting the native
softwoods to pulp of kraft quality without using
reduced sulfur compounds.
Two solvent pulping processes have been ex-
tensively researched at pilot scale and one will
soon be in commercial operation. Both use alkaline
conditions, which so far seem to be essential to
produce high strength softwood pulps.
Organocell
The Organocell process, soon to begin commercial
operations (430 tons per day of fully bleached fluff
pulp) at Kelheim, uses a soda-AQ-methanol cook
to obtain a pulp with a strength somewhat below
that of kraft but eminently suitable for fluff pulp.
The Organocell mill resembles a kraft mill in many
respects, except that the continuous digester vessel
has thick walls to withstand the extra pressure from
the methanol vapor. The recovery furnace will be
run in a fully oxidizing condition with very little
smelt but a heavy carryover of the sodium car-
bonate ash (thus it will need an oversized electro-
static precipitator). The mill also has a methanol
78
-------
B.I. FLEMING
recovery unit, and the bleach plant is planned to be
chlorine-free with a medium consistency ozone
(OZP) sequence.
The capital cost of greenfield Organocell mills
will be about the same as that of a conventional
kraft mill. Although it needs high-pressure equip-
ment, flame-proof electrical gear, and methanol
recovery units, compensation is obtained in the
form of a smaller, cheaper (fully oxidizing) recovery
furnace (Murrinen et al. 1989).
Organocell operating costs, however, will ex-
ceed those of kraft because of the need for nitrogen
padding, AQ addition (which adds about $1 7 per
ton of pulp), and increased lime usage. Extra power
and steam will be required to operate the methanol
recovery, but no makeup methanol is anticipated.
That is because methanol is generated during
alkaline pulping and is expected to balance the sol-
vent losses.
Alkaline Sulfite Anthraquinone Methanol
Alkaline sulfite anthraquinone methanol (ASAM)
pulping is the only emerging pulping process that
can produce softwood pulps that consistently ex-
ceed kraft pulp strength (Zimmerman et al. 1991).
The pulps' viscosities are remarkably high because
of the low alkalinity at which the cooks are carried
out (Kordsachia, 1988; Zimmermarj et al. 1991).
They also have good bleachability (Zimmerman et
al. 1991) and can be cooked to low kappa numbers
(Pattetal. 1990).
The disadvantages are in the cost of liquor
preparation and chemical recovery. Besides the
usual additional costs associated with solvent pulp-
ing (pressure vessels, flame-proof items, nitrogen
padding, solvent rectification column), ASAM also
needs a full sulfite recovery system plus a Tomlin-
son recovery boiler, lime kiln, and recaust unit
(Fuchs et al. 1991). In fact, ASAM needs three
separate recovery loops (see Fig. 1) to recover
methanol, caustic, and sodium sulfite. Even though
the lime kiln and recaust unit can be much smaller
than for kraft, the additional items are expected to
raise the capital cost of an ASAM plant 10 to 20
percent above that of kraft (Maddern, 1991).
Operating costs at first sight also appear to be
higher; the AQ alone adds about $17 per ton of
pulp to operating costs. The inorganic chemical
charge and the digester operating temperature are
also higher, both of which increase the operating
costs compared to kraft. However, much of the in-
crease is compensated by the higher bleached yield
of ASAM pulp (45.5 percent vs. 43.5 percent).
These yields are calculated from data in Zimmer-
man et al. (1991) after allowing for recooking of
rejects.
WOOD
PULP
Figure 1.—Chemical recovery cycles for an ASAM pulp
mill.
Though ASAM makes excellent pulp, this
process is definitely the most complex of the
emerging technologies. The capital cost is likely to
be quite high. Operating costs are also likely to ex-
ceed kraft costs unless TCF pulps are being
produced, in which case ASAM's low kappas and
good bleachability become very significant.
Conclusion
The kraft process has gradually risen to dominance
as a result of continual refinements. There have al-
ways been competing processes that looked good
at laboratory scale but few managed to remain
promising after extended plant trials. Of the six
competing processes discussed here, none seems
destined to replace kraft as the major source of vir-
gin chemical pulp for papermakers.
Soda-AQ pulping will be restricted largely to
nonwood pulping and a handful of hardwood
mills. Once nonchlorine bleaching of kraft pulp is
made cheaper, acid sulfite pulping will lose its only
current advantage over kraft. BCTMP will continue
to nibble at the kraft pulp market, but in many
paper grades it cannot be used as a substitute. The
Alcell process will find a niche in locations where
its small economic size is important. Development
beyond that point will depend on finding more out-
lets for the lignin than cellulose.
The hybrid solvent processes Organocell and
ASAM are very significant in Germany where kraft
mills are not welcome and emission regulations are
strict. Neither technique seems capable of directly
challenging kraft; nevertheless, the start-up of these
processes in Germany will be followed with keen
interest in North America.
79
-------
Alternative and Emerging Technologies — Pulping
References
Coettee, B., C.J. Davies, F.E. Mera, and L.K. Swift. 1985. Practi-
cal steps leading toward the effluent-free mill. Tappi J.
68(4):92-97.
Evans, T. 1992. Start-up of Millar-Western's zero discharge
BCTMP mill in Meadow Lake. In Proc. Pacific West.
Branch Meet. Canada Pulp Paper Ass. Jasper, Alberta,
Canada.
Fuchs, K.P. Rimpi, and C. Brown. 1991. Chemical recovery sys-
tem for an ASAM mill. Page 259 in Proc. Pulping Conf.
Technol. Ass. Pulp Paper Indus. Orlando, FL.
Holton, H.H. 1977. Soda additive softwood pulping: a major
new process. Pulp Paper Can. 78(10):T218.
Kordsachia, O. and R. Patt. 1988. Full bleaching of ASAM pulps
without chlorine compounds. Holzforschung 42(3):203.
Maddern, K.N. 1991. Bleached market pulp: an assessment of
alternatives to the kraft process. Page 81 in Proc. Int. Conf.
Kraft Mills. Melbourne, Australia.
Murrinen, E., J. Sohlo, T. Vanhanen, and E. Kivela. 1989.
Recovery of chemicals from Organocell wood-pulping
processes. Page 223 in Proc. Wood and Pulping Chem.
Symp. Technol. Ass. Poster Sessions. Pulp Paper Indus.
Raleigh, NC.
Patt, R. et al. 1990. The ASAM process — competitor to kraft
pulping? In Proc. 7th Sunds Defibrator Tech. Seminar. Pori,
Finland.
Petty, G. 1989. Canadians pioneer a small-scale pulp mill.
Paper Technol. 3(X2):10.
Pulp and Paper Institute. 1992. Chlorine issue is now resolved.
PPI This Week 7:21.
Zimmerman, M., R. Patt, and O. Kordsachia. 1991. ASAM pulp-
ing of Douglas fir and chlorine-free bleaching. Page 115 in
Proc. Pulping Conf. Technol. Ass. Pulp Paper Indus. Orlan-
do, FL.
80
-------
Panel 3:
Alternative and Emerging
Technologies — Pulping
Question and Answer Session
m Norman Liebergott, DuPont Canada, Inc.: First, I
have a question for Bruce Fleming. That was a good
speech, Bruce. In your younger years, when you
were doing research with me, we looked at many
oxygen pulping processes. Now there is something
from Russia called the pulsating oxygen cooking
process. Can you say anything about that?
• Bruce Fleming, Boise Cascade: Pulsating cook-
ing processes are odd. Do they put oxygen into the
digester?
• Norman Liebergott: Yes.
• Bruce Fleming: I find it hard to imagine how the
fibers can be scraped off as they're cooked and
removed from the digester without interfering with
the liquor flow. Perhaps Brian or the digester ex-
perts would know. I can see how you can cook
chips -and pass the liquor through a column of
chips, but not once you start scraping off the fibers
and producing pulp. Remember that the consisten-
cy in the digester, if you think of it that way, is about
20 to 25 percent. There's not much liquor and lots
of wood, which is fine as long as you keep the
fibers packed together in chip form. When you start
to scrape them off and get pulp, how can you get
the liquor through them? The answer to your ques-
tion is that I don't have enough information on the
Russian process to know how well it would work,
and I find it hard to understand.
• Norman Liebergott: Brian, you were showing
how much the nonchlorine or totally chlorine-free
(TFC) pulps depend on kappa number decreases in
the digester, and we know what the Modified Con-
tinuous Cook (MCC) and the SuperBatch™ can do.
Have you ever tried, on a commercial scale, the ad-
dition of anthraquinone to an MCC to further lower
the kappa number, while yet maintaining the actual
yield?
• Brian Greenwood, Kamyr, Inc.: In studies that I
have participated in, we have never done anthra-
quinone in MCC or any MCC digester on a com-
mercial scale. However, the laboratory results do
show that you get the same yield benefits from
anthraquinone with these processes as you do from
conventional processes. In addition, it looks like
the effect of a polysulfide in these processes and
anthraquinone would be added to bring the yield
up. But it has not been done commercially.
• Unidentified Speaker: I think I can answer
Norm's questions. The Russians have a procedure
for taking the fibers out of the digester, which, I
think solves the circulation problem. As the fibers
are loosened by the delignification action, they are
taken out of the pressure vessel and treated else-
where. The answer to the question about anthra-
quinone plus extended delignification is that it
works very well. We are doing that at several loca-
tions. Now, my question is for Lars Ake. I don't
think I heard you say it in your presentation, but I
wanted to clarify it. Was all the data you showed
laboratory data?
• Lars-Ake LJndstrom, Sunds Defibrator Indus-
tries, AB: Not quite all of it. Some results were
produced using mostly mill produced Super-
Batch™ kraft pulps. The AOX data or effluent char-
acteristics were produced in laboratory bleaching
experiments on different types of pulps. So it is pos-
sible to get a relationship of COD, color, and BOD
versus kappa number of unbleached pulp.
81
-------
Alternative and Emerging Technologies — Pulping
• Unidentified Speaker: In other words, there real-
ly is a mill that's producing bleached pulp for com-
mercial use to Kappa 15? And oxygen bleaching to
Kappa six?
• Lars-Ake Undstrom: You are going to see that
happen next year. Today, we are several develop-
mental steps away from SuperBatch™ pulping. We
have two mills today that produce oxygen-
bleached, softwood kraft pulp with a Kappa level in
the range of 8 to 12. That is quite a development of
the process, I think. The implementation of Super-
batch™ cooking will happen this year, and several
mills will follow next year.
• Unidentified Speaker: A number of exciting
things are happening, but I think we need to be
careful to draw a distinction between what is hap-
pening and what we think or hope will happen.
• Lars-Ake Undstrom: I agree with that.
• Neil McCubbln, N. McCubbin Consultants, Inc.:
A couple of questions for Lars Ake. You mentioned
cooking softwoods down to a kappa number of
about 10 with your extended cooking process.
What were the effects on pulp yield when you went
to this number?
• Lars-Ake Undstrom: Compared to conventional
kraft cooking, which took a kappa number of about
30, the yield will be lower. What we have seen in
comparing this process to commercial cooking is
that we improve the yield at the given kappa num-
ber. That means that you can cook the pulp, the
chips, to a lower kappa number without severely
loosing yield.
• Nell McCubbin: You talk about the integration of
extended cooking with oxygen delignification and
how that affects the yield. If you use the batch
process and cooking, would the coverage be the
same? Can you comment on how it might differ?
• Lars-Ake Undstrom: The results that we have
achieved in mill-scale and lab trials show that it is
possible to pulp the kappa number down to 10 with
a yield of about 44 percent, as compared to con-
ventional kraft cooking down to a kappa number of
30 with a yield of about 47 percent. So there is a
drop in yield when you extend the delignification.
• Nell McCubbin: My other question was, have
you retrofitted SuperBatch™ in any other batch
digester mills? Can you comment on the feasibility
of that?
• Lars-Ake Undstrom: Well, as I said, the batch
cooking process has developed over, let's say, 10 or
12 years. And in that development we have
retrofitted digester plants to approximate the
SuperBatch process, but we have not as yet
retrofitted any digester plants fully.
• Douglas Reeve, Pulp and Paper Centre, Univer-
sity of Toronto: Also for Lars Ake, a point of
clarification. You suggest that the amount of pulp
produced by oxygen delignification worldwide is
50 percent of the total kraft pulp produced. Given
that the United States uses oxygen delignification
for only 25 percent of its pulp and given that this
figure is even lower in Canada, do you not mean
that outside North America, the total is 50 percent. I
think that 50 percent worldwide is an excessive
claim.
• Lars-Ake Undstrom: Worldwide is approximate-
ly all the world including North America. My un-
derstanding is that oxygen delignification now
exceeds 50 percent of all pulp produced. It is a con-
troversial subject, obviously. I must say that I in-
clude also, the ... capacity.
• Douglas Reeve: What capacity?
• Lars-Ake Undstrom: Capacity that hasn't started
up yet in the mills that have decided to install
oxygen delignification.
• Douglas Reeve: My question relates to your
recovery of ozone'filtrate and your recycling of
spent gas from the ozone reactor. You showed two
very neat recycles on your process flow chart. I
wonder if you could advise us as to the develop-
ment of those two recycles. They are exceedingly
demanding technically.
• Lars-Ake Llndstrom: That is true. In this context,
I would like to mention the enormous amount of
work by Union Camp. It has extensively researched
the recycling of the spent ozone gas and the recy-
cling of the ozone bleaching spent liquor. I agree
with you that one has to look at the potential
problems associated with operating an acid delig-
nification process inside an alkaline fiber line. We
are very positive that we can achieve the results I
showed you earlier today, and we will know this for
sure next month when Union Camp implements
recycling at the Franklin Mill. In new develop-
ments, you can't always answer every question by
running laboratory trials. You have to implement
the technology in full scale to find the final
answers. I think that Union Camp has set a very
bold objective, namely, to find out about this.
82
-------
QUESTION & ANSWER SESSION
• Tom McDonough: Lars, You said that you are op-
timistic about the possibility of achieving what you
showed us in your presentation. Does that mean
you are optimistic about achieving 100 percent of
the recycled ozone filtrate, or do you think there
will have to be a purge in the system?
• Lars-Ake Undstrom: I am optimistic about recy-
cling 100 percent of the ozone filtrate.
• Dick Valley, Michigan Pulp and Paper Corpora-
tion: Bruce, were your cost comparisons based on
the actual physical cost of producing the pulp or do
they include the necessary environmental costs as-
sociated with different types of pulping? In other
words, some have air emission problems, some
don't.
• Bruce Fleming: This is true. Let me think about
this question because the answer is different for the
different processes that I talked about. The Or-
ganocell figure was the total cost to build a mill, be-
cause that firm has just built one that's about to start
up. Alkaline sulfite anthraquinine methanol
(ASAM) plants would need some environmental
controls on the recovery furnace, because ASAM
uses a high sodium sulfite recovery furnace. That I
did not take into account; I figured that there is
going to be a higher capital cost in kraft anyway.
We added 10 to 20 percent to that process because
of the methanol recycle loops and the higher pres-
sure of the digester. So, in that case, there's an addi-
tional cost for environmental control. For Soda-AQ
and Alcell™, the air emission controls are insig-
nificant. They don't apply in that case as compared
to kraft.
• Pete Radeckl, Michigan Technological Univer-
sity: I would like to commend our foreign visitors
on some of the efforts that were mentioned in
regard to demonstration plants and otherwise for
some of the alternate technologies. My question is
primarily to Bruce. Do you have any feel for the
level of research and development funding that
North American companies are expending on alter-
nate processes, or do you think that those might be
misdirected funds?
• Bruce Fleming: I wouldn't think that such
developments would be misdirected, but I don't
have any feeling for the -amount of money that
North Americans spend on research and develop-
ment. No doubt a lot of this research is going on in
Germany. The reason is that there has never been a
kraft industry in Germany. The kraft process has not
been permitted in western Germany since the war.
So the Germans have quite a bit of softwood. They
are able to pulp spruce by the sulfite process to
make the totally chlorine-free sulfite pulp that they
use very effectively. But their pine is exported to
countries like Sweden and Austria where kraft
pulping is permitted; then the pulp is returned to
Germany.
So Germany has had a tremendous incentive to
develop a nonkraft alkaline pulping process to deal
with this pine wood. And there has been govern-
ment funding for this development. That's why so
much research has been done there and it is very
satisfying to Germany that these processes are
being watched here with great interest. They are
not quite economically up to kraft yet. We don't
have here the same impetus to do research in the
alternative processes that the Germans do, but, of
course, U.S. and Canadian companies are develop-
ing the Alcell™ process. So there is research in al-
ternative pulping going on in North America.
• Perttl Vlsuri, Ahlstrom USA, Inc.: I have a com-
ment rather than a question to supplement Mr.
Fleming's presentation. One successful way of
making up for the additional capacity needed in the
recovery boiler has been implemented in several of
our mills. It requires a heat treatment on the black
liquor to lower the viscosity. This way you can have
higher percentages of dry solids going to the
recovery boiler, which adds capacity and has
several other advantages, including less need for
waterwashing the steam pipes.
• Lubomlr Jurasek, Pulp and Paper Research In-
stitute of Canada: I have a question for Dr.
Lindstrom. You mentioned a modified lignin
process, a sequence of ZXP. What does the X stand
for? Is it xylanase, or is it a chelator?
• Lars-Ake Lindstrom: The X stands for a chelating
stage, which is necessary to remove the heavy me-
tals.
• Lubomir Jurasek: We often use X for xylanase;
for the enzymatic, we use Q, at least in Canada. If
you did not use enzymes, why did you use that? It
seems to be beneficial, but I would place it a little
earlier in the sequence.
• Lars-Ake Lindstrom: I am sure there are various
alternatives to improve pulping and bleaching
technologies. I discussed only the few that I know
best and have been personally involved with. And,
yes, there are different ways to improve these situa-
tions.
83
-------
Bleaching of Kraft Pulps
A Research Perspective
Peter Axegard, Birgit Jacobsson, Sten Ljunggren, and Nils-Olof Nilvebrant
Pulp Department
Swedish Pulp and Paper Research Institute
Stockholm, Sweden
The bleaching process for chemical pulp
manufacture is undergoing a dynamic devel-
opment. In a few years, molecular chlorine
will be replaced almost completely by a combina-
tion of oxygen and chlorine dioxide. The standard
sequence in Scandinavia for market softwood kraft
pulp is O D(EPO)DD. Strict environmental de-
mands can best be met by using chlorine dioxide,
oxygen, and peroxide.
Two strong trends have appeared in the
development of the bleaching process. The first is
totally chlorine-free (TCP) bleaching; the second is
the closed-cycle mill concept. The alternatives for
TCP bleaching include hydrogen peroxide, oxygen,
ozone, enzymes, reducing agents, and maybe most
important, modified extended draft cooking. There
is a great potential for improvements in TCP
bleaching. Ozone is probably the most interesting
chlorine-free bleaching chemical because of its
very good bleaching effect; however, the complex
radical chemistry of this particular process is not
fully understood.
The closed-cycle mill concept is still far from a
reality, but it is more possible now than it was a few
years ago. From a broader perspective, such a mill
is a fit complement to the idea of sustainable
development. The kraft process has natural bleeds
for many elements that enter the mill with the wood
and raw water. One of the major challenges in the
closed-cycle mill is the handling of manganese.
Development Until 1992
During the last two decades, considerable progress
has been made in reducing the formation of adsor-
bable organic halogens (AOX) in the mills that
manufacture bleached chemical pulp. This
progress is indirectly illustrated in Figure 1, which
shows the amount of chlorine consumed per ton of
bleached pulp over the last 15 years in Sweden.
Eighty-five percent of the Swedish production of
bleached chemical pulp is kraft; 15 percent is sul-
fite pulp.
The big decrease in the consumption of
molecular chlorine has resulted in a corresponding
decrease in the formation of AOX (Swed. Forest
Indus. Water Pollut. Res. Found. 1991; Hultman,
1992). From 1970 to 1986, the AOX formed in the
process decreased from about 8 kg to about 4 kg
per ton of pulp in Sweden. The AOX discharged per
ton of pulp was reduced another 75 percent by
1991, for a total AOX decrease of about 90 percent
since 1970.
The introduction of different techniques for
reducing the bleaching effluent is shown in Figure
2. Starting with the "conventional" sequence
CEHDED in the early 1970s, the first step was to in-
stall oxygen bleaching in a number of mills. This
change is the main reason for the large decrease in
chlorine consumption. A gradual replacement of
chlorine by chlorine dioxide also contributed as
did the fact that an increasing number of mills
began to treat the effluents biologically in aerated
lagoons.
The standard sequence in Sweden in 1992 for
softwood kraft pulp is O D(EPO)DD; oxygen delig-
nification, 100 percent CIO2 in the prebleaching
and reinforced alkaline stages. The main charac-
teristics of this sequence are a low formation of
AOX, no formation of polychlorinated compounds,
an extremely low level of particles in the pulp,
good pulp strength, and good brightness stability.
The current low level of AOX, around 0.5 kg
per ton, is achieved by using this bleaching se-
quence. Even lower levels can be reached by com-
bining this sequence with modified extended kraft
84
-------
P. AXECARD ET AL
*g/t
70 -T
60 -
50 -
40 -
30 -
20 -
10 -
£
I
to
I
I
5
I
§
I
§
I
§
i
OO
tn
\
CM
OO
CTl
I
ro
OQ
01
I
s
I
IT)
03
en
\
-------
Alternative and Emerging Technologies — Bleaching
cooking, external treatment, and good process con-
trol. At this low level, the AOX value has no sig-
nificant environmental impact.
The impact on surrounding waters cannot be
explained only by the presence of discharged or
natural AOX and specific organochlorine com-
pounds. Both Canadian (O'Connor et al. 1991) and
French (Charlet, 1991) studies have shown that
there is hardly any correlation at all between
AOX/EOX and chronic or acute toxicity. Non-
chlorinated extractives originating from wood have
also recently been shown to have effects on liver
enzyme activity in fish (Lehtinen, 1991).
Evidence has been found for the existence of
such "natural AOX" (Crimvall et al. 1991). Ancient
groundwater samples have been shown to contain
organochlorines, but these tend to have low
chlorine-to-carbon ratios, which makes them more
easily biodegraded and gives them low toxicities.
There also seems to be a "natural dehalogenera-
tion." Thus, natural AOX is both formed and
degraded by biological processes (Fleming, 1992).
Despite these data, the market continues to
show a strong interest in TCF bleaching. Today
about 5 percent of the bleached kraft pulp in
Sweden is TCF bleached by a combination of ex-
tended kraft cooking, oxygen, hydrogen peroxide,
and, occasionally, enzymes.
Potential for Different
Bleaching Chemicals
Chlorine Dioxide
Chlorine dioxide (CIO2) is the most effective
chemical in a modern bleaching plant. It is selec-
tive, relatively cheap, and relatively insensitive to
process disturbances.
Furthermore, the amounts of chlorinated dis-
solved material in the effluents are lower from a
bleach plant using chlorine dioxide than from a
bleach plant using a sequential chlorine/chlorine
dioxide stage. The chlorinated material from a
D100 stage, mainly consisting of chlorinated
phenolic lignin residuals of different molecular
weights, has a low degree of chlorination per
aromatic residue. Primarily, monochlorination
seems to occur on the lignin matrix in the pulp
during the 100 percent chlorine dioxide treatment
(Ljunggren, 1991). This occurs together with ring-
opening reactions and the formation of acid end
groups that are necessary for lignin dissolution in
the first bleaching step. The dominant dissolved
phenolic organochlorine compounds are thus of
monochloro nature — some dichlorophenolics do
exist — but hardly any tri- or higher chlorinated
compounds (Misted et al. 1991).
Chlorine dioxide is also very beneficial in
degrading polychlorinated phenols to less chlori-
nated compounds, something that we have ob-
served in model compound studies (see Fig. 3). This
behavior can also contribute to the negligible
amounts of tri-, tetra-, and higher chlorinated com-
pounds observed when bleaching with a mixture of
chlorine and chlorine dioxide.
The toxicity equivalency factor, relating the
chronic toxicity of an individual chlorophenol to
that of pentachlorophenol, shows a drastic de-
crease when the chlorine gas consumption is
decreased and with a decreased kappa number (see
Fig. 4).
Microtox tests are valuable tools for screening
toxicities (Renberg, 1992) and have been per-
formed on 100 percent CIO2 mill effluents after ex-
posure to an aerated lagoon. No toxicity could be
measured, which indicates no toxicity at least on
marine bacteria (Dahlman, personal communica-
tion).
Effluents from pulps bleached with chlorine
dioxide seem to have low chlorine-to-carbon ratios
(see Table 1). It is of interest to compare this level
with figures reported for Swedish chlorinated drink-
ing water: 0.003 to 0.015 chlorines per carbon
atom (CI/C) (Annergren et al. 1990). In our studies
of the isolated lignins from pulps bleached with
100 percent CIO2 we have found even lower ratios
(0.005 CI/C) in the residual lignin in the pulp than
in the dissolved high molecular lignin residues in
corresponding bleaching effluents.
Table 1.—Fraction of chlorine per carbon atom (CI/C)
In the high molecular part of lignin during bleaching.
AMOUNT D IN PREBLEACHING
CI/C IN EFFLUENT
30
50
80
100
0.035
0.025
0.021
0.011
In the future, there may be possibilities to fur-
ther decrease the amount of chlorinated organics
by optimizing the bleaching process parameters —
for example, through the use of higher or better
controlled pH levels and the addition of chemical
additives.
Enzymes
Great interest exists in the use of enzymes, par-
ticularly xylanase, in bleaching. Xylanase itself
does not bleach, but it does seem to improve
bleachability in the later stages. The principle be-
hind this theory is illustrated in Figure 5. The basic
theory is that the enzymes "soften" the fiber struc-
ture so that the lignin is more easily attacked in later
86
-------
P. AXEGARDETAL
-__ Dechlorination
Ring-opening
Demethylation —>
Hydroxylation __>
Further degradation
Figure 3.—Chlorine dioxide can degrade polychlorinated phenols to less hazardous compounds. —> = further
degradation in the alkali stage via corresponding quinones.
TEQ. g PCP ptp
Kappa 28
TEQ. g PCP ptp
Kappa 10
0.2
mult. act. Cl
mult. act. Cl
Figure 4.—Chlorinated phenolics (expressed as toxic equivalents of pentachlorophenol (PCP) in g/t of pulp) are
dramatically decreased by modifying the bleaching process or by decreasing the Kappa number.
bleaching stages. The benefit of enzymes, however,
seems to decrease with lower kappa numbers and
to be marginal in modern systems of TCP bleach-
ing. Moreover, the yield loss that accompanies the
use of enzymes will increase the wood costs and
increase the load of chemical oxygen demand
(COD).
Oxygen
Oxygen is an environmentally friendly chemical
but unfortunately the delignification rate in oxygen
bleaching is slow and has to be interrupted at about
50 percent of delignification because of too severe
loss of carbohydrates. The reason for this inefficient
delignification is the nearly nonexistent reactivity of
the nonphenolic structures in lignin. Oxygen reacts
only with free phenolic groups in the residual lignin
in kraft pulps (see Fig. 6).
The main benefit of using oxygen in the process
is after the cooking or bleaching steps in which
phenolic groups have been liberated, that is, after
kraft pulping and in the alkaline extraction stages.
However, the reactivity of the phenolic groups in
certain lignin structures, for example, in biphenyl
87
-------
Alternative and Emerging Technologies — Bleaching
Indirect release of lignin-carbohydrate linked lignin
Xylanase
Lignin
Xylan
~~ Cellulose
Uncovering of lignin
Xylanase
Figure 5.—Hypothesis for the effect of enzymes on bleachability.
Phenolic OH-groups
( % of C9-units )
30-
20-
10-
g-pulps
kraft pulps
10 20 30 40 50
Kappa number
Figure 6.—Phenolic hydroxyl groups in residual lignins.
During oxygen bleaching the phenolic groups in resid-
ual lignin decrease rapidly at first, indicating that
oxygen reacts quickly with these groups.
or cross-linked lignin structures, is very low (Ljung-
grenetal. 1991).
Figure 7 shows that the relative rates become
very different for free phenolic (guaiacyl) and
biphenolic cross-linked structures during oxygen
bleaching.
The cross-linked structures are relatively stable
and are partly accumulated in the oxygenated
15-
5:
A-
3-
2-
1-
•^
Stilber
e
En
ol et
ner
Propyl-
guaiacol
„
p-aryl ether biguaiacol
I I 1 1
Figure 7.—Relative rates during oxygen bleaching con-
ditions of some models for phenolic structures present
in residual lignin.
residual lignin. The efficiency of oxygen in delig-
nification would therefore increase if these
biphenolic groups could be made reactive, and
would be even better if methods could be found to
cleave nonphenolic structures during oxygen delig-
nification.
88
-------
P. AXECARD ET AL
Hydrogen Peroxide
Hydrogen peroxide has gained more interest and
attention as a delignifying agent in the various steps
of a bleaching process, even for alkaline produced
chemical pulps. Stabilized alkaline hydrogen
peroxide in the absence of metal ions is essentially
a brightening and not a delignifying agent. Such
brightening is a result of the oxidation of the
chromophores in lignin by the perhydroxyl ion
HOO"(dissociated peroxide). However, neither this
ion nor hydrogen peroxide itself is able to react
with or oxidize nonphenolic or phenolic structures
and delignify the pulp without appreciable yield
losses. For this reason hydrogen peroxide has been
called a lignin-preserving agent. To use hydrogen
peroxide as a delignifying agent, it must be partially
decomposed. Peroxide decomposition is necessary
for phenolic structures of the type present in
residual lignin to be attacked by hydrogen peroxide
(Agnemo and Gellerstedt, 1979; Smith and Mc-
Donough, 1985; McDonough et al. 1987). The
decomposition involves formation of radical
species that can attack phenolic lignin units:
HOCT
HO- + 02- + H20
The decomposition occurs spontaneously in
the presence of transition metal ions to different
degrees depending on the kind of metal ion. The
relationship between the catalysis of H2O2 decom-
position and the extent of phenol association of a
cross-linked lignin structure model has been
studied in presence of metal ions such as copper,
iron, manganese, and iron cyanide (Smith and Mc-
Donough, 1985). The ratio of the rates of H2O2
decomposition and lignin model oxidation in-
creased in the presence of iron and manganese.
This ratio suggests that these metals consume H2O2
through decomposition to oxygen.
However, the results of copper and iron
cyanide in this example indicate that not all metal
species may be considered detrimental. Thus, it
may be possible to increase the extent and rate of
delignification for a given hydrogen peroxide
charge by controlling the levels and types of metal
ion species in the pulp. It is apparent that the
decomposition of hydrogen peroxide must be con-
trolled to some desirable level. It may, for instance,
be necessary to limit the effect of the decomposi-
tion catalysts by adding an inhibitor. Such in-
hibitors are complexing agents with metal ions, for
example, ethylenediaminetetraacetric acid (EDTA)
or silicate (McDonough et al. 1987). An interesting
metal catalyst is manganese; it probably con-
tributes to decomposition of peroxide and is direct-
ly involved in delignification via increased
phenoxy radical formation from phenolic lignin
units. Thus, by finding methods to direct man-
ganese ions to suitable areas in the cell wall matrix,
for example, to its lignin rich parts, it should be pos-
sible to enhance the efficiency of hydrogen
peroxide (see Fig. 8) (Vannerberg, 1992).
7^feM£
EDTA
Cellulose
Lignin
J^Polyoses
Celluose
Ligni
j^Polyoses
Figure 8.—The selective removal of manganese. Catalytic metal ions such as manganese are in the fiber wall. Treat-
ment with the complexing agency EDTA removes the catalyst from the cellulose parts so that the remainder is left as-
sociated with the lignin (Vannerberg, 1992).
89
-------
Alternative and Emerging Technologies — Bleaching
Ozone
Ozone is a third very promising nonchlorine
bleaching chemical with big potential as a delig-
nifying and bleaching agent (Figs. 9 and 10).
Ozone has a great lignin-degrading ability, similar
to that of chlorine dioxide, but unfortunately ozone
also degrades cellulose and results in bad selec-
tivity (Liebergott et al. 1992). In contrast to oxygen
and peroxide, ozone reacts with both phenolic and
nonphenolic lignin structures. Thus, ring-opening
reactions of the aromatic ring occur and form
acidic groups that facilitate the lignin dissolution
(Patt et al. 1991). Cleavage of nonphenolic struc-
tures gives a comprehensive degradation of the lig-
nin matrix (Eriksson and Gierer, 1985). These direct
reactions take place quickly and extensively in an
acid environment. But ozone, like chlorine
dioxide, is not very stable in an alkaline solution; it
decomposes and becomes inactive. However,
ozone also reacts indirectly with the carbohydrates
in the pulp causing a poor selectivity. These in-
direct reactions, caused by water, are radical in na-
ture. Thus, in developing the ozone bleaching
process, research should be directed toward
processes in little or no water, and to the suppres-
sion of the radical formation.
ISO Brightness, %
Kappa number, %
30-
20-
10-
1000
2000 3000
Bleaching agent, OXE ptp
Figure 9.—Kappa number after prebleaching of a
softwood kraft pulp with different bleaching chemicals.
See Table 2 for conversion to OXE. The range for ozone
depends on whether four or six electrons are used in
ozone bleaching.
Hydroxyl Radicals
Cellulose and hemicellulose degradation is ini-
tiated by radicals abstracting hydrogen atoms from
the sugar unit and thereby creating a p-elimination
reaction. This leads to random cleavages in the car-
bohydrate chain. The main radical causing this
damage to the cellulose is the hydroxyl radical
90-
100 200
Bleaching agent, OXE ptp
Figure 10.—Brightness response of CIO2 and Z on
O(C+D)(E+D) prebleached softwood kraft pulp. See
Table 2 for conversion to OXE. The range for ozone
depends on whether four or six electrons are used in
ozone bleaching.
HO'. It is also extensively reactive with lignin,
causing both degrading reactions (during peroxide
decomposition) and hydroxylation reactions (to a
lesser degree). The latter reaction makes the lignin
more hydrophilic and easier to dissolve (Terashima
and Tatsumi, 1985). Its reactions are very unselec-
tive and must be controlled by radical scavengers.
Such scavengers can be solvents (Brolin et al.
1991), organic complexes, phenols or even lignin
itself (lacobson et al. 1991). Even chlorine dioxide
is a radical scavenger, which explains the good
selectivity of chlorine dioxide during bleaching.
In general all these chlorine-free chemicals —
oxygen, peroxide, and ozone — generate hydroxyl
radicals and other destructive radicals for the cel-
lulose, which creates selectivity problems during
delignification with these chemicals. Development
of the proper process conditions and the use of ad-
ditives is necessary to achieve a good pulping
process.
Oxidation Equivalents, OXE
Old bleaching sequences like CEHDED and
CEDED, which only use oxidative chemicals con-
taining chlorine, can be adequately described by
active chlorine or available equivalent chlorine.
Modern sequences that use chlorine dioxide,
oxygen, and hydrogen peroxide use a lot of oxida-
tion power that is not reflected in the consumption
of active chlorine.
One solution to this dilemma is the concept of
oxidation equivalents, OXE (Grundelius, 1991).
OXE is defined as follows: 1 OXE = the amount of a
substance that consumes \ mole of electrons when
the substance is reduced.
90
-------
P. AXEGARD ETAL
All oxidative bleaching chemicals can easily be
converted to OXE according to Table 2. All chemi-
cals here are assumed to be reduce to Cl" or hhO.
Between four and six of the six electrons available
seem to be used for bleaching reactions in ozone
bleaching. The number depends on whether the
reduction of ozone stops at intermediate peroxides
(hydrogen peroxides and organic peroxides). In this
case, only four electrons are used. If these
peroxides can react with lignin at this low tempera-
ture and pH, all six electrons can theoretically be
used. In the tables and figures that follow, it has
been assumed that ozone uses all six electrons.
Table 2.—Relationship between molecular weight
and oxidative equivalents for different bleaching
chemicals.
CI2
CIO2
NaCIO
02
H202
03
(03
Mw
70.914
67.457
74.448
32.000
34.018
48.000
48.000
E7
MOLE
2
5
2
4
2
6
4
REDUCTION
TO
cr
cr
cr
H2O
H2O
H2O
Peroxides/
O2/H20
gPER
MOLEE'
35.46
13.49*
37.22*
8.00
17.01
8.00
12.00
OXE/
KG
28.20
74.12**
26.86**
125.00
58.79
125.00
83.33)
*35.46 g active Cl mole e-
"28.20 OXE/kg active Cl
Pulp Properties
Pulp properties can be negatively affected in cook-
ing and bleaching. If these operations are not run
properly, difficulties in reaching high brightness,
loss of pulp strength, loss of beatability, and
deteriorated cleanliness may occur.
Brightness
Traditionally the brightness of bleached chemical
market pulp has been above 88 percent ISO to
guarantee a high degree of cleanliness of bark and
shives. This rating also improves brightness
stability, which is important for high quality print-
ing and writing papers. High brightness is easily
reached with sequences like CEHDED, O(C+D)
(EO)DED, and O D(EPO)DD where there is a
relationship between the kappa number and the
brightness (see Fig. 11) characterized by a limited
increase in brightness down to kappa numbers 5-
10. Below this level, a steep increase in brightness
occurs with decreasing kappa numbers. This in-
crease in brightness at lower kappa numbers is
much greater for hydrogen peroxide and ozone.
Ozone and peroxide are to some extent lignin-
preserving bleaching agents. At a certain bright-
ness, the lignin content is higher for these pulps.
Studies of brightness reversion on ozone and
ISO-Brightness, %
90 -Itx
L Peroxide
10
20
30 f.0
Kappa No.
Figure 11.—Principal relationship between brightness
and Kappa number of softwood kraft pulps.
peroxide bleached pulps can therefore be of
interest.
Table 3 shows the approximate brightness
levels that have been reached with TCF-bleaching.
The development has been very rapid. A few years
ago it was deemed impossible to achieve full
brightness with TCF-bleaching while maintaining a
good pulp quality. Today it has been shown to be
possible to produce a pulp in the laboratory with
full brightness using TCF-bleaching while main-
taining a surprisingly high pulp quality. One
promising bleaching sequence is OQ(EPO)Z(EP),
shown in Table 3, which consumes considerable
amounts of hydrogen peroxide in addition to some
ozone. Unfortunately the cost is extremely high,
especially if the level of transition metals like man-
ganese is uncontrolled.
Table 3.—Approximate brightness values obtained
for softwood kraft pulp for different TCP sequences
with an acceptable strength potential. Q = chelating
agent.
ISO BRIGHTNESS (%)
PROCESS SCHEME
Conv. kraft
Conv. kraft
Mod. kraft
Mod. kraft
Mod. kraft
—
02
Oz
02
02
Q(EP)
Q (EPO)
Q (EPO)
Q (EPO) Z
Q (EPO) Z (EP)
MILL
60
75
80
—
—
LAB
75
80
85
88-90
Pulp Strength and Beatability
All internal process measures previously discussed
can cause carbohydrate degradation if they are car-
91
-------
Alternative and Emerging Technologies — Bleaching
ried beyond a critical point. Two types of car-
bohydrate degradation cause poor pulp quality:
damages to cellulosic chains cause loss of pulp
strength, and hemicellulose loss makes the pulp
harder to beat.
Loss of pulp strength occurs if the delignifica-
tion is pushed too far in kraft cooking and oxygen
bleaching. Loss of hemicellulose and the resulting
loss of beatability can occur in the kraft cook and in
oxygen bleaching if the delignification is carried
too far. In short, too much reduction in kappa num-
bers can be detrimental to both beatability and loss
of pulp strength.
Loss of pulp strength can also occur in the
bleach plant. The risk for this increases with in-
creased use of less selective chemicals like oxygen,
peroxide, and ozone. Modern sequences with 100
percent ClO2-substitution require more intensive
conditions in the E1- and final D-stages. This also
increases the risk for loss of pulp strength. The
general rule is that the more oxidation power used
as oxidation equivalents, the higher the risk for loss
of pulp strength.
One way of comparing different sequences is
on the basis of their consumption of oxidation
power expressed as oxidation equivalents, OXE, as
discussed in the previous section. Table 4 shows
different commercial sequences with respect to
their OXE. The conventional CEHDED-se'quence
has a very low OXE consumption. The introduction
of oxygen bleaching and oxidative extraction in-
creases the OXE-demand significantly. The latest
development, with no molecular chlorine, follows
this trend.
In Table 5, four sequences under development
are shown. The sequence with the hydrogen
peroxide stage prior to final bleaching with DPD
increases the OXE-demand. However, the system is
not yet fully developed.
Ozone is a very efficient bleaching agent. It is
about as efficient as chlorine dioxide (see Fig. 9). In
the second and third sequences in Table 5, using
about 6 kg ozone per ton of pulp has decreased the
use of chlorine dioxide down to 26 and 16 kg of Cl
per ton of pulp respectively. An O D (EOP) DD se-
quence usually needs more than 50 kg of Cl per ton
of pulp at a kappa number about 15. The high OXE
demand in the peroxide-ozone sequence results
from the large use of hydrogen peroxide, about 30
kg per ton of pulp. The peroxide demand is likely to
decrease with further development. Unfortunately,
ozone is also efficient in degrading carbohydrates.
At present, extensive use of ozone is not possible
with retention of market pulp strength. In limited
amounts ozone can be regarded as a very interest-
ing bleaching chemical provided that the high in-
vestment cost for the ozone generator can be
accepted.
Cleanliness
Figure 12 (Annergren, 1990) summarizes the effect
on pulp cleanliness of some internal process
measures. The net effect of the sum of lower kappa
number, decreased multiple, and increased share
of CIO2 is that cleanliness will be improved,
making it possible to lower the brightness target
somewhat. A modern sequence like O D(EPO)DD
thus gives a very clean pulp.
But ozone is a very inefficient agent for bleach-
ing shives and bark particles because the reaction is
very fast and therefore the ozone is not given time
to diffuse into particles. A limited use of peroxide is
Table 4.—Bleaching chemical consumption expressed as OXE (see Table 2) for industrial softwood kraft bleach-
ing sequences. This comparison is made at an ISO brightness 90 percent
SEQUENCE
CEHDED
O(C85+D15)(EO)DED
O(D70C30) (EPO) D (E+ P) D
OD(EPO)DD
OD(EPO)DD
KAPPA
NUMBER
32
20
16
16
10
CONSUMED OXE.
ptp O2 INCLUDED
2,500
3,900
3,900
4,100
3,300
CONSUMED OXE,
ptp AFTER O2
2,500
1,500
1,500
2,100
1,300
OXE/KAPPA
AFTER O2
78
75
94
110
130
Table 5.—Bleaching chemical consumption expressed as oxidation equivalents, OXE, for softwood kraft bleach-
ing sequences under development The comparison is made at an ISO brightness 90 percent. Q = EDTA or
DTPA; Z = ozone.
SEQUENCE
OQPD(E+P)D
0(DZ)(EPO)DD
OZ(EPO)DD
OQPZP
KAPPA NUMBER
AFTER O2
16
14
16
10
CONSUMED OXE,
ptp O2 INCLUDED
4,400
4,360
3,690
4,390
CONSUMED OXE,
ptp AFTER O2
2,400
2,360
1.690
2,390
OXE/KAPPA
AFTER Oa
150
175
109
239
92
-------
P. AXECARDETAL
Shives and
dirt specks
Decreased Y/
multiple!^
Lower
kappa
number
Acceptance
limit
Brightness
Figure 12.—Typical development in shlves and dirt
specks with increasing brightness. The shaded area
shows a normal range of variation. The length of the ar-
rows Indicate the relative importance of the variables.
also negative for bleaching shives and bark. How-
ever, bleaching with a large amount of hydrogen
peroxide characterized by a high concentration
and a long retention time, efficiently removes the
particles.
Bleaching in the Closed-cycle
Pulp Mill
A completely closed pulp mill is not possible be-
cause everthing — the pulp fibers (the product),
wood water, chlorine, silicon, phosphorus,
aluminum, nitrogen, potassium, and the transition
metals that enter with the wood and the raw water
— has to leave the system. The kraft process, how-
ever, has a number of built-in methods by which
different elements can be eliminated in a controlled
way. Overall, the pulp and paper industry is
amenable to the idea of sustainable development
(see Fig. 13). The only input is solar energy and the
output is energy to communities and industry.
Everything else is part of closed loops such as
recycled fibers, energy from worn out recycled
fibers, ash with minerals and nutrients that are
beneficial to the forest as alkali and trace elements,
and the formation of CO2 is in balance with the up-
take in the forest.
This is oversimplified but it is clear that the pre-
requisites for sustainable development are here.
A diagram of a pulp mill in a "natural cycle" is
given in Figure 14.
The cornerstone in the fiber line in a "closed-
cycle" pulp mill is extended modified cooking and
oxygen bleaching in one or two stages. This
bleaching can be TCF, or it may use a limited
amount of CIO. The TCF bleaching is based on
ozone and peroxide probably combined with one
or two reducing stages. There is no principal prob-
lem to handle a small amount of CIO2 in a "closed
cycle" mill provided the total input of chloride ions
is below 3 to 4 kg of chloride per ton of pulp. It
must be pointed out that the TCF alternative also re-
quires a controlled bleed of chloride ions because
of their presence in wood and in raw water. The
acid filtrate, which contains transition metals, cal-
cium, and phosphorus, can be bled out from the
lime cycle. The alkaline filtrate can be used as
washwater.
The TCF bleaching may oxidize a small
amount of Cl" to Cb, which could cause a limited
chlorination. This chlorination can be regarded as
"natural" and compared to natural chlorination that
is enzyme-induced (Grimvall et al. 1991). The level
of organically bound chlorine in the pulp will
probably be similar to that of a modern bleaching
sequence with a limited amount of CIO2-
Conclusion
The environmental impact from chlorinated or-
ganics is greatly reduced by the use of sequences
like OD(EPO)DD. In the future, it may be possible
to reduce the use of chlorine dioxide to a level
below the acceptable chloride input to the
recovery cycle without problem. It may also be
possible to continue lowering the formation of
AOX.
Bleaching without chlorine-based chemicals
(TCF bleaching) is developing dynamically. The
main problems are its high cost and potential
strength loss if the bleaching is carried to excessive
brightness. Today, softwood kraft pulp can be
bleached to an ISO-brightness of 80-plus, and the
potential for further development seems to be great.
Proper handling of metals in pulp processing is a
key factor.
The use of oxidation equivalents (OXE) for
quantifying the use of bleaching chemicals is
recommended in modern sequences because it in-
creases the understanding of the bleaching se-
quence. The best strength potential is normally
reached when the use of OXE is low.
The future closed-cycle kraft pulp mill fits well
with the idea of sustainable development. The
bleaching chemicals in such a system might be
oxygen, peroxide, and ozone. Chlorine dioxide
may be needed for high brightness and good pulp
strength.
93
-------
Alternative and Emerging Technologies — Bleaching
Figure 13.—Diagram of pulp and paper from a LCA perspective in sustainable development. LCA = life cycle analysis;
white arrows = organic substance; black arrows = inorganic substance; shaded arrows = energy
PREBLEACHING
(DEPITCHING)
FINAL BLEACHING
(DECHLORINATION)
Figure 14.—Pulp mill emissions are allowed if compatible with sustainable development. The kidneys of the pulp mill
are located so that the substance concentrations do not accumulate to critical levels. White arrows = organic sub-
stance; black arrows = inorganic substance; shaded arrows: energy
94
-------
P. AXEGARD ET AL
References
Agnemo, R. and G. Cellerstedl. 1979. The reactions of lignin
with alkaline hydrogen peroxide. Part II. Factors influenc-
ing the decomposition of phenolic structure. Acta Chem.
(331:337-42.
Annergren, C. 1990. Environmental harmonization of high
quality bleached kraft pulp production — a high tech
development. Pages 66-83 in Proc. 24th EUCEPA Conf.,
May 8-11, 1990. Swed. Ass. Pulp Pap. Eng. Stockholm,
Sweden.
Annergren, C., P.-O. Lindblad, and F. Osterberg. 1990.
Chlorinated organic matter in bleached kraft pulp — effect
of important process variables. Pages 185-94 in 1990
Tech. Ass. Pulp Pap. Indus. Conf., Oct. 14-17, 1990.
Toronto, Ont., Can.
Brolin, A., J. Gierer, and Y. Zang. 1991. Delignification of
softwood kraft pulps by oxygen containing species in
acetic acid media. Pages 205-09 in Proc. 6th Int. Symp.
Wood. Pulp. Chem., April 29-May 3, 1991. Melbourne,
Australia.
Charlet, P. 1991. An examination of the relationship between
AOX, EOX, and acute and chronic toxicity. Pres. Swed. En-
viron. Prot. Agency Conf., Nov. 19-21, 1991.
Saltsjobaden, Sweden.
Dahlman, O. 1992. Personal communication. Swedish Pulp
and Paper Research Institute. Stockholm, Sweden.
Eriksson, T. and J. Gierer. 1985. Studies on the ozonation of
structural elements in residual kraft lignin. J. Wood Chem.
Technol. (5)1:53-84.
Fleming, B.I. 1992. The organochlorine spectrum: mills, public
must discern toxic, nontoxic. Pulp Pap. (66)4:59-62.
Grimvall, A. et al. 1991. Organic halogens in unpolluted waters
and large bodies of water receiving bleach plant effluents.
TappiJ. (94)5:197-203.
Grundelius, R. 1991. Oxidation equivalents, OXE —an alterna-
tive to active chlorine. Pages 49-58 in Proc. Swed. Ass.
Pulp. Pap. Eng. Int. Pulp Bleaching Conf., June 11-14,
1991. Stockholm, Sweden.
Misted, I.A., R.V. Ganovas, and G. Ruscitti. 1991. The effect of
100 percent chlorine dioxide substitution on delignifica-
tion in the D,E(EP) and Eo stages. Pres. Tech. Ass. Pulp Pap.
Indus. Pulping Conf., Nov. 3-7,1991. Orlando, FL
Hultman, B. 1992. The forest industry and the environment.
Page 39 in Proc. 4th Int. Conf. Swed. Ass. Pulp Pap. Eng.,
May 19-22,1992. Bologna, Italy.
Jacobsson, B., P. Lindblad, and N.-O. Nilvebrant. 1991. Lignin
affects the attack of ozone on carbohydrates. Pages 45-58
in Proc. Swed. Ass. Pulp. Pap. Eng. Int. Bleaching Conf.,
June 11 -14, 1991. Stockholm, Sweden.
Lehtinen, K. 1991. Environmental fate and effects of bleached
pulp mill effluents. Poster Pres. Swed. Environ. Prot. Agen-
cy Conf., Nov. 19-21,1991. Saltsjobaden, Sweden.
Ljunggren, S. 1991. The chemistry of bleaching with chlorine
dioxide. Poster Pres. Swed. Ass. Pulp Pap. Eng. Int. Pulp
Bleaching Conf., June 11-14,1991. Stockholm, Sweden.
Ljunggren, S., G. Gellerstedt, and M. Pettersson. 1991. Chemi-
cal aspects on the degradation of lignin during oxygen
bleaching. Pages 229-36 in Proc. 6th Int. Symp. Wood
Pulp Chem., April 29-May 3, 1991. Melbourne, Australia.
Liebergott, N., B. van Lierop, and A. Skothos. 1992. A survey of
the use of ozone in bleaching pulps. TappiJ. (95)1:145-52.
McDonough, T.J., R.C. Kirk, B. Backlund, and L. Winter. 1987.
Catalysis in peroxide delignification. Pages 165-72 in
Tech. Ass. Pulp Pap. Indus. Int. Oxygen Delignification
Conf., June 7-12,1987. San Diego, CA.
O'Connor, B. et al. 1991. A study of the relationship between
laboratory bioassay response and AOX content for pulp
mill effluents. Pres. Swed. Environ. Prot. Agency Conf.,
Nov. 19-21,1991. Saltsjobaden, Sweden.
Patt, R., M. Hammann, and O. Kordsachia. 1991. The role of
ozone in chemical pulp bleaching. Holzforschung 45:87-
92.
Renberg, L. 1992. The use of cost-effective chemical and
biological bleaching plant effluents. Pages 31 7-30 in Proc.
Tech. Ass. Pulp Pap. Indus. Environ. Conf., April 12-15,
1992. Richmond, VA.
Smith, P.K.and T.J. McDonough. 1985. Transition metal ion
catalysis of the reaction of a residual lignin related com-
pound with alkaline hydrogen peroxide. Svensk Pap-
perstidn88(12):R106-12.
Swedish Forest Industry Water and Pollution Research Founda-
tion. 1991. Project Environment 90 (in Swedish). Final
Rep. Skogsindustrierna. Stockholm, Sweden.
Terashima, N. and K. Tatsumi. 1985. Oxygen degradation of lig-
nin VII, degradation of dehydrodivanillic acid with
hydroxyl radicals. Mokuzai Gakkaishi (31)9:761-65.
Vannerberg, N.-G. 1992. The reactions of lignin with alkaline
hydrogen peroxide. Part II. Factors influencing the decom-
position of phenolic structure. Acta Chem. (33):337-42.
95
-------
The Emerging Technology of
Chlorine Dioxide Delignification
Douglas W. Reeve
Pulp and Paper Centre
University of Toronto
Toronto, Ontario, Canada
Chlorine dioxide delignification, or 100 per-
cent substitution of chlorine dioxide for
chlorine, is an emerging industrial technol-
ogy. Chlorine dioxide can be used as the sole
oxidant for bleaching kraft pulp to full brightness
with excellent pulp strength and cleanliness.
Chlorine dioxide is an extremely effective bleach-
ing agent and should not be casually abandoned in
favor of nonchlorine, or totally chlorine-free
bleaching.
Chlorine dioxide has traditionally been used in
latter bleaching stages, that is, for chlorine dioxide
brightening, during which the pulp is retained in
large towers for many hours at medium consistency
(12 percent fiber in aqueous suspension). The
emerging technology, chlorine dioxide delignifica-
tion, uses chlorine dioxide as a complete substitute
for chlorine in the first stage of bleaching.
Chlorine dioxide substitution for chlorine was
first described in the 1960s, but was not immedi-
ately accepted because of its high operating cost
and because substantial amounts of acid were
produced in chlorine dioxide generators. In a 1985
survey, only eight North American mills were using
substantial substitution and none was using 100
percent substitution. However, in a recent survey of
Canadian mills, it is evident that substantial sub-
stitution has become standard operating procedure.
Chlorine dioxide delignification, or complete sub-
stitution, has also recently emerged in some
Canadian mills.
Chlorine dioxide delignification is completely
compatible with other emerging technologies, such
as extended delignification in kraft digesters, oxy-
gen delignification, lignin leaching of unbleached
pulp, enzyme treatment, and ozone bleaching.
Each of these techniques decreases the lignin con-
tent of pulp before it reaches the chlorine dioxide
delignification stage. Chlorine dioxide delignifica-
tion is also compatible with aggressive alkaline ex-
traction using oxygen or hydrogen peroxide.
Indeed, when these treatments are aggressive
enough to threaten the pulp's cellulose strength, the
gentle but effective treatment of chlorine dioxide is
necessary to produce pulp of good quality.
The development of on-site generator technol-
ogy to produce chlorine dioxide at an acceptable
price with acceptable by-products is vital to the
success of chlorine dioxide delignification. All gen-
erators are based on reduction of sodium chlorate
in strong acid solution. The R3/SVP™ technology,
dominant in the 1970s and 1980s, produced sig-
nificant chlorine by-product with the chlorine
dioxide solution. But chlorine formation is virtually
eliminated by switching to methanol as the reduc-
ing agent. This technology, called the R8/SVP-
Lite™ technology, emerged in the late 1980s and
now operates in many mills.
The other by-product from chlorine dioxide
generators — a form of sodium and sulfate ions —
must also be managed. The sodium sesquisulfate
[Na3H(SO4)2] formed in R8/SVP-Lite™ generators
is strongly acidic and usually in excess of pulp mill
sodium and sulfur makeup requirements. A new
process to recover sulfuric acid from the sesquisul-
fate, the R10™ process, has now been installed in
several mills. The sodium sulfate that remains can
be recovered through an electrochemical conver-
sion of the sodium sulfate into sodium hydroxide
and sulfuric acid.
96
-------
D.W. REEVE
In the R9™ process, electrochemical conver-
sion is linked to the R8 generator, chlorine dioxide
and sodium hydroxide are produced, and there are
no by-products. Chlorine dioxide generation
directly from chloric acid, another process under
development, would also completely eliminate by-
products.
Industrial Application of
Chlorine Dioxide Delignification
A recent survey of 39 Canadian mills that produce
bleached kraft pulp (34 mills were represented)
provides a clear picture of the rapid emergence of
chlorine dioxide delignification in Canada (Pryke et
al. 1992). In 1991, 5.4 million metric tons of
softwood and 1.5 million metric tons of hardwood
pulp were produced using substantial substitution
(25 to 75 percent), and a total of 1.3 million metric
tons of softwood pulp was produced using 100 per-
cent substitution. Total production in Canada in
1991 was 9.4 million metric tons; 87 percent was
produced by substantial or 100 percent substitution
— an extremely rapid rate of adoption of this prac-
tice (see Fig. 1).
Number c« Bleach
<1M7
1088 1980 1000 1001
Year When Substlutlon Began
1992
Figure 1.—Chlorine dioxide substitution practice.
Twenty bleach plants have had commercial
runs of 100 percent substitution and another 11
have run trials. According to the survey, the main
motivation for substantial substitution is to
decrease dioxins, furans, and other organo-
chlorines in pulp mill effluent. The principal source
of market pressure is in Western Europe; there does
not appear to be much pressure in North America.
The survey also requested information on ad-
vantages and disadvantages. The advantages of 100
percent substitution were many (see Fig. 2). Many
mills attained expected benefits of diminished
dioxins and furans. Many mills reported nondetec-
table concentrations were achieved by substantial
substitution and by 100 percent substitution. The
expected decreases in adsorbable organic halogens
(AOX) and color in effluent were confirmed. A few
bleach plants reported reductions in effluent
chemical oxygen demand (COD), acute toxicity,
and sublethal toxicity. Pulp quality was enhanced
in many mills. Viscosity, strength, shive/dirt
removal, pitch removal, and brightness reversion
were up and sodium hydroxide consumption was
down.
CHEMICALS
Bleaching costs
NaOH Consumption
Cl -NaOH Balance
Na/S Balance
BLEACHED PULP
Dioxins & Furans
Organ octilorine
Market Acceptance
Viscosity
Strength
Shlve/DIrt Removal
Pitch
Brightness Reversion
Brightness Limit
EFFLUENT
Dioxins & Furans
AOX
Colour
COD
Acute Toxicity
Sublethal Toxicity
0 6 10 15 20 26
Number of Bleach Plants
Figure 2.—Advantages of 100 percent substitution.
Cost was the main disadvantage reported for
100 percent substitution (see Fig. 3). Two bleach
plants reported decreased costs, while 24 bleach
plants reported increased costs. Reported increases
ranged from Can$9 to Can$15 per metric ton of
pulp. Many mills found the imbalance in pur-
chased sodium hydroxide and chlorine to be a dis-
advantage. Another disadvantage of increased
chlorine dioxide substitution is the production of
more sodium sulfate by-product than is required for
pulping chemical makeup. Many mills reported a
lower brightness limit when 100 percent substitu-
tion was used. To increase final brightness, some
mills used hydrogen peroxide to supplement caus-
tic extraction stages.
The advantages and disadvantages of substan-
tial substitution (25 to 75 percent) were similar with
several notable exceptions. Brightness limit was not
a major problem. In some cases, the cost of im-
plementing substantial substitution was much
lower than the cost of implementing 100 percent
substitution; the cost for substantial substitution
may range from Can$2 to Can$4 per metric ton (16
97
-------
Alternative and Emerging Technologies — Bleaching
CHEMICALS
Bleaching costs
NaOH Consumption
d -NaOH Balance
NaVS Balance
BLEACHED PULP
Dioxins & Furam
Organochlorlne
Market Acceptance
Viscosity
Strength
Shlve/Dirt Removal
Pitch
Brightness Reversion
Brightness Limit
EFFLUENT
Dioxins 4 Furans
AOX
Colour
COD
Acute Toxtoty
Subtethal Toxldty
0 5 10 15 20 25 30
Number of Bleach Plants
Figure 3.—Disadvantages of 100 percent substitution.
mills). In some cases (11 mills), there was a saving
of Can$2 to Can$4 per metric ton of pulp.
The average softwood kappa number for these
Canadian mills was 27 — still higher compared to
the low lignin pulps of leading edge technologies.
Neither oxygen bleaching nor extended delig-
nification are widely practiced in Canada to date.
Substantial and 100 percent substitution chlorine
dioxide delignification have been adopted much
more rapidly because of lower capital costs and
benefits more attuned to the needs of the Canadian
industry. We are presently expanding this survey to
the United States and the rest of the world and ex-
pect to have the results compiled in the near future.
Widespread adoption of this technology would
be possible with sufficient capital expenditure for
conversion or construction to expand chlorine
dioxide generation capacity. One potential impedi-
ment is the problem of the source of sodium
hydroxide for caustic extraction. A nonelectrolysis
source must be found to produce chlorine, and
sodium hydroxide must be found. Because caustic
extraction is always a necessary part of bleaching,
this problem is not unique to chlorine dioxide
delignification. It applies equally to all non-Cb
bleaching. One obvious alternative source is caus-
ticization of sodium carbonate incorporated with a
lime reburning cycle. The sodium carbonate may
be mined or may be taken from the kraft recovery
cycle; the lime reburning operations can be remote
from the pulp mill or integral with the existing kraft
mill operation.
Environmental Factors
Substantial chlorine dioxide substitution's numer-
ous environmental benefits have been extensively
described in the literature and validated by mill
studies, particularly with respect to dioxins,
chlorinated organic compounds, color, and, with
less certainty, biological impact. At 100 percent
substitution, no dioxins or furans are detected in
pulp or in mill effluent, as found in mill operations
(Wilson etal. 1991; Morgan etal. 1991).
Highly chlorinated phenolic compounds also
decrease with substantial substitution. In one mill
operating at 60 percent substitution, an increase to
100 percent substitution resulted in a further
decrease in chlorinated phenolic compounds of 94
percent (Wilson et al. 1990). In another mill study,
polychlorinated phenolic compounds were non-
detectable at 100 percent substitution, with the ex-
ception of dichloroguaiacol (Morgan etal. 1991).
Chlorinated organic matter, measured as AOX,
also decreases as chlorine dioxide is substituted for
chlorine. Furthermore, the character of the material
changes as substitution increases, becoming less
chlorinated and more oxidized. Most of the
material is quite water soluble and has little tenden-
cy to bioaccumulate. It has recently been shown
that approximately 50 percent of bleach plant ef-
fluent AOX is readily photolysed by sunlight to
produce chloride ion (Caron and Reeve, 1991).
No attempt will be made in this paper to deal
with the considerable controversy about bleach
plant effluents and their environmental impact.
Chlorine dioxide delignification certainly de-
creases the discharge of various pollutants of con-
cern and so is a step is the right direction.
When chlorine dioxide is used in pulp bleach-
ing, chlorate ions are formed and will appear in
bleach plant effluent. Obviously, increases in the
use of chlorine dioxide will increase the formation
of chlorate ions. However, chlorate can be readily
removed from bleach plant effluent by anaerobic
biological treatment or by treatment with sulfur
dioxide.
Economic Factors
One of chlorine dioxide delignification's great vir-
tues is that it can be used in existing bleaching
equipment at virtually all mills. Some very small
piping changes are required and, in some cases, a
new mixer may be required. However, existing
chlorination stage pumps, piping, mixers, towers,
and washers can all be used. This compatibility is a
significant savings. Usually, however, increased
chlorine dioxide generator capacity will be re-
quired, and existing generators must be upgraded
98
-------
D.W. REEVE
or replaced. For example, the capital costs to in-
crease the generator capacity in Ontario's kraft
mills was estimated by McCubbin et al. (1991) to
range from Can$2 million to Can$20 million per
plant with an average cost of about Can$9 million.
The operating cost of chlorine dioxide delig-
nification will also be site-specific. In some cases,
adoption of 30 to 50 percent substitution has been
found 'to decrease costs. However, for 60 to 100
percent substitution, cost increases are to be ex-
pected. As noted earlier, the survey found 100 per-
cent substitution costs Can$9 to Can$15 per metric
ton of pulp more whereas McCubbin et al. predict
cost increases of only Can$3 to Can$9. Implemen-
tation of oxygen and extended delignification will
decrease operating costs, so long as there are no
changes in pulp mill capacity. Both oxygen and ex-
tended delignification dissolve more material,
which is then recovered and burned in the recovery
boiler. If the mill capacity is limited by the recovery
boiler capacity, as is often the case, then this extra
material can only be recovered at the expense of
mill production. This reduction can add significant
financial burden to the project.
Pulp quality factors are particularly important
for market pulp producers and an extremely impor-
tant economic factor for all producers. Although
brightness ceiling may be a problem for some
species, chlorine dioxide delignification provides
very high quality pulp. Pulp strength is retained and
pulp cleanliness with respect to dirt, shives, and
pitch is excel lent.
Because chlorine dioxide delignification is the
subject of considerable research and development,
lower costs and better performance can be ex-
pected in the future. Chlorine dioxide delignifica-
tion is compatible with emerging pulping and
bleaching technologies and with bleach plant ef-
fluent recovery and treatment technologies.
Chlorine dioxide delignification is a valuable part
of the solution to pollution prevention; it can pro-
vide high pulp quality with low capital cost.
References
Caron, R.J. and D.W. Reeve. 1991. Environmental photolysis of
chlorinated organic matter discharged in kraft pulp bleach-
ing effluents. Pages 69-74 in Proc. 1991 Pulp Pap. Indus.
Environ. Conf. Tech. Sec., Can. Pulp Pap. Ass. Montreal,
Que., Can.
McCubbin, N. et al. 1991. Best Available Technology for the
Ontario Pulp and Paper Industry. Rep. ISBN 7729-9261-4.
Ontario Ministry Environ. Toronto, Onl., Can.
Morgan, J., A. Thakore, and K. Kranza. 1991. Mill scale evalua-
tion of pulp chlorination systems. Proc. 1991 Int. Pulp
Bleach. Conf., Swedish Ass. Pulp Pap. Eng., June 1991.
Stockholm, Sweden.
Pryke, D.C., M. Dumilru, R. Cunnington, and D.W. Reeve.
1992. A survey of chlorine dioxide substitution in
bleached kraft mills in Canada. Pres. Can. Pulp Pap. Ass.
Tech. Conf., May 14-16,1992. Jasper, Alta., Can.
Wilson, R. et al. 1991. Mill experience with chlorine dioxide
delignification. Pages 219-52 in Proc. 1991 Int. Pulp
Bleach Conf., Swedish Ass. Pulp Pap. Eng. Stockholm,
Sweden.
99
-------
Bleaching Papermaking Pulps
with Oxygen and Ozone in a
Commercial Installation
William H. Trice
Executive Vice President
Union Camp Corporation
Wayne, New Jersey
Ozone has been investigated extensively over
the past 15 to 20 years as a chemical to
replace chlorine and chlorine dioxide in the
bleaching of wood-derived pulp fiber used in
making paper and related products. However, its
use was never commercialized because of the low
strength of the paper and the cost of using ozone in
place of chlorine-based compounds.
Ozone Bleaching at Union Camp
Union Camp, in the mid-1970s, launched an inten-
sive research effort to develop suitable technologies
to eliminate chlorine-based bleaching chemicals
and to make the filtrates from the various bleaching
stages compatible with the kraft recovery cycle. In
this way, the organic material coming from the
bleach plant could be concentrated and burned in
the kraft recovery cycle, causing very significant
reductions in five-day biological oxygen demand
(BODs), color, water usage, and chlorine-contain-
ing materials, although the latter was not the re-
search's primary objective. Research results led to
the use of oxygen before the first chlorine stage on
all bleach lines installed by Union Camp since the
late 1970s.
By the mid-1980s, the drawbacks of using
ozone following an oxygen stage had been over-
come in the laboratory. A pilot process tested an
ozone bleaching stage on 25 tons per day. The pilot
plant's success led Union Camp to commercialize
the ozone extended delignification (OZED) bleach
sequence for Southern pine fiber at its Franklin, Vir-
ginia, mill with startup commencing in July and
August 1992.
The OZED (oxygen-ozone-caustic extraction-
chlorine dioxide) technology makes most of the
filtrates from the various stages compatible with the
kraft recovery cycle. Water consumption is re-
duced, as are pollutants in the bleach plant effluent
going to the secondary waste treatment system.
Union Camp's Franklin, Virginia, mill is one of
the largest uncoated printing and writing mills in
the world, and is located on the Blackwater River, a
tidal tributary of the Chowan River. The Black-
water's flows are such that the Chowan is only able
to receive well-treated effluent during the late fall
and winter months. A hold-and-release ponding
system accumulates the effluent for eight months
and then releases it in sequence during late
November, December, January, February, and early
March. This system has been in operation since the
mid-1960s with occasional enhancements.
Given the need to conserve water and reduce
effluent volumes, in 1970 the company researched
and installed a CEDED (chlorine-caustic extraction-
chlorine dioxide-caustic extraction-chlorine diox-
ide) sequence at the Franklin mill. The sequence
incorporated full countercurrent recycling of the
filtrates, as shown in Figure I. This development cut
water usage by more than 50 percent and, as far as I
am aware, was the first bleach line to employ this
technology.
During the early to mid-1970s, oxygen bleach-
ing was developed in France and Scandinavia and
first applied commercially at the South African Pulp
and Paper Industries' mill in South Africa. The tech-
nology offered significant incentives for reducing
BODs, chemical oxygen demand (COD), color,
and chlorine consumption. Union Camp's inves-
100
-------
W.H. TRICE
I
>ED
ISiSi:
t
Wash
Water
*
iSmf::
*
: Recovery
~; *l/fy i~v'' >/,*/
V Y>
Ki. V.
r
V
+
i
r
fBf
1 Chlorine Caustic
SEWER - All Bleach PI,
•*-
i
:fDf:
Chlorine
Dioxide
ant Chemicals
-
i
i>,;-:''^ .-.',•-.
-
Wash
Water
I
,p>
Caustic Chlorine
Dioxide
and all Dissolved Oraanics
Bleached
Figure 1.—The CEDED sequence.
tigations of its use on Southern pine and hardwood
kraft pulps resulted in the installation of an oxygen-
based sequence (see Fig. 2). This installation, a
nominal 800 to 900 tons-per-day kraft Southern
mixed hardwood bleach line, was started up in
1980, making it one of the first of its kind in North
America. About one-half of bleach plant effluent
pollutants are eliminated because about half of the
lignin remaining in the unbleached kraft pulp is
removed in the oxygen stage and recycled to a kraft
recovery cycle for evaporation and burning. During
the 1980s, we employed the same process to
bleach both Southern pine and hardwood kraft
pulp at our new Eastover, South Carolina, mill.
Our ultimate goal, however, was to make the
filtrates from all bleach stages, where most of the
dissolved organics originate, compatible for recy-
cling to the kraft recovery cycle. We wanted to
reduce BODs, color, and effluent volume. Reduc-
tion of chlorinated organics was not an objective
but a result of making the filtrates compatible for
recycling to the kraft recovery cycle.
The new process is based on ozone replacing
the combination of chlorine/ClOa in the stage fol-
lowing the oxygen first stage (see Fig. 3). Ninety
percent of the organic material removed in the
bleaching process is now recycled and burned in
the kraft recovery cycle.
Summary and Results
The use of ozone was and continues to be well-re-
searched at the laboratory level. However, ozone
was not commercialized until recently because of
high chemical cost and the strength of low paper-
making pulps. Union Camp overcame these
problems in laboratory studies conducted from the
late 1970s to the mid-1980s. As noted previously,
in 1985, we built a $6 million pilot plant at
our Eastover mill. The pilot plant allowed us to get
the data necessary to scale up the process; that is,
to firm up the reactor design and investigate
process parameters associated with filtrate recy-
cling.
CED
1"*"
OC/l
^ -
i*
ED
t
sV-wOom**
DED
i
mj^i
•
.
&jM&id
—
Iffl
1
— *•>
^~-
Wash
Water
\
•;~p>tv^-v.;f-
Washing
I
Recovery ,
^?v , vf *
i
*2f*!m
- '• • ^\J :•
\-
SEWEF
Wa
Wa
ss f -1-
t
.RecoVety;
.•^'V,^:/'
-^
\
ilorine
\ - All E
sh
ter
f
,-:>nM;::
•'-•.^J-f.
—
\ '
*£? t~*xtj--: .
&%, l-"-:^:~ •
:;vLZ-~-:: n
i r
^ :!E) j| ^
1 '
f,- -••.:• '••'•' .»fS:>.: •
!>?(lr*:®!&
wE%" *•
Wash
Water
I
Caustic Chlorine Caustic Chlorine
Dioxide Dioxide
3leach Plant Chemicals and all Dissolved Organics
Wash
Water
1
rv'ry .
\
!•• El —
{
."D"';r
(Oxygen 1 Chlorine cJtsfo Chlorine
| T Chlorine Dioxide Dioxide
45% Lignin SEWER - Only 55% of Dissolved Organics
a.
5
u
-^- 5
^"~ 0)
m
JO.
"8
-i
CD
Removal
Figure 2.—CEDED sequence and OC/DED sequence
101
-------
Alternative and Emerging Technologies — Bleaching
CEDED
Wash
Water
Chlorine Caustic
Wash
Water
1
4 4 4
Chlorine Caustic Chlorine
Dioxide Dioxide
SEWER - All Bleach Plant Chemicals and all Dissolved Organics
Bleached Pulp
1
£st\J;i
1 Chlorine
1 *
^ *,' IttM * f >J
Caustic
Wash
Water
t
fcW?
:<;:,L/t-
Chlorine
Bleached Pulp
T Chlorine Dioxide Dioxide
SEWER - Only 55% of Dissolved Organics
Wash
Water
Wash
Water
LTTLf
Oxygen
Figure 3.—Adding the OZED sequence.
After about four years of pilot plant studies,
Union Camp decided to build the 1,000 tons-per-
day softwood bleach line at our Franklin mill that
was started up this summer. As far as I am aware,
this is the first commercial ozone bleach line with
filtrate recycling. There are other ozone bleach
lines in various stages of construction, principally
being installed to eliminate bleaching with chlor-
ine-containing compounds but in these instal-
lations, the dissolved organic materials are still sent
to end-of-pipe treatment systems or discharged
directly to the receiving waters with no treatment.
The pollution prevention aspects of the process
are shown in Tables 1 through 3. Typical values for
BODs, COD, total organic halides (TOX), chloro-
form, color, and effluent volume are shown in Table
1 for Southern pine and hardwood pulps. The
values are extremely low. Also, dioxin was non-
detectable in the pulp and the filtrate from the last
chlorine dioxide stage. For comparison's sake, the
percent reduction in these parameters versus a
CEDED and O(C/D)ED sequences with 30 percent
substitution of dioxide for chlorine in the second
stage are shown in Table 2 at an 83 GE level of
Ozone
Caustic
Chlorine
Dioxide
SEWER-< 10% of
Dissolved Organics
Table 1.—Typical environmental emissions from
OZED bleaching to produce 83 G.E. brightness pulp
(all but D stage filtrates are recycled).
PINE
HARDWOOD
TOX*, kg/air-dried ton (ADT), pulp
TOX, kg/ADT, effluent
Chloroform, kg/ADT
BODs, kg/ADT
COD. kg/ADT
Color, kg/ADT (chloroplatinate test)
Volume of effluent, m3/ADT
Volume of effluent, gal/ADT
0.04
0.075
0.0015
2.0
6.0
1.5
7.5
1,800
0.03
0.06
0.0015
1.0
2.0
0.5
7.5
1,800
Total organic halides (also known as AOX, adsorbable organic
halogens)
brightness (GEB = General Electric Brightness: the
whiteness of pulp versus an absolute standard ex-
pressed as a percent). The effluent volume is cut in
half. Color, BODs, and COD are reduced about 80
to 95 percent or more.
Table 3 expands the comparison to other wood
species at market pulp brightness and a wider range
of bleach sequences. The percent reduction in
color, BODs, TOX, and COD is similar for the
102
-------
W.H. TRICE
Table 2.—Percent reduction in environmental emissions from OZED in producing 83 G.E. brightness pulp.
PINE
HARDWOOD
COMPARED TO CEDED COMPARED TO O(DC)ED COMPARED TO CEDED COMPARED TO O(DC)ED
TOX*. pulp
TOX, effluent
Chloroform
BODs
COD
Color
Volume of effluent
86
99
99
88
91
99+
86
67
98
98
69
73
96
47
85
98
99
88
91
99+
86
77
97
98
77
85
96
47
•Total organic halides
Table 3.—OZED percent reduction in bleach plant effluent 90 G.E. brightness pulp.
PERCENT REDUCTION WITH OZED
COMPARED TO REFERENCE SEQUENCE COLOR
Birch
Southern hardwood
Southern hardwood
Eucalyptus
Spruce/pine
Hemlock/Douglas fir
Southern pine
Southern pine
ODEDED
CEDED
O(D3oC)ED
CEDED
O(D?oC)EDED
CEDED
CEDED
0(D3oC)ED
88
99
96
98
98
96
99
96
BODs
76
88
78
87
—
91
88
69
TOX
71
98
97
97
97
84
99
98
COD
58
91
90
88
85
92
91
73
Table 4.—Tear obtained at a given tensile.
TEAR, dm1
Scandinavian birch
Southern mixed hardwood
Brazilian eucalyptus
Scandinavian spruce/pine
Canadian hemlock/Douglas fir
Southern pine
G.E.
BRIGHTNESS
89
88
89
89
88
88
CONVENTIONAL^
EOUENCE
75
87
88
145
154
108
OZED
SEQUENCE
75
85
86
135
161
111
AT TENSILE.
km. ofF2
6.0
6.0
6.0
7.5
7.5
7.5
'Energy required to tear a piece of paper into two pieces
'Force needed to break a piece of paper
various sequences, wood species, and at the higher
brightness level.
The strength of pulps bleached with this se-
quence, or slight variations of it, is comparable to
the strength resulting from a basic CEDED se-
quence or its variations that incorporate oxygen as
a first stage. Strength becomes harder to maintain
as brightness is increased, but even in the market
pulp brightness range, tear at tensile is equal for
pulps from several different wood species (see
Table 4). We have data in the 83 GEB range for
southern pine that also show strengths comparable
to OC/DED sequences.
At this point, based on laboratory and pilot
plant work, we believe that the basic sequence
shown, or variations of it, can produce bleached
pulps with acceptable strengths over a brightness
range that includes market pulp brightness and on
the wood species of commercial interest around
the world.
A logical question is whether the last chlorine
dioxide stage can be replaced with a hydrogen
peroxide stage. The most I am willing to say at this
conference, based on laboratory work, is that
modifications to the basic ozone sequence can be
made to incorporate hydrogen peroxide. This
modification makes the process chloride ion-free at
increased cost and with some limitations on the
range of brightness at which strengths are com-
parable to pulps produced with conventional se-
quences. It is easier with some wood species than
others to make acceptable pulps using hydrogen
peroxide.
Variable and Capital Costs
Union Camp has found variable and capital costs
to be quite site-specific and dependent on what
costs can be avoided in other parts of the operation
outside the bleach plant proper. The percent reduc-
103
-------
Alternative and Emerging Technologies — Bleaching
Table 5.—OZED percent reduction in bleaching chemical costs to produce 90 G.E. brightness based on raw
material costs.
CONVENTIONAL BLEACHING
100% SUBSTITUTION
REFERENCE SEQUENCE
\ REDUCTION
REFERENCE SEQUENCE
% REDUCTION
Birch
Southern hardwood
Eucalyptus
Spruce/pine
Hemlock/Douglas fir
Southern pine
O(DC)EDED
CEDED
CEDED
O(DC)EDED
CEDED
CEDED
42
20
16
35
38
55
ODEDED
DEDED
DEDED
ODEDED
DEDED
DEDED
47
52
46
32
61
68
tion in bleaching chemical cost to produce 90 GEB
pulps using different sequences are shown in Table
5. As chlorine dioxide is substituted for chlorine,
the reduction in bleaching chemical cost can be as
much as 68 percent on Southern pine. Typical
market prices were assumed for the various chemi-
cals except ozone, where the on-site generation
cost was most appropriate.
Capital costs for the ozone stage and the ozone
generation equipment generally adds 20 to 30 per-
cent to the capital cost for the bleach line over an
OC/DED sequence. However, it is frequently pos-
sible to offset most, if not all, of this added cost
through elimination of chlorine unloading and han-
dling systems, a smaller CIO2 plant and smaller
end-of-pipe waste treatment facilities. No addition-
al evaporator capacity is required, and only 3 per-
cent more recovery boiler capacity is required over
oxygen-based sequences. For a new mill or a sig-
nificant expansion of an existing site, the capital
costs may well be equivalent. Clearly, this analysis
of the pollutant abatement advantages and average
variable and capital costs associated with ozone
bleaching suggest that it will be a commercially im-
portant technology for bleaching kraft pulp.
104
-------
Saving Bleaching Chemicals and
Minimizing Pollution with Xylanase
Lubomir Jurasek
Head, Biological Chemistry Section
Michael G. Paice
Senior Scientist
Pulp and Paper Research Institute of Canada
Pointe Claire, Quebec, Canada
The use of chlorine in pulp bleaching is a
source of environmental concern since the
process results in a discharge of chlorinated
organic compounds to receiving waters. In
response to this concern, the international pulp and
paper industry is modifying or completely changing
its bleaching technology. The trend is to reduce the
use of elemental chlorine by substituting chlorine
dioxide, thereby preventing the formation of
dioxins and minimizing the production of other or-
ganochlorine compounds (Berry et al. 1989). In ad-
dition, several new processes are being developed
to eliminate the use of chlorine chemicals and to
bleach pulp using only oxygen, hydrogen peroxide,
ozone, or other chemicals (Liebergott et al. 1984).
These alternative processes are more expensive
and may damage pulp strength and other properties
if used at high chemical charges.
Xylanase Works with a Variety
of Bleaching Processes
Biotechnology is playing a role in the transition to
chlorine-free bleaching. Viikari et al. (1986) dis-
covered that a brief treatment of pulp with the en-
zyme xylanase enhances pulp bleachability. The
effect is illustrated in Figure 1. In this case, pretreat-
ment of the softwood pulp with xylanase resulted in
15 to 25 percent savings of chlorine needed to
bleach pulp, with an average saving of about 15
percent. Xylanase's efficacy seems to be correlated
with its ability to depolymerize xylan, a normal
component of pulp. The xylan may entrap or
covalently bond the lignin chromophores in the
pulp.
The mechanism proposed by Paice et al. (1992)
is illustrated in Figure 2. Depolymerization of xylan
allows lignin to diffuse more easily from the fiber
wall. As a result, lower charges of bleaching chemi-
cals can remove lignin to a desired degree. This
mechanism allowed us to predict that xylanase will
aid bleaching not only with chlorine but also with
other bleaching chemicals, and its efficacy has now
been confirmed in bleaching sequences using
chlorine dioxide, oxygen, hydrogen peroxide, and
ozone.
CONTROL
40
35 I
Chlorine, %
Figure 1.—Effect of xylanase on subsequent chemical
bleaching of black spruce kraft pulp. Initial Kappa num-
ber = 30.1. (From Paice et al. 1992).
Applying Xylanase in a Mill
The application of xylanase in a mill is very simple
— usually only a small laboratory pump is needed
to deliver the enzyme solution at a flow rate of ap-
105
-------
Alternative and Emerging Technologies — Bleaching
—Cellulose
^Glucomannan
— Xylan
-Residual Lignin
— Xylan
— Glucomannan
-Cellulose
Figure 2.—Proposed structure of secondary wall of un-
bleached kraft pulp, based on model of Page (1976). Ar-
rows show sites of xylanase attack. Subsequent
opening up of the xylan structure results in increased
diffusion of residual lignin and decreased size of lignin-
carbohydrate fragments. (From Paice et al. 1992).
proximately 1 liter per minute to the pulp system. It
is also necessary to adjust the pH levels to a range
compatible with the enzyme activity, somewhere
between four and nine. Estimates for the capital
cost of enzyme delivery and pH adjustment vary
from Can$10,000 to Can$100,000. Some mills al-
ready adjust the pH levels to minimize pitch
problems. In these mills, the capital cost is even
lower. Figure 3 shows an example of a system used
recently in a Canadian mill in which the Pulp and
Paper Research Institute of Canada conducted a
trial with a commercial enzyme supplier (Scott et
al. 1992).
PH
PROBE
0100
(STOCK
PUMP
Figure 3.—Process equipment for Canadian mill trial
with 100 percent chlorine dioxide substitution. (From
Scon et al. 1992).
The pH level of the pulp was adjusted to 5.5 by
adding sulfuric acid through a shower after pulp
washing, and the enzyme was added to the repul-
per. Additional mixing was provided by a high con-
sistency pump and the enzyme reaction took place
in the brownstock storage tower during its normal
retention time of 1.5 hours at 55"C. As soon as the
enzyme worked its way through the pulp system,
pulp brightness sensors registered an increase (after
the third bleaching stage). This result allowed the
setpoint of chlorine dioxide sensors to be lowered.
Thus, the chlorine multiple was decreased from
0.265 to an average of 0.19. The lowest chlorine
multiple tested was 0.173 and yet the plant con-
tinued to produce fully bleached pulp. Reduction
of the chlorine multiple led to a decrease of adsor-
bable organic halogens (AOX) emission from 0.95
to 0.75 kg per air-dried finished ton (ADFt) (see Fig.
4), based on samples taken after the biotreatment
basin.
1.4
13
1.2
1.1
1
oa
OA
0.7
0.6
OS
OA
0.94 kg/ADR
.Control
With
0.75 kg/ADR
7 8 9 10 11 12 13 14 IS IB 17
Sampling Dates (December 1991)
Figure 4.—Total bleach plant effluent AOX after 24-hour
biotreatment in a biobasin. (From Scott et al. 1992).
The reduction of AOX emissions was propor-
tional to the decreased charge of chemicals needed
to accomplish pulp bleaching to a given brightness.
Strength of fully bleached pulp was measured
during the mill trial and no changes were observed
when compared to a control period before the trial.
Thus, the application of xylanase resulted in chemi-
cal savings and reduction of pollutants while fully
maintaining the pulp quality.
Positive results were also reported from mill tri-
als with chlorine-free technologies. Genencor In-
ternational reported recently that in a bleaching
sequence employing oxygen and two alkaline
peroxide extractions, the pulp brightness increased
by 2 to 4 points with no adverse effects on pulp
strength.
The quality of the enzyme and the process con-
ditions are an important consideration. Overdosing
with the enzyme may result in unacceptable pulp
yield loss. Contamination with traces of cellulase
can severely damage pulp strength and must be
avoided.
Xylanase is available in industrial quantities
from several commercial suppliers. Table 1 lists
sources that are known to us at this time. The en-
zymes are sold as concentrated liquids and the
amount required for a ton of pulp is therefore very
small. The enzyme cost per ton of pulp is variable
and depends on dosage required. The economy of
106
-------
L. JURASEK & M.C. PAICE
Table 1.—Industrial xylanase suppliers (alphabetical list).
SUPPLIER
Alko, Biotechnology Division, Finland
Tel. in Canada: (416) 881-9639
Genencor International, Inc., U.K.
Tel. 44-737-773732
logen Corp., Canada
Tel. (613) 733-9830
Novo-Nordisk Bioindustrials, Inc., USA
Tel. (203) 790-2671
Sandoz Chemicals, USA
Tel. (704)331-7334
Voest-Alpine Industrieanlagenbau, Austria
Tel. 43-732-592-3681
PRODUCT
Ecopulp
Albazyme 10
Albazyme 40
Xylanase (two types)
Pulpzyme HA
Pulpzyme HB
Cartazyme HS
Xylanase production line
OPTIMUM pH
5-6
6-7
7.5
5-6
7-8
5-6
7-8
4-5
6-7.5
OPTIMUM TEMPERATURE
('CELSIUS)
55
60
65
55
55
55
55
50
65-75
Table 2.—Xylanase technology status (approximate data).
Commercial use
Mill trials
TCP vs. chlorine bleaching
Softwood vs. hardwood
Kraft vs. sulfite
10 mills total; 6 in Europe, 4 in Canada.
85 altogether; 45 in Europe, 24 in Canada, 15 in the United States, one in Japan.
Most xylanase trials were in combination with chlorine/chlorine dioxide bleaching technologies.
Trials with totally chlorine-free technology are on the increase.
15 mill trials were with hardwood, the remaining 70 with softwood.
Only one mill trial was performed in a sulfite mill.
the process improves in combination with high
chlorine dioxide substitution levels. Table 2 sum-
marizes the current commercial state of the tech-
nology. It is evident that the process is gaining
acceptance particularly in Europe and in Canada,
and that xylanase will become more and more
common in the paper and pulp industry worldwide
over the next few years.
References
Berry, R.M. et al. 1989. Toward preventing formalion of dioxins
during chemical pulp bleaching. Pulp Pap. Can. 90(8):48-
58.
Liebergotl, N., B. Van Lierop, G. Teodorescu, and C.J. Kubes.
1984. Bleaching a softwood krafl pulp without chlorine.
TappiJ.67(8):77-80.
Page, D.H. 1976. A note on the cell-wall structure of softwood
iracheids. Wood Fibre 7:246-48.
Paice, M.C., N. Curnagul, D.H. Page, and L. Jurasek. 1992.
Mechanism of hemicellulose-directed prebleaching of
kraft pulp. Enzyme Microbial. Technol. 14:272-76.
Scolt, B.P., F. Young, and M.G. Paice. 1992. Mill-scale enzyme
treatment of a softwood krafl pulp prior to bleaching. Proc.
1992 Pacific and Western Can. Pulp Paper Ass. Meet.
Jasper, Canada.
Viikari, L. et al. 1986. Bleaching with enzymes. Pages 67-69 in
Proc. Third int. Conf. Biolechnol. Pulp Pap. Indus., June
16-19, 1986. Swedis Pulp Paper Res. Insl. Stockholm,
Sweden.
107
-------
Panel 4:
Alternative and Emerging
Technologies — Bleaching
Question and Answer Session
• Med Byrd, North Carolina State University: I
would like to direct this question to Dr. Jurasek and
Dr. Axegard. It seems that the beneficial effect of
enzymes depends on whom you ask, on whether
the person is working with enzymes or not. People
who are working with enzymes show a beneficial
effect and, indeed, mill applications and trials are
going on at a pretty good clip. However, when you
talk to the people working with the more conven-
tional nonconventional bleaching agents, like
ozone, chlorine dioxine, oxygen and peroxide,
they will say, as Dr. Axegard pointed out, that en-
zymes add little or no benefits to a modern bleach
sequence. Can you help explain the disparity in
these views that we hear all of the time?
• Lubomir Jurasek, Pulp and Paper Research In-
stitute of Canada: It is reported that the use of en-
zymes allows one to decrease the chemical charge
of chlorine dioxide and chlorine by about 20 per-
cent with oxygen; with hydrogen peroxide and
ozone, enzymes are somewhat less effective, so the
chemical charge decrease is only about 10 percent.
This may be due to the state of... in the pulp and
the mechanism of the bleaching. But what off-sets
the decreased efficiency of the enzyme is the in-
creasing price of the chemicals being used as
chlorine substitutes. With chemicals such as ozone,
one tries to keep the concentrations and charges as
low as possible because of the possible danger of
viscosity of the pulp — any help from xylanase is
appreciated.
• Peter Axegard, Swedish Pulp and Paper Re-
search Institute: Maybe we have compared dif-
ferent systems. We can assume that enzymes are
quite large molecules that are basically directly on
or close to fiber surfaces. So in systems in which
you have precipitation of lignin and carbohydrates,
enzymes are quite likely to help. For instance, if
you are losing pH or alkalinity, you may be helped
by enzymes. Such cases are quite common, but in
my mind, they are a poor reference. Enzyme use is
experimental.
• Norman Liebergott, DuPont Canada, lnc.:\ have
two questions. Peter, you picked the sequence
OQ(EPO)Z(EP) as your best one. But I don't under-
stand why you put the Q in that certain spot. Is it to
improve or enhance the EPO? But we also found
that a small Q before the Z, enhances the Z, or after
the Z will enhance the second EP, there is still left...
in the pulp that for some reason the ozone does not
get moved.
• Peter Axegard: I guess there is some truth in
what you say. The sequence can be developed.
That's one answer.
• Norman Liebergott: There are many answers.
The same thing I'm pointing out to Imo there.
When you looked at your sequence and replaced
the chlorine dioxide, should we say with ozone, if
you also look at the gain before peroxide stage, you
find that after the Z stage, a chelation stage is very
important. Have you tried that in your lab or pilot
plant?
• William Trice, Union Camp Corporation: I think
we have tried just about everything in the lab. I am
not sure that I want to comment on that. I think
108
-------
QUESTION & ANSWER SESSION
most people have found that chelation of metal
ions is a necessity for peroxide bleaching. I really
don't think that there is any evidence to change
that.
• Lubomlr Jurasek: But many people think that if
you are doing an ozone stage at lower pH (and
most people do), that this would remove the metal
ions, but unfortunately it doesn't. This is why when
people say they can recycle the whole ozone ef-
fluent without going backward and . . ., I say good
luck to you because the metal ions do build up in
the system.
• William Trice: How you handle the filtrates is a
significant part of the technology. It is not as easy as
it looks, I'll give you that.
• Lubomlr Jurasek: The last question was about
using enzymes. Enzymes have a certain effect on
certain bleaching sequences at a certain cost rate. It
depends on what you want to spend and what you
want to get. Some people have said that a one or
two point brightness gain for a TCP sequence is
very important because they must maintain bright-
ness and for that they would or would not use en-
zymes.
• Mark Floegel, Greenpeace: I have a question for
Douglas Reeve. Traditionally, technology in the
pulp and paper industries has been slow to change
but I think most people would agree that change is
becoming rapid. You were talking about chlorine
dioxide substitution as being driven by reductions
in AOX and market pressure. Then you noted that
one of the highlights of the chlorine dioxide sub-
stitution is getting the company to invest in a large
generator system. Given the market pressure that
I'm reading about in the trades today, the already
burgeoning market for TCP pulp and British
Columbia's zero discharge regulation for the year
2002, aren't you recommending a 20-year invest-
ment for a 10-year technology?
• Douglas Reeve, Pulp and Paper Centre, Univer-
sity of Toronto: No. I am not persuaded that the
universe will unfold as you have described. I am
not persuaded that the British Columbia zero dis-
charge regulation will stick by the year 2002 — just
as the ban on nuclear power in Sweden is unlikely
to stick — because many economic realities have
to be faced before that time. I think the develop-
ment of the TCP pulp market in North America
remains to be seen. Who knows whether North
American consumers will accept the higher costs
and lower quality for TCP pulps? I think that
remains to be seen.
• Mark Floegel: The question that I am asking is
whether you are asking the industry to take that
gamble. You have a version of the way the world
will unfold and so do I, but in the balance is a very
expensive investment.
• Douglas Reeve: I am describing what has taken
place in Canada and I am describing an alternative
for modifying a bleaching sequence to solve part of
the problem of pollution prevention.
• Richard E. Phillips, International Paper: We
have run numerous mill trials and literally dozens
of laboratory experiments on every commercially
available enzyme. And their effect, if they have any
effect at all, is less than 10 percent. I suggest that we
may be more technologically advanced. I think, as
Peter AxegSrd pointed out, the better your oxidative
extraction stage is, the better your first bleaching
delignification stage is, the less effect you will see
with enzymes. In addition to that I would submit
that those people who practice extended delig-
nification are probably removing much of the lig-
nin that is potentially soluble by virtue of the
enzymes that may be acting on the hemicelluloses
in preventing the lignin to come out. So we do not
see much effect and we are not very excited about
enzymes. We don't see them as cost effective at this
point — but for a different reason from the one that
your Canadian colleague has proposed.
• Bruce Fleming, Boise Cascade: Peter, on one of
your earlier slides, you had the words, "TCP Market
Pressure." Mr. Floegel just referred to it again. I
would like to investigate what this market pressure
is. We hear a lot about market pressure, and yet I
understand in Sweden, when the Aspa company
started making TCP pulp, the . . . pulp mill had to
take downtime for inventory control and they were
only making about 200 tons a day of TCP pulp.
What is the depth in the TCP market, and is there
really any pressure there?
• Peter Axegard: There is definitely an interest
larger than the current volume. One of the reasons
Aspa discontinued production was that they had a
competitor, I think, of higher quality. They went
back to chlorine dioxide bleaching because there
were other producers of TCP that made better
quality.
• Bruce Fleming: Can you give us an estimate of
the amount of TCP pulping in Sweden?
• Peter Axegard: I think it is quite small. I couldn't
guess, but let's say around 5 percent of the
bleached kraft pulp. A session tomorrow or the day
after may bring this topic up again.
109
-------
Alternative and Emerging Technologies — Bleaching
• Ken Wlesner, Wisconsin Department of Natural
Resources: In Wisconsin, the industry emits about a
million pounds of chloroform annually. Most of our
discussions have focused on reducing dioxins and
furans, and since we seem to whip that problem,
maybe we could move on to the other. The ques-
tion I have is whether the process modifications
we're making that primarily focus on dioxin and
furan reduction are also as effective in trying to
knock down the chloroform emissions. These come
off the bleaching stages as well as releases to the
biological wastewater treatment plan.
• Douglas Reeve: As you increase substitution in
the chlorination stage, chloroform production is
dramatically decreased, and chloroform is certainly
not manufactured in the treatment plant. If it is
manufactured in the chlorination stage or the
hypochlorite stage, which is where it has pre-
viously been manufactured in greatest amount,
then it would be blown out in the treatment plant.
So. If it's not manufactured when you use substan-
tial substitution, it's not going to appear in the treat-
ment plant.
• Ken Wiesner: Is chloroform measured as part of
AOX?
• Douglas Reeve: No, it is not.
• Norman Llebergott: May I return to Doug Reeve
and his friend from Greenpeace. A lot of the
Canadian mills are looking at using a small D stage
up front, that is, using chlorine dioxide in a lower
amount than you would normally use for complete
delignification. Then a very strong EOF stage would
be used followed by a PDF or a DPP or whatever
you want to call it. This sequence can produce 89
to 90 brightness pulp, with very low levels of AOX
— in mill trials sometimes as low as .5 or .4. This
produced very good pulp and had very good ef-
fluent qualities, too. So when people say that they
are still thinking about investing in chlorine
dioxide, there's still something there, I think.
• Nell McCubbln, N. McCubbin Consultants, Inc.:
Permit me to mix a question and a comment. With
respect to TCP pulp capacity, my figures point to a
capacity of 3-million tons per year for totally
chlorine-free bleached kraft pulp; and to sales of
about half a million tons per year. Now, these
figures disagree with the oft-repeated statement by
Greenpeace that if the nasty old industry would
only make totally chlorine-free pulp, the world
would rush to buy it. I wonder if anyone can throw
out better figures than mine — which I got by phon-
ing around prior to a meeting three weeks ago. Can
someone come up with better numbers particularly
for TCP sales? Is half a million a good estimate?
• Ladd Seton, Fraser Paper: You are stealing my
thunder. The day after tomorrow we have a session
on market pulp and these are, in fact, the topics that
I plan to address. And I believe that you are asking a
very valid question. I think the market question is
very important, so please come on Thursday after-
noon.
110
-------
Wednesday, August 19,1992
TRADE-OFFS, PERFORMANCE,
AND GOVERNMENT ACTIVITIES
PANEL i: Trade-off Issues
PANEL 2: Technical Perspectives — Specifications
PANEL 3: Technical Perspectives — Performance
and Cost
PANEL 4: Government Activities
PANEL 5: EPA Activities
-------
The Properties of Pulps Bleached
in Low-Chlorine or Non-Chlorine
Sequences
Norman Liebergott
Special Consultant
DuPont Canada, Inc.
Laval, Quebec, Canada
Commercial bleaching sequences applied to
chemical pulps have shown many improve-
ments in the last 20 years. They produce ac-
ceptable products while conforming more and
more with energy and environmental restrictions.
The increased use of chlorine dioxide, oxygen, and
hydrogen peroxide are apparent in improved
bleaching stages. Better equipment design is also
improving the technology of bleaching. New
mixers, new washers, medium-consistency equip-
ment and better control systems improve the ef-
ficiency of the bleaching process. With all this
activity in the pulp manufacturing area, three ques-
tions arise: (1) Why should pulp be bleached? (2)
Why is pulp bleaching technology changing? and
(3) What are the best bleaching sequences?
1. Natural fibers (from wood or other sources)
obtained from a pulping process vary from a manila
white to a dark brown depending on the pulping
process. The colored material in the pulp comes
from lignin and its reaction products, resins and
degraded polysaccharides. There are many
answers to the question why we bleach but to me
"to make the pulp suitable for the desired end use,"
is the primary one.
2. Pulp bleaching technology is changing be-
cause of environmental concerns. The North Amer-
ican pulp and paper industry is committed to
making changes in the bleach plant to suppress the
discharge of undesirable by-products into the
receiving water environment. The by-products of
particular concern are chlorinated organic com-
pounds formed during a chlorination stage in
which molecular chlorine is the main bleaching
constituent. Their elimination naturally hinges on
using less chlorine in the bleach plant (Berry et al.
1991). Several options are now commercially vi-
able that can decrease the chlorine usage in the
bleach plant; see, for example, Axegeird et al. 1991 ;
Basta et al. 1990; Bowen and Hsu, 1990; and
Liebergott et al. 1991. The most common option is
to use chlorine dioxide instead of chlorine in the
chlorination stage (Pryke et al. 1991). By resorting
to oxidation reactions to delignify the pulp, the
resulting effluents contain less adsorbable organic
halogens (AOX) and the chlorolignins are consider-
ably less toxic than those produced when bleach-
ing with molecular chlorine (Berry et al. 1991;
Liebergott etal. 1991).
3. The choice of a bleaching sequence and the
technology for such a sequence depends on
(a) Whether the species is wood or nonwood;
(b) The cooking process;
(c) The chemical, physical, and optical
qualities desired in the bleached pulp;
(d) The quality of the effluent (whether it meets
no-detect levels for dioxins or furans, has
low or no AOX and chloroform, and low
chemical and biological oxygen demand
[COD] and [BOD] and color);
(e) Whether primary, secondary, or tertiary
treatments of the effluent are available;
(f) Whether the recovery boiler has excess
capacity;
(g) The present bleaching sequence;
(h) What equipment can still be used; and
(i) How much new capital funds are available.
112
-------
N. LIEBERGOTT
Table 1.—Typical pulp strength characteristics.
Burst Index
kPa.m2/g
Tear Index
mN.M2/g
Tensile
meters
ACID SULFITE
4.5 -7.5
7.5 - 9.5
7,5000 -
8,5000
BI-SULFITE
6.0 - 8.0
8.5 - 9.5
10,5000-
11,500
HIGHY1ELD SULFITE
3.0 - 6.0
8.0-11.0
3,500-
6,500
ALKALINE SULFITE
8.0-10.0
10.0-12.0
11,000-
12,000
KRAFT
8.0-10.0
10.0-12.0
11,000-
13,000
all at free ness 300 CSF
The objective of this paper is to consolidate the
various new pulping and bleaching processes and
evaluate the effluent properties and the pulps. This
evaluation will help particular mills select the most
appropriate sequence.
Kraft Pulping and Bleaching
Some typical pulp strengths for a spruce and bal-
sam pine mixture produced by different pulping
processes are shown in Table 1. The kraft pulping
process produces pulp with high strength charac-
teristics that can sometimes be equalled by the
alkaline sulfite pulping technique.
The initial removal of lignin is accomplished in
the cooking process. However, these pulping
processes cannot completely remove the lignin
without seriously degrading the carbohydrate frac-
tion and affecting the yield and strength of the pulp.
Bleaching is a continuation of the pulping process
and chlorine is usually used in the first bleaching
stage. This use of excessive quantities of chlorine
has led to concern for the environment, and dif-
ferent strategies to decrease the chlorine have been
used.
Because the quantity of chlorine necessary to
bleach pulp is a function of the kappa number of
the pulp, a lower kappa number before the
chlorination stage means lower chlorine usage
(Liebergott et al. 1991). Several methods can be
used to decrease the kappa number of the
brownstock.
Extended Dellgnlflcatlon
Conventional kraft pulping produces bleachable
grade pulps at kappa numbers of 28 to 32 on
softwoods and 15 to 22 on hardwoods. Lower
kappa numbers can be obtained by modifying the
pulping process to improve the selectivity of delig-
nification.
Extended delignification, such as modified
continuous cooking (MCC) (Macas et al. 1991),
rapid displacement heating (RDM) (Andrews et al.
o_
Pulp Kappa No.
SWK
30.3
D Ext. SWK 24.7
HWK
15.8
O Ext. HWK 10.9
0 10 20 30 40 50 60 70 80 90 100
% CIO2 in "C" stage
Figure 1.-Less AOX Is formed In the bleach effluents
when a pulping process dellgnlfies to lower kappa num-
bers, and when more chlorine dioxide Instead of
chlorine Is used In the C-stage.
1991) or extended SuperBatch kraft™ cooking
(Boman et al. 1991) decreases the kappa number of
the brownstock and hence the chlorine charge (Fig.
1). These techniques are presently operating in
several Canadian and U.S. mills. Sulfite pulping
can also be modified to decrease the kappa num-
ber.
Oxygen Dellgnlflcatlon
Oxygen-type delignification in prebleaching stages
(O, EO and EOF) decreases the kappa number prior
to chlorination and thus the effluent loading (BOD,
COD, color, AOX, chlorinated phenolics and
toxicity to fish) emanating from the bleach plant
(Liebergott et al. 1991). The delignification ex-
pected from the various oxygen-reinforced stages is
shown in Table 2. An oxygen-type delignification
may decrease the kappa number of softwood kraft
pulp from 30 to a range as low as 16 to 22 and thus
decrease the AOX in the effluent of a (Cgo+DioXE-
O)DED bleaching sequence from 6 kg per tonne to
3.9 (Fig. 2).
113
-------
Trade-off Issues
£.
3
Spruce-Fir-Plne Kraft
Kappa No.
• Unbl. 30.0
D Eo 23.5
• Eop 20.5
O O 16.6
0
< 5
*rf
ID
E
100
Percent CIOz substitution in C-stage
Fig. 2 Less AOX Is formed in the bleach effluents when
the pulps are delignlfled to lower kappa numbers, and
when more chlorine dioxide instead of chlorine is used
in the C-stage.
Table 2.-Type and Efficiency of Pre-treatment Stage
STAGE
p
EO
EOP
O
POSSIBLE DECREASE IN KAPPA NO. OF BROWNSTOCK
20%
25%
30-35%
40-50%
Enzyme Pretreatment
The concept of using a hemicellulose to improve
pulp bleaching was originally presented in 1986
(Viikari et al. 1986). Many other reports followed
showing that laboratory treatments of brownstock
with selected enzymes of the hemicellulytic type,
particularly xylanase, hardly affect the kappa num-
ber of the pulp (Liebergott and van Lierop, 1978;
Liebergott et al. 1984; LaChenal and Taverdet,
1991; Lindholm, 1991). The chlorine requirement,
however, decreases by about 30 percent to achieve
the same "C"Eo kappa number as its untreated
counterpart. This recent technology has been suc-
cessfully tried in 10 mills. Apparently, the xylanase
modifies the hemicellulose such that the chlorine is
capable of removing a greater fraction of the lignin.
Xylanase pretreatment does not affect pulp
strength.
Decreasing the Kappa Factor
The most efficient bleaching is obtained by remov-
ing the bulk of the lignin in the first chlorination
and extraction stages. This removal is accom-
plished by applying a specific quantity of chlorine
which is related to the kappa number of the pulp
entering the stage. This chlorine requirement is
conveniently expressed as kappa factor or active
chlorine multiple, which is derived from the total
active chlorine charge (expressed as percent on
oven-dry pulp) divided by the kappa number of the
pulp entering the chlorination stage. Thus, an un-
bleached pulp at a kappa number of 30 would re-
quire a charge of 6.6 percent active chlorine on
pulp, based on a kappa factor of 0.22.
A decrease of the kappa factor from 0.22 to
0.17 can be accomplished by reinforcing an oxida-
tive extraction stage with peroxide (Eop). By im-
proving the efficiency of the extraction stage, less
chlorine is required in a "C"(Eop) process than
"C"(Eo) to achieve the same kappa number (Table
3). Magnesium sulfate should be added to the Eop
extraction to retain pulp strength (see Fig. 3).
Table 3.-Varing the active chlorine multiple in "C."
PROPERTIES AFTER "C" Eo
"C"Eo-STAGETYPE
(Cgo + Dio) Eo
(Coo + Dio) Eo
(Cgo + Dio) Eop
(DsoCso) Eo
(DsoCso) Eo
(DsoCso) Eop
4.0 kb HaOz/t pulp in Eop
ACM
.22
.17
.17
.22
.17
.17
KAPPA
NO.
3.4
5.1
3.8
2.8
4.8
2.7
AOX
kg/ADTBP
5.6
4.4
4.6
3.7
2.8
2.7
18
.0)16
Z 14
E
$ 12
c3 10
H
8
Softwood Pulp
CgoD,0(Eop)DED
MgSO4
• 0.25%
• 0.00%
6
14
8 10 12
Breaking Length, km
Figure 3.-Effect of MgSO4 in the EOP stage on pulp
strength.
High Chlorine Dioxide Substitution
An increase in the substitution of chlorine dioxide
in the chlorination stage from 50 to 100 percent in
the (DcXEo)DED sequence also decreases the
chlorinated phenolic compounds, color, and AOX
in the effluent and eliminates a large portion of the
toxicity to fish (see Fig. 2). High chlorine dioxide
substitution (70 to 90 percent) does not, however,
substantially lower the BOD and COD values of
the effluent. One hundred percent chlorine dioxide
substitution in the chlorination stage decreases the
114
-------
N. LIEBERGOTT
AOX in the effluent by 70 to 80 percent and the
chlorinated phenolic compounds by 95 percent.
Several mills have tested this technology and
confirmed the laboratory results (Pryke et al. 1991).
High substitution of CIO2 (100 percent) increases
the "C"(Eo) kappa number which in turn causes
lower brightnesses after DED brightening. Using
peroxide in the oxidative extraction and the E2
stages can overcome the deficiencies of high CIO2
substitution. Magnesium sulfate added to the Eop
and £2 stages protects pulp viscosity (Table 4). As
the CIO2 generation capacity expands, more mills
will use this technique to comply with environmen-
tal regulations.
Table 4.—DiooEo and DiooEop dellgnlflcatlon of a
softwood kraft pulp
Kappa No., 29.5; Viscosity, 41.0 mPa.s
Extraction Stag*
MgSO4 KAPPA VISCOSITY AOX CHLORATE
% NO. mPa.« kg/ADTBP kg/ODTP
Eo
Eop
Eop
0
0.4
0.4
0
0
0.05
4.6
3.2
3.3
35.5
28.7
34.9
1.51
1.59
1.58
4.68
4.64
4.63
Conditions: Dioo; Consistency, 3.5%; 40 mins.; 40*C; pH2.3.
Active Chlorine Multiple, 0.22; D charge, 2.46%, CIC-2 on
pulp O.D. basis.
Eo and Eop, Consistency, 10%; 60 mins.; 60'C; 02 pres-
sure, 20 psig for 10 mins.; NaOH charge, 2.30%.
The effect of three different bleaching tech-
niques on the tear breaking length relationship of a
softwood kraft pulp are shown in Figure 4. Lower-
ing the chlorine multiple using Dioo and an en-
zyme as a prebleaching stage did not affect the
strength relationship; all the points fell on the same
curve.
18
.J3M6
CM
E
Z 14
E
12
10
8
ISO Brightness 90%
Sequence
AD100(Eop)DED
TXD100(Eop)DED
6 8 10 12
Breaking Length, km
14
Figure 4.-The effect of different bleaching sequences on
pulp strength.
Elimination of all Chlorine Compounds
Concern over the presence of chlorinated organic
compounds in bleach effluents is leading the in-
dustry to examine alternatives to chlorine-based
compounds in the pulp bleaching process.
Chlorine compound-free bleaching sequences
would most likely incorporate combinations of
stages using chemicals such as those shown in
Table 5. None of the combinations reported to
date, however, can be applied commercially with
the same efficiency and producing the same pulp
quality as do sequences containing some chlorine-
based chemical, notably chlorine dioxide, which is
far less problematic than molecular chlorine.
Table 5.-Alter natives to chlorine compounds
Oxygen
Peroxide
Ozone
Peracetic Acid
Hydrosulfite
Chelating Agents
Thiourea dioxide
Oxygen-Peroxide Bleaching Sequences
It is anticipated that a totally chlorine-free (TCP)
bleaching process will rely mainly on an efficient
delignification and peroxygen compounds to in-
crease the brightness of an unbleached pulp.
Hydrogen peroxide is used extensively to brighten
mechanical pulps, and its successful application
depends on a chelating step to remove metal ions
that promote rapid decomposition of the active per-
hydroxyl ion. The conventional chlorine-contain-
ing bleaching stages are known to remove metal
ions; therefore, a chelation step in a conventional
sequence prior to a peroxide stage is not necessary.
When chlorine compounds are eliminated from
pulp bleaching, metal ion content becomes an im-
portant consideration (Pye and Lora, 1991).
Basta et al. (1991) reported that a softwood
kraft pulp can be bleached to a 70 to 75 percent
ISO brightness using the O-Q-P (Q = chelation
step) sequence, which they called the Lignox™
Process. These brightness levels can be achieved
by washing the pulp after the chelation step and by
using high temperatures and long retention times in
the peroxide stage.
The Effect of Kappa Number before P
on Brightness
The brightness and kappa number obtained after a
Pi-stage correlated directly with the kappa number
of the pulp prior to the QP treatment (see Fig. 5).
Application of QP stages to a pulp at a kappa num-
ber of 22 resulted in a brightness of approximately
115
-------
Trade-off Issues
Oao
(0
S75
o
£ 70
o>
*ll
m
s*65
60
>w
**v
^
"V.
,
•^
^
^
•,
A
\
1
N>
M
•
\
1
A
»
! 10 12 14 16 18 20 22 24
Kappa Ho. before QP
^_ • OP • OOP A EopQP
Figure 5.-The tear versus breaking length curve shows
no difference in strength in pulps bleached via
Cso+dioEoDED and O(ZPE)PY.
~2 4 6 8 10 12 14 16 18 20 22 24
Kappa tto. before QP
Figure 7.-Trte kappa number before chelation and
perioxide stages as a function of sulfite pulp brightness.
so
12 r
O
CO
«•,
8
'80
I 75
&
22
24
8 10 12 14 18 18 20
Kappa No. before QP
• QP • OOP A EopQP
.^ O QPP D OQPP A EopQPP
Figure 6.-The effect on brightness of adding a second
peroxide stage to a given kappa number.
CD
V1
•o
O" 10 20 30 40 50 60
Kappa No.
Figure 8.-The effect of low kappa numbers and bleach-
ing processes as a function of pulp strength.
62 percent, but by lowering the kappa number to
10 using a combination of extended cooking and
oxygen delignification, the brightness after QP was
as high as 80 percent. A kappa number of 16 was
required for the peroxide stage to produce a bright-
ness of nearly 70 percent. The method used to
lower the kappa number before the QP stage did
not affect the brightening capability of the P-stage.
The brightness after QP tended to fall on the
same line whether the pulp was conventionally
cooked and (EOP)- or O-delignified, or cooked to
low kappa numbers without the inclusion of an
(EOP) or O delignification stage. A second P-stage
(2.5 percent H2O2 on pulp) applied to the QP-,
OQP- or (EOP)QP-treated pulps increased the
brightness by 5 to 13 points (Fig. 6). Figure 7 shows
the relationship between brightness and the kappa
number for sulfite pulps. Higher brightness can be
achieved with a sulfite pulp because of the nature
ofthelignin.
Pulp Strength
Data on the tear index at 12 km breaking length
versus kappa number relationship (see Fig. 8) was
supplied by a mill using MCC and oxygen bleach-
ing. Strength depended on the kappa number
produced at that time. Oxygen delignification can
involve a small loss in pulp strength. If the pulp
strength is decreased as the kappa number
decreases, further bleaching may result in further
strength losses.
The handsheet strength properties of pulps after
different bleaching sequences are shown in Table
6. On the spruce pine pulp run Q Eop QP at 70
percent ISO brightness, a substantial decrease in
pulp strength properties occurred when mag-
nesium sulfate was erroneously not added to the
pulp. The repeat run at 73 percent brightness, with
MgSO4 included in the bleaching liquor, showed
good strength retention.
116
-------
N. LIEBERCOTT
10 r
tf
7
Pulp Kappa No.
• Kraft 18.0
•Alcell 32.0
9
10
04 5 6 7 8
Breaking length, km
Figure 9.-Curves for tear strength vs. breaking length
for a conventionally bleached pulp and an O(ZPE)Y-
bleached pulp at 88-90% ISO brightness.
20
0> 18
^ 16
x"
•§ 12
a 10
ISO BRIGHTNESS 9O%
• (C9o+DlO)(EO)DED
AO(ZPE)PY
8 10 12
Breaking length, km
14
Figure 10.-O(ZE)QP bleaching of Alcell* and kraft
hardwood pulps.
Table 6.-Strength properties of pulps
KRAFT PULP
White Spruce
Londgepole Pine
Spruce/Pine
Mixed Hardwoods
CDEoDED
DEopPDP
QEopQPDP
QEopQPDP
DIOOEopDED
QEopQP
Q(OP)QP
Q(Eop)QPQP
CDEoDED
QOQP
QEopQPP
BULK
Cm3/g
500*
90 1 .45
89 1.37
89 1.50
89 1 .51
90 1 .41
70
73
82
92
85
85
.38
.39
.37
.51
.56
.56
300
1.35
1.32
1.32
1.32
1.35
1.32
1.33
1.34
1.33
1.38
1.37
BURST
kPa.m2/g
500 300
9.0
8.60
8.21
8.90
8.9
8.6
8.8
8.6
4.0
3.2
3.8
9.7
9.65
8.67
9.7
9.6
9.5
9.7
9.6
5.9
5.2
5.6
TEAR
MNm2/g
500
12.0
11.0
8.4
12.1
10.4
9.9
10.8
10.0
8.5
7.9
8.3
300
10.6
9.5
7.7
10.5
9.2
9.5
9.2
9.3
8.5
8.4
8.4
BREAKING LENGTH
km
500 300
10.9
11.7
10.9
11.2
10.6
11.5
11.6
11.5
6.7
5.1
6.2
12.0
12.4
11.2
12.1
11.9
12.8
12.0
11.9
9.0
8.2
8.5
*ml CSF
Bleaching with Ozone
Ozone is capable of delignifying an oxygen-treated
pulp to kappa numbers of 5 to 6 (Liebergott, 1972;
Liebergott and van Lierop, 1978; Liebergott et al.
1984; LaChenal and Taverdet, 1991; Lindholm,
1991). The conditions, however, must be carefully
controlled to prevent cellulose degradation. This
factor limits the commercial acceptance of ozone
as a lignin-removing agent. Various techniques are
being investigated to improve the selectivity of
ozone delignification. Pulp properties after
O(pZE)PY bleaching to 90 brightness were com-
parable to CdEoDED bleaching (Fig. 9). Compared
to the ODiooEoDED bleaching of softwood kraft
pulps that is now in commercial use, the OZEoPY
sequence produced effluents with about the same
BOD, COD, and about 20 percent less color
(Liebergott and van Lierop, 1978). Ozone bleach-
ing is being done at the Union Camp mill located in
Franklin, Virginia.
Solvent Pulping
Air pollution from kraft mills has reached serious
proportions because of the industry's expansion as
a whole and because of the tendency to install mills
with extremely high pulping capacities. Equipment
is available that if properly installed and main-
tained, is capable of reducing the emission of sulfur
compounds from a kraft mill to very low levels.
Nevertheless, even using the most effective pollu-
tion control systems, there may still be an oc-
casional release of high concentrations of
malodors. Any modification of the kraft process
would result in reduction of the quantities of
methyl mercaptan, dimethyl sulfide, and dimethyl
disulfide produced per tonne of pulp would clearly
be of great value. The use of a pulping process that
does not use sulfur as a chemical in the process
should not produce associated malodor. Three
types of sulfur-free process have been suggested:
117
-------
Trade-off Issues
56789
Tensile strength, km
10
11
Figure 11 .-Bleaching of Spruce Kraft and ASAM pulps.
Z
8"
•o
"i
28 r
,26
24
22
20
18
16
Pulp Yield, % Kappa No.
• Kraft 46.5 30.2
• ASAM 48.4 22.1
40 50 60 70 80
Tensile index, Nm/g
90
100
Figure 12.-OZEP bleachng of Douglas Fir Kraft and
ASAM pulps.
solvent pulping, soda-oxygen delignification, and
oxygen-alkali pulping.
Although solvent pulping was first proposed in
1931, the processes closest to commercialization
are Alcell , Organocell, and the alkaline sulfite-
anthraquinone-methanol (ASAM) process.
AlcelP Process
The Alcell® process, now owned by REPAP, Inc.
(Pye and Lora, 1991; Cronlund and Powers, 1991),
is being pilot tested as a batch system. It uses wash
liquor displacement at the end of the pulping
period to separate the extracted lignin.
The process uses 60 percent aqueous ethanol
for a cooking time of one hour at 195 °C and 400 psi
in the digester. Plans have been made to expand
the plant to 300 tonnes per day, using a continuous
digesting process with 50 percent ethanol and a pH
of 4 (because of wood acids). Because no catalysts
are added in the Alcell® processes, only hard-
woods can be effectively pulped.
Alcell® operates a 15-tonnes per day demon-
stration plant in Newcastle, New Brunswick,
Canada, where hardwood solvent brownstock is
blended with kraft pulp and bleached for use in
lightweight coated paper production.
Oxygen delignification of an Alcell® mixed
hardwood pulp (maple or poplar and birch)
produced a pulp with a kappa number of 9.9.
Ozone treatment increased the brightness to 62
percent (0.5 percent ozone on pulp) and to 79 per-
cent when a 1 percent ozone charge was used.
Peroxide treatment produced a final brightness of
89 percent with strength properties comparable to
those of a kraft hardwood pulp (see Fig. 10).
Organocell Process
The Organocell process was adapted to include
softwoods and can involve the addition of sodium
hydroxide and anthraquinone to chips preimpreg-
nated with methanol (Kleinert, 1974; Maston and
Granzow, 1982). The caustic must be recovered,
of course, and this necessitates some type of caus-
ticization or electrolysis. A 5-tonnes per day pilot
plant has been operating several years, producing
laminate paper grades and trial runs of a variety of
other printing, fluff, and tissue papers. Organocell
Thyssen GmbH plans to open the first commercial
solvent pulp mill (430 tonnes per day) later this
year, rebuilding a shutdown sulfite mill in Kelheim,
Germany. Spruce will be pulped with temperatures
of 165°C with 30 percent methanol in one stage in
a specially designed Kamyr, Inc., continuous
digester that was erected last summer.
ASAM Process
The Alkaline Sulfite-Anthraquinone-Methanol
(ASAM) process was developed in Germany, and a
3-tonnes per day digester pilot plant was installed
in April 1990 (Schubert and Fuch, 1992). The
process allows high-yield, kraft-type strength, and
bright, chlorine-free bleachable pulp. Relatively
easy kraft mill conversion is claimed, but no sig-
nificant savings in capital cost per tonne when
causticization is required. Although this process
cannot be called sulfur-free, it has certain ad-
vantages in pulping. The strength of the bleached
ASAM pulp after non-chlorine-compound bleach-
ing is species dependent: spruce pulp responded
excellently (see Fig. 11), while a Douglas fir
showed some strength loss (Fig. 12).
116
-------
N. LIEBERGOTT
Conclusion
Considerable strides have been made over the past
years to modify the design and operation of bleach-
ing plants to reduce undesirable chemicals in the
wastewater discharge. A major thrust has been
placed on cutting back on the use of chlorine in the
bleaching process.
Work is continuing in many laboratories and
pilot plants around the world to evaluate the
feasibility of bleaching hardwood and softwood
kraft and sulfite pulps without chlorine com-
pounds. It is equally important to gain an under-
standing of the effects the new pulping and
bleaching processes have on the properties of pulp.
References
Andrews, E.K., H.-M. Chang, and H. Jameel. 1991.
Bleachability of RDH-kraft pulps. Emphasis on low kappa
with effluent characterization. Page 67 in Proc. Interna-
tional Pulp Bleaching Conference, vol. 3. Stockholm,
Sweden.
Axegard, P., P.-O. Lindblad, I. Popke, and M. Puukko. 1991.
The Matrix for softwood kraft pulp — pulp quality and ef-
fluent load. Page 1 in Proc. International Pulp Bleaching
Conference, vol. 3. Stockholm, Sweden.
Basta, J., L. Holtinger, J. Hook, and P. Lundgren. 1990. Tappi J.
73(5):155-160 (1990).
Basta, J., L. Holtinger, P. Lundgren, and H. Fasten. 1991.
Reducing levels of AOX — Part. 3. Lowering of kappa no.
prior to CIO2 bleaching. Pages 23-33 in Proc. Internation-
al Pulp Bleaching Conference, vol. 3. Stockholm,
Sweden.
Berry, R.M., et al. 1991. Pulp Paper Can 92(6):T155-T165.
Boman, R., M. Dahl, L.-A Lindstrom, and S. Nord£n. 1991.
Pulps produced in extended super batch kraft cooks show
good bleachability in chlorine-free bleaching sequences.
Page 35 in Proc. International Pulp Bleaching Conference,
vol. 3. Stockholm, Sweden.
Bowen, J., andJ.C.L. Hsu. 1990. Tappi J. 73(9):205-217.
Cronlund, M.C., and J. Powers. 1991. Bleaching responses of
Alcell* organosolvent pulp using conventional and non-
chlorine bleaching sequences. TAPPI Pulping Conference
Preprints, Orlando, FL.
Kleinert, T. 1974. Tappi J. 57(8): 99-102.
LaChenal, D., and M.T. Taverdet. 1991. Improvement in
Ozone Bleaching of Kraft Pulps. Pages 33-34 in Proc. In-
ternational Pulp Bleaching Conference, Stockholm,
Sweden.
Liebergott, N. 1972. U.S. Patent 3,663,357.
Liebergott, N., et al. 1991. Pulp Paper Can 92(3):84-90.
Liebergott, N., and B. van Lierop. 1978. The Use of Ozone in
the Bleaching and Brightening of Wood Pulp. TAPPI
Oxygen, Ozone and Peroxide Pulping and Bleaching
Seminar. New Orleans, LA.
Liebergott, N., B. van Lierop, B.C. Gamer, and G.J. Kubes.
1984. Tappi J. 67(8):76-80.
Lindholm, C.-A. 1991. Some effects of treatment consistency in
ozone bleaching. Pages 1-18 in Proc. International Pulp
Bleaching Conference, vol. 3. Stockholm, Sweden.
Macas, T.S., E.J. Jiang, E.S. Becker, and B.F. Greenwood. 1991.
Achieving high brightness pulp and good strength without
any chlorine bleaching compounds. Page 67 in Proc. Inter-
national Pulp Bleaching Conference, vol. 3. Stockholm,
Sweden.
Maston, R., and S. Granzow. 1982. Ethard-alkali pulping, Tappi
J.65(6): 103-105.
Pryke, D., et al. 1991. Mill experience with chlorine dioxide
delignification. Pages 219-52 in Proc. International Pulp
Bleaching Conference, vol. 3. Stockholm, Sweden,
Pye, E.K., and J.H. Lora. 1991. The Alcell* process: A proven
alternate to kraft pulping. Tappi J. 74(3):113-16.
Schubert, H.L, and K. Fuch. 1992. Chlorine-free bleaching of
ASAM and sulfite pulps with countercurrent waterflow.
Proc. Nonchlorine Bleaching Conference, Hilton Head,
SC.
Vlikari, L., et al. 1986. Bleaching with enzymes. Pages 67-69
in Proc. Third International Conference on Biotechnology
in the Pulp and Paper Industry. Stockholm, Sweden.
119
-------
Trade-Off Issues — The Impact of
Pollution Prevention Techniques on
Paper Products
Gerard P. Closset
Vice President—Corporate Technology
Champion International Corporation
West Nyack, New York
At this conference, we have heard many
speakers describe a variety of bleaching se-
quences, both old and new, and their impact
on emission loads. I will take us beyond the pulp-
ing and bleaching processes to show you some of
the implications these new sequences have on
productivity and on the quality of the products our
industry manufactures.
For the most part I will base this paper on my
experience with the pulp and paper grades that my
company, Champion International, manufactures
in its large integrated kraft mills. The paper grades
are referred to as "free-sheet" grades and they are
used for making a variety of products used in the of-
fice and by consumers. They include the kind of
papers you are all familiar with, such as envelopes,
bond, tablet, copier paper, and so on. They also in-
clude coated papers suitable for use in magazines,
such as National Geographic, Architectural Digest,
and Mademoiselle. The pulp brightness required to
make these grades is about 85 ISO, and a mix of
softwoods and hardwoods is used.
My company also manufactures both soft- and
hardwood market kraft pulps, which have a bright-
ness requirement of 90 ISO. These market pulps
and the pulps used to manufacture the coated and
uncoated paper grades are made by the kraft
chemical pulping process and bleached with
chlorine and chlorine dioxide.
Before I start discussing trade-offs, let me talk
briefly about the driving forces that are causing
change in the pulp and paper industry today. Of the
two major forces active today, the first one is the
customer. The pulp and paper industry is very cus-
tomer oriented. Some companies sell products
directly to consumers while others, such as Cham-
pion International, for the most part, sell to com-
panies that add value and make their own final
product for sale to their customer. For example,
publishers buy our coated paper grades to make
magazines, and converters buy the uncoated
grades to make envelopes, tablets, or some other
final product. I want to emphasize the fact that we
don't dictate requirements to our customers. They
tell us what they want, and we do our best to fulfill
their needs.
Regulation is the other major force driving
change in our industry. Environmental regulations,
such as those derived from the Clean Air Act and
pollution prevention programs, are a focus and an
impetus for the research that our industry is carry-
ing out and for changes in process technology and
raw materials. Thus, our goal is to provide our cus-
tomers with the products that they want while fully
meeting our environmental obligations. Otherwise,
we will not remain economically viable and com-
petitive in an increasingly regulated and global en-
vironment.
Distinguishing Paper Uses and
Attributes
Paper is an engineered product with a very com-
plex structure. Though we usually think of paper as
merely a surface, it is three dimensional, and its
thickness (caliper) is extremely important in deter-
mining its performance. Simply stated, papermak-
ing involves building structures to perform for very
specific end uses. Tissue paper, for example is
designed to provide a fair amount of absorbency.
120
-------
C. P. CLOSSET
By contrast, paper for magazine publishing is
designed quite differently.
The goal for publication papers is to hold the
ink on the surface of the paper to enhance good
image and color reproduction — what we in the
trade call "ink snap." However, a small amount of
absorbency is also required to anchor the ink on
the paper so that it won't scuff. The sheet is en-
gineered, therefore, to provide a balance between
these two competing properties, and its production
requires considerable know-how. Copy paper of-
fers another means of reproducing words and im-
ages, but its requirements are completely different
from those needed for performance on a commer-
cial press. And the requirements for packaging
papers are a different story altogether.
Quality is as important in paper products as it is
for automobiles or televisions. Whatever we do, we
cannot compromise the quality our customers ex-
pect of our products. Let me talk about some of the
parameters that affect product quality. I will begin
with strength, which essentially represents the
paper's ability to resist tear. Strength is a function of
the fiber species, how they are pulped, bleached
and refined, the chemical additives used during the
process, and how they are formed on the paper
machine. The fact that so many previous speakers
have emphasized pulp strength underlines the im-
portance of this property.
First, the level of strength required will vary for
different paper grades. Paper is made in a con-
tinuous process and a certain amount of strength is
necessary for the web to run continuously. If we
have too many breaks on a paper machine, produc-
tivity is going to decline and with it, profitability.
Too many breaks on the paper machine also erode
product quality because of the up and down nature
of the process in that mode. Essentially, a paper
machine is like an assembly line; it needs to run
smoothly and steadily. In a highly capital intensive
industry, achieving a high level of productivity is a
must.
Our customers, the people who use our paper,
face the same issue. Let's consider publication
papers, which are sold to publishers for printing
magazines on high-speed printing presses. The
printer also wants a web of paper that runs con-
tinuously, without breaks. Too many breaks on the
press result in inconsistent quality because the
printer is constantly adjusting the printing press,
changing roller pressure, changing ink tack, clean-
ing up the blankets, and so on. The same situation
applies to the office environment, where high-
speed copiers are expected to produce large num-
bers of copies without interruption due to paper
jams. This issue of productivity and consistency is
extremely important to papermakers, printers, and
office workers.
Those of us who make copy paper think of
copiers and laser printers more as torture chambers
than as printing devices. If the paper is not en-
gineered precisely, it may "curl" and jam the
machine, particularly in duplex (two-sided) print-
ing. Curl is a scrolling of the sheet of paper caused
by dimensional instability brought about by the
heat and pressure of the process. A paper jam in a
high-speed copy machine is not a pretty sight, and
it is not appreciated by office workers and
managers responsible for productivity. The trend in
copiers and laser printers today is to increase speed
and output, and as a result, the demands on paper
are also increasing.
The appearance of the paper is another impor-
tant aspect of product quality. In the pulp and paper
industry, appearance is defined by the paper's opti-
cal properties and its cleanliness. The optical
properties include brightness, opacity, and shade.
Cleanliness is most often measured by the absence
of dirt specks on the sheet. These specks are un-
desirable because if they are of a certain size they
can have a negative impact on the aesthetics, that
is, the "look," of the sheet, or they can be mislead-
ing in automatic optical scanning machines. On
scanning machines, a speck of dirt can look like a
piece of information, a period or a comma, for ex-
ample. This "reading" can, in turn, lead to serious
errors in the printing and subsequent interpretation
of certain documents, such as a bank statement or
an insurance claims summary.
Our customers do not expect to be slowed
down or misled by such imperfections and would
not tolerate them for long. Although the lack of op-
tical properties or cleanliness generally does not af-
fect runability on a printing press, the publisher or
art director who purchases our paper would be
very unhappy if it does not meet requirements. The
industry and its customers have developed very
specific standards for these properties and our cus-
tomers expect that we will deliver papers that con-
sistently meet these specifications.
I want to emphasize again that I am speaking
from the perspective of a North American manufac-
turer and supplier, and that I realize that conditions
are very different in certain parts of Europe. In
North America, our customers tell us that they want
environmentally friendly products, but it is very
clear that they don't want to give up quality or pay
higher prices.
121
-------
Trade-off Issues
Emissions Control and Trade-offs
Now let's focus again on bleaching chemicals and
the different bleaching processes used in our in-
dustry, since they contribute a substantial share of
the emissions produced by a pulp and paper mill.
There are essentially three approaches to reducing
emissions: we can reduce the use of existing
bleaching chemicals, use different bleaching
chemicals, or switch to different bleaching proces-
ses.
What trade-offs need to be recognized and
made part of this context? First, if we simply reduce
the use of conventional bleaching chemicals, the
obvious trade-off is low brightness. We have al-
ready determined that North America has no real
market for low-brightness pulps at this time, and
that most customers are not interested in low-
brightness pulps even at lower prices.
If we use different bleaching chemicals, for ex-
ample, chlorine dioxide or hydrogen peroxide, we
find that pulp quality can be maintained, albeit at
increased cost. The problem or trade-off is that cus-
tomers are generally unwilling to pay more for a
molecular chlorine-free sheet or for one that is
made with chlorine dioxide and hydrogen
peroxide. In that case, the industry has to absorb
the increased cost.
If we look at new bleaching processes, such as
the one using ozone, we find that the trade-offs are,
in general, lower pulp strength and — even more
important — more difficulty in controlling quality.
Inconsistent quality can only result, as I mentioned
earlier, in lower productivity on the paper machine
and rejection by the customer.
Impact of Bleaching Sequences
Let us briefly review the trade-offs associated with
some of the bleaching sequences that were pre-
viously discussed in this conference. These trade-
offs are illustrated in Figures 1 through 5. The data
shown in these figures are from commercial
processes and experimental evaluations carried out
by Champion International and they are in good
agreement with the results of similar studies pub-
lished in the literature. Beginning with a sequence
that would have been typical 10 years ago (at the
extreme left of the figures), we go on to show the ef-
fects of increasing the level of chlorine dioxide sub-
stitution (moving left to right); a totally chlorine-free
(TCF) sequence; and two experimental sequences
in which bleach plant filtrates are recycled to the
recovery process.
Increased levels of chlorine dioxide substitu-
tion reduce the biochemical oxygen demand
(BOD), adsorbable organic halogens (AOX) and
color in the plant's emissions. In commercial and
laboratory experience, when an increased level of
chlorine dioxide substitution is combined with ex-
tended delignification, these emissions are further
substantially reduced. Please note that all of these
sequences still allow the papermaker to achieve the
85 brightness level that is required to manufacture
if
Jo
x
. 0.
0)
M m
0) —
C -O
a
D f
a ±:
EXPERIMENTAL
<--closed bleach plants->
Bleaching Sequence CBCH
(C+D10)(EO)D 0(050/C)(EO)D 0(D50/C)(EO)D 00(EOP)D OX(EP)P 00(EOP)D
X=chelalion
COTD
extended extended extended extended extended
Kraft Pulping conventional conventional conventional delignification delignification delignification delignification delignification
Figure 1.-Maximum Pulp brightness with acceptable pulp quality for various bleaching sequences.
122
-------
C. P. CLOSSET
X 3
D.
t> ^
M
TJ
10
9-
8 -
7-
6-
5-
4 -
3-
2-
1 -
EXPERIMENTAL
<--closed bleach plants-->
Bleaching Sequence CBCH (C+D10)(EO)D 0(D50/C)(EO)D 0(050/C)(EO)D 00(EOP)D OX(EP)P
00(EOPP
OZED
X=chelation
extended extended extended extended extended
Kraft Pulping conventional conventional conventional delignification delignificafon delignification damnification delignification
Figure 2.-Reduction In AOX through bleach plant evolution.
40
c
a
o
O a.
O> »;
>> O
55
a _-
« Q
£ O
o m
m
35 -
30-
25 -
20-
EXPERIMENTAL
<--closed bleach plams~>
Bleaching Sequence C8HDH
(C+D10)(EO)D 0(D50/C)(EO)D 0(D50/C)(EO)D OD(EOP)D OX(EP)P 00(EOP)D OZH)
X=chelalion
extended extended extended extended extended
Kraft Pulping conventional conventional conventional delignification delignification delignification delignification delignification
Figure 3.-Reductlon In biochemical oxygen demand through bleach plant evolution.
123
-------
Trade-off Issues
3
Q.
o
o
o
o
600
550 -
500 :
450 -
400 -
350 -
300-
250-
200 -
150-
100 -
50 -
color
EXPERIMENTAL
<--closed bleach plants—>
Bleaching Sequence CEH3H (C+D10)(EO)D 0(D50/C)(EO)D 0(D50/C)(EO)D 00(EOP)D
OX(EP)P 00(EOP)D
X-chelalion
extended extended extended extended extended
Kraft Pulping conventional conventional conventional delignification delignification delignification delignification delignificadon
Figure 4.-Reduction in total bleach filtrate color through bleach plant evolution.
100
E O
•»
O .
a —
o o>
90 -
80-
70 -
60-
50-
40-
30-
20-
10-
EXPERIMENTAL
o-closed bleach plants-->
Bleaching Sequence CEHDH (C+D10)(EO)D 0(D50/C)(EO)D 0(D50/C)(EO)0 00(EOP)D
OX(EP)P
X=chelalion
CXHEOP)D
extended extended extended extended extended
Kraft Pulping conventional conventional conventional delignificalion delignification deligniliealion delignification delignification
' range of estimate +[0.1 (cost from figure)]/2
Figure S.-Estlmated bleaching chemical costs for various bleaching sequences.
124
-------
C. P. CLOSSET
free-sheet grades of paper. In fact, as we go up in
chlorine dioxide level beyond 50 percent, we find
that the brightness ceiling actually goes up (see Fig.
1). Experiments with totally chlorine-free sequen-
ces, such as OX(EP)P, have yielded low-brightness
ceilings, around 70 to 72, but they also further
reduce BOD and color and bring AOX to extremely
low levels. As indicated in Figure 5, operating costs
are higher for some of these sequences, particularly
for the totally chlorine-free sequence — there, the
costs are more than double.
Let me talk about the two sequences on the ex-
treme right hand side of the figures. These sequen-
ces are experimental in that the bleach plant's
filtrates are recycled to recovery, and ozone is used
as a bleaching chemical in one of them. (The
OZED sequence will become commercial with
Union Camp's startup of its ozone bleach line at
Franklin, Virginia, later this year). The advantage of
the OZED sequence is that, with no chlorine com-
pounds in the first three stages, the bleach filtrates
can be recycled to the recovery boiler with little
fear of corrosion since few chlorides will be in the
system.
We believe that there is a great deal of potential
in doing the same with the OD(EoP)D sequence.
The elimination of molecular chlorine reduces
chloride levels, and the use of chlorine dioxide al-
lows us to continue to make an extremely good
quality product. Allowing for good research and
some time, we believe that we can develop the
technology to recycle the bleach filtrates produced
by the OD(EoP)D sequence. As shown in Figures 3
and 4, emissions would be equal to those produced
by the OZED sequence. The OD(EoP)D sequence
also achieves greater color and BOD reductions
and approximates the AOX levels of the TCF se-
quence. According to our projections (Fig. 5), recy-
cling of bleach plant filtrates would not raise
operating costs, although the expenditure of capital
monies would, of course, be required to install the
process.
Conclusion
I have discussed only a few of the trade-offs as-
sociated with the new bleaching processes being
proposed today. These trade-offs are very real and
they directly impact our industry's ability to com-
pete and remain viable on a worldwide scale. We
are ready to take on the challenge of developing
technologies that will help us meet future environ-
mental regulations while still preserving our
economic viability. In the longer term, we realize
that we must work toward fuller closure of our mills
and the recycling of bleach plant filtrates is a criti-
cal first step. TCF bleaching is not the only way to
achieve that first step.
A number of initiatives have begun in the in-
dustry and in research institutions around the world
to investigate the recycling of bleach plant filtrates.
The technology is not yet fully developed, but I
think it shows great promise. If it becomes a reality,
the AOX now present in the effluent from kraft
bleach plants could be reduced to extremely small,
probably non-detectable, levels. This prospect is an
attractive one because the environmental goals of
TCF bleaching could be achieved while still
preserving the use of our best bleaching chemical,
chlorine dioxide. This achievement would, of
course, ensure that the industry could continue to
deliver quality products to its customers and main-
tain its long-term competitive posture — which, I
hope, is a shared goal of all the people attending
this conference.
125
-------
Unbleached Coated Kraft
for Beverage Cartons
Rune Anderson
Director
Frovifors Bruk AB
Frovi, Sweden
Frovifors Bruk AB (FROVI) is a rather small pulp
and board mill producing about 200,000
metric tons of coated and uncoated paper-
board per year. The mill is situated in Frovi, a city in
the middle of Sweden in a typical woodland dis-
trict. The water supply comes from a small river that
goes right through the mill. The effluent goes back
to that river a few hundred meters downstream just
before the river forms a lake. Many vacationers, in-
cluding our employees, swim in the lake and keep
summer houses there.
FROVI has produced pulp and paper in the
same location since the 1890s. For a long time the
primary products were unbleached kraft market
pulp and thinner grades of kraft paper. The market
for these products gradually deteriorated, and in
1979 the board of directors decided to make a
major investment in a large paperboard manufac-
turing machine, which would also be capable of
coating the material. Several related modifications
were made to the pulp mill at that time.
As previously noted, FROVI's effluent is dis-
charged into a small river. That river feeds into a
larger river, which eventually becomes part of the
water supply for Stockholm. Because water quality
was a concern and because technology was limited
in 1979, it was considered impossible to produce
bleached pulp. So, partly inspired by some far-
seeing U.S. companies, and partly in cooperation
with a prospective customer, the mill was set up to
produce unbleached coated kraft board, mainly for
use in beverage cartons.
Quality Requirements
FROVI customers are interested in buying a
material with a specific bending resistance that
holds print well at the lowest possible weight (and
lowest possible cost per square meter). The cus-
tomer additionally assumes that a number of other
important criteria will be met during conversion,
transport, and at the product's destination. The
criteria include
• physical, chemical, and biological cleanli-
ness;
• manufacturing in accordance with ap-
plicable laws and regulations;
• sufficient strength perpendicular to the plane
to withstand the strain and stress in printing
and polyethylene (PE)-coating;
• resistance to edgewise penetration of some
liquids occurring in the filling operation (hot
hydrogen peroxide for aseptic packages) or
after filling (lactic acid imitating the liquid
being filled in the carton); and
• quality consistency within and between
board productions.
Pulp and Board Mill Cleanliness
For optimal strength, wood should be processed
into pulp having fairly high Kappa numbers (65-
70). The problem is to get pulp that is free from
physical impurities. Chip quality is important. We
try to ensure that by careful debarking, thickness
screening (maximum thickness = 8 mm), and pre-
steaming before processing.
After the on-line refining process, the pulp is
screened twice; the first is a hole screen (diameter
[0] = 2.0 mm) and the second, a slot screen (slot
width = 0.45 mm) (see Fig. 1). The "accepts" from
the second screen have a high degree of cleanliness
and are used for the outer plies in the board
machine.
126
-------
K. ANDERSON
i ** tote
2 ; slotted screen
Figure 1.—Pulp supply flow sheet.
The rejects from the primary , screens.,go
through a secondary screening, which,-is basically
the same as the primary system (hole 0 = 2.6 mm,
slot width = 0.40 mm). Secondary rejects are han-
dled in a separate reject system encompassing a
thickener, a refiner, and a reject screert. Accepts
from the secondary*screening are used in the center
pliesdf the board riiachihe.
Chemical purity is'yital to avoid off-taste in the
packaged liquid. FROVI achieves pulp purity
through careful pulp washing in four steps using, in
order, a digester high heat washer, an atmospheric
diffuser, a drum washer, and screw presses,
The wash loss is about 6 kg Na^SCVper ton.
After final washing, the dissolved organic material
content of the^pulpjS'Usualy 4 to 6 kg-per ton (as
CCJD),. We also believe, that it is essential for.the
wet-end chemistry of the board sy$tem to keep the
kraft mill; water separate from the board mill water.
The screw presses (Fig. 2) are excellent for that pur-
pose. (
Biological.;purity is achieved through good
working routines, Periodic shutdowns for system
cleaning are important parts of such rbutinestjt is
also important to check that the design of tanks,
chests, and other equipment prevent stagnant
zones, where biological activity can thrive.
Board Machine
To meet the quality requirements discussed earliei
(see'Fig>2), the board machine and-th'e wet "end of
the board machine were designed to create the best
possible formation of the sheet. The board machine
is equipped with four fourdrinier units -7- a bottom
ply, two center plies, and a top ply. Top and bottom
plies consist of 100 percent unbleached softwood
kraft pulp,of high physical cleanliness. The center
plies consist of a mixture of unbleached kraft pulp
and chemithermomolecular pulp (CTMP); The
CTMP is purchased market pulp with extractive
content below 0.15 percent. It is used to improve
sheet caliper and thus bending stiffness. '
The kraft pulps for top, bottom, and center plies
are refined separately so that the,best conditions for
bending stiffness and Z-strength are metrAll four
plies go through a multistage cleaning to ensure
cleanliness. Catalytic decomposition of pulp resin
into low molecular, bad-smelling hexanal is avoid-
ed by using chelating agents in the stock system.
In our mineral-rich part of Sweden, where the
wood has a fairly high content of heavy metals, in-
cluding manganese, this procedure is particularly
important. Each ply has separate dual-sizing, sys-
tems. Dual-sizing means that a combination of
cationized rosin size and AKD is used to obtain suf-
127
-------
Trade-off Issues
Wetend
Press section
Tl ^ -TT-^. ^'VS^-^^--'0--~^-^^^0-^^-^---g-*
Coater Brush glazing machine Tambour
Figure 2.—Board machine.
ficient edgewise penetration resistance against hot
concentrated hydrogen peroxide and lactic acid.
Ply-bond strength is obtained by deposit of thin
layers of highly refined unbleached pulp on the
base wire in two critical positions. Small hydraulic
headboxes are used, thereby avoiding the use of
spray starch and other materials.
. Print-side smoothness is improved by using a
Yankee cylinder and a hot calendaT prior to the
coating sections,
" Two blade pre-coaters and an air knife coaler in
the coating section are used to create even
coverage and specified brightness. The reverse side
rod unit is used for starch treatment of the back
side, mainly to avoid fiber dusting. The coatings are
dried by hot air and two infrared treatments.
Environment
As part of our company's environmental policy, we
deliberately admit that we as a producer of pulp
and paperboard are influencing the environment in
a negative way. At the same time we state that it is
the responsibility of all company employees to
minimize that influence. •'
FROVI has been working actively for more than
20 years to reduce pollution to air and water. In the
early 1970s, we installed an aerated lagoon that
still operates in a modified state. The important
task, however, is not external cleaning but internal
efforts of the producing departments to stop con-
taminating the main effluent. Mill water systems
have been contained to a great extent. All major
sulfur-containing flue gases are scrubbed, and the
recovery boiler and biofuel boiler are continuously
monitored. We recently installed a membrane-fil-
tering system for low consistency spills of coating
color, to eliminate the risk involved in discarding
coated pigments (TiOa) into a body of water that
eventually feeds into the local river (see Fig. 3). The
spill, therefore, will be recovered and reused as
coating color.
As there is no bleaching in the plant, difficulties
with dioxins and other potential carcinogens do no
occur. (FROVI pulps and water have been analyzed
and found negative.) The mill efforts are therefore
concentrated on biological and chemical oxygen
demand (BOD and COD), sulfur dioxide (SO2),
nitrogen oxide (NOX), and suspended solids. Table
1 shows today's (1992) emissions together with the
limits issued by the Swedish authorities. Figure 4
shows the development since 1986 in BOD? dis-
charge to the effluent. BOD is considered to be a
more important parameter in our downstream lake
than COD. In the same way Figure 5 shows the
total discharge of processed sulfur from the mill.
Other environmentally important parameters
exist. It has often been claimed that wood resin in
the effluent is toxic for fish and lakebottom fauna.
For that reason we make yearly investigations of the
bottom fauna both in the river close to the mill and
at a distance in the lake. All tests indicate more
diversified populations of bottom-dwelling plant
and animal life.
The fishing has improved significantly. Pike
perch is abundant today about 1 kilometer down-
stream from the mill. Our final goal will be to estab-
lish fly-fishing for rainbow trout in the nearby river.
Conclusion
Since the early 1980s, FROVI has produced be-
tween 500,000 and 1 million tons of unbleached
coated paper for the European market. We believe
that this product makes a clean, strong, and useful
beverage carton that has a minimal negative impact
on the environment. Compared to other products,
the energy consumption is low. Coated paperboard
has been tested a number of times at an authorized
research institute that certifies that "the material
can be used safely for food packaging. It may stand
in direct contact with dry, moist, and fatty food-
stuffs." The same kind of unbleached pulp is also
used for the production of coffee filters by another
company.
128
-------
R. ANDERSON
. 0,5 - 2,0 % dry solids content
23 - 46 % dry solids content
Figure 3.—Recovery of coating color spill.
Figure 4.—Discharge of BOD?, 1986 to June 1992.
129
-------
Trade-off Issues
KG/TP
2.5
30
25
20
1.5
1.0
05
1987 1988 1989 1990
Figure 5.—Discharge of process sulfur, 1987 to June 1992.
1.5
PERMITTED
LEVEL
ACTUEL
DISCHARGE
1991
1992
The question is thus: Are there any disad-
vantages? Yes, there are; during prolonged contact
with water — in some markets, old-fashioned ice
boxes are used for cooling instead of refrigerators
— the coating layer underneath the polyethylene is
affected and packages can deteriorate, as do other
coated products.
The rather thick coating necessary for bright-
ness and good coverage make it difficult to achieve
the same bending stiffness yield as the best un-
coated duplex grades. Adding disadvantages and
advantages together, however, we believe that un-
bleached coated paperboard definitely has an im-
portant position on the market.
Table 1.—Permitted and actual discharge to water
and air.
AVERAGE
1992
UNIT SET BY
THE AUTHORITY
COD
BOD
Susp. solids
Process—S
NOX
t/d
Vd
kg/d
kg ptp
kgptp
6.8
0.5
48.0
0.2
2.2
9.0
1.2
200.0
1.5
130
-------
Panel 1:
Trade-Off Issues
Question and Answer Session
• Jens Folke, European Environmental Research
Croup: My question is for Rune Anderson. We
were told yesterday that ozone bleaching could be
the way to a completely closed kraft mill and we
were also told that this is far into the future. Now
you have an unbleached operation and I would like
to hear about the specific loadings from your un-
bleached pulping operations and about the
problems you might have to close up that part of
your mill. You also mentioned low energy con-
sumption. I wonder, do you have any figures in
terms of gigajoules per ton of product?
• Rune Anderson, Frovifors Bruk AB: The figures I
mentioned for discharge from the mill are the total
discharge. It is not only the board mill but the board
and the pulp mill.
• Jens Folke: If you could split these figures and
give only the figures for your unbleached pulping
operation, do you have any data on that? Maybe in
terms of cubic meters per ton of pulp, or maybe in
terms of COD coming from the pulping operation?
• Rune Anderson: Not specifically. I am sorry, but
the figures you have are from the main effluent off
the aerated lagoon. I mentioned a figure for the
chemical oxygen demand (COD) of the pulp before
it reaches the board mill: that number is 4 to 6 kilos
per ton, but it only measures COD.
• Jens Folke: Why is your pulping operation not
completely closed?
• Rune Anderson: It is more or less closed. Of
course, we have a discharge of waters; the total
water consumption in the mill is about 30 cubic
meters per ton, of which about 10 to 12 cubic
meters are from the board mill.
• Jens Folke: So even though you have an un-
bleached operation and therefore no theoretical
hindrance, you still have to have some outlet from
your unbleached operation?
• Rune Anderson: Yes. It is important for the wash-
ing efficiency to use a large quantity of water. That
may be a disadvantage, but we have to do it.
• Jens Folke: On energy consumption . . do you
know how many gigajoules you use per ton of
pulp?
• Rune Anderson: In the board mill, the kilowatt-
hours used per ton of board are around 600, and
the pulp mill uses around 700. The total consump-
tion of electricity is around 1,300 kilowatt-hours
per ton.
• Jens Folke: Is the rest of the energy self-supplied
from the pulping operation?
• Rune Anderson: Part of this energy is generated
inside the mill, and a back press at Arben supplies
about half of that energy.
• Jens Folke: So how much comes from external
sources?
• Rune Anderson: About half, about 600 to 700
kilowatt-hours per ton.
• Med Byrd, North Carolina State University: I
direct my question to Dr. Closset. When we talk
about trade-offs we often look at the short-term
trade-offs to the things that affect us right now, for
example, brightness, strength, and customer ac-
ceptability. Particularly in your type of products, do
we look enough at the long-term trade-offs when
we make a fundamental shift in the bleaching
131
-------
Trade-off Issues
process followed by a fundamental shift in closing
up the mill effluents? Couldn't these shifts cause an
increased concentration of different ions? Is there a
way to estimate or to research the effect that this in-
crease could have on the long-term performance of
critical quality papers, for example, on brightness
reversion, yellowing, and long-term decomposi-
tion?
• Gerard Closset, Champion International Cor-
poration: I think that these are precisely the things
we should look at very carefully when we begin to
use new bleaching sequences. In fact, we try to es-
tablish technical alliances with our customers so
that we can work with them into the future, to make
sure that we have the technology to meet their fu-
ture needs. When we look at new bleaching tech-
nologies, we have in mind the long view. Again, the
new bleaching sequences will be commercialized.
Our main focus is to ensure that we can continue to
make these products — or the products that our
customers will require in the future.
• Med Byrd: And you feel that we can accurately
simulate the long-term performance of this technol-
ogy in the laboratory or pilot plant? Do we really
have the tools to simulate long-term performances
of these changes in the process?
• Gerard Closset: Yes, I think we can go a long
way toward establishing the impact of these chan-
ges in the laboratory.
• Bruce Fleming, Boise Cascade: I have some
comments for Norm. I enjoyed your talk, which
was packed with useful information, as always. I
also enjoyed the baby pictures; they were very
clean, with no poo-poo. And it was the same in my
talk yesterday: there was no poo-poo in my remarks
about ASAM. I want to get that clear. I did not say
that ASAM pulp was in any way inferior. In fact, on
the contrary, I think it's excellent pulp. So I think
possibly that bit of my presentation was
misunderstood. I hope it will be clearer in my
paper, which should be available today.
• Norman Llebergott, DuPont Canada, Inc.: What
you said was that for certain species ASAM pulp is
very good but for some species it does not turn out
as well. One of the species, Douglas Fir, has been
used at two meetings to show that pulping by
ASAM is not as good as the kraft pulping process.
There are many hardwood species and softwood
species that do come up to spec, even though some
species do not respond.
• Bruce Fleming: Well, there's a paper in the
TAPPI journal on Douglas Fir in which the conven-
tional bleaching of that pulp was very good, as
good as kraft. I don't know what happened with the
ozone bleaching results that you show here. But I
think something probably went wrong with the
ozone bleaching in that case.
• Norman Llebergott: These are not our results;
they were published by the ASAM group.
• Bruce Fleming: But the conventional bleaching
of that pulp showed good strength. There's deficit
in the ozone bleaching and I'm not sure why that is.
But all the data that I've seen on ASAM pulp and
our own testing on the sample of pulp obtained
from a pilot plant in Germany shows that the pulp
is equivalent to kraft in strength whether un-
bleached or bleached conventionally. In all
respects, it looks pretty good and often exceeds
kraft strength.
• Norman Llebergott: But I'll say it again. Though
many species respond well to ASAM, there are a
couple species — they don't know why — that do
not respond with the same characteristics as they
do in the kraft process.
• Said Abubakr, University of Wisconsin: My
question concerns the strength properties. Mr.
Liebergott, you said in your presentation, based on
other people's information, that the strength
properties of nonchlorine bleached pulp are a little
less than kraft chlorine bleached pulp. My ques-
tion, are any data in the literature based on the ac-
tual operation of these papers in paper machines?
• Norman Llebergott: Very little. We hear that
some data are available, but the manufacturers
themselves who are making the paper from TCF
pulps have some problems. One problem is run
ability; they do not seem to run as well on high
speed machines. As I mentioned before, handsheet
properties are one thing, and handsheet properties
sometimes look good, but you will hear about
problems in running this pulp. We have adapted to
it, but it still has a number of breaks and things.
These problems make us think about what will
happen in the future when these pulps are finally
recycled. Recycled pulps are going to be even
weaker. So if the pulp is weaker (than kraft) to start
off with, how much can it contribute to recycled
pulp strength and how much more aversion fiber
are we going to have to put in to strengthen those
pulps? Remember back to the groundwood days,
when we had to have a certain amount of sulphite
or bleached kraft pulp in order to get the pulps to
run on the machine. I think we have a lot to learn,
and that we're still new in this game. So, if people
say the answer to pollution is TCF, that's just not a
132
-------
QUESTION & ANSWER SESSION
complete answer. More research is needed and
should be done, not only in the lab but also on
machine runs to see exactly how these papers per-
form.
• Susan Cohen, Environmental Defense Fund: A
question for Mr. Anderson. Can you tell us when
your product was developed, how long it took,
what kind of customer demand compelled you to
make the change, and what the product looks like?
• Rune Anderson: We started the machine in mid-
1981 and the first commercial deliveries of the
product I am referring to began in 1982. The
product development took about half a year. We
have one big customer, Tetra Pak, who is present
here tonight.
• Susan Cohen: And was it a dioxin problem that
moved this product?
• Rune Anderson: That was always a problem with
the liquid packaging board. But we had no bigger
problems with that particular grade than with other
grades.
• Ray Chalk, World Bank: I would like to pursue
that same question. In all my many trips to Sweden,
I see milk and fruit juice and other consumer
products packaged in bleached boards. Are you
using this unbleached board at all in Sweden to
package things like milk?
• Rune Anderson: I think most of the milk in
Sweden is packed in what we call brick packages,
which are the Tetra Pak line of packages. Products
packaged in unbleached cardboard in Sweden
have additional costs. Normal square packages are
also used in Sweden. They are duplex board, most-
ly uncoated.
• Jessica Landman, Natural Resources Defense
Council: Does your packaging look different to the
consumer's eye from the packaging made with
bleached board?
• Rune Anderson: No, I don't think so.
• Norman Uebergott: Can you put lost kids on
your packages too?
• Rune Anderson: The board is printed in
flexographic rotogravure.
• Jim Foster, Westvaco Corporation: Given that
the value of brown fiber is less than white pulp,
could you, Mr. Anderson, comment on the
economics of the recyclability of the liquid packag-
ing based on an unbleached fiber?
• Rune Anderson: No.
• Norman Uebergott: You know very well that
recycling mills can handle a certain amount of
ledger, pure ledger or color ledger. They can also
handle a certain amount of wood fiber. But the mo-
ment unbleached fiber comes into the mill, it's a
problem because it leaves specks. At this point, you
have to go into all kinds of things, oxygen and other
chemicals, to attempt to handle those specks. Im-
agine having a large amount of fiber like that; you'll
probably have to come up with a completely dif-
ferent recycling scheme.
133
-------
Paper Specifications and Pollution
Prevention — An Industry View
Virgil K. Morton, Jr.
Vice President, Paper Group
American Paper Institute
New York, New York
do not know who was responsible for the recep-
tion last night. It was unique, I thought, to see so
many interest groups talking with one another
and exchanging warm fuzzies. Indeed, the
euphoria made me very weak. I even promised
Margaret Rainey that if I had time left from my talk
this morning, she could have it. And I promised her
I would be very much to the point. She promised
me the same thing and we agreed to disagree,
which I think is good because we can do that on an
intellectual basis.
The Pollution Prevention
Hierarchy
I will begin my presentation with a common hierar-
chy of approaches to solid waste management, but
do not be too concerned: I am not going to talk
about landfills. I am not going to talk about solid
wastes in the way that we do generally, but I would
like to discuss the recycling issue as it pertains to
our industry. The paper specifications that concern
us are physical and optical properties. We are in
fact preventing pollution through new processes,
and I will use the recycling area as one example of
pollution prevention that we clearly understand
and can identify with. Obviously, recycling, waste
to energy, composting, landfilling, and market-
based source reductions are all parts of the hierar-
chy.
But the process involved here goes to a ques-
tion that was raised yesterday: What is the industry
spending to help "prevent pollution" rather than
simply "contain" it at the end of the pipe? Clearly,
recycling alone is not going to prevent pollution,
and our industry must not stop there. A com-
prehensive approach is needed and new processes
that will in fact reduce pollution rather than depend
on secondary treatment and "end-of-pipe" ap-
proaches. Yesterday we noted the significant in-
crease in the production of paperboard and pulp.
Today, I ask you to note the tremendous drop in
purchased energy. Other processes are reducing
pollution — not just scrubbers and other types of
things, but at the source. That is a very important
point. The American paper industry (in the United
States) is taking a proactive approach to become
part of the overall solution. Pollution prevention is
a key to the municipal solid waste problem, and the
entire industry is demonstrating our commitment to
pollution prevention leadership, which we believe
begins with special efforts in the recycling area.
The first result of pollution prevention planning
was the establishment of the goal: a 40 percent
recycling of our product by 1995; that is, 40 per-
cent of all paper consumed in the United States will
be recovered for domestic use or export by 1995. I
think the goal is even more striking since over 50
percent of the newsprint consumed in this country
comes, in fact, from Canada, and we are going to
recover 40 percent of that as well. In doing so, we
have made a public commitment that we can ex-
pand and use. The goal has become the center-
piece of our solid waste program, and it has in fact
earned us good will and credibility.
Paper Types and End Uses
To further demonstrate the industry's commitment
and show what we can do, I'd like to look at some
of the paper grades that the Federal government
buys — and not just the government but also the
public. Since this is a U.S. Environmental Protec-
tion Agency conference, I am using government
figures and some anecdotal information to show
the capital commitments for new expansion and for
134
-------
V.K. NORTON, JR.
added capacity and retrofits that will help reduce
pollution. Then we will break these down in terms
of specifications, and what is, we hope, intended
for the customers.
First, let's look at newsprint. Between now and
1994, newsprint production will consume more
than 1 million additional tons per year of recovered
newspapers and magazines. Second, lefs look at
printing and writing paper with its overall capacity
expansion rate of 2.7 percent per year. The use of
recovered paper in that particular grade will in-
crease 32 percent by 1994, mostly in deinking
grades. Third, three of five planned new tissue
machines will use recovered paper exclusively.
These machines use new processes and technology
that goes to the very source of what this conference
is about. They help reduce and prevent pollution.
Fourth, consider container board. We expect
recovered paper in this area to grow at ap-
proximately 8 percent per year —nearly five times
faster than the projected overall growth for con-
tainer board, which is projected at 1.7 percent per
year.
Our investment, our use of capital, is unprece-
dented. Over 101 publicly announced projects
will be capitalized between 1990 and 1995. In that
area alone, on the question whether the industry
can put a price on its spending for pollution abate-
ment, the answer is no. We can't. One of the
reasons is that capacity growth depends on modern
processes, and these processes, in fact, reduce pol-
lution. We are preventing pollution in each new
investment and these total capital costs are part of
the overall cost of reducing pollution. The industry
should be credited accordingly.
Recycling is driven by two forces. Number
one, it is driven by public policy, government
policy, and expectations. It is also driven by the
product's end use. Remember I said, or I meant to
say, that I wanted to speak about the policy role
first. Now let me add that demand for specific
paper grades should, in fact, be based on the func-
tion that customers expect a particular piece of
paper or paperboard to perform.
Understanding Paper
Specifications
Each type of paper is unique. There are different
grades. They possess different physical and optical
properties that allow them to meet an extraordinari-
ly wide variety of functions. It may be simplistic to
say, but I think we need to come back to the basics.
And it is basic to say that for your informed pur-
chase of paper, we acknowledge that paper is not
just paper. Buying paper just because it is
"recycled" or "chlorine-free" ignores the fact that
there are certain physical and optical properties re-
quired for the function or the end use that the paper
will be used to accomplish. One of my colleagues,
Dr. Ron Slinn of API puts it this way, and I would
like to give some examples of how this notion fits.
In its most common form, paper is seen as thin
sheets that carry messages. These sheets are
newsprint, printing and writing papers, and office
papers. Then we have tissue and toweling papers
for use in several other sanitary and hygienic ap-
plications, and the tough, flexible papers used in
shopping bags and wrapping papers. The porosity
of some papers makes them ideal filters in both air
and liquid applications, transportation, medical,
and many other applications. And, finally, we dis-
tinguish paperboard from paper in generic terms
only by its thickness — if it's more than 12-
thousandths of an inch, we look at it as paperboard.
Its stiffness, folding ability, flexibility, and compara-
tive lightness make it ideal for food packaging.
Paperboard also makes a variety of shipping
containers coated with resins, wax, or plastic. It is
often the principal component of liquid and
microwaveable containers as well as water resis-
tant protective sheeting. Paper also forms many
specialty products. Paper can range from dis-
posable surgical gowns and hospital bedding to in-
stallation for electrical wiring and printed circuits.
Then, when we talk about blends, we are talk-
ing combinations or composites with other
materials. We find paper blends in laminates for
furniture, multiwall sacks, and food packaging with
foil. This litany of anecdotal data serves, I hope, to
drive home a very basic point. Purchasers of paper
should first determine the physical and optical
properties required to fulfill the function they have
in mind. Some paper and paperboard products
perform better if they are whiter and brighter. But
the products themselves are not bleached to reach
this characteristic. It is of course, the pulps from
which paper and paperboard are made that are
bleached. And as I mentioned earlier, a whiter and
brighter surface can improve the performance of a
paperboard product with contrast for legibility.
That quality is very important in printing and writ-
ing papers and in magazine advertising, where
visual clarity and high appeal are critical. These
products, I must say, are market driven.
How many of us are over 45? I have 20-20
vision and an eye problem called astigmatism. At
night, if there is not a good contrast between the
print and paper, or if I am in an area that is not well
lighted, I can't read. That is the practical reason for
insisting on contrast. Now, let's talk about address-
ing your needs and the progress the industry is
135
-------
Technical Perspectives — Specifications
making. We are beginning to have a knowledge of
paper and to move from lack of understanding to
one of positive differentiation. The objective is to
gain fair treatment of the specifications of unique
papers. You should know that there are reasons for
brightness, strength, and opacity. But what is the
reason for totally chlorine-free papers? Is there a
practical reason? That is what you need to know
when you are talking and working with changing
paper specifications. As an industry, we endeavor
to know what those specifications are, and what
your demands are, and we are going to meet your
needs if they are technically and economically
feasible, if they do not risk the loss of paper's physi-
cal and optical properties, and if we can do it in an
environmentally safe way.
The Paper Industry's
Commitment
Our use rate (see Fig. 1) shows the industry's com-
mitment to recycling even during a recession.
Despite a general production slow down, the curve
increases. However, I have another message for
you as well, which is time. It takes time for this in-
dustry to change and move. Take, for example, the
typical schedule behind the supply of and demand
for recovered paper in Figure 2. Notice how fast
we can turn on collection systems to get paper.
Notice how much longer it takes to get a machine
or other facilities in place to use this recovered
paper. This time lag affects the whole process of
the paper industry. We need time.
We are in fact moving. We are in fact com-
mitted to the increased use of recovered paper, and
we are way ahead on this score (see Fig. 3). The 40
percent goal is going to be met, but it won't be easy.
You can help the paper industry to determine
legitimately what is needed, why it is needed, and
then create a booming demand for the papers you
have identified based on actual need.
Percent
30
28
26
24
22
30
29%
28
26
22
i i i i i i i i i i i i i i i i
1970 72 74 76 78 80 82 84 86 88 90 92
Source: API
Figure 1.—Recovered Paper Use In the United States.
136
-------
V.K. MORTON, JR.
SUPPLY
(Collections)
DEMAND
(Mill Use)
Figure 2.—Recovered paper supply and demand.
Percent
42
TIME
40
38
36
34
32
30
28
26
24
22
36.7
33.6
30.6
26.7
J L
I I I I I I I L
J L
J L
1980 82 84 86
Figure 3.—Paper recovery in the United States.
88
90
92
94
96
42
40
38
36
34
32
30
28
26
24
22
137
-------
Opportunities and Barriers for Using
Chlorine-free Paper in North America
Howard Sproull III
President
Eco Paper Source
Chicago, Illinois
Far more than two years, Eco Paper Source has
marketed totally chlorine-free (TCP) paper to a
wide audience, gaining in the process consid-
erable insight into the opportunities and barriers
surrounding the acceptance of these papers. This
paper highlights factors that either restrict or ac-
celerate interest in and use of chlorine-free paper.
Chlorine-free paper can be characterized as an
intellectual choice. The technical issues behind the
choice require thoughtful consideration. In general,
the choice is not for those who are settled in a path
of conformity, but for those who earnestly seek out,
demand, and welcome meaningful environmental
solutions.
Benefits of Chlorine-free Paper
The main factors affecting the use of chlorine-free
paper are cost, availability, performance, educa-
tion, and perception. No restrictions or penalties
apply to availability and cost.
Availability is a function of landed inventory
and mill capacity. The capacity to produce chlor-
ine-free paper in grades that Eco Paper Source
markets already exceeds 1 million tons per year.
When landed inventory is insufficient to cover a
given project, a direct mill shipment is convenient
and easily attained. Direct mill shipments take four
to seven weeks — a normal and reasonable time
frame.
Nor is cost a barrier. It is usually the catalyst. If
we can save the client money, or if our papers are
similar in cost to equivalent products, we'll get the
order.
Chlorine-free paper performs well in press
runs, according to printers. I hasten to add that
when asking a printer for an opinion, a positive
response usually means a lack of negatives. Yet,
with chlorine-free paper, the printers are eager to
rave about how clean the sheet runs; how quickly
they reach color targets; and how quickly they are
able to get press sheets approved by the print buyer.
So the good news is that people who want to
use chlorine-free paper need only ask for it. There
is no pricing penalty, no sacrifice in quality, and no
resistance from the printer. That chlorine-free
papers are a meaningful environmental alternative
makes them an optimal choice.
Obstacles to Chlorine-free
Paper Use
The key barriers to acceptance of chlorine-free
paper are education and perception. The chlorine-
free choice requires an audience willing to con-
centrate on a new subject matter that is relatively
complex. It requires study to understand the impact
of chlorine on the environment during the last 75
years of paper production and the difference be-
tween inorganic and organic forms of chlorine.
Chlorine-free paper is a choice that requires an
audience willing and able to learn.
Why, then, do people accept or reject chlorine-
free paper? Why do they print or choose not to print
on environmentally benign paper whose produc-
tion yields health and safety benefits that are com-
pelling, tangible, and meaningful? The answer is
perception. It is one thing to provide information
and education. Action results from perception.
Perception involves the following questions. Is
chlorine-free paper a truly environmental product?
If so, can my client understand the issue? If the
answer to these questions is yes, then this customer
will use chlorine-free paper. Since 1989, I have
made hundreds of presentations and thousands of
telephone calls. I've mailed literature, samples, and
information to thousands of people, including cor-
porate end users, printers, designers, paper mer-
chants, and advertising agencies.
138
-------
H. SPROULL, III
The degree of interest generated by these con-
tacts is directly related to perception. I am pleased
to report that a vibrant, actively interested segment
of this population now insists on using chlorine-
free paper. Why does this group select chlorine-free
paper? They understand the issue. These con-
sumers can be characterized as proactive and
quality-conscious. They have accepted the chal-
lenge of seeking out the best available environmen-
tal choices, and they have concluded that
chlorine-free paper is the meaningful course to follow.
These individuals are equally concerned with
performance. Their research and experience has
shown that recycled paper doesn't deliver all the
results they want. They know that postconsumer
content is the only true measure of recycling's en-
vironmental impact.
Paper grades suitable for printing that also have
high levels of postconsumer content (50 percent or
more) are a very small portion of certain paper clas-
ses. They are currently priced at a premium com-
pared to papers with less postconsumer content,
and they also exhibit greater resistance to normal
press speeds.
Cost, Performance, and Availability
Cost is not a problem. As mentioned earlier, the
cost of chlorine-free paper has in all cases been less
or equivalent to competing papers. In my opinion,
surveys that say people are willing to pay more for
environmental substitutes are not accurate. They
make good newspaper copy and nice 45-second
radio spots, but if you stand in the checkout line,
call on a printer, or talk with a designer or a non-
profit group, the important factor is lower paper
cost. Again, across the board, Eco Paper Source
sells chlorine-free paper at a cost that saves or
meets the client's budget.
Performance includes many elements, but its
definition here is tied to the following question.
Does chlorine-free paper present any significant
performance difference to the grade for which it is
substituted? The answer is twofold. No significant
difference is noted if the substitute is a virgin fiber
chlorine-bleached paper, and a significant dif-
ference is noted if the substitute has a recycled
component. Quality suffers as postconsumer con-
tent increases. The chlorine-free sheet runs cleaner,
which means a happy press crew.
The chlorine-free sheet reproduces the dot with
greater consistency, which means sharper images
and screens. The chlorine-free sheet is uniform,
which means mottle-free solids. When a printer
tries to print a high quality, multiple unit, process-
and-match color job on a recycled sheet, he is
trying to make a silk purse out of a sow's ear. When
printers run a chlorine-free sheet, they have noth-
ing special to watch for — no special inks, no spe-
cial settings, no adjustment to production speed, no
headaches. No performance barriers exist when
using chlorine-free paper.
Chlorine-free paper is plentiful and easily at-
tained by those who want it. Eco Paper Source has
satisfied virtually all inquiries with a chlorine-free
offering. Our chlorine-free papers are appropriate
for all types of corporate literature and office use.
Education and Perception
Education has proven to be a significant obstacle.
People are slow to act positively on what they have
learned. The issues of dioxin contamination, or-
ganochlorine poisoning, toxic waste, and the
chemistry of chlorinated aromatics are difficult to
simplify. Exposing people to these facts causes
some discomfort. They may begin to realize the sig-
nificance of the issue but later find it easy to ignore.
Damage control measures taken by mill repre-
sentatives who call on the same groups compound
this loss of retention and interest by suggesting that
the whole chlorine issue is a nonissue. Thus, the
educational process becomes a formidable ob-
stacle. There are, however, individuals who seek
out information about the issue and having done
so, eagerly embrace the chlorine-free substitute.
Perception is a complex obstacle to acceptance
and use of chlorine-free paper. People and or-
ganizations shroud themselves in environmental
images. Environmental image-making perception
management are an important marketing agenda. A
bandwagon phenomenon can occur. The effect of
this phenomenon, however, is a confining one. The
parade has room only for one band; additional per-
formers are excluded. This phenomenon is charac-
terized by statements such as "We only use
recycled paper," or "If it is not recycled, our
audience will not get it, so we don't want to rock
the boat," or "People can relate to a landfill, I don't
think they care about what disappears into the
water and air," or "Who else is using this paper?"
When questioned further, many will admit that
the recycled paper they use has minimal or in fact
no postconsumer content, but since they can get an
"environmentally friendly" logo on it, it really
doesn't matter. What matters is the convenience of
using something that delivers the image, although it
has only nominal substance. As a result, many
communication professionals use popular symbols
to "greenwash" audiences. Nevertheless, a vibrant,
active user's group does exist and does stand out as
a standard-bearer for the environmentally safe al-
ternative. As an issue of health and safety, the
chlorine-free choice is one that can be highly satis-
fying! It requires no compromises and sends an ap-
propriate environmental message.
139
-------
The Original U.S. Chlorine-free
Paper Producer Looks Ahead
Archie Beaton
Specialty Paper Sales
Lyons Falls Pulp & Paper
Crystal Lake, Illinois
Far those of you not familiar with Lyons Falls
Pulp & Paper, I represent the original and only
chlorine-free producer of uncoated free sheets
in North America. We are a very small, integrated
mill, producing roughly 80,000 tons per year. The
need in today's market is to specialize — to
produce specific products for specific markets. At
Lyons Falls Pulp & Paper, we work to meet the cur-
rent needs of a varied market looking for chlorine-
free paper products.
Our production capabilities range from tree
harvesting to the production of hydrogen peroxide
bleached pulp and uncoated free sheet grades — a
range that allows us to produce chlorine-free
products for many markets. These markets include
the publishers of books, magazines, and newslet-
ters; food packagers; manufacturers of personal
care products; manufacturing and service corpora-
tions; environmental groups; and universities.
The market is enormous for any paper applica-
tion open to using a chlorine-free product. As for
the issues surrounding chlorine in the pulping
process versus products produced without
chlorine, we should draw a line in the sand. Com-
panies producing chlorine-free products are not a
threat to the paper industry, though it may certainly
have signaled a trend for the chlorine industry.
According to the July-August 1992 issue of
Chemical Business, "Chlorine is fading from the
paper scene":
The reason for the decline is concern
about hazardous chlorine compounds that
may be left in the paper or in the process
waste stream. As much as 10 percent of
the bleach applied may form
lignin-derived chlorinated organics that
end in the plant effluent, with traces
sometimes in the paper. Dioxin is one of
these chlorinated organics and, while its
toxicity is still intensely debated, dioxin is
undesirable by any standard.
Concerning this substance, the U.S. Environ-
mental Protection Agency (EPA) says that "all U.S.
residents now have dioxin in their body tissues in
amounts averaging seven parts per quadrillion"
(Magner, 1992); and the U.S. Food and Drug Ad-
ministration says that sport fish have the highest
amounts, but traces of dioxin also get into food that
is stored or cooked in chlorine-bleached paper.
Many presenters at this conference have dis-
cussed eliminating dioxin from pulp and paper
products. We seem to be heading in the right direc-
tion. As the pioneers of recycling products
developed a value-added market for recycled
papers, so we appear to be creating a market for
chlorine-free products. This market shares its
dividend with the environment and the industry
through cost savings in chemicals and less environ-
mental impact.
EPA Special Assistant to the Administrator of
Water Mark Luttner has noted that he is "not aware
of any environmental problems with hydrogen
peroxide" (Dutton, 1992). Other studies are more
definitive: "Hydrogen peroxide breaks down into
hydrogen and oxygen, making it possibly the most
environmentally benign chemical used by the pulp
and paper industry" (Armstrong and Scott). No
dioxins, no furans, no organochlorines, no chlorine
gas or other costly pollutants to clean up!
The documentation of advantages can be
found in the European market, which has made
great strides in producing a wide variety of
chlorine-free products, from tissues and fine writing
paper to tampons and coffee and tea filters. The
140
-------
A. BEATON
makers of chlorine-free products continue to ex-
pand their product line and update their processes.
Chlorine-free bleaching is now the preferred
process in Europe. U.S. producers are not only lag-
ging behind the Scandinavians and Germans; they
are also behind the Canadians.
The Howe Sound Story and
Its Effects
A 1990 Canadian Broadcasting Company produc-
tion, "Howe Sound: Poisoned Waters," dramatized
the problem:
Howe Sound, just north of Vancouver, is
at the center of an environmental battle.
Toxic chemicals from two pulp mills have
contaminated the inlet, forcing a halt to
fishing and shellfish harvesting there.
This story featured two pulp mills located on a
small, beautiful inlet. On a wider scale, it disclosed
how environmental groups are trying to force
government and industry to account for their ac-
tions. The fight being waged at Howe Sound over
pulp mill pollution is starting to be fought else-
where in Canada and the United States.
A story with the same implications is happen-
ing today on the Fenholloway River in Florida, the
Pascagoula River in Mississippi, the Noches River
in Texas, the Androskogen River in Maine, and on
the shores of Lake Michigan, among other places.
Today one of the pulp mills in Howe Sound has
joined the ranks of pulp makers who produce total-
ly chlorine-free (TCP) kraft pulp. This mill is using
hydrogen peroxide to attain a General Electic (G.E)
standard brightness of 72 to 80. The pulp will be
sold to German customers for a variety of products.
In the United States, everyone is constantly talking
about brightness: "The numbers are 86 to 90"; "our
top numbers are 77 to 78." In many situations those
numbers are beyond what's really needed.
For example, we made some paper this year for
a reply card user. The company's agency got
printed samples containing 100 percent coverage.
The agency rejected our 74. When we discussed
the cost savings and pulp retention issues with the
end user, however, they overrode the agency,
preferring less brightness.
In British Columbia, regulators want all adsor-
bable organic halogens (AOX) out of all pulp ef-
fluent by 2002. In effect, these rules will force pulp
producers to stop using chlorine and chlorine com-
pounds in the bleaching process. British
Columbia's Environment, Lands, and Parks Mini-
ster, John Cashore, recently acknowledged that
pulp producers "have already made significant im-
provements, as have many of our own pulp mills,
but the protection of our fragile environment is
para-mount" (Pulp Paper Week, 1992).
In dealing with those who are informed about
organochlorines, dioxins, and furans, the need for
papers produced without chlorine is utmost. Those
who are misinformed will cite such figures as this:
300 million tons of chlorine compounds are
naturally released by seawater each year (Georgia-
Pacific, 1992). But chlorine on its own is not the
issue — it's the result of using it during the pulping
process that is controversial.
Dioxins are 1,000 times deadlier than cyanide
and thalidomide. "Dioxins do not occur naturally,
nor are they intentionally manufactured by in-
dustry, except in small amounts for research pur-
poses," U.S. Assistant Surgeon General Dr. Barry
Johnson told a House subcommittee (Johnson,
1992).
Organochlorines are made up of thousands of
chemicals, of which 300 have been identified, 30
fall into the most deadly category, and 700 can't be
categorized. Ask the people whose wells have been
contaminated.
One community has tried for two years to iden-
tify what's in their drinking water. Ground con-
tamination surrounding a chlorine bleaching pulp
mill forced these resident to drink, bathe, and wash
their clothes in bottled water graciously supplied
by the mill. Their own employees cannot drink
water from the mill's wells (Hauserman, 1991).
This says something to us. We may be afloat
with water, but don't drink it unless it comes in a
bottle. The pollution is sometimes colorless, most
times odorless, and all the time dangerous.
Dioxins, furans, and organochlorines are find-
ing their way into our food chain. It doesn't matter
that we are talking so many parts per million, tril-
lion, or even quadrillion — what matters is that
these chemicals are being found in dairy products,
beef, pork, lamb, venison, poultry, and produce; in
our water and air, and in the breast milk of nursing
mothers (Schmidt, 1992). Is this the legacy we want
to pass on to our children? Shouldn't they have a
choice?
Chlorine-free products manufacturers are look-
ing for partners in our industry among companies
with whom we do not compete directly. We can
add an environmentally sound paper to your
product mix. Many of you here are part of larger or-
ganizations or operate as separate profit centers.
We have products to satisfy your international and
environmentally concerned customers. We believe
there really is a need for chlorine-free products.
141
-------
Technical Perspectives — Specifications
Is There a Market for
Chlorine-free Products?
I receive many phone calls each day from govern-
ment agencies, environmentalists, food packagers,
sanitary product manufacturers, and others asking
what products we make that would be suitable for
their use. Each caller wants to start using chlorine-
free paper in his or her operations, even if it's just
for copiers. The purchasing agent for a company in
San Diego, California, told me he spends $200,000
per year on copy paper and "I want to put my
money where my mouth is." He thinks that many
organizations want to talk about the environment
but aren't willing to spend extra to make positive
changes. We discussed the price differential along
with limitations. He placed an order and continues
to use our cut-size even with its limitations, which
include high-speed copier "curl" (causes machines
to jam) and brightness.
Complaints about chlorine-free paper have in-
cluded poor print quality and poor performance on
printing presses. Our experience has shown that
chlorine-free bleached paper is equal or superior to
our current competitors' bleached paper in print
quality and ease of reading. A publisher of a recrea-
tional magazines who is currently using a coated
No. 4 gloss sheet called us. He is concerned about
the Gulf of Mexico where his photographers often
work. A mutant fish called "the bearded lady," a
female fish with male characteristics, has appeared
in the Gulf. The breeding grasslands are being
devastated by river-borne effluents. We ran a trial
for him of our chlorine-free uncoated free sheet.
The photos don't "pop," and some detail is lost, but
the trial is a success overall. He says his company
can compensate with different film to maintain the
photographs' detail and high quality, and the com-
pany can still support manufacturers who offer an
alternative to chlorine bleaching.
If we allow the perception to grow that our in-
dustry doesn't care about the environment, that we
won't support anyone who produces chlorine-free
products, and that we aren't interested in water
quality or the food chain, we will be engaging
needlessly in a battle we cannot win.
References
Armstrong, L. and A. Scott. Stop the Whitewash. HarperCollins
Publishers Ltd.
Dutton, G. 1992. Chlorine fading from paper scene? Chem.
Bus. July-August 1992 issue.
Georgia-Pacific. 1992. Environmental Update. Spring 1992.
Issue I.
Hauserman, J. 1991. State links dirty wells to P&G mill. Tal-
lahassee Democrat. July 21,1991.
Johnson, B. 1992. Testimony before House Human Resources
and Intergovernmental Relations Subcommittee, June 10.
Gov. Operat. Comm. Washington, DC.
Magner, M. 1992, March 15. Dioxin — in about-face, U.S.
warns of health danger. St. Louis Post-Dispatch 114(75).
Pulp and Paper Week. 1992. B.C. wants AOX out of effluent by
2002: pulp makers worry over cost. January 27, 1992.
Schmidt, K. 1992. Science and society puzzling over a poison.
U.S. News World Rep. April 6, 1992.
142
-------
Issues and Needs Affecting
Paper Purchasing Decisions
An End User's View
David J. Refkin
Director, Environmental Affairs
Assistant Director, Paper Purchasing
Time Inc.
New York, New York
Time Inc. welcomes opportunities to discuss
the difficult and challenging environmental
issues facing the pulp and paper industries
and their end users.
Time Inc. is the largest magazine publisher in
the United States. In addition to our flagship, Time,
we publish Life, Sports Illustrated, People, Enter-
tainment Weekly, Fortune, Money, Southern Living,
and Sunset, as well as several other titles. The
majority of our magazines are printed on light-
weight coated groundwood No. 5 paper. In 1992,
we will purchase 220,000 tons of paper from
domestic suppliers. In addition to lightweight
coated groundwood paper, we buy small amounts
of coated and uncoated free sheet. In 1992, we will
purchase more than 27,000 tons of recycled paper
— 12 percent of total purchases. Before 1991, we
did not buy recycled paper.
Product quality is a critical aspect of our paper
purchasing decisions. Our magazines' readers and
advertisers demand high quality paper. This
demand is a challenge for our paper suppliers, be-
cause we most often use 32-pound coated ground-
wood. We are forced to use lighter-weight papers
because of high postal and distribution costs.
Time Inc. works closely with its paper suppliers
to develop paper grades of superior quality. Our
most critical quality specification is opacity. Attain-
ing high opacity readings on a 32-pound sheet is
particularly difficult. In 1990, after three years of
partnership with our suppliers, we were able to
reach our opacity targets and change our three
largest magazines from 34-pound paper to 32-
pound paper.
Other important paper characteristics are gloss,
brightness, smoothness, and strength. Paper gloss
and brightness enable our advertisers to showcase
and differentiate their products. When a new
generation of presses enters U.S. pressrooms, we
will be asking lightweight paper to run through a
press at speeds of over 3,000 feet per minute, or
nearly 40 miles per hour. Without appropriate
strength characteristics, web breaks occur and the
presses shut down. Then dispatch schedules are
missed, and the magazines arrive late to sub-
scribers.
Suppliers Are Located in
the United States
We buy all of our groundwood paper from mills in
the United States. Generally speaking, these grades
are a mix of groundwood, thermomechanical, and
kraft pulps. Some of our suppliers manufacture
their own kraft pulp, some of them purchase kraft
from subsidiaries of their parent companies, and
others purchase kraft on the open market. All
recycled deinked pulp is purchased from other
manufacturers.
Many factors affect our choice of paper sup-
plier. Our mass-volume magazines must be printed
on lightweight paper to minimize distribution costs;
143
-------
Technical Perspectives — Specifications
therefore, the ability to manufacture these grades is
important. Our three major weeklies are printed at
eight plants throughout the United States; therefore,
the geographical location of the mill is important.
In addition, we spend close to $200 million per
year on paper; therefore, pricing is a major issue.
We favor suppliers who take innovative and cre-
ative approaches to papermaking and customer
service.
These factors are important, but two other con-
siderations are most critical in selecting a paper
supplier. We insist on consistently high quality
paper, and the suppliers' ability and willingness to
enter into a close partnership with Time Inc. We
meet formally with mill managers every two
months to review adherence to quality specifica-
tions and to work on product enhancements. Infor-
mally, we talk with our suppliers daily. We believe
our magazines are the best quality publications in
their respective fields, and that quality must be
reflected in their print and paper. We expect a great
deal from our suppliers and, in return, we give
them much back.
Environmental issues play an increasingly im-
portant role in our paper purchasing decisions and
production methods. In 1990, Time Inc. started
testing uncoated, recycled paper for use as sub-
scriber reply cards. Today, 80 percent of our ton-
nage for this product is recycled. In 1990, we also
started working with our suppliers on developing a
recycled coated groundwood paper for use in our
magazines. Following 18 months of hard work, and
some resistance, the mills developed a recycled
paper of equivalent quality to new paper at basis
weights of 38 pounds and up. In January 1992,
Entertainment Weekly became the first major non-
environmental magazine to switch permanently to
recycled stock. Entertainment Weekly was fol-
lowed by Parenting in February, Hippocrates in
March, and Health in April. In its November 1992
issue, Sunset magazine, with a circulation of 1.5
million copies, will make the switch.
In addition to the pioneering role we played on
recycled paper, we have tested soybean inks,
reduced our use of polybags, started a recycling
program for old magazine racks, and encouraged
the collection of old magazines for recycling pur-
poses. For the last two years I have been a member
of the Paper Committee of the Recycling Advisory
Council. Funded by the U.S. Environmental Protec-
tion Agency (EPA), this group has performed a
major public service by proposing definitions for
recycled paper.
Complexities of Chlorine Bleaching
Reducing the amount of paper destined for U.S.
landfills, and encouraging the use of recycled
products is a relatively straightforward issue com-
pared to the complexities surrounding the issue of
chlorine bleaching. Many diverse opinions exist on
this issue.
Many would argue that the paper industry has
already spent over $1 billion to reduce dioxin and
adsorbable organic halogens (AOX) levels and
have done so dramatically, primarily through high
levels of chlorine dioxide substitution for chlorine
and through the use of oxygen delignification. On
the other hand, some groups believe that only a
complete switch to totally chlorine-free (TCF) paper
can bring mill effluent dioxins down to acceptable
levels.
These are complex issues. Are there right and
wrong answers? We may never know. Some of the
latest studies are chilling and raise some serious is-
sues, but what is a feasible answer? Is ozone
bleaching a solution? What levels of dioxin and
AOX pose a threat? Until these questions can be
answered with reasonable certainty, it seems
foolish for paper and pulp mills to spend billions of
dollars chasing the last chlorine molecule. Do we
know what the potential dangers are of ozone
bleaching? Is sulfite pulping more of an environ-
mental concern than chlorine bleaching? Is the use
of TCF paper in conflict with the use of recycled
paper? These are not easy questions to answer, but,
answers need to be found so that all sectors of the
industry and its end users can make rational
decisions.
Conclusion
Time Inc. wants to be a leader in environmental is-
sues. Afterall, we are the ones who named the Earth
Planet of the Year in 1988, instead of designating a
Man of the Year. We have been a pioneer in the
development and use of recycled coated paper.
One day, after scientists have reached a consensus,
society may determine that billions should be spent
on new bleaching methodologies. The paper
industry's research and development capability
needs to expand so that if this day comes, industry
will be ready to respond. This transition will take
time, however, and the quality concerns noted ear-
lier cannot be ignored. Before the paper industry is
forced to spend this money, we had best make sure
that it is indeed the prudent course to take. None of
us can afford to make the wrong choice.
144
-------
Apple Computer's Project Jordache
— The Switch to Kraft Packaging
Erin Craig
Corporate Environmental Programs Manager
Apple Computer, Inc.
Cupertino, California
Late in 1990, several Apple groups involved in
the specification and use of paper products
formed an environmental task force. The task
force's goal was to examine the company's prac-
tices to determine whether they could improve
Apple's environmental performance relative to
paper products. Members of the task force repre-
sented a wide range of company functions, includ-
ing
• Creative Services — responsible for Apple's
visual image, its creation and the technical
specifications necessary to maintain the
Apple look;
• Instructional Products — responsible for
user manuals;
• Packaging Engineering — responsible for the
specification and testing of protective pack-
aging materials;
• Worldwide Supply Base Management —
responsible for managing and qualifying our
vendor base;
• Worldwide Product Marketing — respon-
sible for ensuring customer-driven solutions;
and
• Environmental Health and Safety — respon-
sible for providing technical environmental
assistance.
The task force identified protective packaging
as an area in which environmental improvements
visible to the customer could be made. Project Jor-
dache — Apple's code name for its packaging
redesign project — was born.
Product Objectives
The project had several objectives. First, the task
force wanted to revitalize Apple's product packag-
ing to show design improvements and innovation.
Second, it wanted to use environmentally pref-
erable materials. Finally, the task force strove to
reduce packaging material and production costs.
These objectives were to be met with Apple's exist-
ing standards for packaging strength and product
protection. A communications plan, materials in-
vestigation, sourcing investigation, printing and
shipping tests, and a return-on-investment model
were developed to define the project parameters.
The communications plan outlined what Apple
hoped to communicate to customers through the
new design. The design was to reinforce Apple's
reputation for innovation and change. It was to be a
bold and confident design. It had also to respond to
a changing market and to changes in Apple's dis-
tribution strategies.
When Apple first introduced its "white box"
packaging and computers, sales were largely con-
fined to exclusive Apple dealers who used trained
staff and product demonstrations as key in-store
features. As computers proliferated in the
marketplace, however, many consumers became
more savvy and more price-conscious. They no
longer needed retail consultations, and they
demanded lower prices. In response to this trend,
Apple has moved to new distribution channels,
such as computer superstores and consumer goods
retailers. These channels demand a box design with
high shelf impact that can also be a stand-alone dis-
play item.
145
-------
Technical Perspectives — Specifications
The materials investigation team researched
ways to improve environmental sensitivity in pack-
aging. The bleached white outer liner of Apple's
boxes, the hallmark of Apple's "white look," was
targeted for change. A wholesale changeover from
the white look to kraft was considered, as were al-
ternative whites, such as 100 percent postcon-
sumer office paper. Postconsumer recycled content
was established as a target for all liner options.
To achieve the environmental advantages of-
fered by kraft liners without losing Apple's "white"
identity entirely, the materials investigation also
suggested using white ink on the kraft liner.
The sourcing investigation turned up few liner
options. The alternative whites were not available
on a worldwide basis. (Apple's procurement
strategy is to use materials local to our manufactur-
ing sites whenever possible. In addition, the
materials must be available to our original equip-
ment manufacturers around the world.) Non-
chlorine bleached white liner was not investigated
in any detail; even in initial discussion the kraft op-
tion was highly rated with both the environmental
and bold design change objectives.
The sourcing investigation also revealed that
kraft liner was widely available, in most cases from
existing suppliers. The kraft color, however, varied
from region to region. European kraft was a choco-
late brown; Asian kraft was almost yellow. The
white ink was also widely available, though the
print quality varied from supplier to supplier.
The printing and shipping tests were designed
to test the performance of the identified material
options under realistic use conditions. No. 1 white
ink, black ink, and colors were printed on a variety
of kraft liners by different suppliers. Test boxes were
packed with products and shipped using normal
Apple shipping channels to determine the impact
of shipping on the materials' visual appeal. These
tests revealed some important factors for applica-
tion later in the design process. The white inks
could be printed successfully on kraft, and had a
tremendous visual impact; however, their print
quality was inconsistent. Some samples were
blotchy, and some printers had difficulty running
the ink.
The shipping test also demonstrated a striking
difference in visual quality between original Apple
white boxes and the test kraft boxes when the end
user received them. Apple knew that the white
boxes created problems for some resellers because
they were dirty and scuffed after shipping. Apple
distribution centers routinely rejected dirty boxes
and replaced them with Apple boxes that had been
sent separately. This practice created a fair amount
of waste, both environmentally and economically.
The kraft boxes, though equally scuffed and dirty
from shipment, did not appear to be so badly
damaged. The task force estimated that a switch to
kraft boxes could result in a 40 percent reduction in
box rejects.
The return-on-investment model was the initial
cost investigation. It estimated the capital required
to make a complete design change, and compared
those costs to projected savings based on the
materials and sourcing investigations and the print-
ing and shipping tests. The total project costs were
estimated to be $400,000, and the projected
savings, based on a kraft liner, totaled more than $3
million for the first 18 months of implementation.
These savings derived largely from a materials cost
reduction of approximately 50 percent.
Product Design
Based on these encouraging results, Apple
proceeded with the box design. The artists were
given free rein to develop a new look for Apple.
They were told only that the design would be
produced on kraft boxes, that the boxes should be
limited to two colors, and that Apple was interested
in exploring white ink. The designers produced a
wide variety of designs, the most promising of
which were printed on test boxes for consumer re-
search and presentation to Apple senior manage-
ment.
Apple conducted consumer research in the
United States, Germany, France, and Japan to
determine whether the box design would positively
or negatively affect consumers' intent to purchase
an Apple product, and whether the brown box
communicated that the product was technological-
ly advanced. The research indicated that con-
sumers' intent to purchase was somewhat
negatively affected by the brown boxes, until they
were informed that it had environmental benefits.
At that point, they changed their opinion and were
either neutral between the boxes, or favored the
brown boxes.
Research also indicated that all box colors
(white and the three shades of kraft) were equally
effective at communicating the message of a tech-
nologically advanced product in the United States,
while in Europe and Asia, the white and medium
brown boxes were somewhat more effective at
conveying this message than the dark brown and
yellow-brown boxes.
The task force also surveyed the manufacturing
sites that would be responsible for localizing the
box design, procuring materials, and managing the
original equipment manufacturers. They empha-
sized the need for generic product images with few
146
-------
E. CRAIG
words to simplify localization, the need for local
materials and supplier availability, and a concern
regarding labels unrelated to the new design.
With this research completed, the task force
presented the project to Apple senior management
for approval to go ahead with the new boxes for the
fall 1991 product introductions. The project was
approved, and the task force proceeded to im-
plementation.
Implementation
The implementation phase included identifying
and qualifying actual suppliers, and identifying a
product cost outlay model to determine which
Apple products were close enough to obsolescence
to forego redesigning their boxes. Then we had to
create the final design (and artwork for other
products), identify production constraints among
our direct suppliers and our original equipment
manufacturers, confirm the environmental benefits
of the design change, and decide on the education-
al and promotional plan for the new box. These
phases were prerelease absolutes; in addition,
Apple needed to update the print/packaging sup-
plier qualification documents and the Apple Print
Production Standards binder to reflect the new
design.
Although most of our existing suppliers could
supply kraft boxes, it was necessary to identify and
qualify additional suppliers to ensure materials
availability, cost, and quality. At the same time, we
examined the availability of postconsumer content
at these suppliers to meet our increased recycled
content objective.
The product cost outlay model showed that for
each of approximately 150 products on the market,
the changeover to a new box would cost ap-
proximately $1,700. The ongoing cost savings at-
tributed to the new design was about 50 cents per
box. Therefore, Apple would need to purchase at
least 3,400 boxes of any particular product for the
design change to "pay back" for that product. The
new design was not implemented for products that
were either so close to obsolesence or sold in such
small quantities that they would not "pay back."
The final box design and artwork reflect a black
design, with a heavy dot photograph of the
enclosed product. The product identifier (for ex-
ample, "Macintosh llsi") was designed in white,
though the option remained to print it in black, or
to print some in black and some in white. The
design required no color separation, so only one
film was prepared for each product. In the final
stages of implementation, the decision was made to
print our major product lines with the white iden-
tifier, while others were printed in black. This
decision meant cost savings, and allowed Apple to
control the quality of the white ink suppliers very
strictly.
Inconsistencies among suppliers of the white
ink printing remained the key production con-
straint. The white ink suffered from contamination
problems at some printers, thus darkening the final
printed boxes, while other printers had trouble run-
ning the viscous ink in their machines. Rather than
attempt to address these issues at all printers, we
decided to focus on using white ink for our major
product boxes, while allowing the original equip-
ment manufacturers' product boxes to be printed
using black ink only. This decision reduced both
the cost and the time associated with implementing
the change at our original producers, though the
visual impact of the all-black boxes is somewhat
less than the black-and-white combination.
A critical component of the implementation
phase was to determine, for our particular supply
base, whether the switch to kraft boxes would ac-
tually result in environmental benefits. We con-
tracted with Scientific Certification Systems, Inc.,
(SCS) of Oakland, California, to assist us with this
determination and to provide a third-party analysis.
SCS compared the environmental effects of three
corrugated box liners: bleached (white) liner, with
all virgin materials; unbleached (brown) liner with
all virgin materials; and unbleached (brown) liner
with high recycled fiber content.
They surveyed seven linerboard mills, five in
the United States and two in Scandinavia, in order
to establish environmental performance in the
areas of resource use, emissions, energy use, and
toxic and hazardous waste use and release. The
data were collected from the suppliers themselves
without the benefit of an audit. However, the data
derive in large part from legal requirements such as
permit monitoring and community-right-to-know
submissions. Their validity rests on the force of
these legal requirements.
The mills surveyed represented current and
prospective suppliers to Apple operations. The sur-
vey conclusions showed that converting Apple cor-
rugated cardboard packaging from bleached virgin
to unbleached virgin will result in the release of
fewer toxins — organochlorine compounds, such
as dioxin, furans, and chloroform — into the en-
vironment. Converting from bleached to un-
bleached virgin pulp will also reduce the energy
required to produce Apple packaging for similarly
designed and operated mills. It may also reduce the
amount of water pollutants.
It was more difficult to generalize conclusions
regarding the incorporation of high recycled fiber
147
-------
Technical Perspectives — Specifications
content, though the one mill surveyed that
manufactured only 100 percent postconsumer un-
bleached liner was clearly the superior environ-
mental performer.
The final implementation step was to decide on
a consumer education plan. Our research had
shown that customers preferred the brown box
when they were informed of its environmental
benefits, but that those benefits were not apparent
without information. Therefore, we developed and
inserted into each package a small flier that ex-
plains the box's environmental benefits. The flier is
now being replaced with a permanent, shorter mes-
sage on the outside of the box.
Conclusion
The jordache Project continues to meet as the
Apple Print and Packaging Environmental Task
Force, which is chartered to effect the continuous
improvementof Apple's print and packaging mater-
ials. The task force has established specifications
for recycled content in corrugated boxes, analyzed
several alternative protective packaging materials
and systems, and ensured that Apple's packaging
suppliers do not use heavy metals in their packag-
ing materials. Future focus areas include paper in
our user manuals and a continuing reduction in the
volume of packaging present overall with Apple's
products.
148
-------
Panel 2:
Perspectives—Specifications
Question and Answer Session
• Richard Phillips, International Paper: Question
for Mr. Beaton. I wonder if in the process of extoll-
ing the virtues of your chlorine-free paper, you tell
your customers that you discharge 3 times the
amount of BOD, 5 times the amount of SO2, and 20
times the amount of color than another well-known
mill in the state of New York? And do you tell your
customers that your paper contains measurable
levels of chlorinated furans?
• Archie Beaton, Lyon Falls Pulp and Paper: Those
are technical things that I am not prepared to dis-
cuss. I'm a marketing person, not a technician.
• Richard Phillips: You must know whether you
tell your customers those things. You told us what
you tell your customers.
• Archie Beaton: I don't think that we got definite-
ly into that. I tell our customers that they have an
opportunity to buy something that we can provide.
There are customers who are looking for chlorine-
free products. We produce a chlorine-free product
that meets their needs. That's all.
• Richard Phillips: So you tell them a very small
fraction of the whole environmental story.
• Archie Beaton: As I think many of us do.
• Barry Patrle, Stone and Webster Environmental
Services: Mr. Sproull, in your use of the terminology
for chlorine-free papers, are the products that you
sell chlorine element-free or totally chlorine-free?
What is the definition of chlorine free in your
products? In 100 percent of them?
• Howard Sproull, ECO Paper Source: Thank you.
That is a good question. I meant to clarify that
before I started, because it is a nomenclature prob-
lem. The possibilities are elemental chlorine-free,
molecular chlorine-free, totally chlorine-free,
chlorine-free, and chlorine dioxide-free. The only
term that is not confusing is totally chlorine-free
and the products that I deal with are all totally
chlorine-free.
• Archie Beaton: From the Lyons Falls standpoint,
we do not produce every product that we make
100 percent chlorine-free. All the pulps that we
produce are chlorine-free. We produce about 70
percent of our own pulp. We need to purchase 30
percent of that pulp on the open market. That 30
percent pulp is not chlorine-free. So when we are
producing a chlorine-free product for the customer,
we will purchase the softwood chlorine-free pulp
to produce the 100 percent chlorine-free product.
• Barry Patrle: Is that totally chlorine-free?
• Archie Beaton: That is totally chlorine-free.
• Barry Patrie: Even the ones you produce your-
self?
• Archie Beaton: All the pulp that we produce
ourselves. No chlorine dioxide used at all.
• Jens Folke, Environmental Research Group,
Denmark: Some of these issues, totally chlorine-
free papers and papers containing recycled fibers,
originated in Europe. To give you a perspective of
why this is so, I'll use two minutes, if I may. As we
said yesterday, the Germans have the largest pulp
and paper market in Europe. They have about 13
mills that are all sulfite mills. The only competitive
edge for a sulfite mill is that it's an easier pulp to
bleach. Thus, the Germans were interested in get-
ting the AOX level down to zero because that
would increase their competitive edge.
149
-------
Technical Perspectives — Specifications
Now, they have a similar interest in recycling
because every piece of paper that is sold on the
German market contains a certain amount of
secondary fibers. And why is that? Because all the
virgin fibers are supplied from Norway, Sweden
and Finland. If you persuade the consumer to buy
paper with secondary fibers only, the result will be
that rather than expanding a mill in Norway you
will expand a mill in Germany. The consequences,
just to take the recycled fiber, is that in Scandinavia
and northern Germany you have an excess of about
5 million cubic meters of wood that is very well
suited for pulp.
The way we grow the forests may be slightly
different because it's a sort of plantation. We plant
the trees and they grow for approximately 70 to
150 years. We harvest it twice during that period,
and thin it. These thinnings are utterly important for
the whole economy of the forest because if we
don't thin them, then the wood at the end will be of
poorer quality and the whole economy of the forest
would decline including the replantation projects.
So. This recycling would put all the Swedish
paper machines idle and give the capacity to Ger-
many instead. Sweden, Finland, and Norway
would become merely a pulp supplier to the
central European market. I think it's important to
understand the market forces behind pollution con-
trol and these remedial issues. I'm not going to dis-
cuss whether recycled fiber makes good or bad
paper but the most important thing is to control the
waste. It's the waste you want to eliminate from
your cities and dumps, and if you do, you'll be
okay. Collect all the waste paper. But remember
there's another use for waste paper, namely energy,
the substitute for fossil fuels. If you take all the
waste paper in Munich and ship it back to Sweden,
I suggest you install a steam engine in your ship and
feed it with all the paper. See how much is left
when you get back to Sweden.
• Mark Floegel, Greenpeace: I have a question for
David Refkin. I was interested in your presentation
and your partnership with mills to get from 34 Ib
down to 32 Ib papers and the 18 months it took to
get to recycled content. I have also had conversa-
tions with folks at Time and as a result Time pub-
lished an announcement in January regarding
chlorine-free paper, saying that Time is interested in
chlorine-free paper and intends to switch to
chlorine-free paper when it becomes practical to
do so, in terms of quality and cost. I am surprised
you didn't address that in you remarks today. Since
that time I have heard talk from within the industry
and from various government regulators, that Time
is backing away from that statement. So I've got a
printed statement on the one hand and a lot of
backscatter on the other. Is Time backing away
from its statement? I was wondering if you could
clear the record for us today.
• David Refkin, The Time Inc. Magazine Com-
pany: What I tried to do in my speech was outline
the publishing side of our position on this topic.
Since 1923, I think, Time has had a reputation
within the publishing industry of having a separa-
tion of church and state; that is, our editorial side
operates independently of our publishing side and
vice versa. What was printed in Time magazine in
January was the viewpoint of the editorial side of
our business, not necessarily the viewpoint of the
publishers.
What I tried to outline today was the fact that
we are an environmental company; we've done a
lot of things in that direction. However, before we
jump in one direction or another with regard to the
issue of chlorine-free pulp, we still have many
questions that need to be answered. I don't think
there's been a consensus reached on the evidence
yet. When and if a consensus is reached that the in-
dustry needs to change, then Time will support that
change. But I don't think we've reached that posi-
tion yet.
• Mark Floegel: For clarity, on two points — one
on mine and one on yours. I didn't speak to anyone
on the editorial side. I spoke to your boss and your
boss's boss on the publishing side. What you're
saying is that you are not working in partnership
with your suppliers to develop a chlorine-free
paper like you worked in partnership to develop
the recycled paper and like you worked in partner-
ship to develop the lighter weight.
• David Refkin: At this point in time, the answer is
that we are not.
• Steve LevKas, Environmental Defense Fund: My
question is for Mr. Sproull. I'm curious to know to
what extent your company is involved in marketing
reduced brightness papers if high brightness is not
essential to functionality? I'd like to know if you are
doing that, what your experiences have been in
overcoming the education and perception
obstacles that you identify?
• Howard Sproull: Brightness levels come into a
performance category and really depend on what a
particular end use might be. Quite frankly, I very
seldom hear any objections to brightness. So in that
respect, it's not so much a part of the education
process.
• Steve Levltas: Are you marketing any products,
whether file folders, legal pads, or copying paper,
that have reduced brightness? If so, are you finding
consumer acceptance?
150
-------
QUESTION & ANSWER SESSION
• Howard Sproull: Basically, I'm involved with
printing papers, not so much with converted
products like folders and so forth. The lower bright-
ness is only relevant to one area of the paper that I
sell. In that respect, the people buying that product
have no objection to it. There are obviously people
that I've talked to that do have an objection to
lower brightness and don't buy the product, but
reduced brightness may not be the only reason.
• David Assmann, Conservatree: I have two ques-
tions for Virgil. First, the chart you showed at the
beginning of your presentation with recycling at the
top and resource reduction at the bottom, turns the
traditional reduce, reuse, recycle notion upside
down, but my question is the second item you have
on that list, namely, waste-to-energy. I have a copy
of a chart that API put out that lists the sources of
dioxins in the atmosphere, and at the top of the list
is municipal waste incineration. How do you make
that consistent with having waste-to-energy as the
second item on your list in terms of pollution
prevention?
My second question concerns the chart that
shows a graph of wastepaper use rates that starts at
24 and goes to 30. Of course, it looks impressive
when you take only a small part of the scale, but
how can we say that it is adequate when it's well
below the global average? Slovenia, for example,
has a 72 percent wastepaper use rate. Venezuela's
rate is 60 percent. We're running way behind a lot
of other countries. Those are my questions.
• Virgil Norton, American Paper Institute: Let me
answer your first question very straightforwardly. I
think I mentioned that those items on the chart
were not necessarily in the hierarchical order that
we are accustomed to. It was not meant to show
any rank order. It was a matter of when I wrote the
items down to prepare a slide — that's the way they
came out, and that's the way I used them. I had no
intention of changing the hierarchy. There was no
ranking order, but the slide looked better.
With reference to our collection rate, I think if
we are objective about it, we must look at countries
like Germany and Japan where the recovery or col-
lection rate of wastepaper is somewhere between
48 and 50 percent on a national average. Japan has
been at this for well over 30 years. It took them
some time to obtain the 50 percent rate, and they
have difficulty maintaining it. They keep dropping
to 47 and a fraction, or what have you. The same
thing is true in Germany. I believe what my slide
showed was a very significant increase. Whether
you put it on a large or small scale, going from
where we were to where we are in a matter of three
years is a rather dramatic increase.
This increase is like saying that President Bush
started at a 37 percent favorable rating in the polls
and suddenly hit 52 percent. Gee, he started at a 37
percent base. Still, I think he'd be happy to have a
52 percent rating right now. That's the image I
would apply to our collection rate, David, though
you and I may politely disagree. I think we have
something we can truly hang our hat on, and I do
not feel that we are so woefully slow. If anything, I
think we are showing a tremendous commitment.
The other thing I wanted to point out that was not
mentioned in your question is that this improve-
ment has occurred during an extended recession-
ary time.
• David Assmann: Just one final thing on that. Our
wastepaper use rate in 1951 was 32 percent.
• Judy Usherson, Center for Earth Resource
Management Applications, Recycle Paper News: I
have a comment for Mr. Sproull, who seems to be
pitting chlorine-free paper against recycled paper
as a marketing strategy. I think that's unfortunate. I
believe recycled papers are making a significant
contribution to several sets of environmental
problems. We work very closely with major high-
volume printers and others interested in the subject
of recycled paper, and the performance deficien-
cies that Mr. Sproull cited do not seem to pan out
when we talk to these people. The Center for Earth
Resource Management would be very pleased to
put you in touch with printers and users who are
very, very happy with the high quality of the
recycled papers they are using. I would also like to
comment that importing totally-chlorine free
papers from other countries is not doing anything to
encourage the paper industry in North America.
• Richard Valley, Michigan Pulp and Paper Cor-
poration: I have a question for the panel generally.
We've been talking about brightness loss when we
get away from chlorine bleaching. We've been
talking about some vague level of brightness. Now
historically, if we wish to go back 10, 15, 20 years,
when we talked about a white paper then, we were
talking 90 brightness, 90 ISO brightness. We talked
about semibleached papers below 80. Semi-
bleached implies that they were not fully bleached;
they were not white. They were something less
than white, creamy, if you wish, or slightly yel-
lowish. Would the panel care to comment on what
their customers perceive as "an acceptable white
paper" today in terms of ISO brightness? Above 80,
above 82, above 85? I'm just curious because we
talk so vaguely about brightness, and I think it's a
very important property of paper, particularly of
pretty paper.
151
-------
Technical Perspectives — Specifications
• Virgil Norton: I'd like to comment on that based
on my 27 years experience in the industry of selling
and marketing. One of these days I'm going to be-
come a consultant to the paper industry like some
of the younger people. They're learning faster than I
am. When I talk brightness and whiteness, they are
not the same. I think it is very important to know
what the printed piece is going to be. And, obvious-
ly, there's a difference between coated and un-
coated.
Now when you look at API statistics, we break
the brightness range into 1's and 2's, and our
premium brightness papers are Vs. The industry of
designers, publishers, and printers accept one
range; others may accept something else. There is
also a publication called the competitive grade
finder. So the "brightness level" becomes a discus-
sion about a number 1 sheet, a number 2 sheet, and
a number 3 sheet. If someone were to put number 1
or 2 uncoated bond through a copy machine for
everyday office copies, that's really not needed. In-
stead of buying a number 1 or 2 uncoated sheet
they could buy a 3 or 4; and whether it was totally
chlorine-free, virgin or recycled, would also make
no difference — as long as it performs for the end
use. That's my rule of thumb for all my years of ex-
perience. That's really where it's at in terms of
brightness. Now, let's go to whiteness. Whiteness is
a color.
• Richard Valley: That's not the question I'm as-
king. I agree, that there are number 1 and number 2
sheets. But what, for instance, is the minimum ISO
brightness for a number 2 sheet? Just so we're all
more or less on the same level.
• Virgil Norton: I don't have the numbers in front
of me. But there is an accepted brightness level that
says this sheet is a number 1 as viewed within a
brightness total.
• Richard Valley: There are ranges, agreed. But
what does it mean when someone says, "Yes, I can
substitute a number 3 sheet"? I'm also a great
believer that we spend an awful lot of money
making white paper we don't need and ignoring
the environment. We buy an awful lot of extremely
white paper that glares at you when you read it. But
that's beside the point. The question again comes
down to this simple statement: We don't need all
this brightness. What brightness do we need?
• Virgil Norton: It depends on the end product.
• Richard Valley: That's extremely important to
keep in mind in our overall discussion.
• Archie Beaton: Let me comment on that. One
thing that I've noticed is that our papers have only a
77-78 brightness level that doesn't fit every applica-
tion, which is what Virgil was talking about. How-
ever, I've got printed samples here, and the way I
address the issue is by asking the customer, "Are
you printing something that's going to have full
coverage? Is ^he reverse white out that's in this
paper going to make a difference in the quality of
the print job? No. Are there cost savings? Yes.
When you're printing something that will fill the
page, it doesn't really matter if it's an 80 brightness
or an 86 brightness. Whiter than white is an old ad-
vertising maxim, an old chestnut that conjures up
images of something pristine and crisp and clean. It
was all brought on by advertising agencies. I think
really that the cry I'm hearing among some of our
customers is that beige is better.
• Ann Hlllyer, West Coast Environmental Law As-
sociation: Some work is beginning to be done in
British Columbia on an industrywide basis looking
at or trying to look at the emerging market for total-
ly chlorine-free products in respect to customers of
the pulp companies in British Columbia. My ques-
tion is for Mr. Morton or anyone else on the panel
who can answer it. Is there industrywide work
going on in the United States to get a handle on
what that emerging market is? I've heard a lot of
discussion about individual companies and in-
dividual customers, but I'm wondering if, on a
broader basis, there's any effort to analyze the
projected buying patterns of companies in the
United States. Will there be a market for totally
chlorine-free products or some of the other
categories that we have talked about? And second,
has any analysis been done on the number of mills
that are anticipating bringing some of these
products on line and their actual time frames for
that?
• Virgil Norton: Is API doing anything nationwide
was your first question. From API's perspective,
market analysis is something that belongs to the in-
dividual companies because, obviously, our mem-
ber companies have the right, the opportunity, and
the wherewithal to choose their bleaching systems.
API does not, as an association, promote chlorine
bleaching or totally chlorine-free bleaching. We
have membership on both sides of the issue. What
we do want to protect are their individual rights.
From an industry perspective, and contrary to what
Archie may have said a little earlier, it is our feeling
that not too much has yet been proven. There is
some junk science out there. We need better
science to determine what really is the case when it
comes to chlorine bleaching or totally chlorine-free
bleaching. The question comes down to — and
Mary I'm sorry I gotta say this — "Where's the
beef?" Is it really necessary, for whatever reason, to
152
-------
QUESTION & ANSWER SESSION
embrace totally chlorine-free bleaching? That's up
to the individual companies to determine. It's up to
them to determine which market niche they, in fact,
want to fulfill. It's part of their marketing.
• Ann Hlllyer: My question wasn't whether or not
you agree with the market trend. It was whether or
not the industry here is trying to anticipate the
market trend. Just like people who manufacture
cars want to know whether in five years people will
want small or big cars. Is there any comprehensive
work being done to analyze the trends?
• Virgil Morton: It's still a marketing question for
individual companies and not in the purview of our
association.
• Mod Byrd, North Carolina State University: I'd
just like to make a comment. I think we can see,
even in these brief discussions, the volatility and
complexity of the issue surrounding environmen-
tally compatible processes and paper products, but
I think that it's really important. Dr. Phillips com-
mented on an important aspect of it, namely, that
we, as an industry, must maintain a reasonable, ra-
tional, research-based and systems view of the ul-
timate solution: the production of good quality
products with good environmental performance.
If we only meet short-term consumer demands,
public demands, whether rational or not, will esca-
late. If we all rush lemminglike to the next bleach-
ing or pulping process that shows promise without
maintaining an overall systems analysis of what
we're really doing, we could end up with inferior
quality products. We could end up harming the en-
vironment by simply trading water pollution for air
pollution, toxins in one place for toxins in another
place. Ifs important that we maintain our ground-
ing in good science and examine systematically
what the final solution needs to be. If we do that,
we're going to come out okay.
• Bruce Fleming, Boise Cascade: I have a com-
ment and a question for Mr. Sproull. I was very dis-
appointed to hear you come out so strongly against
recycling because my company is moving very
quickly in that direction — and this is true for the
industry as a whole in the United States, as we
heard Mr. Morton say. So I wasn't pleased to hear
you so down on recycling. My question concerns
the nature of the chemical pulp that goes into your
chlorine-free paper. I'm trying to figure out what it
must be. Is it sulfite pulp that you put in the
chlorine-free paper?
• Howard Sproull: The suppliers that I work with
manufacture totally chlorine-free paper. A number
of them are from Germany, and one is from Hol-
land. The pulp sources that they use are various.
Two of the mills are fully integrated; another is
sourcing pulp on the open market that's chlorine-
free. The integrated facilities use the sulfite-based
process, but I'm not certain of the fiber supply in
the nonintegrated facilities.
To answer your comment about my being
down on recycled papers. I did not want to leave
that impression. What I really meant to do, basical-
ly, was to show the perceptual barrier to other alter-
natives that people wrap themselves up in by
saying that they use recycled paper. What I tried to
do is open us up a little, to help us realize that recy-
cling is not the only answer. In the process, I do
question these people about the "recycled" paper
they're using.
I can give you a case in point without mention-
ing any names. A year and a half ago, I was talking
to a designer about using chlorine-free paper as an
alternate in a high-end, highly visible publication
for a health care organization. And they basically
did nothing with it. When I called them back, about
a year later, they said "Oh, we're using recycled
paper." And I said "What is the grade and the name
of the paper that you're using?" They told me, and I
said, "Well, does that have any postconsumer con-
tent?" But they didn't know. So I said, "Isn't that
why you're using recycled paper to demonstrate
some meaningful impact on landfill, and isn't
postconsumer content the only true measure of the
recycled paper's impact on landfill?" "Well yes,"
they said, "but we don't know." Of course I already
knew that it had no postconsumer content. So what
I say is, I'm not down on recycled paper. I'm sorry
again, if I left that impression; I'm absolutely not.
What I'm exposing is the fact that people want to
do something for the environment but tend to
cloister themselves within a choice once they've
made it. That's really the point I was trying to make.
• Bruce Fleming: One final comment. You said
that printers love the chlorine-free paper that you're
supplying. I think that part of your talk would have
been more impressive had you given us data to
support that statement, perhaps showing what type
of press they were using, and its running speed and
so forth.
• Howard Sproull: I can comment very briefly on
that. Basically, the product is a sheet-fed coated
paper, a number 1 quality, that prints on sheet-fed,
five-unit or more, 40-inch presses, running
anywhere from 8,500 to 12,000 impressions per
hour. Its performance characteristics include a min-
imal amount of make-ready time, and printers also
report that a minimal amount of wash-up is re-
quired. Again, I'm not down on recycled paper. But
153
-------
Technical Perspectives — Specifications
when pressmen run recycled paper, they tell me
they're pulling their hair out, fighting the stuff. I'm
exaggerating perhaps but also reflecting their com-
ments. What they usually mean is that the/re chas-
ing hickeys through it. They've got to stop and
wash the blankets every 3,000 to 4,000 impres-
sions and that does not happen with chlorine-free
paper. In fact, in one particuJar case, the printer
mentioned that he'd run 8,000 impressions without
stopping to wash the blanket and when he looked
at it, indeed, there was no need to do so.
• Virgil Norton: Obviously, I represent recycled
mills and virgin mills, so when a statement like this
is made I have to say something, in all fairness, to
protect my recycling mills. I think it's a known fact
in the printing industry that the longest-held view
prevails. Sometimes if you just let a pressman know
he's dealing with recycled paper, it won't work.
When I was in sales, if we went into pressrooms
where the front office wanted to buy a paper and
the pressman absolutely knew it wouldn't run, if we
did little things like change the wrappers on it, it
was amazing how well it ran on the third shift. So
while there are some problems with recycled paper
in terms of print quality, there's also some problems
with virgin sheets. We do have excellent recycled
sheets that will perform well for their intended use.
• Susan Cohen, Environmental Defense Fund:
May I suggest a number on the brightness issue?
Random House uses a free sheet in its trade
hardback books that is about a 77 brightness.
154
-------
The Right Balance —
Environmental Responsibility and
the Competitive Edge
Clifford T. Hewlett, Jr.
Vice President, Government Affairs
Georgia-Pacific Corporation
Atlanta, Georgia
The pulp and paper industry in the United
States has invested billions of dollars over the
last 20 years to meet standards set by the
Clean Air and Clean Water acts as well as hazard-
ous waste laws. Our air, water, and land are cleaner
now as a result. But groups outside the industry are
pushing us to implement ever more drastic environ-
mental actions that provide little or no benefit to
human health or the environment beyond the sig-
nificant benefits we have already achieved. Never-
theless, these ideas have the capacity to funda-
mentally affect the competitive structure of the in-
dustry worldwide. Three key issues dominate: first,
what do we mean by chlorine-free? Second, what is
the industry being asked to reduce, and what
benefits will be gained? Third, and finally, what are
the economic impacts of these changes?
Pollution Prevention Progress
Let's consider the progress this industry has made in
pollution prevention. Today, U.S. mills are already
meeting effluent pollutant discharge levels that are
targeted for 1995 by other paper-producing na-
tions. Our industry uses 60 percent less water per
ton of product than it did just over two decades
ago. Since the Clean Water Act's implementation,
the total biological oxygen demand (BOD) of in-
dustry wastewater. has been reduced by 70 percent,
while paper production has increased by 50 per-
cent. The pulp and paper industry is among the
world's most efficient users of fuel. Through use of
waste by-products, our industry produces more
than 56 percent of its own energy needs. Over the
last two decades, oil consumption has been
reduced by more than 60 percent, and fossil fuel
and energy consumption per ton of paper have
been reduced by almost 50 percent. To put that in
perspective, because our industry cogenerates
more than 50 percent of its electricity needs, we
save 24 million barrels of oil annually. Industry air
pollution control technologies now remove more
than 97 percent of the particles generated in the
pulp and papermaking process. Virtually every new
solid fuel boiler and piece of process equipment
achieve a particle removal rate of almost 100 per-
cent.
The U.S. pulp and paper industry is the world's
largest paper recycler, recovering almost 31 million
tons of paper for reuse last year. We have set a goal
of 40 percent recovery by 1995.
On the resource side, last year the U.S. forest
products industry planted nearly 1.7 billion seed-
lings. Twenty percent more forested timberland ex-
ists today than 20 years ago. Georgia-Pacific and
other U.S. pulp and paper manufacturers are also
participating in U.S. Environmental Protection
Agency's voluntary 33/50 pollution prevention pro-
gram. In fact, the industry has already realized
EPA's goal for lowering dioxin discharges, reducing
them by 80 percent. Georgia-Pacific's efforts here
have resulted in nonmeasurable levels of dioxin in
9 of our 10 bleached mill effluents. We have com-
mitted the capital to achieve this nonmeasurable
result at the remaining mill, which even now meets
its state's dioxin water quality standard. We are
well on the way to meeting the other pollution
reduction goals for the 33/50 program (see Fig. 1).
The U.S. industry recently adopted its own set
of environmental, health and safety, and forestry
principles that formalize our commitment to a
155
-------
Technical Perspectives — Performance and Cost
Grams Per Year
30
25
20
15
10
5
85% Reduction
From Baseline
93% Reduction
From Baseline
1988
(Baseline)
1992
(1st Qtr)
1995
(Predicted)
Figure 1.—Georgia-Pacific Corporation EPA 33/50 plan
summary: dioxin effluent reductions. Dioxin expressed
as 2,3,7,8-TCDD and 1/2 of detection limit concentration
used for nondetect values. Annual nominalized effluent
values and single quarter effluent analysis used In cal-
culating mass values. Facilities having nondetect in
baseline, and all other samples, are excluded.
healthy environment. With these accomplishments
and ongoing initiatives, I believe the U.S. pulp and
paper industry is meeting the pollution prevention
challenge.
Let's put these efforts into perspective. As Fig-
ure 2 illustrates, the industry contributes about .25
percent to this country's Gross National Product,
and yet, we account for nearly 2.5 percent of total
U.S. industry expenditures on pollution control.
Certain environmental factions, however, do not
believe that this is enough. They believe that
whatever industry does, it will never be enough to
safeguard public health and the environment. That
attitude has led us to a critical juncture in the his-
tory of the pulp and paper industry — specifically
the heated debate about the use of chlorine com-
pounds to bleach pulp and paper products.
Pollution Control Capital Expenditures Value Of Shipments
Figure 2.—1986 to 1990 pulp mills share of U.S. industry
pollution control capital expenditures is five times their
share of value of shipments.
Defining Chlorine-free
Does chlorine-free mean reducing or eliminating
the use of chlorine gas with chlorine dioxide sub-
stitution? Do we measure success in the reduction
of chlorinated prganics of concern? Or do we mean
the use of no molecular or elemental chlorine
anywhere in the manufacturing process? The
answer is that trying to make the world chlorine-
free, as some organizations would like, is impos-
sible because nature is replete with chlorinated
organics. As reported by the Swedish Environmen-
tal Protection Agency, more than 220 million tons
of chlorinated organic compounds — nearly 3,000
times the amount discharged by the U.S. paper in-
dustry — are produced naturally by marine or-
ganisms in the Atlantic Ocean each year.
The next question we must answer is, "What is
the industry being asked to reduce, and what
benefits will be gained?" Most environmental
groups are stressing the elimination of bioac-
cumulative chlorinated organics. Are they talking
about dichlorodiphenyltrichloroethane (DDT)? It's
not produced by the pulp and paper industry.
Polychlorinated biphenyls (PCBS)? Not us, either.
Dioxin? The U.S. pulp and paper industry has vir-
tually eliminated the problem. In fact, pollution
control measures in the United States have already
led to substantial reductions in all chlorinated or-
ganics. All chlorinated organics are not created
equal. Most are benign, although a few may be
toxic, including some of those produced naturally.
Only a tiny fraction of all chlorinated organics are
generated by human activity. At a typical pulp mill,
90 percent of the chlorine used in the bleaching
process ends up as common salt, while the remain-
ing 10 percent combines with the various con-
stituents to form chlorinated organics — 99.96
percent of which are benign.
To put exposure levels into some perspective:
based on current available scientific information
used to determine the "no observable adverse ef-
fect level" (NOAEL), the concentrations of each
chlorinated organic, when present in mill effluent,
are below the NOAEL for these compounds.
The EPA effluent guideline program focuses on
28 chlorinated organics that it considers of con-
cern. Only 10 of the 28 are found in bleached pulp
mill effluent, and those only occasionally. So using
the level of adsorbable organic halogens (AOX) in
the effluent as an environmental measure requires
caution. AOX is not a reliable indicator of environ-
mental effects because it doesn't pinpoint the or-
ganics of interest. It is a relatively inexpensive
analytic chemistry indicator of the presence of all
chlorinated organics in the waste stream. AOX also
fails to consider issues of equal importance to the
156
-------
C.T. HOWLETT, JR.
environment, such as what environmental benefits
will be gained? All indicators today say that the en-
vironmental benefits to be gained from eliminating
the use of chlorine compounds in the pulp bleach-
ing process are insignificant.
Advanced methods in aquatic biology and
chemical analysis are being used to examine the
potential environmental impacts of current and
new technologies. To date, there are no indications
that totally chlorine-free (TCP) technology is en-
vironmentally safer than chlorine-based processes.
Bleaching per se may not be the relevant issue. In
fact, at a 1989 Technical Association of the Pulp
and Paper Industry conference, an international
panel of scientists concluded that no marked dif-
ference exists in toxicity between properly treated
chlorine-bleached and nonchlorine-bleached ef-
fluents. In addition, effluents from any new bleach-
ing technologies will need to be carefully
monitored to determine their environmental ef-
fects.
Advocates of totally chlorine-free bleaching are
quick to argue that the technology and its costs
would be phased in over time. They say innova-
tions will appear, increasing both TCP pulp produc-
tion and quality, and bringing product prices down.
This situation has led some countries to pursue a
commercial agenda mandating TCP production,
which would make today's high-cost TCP mills the
low-cost producers, while turning currently low-
cost mills into high-cost producers.
Comparing U.S. and Other
Countries' Industries
For the last 20 years, the U.S. pulp and paper in-
dustry has made substantial capital investments
and incurred higher operating costs to meet the en-
vironmental challenge. Other countries have not
made similar demands on their pulp and paper in-
dustry. U.S. environmental investments have
achieved a performance level that shows no
marked difference between properly treated
chlorine-bleached and nonchlorine-bleached ef-
fluents. Pulp and paper industries that have not
made such investments should not be able to create
a climate in which the U.S. industry has to abandon
what it has done, in the name of being new and dif-
ferent or politically correct. These new tech-
nologies must pass the test of time; they must prove
whatever benefits they may offer as the existing
technology has done. This leads to my final ques-
tion — what are the economic impacts of these
changes? To put it simply, the economic costs of
changing processes are significant — for industry
and society.
Figure 3 shows the amount of money pulp mills
have spent or will spend to go to ever higher levels
of chlorine dioxide substitution to achieve
specified reduced levels of AOX. The industry
today is already in the 1.5 kg AOX per ton of pulp
range. Companies have achieved success by
foregoing increased production from current
capacity. Mills have been forced to use excess
recovery boiler capacity to recover solids rather
than expand pulp capacity as had been planned. At
"no AOX" levels, which means absolutely no
molecular or elemental chlorine or chlorine
dioxide is used, capital and operating costs are sig-
nificant factors, but the opportunity cost is equal to
the other two combined. The issue is not whether
AOX can be removed. It can be if enough time and
money are expended. But we have to ask how
much is enough when we're siphoning off scarce
capital to install technologies that have little or no
environmental benefit — capital that could be used
to make our mills more competitive.
In human terms, the impact of AOX reduction
on potential jobs is negative. Jobs are displaced be-
cause capital that was employed with the expecta-
tion that it would yield economic benefit through
expansion has now been used for AOX controls.
For example, National Economic Research
Associates' figures show that when AOX levels are
reduced to 1.5 kg per ton, fewer than 1,500
workers are displaced. At 0.5 kg per ton reductions,
up to 5,000 workers lose their jobs; at "no AOX"
levels, the number of displaced workers rises to
more than 36,000.
Secondary employment is also affected. Jobs in
related industries are displaced because of lost ac-
tual capacity or potential capacity at local mills —
victims of the multiplier effect industry has on the
surrounding community. This analysis does not
reflect mills operating under high variable cost
structures, where adding more environmental con-
trol costs to these mills might force them to close.
We don't have any data on the magnitude of such
an effect, but it stands to reason that if you run a
relatively high-cost mill, it will be noneconomic
sooner with additional environmental costs. While
other mills will make up the capacity that is lost, a
resulting loss in relative worldwide competitive-
ness will diminish the likelihood that these offset-
ting capacity additions will occur in the United
States.
Diminishing the U.S.
Competitive Position
Competitive strength is the final component in our
consideration of the economics of these changes —
157
-------
Technical Perspectives — Performance and Cost
Billions Of 1991 Dollars
20
15
10
o
1.5 kg/Ton 0.5 kg/Ton No AOX
Proposed AOX Control Level
Present Value Of
Capital Costs
Present Value Of
Annual Operating Costs
Present Value Of
Opportunity Costs
Figure 3.—Costs incurred by pulp mills to reach various AOX reduction levels.
their effects on the U.S. pulp and paper industry's
competitive position. Fortune magazine recently
identified this industry as one of the few U.S. in-
dustries that is competitive worldwide.
If we have to make process changes that are not
warranted by sound scientific evidence, while our
competitors in other countries don't, our competi-
tive position will erode. Table 1 shows how much
our competitive advantage will decline relative to
some of our key competitors should U.S. pulp and
paper manufacturers be required to install tech-
nologies to eliminate AOX completely. It's impor-
tant to remember that the United States also
imports pulp. As costs of U.S. pulp and paper in-
crease, our domestic markets are more vulnerable
to imports.
A cash flow analysis shows the impact on
return on investment for a mill with AOX reduction
achieved through high chlorine dioxide substitu-
tion compared with a mill trying to achieve total
AOX removal (see Fig. 4). At the baseline, at a given
pulp price, installing equipment to make totally
chlorine-free pulp results in a reduction of 60 per-
cent on the mill's rate of return. A 10 percent drop
in the price of pulp results in a more than 40 per-
cent reduction in rate of return at the mill that has
achieved AOX reduction through high chlorine
dioxide substitution versus a drop of 90 percent on
rate of return for the mill trying to achieve total
AOX removal. At a 13 percent drop in market pulp
prices, the total AOX removal mill has no return on
investment.
Prices for commodity products such as market
pulp have fluctuated within these percentage
ranges in recent years, adding to the risk factor for
such substantial capital investments. Throughout
this debate, we must remember that the market-
place is the key. Traditionally in our market
economy, demand determines the product mix in
the marketplace. This supply and demand equation
makes the market efficient. Some interested parties
see "explosive" growth in markets for TCP pulp.
The facts suggest otherwise.
According to Hawkins Wright, an independent
international consulting firm, TCF pulp currently
accounts for less than 1 percent of the world's total
158
-------
C.T. HOWLETT, JR.
Table 1.—Competitive position of U.S. pulp producers in major export markets with and without AOX controls
imposed.
IMPORTER
Japan
Germany
United Kingdom
EXPORTER
Canada
Brazil
Scandinavia
Canada
Brazil
Scandinavia
Canada
Brazil
Scandinavia
NO CONTROL
U.S. ADVANTAGE
$63
($24)
$235
$55
($87)
$126
$55
($87)
$131
AOX ELIMINATION
U.S. ADVANTAGE
$17
($70)
$189
$9
($133)
$80
$9
($133)
$85
PERCENT DECLINE
IN U.S. ADVANTAGE
73.0
191.7
19.6
83.6
52.9
36.5
83.6
52.9
35.1
Costs are production costs in each producing country plus shipping costs to each major importing market. U.S. costs increase as a result of
AOX reduction controls. Advantage refers to the difference in total costs for U.S. exporters to each market and the costs of each competitor. A
negative result indicates a U.S. disadvantage. AOX controls reduce the advantage of U.S. producers.
pulp production. Several high-cost European sulfite
pulp mills have seized the opportunity to establish
niche markets in this pulp. These pulp grades are,
however, inferior in quality and more expensive
than those presently manufactured by the majority
of world pulp producers, who utilize kraft pulping
technology.
Therefore, we must be wary of attempts by spe-
cial interest groups to mandate demand for one
product over another. This kind of intervention
throws the market off and often results in con-
sumers not getting the kind of products they want
as well as forcing the market into a high-cost mode.
If the goal is for an industry to have minimal en-
vironmental impact, the most efficient and cost-ef-
fective way to achieve that is for government
environmental policymakers to set standards and
guidelines — for product quality and safety, and
environmental and health effects — let industry fig-
ure out the best way to meet those standards, and
let the market run its course.
Look at what the U.S. pulp and paper industry
has done. We've had decades of expenditures for
environmental controls with corresponding en-
vironmental benefits. We've recently reduced
dioxin to nonmeasurable levels in virtually all mills,
with significant additional capital and operating
costs. Other chlorinated organics of interest have
also been reduced correspondingly. We have been
successful in the area of environmental control
while maintaining our competitive advantage. We
simply ask that the investments we've made not be
forsaken, that costs incurred have a commensurate
measurable benefit, and that our relative world
competitive position be maintained.
The pulp and paper industry is among the first
to agree that government has an obligation to
safeguard the public and set standards for environ-
mental performance by industry. What industry is
saying, however, is that we need the flexibility to
meet performance standards in the most efficient,
cost-effective way. In addition, the market must be
co
I
6
£
3
o>
cc
CO
8
100
80
60
40
20
£ 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
% Loss In Selling Price
Figure 4.—Cash flow analysis: loss of ROI with pulp price reductions.
159
-------
Technical Perspectives — Performance and Cost
allowed to dictate changes in product mix rather momentum by working in partnership with regula-
than have changes mandated for it. The pulp and tory and environmental organizations to ensure
paper industry is meeting the environmental chal- that environmental expectations continue to be met
lenge. The important thing now is to maintain this in the most effective way possible.
160
-------
A Chlorine-free Paper Economy
Europe on the Verge
Margaret Rainey
Greenpeace Paper Campaign
Goteborg, Sweden
Greenpeace, an economically and politically
independent organization working on en-
vironmental and disarmament issues in 30
countries, began working on pulp and paper issues
in Europe eight years ago, highlighting the environ-
mental impact of chlorinated effluents. The cam-
paign has since grown to international proportions.
Paper is a unique natural product, fully
biodegradable, recyclable, and made of a poten-
tially renewable resource. Its production could be
an excellent example of how clean production
technologies can be used throughout a product's
life cycle. Instead, shortsighted forestry practices
combined with ecologically insensitive production
technologies and wasteful consumption habits
have made paper and its manufacture an environ-
mental hazard.
The Greenpeace Paper Campaign focuses on
maintaining forest biodiversity, reducing overcon-
sumption of paper products, increasing paper recy-
cling, and reducing the toxicity of pulp mill
effluent. Discontinuing the use of chlorine chemi-
cals in pulp bleaching is one of the most obvious
requirements for environmentally sustainable
paper production.
Chlorine-free Bleaching
Greenpeace's use of the term "chlorine-free" refers
to paper that is manufactured without any use of
chlorine chemicals; that is, none of the paper's in-
gredients (new pulp, recycled paper, or minerals)
are processed using chlorine-based chemicals,
whether inorganic (chlorine, chlorine dioxide, or
hypochlorite in fiber or mineral bleaching) or or-
ganic (chlorinated dyes, wet-strength or retention
agents, or slimicides). In this way the formation of
anthropogenic, persistent chlorinated compounds
is avoided completely. Collected paper that con-
tains chlorine-bleached pulp should be reused but
not rebleached with chlorine. The incineration and
landfilling of collected paper are environmentally
inferior alternatives to recycling.
In Europe, the term "chlorine-free" is applied
by some representatives of the pulp and paper in-
dustry to paper manufactured with an effluent con-
taining 0.1 kg or less of adsorbable organic
halogens (AOX) per metric ton. AOX is used to
measure organochlorines in pulp mill effluent.
Some producers define chlorine-free as paper con-
taining pulp bleached with chlorine dioxide.
Greenpeace considers these definitions to be
dishonest and misleading.
Some representatives of the pulp and paper in-
dustry do apply the same definition of chlorine-free
that Greenpeace uses. Swedish pulp producers
Sodra Cell and three of Germany's largest paper
producers — PWA, Hannover Papier, and
Scheufelen — have made their position public in
major marketing campaigns. Because of a demand
for such products, Stora-Feldmuhle, another of
Germany's largest paper producers, has decided to
market truly chlorine-free papers; however, this
firm still retains the definition: low-chlorine is equal
to "chlorine-free."
If the Swedish pulp and paper industry keeps its
discharge level at under 0.1 kg AOX per ton of
paper, tens of thousands of tons of organochlorines
will be discharged each year under the banner of
"chlorine-free" products. Most mills in Sweden are
at this level today.
Organochlorine compounds are recognized as
a major pollution problem because of their toxicity,
persistence, and bioaccumulation properties. Many
of the organochlorines identified in pulp mill ef-
fluent are highly toxic, and many of the seemingly
less toxic organochlorines may be biotransformed
into more hazardous compounds (Sodergren,
1991).
161
-------
Technical Perspectives — Performance and Cost
Recent studies in Sweden and elsewhere have
linked serious environmental damage to pulp mill
effluents at discharge levels of about 1 kg AOX per
metric ton of pulp. Effects on fish include bioac-
cumulation of pulp mill-specific chlorinated com-
pounds, skeletal deformities, fin erosion, disease,
reduced growth, impaired reproduction, and in-
creased detoxification activity. Mussels and shrimp
living in areas contaminated with pulp mill effluent
have been found to have shell damage and im-
paired reproduction.
Growth damage to vegetation and biodiversity
degradation have been observed in the aquatic en-
vironment near pulp mill effluent outfall. The link
between chlorate discharge from pulp mills and
damage to wrack (Fucus veiculosus), a kind of
seaweed that is the most important plant in the Bal-
tic Sea, has been verified (Sodergren, 1991). Large-
scale and persistent organochlorine contamination
of Baltic Sea sediments has been established and
linked to chlorine bleaching. It was found that a
major part of the extractable organochlorine (EOCl)
discharged in the Baltic since World War II still
remains in the sea's sediments (Sodergren, 1991).
The toxicity of bleached pulp mill effluent is
made up only in part by the chlorinated fraction.
Some of the negative effects described earlier can
be caused or amplified by naturally occurring toxic
substances in the wood, which the mills discharge
into the aquatic environment in unnatural con-
centrations. Heavy metals and fatty and resin acids
are examples of such compounds. Chlorine-free
bleaching not only greatly reduces the toxicity of
pulp mill effluent, it also allows for recirculation of
the effluent, because corrosive by-products such as
chlorides are no longer present. Since other harm-
ful anthropogenic compounds may also form in
chlorine-free bleaching processes, recirculation, or
closing the loop, is a valuable way to prevent these
compounds from entering the aquatic environ-
ment.
After switching to chlorine-free bleaching, a
sodium-based sulphite mill in Sweden, Domsjoe
(owned by MoDo), reduced its chemical oxygen
demand (COD) discharge by 75 percent through
recirculation. The application of recirculation to
chlorine-free (and low chlorine) kraft mills is being
studied intensively. Nevertheless, even if recircula-
tion of pulp mill effluent from mills using chlorine
dioxide should succeed, Greenpeace will still op-
pose the use of this bleaching chemical. Chlorine
dioxide is a chlorine chemical and all such sub-
stances must be seen in a wider perspective, from
their manufacture and transportation to use, con-
version, and discharge. A large part of the
chlorinated compounds end up in products and be-
come environmental hazards when they are
landfilled or incinerated. At every step,
anthropogenic chlorinated compounds enter the
environment.
Per-Olov Lindblad of the Swedish Pulp and
Paper Research Institute widens the concept of
closed-loop pulp production and recommends
taking into consideration everything from "natural
and human demands on forests to the final
consumer's needs" (Lindblad, 1992). The only
thing that would go in and out of Lindblad's closed
system is solar energy and energy for warming
houses and for use in other industries. All other
flows would remain in the closed cycle: recycled
fibers for use in new paper, energy from decom-
posed recycled fibers, ash containing minerals, and
nutrients would be returned to the forest as alkali
and useful trace elements; and the release of car-
bon dioxide and activated nitrogen would be in
balance with the forest's ability to absorb it. Conse-
quently, Lindblad writes:
At any given mill, the process could only
become reasonably closed outside the
mill's gates and perhaps it would be better
to call it "an ecologically balanced
process," where in each case the condi-
tions are that outflow is only allowed if it
can enter into a natural waste cycle in a
way that is balanced and sustainable.
This vision could be realized in part by install-
ing a system of "kidneys" within the mill for internal
purification of the waste streams. Some of the "kid-
neys" needed for inorganic substances, according
to Lindblad, are an optimized bark boiler, a re-
covery boiler, and electric filtration. For organic
substances, debarking and chipping optimization,
straining, and delignification are examples of
necessary "kidneys" (Lindblad, 1992).
Chlorine-free Bleaching's
Economic Advantages
Axel Spring Verlag, a leading German publisher,
conducted a survey in 1991 that showed that 46
percent of the German consumers who responded
to the survey do not buy products from firms that
have acquired a bad name with regard to environ-
mental protection; 42 percent prefer to buy
products from companies known for their commit-
ment to the environment, and 89 percent were will-
ing to accept lower quality, more environmentally
friendly, paper in products such as newspapers and
magazines. Respondents showed a strong willing-
ness to pay more for magazines printed on environ-
mentally friendly paper: 70 percent said they
162
-------
M. RAINEY
definitely would do so, and 14 percent said
probably (Strecker and Ernst, 1991).
European magazines are taking advantage of
the growing environmental awareness. The four-
color French magazine, Maison & Jardin (House
and Garden), added a label to the cover of a recent
issue that said, in large letters, "Papier 100%
Recycled" Large paper buyers who have decided to
switch to chlorine-free papers are forced to turn to
European suppliers, as these products are not yet
available in quantity in Canada or the United
States.
Undetermined costs related to chlorine bleach-
ing other than loss of business include lawsuits and
possible liability for large-scale cleanup. Georgia-
Pacific has lost two major liability suits for dioxin
contamination downstream from their Leaf River
plant in Mississippi. The compa / faces payments
of millions of dollars and its insurer refuses to cover
the claims. Still pending are an additional 159 law-
suits filed by plaintiffs who claim they have suffered
harm after eating fish contaminated by dioxins from
the plant. International Paper and Champion Inter-
national have faced similar suits.
Mill refitting for chlorine-free bleaching con-
sists of process changes related to both pulping and
bleaching. Modified cooking, improved debarking,
and improved washing are examples of changes
that facilitate the switch to chlorine-free bleaching.
In general the bleaching or delignification proces-
ses that are substituted for chlorine-based ones are
oxygen- and peroxide-based. Ozone bleaching
technology is being used to bleach kraft pulp to
whitenesses that exceed 80 ISO brightness.
Refitting costs vary greatly from mill to mill.
The following list shows the estimated costs of
some process changes for a mill producing 500
metric tons per day:
• Modified cooking — $58 million to $67
million.
• Oxygen bleaching — $24 million to $33
million.
• Peroxide bleaching stages — $1 million to
$4 million.
• Ozone (80 to 90 ISO) — $17 million.
The production costs of chlorine-free pulps are,
however, higher than those of chlorine-bleached
pulps, mainly because peroxide and oxygen are
significantly more expensive per metric ton than
chlorine chemicals. It should also be noted that at
present most chlorine-free pulps are produced in
batches that demand a certain recalibration of mills
where chlorine bleaching is still being carried out.
If a mill switches entirely to chlorine-free bleach-
ing, lost production time and personnel costs will
be avoided. At present chlorine-free kraft pulp costs
about 15 percent more than the chlorine-bleached
equivalent.
If customer demands for unnecessarily high
paper whiteness were reduced, the amount of
bleaching chemicals needed would be reduced ac-
cordingly. This reduction would save chemicals
and energy and help close the price gap between
the two kinds of pulp. Mills would save on bleach-
ing chemicals, and they would not have to invest in
expensive technology, like ozone bleaching, to
bleach pulp to high whiteness levels. Many paper
producers agree that 85 ISO pulp is sufficient for
nearly all paper grades. Chlorine-free pulp at sig-
nificantly lower whitenesses (70 ISO) has been
used with success in light-weight coated papers.
British Columbia, Canada, became the first
government entity in the world to set a date for a
total ban on chlorine bleaching: 2002. Ontario is
considering following suit. A May 1990 draft
recommendation from the German government
stated that all use of chlorine-bleached fibers
should be avoided. In June 1991, the Norwegian
minister of the environment called on the other
Nordic country environmental ministers to join him
in a ban of all chlorine-bleaching agents by 1999.
The Swedish government has stated that the dis-
charge of all substances from the pulp and paper in-
dustry that are toxic to the environment should end
by 2000.
Chlorine-free Mills and
Their Customers
The amount of chlorine-free pulp on the market has
increased dramatically during the last year. Of
Sweden's bleached chemical pulp capacity —
about 5 million metric tons — 70 percent could be
produced chlorine-free if the market demanded
such quantities. During 1992, about 10 percent of
the Swedish bleached kraft-pulp production will be
chlorine-free. In Finland, about one-third (or 1.4
million metric tons) of the chemical pulp capacity
can now be produced chlorine-free. The entire
German production of sulfite chemical pulp is al-
ready chlorine-free. A new chlorine- and sulfur-free
mill, using the Organocell® technology, will be
completed in Germany within the year. It will have
a capacity of 150,000 metric tons.
Low chlorine and chlorine-free pulp produc-
tion has led to a dramatic decrease in the use of
chlorine gas in Sweden. In 1970, 230,000 tons of
chlorine gas were used for pulp bleaching; in 1991,
33,000 tons were used; and during 1992, 5,000 to
10,000 tons will be used. During 1993, the use of
163
-------
Technical Perspectives — Performance and Cost
chlorine gas by Swedish pulp mills will cease en-
tirely.
Sodra Cell, the largest market pulp producer in
Europe, announced recently its intention of making
its entire capacity, about 1 million metric tons of
bleached kraft pulp, available chlorine-free. The
company has installed ozone bleaching at its
Monsteras mill (capacity 335,000 metric tons), with
production slated to begin in September 1992. By
the end of the year, the Monsteras mill should be to-
tally chlorine-free. Sodra is producing chlorine-free
softwood kraft now at 80-plus ISO. Several other
mills in Sweden and Norway have plans for install-
ing ozone bleaching technology.
Consumer demand for chlorine-free products
has been mostly felt in Europe, where the four
major pulp and paper buying countries together
import more than 8 million metric tons of pulp, or
10 percent of the world's annual production.
Bleached chemical pulp imports in 1991 to some
European countries were reported as follows:
• Germany — 3,075 million metric tons;
• France — 2,091 million metric tons;
• UK—1,401 million metric tons; and
• Italy—1,785 million metric tons.
The printing and writing sector uses 40 percent
of the global production of pulp and paper and 80
percent of the chlorine-bleached pulp. In this sec-
tor, especially in magazine papers, the demand for
chlorine-free paper is very strong.
Each year Germany uses 2 million metric tons
of light-weight coated magazine paper. Green-
peace chose to work with this market in particular.
In March 1991, we released Das Plagiat ('The
Plagiarism"), a spoof on one of Germany's largest
weekly newsmagazines, Der Spiegel. The most im-
portant difference between Das Plagiat and Der
Spiegel was that the Greenpeace magazine was
printed on the world's first chlorine-free light-
weight coated magazine paper. The Plagiat paper
was about 2 percent less white than the Spiegel
chlorine-bleached paper. We wanted to demon-
strate high quality, four-color printing on a paper
that was a little less white. The German paper in-
dustries and magazine publishers' branch organiza-
tions reacted immediately. In a joint press release,
they announced that they would use chlorine-free
papers as soon as they were made commercially
available.
Shortly afterward Der Spiegel, with a circula-
tion of about 1.2 million, stated its intention to
switch to chlorine-free paper as soon as it was
made available. Now, one year later, Der Spiegel
manages to print an average of 30 percent of each
magazine on chlorine-free paper. Der Spiegel finds
the two papers so equivalent that they do not
hesitate to use both in the same issue. Other
magazines, such as CEO, SPORTS, and ART,
produced by Gruner & Jahr, Der Spiegel's publish-
er, are now chlorine-free.
Stern, another of Germany's largest weekly
newsmagazines with a circulation of about 1.3 mil-
lion, has changed much of its super calendar (SC)
magazine paper to chlorine-free. Austria's major
news weekly, Profit, changed its SC paper to
chlorine-free in May and stated in an editorial,
"This (paper) is at present somewhat more expen-
sive, but the company deemed this contribution to
environmental protection worth the sacrifice."
In January 1992, after receiving 22,000 post
cards from Greenpeace supporters demanding
chlorine-free paper, TIME magazine announced in
an editorial that "Most of our paper suppliers are far
along with their plans to eliminate chlorine-
bleached pulp. We will use this alternative paper as
soon as it is practical to do so."
McLean-Hunter, Canada's largest magazine
publisher, announced in July 1991 that it would
switch to chlorine-free paper in its more than 200
magazines as soon as the paper was made avail-
able. The largest magazine publisher in Quebec,
Publicor, has also announced that it will switch to
chlorine-free paper. The largest chain of copying
centers in the United States, Kinko's, has also stated
its intention of switching to chlorine-free and
recycled papers.
The annual catalog published by the furniture
retailer IKEA is one of the largest color printing jobs
in the world, demanding 40,000 metric tons of
paper and read by millions of people each year in
25 countries. The recently distributed 1993 IKEA
catalog is printed on chlorine-free 51-gram light-
weight coated magazine paper, which is also
guaranteed not to contain pulp from old-growth
forests. In addition, IKEA reviewed all glues, lac-
quers, and printing inks used in the catalog that
could disturb recycling.
The changes in IKEA's catalog paper were
worked out in cooperation with Greenpeace. By
systematically examining the environmental
aspects of its paper, IKEA managed to avoid con-
tributing to some of the most serious environmental
problems caused by the pulp and paper industry.
Because of reduced paper prices, the 1993 catalog
did not cost more than in previous years, even
though the new paper actually represented an extra
expense. IKEA was, however, willing to pay more
for a more environmentally sound catalog. The
paper suppliers of the IKEA catalog were all
European corporations.
164
-------
M. RAINEY
The chlorine-free light-weight coated paper
meant a marginal reduction of whiteness, but no
adjustments were necessary in the printing. The
bulk and printability were equivalent to those of
chlorine-bleached paper and the opacity was
somewhat improved. The catalogue was printed
simultaneously by most of the major printers in
Europe. One of the largest, Germany's Cruner
Druck, found that the chlorine-free paper supplied
by IKEA "posed no unusual problems in terms of
printability, web breaks, or quality which origi-
nated and/or could be traced back to the use of
chlorine-free pulp in the paper (K. Veit letter to
Greenpeace, August 14,1992).
The next logical step is for magazine and other
paper products to contain a high recycled fiber
content. There are super calendar papers currently
available that consist of 40 percent postconsumer
recycled fiber. Several pulp and paper industries in-
tend to build super calendar paper machines in the
near future that can accept a high percentage of
recycled fibers. Japanese manufacturers have come
far with postconsumer recycled-fiber content in
lightweight coated papers reaching 80 percent.
Chlorine-free light-weight coated papers contain-
ing as much as 50 percent recycled fibers are being
developed in Europe and should be on the market
in the near future.
Conclusion
Greenpeace estimates that in the near future it will
be difficult to sell pulp bleached with chlorine
chemicals, or paper containing such pulp, in such
European markets as Germany and the United
Kingdom. Two of the remaining obstacles to a total-
ly chlorine-free paper economy in Europe are
• the unethical selling of low-chlorine
bleached pulps as "chlorine-free," thereby
undercutting the higher price of truly
chlorine-free pulps; and
• the lingering unwillingness of large pulp
buyers to pay more while simultaneously
accepting lower whiteness levels.
Consumer awareness will put a stop to false
marketing strategies. Products like the IKEA catalog
show that it is possible to use pulps at lower white-
ness levels and achieve good results. The higher
price of chlorine-free pulps must be viewed in
relationship to the inestimable environmental costs
of chlorine bleaching and open-loop pulp produc-
tion.
The goals for environmentally sustainable
paper production are to
• maintain forest biodiversity, for example, by
stopping the use of old-growth forests;
• achieve a totally chlorine-free pulp and
paper industry;
• remove all remaining toxics from the
effluent; and
• increase recycled fiber use.
References
Lindblad, P.O. 1992. The completely closed-loop pulp mill —
Utopian or realistic? Svensk Papperstidning 95(9):25-30.
Sodergren, A. 1991. Environmental fate and effects of bleached
pulp mill effluents. In Proc. Swed. Environ. Prot. Agency
Conf., November 19-21, 1992. Dep. Ecol., Lund Univ.
Stockholm, Sweden.
Strecker, M. and O. Ernst. 1991. Qualities of paper — qualities
of the environment: the consumer's view. Pres. Pulp and
the Environment, Fincell Environ. Seminar 3, September 9,
1991. Finncell. Jyvaskyla, Finland.
Veit, K. 1992. Persona! letter to M. Rainey, Greenpeace. August
14,1992. Goteborg, Sweden.
165
-------
Performance and Cost
in Pollution Prevention Practices
Richard N. Congreve
Group Vice President
Potlatch Corporation
San Francisco, California
Recycling and pollution prevention are not
new or novel ideas in our industry. They
have been batted around, to one degree or
another, since its beginning more than 300 years
ago, driven by changing economics, technology,
and recently, societal values. To illustrate my point
— I started my career in 1947 in a recycling paper-
board mill that was then 50 years old. This sup-
posed "temporary" mill job, which paid me $1.13
an hour when I started, lasted 15 years and paid for
my schooling in chemical engineering. I mention
this background to establish my qualifications for
the observations that follow.
The industry recognized the need to better un-
derstand water pollution in 1943, when it estab-
lished the National Council for Air and Stream
Improvement (NCASI) — a full 27 years before the
creation of the U.S. Environmental Protection
Agency. The organization added oversight of air
improvement in 1956 and solid waste in 1968.
NCASI is still the industry's primary research arm in
these areas.
Forty-five years ago, pollution prevention was
limited by the industry's technical inability to iden-
tify, control, or prevent the many undesirable emis-
sions, discharges, and solid wastes that we have
since defined. At that time, recycling was driven by
economics, which made waste paper — in a
variety of grades similar to that which is recycled
today — more economical to use because it was
readily available in urban areas. Virgin pulp was
more costly to use because it was produced in rural
areas and included freight costs.
My experience has made me keenly aware of
the limitations of recycled products in terms of
product quality, economics, and pollution control.
In earlier days, we used 450 tons per day of waste
paper to gain 300 tons of pulp. The remaining 150
tons went to the sewer or the city dump. Though
we have progressed technologically, similar ratios
apply today to recycling.
The postwar period brought population
growth, economic growth, and expanding technol-
ogy to many industries, ours included. A higher
living standard followed, precipitating many changes
in attitudes and values. Those of us who were
children of the Depression began to shed the
economic insecurities gained during those years of
deprivation. We began to appreciate and demand a
better environment.
One incident from 1952 illustrates this change
in values. I was plant engineer at the Chicago recy-
cling mill at the time, and I received a phone call
from Mr. McCormick, owner of the Chicago
Tribune, complaining about the dark smoke from
our coal-fired boiler stack. Twenty years before, at
the height of the Depression, smoke from a factory
stack in Chicago was a welcome sign of work and a
paycheck.
The paper and pulp industry was in the
forefront in responding to changing values — we
promoted recycling, pollution prevention, and
technological change in an aggressive and con-
structive way. When I joined my current employer,
Potlatch Corporation, in 1962, it was a company
engaged in growing trees to produce lumber and
plywood and using residual wood waste to
manufacture bleached kraft pulp. Our company
initiated the process of using scrap wood for
bleached kraft in Lewiston, Idaho, in 1950. It was a
much better alternative to burning wood waste,
which was the common practice, and landfilling
was not a practical solution even then in Idaho.
Potlatch's pioneering efforts in the use of wood
waste were accompanied by evident opportunities
for reducing odor and particulate and other dis-
charges, white simultaneously improving product
quality and lowering costs. In 1960, market
166
-------
R.N. CONGREVE
demand for improved product quality had led to a
change in the bleaching process from CEHEH
(chorination-caustic extraction-hypochlorite reac-
tion-caustic reaction-hypochlorite) to CEHED (first
four stages, then chlorination with chlorine
dioxide). The change also resulted in reduced
chemical costs and lower biological oxygen
demand (BOD) loadings.
Incidentally, Potlatch is a relatively small com-
pany — 18th in size in the U.S. paper industry — in
a highly capital- and labor-intensive business. For
that reason, we have always considered it in the
best interest of our employees and investors to stay
modern and cost-competitive, but we have been
unwilling to "bet the company" on unproven
processes or untested markets. We have followed
emerging technologies, employed both mill techni-
cal resources and our own research and develop-
ment activities, and used the increased knowledge
to guide capital improvements and address market
concerns. We've followed the totally chlorine-free
bleaching processes and believe we can learn
much from them. But we also find no evidence that
they are more environmentally friendly than the
process they would replace. They may, in fact, be
less environmentally friendly because they
generate aldehydes and ketones.
Since the early 1960s, the company's Idaho
operations have been modernized and have grown
threefold in response to the availability of, and
need to use, waste wood from the region's forest
products producers. We now operate a state-of-the-
art bleached kraft mill with 100 percent forest and
sawmill waste wood. We have just completed a 10-
year, multiphased modernization that culminated
this summer in the installation of a new bleaching
operation featuring modern pressure washers, high-
consistency oxygen delignification, 70 percent sub-
stitution of chlorine dioxide in the chlorination
stage, followed by an oxygen-enhanced extraction
stage, and a final dioxide stage.
These changes, too, were motivated by the
need for improved product quality and competitive
cost structures. But they have also resulted in less
dioxin in our product and effluent. Our effluent ad-
sorbable organic halogens (AOX) are well below
1.5 kg per ton and our secondary pond BOD load-
ings have dropped by 60 percent. Chloroform
generation has dropped by 70 percent. None of
these were major environmental issues when the
technology was chosen for facility modernization
in 1981.
Potlatch's second bleached kraft mill, built in
Arkansas in the late 1970s, has made similar changes.
With increased washing efficiencies, the elimina-
tion of petroleum-based precursors, added oxygen
enhancement in the extraction stages, and more
than 70 percent substitution of dioxide in the
chlorine stage, we have today effluent and products
with nondetectible dioxin and adsorbable organic
halogens of less than 1.5 kg per ton.
We have a third bleached kraft mill in Cloquet,
Minnesota, and we have recently received a permit
to modernize and expand it over the next five
years. When the modernization is complete, the
technology installed there will produce pulp for
high-quality printing papers that will be free of
elemental chlorine.
These changes of process and equipment
epitomize the essence of pollution prevention
rather than "end of pipe" treatment, and are typical
of the approach Potlatch is taking on several fronts.
We have made significant strides, for example, in
energy efficiency by installing huge multifueled
boilers at our Idaho and Minnesota pulp mills and
smaller units at our wood products operations in
Arkansas and Minnesota. These boilers allow us to
use regionally generated wood wastes as a fossil
fuel substitute and, in combination with cogen-
erated electricity; have increased our energy self-
sufficiency more than 75 percent. This substitution
not only reduces undesirable emissions; it also con-
serves nonrenewable resources.
Pollution prevention can also be achieved
through smaller, less obvious operational changes
that contribute to both environmental and eco-
nomic efficiency. To that end, we have attempted to
build the concept of pollution prevention into our
corporate culture by encouraging employee in-
volvement at all levels. In Idaho, for example, our
hourly and salaried employees have established a
Waste Reduction and Pollution Prevention commit-
tee, the WRAPP team. Its goal is to expand the pol-
lution prevention ethic throughout the operation.
Something as simple as conserving water
wherever possible can add up to significant savings
and, at the same time, cut emissions. The WRAPP
team has suggested ways to reduce water use by
thousands of gallons a day in Idaho. What we don't
use we don't have to treat.
Pollution prevention makes economic and en-
vironmental sense, and we're proud that our
processes and products are environmentally safe
and friendly. But there are many trade-offs. Potlatch
plans to continue its commitment to improved pol-
lution prevention in cooperation with the
regulatory agencies, while playing a constructive
role in maintaining the clearly superior environ-
mental record and competitiveness of the paper in-
dustry in this country.
167
-------
Panel 3:
Technical Perspectives
Performance and Cost
Question and Answer Session
• John Festa, American Paper Institute: Margaret,
in your handout you say that recent studies in
Sweden have linked pulp mill effluents containing
absorbable organic halogens to serious environ-
mental damage. And you mentioned a conference
in Sweden last November that I also attended.
Now, if I'm not mistaken most pulp mills in Sweden
discharge into the Baltic Sea or into rivers or
tributaries that flow into the Baltic. At the con-
ference, the one you mentioned, a Swedish EPA
publication was circulated that indicates that the
Baltic Sea is pretty unique from an environmental
standpoint.
Let me read from the Swedish pulp publication,
if you'll bear with me.
The Baltic Sea is particularly vulnerable to the
toxic organic pollutants released by industrial
society. There are several reasons why this is the
case. The Baltic is the final destination for dischar-
ges and land runoff from a cluster of highly in-
dustrialized countries, yet it is little more than an
inlet, a virtually enclosed sea. Ifs sole link with the
world ocean consists of three straits at its south-
western end which permit only limited water ex-
change. ... It is also a cold sea with a short
reproductive season. The Gulf Botany, the Baltic's
northern flank is frozen over from December to
May. Only a few different species thrive in these
chilly brackish waters, making food chains extra
sensitive to disturbance.
I think one needs to be very careful in ex-
trapolating data from the Baltic Sea to other water
bodies that are not comparable. In this country, the
Paper Industry's National Council for Air and
Stream Improvement, has conducted experimental
stream studies for over 15 years and in these studies
fish have been exposed to bleached kraft mill ef-
fluent at different concentration levels. Yet, to date,
the studies show normal growth, survival, and
reproduction in fish exposed to well-treated mill ef-
fluent. In addition, histopathology has not shown
any lesions in the fish.
• John McGlennon, Moderator: Are you leading
up to a question, or are you about to complete your
comment?
• John Festa: It's a comment, but I think it's well
worth making. The National Council has published
the results of its studies recently, and if you're inter-
ested I have copies of those papers. In Sweden, if
I'm not mistaken, less than 50 percent of the pulp
mills have secondary treatment. In this country, vir-
tually all pulp mills have secondary treatment. That
makes a big difference. Thank you.
• Margaret Ralney, Greenpeace: For your infor-
mation, 30 percent of the kraft mills have secon-
dary treatment. But anyway, what they have
emphasized are internal process changes, not ex-
ternal treatment. As far as not extrapolating results
from the Baltic to use on other pulp mills, some of
the studies presented here are lab studies. And labs
are the same everywhere, I hope. I'd just like to say
that I think this is a very important discussion and I
hope that we can have it sometime. I feel that
people aren't very happy about discussing it right
now. Yes, next year, same time, same place, let's
talk about it. I'll give a presentation.
168
-------
QUESTION & ANSWER SESSION
• John Festa: You're right that this isn't the time or
the place and the forum hasn't really been set up for
the discussion. But it's clear to me that everybody's
dying to talk about it.
• Mark Floegel, Greenpeace: Briefly, as an aside
to John. If we're talking about studies, there is one
that was not funded by the pulp and paper industry.
In fact, it came from the International Joint Com-
mission, an independent body, whose members are
appointed by the United States and Canada. Their
biannual report, issued just a few months ago,
recommends that all industrial chlorine discharges
to the Great Lakes be discontinued. You may want
to take a look at that.
Out of deference to Mary Ellen Weber and
some discussions that we've had about how many
angels can sit on a pin, I'm not going to address any
of what I consider to be the egregious misrepresen-
tations by Kip Hewlett in his presentation. How-
ever, let me ask him about money, which I think we
are allowed to talk about. In your presentation, Kip,
you talked about the jobs that you feel have been
lost because the industry has had to invest in en-
vironmental technology. Now, of course, my ex-
perience with corporations is that this money
probably wouldn't have gone to jobs but to execu-
tive bonuses. But you're theorizing that jobs could
have been created.
I want to get your feedback on some of the real
numbers that Margaret referred to. The fact the
Georgia-Pacific has now lost two lawsuits in the
state of Mississippi with total damages of, I believe,
$3.25 million, because of discharging chlorine-
based chemicals in the Leaf River Mississippi pulp
mill. In addition to the two suits that have been lost
already, 8,000 others pieces of litigation have been
filed. Your insurance carrier, Aetna, has declined to
pay for these damages and your own shareholders
are suing Georgia-Pacific because you failed, al-
legedly, to file this litigation in your SEC filings.
These are real dollars and this does not even begin
to count whafs going on in the fishing industry in
coastal America as a result of toxic pollution from a
variety of industries. But, at least in terms of these
lawsuits, the courts have directly tied your use of
chlorine to property damage, trespass, and
nuisance to property owners downstream. So we're
talking about real dollars. That money represents
income that has been lost, jobs that have been lost,
hardships that have been endured in a monetary
sense. We're not talking about the environment or
health, we're just talking about the economy. Could
you comment on that?
• John McGlennon: I would like to remind the
speakers that we are still talking about pollution
prevention technology and alternatives to achieve
pollution prevention from a technical point of view,
but if Kip wants to comment on this, he's welcome
to do so.
• Clifford T. "Kip" Hewlett, Georgia-Pacific Cor-
poration: Well, I want to correct some misstate-
ments and mischaracterizations. First, with regard
to the shareholders, that suit was filed by the same
plaintiff lawyer in Mississippi who filed all these
other lawsuits.
• Mark Floegel: I believe that's incorrect. It was an
Atlanta law firm that brought the shareholder's suit.
• Clifford Hewlett: Well, if you look at all co-
counsel, you'll discover that there's a synergy there.
Second, I think that if we want to have a discussion
about the current litigious nature of society in the
United States, that is also best left for another sym-
posium. I would simply point out (1) that both cases
are on appeal and (2) that the mill, from the date
that dioxin was discovered until now has gone to
100 percent CIO2 substitution. Over the last few
years, there has been both no measurable dioxin
and, according to the latest data, no measurable
chlorinated phenolics in that mill effluent.
I don't want to try these cases here, but so the
audience will understand, the first case was
trespass. It dealt with the allegation that dioxin had
found its way onto the property of riparian land-
owners. The judge in that case did not allow the in-
troduction of any data to show that actual dioxin
levels were not present in the properties involved.
The second case was a fear case, and that case,
frankly, got way out of control. It may be some time
before we figure it out — in part because of wit-
nesses, in part because of problems with rules of
evidence. Both cases are on appeal. The bottom
line is that this mill, in fact, has no dioxin or
chlorinated phenolics. We've made the changes,
and we were one of the first mills in the country to
do so.
• Mark Floegel: I, too, would have liked to stay on
technical things, but it was Mr. Hewlett who took
us off into jobs. From a legal point of view, please,
just one last point.
• John McGlennon: This discussion could go on
and on. You can still have it, but I'm not sure it's
constructive to take up the time of 300 people to
listen to it.
• David Bailey, Environmental Defense Fund:
Maybe I can keep us on track in terms of pollution
prevention. I accept the fact, as I'm sure most of the
paper industry does, that both sides are going to
169
-------
Technical Perspectives — Performance and Cost
make claims and statements that they believe to be
correct and true, which are, in fact, debatable. But I
would like to focus on one point and ask whether it
will be in the speakers' papers or in the proceedings
when they're finally published. Or, perhaps, Mr.
Congreve or Mr. Hewlett would like to comment at
this time. I hear repeatedly and have heard for the
last several days that there are no detectable levels
of dioxin in "x" company's effluent or process. I'd
like to know if there's any commonality about what
level of detection we're talking about here. Are you
familiar with the level of detection that these state-
ments refer to? Because I think that does relate to
whether we are having pollution prevention.
• Clifford Hewlett: Only one or two commercial
labs in the country are really in a position to do this
kind of testing. I believe the detection limit in water
effluent is down to about 10 parts per quadrillion.
• David Bailey: Just as a suggestion then, or a brief
comment. It really doesn't help the argument, I
don't think, to say that you're below 10 parts per
quadrillion because that number still doesn't
answer the question of where you are in relation to
where you need to be. It doesn't say where you are
vis a vis a standard. So, I would be a little cautious
about those claims. If anyone has done better than
that on an experimental basis, or whatever, and can
compare their effluents to lower levels of detection,
that might have more relationship to the standards
that are flying around right now. It might be helpful
to everyone.
• Gayle Coyer, National Wildlife Federation: I'd
like to ask for a few points of clarification and one
of them refers to the exact same question that was
commented on by the previous speaker: the levels
of detection issue. Mr. Hewlett's talking about a
detection level of 10 parts per quadrillion. Mr. Con-
greve, can you give us this same information? What
is your level of detection?
• Richard Congreve: Ours is less than 2 parts per
quadrillion.
• Gayle Coyer: Less than 2 parts per quadrillion.
Since it is obvious that the level of detection is a
moving level right now, I would like to request that
all speakers from now on define what level of
detection he or she uses. I think this clarity would
help our discussion a lot. The second thing, and
again, I'm not going to debate the toxicity informa-
tion here. But I would like to know from Mr.
Howlett if he would give us the citation for the ex-
pert panel of international scientists who conclude
that there's no difference in toxicity. I think it's a
very important reference.
• Clifford Howlett: Yes, it's published.
• Gayle Coyer My third point has to do with your
charts. I am trying to understand your graph about
the jobs that will be lost to the different levels of
AOX reduction. Your statement was that the
amount of money used for AOX reduction stands
for jobs that won't be created. Is that what you were
signifying?
• Clifford Howlett: They're not available. The in-
vestments that have been made over the last 5 or 10
years are an example of what is recoverable. You
may make the investment and deliberately oversize
with the anticipation that down the road you'll add
another machine and use the additional capacity.
That possibility factors into the decision that you
make in asking your board of directors to approve
the capital expenditure. But to retrieve solvents for
achieving the kind of AOX and dioxin reduction
levels that the industry has experienced requires
that you absorb some of that planned capacity ad-
dition. That capacity addition is real; those are real
dollars invested and real capacity that's lost. In ad-
dition, there are secondary employment impacts
from the foregone production that I discussed in
those four slides, the three maps and one chart.
• Gayle Coyer: So you actually looked at what the
planned capacity addition was in different mills in
the United States and worked from a planned
capacity addition statistic?
• Clifford Howlett: With what was in the mills.
This data is real world data.
• Gayle Coyer: This planned capacity is currently
not being used and you're saying that the reason it's
not being used is because the additional capacity
may be required to go into further AOX reductions?
• Clifford Howlett: It could be, or it could be used
as part of the process control to reduce the level.
• Gayle Coyer: The relationship may not be quite
that simple. A number of other factors may in-
fluence what those alternative investments might
be. I would also like to submit that, at least to some
extent, tougher and stronger environmental control
regulations have kept the industry at a globally
competitive rate with modernizations on line.
• Clifford Howlett: I don't disagree with that
analysis. The key here is that the economic viability
of the industry enables you to make those kinds of
170
-------
QUESTION & ANSWER SESSION
environmental investments. They go hand in hand,
and they are not in conflict with each other. In fact,
I think they mutually support each other.
• Richard Congreve: I disagree with Kip a little. I
don't agree that we've been forced into these so-
called major changes because of the regulations.
What we did in our mill in Lewiston, Idaho, was a
process totally conceived in 1981 but it meets
every regulation that has been implemented since
that particular time. So I do believe there are a
number of mills in our industry that have aggres-
sively improved their prevention pollution efforts,
and not because of regulations, as inferred.
• Steve Levitas, Environmental Defense Fund: If I
could ask a follow up question to Mr. Hewlett. Did
you do that economic analysis yourself on the cost
of AOX reductions and if so, can we get a copy of
the background research that produced those
slide?.
• Clifford Hewlett: Yes, we'll include that in the
report.
• Steve Levitas: If I could make a brief comment. I
think everybody recognizes that there are profound
differences of opinion on how pollution affects
health, on the performance of alternative technol-
ogy, and on economics. The question for all of us is
how we're going to make constructive progress.
One way would be to debate these issues in-
definitely. I would suggest, however, that debate
has not been a productive way to deal with en-
vironmental conflict in the past, and it's not going
to be productive now. Indeed, I think the orienta-
tion of this conference reflects the hope that there's
a different way to proceed. Why don't we sit down
and figure out ways to address the performance and
economic issues in a way that will meet the
industry's and society's needs. Mr. Hewlett, I
thought you did an excellent job of charting out ex-
actly the wrong directions for making progress, and
I think we ought to try to get on track.
• Jessica Landman, Natural Resources Defense
Council: My question is also for Mr. Howlett. You
stressed in your presentation the importance of
providing exactly the product your customer wants
and not having the product quality, its type, or per-
formance dictated by the government. That is, you
want to satisfy the market that you believe exists. In
light of that I wanted to ask you to tell us, if you
would, what was behind the memorandum that
Georgia-Pacific sent to its customers, informing
them that chlorine-free products are inferior and
you will not be making them available to your cus-
tomers even if they have an interest in buying
them? This memo was subsequently reprinted in a
trade journal.
• Clifford Howlett: The letter that we sent to our
customers was based on using a high chlorine
dioxide substitution process that achieves non-
measurable levels of dioxin in the effluent, recog-
nizing that this result is nonmeasurable given the
current ability of commercial labs to measure
dioxin. First, we are not committed to the abandon-
ment of the chlorine dioxide investment that we
have made. Second, if we are going to look at total-
ly chlorine-free technologies, it is our under-
standing that they have not yet been commercially
approved, and we are not in a position to offer
pulps made from those processes to our customers
at this time. That was just the point of the letter.
171
-------
Costs and Benefits of Various
Pollution Prevention Technologies
in the Kraft Pulp Industry
Neil McCubbin
N. McCubbin Consultants Inc.
Foster, Quebec, Canada
I J raft pulp is manufactured in the United
y\ States from nearly all commercially avail-
I \able wood species. About 55 million tons
per year are manufactured, 30 million of which are
bleached and used mostly for printing and office
papers and tissue products. Some kraft pulp is ex-
ported, and significant quantities are imported,
mostly from Canada and South America. Pulps
manufactured by sulfite, mechanical, and deinking
processes are being used to a modest but increasing
extent to replace bleached kraft pulp in certain
markets.
The manufacture of bleached kraft pulp is a
major but not dominant source of water pollution
in the pulp and paper industry. With respect to pol-
lution prevention measures, bleached kraft mills in
the United States range from the best in the world
to about average, compared with the other pulp
producing countries. The characteristics of mill ef-
fluent discharged in this country are probably
somewhat better than average, since 97 percent of
our bleached kraft mills have secondary effluent
treatment. In other pulp producing countries, from
50 to 100 percent of mills have secondary treat-
ment.
This paper discusses only the manufacture .of
paper grade bleached kraft pulp, for market or for
on-site use in an integrated paper mill. The Interna-
tional System of units (SI, Systeme International) is
used throughout, unless otherwise noted.
Environmentalists have focused their attention
on the kraft pulp bleaching processes because so
many of the most widely known, persistent pol-
lutants discharged by the pulp and paper industry
originate in that part of pulp manufacture. But the
prebleaching pulping processes are also significant,
and many measures that reduce or prevent the for-
mation of pollutants in the bleach plant are imple-
mented upstream in the pulping operations.
An Example Mill
Mills in the United States vary from large, simple
modern mills with one single production line
manufacturing one single product to complex mul-
tiproduct, multiline mills. In the 90 existing U.S.
bleached kraft mills, pulp capacities vary from
about 300 tons per day to 3,000 tons per day.
References to capital costs in this paper are all
for retrofitting pollution prevention technologies to
a 1,000 air-dried ton per day, single line mill using
typical 1970s technology. This technology includes
wet debarking, traditional batch digester cooking, a
brown stock washing system operating with 20
kilograms per ton of salt cake loss, and a bleach
plant with 10 percent chlorine dioxide substitution.
The mill process in Figure 1 operates to this
description, except that an oxygen delignification
stage and a condensate stripper have been added.
Figure 1 also incorporates a continuous digester in-
stead of a batch system.
The effluent discharged to the biological treat-
ment system from such a mill would have a biologi-
cal oxygen demand (BOD) of 35 kilograms per ton
and 5.3 kilograms of adsorbable organic halogens
(AOX) per air-dried ton of pulp.
This base case mill has not implemented any of
the pollution prevention technologies discussed in
this paper, whereas most mills have implemented
some, and a few mills have all feasible pollution
prevention technologies in operation. The capital
costs, operating savings, and attainable reductions
172
-------
N. McCUBBIN
BLEACH PLANT
MULTIPLE EFFECT EVAPORATERS
LEGEND I
r """ PULP LINE
* BLACK LIQUOR
—BOTHER FLOWS
Figure 1.—Example of a kraft mill flowsheet with oxygen delignification.
in effluent discharges in typical U.S. mills will
generally be lower than the data presented here,
because of the prior implementation of pollution
prevention technology.
Current pulping and bleaching technologies
have been described by many authors, including
Kocurek (1986-89) and McCubbin et al. (1991).
Available Technologies
There are many technically proven ways of reduc-
ing or eliminating the formation of pollutants
during the manufacture of bleached kraft pulps.
Much attention has been focused on the technol-
ogy and design of new mills. One can expect, how-
ever, that only a few new bleached kraft mills will
be built in the United States during the next
decade. The key environmental, technical, and
financial challenge is to define and retrofit the most
appropriate environmental protection technology
in the 90 existing bleached kraft mills.
The interrelationships among available pollu-
tion prevention technologies are complex, and the
optimum selection for each mill depends on the
site, the product specifications, and most of all, on
the type, obsolescence (or otherwise), and general
condition of existing systems. Unless otherwise
noted, the technologies discussed herein have been
proven in mill service for at least a year, and are
available from several established, competitive
vendors of pulp processing equipment and systems.
Dry Debarking
Logs must be converted to chips to feed kraft
digesters. Prior to this, the outer bark and dirt con-
tamination must be removed. The process for carry-
ing out this operation is termed debarking and may
be a wet or a dry process. The wet process causes
resin acids and other, mostly nonpersistent, toxic
and highly colored substances to leach out of the
bark and be discharged with the effluent.
Dry debarking is more desirable environmen-
tally than wet debarking and has been almost
universally adopted in new mills and modern-
ization projects for wood preparation systems built
since the mid-1970s. The industry is moving steadi-
ly toward dry debarking, since the proportion of
wood now purchased in the form of (dry debarked)
chips from sawmills is increasing.
The cost of a new dry wood preparation system
is very similar to an older design wet system. Con-
version of a wet system to dry operation for the ex-
ample mill would cost between $10 million and
$20 million, while the annual operating costs
would probably be little changed.
Referring to Figure 1, the debarking drum
would be replaced by either a dry drum or a multi-
173
-------
Technical Perspectives — Performance and Cost
knife mechanical chipper, and the woodroom ef-
fluent flow would be eliminated. This change
would reduce the contribution to mill effluent by
the wood preparation department to nearly zero, a
reduction in the mill effluent flow by as many as 25
cubic meters per ton of pulp. The BOD of the un-
treated effluent would also decrease by several
kilograms per ton depending on initial conditions.
Since biological treatment systems are quite effec-
tive in treating such wastes, the improvement in
final effluent quality would be modest. Obviously,
dry debarking would be essential in a zero effluent
mill.
Extended Cooking
In conventional kraft cooking, the complete charge
of chemicals (sodium hydroxide and sodium sul-
fide) is added to chips simultaneously, leading to
high concentrations that gradually fall off as the
process proceeds. The wide range in chemical con-
centration leads to aggressive chemical action at
the beginning of a cook and very gentle pulping at
the end. In the 1970s, the Swedish Forest Products
Laboratory developed the concept of "modified"
cooking. (Hartler, 1978; Teder and Olm, 1980). The
approach was to level off the alkali concentration
throughout the cook so that the initial action would
be less aggressive, and to allow additional lignin to
be removed in the latter stages of the process.
This process has become more popularly
known as "extended cooking," and in the late
1980s, vendors of both batch and continuous
digester systems developed practical, commercial
kraft pulp cooking systems based on Hauler's
modified cooking concept. MacLeod (1992) and
Whitley et al. (1990) have presented recent updates
on extended cooking technology.
In the Modified Continuous Cooking (MCC®)
process, the cooking liquor (white liquor) is added
at several points, instead of only in the chip feed to
the digester as is indicated in the conventional con-
tinuous digester shown in Figure 1. In many current
continuous digesters, the pulp is washed with hot
black liquor in the lower "wash zone" of the
digester. Several mills have added white liquor to
this wash circuit, and installed heat exchangers to
raise the temperature to levels normal for cooking
pulp. This is known as the Extended MCC (EMCC®)
process, and is the variation of most interest for
retrofitting to existing operations.
Several mills using their own engineering
knowledge have modified their continuous
digesters to take advantage of Hauler's modified
cooking concepts. Kamyr, Inc., the only United
States supplier of continuous digesters, also under-
takes conversions routinely.
• Modified Batch Cooking. For batch digesters,
implementation of extended cooking technology
also involves maintaining liquor concentrations at
a more uniform level throughout the cooking cycle.
Patents were granted to Fagerlund, and the success
of the Modified Batch Cooking (MBC) process was
reported by several groups (Andrews, 1989).
The MBC process involves saturating the chips
with warm black liquor under pressure to improve
air removal and liquor penetration, creating more
uniform cooking conditions. The warm black liq-
uor is displaced with hot black and white liquor
and the chip charge is then cooked. After cooking,
the hot (spent) black liquor is displaced with wash
liquor from the first brown stock washer, and stored
to provide the hot black liquor for a subsequent
cook. The process was developed to reduce steam
requirements, and is technically quite effective.
MBC equipment is much more complex than
conventional batch digesters; it includes several
pressure vessels at least as large as a digester and
extensive piping, valves, and control systems. The
complexity increases as the number of digesters in-
creases. Although the basic cycle is simple in con-
cept for a single digester, it requires careful sched-
uling to operate several digesters simultaneously,
even in theory. In practice, major production losses
in process conditions and pulp quality can occur
because of equipment failure and operator error.
Two well-established vendors offer MBC sys-
tems commercially. Beloit, Inc., markets the Rapid
Displacement Heating (RDH) System and Sunds
Defibrator, Inc., markets the SuperBatch™ System.
Extended cooking to kappa number levels of 15
to 18 for softwood and 8 to 10 for hardwoods using
the rapid displacement heating process were
described by Andrews (1989). Somewhat similar
results were reported by Pursianen et al. (1990)
using the SuperBatch™ process in two Scan-
dinavian pulp mills.
Current extended continuous cooking technol-
ogy will allow pulps to be produced at kappa num-
bers of under 10 for hardwood and kappa numbers
under 15 for softwood. This corresponds to lignin
contents of about 1.5 percent and 2.3 percent,
respectively. Full-scale mill experience has
demonstrated that these low kappa pulps have
strengths equal to those of the 25 to 35 kappa pulps
produced by conventional cooking methods (El-
liott, 1989; Whitley et al. 1990). The Longview
Fibre mill pulped to very low kappa with only
modest loss in strength (Haas, 1990). The pulp vis-
cosity was low, but under extended cooking condi-
tions, the viscosity is not a valid indicator of pulp
strength.
174
-------
N. McCUBBIN
These experiences suggest that extended delig-
nification within the digester has not yet been ex-
ploited to its maximum potential, and that further
developments can be expected over the next few
years. The limiting factor could well be yield loss. If
the operating techniques or equipment modifica-
tions can be developed so that postbleaching yield
is acceptable, or the loss minor, then very low lig-
nin content pulps will be produced in the future by
extended cooking technologies.
That some loss in cooking yield occurs when
cooking to very low kappa numbers is indicated in
Figure 2 (Gullichsen, 1991). For example if a mill
were cooking to 38 kappa, the yield would be 47
percent. If the process is modified to operate with a
kappa number of 20 leaving the digester, the yield
would be 45 percent. If the kappa were lowered to
15, the yield would be 43.5 percent. However, this
loss is partially or perhaps completely offset by the
substantial reduction in screen rejects from the
cooked pulp. The pulp from conventional cooks
contains 2 to 3 percent knots and poorly cooked
fiber that must be removed from the pulp by the
brown stock screening system. In principle, these
screen rejects can be recovered by reprocessing,
but few mills accomplish this because of practical
difficulties in operating the reject recovery process.
• Current Installations: Capital and Operating
Costs. Martin MacLeod (1992) presented data in-
dicating that the world capacity for extended cook-
ing of kraft pulps was approximately 11 million
tons per year or about 20 percent of world
bleached kraft capacity. Seventeen of the 34 instal-
lations listed by MacLeod were in the United
States. Approximately half the installations listed for
continuous digesters were retrofits to existing in-
stallations, while the remainder were new
digesters. Only one of the seven batch digester in-
stallations listed was a retrofit.
The capital cost of retrofitting extended cook-
ing to our example mill would be $46 million. A
reduction of $3.5 million in annual operating costs,
would result primarily from the reduced demand
for bleaching chemicals. This estimate assumes that
all available chlorine dioxide is used to raise the
substitution in the first chlorination stage.
The capital cost is high because the only
proven way of implementing extended cooking in
the example mill requires the installation of a new
continuous digester. There would also be an addi-
tional, intangible benefit resulting from the mod-
ernization of the digester department, which
cannot be easily quantified.
Yield
% of Wood
Fully
bleached
Oxygen dellgnlfIcailon
Bleaching
15 20
Kappa Number
Figure 2.—Yield vs. kappa for extended delignification and bleaching softwood kraft.
Source: Gullichsen 1991
175
-------
Technical Perspectives — Performance and Cost
If the mill had a continuous digester, the cost to
convert it to extended cooking would probably be
about $12 million less. In the unlikely event that it
had a post-1980 continuous digester, it may well be
feasible simply to convert the wash zone to an ex-
tended cooking zone, at a capital cost of about
$4 million.
Regardless of the capital cost, the environmen-
tal benefits and changes in operating costs would
be similar (see Table 1 for more cost details).
Brown Stock Washing
As indicated in Figure 1, the pulp is washed
downstream of the digester to recover the cooking
chemicals and organic material extracted from the
wood. Any of the material not recovered in the
washers will be discharged with the mill effluent.
Washer losses are conventionally expressed in
terms of the salt cake loss, and a loss of about 900
kg of salt cake per ton of pulp would represent zero
washing efficiency. In the past, it was not uncom-
mon for washing systems to lose over 50 kg of salt
cake per ton of pulp, but most mills today lose less
than 20 kg per ton, and the best are well below
10 kg per ton. The loss of lignin and related organic
matter is roughly equal in magnitude to the salt
cake loss.
Improvements in brown stock washing reduce
discharges of biological oxygen demand, chemical
oxygen demand, resin acids, color, and lignin. The
focus of this paper, however, is on chlorinated sub-
stances. It is generally considered that the washer
loss should be under 10 kg of salt cake per ton of
pulp if oxygen delignification is to be successfully
implemented. Thus, costs for oxygen delignifica-
tion technology must include the addition of a
brown stock washing stage. The technology is
straightforward and well known. The capital costs
would be approximately $8 million, and the value
of recovered chemicals about $1.4 million per
year.
Table 1.—Capital and operating costs for selected pollution prevention measures.
CAPITAL
COST
PROCESS OPTION ($ MILLION)
Base case example mill
Maximum substitution with
Eop & existing CIO2 capacity
Extended cooking (if batch
digesters exist)
Extended cooking (if older
continuous digester)
Extended cooking (if suitable
continuous exists)
Oxygen delignification
100% substitution without Eop
50% substitution without Eop
100% substitution with Eop
Extended cooking with Eop
Oxygen delignification with
1 00% substitution
Extended cooking with
oxygen delignification
Extended cooking with 100%
substitution
Extended cooking with OD
and 1 00% substitution
Extended cooking with OD
and Eop
0.0
2.8
45.6
32.6
4.6
27.5
15.9
5.0
13.6
47.0
34.7
71.6
54.5
75.2
73.0
ANNUAL
SAVINGS
($ MILLION)
0.0
0.5
3.4
2.8
3.7
3.3
(7.1)
(1.9)
(3.2)
3.3
2.0
6.0
0.07
4.6
4.4
SUBSTITU-
TION
PERCENT
11
30
21
21
21
21
100
50
100
57
100
68
100
100
84
AOX
(per bio)
kg/t
5.3
3.4
2.6
2.6
2.6
2.6
2.1
1.9
1.5
1.3
1.1
1.0
1.0
0.7
0.6
DETECT
TCDD/F
Yes
Perhaps
Yes
Yes
Yes
Yes
No
Marginal
No
No
No
No
No
No
No
REDUCE -
BOD
kg/day
0
0
7,500
7,500
7,500
13.200
0
0
0
7,500
13.200
16,400
7,500
16,400
16,400
INCREMENTAL POWER
ON-STTE
MEGAWATT
0.0
0.0
0.0
0.0
0.0
2.0
0.0
0.0
0.0
0.2
2.0
2.0
0.0
2.0
2.2
OFF-SITE
MEGAWATT
0.0
(2.6)
(3.4)
(3.4)
(3.4)
(3.5)
5.3
(2.7)
1.7
(5.3)
(1.6)
(5.9)
(0.1)
(4.6)
(6.3)
Costs are for the example mill discussed herein and should be interpreted in conjunction with the comments in the text. Values in parentheses
are negative.
"Savings" in parentheses represent a cost.
OD. = oxygen delignification.
Substitution = substitution of chlorine with chlorine dioxide.
Reduce BOD = reduction of BOD to biological treatment.
TCDD detection level = 10 ppq.
176
-------
N. McCUBBIN
Oxygen Dellgnlficatlon
In traditional kraft mills, the unbleached stock pas-
ses to the first chlorine-based bleaching stage im-
mediately after washing. However, since the early
1970s, oxygen delignification has been installed in
many European mills and in a growing number of
mills in the United States and Canada.
Figure 1 shows the fiber line of a bleached kraft
mill flowsheet, including an oxygen delignification
system inserted between the brown stock screens
and the bleach plant. The key pollution prevention
aspect of oxygen delignification is that almost half
the lignin remaining in the pulp after the brown
stock washing is removed in this stage and recycled
to the recovery boiler, where it is burned in an en-
vironmentally sound manner.
Oxygen delignification reduces the kappa
number of the unbleached pulp by 40 to 50 per-
cent, reducing the quantity of organic material to
be extracted from the pulp and discharged to the
mill effluent from subsequent chlorine-based
bleaching stages. The installation of an oxygen
stage will allow most bleached kraft mills to reduce
BOD discharges by approximately 50 percent and
color by 60 percent. Discharges of organochlorines
will be reduced by approximately 35 to 50 percent.
When considering the installation of oxygen
delignification technology, it is necessary to
evaluate its effects on other parts of the mill
process. Equipment that will experience higher
loading due to the oxygen delignification system is
shaded in Figure 1. Notice the increased load on
most of the recovery cycle. In addition, the perfor-
mance of the brown stock washing systems must be
considered, since excellent washing (salt cake loss
under 10 kg per ton and COD under 10 kg per ton)
is a prerequisite for successful operation of oxygen
delignification systems.
• Current Installations. The capacity of oxygen
delignification systems in the United States is
8.1 million tons per year (Johnson, 1992). This is a
greater proportion of total capacity than in Canada
(McCubbin et al. 1991). In Sweden, Japan, and
Australasia, all mills operate, or are in the process
of installing, oxygen delignification systems. The
environmental benefits of oxygen delignification
are generally similar to those of extended cooking.
U.S. mills have implemented this latter technology
to a greater extent than those in Canada and other
countries.
The capital and operating costs for retrofitting
oxygen delignification to the example mill, alone
and in conjunction with other pollution prevention
process modifications, are presented in Table 1.
They are based on a two-stage, medium consisten-
cy system with two-stage, postoxygen washing.
Substitution of Chlorine
Chlorine dioxide is used increasingly to substitute
for the traditional molecular chlorine in the first
(chlorination) stage of the bleach plant. This prac-
tice improves effluent characteristics and pulp
quality. For most mills it is the simplest, most wide-
ly demonstrated, and lowest capital cost approach
for reducing organochlorines, including dioxins. It
does not, however, reduce BOD, or wood extrac-
tives. Relative to the example mill, 100 percent
chlorine dioxide substitution alone could reduce
organochlorine discharges by approximately 60
percent.
In the past, chlorine dioxide substitution was
implemented primarily to improve pulp quality, but
since 1 kg of chlorine dioxide can replace ap-
proximately 2.6 kg of molecular chlorine, there is a
net reduction in the amount of chlorine used, and a
reduction in organochlorine discharges. Today the
principal driving force behind increased substitu-
tion is the reduction of adsorbable organic halo-
gens (AOX), polychlorinated dibenzodioxins
(PCDD), and polychlorinated dibenzofurans (PCDF),
but the advantages in pulp quality remain.
• Equipment, Modifications, and Dloxln Dis-
charge. Most mills operate their existing chlorine
dioxide generation facilities at maximum capacity;
therefore, any increase in chlorine dioxide substitu-
tion would require an investment of about $25 mil-
lion in expanded capacity. It may also be necessary
to upgrade mixing equipment and controls at the
point of adding the chlorine dioxide solution to the
pulp.
Extended cooking, reinforced extraction, and
oxygen delignification reduce the total demand for
bleaching chemicals, which allows some increase
in chlorine dioxide substitution without incurring
any capital costs for upgrading the chlorine dioxide
manufacturing facilities. In all cost estimates used
here, it has been assumed that the mill would elect
to use all chlorine dioxide generating capacity
released by other process changes to increase the
degree of substitution in the first bleaching stage.
For example, installation of extended cooking in
the base case would raise substitution from 10 to
21 percent, while if Eop were also implemented,
substitution could be increased to 57 percent.
On the basis of an extensive review of recent
operating experience in almost 50 Canadian
bleached kraft mills, Luthe et al. (1992) suggest that
dioxins and furans in the final mill effluent will be
177
-------
Technical Perspectives — Performance and Cost
nonmeasurable if the active chlorine multiple
(ACM) is below a threshold value. That value in
turn depends on the extent of chlorine dioxide sub-
stitution. ACM is calculated as the ratio of total ac-
tive chlorine applied in the first chlorination stage
to the incoming kappa number. They suggest that
this limiting ACM can be calculated as 24 / (150
CIO2 Substitution percent). These conclusions
apply only if dioxin precursors (normally in de-
foamers) have been eliminated, as is now normal
practice in Canada and is believed to be the case in
the United States.
If we manipulate the above equation to calcu-
late the substitution level, it becomes: Substitution
percent =(150* ACM - 24)/ACM, which was used
to prepare the table and graph shown in Figure 3.
Luthe et al. (1992) define mill discharges as
"nonmeasurable" if the discharge of 2,3,7,8 TCDD
is under 10 ppq and the discharge of 2,3,7,8 TCDF
is under 30 ppq. They prefer to avoid using the con-
cept of detection level, since any measurement
close to the detection level is liable to be inac-
curate. These criteria are not as low as some may
wish, but they are considered to be the lowest
values that can be determined with reasonable
confidence at the time of writing. It is probable that
many mill effluents described as having "no detec-
table" concentrations of 2,3,7,8 TCDD actually
contain very much less than 10 ppq and would
remain "nondetectable'' even if judged by a more
stringent criterion that may well become practical
as laboratory experience is gathered.
Mills can be expected to achieve lower dis-
charge rates by optimizing the relatively new
bleach sequences introduced in the past few years.
These sequences will reduce the formation of or-
ganochlorines in general, and dioxins in particular.
• Current Installations, Capital, and Operating
Costs. There are no recent surveys of the extent of
chlorine dioxide substitution practiced in U.S.
mills. Examination of the data presented by Luthe et
al. (1992) shows that many Canadian mills have
adopted high levels of substitution (>70 percent). It
is generally agreed by those familiar with the in-
dustry that the United States has not adopted this
technology so widely. Until very recently, this fact
was also true in Scandinavia, but in the past year,
many Scandinavian mills have converted to 100
percent substitution to be able to produce "chlor-
ine-free" pulp. Such pulp would be better
described as "chlorine-gas-free."
The example mill discussed herein would re-
quire an expanded chlorine dioxide manufacturing
plant, improved chemical mixing, and modernized
process controls to implement high or 100 percent
substitution. The capital cost would be ap-
proximately $16 million, and operating costs
Substitution
%
0.
5.
10.
15.
20.
25.
30.
35.
40.
45.
50.
55.
60.
65.
70.
75.
80.
85.
90.
95.
100.
Limiting
ACM
0.16
0.17
0.17
0.18
0.18
0.19
0.20
0.21
0.22
0.23
0.24
0.25
0.27
0.28
0.30
0.32
0.34
0.37
0.40
0.44
0.48
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
* Limiting ACM
PAPRICAN curve predicting the ACM
threshold above which measurable
quantities of dioxins and furans can be
expected.
(Measurable is defined as 2,3,7,8 TCDD>10 ppq or
2,3.7,8 TCDD>30 ppq.)
% Chlorine Dioxide Substitutioi
0.
20.
40.
60.
80.
100.
Figure 3.—Chlorine multiple required to eliminate measurable formation of TCDD/F.
178
-------
N. McCUBBIN
would increase by about $7 million per year. If the
example mill already had an R3® or SVP® process
chlorine dioxide manufacturing system, the latter
could be converted to a methanol reduction
process, and the necessary bleach plant modifica-
tions could be completed for under $5 million,
with the aforementioned penalty in operating costs.
Virtually all chlorine dioxide manufacturing sys-
tems installed since 1970 use the R3® or SVP®
processes. Since the life of a chlorine dioxide gen-
erator is normally under 20 years, it is reasonable to
assume that a large number of the mills in the
United States could profit from this opportunity.
Many have already done so (see Table 1 for costs-
estimates related to raising the chlorine dioxide
substitution in various circumstances).
A dozen United States mills have no chlorine
dioxide on-site. These mills would have to spend
double the capital to upgrade metallurgy in the
chlorination stage and to build a greenfield
chlorine dioxide plant. Several of these mills use
CEH and similar sequences to produce semi-
bleached kraft for integrated manufacture of
newsprint or similar grades. Instead of undertaking
such major capital expenditure, and incurring the
associated high operating costs, it appears probable
that they will simply replace the kraft mill with a
deinking system, to adapt to the current market
demands for recycled content in newsprint.
Reinforced Extraction
Since high shear mixers were developed around
1980, it has become increasingly common for mills
to reinforce the caustic extraction stages (E, in Fig.
1) with oxygen or hydrogen peroxide. Hastings and
Idner (1992) reviewed the current status of this
technology, and showed that it is widely used, with
some installations using only one of these two
oxidants, while some use both. The better systems
generally include a small diameter new bleaching
tower approximately the same height as the exist-
ing E-stage tower.
• Oxygen Reinforcement. Oxygen reinforcement
(Eo) alone can be installed at a capital cost some-
what under $1 million in the example mill dis-
cussed here. Approximately 5 kg of oxygen are
used per ton of pulp, and the principal effect is to
reduce the requirement for chlorine dioxide in the
later (D) stages by approximately 3 kg per ton of
pulp. Initial installations of Eo systems were in-
tended to save costs since 5 kg of oxygen costs only
about $0.75, while 3 kg of chlorine dioxide cost
approximately $3.60. Since control of organo-
chlorines became a major concern, the principal
effect of installing Eo is often considered to be the
opportunity to use the 3 kg per ton chlorine dioxide
savings to replace approximately 8 kg chlorine per
ton pulp in the first (C) bleaching stage. This repre-
sents a reduction of up to 15 percent in organo-
chlorine discharge, but eliminates the cost advan-
tage.
• Hydrogen Peroxide Reinforcement. Hydrogen
peroxide can be used instead of gaseous oxygen to
reinforce the first extraction stage of the bleach
plant. The capital cost is normally trivial, since the
peroxide vendor generally supplies most of the
equipment. However, while the quantity of
hydrogen peroxide used is similar to the oxygen
that would be used in the Eo process variation, the
cost is considerably higher, since the cost of
hydrogen peroxide approaches $1.50 per kg. In a
practical application, if the objective is optimum
reduction of organochlorine formation, the hydro-
gen peroxide charge would be approximately 4 kg
per ton, which would replace 8 kg chlorine per ton
of pulp, reducing organochlorine discharges by up
to 15 percent.
According to Hastings and Idner (1992), more
than 80 percent of the world's bleached kraft mills
use some variation of oxygen/hydrogen peroxide
reinforced extraction. The author is aware of un-
published data showing that well over 90 percent
of Canadian mills do so.
Ozone
Ozone bleaching has been heavily researched, and
many pilot plants have been operated over the past
20 years. Five full-scale systems are under con-
struction as of August 1992, with scheduled start-
up dates late 1992 and early 1993. This technology
offers the possibility of manufacturing totally
chlorine-free bleached kraft pulps, but since it is
not yet proven on a commercial scale, any cost es-
timates would be speculative. (Phillips et al. 1992)
Ozone seems likely to be used following ex-
tended cooking and oxygen delignification, and
promises lower operating costs than current
bleaching processes based on 100 percent chlorine
dioxide substitution.
LIGNOX™and Related Processes
The LIGNOX™ process was first applied in the
Aspa mill in Sweden in 1991. It used hydrogen
peroxide with a chelating agent pretreatment to
lower the kappa number of oxygen delignified kraft
pulp by about 40 percent (Basta et al. 1991). The
LIGNOX™ bleached pulp can be marketed as
semibleached kraft, or bleached to full market
quality with chlorine dioxide, while discharging
179
-------
Technical Perspectives — Performance and Cost
under 0.3 kg adsorbable organic halogens per ton
of pulp.
The LICNOX™ process is patented by EKA
Nobel. The principal bleaching chemical used is
hydrogen peroxide, which has been used to bleach
kraft pulp for many years. The distinguishing fea-
tures of EKA Nobel's process are the use of chelat-
ing agents prior to the addition of hydrogen
peroxide, and the operation of the hydrogen
peroxide stage at relatively high temperatures with
long retention time.
The chlorine-compound-free LIGNOX™ pulp
at Aspa had a maximum brightness of about
70 to 75 ISO, and where it can be marketed in this
semibleached condition, there is no or-
ganochlorine discharge. If the pulp is subsequently
bleached with chlorine dioxide to approach
90 ISO, then adsorbable organic halogens dischar-
ges can be expected to be well under 0.5 kg per ton
of pulp.
More recently, the LIGNOX™ process has been
operated at higher temperatures and benefited from
further research and improved operating know-
how. According to Igerud and Basta (1991), it is
possible to bleach Scandinavian softwood pulp to
75 to 78 ISO brightness with strength properties
comparable to traditional pulps by operating the
chelating stage at high temperature and lowering
the unbleached pulp kappa number to 13 or so
prior to bleaching. This process requires both ex-
tended cooking and oxygen delignification.
Igerud and Basta (1991) conclude that the
bleaching sequence O Q EP Z E could produce
softwood pulps of about 83 ISO brightness — and
with acceptable strength properties. This technol-
ogy, however, is not practiced on a full scale, and
capital cost projections for U.S. mills would be
premature.
There are no LIGNOX™ process installations in
the United States, but extensive research has been
carried out on similar processes based on using a
chelating agent and hydrogen peroxide to replace
most or all of the chlorine dioxide in bleaching. It
seems likely that the most successful applications
of this technology will follow the installation of
oxygen delignification and extended cooking.
There are only a few mills in this category in the
United States at present, but several others are in
the process of installing the equipment.
LIGNOX™ and related processes can be imple-
mented in existing mills with relatively little capital
cost (perhaps for a few million dollars). McCubbin
et al. (1991) estimated that the direct operating
costs for a bleach plant using the LIGNOX™
process would be Can$70 per ton, whereas a mill
using oxygen delignification would manufacture a
similar quality pulp for an expenditure of only
Can$25 per ton.
Enzyme Assisted Bleaching
A year or so ago, only a few industry researchers
knew anything about enzymes, but in the past year
many mills have conducted full-scale trials with en-
zymes as bleaching aids. Researchers are currently
looking at many ways to use various types of en-
zymes to reduce the quantities of chlorine-based
chemicals required to bleach pulp; nevertheless,
the use of brown stock storage tanks as a reactor
seems to dominate mill trials at present.
Enzymes are manufactured from microbiologi-
cal cultures grown under controlled conditions in
closed tanks. After digestion the culture is isolated,
the cells are broken down, and the enzyme of inter-
est is isolated. Proteolytic enzymes have been used
in washing powder for decades to remove protein
spots from cloth. Today, enzymes are being
developed for the pulp and paper industry. One ex-
ample is xylanase, an enzyme that can break the
bonds between cellulose and lignin, facilitating
delignification prior to bleaching, as a supplement,
or perhaps alternative, to oxygen delignification.
Mill trials and commercial operations are based
on adding some commercial variation of xylanase
and acid to the pulp just upstream of the brown
stock high density storage tank. The enzyme has no
readily discernible effect on the pulp in storage, but
the quantity of chlorine (or other bleaching agent
with equivalent oxidizing power) required in the
subsequent bleaching stages is reduced about 25
percent. Quantities of the enzyme used are typical-
ly under 1 kg per ton of pulp, and several kilograms
of sulphuric acid per ton are normally required to
lower the pH to the 4 to 6 range required for the en-
zyme to react as desired. The reaction temperature
has to be under about 60 °C
Some enzyme vendors claim that their product
increases tear strength, with no degradation in
other properties, while others simply suggest no
changes. There appears to be a modest drop in
yield (less than 1 percent) but the overall effect on
pulp yield is not yet clear.
CFI in Canada and Metsa-Sellu at Aanekoski,
Finland, were the only mills mentioned at the non-
chlorine bleaching seminar at Hilton Head, South
Carolina, in March 1992, as using full-scale en-
zyme bleaching aids. However, staff from other
mills indicated that they had been running trials for
several days at a time, and producing significant
quantities of pulp; and informal comments at the
seminar suggested that several mills are probably
using enzymes regularly.
180
-------
N. McCUBBIN
Enzyme manufacturers have indicated that
xylanase is as useful after oxygen delignification as
it is in mills using traditional bleaching processes.
The Aanekoski, Finland, mill has manufactured
over 50,000 tons of totally chlorine-free (TCP)
pulps using an enzyme, oxygen delignification, and
peroxide bleaching. This mill has an MCC®
digester, and its operators have indicated privately
that the premium for TCP pulp is $100 per ton.
It is probable that enzyme technology will be a
routine part of pollution prevention measures in the
near future.
Effluent Characteristics
Dioxlns
The discharges of polychlorinated dibenzo dioxins
(PCDD) and polychlorinated dibenzofurans (PCDF)
differ substantially from one technological process
to the other. Evaluation of much of the available
data on dioxin discharges is complicated by the fact
that all the available data were collected from 1988
to 1991. At the beginning of this period, so little
was known of the technology for reducing dioxin
formation that mills were unable to implement con-
trol measures. Since then, intensive research
programs in Canada, the United States, and
Sweden have made considerable dioxin control
knowledge available very rapidly.
Some control measures, such as the control of
the quality of defoamer additives (Voss et al. 1988),
improved chlorination system control procedures,
and the elimination of phencyclidine (PCP) or PCP-
treated wood chips, were implemented rapidly, at
little cost and without fanfare. There is little doubt
that these measures reduce dioxin formation sig-
nificantly, but there are no surveys available to
judge the extent. Most of the pre-1991 data avail-
able on dioxin discharges from pulp mills is some-
what outdated.
According to Berry et al. (1991), the formation
of dioxins is little affected by the lignin content of
the unbleached pulp, but depends primarily on the
presence of precursors (contaminated defoamers,
chips derived from PCP-treated wood) and the
"chlorine multiple." The latter is the ratio of
chlorine used for delignification in the first (C or
CD) stage of bleaching to the lignin content of the
pulp. It is clear that increasing chlorine dioxide
substitution is desirable from the standpoint of
dioxin control (see Fig. 3).
Berry et al. (1991) conclude, and others agree,
that the installation of extended cooking, oxygen
delignification, or reinforced extraction have little
or no direct effect on dioxin formation. However, in
practical cases, where these latter technologies are
retrofitted, they reduce the total amount of bleach-
ing agents required in approximate proportion to
the drop in unbleached kappa number. Since most
mills operate their chlorine dioxide manufacturing
facilities at capacity, the reduction in the total
bleach chemical demand can be used to raise the
chlorine dioxide substitution ratio, as discussed
earlier, hence reducing dioxin discharges.
Adsorbable Organic Halogens
The discharge of many chlorinated organic com-
pounds depends closely on the lignin content of the
pulp prior to bleaching. McCubbin et al. (1991)
presented the graph shown in Figure 4, which sum-
marizes the effects of combinations of extended
cooking, oxygen delignification, and high chlorine
dioxide substitution on adsorbable organic halo-
gens (AOX) discharges.
AOX discharges from hardwood will normally
be substantially lower, since lesser quantities of
chlorine based compounds are required to bleach
hardwood.
The data in Figure 4 ignore the potential benefit
of raising the substitution level by profiting from the
lowering of demand for bleaching agents when ex-
tended cooking or oxygen delignification, or both,
are retrofitted.
Polychlorinated Phenols
The discharge of polychlorinated phenols has been
shown by Berry et al. (1991) to be highly depend-
ent on the lignin content (kappa number) of the
pulp prior to bleaching. Figure 5 presents a com-
posite of their data and shows the relationship be-
tween the unbleached kappa number and the
pentachlorophenol toxicity equivalent (TEQ) for
softwood pulp in laboratory processing.
The sample mill discussed here manufactures
pulp with a kappa number of 30. If extended cook-
ing or oxygen delignification were installed, the
kappa number could be 16 to 18, lowering the dis-
charge of polychlorinated phenols by 75 percent. If
both these technologies are installed, the kappa
number of the unbleached pulp could be as low as
10, and reduce the discharge of polychlorinated
phenols by somewhat over 90 percent. High
chlorine dioxide substitution also reduces the for-
mation of chlorinated phenols.
Color
Color in bleached kraft mill effluents is not hazard-
ous, and causes little, if any, measurable damage to
the receiving water. It is, however, aesthetically un-
desirable, particularly in rivers with low natural
181
-------
Technical Perspectives — Performance and Cost
8
AOX kg/t pulp
6
5
4
3
2
1
~~ —~ Conventional, 32 Kappa
- - - - Conventional, 28 Kappa
Oxygen delignification
Oxygen delig. & MCC
0% 10% 20% 30% 40% 50% 60% 70%
Substitution in chlorination stage
80%
90%
100%
Figure 4.—AOX discharges for various pulping and bleaching conditions (softwood). AOX discharges are prior to
biological treatment.
14
12
10
8
6
4
2
TEQ.
g PCP/Adt
UB Kappa
10
15
20
25
30
Figure 5.—Formation of pentachlorophenol toxicity
equivalents vs. unbleached Kappa number.
color levels. All the previously discussed tech-
nologies will reduce color substantially relative to
the example mill. Color discharges are roughly
proportional to AOX discharges
Zero Effluent
Many secondary fiber mills and at least one market
pulp mill (Millar Western's Meadow Lake, Sas-
katchewan, Canada) operate with no effluent dis-
charge whatsoever. The technology is not yet
available to operate a bleached kraft mill without
discharging effluent. In principle, the technology
exists to operate unbleached kraft mills effluent
free, but no such operations have yet been realized.
The most obvious obstacle to eliminating
planned process effluents from bleached kraft mills
is the use of chlorine-based bleaching agents,
which lead to the generation of effluents that must
be discharged due to the corrosive nature of the
chlorides in a closed cycle process. Mills repre-
senting approximately 5 percent of the bleached
kraft pulp capacity in the world are capable of
producing semibleached, totally chlorine-free, kraft
pulp. That is, they do not use any chlorine com-
pounds. Only 10 percent of this TCP capacity is
being used, because of weak market demand
presumably related to its high cost (about $50 to
$100 per ton premium) and somewhat inferior
papermaking properties. The brightness for current
TCP pulps is about 75 to 80 percent ISO, whereas
traditional kraft pulps are bleached to provide
82 to 92 ISO. Current TCP pulps have a tendency to
yellow with age, and contain more visible dirt par-
ticles than traditional kraft pulps.
With the exception of high chlorine dioxide
substitution, all pollution prevention technologies
discussed here are logical steps along the path to
zero effluent. Chlorine dioxide bleaching equip-
ment would become obsolete in a mill being con-
verted to operate without any process effluent.
182
-------
N. McCUBBIN
The processes that eliminate the use of chlorine
compounds in bleaching are based primarily on the
use of oxygen in some form, sodium hydroxide,
and sulphuric acid. These substances can generally
be processed successfully in a conventional kraft
recovery cycle. Problems of process control, how-
ever, and the removal of trace elements, mostly me-
tals, will have to be resolved before the closed
cycle kraft mill becomes practical.
Electrical Energy
Energy consumption is another factor in a mill's
pollution prevention cost-to-benefits ratio.
Power Consumption at the Mill
and Off-site
Pollution prevention measures, such as oxygen
reinforced extraction (pulp mixing); chlorine
dioxide substitution (pulp mixing); oxygen delig-
nification (mixing, pumping, and oxygen genera-
tion); the addition of a second vessel to continuous
digester (pumping); and the replacement of batch
digesters with continuous, extended cooking sys-
tems (pumping), can have a significant effect on on-
site power requirements. Data on changes in power
demand at the mill site are presented in Table 2.
The technical options discussed in this presen-
tation change the use of purchased chemicals in the
mill. Most chemicals are purchased by the mill
from third parties who manufacture them from
abundant, naturally occurring raw materials such
as sodium chloride, using electric energy.
The effects of these technologies on power
demands at the mill and off-site are presented in
Table 2, in ascending order of total electrical con-
sumption.
The high substitution of chlorine with chlorine
dioxide, clearly, is the most energy demanding
technology. The most significant factor in this
demand is the energy required to manufacture
sodium chlorate (off-site) for the mill's (on-site)
chlorine dioxide generators. A significant propor-
tion of sodium chlorate used in the United States is
imported from Canada.
Basis for Capital and Operating Costs
The capital cost of retrofitting any of the pollution
prevention technologies discussed in this paper
depends on the existing installations. There are
very wide variations in capital cost for most tech-
nologies. Capital costs include equipment, installa-
tion, and overheads, such as engineering and
project management. They assume that no costs
would be incurred for land purchase, which is
realistic for most mills, since space requirements
are quite small.
The costs of any production losses resulting
from downtime for construction have also been
neglected. This assumption is realistic for most
modifications, since the installation is routinely
carried out while the mill is running, and the few
hours of mill shut-down time required are coor-
dinated with other scheduled downtime, or some-
times with breakdowns of other equipment. In the
case of recovery boiler upgrades, several days or
even a few weeks of boiler downtime could be re-
quired. Mills have generally maintained production
during such periods by shipping black liquor to
other mills for processing, or by storing the liquor in
temporary ponds for subsequent recovery. Such
costs will represent a modest part of the project.
They have not been estimated here.
The principal effects of the pollution preven-
tion technologies discussed here will be on chemi-
Table 2.—Effect of pollution prevention on demand for electric energy.
PROCESS OPTIONS
Extended cooking with Eop
Extended cooking with OD and Eop
Extended cooking with oxygen delignification
Extended cooking (if batch digesters exist)
50% substitution without Eop
Extended cooking with OD and 100% substitution
Maximum substitution with Eop and existing CIOz capacity
Oxygen delignification
Extended cooking with 100% substitution
Base case example mill
Oxygen delignification with 100% substitution
100% substitution with Eop
1 00% substitution without Eop
ON-SITE MEGAWATTS
0.2
2.2
2.0
0.0
0.0
2.0
0.0
2.0
0.0
0.0
2.0
0.0
0.0
OFF-SITE MEGAWATTS
(5.3)
(6.3)
(5.9)
(3.4)
(2.7)
(4.6)
(2.6)
(3.5)
(0.1)
0.0
(1.6)
1.7
5.3
TOTAL MEGAWATTS
(5.1)
(4.1)
(3.9)
(3.4)
(2.7)
(2.6)
(2.6)
(1.5)
(0.1)
0.0
0.4
1.7
5.3
Refer to notes on Table 1 .
183
-------
Technical Perspectives — Performance and Cost
cals and energy consumption. None require in-
creased operating labor, though there may be some
labor reductions following the modernization of
equipment. Equipment maintenance costs will be
increased if new equipment is installed that does
not replace older systems.
The effects of a various technologies on the
capital and operating costs for the example mill are
shown in Table 1.
References
Andrews E.K. 1989. RDM kraft pulping to extend delignifica-
tion, decrease effluent, and improve productivity and pulp
properties. Tappi J. 731: 55-61.
Basta, J., L. Holtinger, P. Lundgren, and H. Fasten. 1991. Lower-
ing of kappa number prior to ClCh bleaching: reducing
levels of AOX. Vol. 3, pages 23-34 in Proc. Int. Pulp
Bleaching Conf. Stockholm, Sweden.
Berry, R.M. et al. 1991 The effects of recent changes in
bleached softwood kraft mill technology on organo-
chlorine emissions — an international perspective. Proc.
Can. Pulp Paper Ass. Spring Conf. Whistler, British Colum-
bia, Can.
Elliott, R.G. 1989. Experience with Modified Continuous Cook-
ing. Pulp Paper Found. Annu. Meet. Univ. Washington.
Seattle, WA.
Cullichsen, J. 1991. Means to Reduce Effluent Pollution of Kraft
Pulp Mills. Pages 185-90 in Proc. 1991 Environ. Conf., San
Antonio, TX. Tech. Ass. Pulp Pap. Indus. Atlanta, CA.
Haas, M.E. 1990. Longview Fibre's experience with MCC.® In
Proc. Pacific Tech. Ass. Pulp Pap. Indus. Sem. on Recent
Modification of Kraft Pulping. TAPPI Press, Atlanta, GA.
Hartler, N. 1978. Svensk Paperstidning 81 (15):483.
. 1983. Svensk Paperstidning. 66 (18) 696.
Hastings, C. and K. Idner. 1992. Current state-of-the-art of Eo,
Ep, and Eop technologies. In Proc. Nonchlorine Bleaching
Sem., Hilton Head, SC. Miller Freeman, Inc. San Francis-
co, CA.
Igerud, L. and J. Basta. 1991. Developments of the LIGNOX™
process. In Proc. European Pulp Paper Week. Bologna,
Italy.
Johnson A.P. 1992. Worldwide survey of oxygen bleach plants.
In Proc. Nonchlorine Bleaching Sem., Hilton Head, SC.
Miller Freeman, Inc. San Francisco, CA.
Kocurek, M.J. 1986-1989. Pulp and Paper Manufacture.
Textbooks, joint Textbook Comm. Paper Industry. Can.
Pulp Paper Ass. Montreal, Quebec, Can.
Lulhe, C.E., P.E. Wrist and R.M. Berry. 1992. An evaluation of
the effectiveness of dioxins control strategies on organ-
ochlorine effluent discharges from the Canadian bleached
chemical pulp industry. Chap. VI in Proc. Can. Pulp Paper
Ass. Spring Conf. jasper, Alberta, Can.
MacLeod, Martin. 1992. A worldwide survey (of extended
cooking installations). In Proc. Nonchlorine Bleaching
Sem., Hilton Head, SC. Miller Freeman, Inc. San Francis-
co, CA.
McCubbin, N. et al. 1991. Best Available Technology for the
Ontario Pulp and Paper Industry. Rep. ISBN 7729-9261-4.
Ontario Ministry Environ. Toronto, Ontario. Can.
Phillips, R.B., J.L. Renard, and L.M. Lancaster. The economic
impact of implementing chlorine-free and chlorine com-
pound-free bleaching processes. In Proc. Nonchlorine
Bleaching Sem., Hilton Head, SC. Miller Freeman, Inc. San
Francisco, CA.
Pursianen, S.S. Hiljanen, P. Uusitalo, and K. Kavasin. 1990. Mill
scale experiences of extended delignificalion with Super-
Batch™ cooking method. Tappi j. 73:115-22.
Teder, A. and L. Olm. 1980. In Proc. EUCPA Conf. 3:1.
Voss, R.H. et al. 1988. Some insights into the origins of dioxins
formed during chemical pulp bleaching. Pulp Paper Can.
89:12.
Whilley, D.L., J.R. Zierdl, and D.J. Lebel. 1990. Mill experienc-
es with conversion of a kamry digester to modified con-
tinuous cooking. Tappi J. 73(1): 103-08.
184
-------
Bleaching Cost and Environmental
Results at a Modern Kraft Market
Pulp Mill
Luigi Terziotti
Vice President, Pulp and Paper Operations
Parsons & Whittemore
Claiborne, Alabama
I plan to share with you the results of bleaching
and environmental operations at the Alabama
Pine Pulp Company, Claiborne, Alabama,
during the plant's first six months of operation. Our
results are from a new pulp mill that incorporates
all the "bells and whistles" of modern conventional
cooking and bleaching technology. The data are
from actual operating conditions, limited in timeli-
ness only by the lag time between collection of
samples and return of actual results. Very few
laboratories are accredited to work on dioxin and
adsorbable organic halogens (AOX).
Adapting to Today's
Operating Climate
Once upon a time, a start-up report would have
focused on the best and fastest way to achieve op-
timum operating conditions. Those goals contained
a lot of self-interest, but they also provided protec-
tion of the ecological system by reducing the exces-
sive use of chemicals, power, steam, and water as
quickly as possible.
Our industry is now faced with a new
"demonology" centered around chlorine. This new
"religion" has been accepted as politically and en-
vironmentally correct by regulators and the public.
There's no need to dwell on it. Because as an in-
dustry we were not effective early on in making our
case clear and credible, now we must accept the
demands imposed on us. Because we produce only
market pulp for sale to domestic and overseas cus-
tomers, if we are going to survive, we have to give
our customers what they want. The loud and clear
message from a vocal minority is this: "We want
high strength, high cleanliness, high brightness,
and, by the way, no dioxin and low AOX. Forget
about price premiums for your pulp."
The Romans said it best 2,000 years ago: "Dura
Lex Sed Lex"; "If you don't like the law, tough
luck."
The Alabama Pine Pulp Company (APP) is the
newest pulp and paper factory designed, built, and
operated by Parsons & Whittemore, Inc., at its
southern Alabama site. First on the site, Alabama
River Pulp (ARP) began operations at the end of
1978 and now produces approximately 1,200
metric tons per day of hardwood market pulp.
Alabama River Newsprint (ARM), a joint venture
with Abitibi Price of Toronto, Ontario, Canada, was
the second addition. It started in mid-1990 and
produces more than 620 metric tons of newsprint
per day. Alabama Pine Pulp started in December
1991 and is designed to produce 1,250 metric tons
per day of softwood pulp.
The New Mill
APP's fiber line consists of a two-vessel Kamyr
hydraulic digester incorporating an extended
modified continuous cooking (EMCC®) process
and high-heat washing (see Fig. 1). After ex-
perimenting with a gamut of kappa number targets
(to specify the degree of delignification), we settled
on a range of 25 to 27 for maximum strength and
full bleachability.
After cooking, the pulp is washed in a Kamyr
pressurized diffusion washer, then screened and
thickened before entering a two-stage, medium-
consistency oxygen delignification system. This
185
-------
Technical Perspectives — Performance and Cost
Figure 1.—Two-vessel hydraulic digester with EMCC* and pressure diffuser.
department includes two pressurized oxygen reac-
tors and two pressure diffusion washers. The pulp is
delignified to a kappa number of 14 or 15 (see Fig.
2).
Bleaching to a 90-plus ISO brightness is done
in a four-stage Kamyr bleach plant. We selected this
system because it operates at medium consistency
throughout, thus reducing the water and energy re-
quirements (see Fig. 3).
A new chlorine dioxide generating plant (SVP
— methanol) was added, with a new electrolytic
plant that provides the full requirements of sodium
chlorate.
Effluent Treatment and
Bleaching Conditions
A third activated sludge module was added for APR,
replicating the original 1978 plant. The plant in-
stock In
H0j^»-
Feed Chute
Wfih MC Pump
MC Mixer
Oxygen
Reaclor
MC Mixer
Oxygert
Reactor
Figure 2.—MC oxygen delignffication system.
LC"
Blow Tube
With MC Pump
Pressure
Oilfuser
Washing
MC Blowlank
Pump
186
-------
L TERZIOTTI
Figure 3.—D iff user bleach plant C/D - EOF -D-D.
eludes a foam tower, primary clarification, equal-
ization basin, cooling tower, enclosed oxygen reac-
tor, secondary clarifier, thickener, and belt presses
for sludge handling. More than 200 metric tons per
day of oxygen are produced on site.
We experimented with various degrees of sub-
stitution and settled on a 100 percent chlorine
dioxide substitution and the elimination of elemen-
tal chlorine as the only sure way of achieving non-
detectable levels of dioxin. Occasionally we
reached this goal at lower substitution levels, but
not consistently. The formation of chlorinated
dioxins and furans is very dependent on washing
efficiency.
Figures 4 to 8 show the effects of various
bleaching sequences on dioxin and AOX in pulp,
plus AOX in the final effluent. The results are im-
pressive, I think, but they do not come cheap.
Figures 9 to 14 show the cost and energy assump-
tions used in our calculations, and the actual
chemical use and cost for the different bleaching
sequences.
2,3,7,8 TCPD Parts Per Trillion (ppt)
12
20% 50% 70%
Chlorine Dioxide Substitution (%)
Figure 4.—APP dioxin In pulp.
AOX (mg/kg)
TOCL (mg/kg)
20% Subs. 50% Subs. 100% Subs.
Percent of C1O2 Substitution, %
Figure 5.—APP AOX data (AOX and TOCI measured as
milligrams per kilogram of dry pulp).
APP
0.38 kg/ton
ARP
Effluent
Treatment
System
Discharge
0.3 1 kg/ton
ARP HW Run at 50% CIO2 Substitution,
APP SW Run at 100% C1O2 Substitution.
Figure 6.—AOX reduction for ARP and APP combined
effluent treatment systems.
APP
0.38 kg/ton
ARP
Effluent
Treatment
System
Discharge
0.25 kg/ton
ARP HW Run at 100% C1O2 Substitution,
APP SW Run at 100% C1O2 Substitution.
Figure 7.—AOX reduction for ARP and APP combined
effluent treatment system.
187
-------
Technical Perspectives — Performance and Cost
APP
1.72 kg/ton
ARP
Effluent
Treatment
System
Discharge
0.71 kg/ton
KWII/ADMT
ARP HW Run at 50% C1O2 Substitution,
APP SW Run at 50% C1O2 Substitution.
Figure 8.—AOX reduction for ARP and APP combined
effluent treatment system.
'C12
'CIO2
•02
•H2O2
' NaOH
• Na_Silicate
' MgSO4
•O3
Cost ($/kg)
0.07
0.88
0.10
1.12
0.29
0.37
0.41
2.43
Energy (kwh/kg)
1.70
9.93
0.66
0.90
1.50
22.05
Figure 9.—Chemical cost and energy.
kg/ADMT
O2 BnMgSCM BBC12 [BNaOH EH2O2 BCIO2)
l> octtVDMCoUU O-UlOQAkfUl) moMx-DEpU
Kappa Ana O2 Stage: 15 15 IS 28 (To Bleach Plant)
(Brightness ISO 90+)
Figure 10.—Chemical usage for different bleaching se-
quences of softwood pulp.
$60.00
S/ADMT
13O2 H!DMgSO4 UHCI2 SNaOH G3H2O2 E3C1O2J
$46.68
$10.00
$0.00
OCZVUfOFoUU
28 (To Bleach Plant)
Kappa After O2 Stage: 15 15 15
Brightness ISO 90+
Figure 11.—Chemical cost for different bleaching se-
quences of softwood pulp.
600
550
500
450
400
350
300
250
200
150
100
50
0
Kappa Alter O2 Stage: 15
BriEhtness ISO 90+
UIOOEoDEpD
28 (To Bleach Plant)
Figure 12.—Energy requirements for different bleaching
sequences of softwood pulp.
kg/ADMT
02 miUMgSCM •Q-DTPA 111
II2O2 63CIO2 EDNaSiOJ
Kappa After O2 Stage:
Brightness ISO
15
90+
10.3
71.9
Figure 13.—Chemical usage for different bleaching se-
quences of softwood pulp.
SI 00.00
$90.00
$80.00
$70.00
$60.00
$50.00
$40.00
$30.00
$20.00
$10.00
$0.00
S/ADMT
3O2 »MgSO4 BQ-DTPA BBNi
3H2O2 EJCIO2 BNaSiO3 HH2SO4,
(S4Z.76)
($87.08)
Kappa After O2 Stage:
Brightness ISO
15
90+
10.3
71.9
Figure 14.—Chemical cost for different bleaching se-
quences of softwood pulp.
Again the final results: the elemental chlorine-
free (ECF) pulp costs $10 to $12 per metric ton
more to produce than conventional pulp, although
the price differential theoretically could be reduced
by $5 per metric ton if no peroxide is used.
Peroxide gives more stability and consistency to the
188
-------
L. TERZIOTTI
final brightness. If a mill does not have an oxygen
delignification stage, it can still produce 90-plus
brightness ECF pulp — albeit at a higher cost —
providing that it starts with a lower than normal
Kappa number (after EMCC® for example, or after a
soft cook).
As for energy, ECF pulp consumes 70 kilowatt
hours per metric ton more than conventional pulp.
Just to service our APR and ARP, 170 kilowatt hours
of electricity must be produced by oil, coal, water-
powered, or nuclear power plants.
Have we tried the production of totally
chlorine-free (TCP) pulp? Obviously yes, but only
in laboratory trials using our brown stock. The best
we could achieve under well-controlled lab condi-
tions was a 70-plus brightness costing $50 per
metric ton more than fully bleached pulp. We
know, however, that 80-plus brightness has been
reported by using an acid stage and the addition of
chelates ethylenediaminetetraacetic acid (EDTA).
We have not tested ozone because it requires a
more complex apparatus and the cost computation
would depend on the process used to produce
ozone. The process has good potential, especially
for integrated mills that do not need the 90-plus
brightness pulp or the fiber strength required in
market pulp. On the other hand, it is possible to
achieve higher brightness by adding one final
dioxide stage to the ozone process. But this sen-
sible solution would give the product little ad-
vantage over the modern conventional system used
by APP. If the ozonized pulp were touched by the
"demon chlorine," it would be deemed unholy and
unfit to use.
Conclusion
Our results reflect only six months of operation. We
will continue to approach optimal chemical and
energy uses, since it takes about two years to bring
a large and complex new mill up to full efficiency
and productivity standards. But, we have achieved
our original goal — nondetectable dioxin in the
products and minimal organochlorines in the ef-
fluent. Our system shows that a conventional
bleaching technology, using the latest pulping and
bleaching processes, can protect the environment.
Our effluent meets all acute and chronic toxicity
tests, which cannot be said of some other chlorine-
free bleaching techniques.
So what about chlorine? The oceans contain
tons of chlorine and produce millions of tons of or-
ganochlorines. In fact, on planet Earth, much more
dioxin is formed naturally than by all the pulp mills
involved in bleaching practices. With an atomic
number of 17, chlorine was obviously formed very
early after the Big Bang, perhaps 15 billion years
ago, and it will be with us a few billion years more.
I think it's safe from extinction — even if we don't
rename Greenpeace according to its Creek roots:
Chlor-peace. I could work for such peace.
189
-------
Challenges in the Development of
Totally Chlorine-free Kraft Pulp
Bleaching Technology
C. Roger Cook
Vice President, Environment
E.B. Eddy Forest Products Limited
Espanola, Ontario, Canada
The E.B. Eddy Kraft Mill in Espanola is working
to develop a chlorine-free bleaching technol-
ogy. Using adsorbable organic halogens
(AOX) as a measure of progress toward chlorine-
free pulp production, the Espanola mill has
reduced its AOX discharge level from 5 kg of AOX
per metric ton (tonne) of pulp to a value of 0.6 kg of
AOX per tonne using a combination of oxygen
delignification, ' modified continuous cooking
(MCC ), chlorine dioxide substitution, and effluent
treatment. The company is now evaluating a series
of options for the next stage, including the develop-
ment of ozone bleaching as one of these options.
A pilot study on ozone bleaching is now in
progress with an expected completion date of early
1993. The decision to invest in ozone technology
will depend on the results of the pilot study and on
the market projections for demand of chlorine-free
pulp and papers. As with all work to date, the com-
pany is looking for equivalent quality, no increase
in variability, a satisfactory bleaching cost evalua-
tion, and overall environmental benefits.
The market for a totally chlorine-free (TCP)
bleached kraft pulp that will also satisfy customers'
demands for quality, value, and environmentally
friendly products is going to increase. Measures of
quality and value are well established and ac-
cepted by producers and customers alike. How-
ever, the methods for assessing environmental
friendliness are not nearly so clear-cut. At the mo-
ment, chlorinated organics (measured as AOX) and
the extent of recycled content are the dominant
measures, but it is unlikely that they will remain the
only measures to assess the environmental impact
of pulp production. Governments around the world
are eager to prevent the proliferation of unsubstan-
tiated environmental claims on product labels.
These so-called Eco Labeling schemes include air
emissions quantities and effluent quality, and they
are also likely to include energy consumption
standards.
At present, the high costs associated with
chlorine-free pulp manufacturing are holding down
demand. Customers are reluctant to pay the extra
premium for TCP pulp. Yet world demand for
chlorine-free kraft pulp is expected to be 2 million
tonnes per year by 1995, or about 6 percent of the
total world demand for kraft pulp — currently,
that's about 30 million tonnes per year. This
demand for TCP pulp would continue to accelerate
if high quality chlorine-free products could be
manufactured at bleaching costs close to current,
conventional costs.
Technological Know-how
The technological challenge is to make high quality
chlorine-free pulp at the right price. Energy use and
the notion of recovering some of the bleaching
chemicals for reuse are part of the economics of the
chlorine-free bleaching process. Alternate bleach-
ing chemicals are more expensive than chlorine on
a pound-per-pound basis. Therefore, if the operat-
ing cost of chlorine-free bleaching is to be held to
reasonable levels, it is apparent that less of the al-
ternate chemical must be used; that is, we must set
the kappa number of the pulp as low as possible.
190
-------
C. R. COOK
Financial Resources and Risks
Having good market research and a good pilot
study on ozone bleaching not only guarantees that
full-scale equipment will produce a salable
product; it also provides the basis for a good busi-
ness plan to secure financing for the project. The
switch to new technology is most easily accom-
modated if it is accompanied by plant expansions
or construction of a new mill. These factors also
have a significant bearing on timing.
The need to survive in a fiercely competitive
marketplace drives the willingness to take risks.
The companies that are now working on chlorine-
free kraft bleaching are also learning how to thrive
in an atmosphere of constant change. Generally
speaking, they are committed to continuous im-
provement and are ready to take calculated risks to
succeed. If TCP pulp can be produced at equivalent
quality and without increasing costs, then the risks
involved with the new technology are manageable.
Overview of E.B. Eddy Company
E.B. Eddy has 1.6 million hectares of forest lands in
Northern Ontario that are managed under a forest
management agreement with the provincial
government. The harvested wood is sent to two
company-owned sawmills and turned into 1 mil-
lion board feet per day of high quality kiln-dried
lumber. The sawmill residues and purchased logs
are shipped to the kraft mill in Espanola where they
are converted into 1,000 tonnes per day of
bleached hardwood and softwood pulp. Fifty per-
cent of this pulp goes into the company's own
paper mills; the remaining 50 percent goes on the
open market. The company makes 700 tonnes per
day of fine and specialty papers, for example, food
packaging, medical grades and lightweight papers,
and some coated grades. In addition, we produce
fine recycled-content papers under the Eagle trade
name in Canada.
The kraft mill was built in 1948. Because of
progressive modernization, the mill's environmen-
tal performance is comparable to mills built today.
In 1983, the company spent Can$200 million to
expand production from 700 to 1,000 tonnes per
day.
Chlorine, Bleaching Costs, and Quality
A planned reduction in chlorine use has occurred
at the Espanola mill over the past 15 years (see Fig.
1). The first significant drop was in 1977 when the
company installed North America's first oxygen
delignification system in the mill's softwood line.
As a result of this success, the company converted
the hardwood line to oxygen in 1980. In the 1983
modernization program, a secondary treatment
lagoon was installed. Improvements to pulp wash-
ing were made in 1988, and increased chlorine
dioxide substitution was instituted in 1989 as part
of the dioxin control program. The AOX discharge
from the mill has decreased from a value of 5 kg per
tonne of pulp in 1976 to the present-day value of
0.6 kg per tonne (C.R. Cook, 1990).
The mill has improved its environmental per-
formance while simultaneously reducing bleaching
costs and improving quality. The oxygen delig-
nification system reduced total mill chlorine con-
Chlorine
Usage
(LbsJAdt) so
160—
140-
120 —
1OO —
80-
60
40-
20-
0-
n
.
r— i 411 Oxygen Dellgnlflcatlon _ _
i Clean Defoamers
«2 Oxygen Dellgnlflcatlon «" CIO« ' 60% Substitution
•
^—
•
Joeconoary irwuimwui
Condensate Treatment . .
i ImnrnuAH
"
-
±
Pulp
, Washlna
_^
^••M
-
\
1
'
Sensors
&.,, .
Bleaching
fVwitrnl*
1
Modified
Continuous
Cooking
.
|
^
•
1975
1980
1985
19901991 1992*
Figure 1.—Significant process changes at the Espanola Mill, 1975 to 1991.
* Expected 1992 Value
191
-------
Technical Perspectives — Performance and Cost
sumption by 30 percent, and softwood bleaching
costs by Can$7 per tonne of pulp based on the
1978 evaluation (F.C. Munro et al. 1978). The sys-
tem paid for itself in about seven years. The savings
from oxygen delignification for hardwood were
somewhat lower than for softwood. The oxygen
system did not change pulp strength, but pulp vis-
cosity decreased slightly. The oxygen system also
provided the flexibility to produce various grades of
pulp tailor-made to customers' needs.
Extended delignification decreased the bleach-
ing chemical demand by 20 percent (F.C. Munro,
1991). This produced significant savings in the cost
of bleaching chemicals. Extended delignification
resulted in more uniform pulp quality and cleanli-
ness, yet its strength remained equivalent to con-
ventional pulp.
The use of increased chlorine dioxide substitu-
tion also had a positive effect on bleaching costs,
mainly because of savings in caustic. The
economics for high substitution were optimal when
the chlorine dioxide substitution level was 50 per-
cent. The substitution produced equivalent quality
pulp in terms of brightness and strength. Thus, the
three most significant changes made to the
Espanola mill for environmental reasons also
produced other benefits.
The Closed Loop Bleach Plant
Replacing chlorine with chlorine dioxide produces
significant environmental benefits; however,
chlorine dioxide still contains the chlorine atom
and still generates sufficient chlorinated organics
during the bleaching process to prohibit the recy-
cling of bleach plant effluent back to the kraft
recovery cycle. If the mill of the future can com-
pletely remove (or substantially reduce) the
chlorine from the effluent — or bleach without the
use of chlorine or chlorine dioxide — then the
caustic used in the bleach plant could be
recovered. The mill of the future will likely be a
closed cycle operation with a much lower caustic
requirement than is necessary today (see Fig. 2).
These mills will use other nonchlorinated bleach-
ing agents such as oxygen, ozone, hydrogen
peroxide, sodium hydrosulfite, and biologically
produced enzymes.
Some mills are interested in developing
chlorine-free and chlorine dioxide free technology
not only to produce chlorine-free pulp but also to
develop a closed loop bleaching plant. It is con-
ceivable that the caustic recovery and the energy
recovery from the closed loop concept could
generate savings.
Status of the E.B. Eddy Chlorine-free
Development Program
The first step in developing chlorine-free technol-
ogy is to get the kappa number of the pulp to as low
a level as possible while maintaining pulp strength.
The K number of softwood pulp now entering the
bleach plant in Espanola is about eight, which is
Atmospheric
Emissions
t
Chemical
Recovery
NaOH
Na,S
Wood Chips
Pulping
22K#
CL CIO. NaOH NaOCI
1 1 1 1
Chlorine Bleaching
Bleached Pulp
Pulping Uquor 4 *
—-— " Bleachery Effluent to
Biological Treatment
Kraft Process of the Future
Atmospheric « « «.. o
Emissions WoodChips O2 NaOH ?
Chemical
Recovery
NaOH
?
Pulping
16K*
Oxygen
Delignification
9K#
Non-Chlorine
Bleaching
Bleached
Pulp
Pulping & Bleaching
Liquors
Figure 2.—Comparison of the kraft process.
192
-------
C. R. COOK
equivalent to a kappa number of about 11. Ozone
pilot studies are being carried out, and a progres-
sive series of pulp bleaching options are now being
evaluated. Note that all three options are modifica-
tions on the existing sequence OD/CEoHD and all
require that the sodium hypochlorite stage be con-
verted to hydrogen peroxide.
• The first option calls for the expansion of the
chlorine dioxide generation capacity and the
removal of elemental chlorine from the
bleaching sequence by using 100 percent
chlorine dioxide in the first stage. Then, once
the elemental chlorine-free (ECF) grade of
pulp is established, convert to ozone bleach-
ing and develop the TCP pulp one bleaching
line at a time.
• The second option is to convert to ozone
bleaching in the first stage but keep the final
D stage in service thereby producing ele-
mental chlorine-free pulp. The final D stage
would not be converted to a nonchlorinated
compound until after the ozone stage was on
stream and proven.
• The third option is to pursue the chlorine-free
routes that have already been established
using lignox like sequences involving chelat-
ing agents, hydrogen peroxide, and enzyme
treatments.
The ozone bleaching pilot studies (i.e., the in-
vestigation of these options) will continue through
1993 in Espanola in conjunction with Kamyr, Inc.,
and Canadian Liquid Air. The ozone pilot plant is
sized for 5 tonnes per day of low Kappa number,
oxygen-delignified brown stock. It is designed to
test low, medium, and high consistency for both
softwood and hardwood species. The objective is
to build on the laboratory work carried out by the
mill and by the Pulp and Paper Research Institute of
Canada (PAPRICAN), while simultaneously provid-
ing engineering data on the possible construction
of full-scale ozone bleaching equipment.
Each of these options will be evaluated on the
basis of three main criteria: quality, cos's, and their
overall environmental benefits, including energy
use. If the ozone pilot results satisfy the criteria,
then it may not be wise to invest in a new chlorine
dioxide generator but simply to proceed with the
second option. If the ozone pilot results show that
more study is needed, it would be better, perhaps,
to pursue the first option and invest in the chlorine
dioxide generator to produce elemental chlorine-
free pulp (ECF) first. Then, when the ozone studies
are complete, the same "phase-in" approach could
be followed as when the mill introduced oxygen
delignification.
The third option is similar to the lignox se-
quence that has produced the first commercially
available TCP kraft pulps. Some quality and cost
questions still have to be answered, however,
before Espanola could settle on this option.
Conclusion
The objective of the E.B. Eddy Company is to
develop the technological know-how to produce
chlorine-free bleached kraft pulp. The decision to
install the technology will depend on economics,
quality, and environmental benefits. The outcome
of the ozone pilot studies is critical to this evalua-
tion.
In the ideal scenario, totally chlorine-free pulp
will be produced at the same cost as conventional
pulp without sacrificing quality. Experience to date
with oxygen delignification, extended delignifica-
tion, and increased chlorine dioxide substitution
has shown that environmental benefits are possible
while reducing costs and maintaining pulp quality.
The customers' assessment of environmental
friendliness is likely to be guided by the Eco Label-
ing programs now being developed by various
governments around the world. The programs will
require producers to attend to more than the adsor-
bable organic halogens in the mill effluent.
References
Cook, C.R. 1990. Organochlorine discharges from a kraft pulp
mill with oxygen delignification and secondary treatment.
Pulp. Pap. Can 41 (8).
Munro, F.C. 1991. Wash zone modified continuous cooking:
mill experience on softwood. Pacific Pap. Expo.
Munro, F.C. et al. 1978. Mill results of oxygen alkaline delig-
nification. Oxygen Peroxide Pulp. Bleach. Sem. Notes.
Tech. Ass. Pulp. Pap. Insl. Atlanta, GA.
193
-------
The Effects of Alternative Pulping
and Bleaching Processes on
Product Performance — Economic
and Environmental Concerns
Lindsay M. Lancaster
Jean J. Renard
Process Technology
International Paper
Mobile, Alabama
Caifang Yin
Science and Exploratory Development
International Paper
Tuxedo Park, New York
Richard B. Phillips
Process Technology
International Paper
Mobile, Alabama
Effluents from bleached kraft mills that have
been well-treated with primary clarification
and aerobic biological treatment have been
demonstrated in comprehensive, well-controlled,
field tests and commercial practice to create no
measurable adverse effects in the aquatic environ-
ment (Natl. Counc. Air. Stream Improve. 1983,
1985, 1989). Much of regulatory agencies' current
concern arises from studies on untreated mill ef-
fluents that show the levels of dissolved wood
resins and adsorbable organic halogens (AOX) con-
tained in undiluted, untreated effluents can be en-
vironmentally harmful. The regulatory concerns
have become political and aesthetic but not health
issues. Therefore, proposed regulations should take
into account the impact on product quality,
economics, and the competitive position of the in-
dustry in the global marketplace.
This study presents analysis and conclusions on
new and emerging pulping and bleaching tech-
nologies, and how they compare either separately
or in combination, in their relative impacts on
product quality, economics, and reductions in the
environmental parameters AOX, color, chlorinated
phenols, and Microtox® toxicity. The study is in-
tended to provide a basis for making decisions on
how much cost industry — and ultimately the U.S.
public — would bear under different requirements
for effluent quality standards.
While this paper deals with cost and
economics, no one should infer that the U.S. paper
industry "pollutes for profit." The U.S. industry has
an outstanding record of compliance with some of
the most stringent discharge standards in the world.
Where it has been shown scientifically that our dis-
charge could potentially harm the environment, the
industry has taken prompt action to abate the prob-
lem. Environmental spending has exceeded $4 bil-
lion since 1988, or approximately 11 percent of the
industry's total capital investment.
194
-------
LM. LANCASTER, J.J. RENARD, C. YIN, & R.B. PHILLIPS
Methodology
In a presentation at the Nonchlorine Bleaching
Conference, held at Hilton Head, SC, in March
1992, L.M. Lancaster, J.J. Renard, and I evaluated
the impact of implementing elemental chlorine-
free (ECF) and totally chlorine-free (TCP) bleaching
processes on kraft pulps cooked either by conven-
tional means or using extended delignification (ED)
techniques, with and without oxygen delignifica-
tion (OD). The alternative processes, and their
combinations, were evaluated in terms of capital
investment, environmental benefits, and relative
operating costs. Using the model mill as a base for
the U.S. industry, we extrapolated to total industry
cost based on 1990 industry bleached pulp produc-
tion (see Table 1).
The model mill (see Table 2 for detailed
description) used as a basis for the study produces
1,320 air-dried tons per day (ADTPD) of bleached
pulp. It is a two-species mill, making 660 tons per
day hardwood and 660 tons per day softwood,
each on a separate fiber production line. The
bleaching sequence to achieve 86 percent bright-
ness for each line was assumed to have been
recently modified to reduce the formation of
dioxin, using the bleaching sequence:
DsoCoEo+pD for softwood and DsoCoEo+pD for
hardwood, each with 50 percent substitution of
chlorine dioxide for chlorine in the first bleaching
stage.
Capital Costs
The equipment needed to convert the model mill to
each alternative modified process was identified in
terms of
• cooking, washing, screening and cleaning,
and bleaching changes;
• equipment needed to evaporate and burn the
organic solids from the cooking and the non-
chlorine bleaching stages; and
• modifications required to produce the addi-
tional cooking liquor necessary for ED and
OD, where applicable, and to reburn the ad-
ditional lime used in the recausticizing
process.
National industry averages were used for all
costs, including equipment, materials, labor, and
indirect costs.
Recovery plant capacity for the model mill was
assumed to be a variable factor. Oxygen and ex-
tended delignification place a higher demand on
the recovery systems because an additional 5 to 10
percent organic and inorganic load is produced
from greater delignification prior to bleaching (see
Table 3). Three possible situations were analyzed.
1. In the first one, the recovery boiler,
evaporators, caustic plant, and lime kiln
have sufficient capacity to support the
modified systems.
Table 1.—Process options considered to reduce environmental impact of model mill.
EXTENDED
PROCESS OPTION DEUGNIFICATION
Dso-^CoEo+pD
DiooEo+pD
ODiooEo+pD
OZEo+pD
OZEo+pP
[ED]Dso-»CDEofpD
[ED]DiEo+pD
[ED]ODiooEo+pD
[ED]OZEo+pD
[ED]OZEo+pP
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
OXYGEN
DEUGNIFICATION
No
No
Yes
Yes
Yes
No
No
Yes
Yes
Yes
100% CIO2
SUBSTITUTION
No
Yes
Yes
Yes
No
No
Yes
Yes
Yes
No
OZONE
BLEACHING
No
No
No
Yes
Yes
No
No
No
Yes
Yes
ECF
No
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
TCP
No
No
No
No
Yes
No
No
No
No
Yes
Table 2.—Pulp mill process equipment
EQUIPMENT
Hardwood digester
Softwood digester
Hardwood washing
Softwood washing
Hardwood screening
Softwood screening
CIOz generator
Evaporators
Recovery boiler
Caustic plant
Lime kiln
Effluent treatment
DESCRIPTION
One vessel conventional continuous
One vessel conventional continuous
Two-stage atmospheric diffuser
Two-stage atmospheric diffuser
Four-stage open
Four-stage open
R-8 (converted from R-3)
Six-effect
Low odor with stationary firing
Conventional design
(2) conventional rotary kilns
Primary clarifier, conventional ASB
CAPACmr
660 ADTPD
660 ADTPD
660 ADTPD
660 ADTPD
660 ADTPD
660 ADTPD
30 TPD CI02
840,000 #/HR
1.200B&WTPD
550,000 #/HR
420 TPD CaO
8-day lagoon
195
-------
Technical Perspectives — Performance and Cost
Table 3.—Recovery system loadings from process modifications.
WITH ED
PROCESS AREA
Evaporators, #/Hr
Recovery boiler,
#BLS/Hr
White liquor, #/Hr
Lime kiln, TPD
CaO
BASE CASE
703,000
161,900
464,600
352
VALUE
729,000
168,000
464,600
374
INCREASE
3.7%
3.8%
5.3%
6.4%
wrmoo
VALUE
733,000
169.000
489,200
368
INCREASE
4.3%
4.4%
4.6%
4.7%
WITH ED AND OD
VALUE
751,000
173,100
510,000
390
INCREASE
6.8%
6.9%
9.8%
10.8%
Table 4.—Capital cost estimate for OD-iooEo+pD.
PROCESS AREA
Knotting and screening
Oxygen delignification
Evaporators
Recovery boiler
Caustic plant
Total
NO UPGRADE
$18,400
37,700
0
0
0
$56,100
CAPITAL COSTS ($000)
MINOR UPGRADE
$18,400
37,700
8,700
21,800
2,200
$88,800
MAJOR UPGRADE
$18,400
37.700
24.500
78,100
8,700
$167,400
2. Sufficient capacity is not there, but the sup-
port systems can be upgraded incrementally
at modest cost to achieve the requirements
of the modified process.
3. The age, the inadequacy of the equipment
capacity even with upgrade, or the
economic equation dictates that the equip-
ment be replaced with totally new units.
To account for the variable composition of the
U.S. industry, for this analysis we assumed that
one-third of U.S. mills would be able to install
ozone (Z), OD, or ED without additional invest-
ment; one-third would require some investment to
upgrade the capacity of the existing systems; and
one-third would require completely new systems
for evaporation, caustic plant and lime kiln, and
recovery boiler. Table 4 shows an example calcula-
tion of the capital cost to convert the model mill to
an ODiooEo+pD process. Our three process
recovery conditions would cost $56.1 million,
$88.8 million, and $167.4 million, respectively.
From the mixed investment requirements for
recovery cycle upgrades, we calculated an average
capital of $104.1 million for the model mill.
Operating Cost
Relevant operating costs for each option were es-
timated, considering operating labor and materials
Table 5.—Operating cost estimate for OD-iooEo+pD.
estimates, maintenance, utilities, and bleaching
chemicals, based on industry averages or
laboratory extrapolations. Table 5 shows an ex-
ample calculation of the operating cost increases of
the ODiooEo+pD process, for each of the three
cases of recovery process requirements. Note the
chemical and utility costs are the same for each of
the cases, but labor and materials vary because
they are estimated as a function of the capital cost.
From this, assuming the same mixed investment re-
quirements as with the Capital Cost section, we cal-
culated an average annual cost increase of $1.26
million for this particular process modification.
Environmental Impact
Based on our own and published mill studies, as
well as laboratory work, including biotreatment
simulation, the impact of each option on discharge
of color, adsorbable organic halogens, and
chlorinated phenolics (expressed as pen-
tachlorophenol equivalents) in biologically treated
mill effluent was estimated. Table 6 collects the
results of the estimated reduction or increase in
each component, when compared with the model
mill. Table 6 also summarizes the capital invest-
ment and the operating cost changes for both the
model mill Base Case and each alternative process
considered. The cost of capital on a per-ton basis
was calculated by the formula:
NET OPERATING COSTS ($000/YEAR)
NET OPERATING COSTS ($000)
NO UPDRAGE
MINOR UPGRADE
MAJOR UPGRADE
Chemicals
Labor
Materials
Utilities
Total
($2.213)
561
224
2,019
$591
($2,213)
888
355
2.019
$1.049
($2.213)
1.674
670
2,019
$2.150
196
-------
LM. LANCASTER, JJ. RENARD, C. YIN, & R.B. PHILLIPS
Table 6. — Cost and environmental
PROCESS OPTION
D5o->CoEo+pD
DiooEo+pD
ODiooEofpD
OZEo+pD
OZEo+pP
[ED]Dso-»CDEcH-pD
[ED]DiooEo+pD
[ED]ODiooEo+pD
[ED]OZEo+pD
[ED]OZEo+pP
CAPITAL COST
($MM)
Base
$18.8
$104.1
$144.3
$144.3
$4.9
$23.7
$109.0
$149.2
$149.2
Impact of process modifications.
OPERATING
COST (J/ADT)
Base
$9.23
$2.73
-$3.73
$13.72
-$6.19
$2.84
$0.61
-$4.88
$12.78
TOTAL
COST ($/ADT)
Base
$13.37
$25.68
$28.08
$45.54
-$5.11
$8.07
$24.64
$28.01
$45.67
%AOX
REDUCTION
Base
67.3
81.1
96.1
96.1
20.3
72.8
85.0
96.9
100.0
%CHLOR/PHENOL
REDUCTION
Base
92.6
95.7
100.0
100.0
19.7
94.1
96.6
100.0
100.0
% COLOR
REDUCTION
Base
30.5
85.1
99.1
99.6
19.9
44.4
88.0
99.1
99.6
Cost of Capital = (I X r)/[1 -(1 +r)'"]
where:
I = the original capital investment
r = the discount rate (8 percent in all cases), and
n = the number of years in the project life (20
years in all cases)
Additional study was conducted on the
Microtox® toxicity of selected process effluents,
and will be discussed later.
Product Quality
In all cases, the selected process modifications
were capable of achieving comparable bleached
pulp brightness and cleanliness. No consideration
was given to decreasing product quality. In the case
of the processes containing ozone bleaching, a
small increment of capital was employed to add a
five-stage hydrocyclonic pulp cleaning system and
a decker/thickener to remove the additional un-
bleached particles anticipated for commercial
practice, based on our laboratory simulations of
this developing process.
With ozone-containing sequences, only com-
mercial application will prove if strength and stiff-
ness comparable to today's high standards can be
achieved. Most laboratory evaluation of pulp entail
a gross examination of major parameters, such as
tensile and tear. As cooking in the digester, and as
oxygen bleaching are pushed to lower lignin con-
tents, subtle differences in fiber properties appear,
and have been found to result in a loss of bending
stiffness that cannot always be recovered by paper-
making techniques.
Discussion
Cost/Effectiveness of Alternative
Processes
The total cost increase per bleached air-dried ton of
production (i.e., cost of capital plus cost of labor,
energy, and materials), as a function of the
projected levels of adsorbable organic halogens,
color, and chlorinated phenols for each alternative
process considered, is depicted in Figures 1 to 3.
Because each bleaching processes is considered
with and without extended delignification, the
specific benefit of this particular change is easily
recognized in reduced cost and effluent pollutant
discharge.
Extended delignification (ED) is a relatively
low-cost modification of a continuous digester that
permits multiple additions of cooking chemicals,
and allows a longer, generally lower temperature
cook in which the extent of delignification
proceeds past the normal level. In conventional
cooking, softwood and hardwood are normally
cooked to kappa numbers 30 and 18, respectively,
but in extended deliginification, this can be
prolonged to kappa numbers of 24 and 14.5
without the normal loss of pulp strength and yield
in the conventional cooking process. We estimated
the cost of converting the two model mill con-
tinuous digesters to ED at $4.9 million, assuming
that no modifications to the recovery cycle are re-
quired to support the additional alkali or recover
the additional organic material.
Similar opportunities do not exist for inexpen-
sively retrofitting batch digesters, which require
more extensive equipment modifications and addi-
tions to carry out ED. For new digester systems,
batch extended delignification is quite competitive
with continuous systems.
Application of ED to the base case bleaching
process of DsoCoEo+pD resulted in an operating
cost reduction of $6.19 per air-dried ton, against
the capital investment of $4.9 million, and
produces approximately 20 percent reductions in
color, AOX, and chlorinated phenols. Of the
processes studied, ED is the only modification that
appears to have economic merit and the ability to
reduce the levels of pollutant discharge.
With the exception of OZEo+pD, with and
without extended delignification, all other process
options added operating cost to the model mill. In
197
-------
Technical Perspectives — Performance and Cost
AOX IN EFFLUENT, KG/ADT
Figure 1.— Cost/benefit for AOX reduction.
[EDJOZED
[ED]OD E D
1 *
..
•;•;
(10)
0 5 10 15 20 25
CHLORINATED PHENOLS IN EFFLUENT (G/ADT)
Figure 2.—Cost/benefit for chlorinated phenols reduction.
198
-------
L.M. LANCASTER, JJ. RENARD, C. YIN, & R.B. PHILLIPS
10
(10)
o
D E D
100 O+p
D—c E D
SO D o*p
[ED]D--CnE D
1 ' SO D o*p
0 5 10 15 20
COLOR IN EFFLUENT (KG/ADT)
Figure 3.—Cost/benefit for color removal.
25
the case of OZEo+pD, the average mill capital re-
quirement of $144.3 million leads to a highly un-
favorable overall financial investment. In fact, the
only process modification examined that was
worse from a financial perspective is the TCP se-
quence OZEo+pP process.
Given that all options are unfavorable finan-
cially, it becomes critical to determine which op-
tions yield the largest reductions in the pollution
parameters under discussion per unit of cost. Each
process modification affects specific environmental
parameters in a different fashion, and thus each are
discussed separately.
A OX Levels Follow Predictable Trend
The levels of adsorbable organic halogens
produced by the various processes are a function of
the pulp lignin content entering the chlorine-con-
taining bleaching stage, the ratio of elemental
chlorine to chlorine dioxide, the ratio of active
chlorine chemicals to pulp lignin content (chlorina-
tion factor) and the degree of waste treatment. AOX
levels follow a predictable trend:
Base Case > 100% Substitution > ED >
Oxygen Damnification > Ozone Damnification.
AOX has never been shown to be a measure of
any environmental parameter of significance, and
its only virtue is that the test is easy to run. AOX ig-
nores the scientific reality that not all organic
chlorides are equally toxic, and that they are only
toxic when present in amounts sufficient to create
toxic effects. An indiscriminate parameter such as
AOX is not of value in a discussion of health or en-
vironmental impacts. Nevertheless, the U.S. in-
dustry has reduced AOX levels by approximately
30 percent in the past four years, largely as a result
of modifications made to reduce dioxin levels.
Table 7 shows that the direct operating cost plus the
cost of capital (Total Cost) for putting into service
the TCP process OZEo+pP would be $31.3t for
each kilogram of AOX eliminated.
If AOX can be shown to be an important
parameter to reduce, a 73 percent reduction could
be achieved at much lower cost ($23.7 million ver-
sus $144.3 million) by adopting the
[ED]DiooEo+pD modification. In fact, the cost of
AOX removal to go from [ED]DiooEo+pD to
OZEo+pP is $93.68 per incremental kg AOX
removed.
The key question from the regulatory point of
view is to determine scientifically the adverse im-
pacts, if any, on human health and aquatic life at
different levels of AOX discharge within the range
produced by these process options. If there are
none, then determine what cost penalties regu-
199
-------
Technical Perspectives — Performance and Cost
Table 7.—Cost effectiveness of AOX removal.
PROCESS OPTION
DSO-+CDEO+PD
DiooEotpD
ODiooEo+pD
OZEo+pD
OZEo+pP
[ED]Dso-*CDEo+pD
[ED]DiooEo+pD
[ED]ODiooEo+pD
[ED]OZEo+pD
[ED]OZEo+pP
CAPITAL COST
($MM)
Base
$18.8
$104.1
$144.3
$144.3
$4.9
$23.7
$109.0
$149.2
$149.2
OPERATING COST
(S/ADT)
Base
$9.23
$2.73
-$3.73
$13.72
-$6.19
$2.84
$0.61
-$4.88
$12.78
TOTAL COST
(S/ADT)
Base
$13.37
$25.68
$28.08
$45.54
-$5.11
$8.07
$24.64
$28.01
$45.67
EFFLUENT AOX
(Kg/ADT)
1.45
0.48
0.28
0.06
0.00
1.16
0.40
0.22
0.05
0.00
Kg AOX
REDUCTION
Base
0.98
1.18
1.40
1.45
0.30
1.06
1.24
1.41
1.45
$/KgAOX
REDUCTION
Base
$13.65
$21.77
$20.09
$31.31
-$17.31
$7.62
$19.93
$19.88
$31.40
lators will require from industry to achieve no
measurable benefit.
Chlorinated Phenols
To date, more than 700 naturally produced organic
chloride compounds have been characterized
(Neidelman and Geigert, 1986), derived by natural
reactions of bacteria, fungi, algae, and higher
plants and animals. A. Grimvall and his co-workers
extensively studied the production of organic chlor-
ide compounds by naturally produced chloroper-
oxidase enzymes, and found significant quantities
of 2,4,6-trichlorophenol produced in peat bogs
(Grimvall et al. 1989; Asplund et al. 1989, 1990;
Hodin et al. 1990). Few chlorinated phenols have
been characterized as toxic to humans or marine
life, and then only at very high levels.
Working under contract for the Ontario Minis-
try of the Environment, McKee et al. (1984) derived
no effect concentrations (NOEC) for fish (acute and
chronic toxicity) and plants for the most common
categories of chlorinated phenols found in in-
dustrial and municipal wastewaters. In all cases,
the NOEC levels were safely above the concentra-
tions typically found in treated mill effluents, even
before dilution with a receiving stream takes place
(Fig. 4 has been constructed to show the contrast).
When these results are coupled with other,
similar characterizations of aquatic impacts and
bioconcentration factors of chlorinated phenolics
10ppb
CD
0.
0.
UJ
D
_l
U.
U.
UJ
o
UJ
UJ
DC
O
UJ
o
z
o
o
1ppb -
100 ppt —
10ppt
MONOCHLOROPHENOLS
40%CIO2SUB
100% CIO2 SUB
TflfCHLOROPHENOLS
TETRACHLOROPHENOLS
DICHLOROPHENOLS
PENTACHLOROPHENOLS
CHLOROPHENOLS
Figure 4.—Comparison of bleached kraft mill effluents with no-effect concentrations.
200
-------
LM. LANCASTER,].]. RENARD, C. YIN, & R.B. PHILLIPS
(McLeay, 1987; Slusaczuk, et al. in press; Yin and
Rabmo, 1992), one must conclude that neither the
quantities of chlorinated phenols from treated ef-
fluents of bleached kraft pulp mills, nor the levels of
chlorinated phenols conceivably bioaccumulated
in fish or through the food chain, are sufficient to
cause environmental concern. The two NCASI
stream studies carried out in well-controlled stream
conditions, reported elevated chlorinated phenol
concentrations in fish tissue, but no effect on the
rainbow trout in terms of numbers, mean weight, or
survival. No effects were found in terms of lesions,
growth, and sexual maturation of individuals ex-
posed as juveniles. Spawning, egg hatching, and
larval development were all comparable to control
streams. It should be pointed out that these studies
were carried out in the early 1980s, before bleach-
ing changes to reduce dioxin were implemented.
As shown in Table 8, in the base case, ap-
proximately 20 grams per air-dried ton chlorinated
phenols are estimated present in treated effluent,
comprising approximately 0.1 percent of the total
AOX. Although this level of discharge is well below
the no effect concentration, the quantity can be
reduced by 93 percent to 1.5 grams per air-dried
ton in the model mill by investing in additional
CIO2 capacity at a cost of $18.8 million, and
changing the bleaching process to DiooEo+pD.
The cost of this process change equates to $0.71
per gram chlorinated phenols removed per air-
dried ton of pulp over the 20-year project lifetime.
To remove the last 1.5 grams per ton in the dis-
charge would require going all the way to TCP
processes, resulting in a cost of $27.45 per in-
cremental gram per air-dried ton decrease in
chlorinated phenols. Such an expenditure is un-
warranted given the absence of adverse effects and
environmental significance at current discharge
levels.
Color
The color of effluent discharged from bleached
kraft mills is largely due to high molecular weight
lignins which have been chemically modified by
either the pulping process or the bleaching process.
This effluent color is totally unrelated to AOX,
BOD, effluent toxicity, or chlorinated phenols. In
some instances, where little or no dilution of
bleach plant effluent is available, color can con-
tribute to reduced aquatic flora by blocking sun-
light (Cove, 1980). But no other environmental
impact has been documented. The color of rivers
with high loadings of bleach plant effluent can
show little or no change, depending on the load of
colored material in the upstream reaches. The color
of river water upstream of mills is frequently due to
chemical compounds of humic acid origin, derived
from decay of wood and plants and chemically
similar to the lignin compounds concentrated in
bleach plant effluent. Of all the environmental
parameters under discussion, color is an issue dis-
tinctly aesthetic in character.
As with the other parameters, production of
color is a function of the lignin content of the pulp
entering the chlorine-containing bleach stage, and
generally follows the same order of process effect
as found with AOX.
Table 9 shows that the costs of color reduction
are high, requiring $0.95 per kg employing the
[ED]DiooEo+pD option to achieve nearly 50 per-
cent reduction, or $2.39 per kg using the OZEo+pP
process to virtually eliminate color from effluent.
By adding ED to the model mill base case bleach-
ing sequence of DsoCoEo+pD, a 20 percent reduc-
tion in color can be achieved with a cost savings.
Toxicity
Many of the recent National Pollutant Discharge
Elimination System (NPDES) permits have required
that treated mill effluents diluted to representative
concentrations be tested with Ceriodaphnia dubia
(water fleas) and Pimephales promelas (fathead
minnow). Recently, the Microtox® test developed
by the Microbics Corporation has found wider use
(Johnson et al. 1991; Swedish Environ. Prot. Agen-
cy, 1990). The Microtox® test measures the toxicity
Table 8.—Cost effectiveness of chlorinated phenol removal.
PROCESS OPTION
Dso->CDEo+pD
DiooEo+pD
ODiooEo+pD
OZEo+pD
OZEo+pP
[ED]D5o->CoEofpD
[ED]DiooEo+pD
[ED]ODiooEo+pD
[ED]OZE0+pD
ED]OZEo+pP
CAPITAL COST
($MM)
Base
$18.8
$104.1
$144.3
$144.3
$4.9
$23.7
$109.0
$149.2
$149.2
OPERATING COST
($/ADT)
Base
$9.23
$2.73
-$3.73
$13.72
-$6.19
$2.84
$0.61
-$4.88
$12.78
TOTAL COST
($/ADT)
Base
$13.37
$25.68
$28.08
$45.54
-45.11
$8.07
$24.64
$28.01
$45.67
EFFLUENT Cl
PHENOL (9/ADT)
20.30
1.50
0.86
0.00
0.00
16.30
1.20
0.68
0.00
0.00
8/ADT Cl PHENOL
REDUCTION
Base
18.80
19.43
20.30
20.30
4.00
19.09
19.61
20.30
20.30
$/Q Cl PHENOL
REDUCTION
Base
$0.71
$1.32
$1.38
$2.24
-$1.28
$0.42
$1.26
$1.38
$2.25
201
-------
Technical Perspectives — Performance and Cost
Table 9.—Cost effectiveness of color removal.
PROCESS OPTION
Dso-^CoEo+pD
DiooEcH-pD
ODiooEc*pD
OZEo+pD
OZEo+pP
[ED]Dso-»CDEo+pD
[EDJDiooEo+pD
[ED]ODiooEo+pD
[ED]OZEo+pD
[ED]OZEo+pP
CAPrTALCOST
($MM)
Base
$18.8
$104.1
$144.3
$144.3
$4.9
$23.7
$109.0
$149.2
$149.2
OPERATING COST
(VADT)
Base
$9.23
$2.73
-$3.73
$13.72
-$6.19
$2.84
$0.61
-$4.88
$12.78
TOTAL COST
(S/ADT)
Base
$13.37
$25.68
$28.08
$45.54
-$5.11
$8.07
$24.64
$28.01
$45.67
EFFLUENT COLOR
(Kg/ADT)
19.16
13.31
2.86
0.16
0.08
15.34
10.65
2.29
0.16
0.08
Kg/ADT COLOR
REDUCTION
Base
5.85
16.30
19.00
19.08
3.82
8.51
16.87
19.00
19.08
$/Kg COLOR
REDUCTION
Base
$2.29
$1.58
$1.48
$2.39
-$1.34
$0.95
$1.46
$1.47
$2.39
toward the luminescent bacteria Photobacterium
phosporeum. When these organisms are exposed
to and come in contact with a toxicant, the toxicant
interferes with their metabolic pathway and at-
tenuates their light transmission in proportion to the
toxicity level of the toxicant. Microtox® toxicity is
expressed as ECso (extinction coefficient), which
indicates the concentration of the toxicant required
to reduce 50 percent of the light output. The test is
quick, cheap, easy, reproducible and, in some
cases, more sensitive to toxicants than the com-
monly used fish and other organisms.
The process modifications considered for the
model mill significantly decrease the original for-
mation of potentially toxic compounds from pulp-
ing and bleaching operations, and also have a
positive impact on the ability of biotreatment sys-
tems to remove effluent toxicity as well as oxygen
demanding material and organic chlorides. The en-
hancement of biotreatability is attributable to the
decreased average molecular weight and degree of
chlorination, and the increase in the oxidative state
of the organic materials in the effluent. Increasing
chlorine dioxide substitution preferentially elim-
inates polychlorinated species in effluents (Fig. 5)
and yields organic chloride products that are more
amenable to biotreatment than conventional
bleaching processes. None of the concentrations of
chlorinated phenols, however, approach levels that
have been found to have effects in acute and
chronic toxicity tests.
The products of totally chlorine free bleached
pulps have not been extensively characterized, but
a comparison of Microtox® toxicity of effluents
m
QL
o.
1,000
500 F-
HI
<
rr
in
o
O
o
CHLORINATED PHENOLS
Untreated Treated
Figure 5. — Effect of chlorine dioxide substitution on biotreatment of chlorinated phenols.
202
-------
L.M. LANCASTER, J.J. RENARD, C. YIN, & R.B. PHILLIPS
from DiooEo+pD and EoZEZ effluents show that
the TCP effluent is more toxic than the 100 percent
chlorine dioxide process effluent before simulated
biotreatment, and some residual toxicity remained
after biotreatment for the TCP process (Fig. 6). We
can be confident that toxicity is completely
removed by biotreatment in the case of Di ooEo+pD
effluent, but sufficient data do not exist to reach the
same conclusion for TCP bleaching effluent, which
contains numerous new anthropogenic com-
pounds of an unknown nature.
o 4
o
X
O
E ZEZ
o
1CXT o+pC
BLEACHING SEQUENCE
Figure 6.—Toxicity of TCP and chlorine dioxide bleach-
ing effluents.
These results are not particularly surprising,
since most toxicity associated with untreated ef-
fluents is from resin acids derived from the wood
and is associated with the cooking and not the
bleaching process. By the Microtox test, only 10
percent of the toxicity of untreated bleached kraft
mill effluent in a modern mill originates with
bleaching, while the remainder is due to the pulp
mill. Chlorinated phenolics of bleaching origin
contribute less than 1 percent of the toxicity of un-
treated combined bleached kraft mill effluent. One
can speculate that chlorine dioxide is a powerful
oxidant which neutralizes the toxic effect of the
wood resins; the TCP process relies on ozone,
which is also a powerful oxidant but apparently not
an effective one on resinous materials.
Cost of Implementing
Reduced-chlorine Bleaching
To extrapolate the results of the model mill calcula-
tions to all U.S. industry, we multiplied the capital
requirement for the 1,200 tons per day (TPD) mill
by the total U.S. industry annual production
divided by the annual production from the model
mill. For example, to arrive at the total U.S. industry
requirement to implement ODiooEo+pD, the
average mill requirement for 1,320 ADT/day
capacity, shown earlier to be $10.4 million, is mul-
tiplied by the ratio of total annual industry tons to
total model mill tons:
104,100,000 X-
Total Industry Capital =
30,690,000 AD lon%<>ar
$1,320 AD ton%ay X
= $6,915,200,000
Table 10 collects the results of the correspond-
ing calculations for each of the other process
changes considered in this study. A range of in-
dustry capital costs, from $325.5 million for im-
plementing ED at each of 105 bleach mills, to $9.6
billion to convert all mills to TCP.
The model's accuracy is unknown, although
we have found that it predicts well both the capital
cost and the operating cost impacts we have es-
timated individually for each of the 11 International
Paper bleached pulp mills. Uncertainty over the
status of existing mills that have already imple-
mented one or more of the process modifications
could lead to inaccuracies in the industry model,
however. Most likely, the number of mills that have
progressed past the technology of the base case is
equal to the number of mills that are not yet at the
base case.
The accuracy of the estimating model is less ac-
curate for any single mill, depending mainly on
how closely it resembles the model mill. Since the
model mill represents the average U.S. mill, the
larger the sample size of facilities being estimated,
the more accurate the model will be. As mentioned
in the discussion of extended delignification, the
technology is more expensive to implement in a
batch digester system than a continuous system. In
that regard, then, the industry cost of implementing
ED must be considered to be understated.
Our analysis assumes that the cost of bleaching
chemicals will remain at present levels. Undoub-
tedly, this assumption understates the cost of sup-
plying caustic soda, a chemical commonly
coproduced at 1.1:1 ratio with elemental chlorine
in an electrochemical process. Imbalances in
demand for caustic without chlorine could create
severe shortages of the former, and result in price
dislocations. To the extent this occurs, this analysis
has understated the industry cost to eliminate
elemental chlorine from the bleaching process.
The analysis assumed that the yield of pulp
from wood for the modified processes is equal to
the yield of pulp from the base case process. Yet,
our laboratory studies consistently show a lower
yield, especially through the use of ED and OD.
203
-------
Technical Perspectives — Performance and Cost
Table 10.—Total U.S. paper Industry costs for modified pulping and bleaching processes.
MODEL MILL
TOTAL INDUSTRY
PROCESS OPTION
Dso-^CoEo+pD
DiooEo+pD
ODiooEo+pD
OZEo+pD
OZEo+pP
[ED]D50->CoEcH-pD
[ED]DiooEcH-pD
[ED]ODiooEo+pD
[ED]OZEo+pD
[ED]OZEo+pP
CAPITAL COST
($MM)
Base
$18.8
$104.1
$144.3
$144.3
$4.9
$23.7
$109.0
$149.2
$149.2
OPERATING COST
(VADT)
Base
$9.23
$2.73
-$3.73
$13.72
-$6.19
$2.84
$0.61
-$4.88
$12.78
TOTAL COST
(S/ADT)
Base
$13.37
$25.68
$28.08
$45.54
-$5.11
$8.07
$24.64
$28.01
$45.67
CAPITAL COST
($BB)
Base
$1.249
$6.915
$9.586
$9.586
$0.325
$1.574
$7.241
$9.911
$9.911
OPERATING COST
($MM/Y)
Base
$283.1
$83.9
-$114.5
$421.2
-$190.1
$87.3
$18.8
-$149.8
$392.1
NPV@8%
($BB)
Base
($2.544)
($5.394)
($6.124)
($9.267)
$883.5
($1.628)
($5.241)
($6.145)
($9.327)
Again, more accurate information on this factor
may cause the industrywide cost estimates to be
understated. There are no provisions in our analysis
to financially write off the investments many mills
have recently made to increase use of chlorine
dioxide. This would understate the projection
made here on the cost of going to TCP.
The cost of electricity assumed for this study is
$50 per megawatt hour, a reasonable average cost,
but subject to substantial regional variation, and
subject to .above-average future escalation for the
electricity-intensive ozone bleaching process. Our
laboratory simulations of TCP bleaching processes
show a consistent tendency toward lower pulp
strength. Although not factored into this analysis, if
this deficit is found in commercial operation, an in-
crease in higher cost softwood pulp use could
result. This analysis is a snapshot of the industry's
state-of-the-art processes.
One should anticipate improvements in the use
of chlorine-containing compounds, just as we have
experienced in recent years. At the same time, we
can also anticipate advancements in the use of
ozone, and, especially, of peroxide. However
quick those improvements come, however, they
must be accompanied by low cost methods to
process the extra load of organic and inorganic
solids through the recovery system, or otherwise
the capital cost penalties will remain high. One
should not overlook the probability that waste
treatment technology will improve, as enzymes
and bacterial colonies are developed with specific
ability to dechlorinate organic matter.
• Implications for New Pulp Mills. A number of
the penalties projected here for reducing the use of
chlorine and chlorine dioxide would not be ap-
plicable to new mill designs to the same extent.
Extra capital costs would be incurred for having to
construct larger units of process equipment to
handle the 5 to 10 percent increases in loadings of
evaporators, recovery boilers, caustic plant, and
lime kiln. But smaller waste treatment plants could
be built in the case where no chlorine-containing
compounds were used. Papermill effluent, typically
high in biological oxygen demand (BOD) loadings,
would still require some form of biological treat-
ment. The [ED]OZEo+pD process shows particular
promise for new mill application, because operat-
ing costs are actually decreased over the base case
process assumed in this study. As industrial ex-
perience with high consistency and medium con-
sistency ozone bleaching processes is gained, new
pulp mill investments might well be designed after
the models that are currently in early stages of
development.
• Implications for Regulations. Historically, the
U.S. Environmental Protection Agency (EPA) has
based its rules on minimizing the impact that in-
dustrial processes have on the external environ-
ment. The Agency factors in the applicable science
to identify true adverse impacts, and considers
economics — with the understanding that all in-
dustries must balance capital spending to meet
their entire spectrum of obligations, which include
worker safety, environmental regulations, customer
demands for quality improvements, maintenance
of existing equipment, and replacement of worn or
obsolete units. If some money is left over, it's not a
bad idea to spend it to improve productivity and
remain globally competitive.
The scientific literature reports no adverse im-
pacts from well-treated, bleached kraft effluents
and points to dissolved wood resins, not adsor-
bable organic halogens, as the greatest contributor
to the potential toxicity of untreated effluents. The
EPA might well consider tightening the design
standards for waste treatment plants and spill col-
lections systems. There is no basis for rules that cur-
tail the use of elemental chlorine or chlorine
dioxide, provided that the user can demonstrate
through field studies the continued absence of ad-
verse environmental impacts.
204
-------
L.M. LANCASTER, J.J. RENARD, C. YIN, & R.B. PHILLIPS
References
Asplund, C., A. Grimvall, and C. Petersson. 1989. Naturally
produced adsorbable organic halogens (AOX) in humic
substances from soil and water. Sci. Total Environ.
81/82:239-48.
Asplund, C., H. Boren, U. Caralsson, and A. Grimvall. 1990.
Pages 475-83 in B. Allard et al. eds. Humic Substances in
the Aquatic and Terrestrial Environment. Springer Verlag.
Berlin, Germany.
Cove, G.W. 1980. Pulp and paper industry wastewater
management. Water Pollut. Control Fed. 52(6):1386.
Grimvall, A. et al. 1989. Organic halogens in unpolluted waters
and larger bodies of waters receiving bleach plant ef-
fluents. Tappi J. 74(5):197-203.
Hodin, F., H. Boren, A. Grimvall, and S. Karlsson. 1990. Forma-
tion of chlorophenols and related compounds in natural
and technical chlorination processes. In Proc. 3rd IAWPRC
Conf. Forest Indus. Wastewaters, June 5-8,1990. Tampere,
Finland.
Johnson, I. and R. Butler. 1991. Papermill effluents — a move to
toxicity-based consents. Pap. Tech. 32{6):21.
Lancaster, L.M., J.J. Renard, and R.B. Phillips. 1992. The
economic impact of implementing chlorine-free and
chlorine compound-free bleaching processes. In Proc.
Nonchlorine Bleaching Conf., March 2-5, 1992, Hilton
Head, SC.
McKee, P.M., R.P. Scroggins, and D.M. Casson. 1984.
Chlorinated Phenols in the Aquatic Environment. Ont.
Ministry Environ. Water Resour. Branch. Ontario, Canada.
McLeay, D.J. 1987. Aquatic toxicity of pulp and paper mill ef-
fluent: a review. Rep. EPS 4/PF/1. Environ. Can. Ottowa,
Ontario, Canada.
National Council for Air and Stream Improvements. 1983. Ef-
fects of biologically stabilized bleached kraft effluent on
warm water stream productivity in experimental streams.
NCASI Tech. Bull. 414. New York, NY.
. 1985. Effects of biologically treated bleached kraft ef-
fluent on cold water stream productivity in experimental
stream channels. NCASI Tech. Bull 474. New York, NY.
. 1989. A Report of the Scientific Panel on Pulping Ef-
fluents in the Aquatic Environment. Special Report 89-08.
New York, NY.
Neidelman, S.K., and J. Geigert. 1986. Biohalogenation, Prin-
ciples, Basic Roles and Applications. Ellis Horwood, Div.
John Wiley. New York, NY.
Slusarczuk, G.M.J., E. Tuznik, and H.P.M. Fromaget. 1992.
Studies of Bioloxicity of Bleach Plant Effluents. Int. Paper
Internal Rep. 92.092. Tuxedo, NY.
Swedish Environmental Protection Agency. 1990. Biological-
chemical Characterization of Industrial Wastewater. ISBN
91-620-1071-9. Solna, Sweden.
Yin, C.F. and S.V. Rabmo. 1992. Chlorine Dioxide Bleaching: Its
Effluent Quality and Biotreatability. Int. Paper Internal Rep.
92.092. Tuxedo, NY.
205
-------
Panel 3:
Technical Perspectives
Performance and Cost
Question and Answer Session
m John Clement, Babcock & Wilcox: I have a ques-
tion for Neil McCubbin. You talked about Miller
Western operating with zero effluent, would you
comment on what they do with the smelt coming
out of the recovery boiler?
• Nell McCubbin, McCubbin Consultants, Inc.:
They have, I believe, the smallest smelt recovery
boiler in the world, certainly the smallest built in
recent years. It's built like a kraft boiler, but remem-
ber there's no sulphur in the process, so the smelt is
molten sodium carbonate, which they solidify and
store. One option is to sell it to a kraft mill. I suspect
that's a good option, since alkalies are becoming
more expensive, and they have it available. They're
considering more seriously, however, the idea of
putting in a small system to recover the sodium
hydroxide using the classic kraft technology. Of
course, they have some solid waste to landfill. Zero
effluent is zero-piped-to-the-river, but they have the
normal sort of solid waste garbage and sludge.
• John Clement: Could you say that right now
they've got 100 percent blow down of the sodium
chemicals from the black liquor?
• Neil McCubbin: That's correct. If I were Miller
Western, I would look very hard at selling that stuff
rather than recycling it. They say there's nothing in
it that wouldn't recycle, but that's a worry. I'd rather
get it out of the way. We'll see whet they do. As I
said before, they have many smart people on site;
they'll find a good answer.
• Med Byrd, North Carolina State University: My
question is for those of you who have been trying to
develop a model for these different options. When
you get into the completely closed option, and
you're totally chlorine-free, and all effluents can be
recycled back to recovery, do your cost estimates
include some way of removing the ions, the power-
ful metals that build up in the system? Is that tech-
nology available?
• Richard Phillips, International Paper: I can tell
you how we handle that. We don't know of any
kidney technology that is available to demetalize
either effluent or pulp. What we assume is that a
chelating stage in the process can serve to remove
metals prior to the ozone peroxide. I think this
process is necessary to give reasonable efficiency,
and it is included in the cost. I didn't say that we
were effluent-free in our model. I simply said that
we were totally chlorine-compound free.
• Roger Cook, E.B. Eddy Forest Products Ltd.: We
are running a five tons per day ozone pilot plant at
the moment in Espanola. It's a Kamyr pilot plant.
We're also working in conjunction with Canadian
Liquid Air, so we're focusing on the ozone bleach-
ing side of things. So far our work on how to com-
plete the recycle hasn't been done. In fact, that's
why I have no real data on the ozone system. We're
going to have to wait until November when our
technical people present the results of their work at
the TAPPI pulping conference.
• Nell McCubbin: My comments on zero effluent
did not include any cost estimates, because I don't
think anyone can make accurate estimates right
now. The metals are obviously a concern. One
thing to notice is that Meadow Lake has been run-
206
-------
QUESTION & ANSWER SESSION
ning since February without any discharge and al-
though it's not a kraft mill they did have roughly the
same metals problem — perhaps worse, because
they rely on peroxide bleaching. They're using the
same wood, and the metals come in the wood. I
suspect you'd also find a lot of metals in kraft mills'
effluents. This what I meant when I said that getting
rid of chlorines is not the whole answer. It's a big
chunk. But then the fun will begin.
• Med Byrd: That's part of the problem. If you do
not have a chelating stage, where is it? And if you
chelate, where does the filter from the chelate go? It
has got to go somewhere, either with the pulp
you're selling or into some technology to fix it.
Given its volume and the dilutions that would be
necessary, won't this be a major, hefty cost right
there?
• Ann Hlllyer, West Coast Environmental Law: I
have some questions for Neil. You mentioned that if
a kraft mill goes to zero effluent, you wouldn't ex-
pect a large increase in energy consumption. I've
been told by process engineers that Meadow Lake
mills increased their energy consumption consider-
ably when they closed the loop. Is the difference
that the kraft process is generating its own energy
and will continue to do so with the recovered ef-
fluent?
• Neil McCubbln: Well, that's one factor. But
remember Meadow Lake evaporates and con-
centrates about 11 cubic meters of effluent per ton,
which is is roughly the amount of black liquor in
the kraft. Kraft mills are already doing that.
Meadow Lake is doing that evaporation in addition
to what a normal bleached chemithermomechani-
cal mill would do. Remember, too, when people
look at the energy, they probably aren't counting
the cost of manufacturing the chlorine off-site.
• Ann Hlllyer: My second question was in relation
to incinerating or putting the recycled effluent back
into the recovery boiler. You mentioned the calls
that you've been getting concerning whether or not
we're going to be putting things into the air. But if I
understood you correctly, you said you thought the
recovery boilers would handle that. Are you also
putting back into the recovery boilers the sludge
from activated treatment systems? And I guess the
follow-up to that is, does your average recovery
boiler have a high enough temperature and long
enough resonance time to be able to do what
you're suggesting it can do?
• Nell McCubbln: A recovery boiler is a very high
temperature, well-mixed incinerator and as such it
can handle the organics from pulping pretty well.
EPA did some studies about 8 years ago, asking, in
the first round of studies, where the dioxin was
coming from. The conclusion that the recovery
boilers were not an issue was quickly reached. The
activated sludge waste, in other words, waste treat-
ment sludge, is not put into the recovery boiler. It is
normally put in the hog fuel boiler. A lot of people
have done that. The modern hog fuel boilers, too,
are much hotter, better mixed incinerators for treat-
ing municipal waste than tended to be common in
the past. So I can't get very worried about burning
sludge. It's always dangerous to say there's no en-
vironmental risk. In 1984, how many people here
could spell dioxin? I know I couldn't. But many
people have looked for trouble with burning sludge
and haven't found any, so I don't worry burning it
in the main mill equipment.
• Ann Hillyer And you're not just talking about
fancy-dancy new recovery boilers, you're talking
about the average run of the mill boiler that's al-
ready installed?
• Neil McCubbin: I'd say most boilers, and certain-
ly most boilers installed since 1970, or modernized
since 1970, and that probably covers 75 percent of
the capacity. Jack Clement from Babcock & Wilcox
will perhaps comment on this question. He knows
far more about boilers than I do.
• Keith Romlg, United Paper Workers Internation-
al Union: I'd just like to offer a comment. The
quality of the discussion here brings us hope that
jobs will not be lost in this industry as a conse-
quence of its failing to change fast enough to meet
market and regulatory pressures — as in fact hap-
pened in so many other industries in the 1980s.
Thank you very much.
• Rebecca Todd, Sierra Club Legal Defense Fund: I
have two questions. First, Mr. Terziotti, I'm curious,
in your move to 100 percent substitution, which of
your customers, or what segments of the customer
population, had requested this move or expressed
interest in substitute products?
• Luigl Terziotti, Parsons & Whittemore: The re-
quest from our customers was not necessarily re-
lated to substitution. It was related to dioxin. And
they wanted us to help them. They didn't want us to
say that we are not integrated or that we just sell
pulp. We decided that we'd make that pledge.
We'd give them no detectable levels of dioxin. This
concern is fairly widespread among customers.
• Rebecca Todd: What specific customers had ex-
pressed a concern about dioxin to you?
207
-------
Technical Perspectives — Performance and Cost
• Lulgl Terziottl: As I said, it was fairly widespread
— from European customers making coated papers
to people making tissue. It was practically
everywhere. We make about 1,000 to 1,200 tons a
day of softwood pulp pine and 1,200 tons a day of
hardwood pulp, so we cover the whole spectrum of
paper manufacturing.
• Rebecca Todd: American, as well as European?
• Lulgl Terziottl: It's about 50-50; 50 percent over-
seas and 50 percent in America.
• Rebecca Todd: I also have a question for Mr.
Phillips and Mr. Trice, if he's here. According to
your model, Mr. Phillips, the additional cost for TCP
pulp was $45 per ton. Is that right? I'm curious how
that compares to what Union Camp is experiencing
or has predicted that they will experience in their
TCP process?
• Richard Phillips: I will defer to Bill Trice, if he's
here, since I think he probably has better facts than
I do. But, you recall that the numbers he gave
yesterday were principally for the process that they
plan to implement at Franklin which has a final
chlorine dioxide stage. In my charts, you'll notice
that the direct variable operating cost, when using a
final chlorine dioxide stage, shows a savings over
current practice. But when you substitute peroxide
for that final chlorine dioxide stage, the costs go
negative very quickly because of the bleaching ef-
ficiency and the high cost of peroxide. But again,
I'll defer to Bill if he's here.
• Rebecca Todd: Thank you.
208
-------
A Consultant's View of European
Government Activities
Jens Folke
Director
European Environmental Research Group
Allerod, Denmark
As an independent consultant, I am not a rep-
resentative of any European government. I
have been involved in regulatory activities as
a consultant for the European Community (EC)
Commission as well as for the Nordic Council of
Ministers, whose members include Denmark, Fin-
land, Iceland, Norway, and Sweden. EC members
are Belgium, Denmark, France, Germany, Greece,
Ireland, Italy, Luxembourg, the Netherlands, Por-
tugal, Spain, and the United Kingdom.
The Nordic countries, particularly Finland and
Sweden, are Western Europe's main pulp suppliers
(see Fig. 1). The EC countries are dominated by
nonintegrated paper and board mills, except for the
production of newsprint from mechanical pulp,
which involves integrated manufacturing. The
main chemical pulp producing countries are
France, Portugal, Spain, and Germany (41 of the 44
chemical pulp mills). In France, 60 percent of kraft
pulp is made from mixed species of hardwood.
Generally, the wood used for pulping in France is
of low quality, which means less efficient debarking
and a pulp that is more difficult to bleach than most
hardwoods.
Germany produces no kraft pulp, only sulfite
chemical pulp. Sulfite pulp is easier to bleach but
not as strong as kraft, so Germany needs to import
large amounts of kraft pulp in the EC (the United
Kingdom, France, and Italy are other major im-
porters). Germany, Italy, France, and Spain have 52
of the 64 mechanical pulp mills within the EC. The
other seven EC countries are either small pulp
producers or produce no pulp at all. Secondary
fibers are used extensively in the EC.
European Environmental
Protection Cooperation
Cooperation among European countries on the
protection of the environment takes place in more
than 20 inter-European or international bodies,
such as the EC, the Office of Economic Coopera-
tion and Development (OECD), the European
Council (established in 1949 and the oldest
European cooperative body), the North Atlantic
Treaty Organization (NATO), and the United
Nations' Economic Commission for Europe (ECE).
Environmental Conventions/Commissions
Environmental cooperation has taken place at 10
conventions, often named for the cities where the
final meeting was held. They include the London
Commission on Prevention of Marine Pollution
from Dumping of Chemical Wastes, the Oslo Com-
mission on Prevention of Marine Pollution from
Dumping of Chemical Wastes, the Paris Commis-
sion on Prevention of Marine Pollution from Land-
based Sources and Rivers, the Helsinki
Commission on Prevention of Marine Pollution
from Dumping of Chemical Wastes or Land-based
Sources and Rivers, and MARPOL (a global con-
vention) on the Prevention on Marine Pollution
from Ships.
International Ministers' Conference
on the Protection of the North Sea
The first International Ministers' Conference on the
Protection of the North Sea was held in Bremen,
209
-------
Government Activities
Pulp Prod. UilillU Pulp Cons.
P&B Prod.
WP Coll.
P&B Cons. B222222 WP Cons. ..
1000t/y # Mills
16000
14000
12000
10000
8000
6000
4000
2000
0
350
300
250
20?
§
<0
Figure 1.—Western European pulp and paper statistics (1989 Pulp and Paper Industry annual report).
Germany, in 1984. The Bremen Declaration dealt
with proposals for the continuous protection of the
North Sea. The second conference was held in Lon-
don on November 24-25, 1987; the third took
place in the Netherlands, March 7-8,1990; and the
fourth is to take place in Denmark in 1994-95.
The first two North Sea ministers' conferences
produced documents that have only proposition
status but have nonetheless been influential. The
ministers' declaration from the second conference
dealt with the following 10 issues:
1. discharge of hazardous compounds
through rivers;
2. discharge of nutritive salts;
3. pollution of the sea through air;
4. dumping and incineration;
5. pollution from ships;
6. pollution from offshore activities;
7. radioactivity;
8. protection of a particularly vulnerable
ecosystem;
9. air surveillance; and
10. scientific investigations.
For the first two issues, the goal was to reduce dis-
charges by 50 percent over the next 10 years. The
ministers recommended an exchange of informa-
tion on emission standards and environmental
quality standards, based on a limited list of substan-
ces or group of substances (which may include
nutrients) or processes. They also supported com-
mon standards based on the newest scientific
evidence and experience and recommended en-
forcement of these standards.
In the appendix to the London Declaration, ex-
amples of potentially significant polluting com-
pounds included persistent halogenated com-
pounds from the organic chemical industry, the
pesticide manufacturers, and the pulp and paper
industry. Chemical compounds, such as poly-
chlorinated aliphatic hydrocarbons and dioxins,
were specifically mentioned.
The ministers' declaration on pulp mills from
the Third North Sea Conference noted that by
1995, the discharge of chlorinated substances
should not, as an average, exceed 2 kilograms of
adsorbable organic halogens (AOX) per ton of air-
dried pulp for bleached softwood kraft; 1 kg AOX
per ton for bleached hardwood kraft; and 1 kg AOX
per ton for bleached sulfite pulp (or any other
equivalent limit if more suitable parameters are
identified).
210
-------
\. FOLKE
Paris Commission
Members of the Paris Commission (PARCOM) are
Belgium, Denmark, France, Germany, Ireland, the
Netherlands, Norway, Portugal, Spain, and
Sweden. The Paris Commission has been directed
to
• examine as soon as possible whether more
suitable parameters than AOX can be iden-
tified;
• develop regulations by 1995 (at the latest) for
best available technology to be used for the
production of bleached kraft pulp; and, in
doing so,
• aim at a maximum content not exceeding 1
kg of AOX per ton of air-dried pulp for all
types of bleached kraft pulp, or an equivalent
value, if more suitable parameters have been
identified.
The Paris Commission meets several times a year.
The last meeting, held in Oslo on June 22-26,
1992, produced a draft proposal noting that as of
1993, a new mill should not exceed as a yearly
average, the following amounts of discharges:
• bleached pulp mill effluents: 1 kg of adsor-
bable organic halogens (AOX) per air-dried
ton (ADt);
• chlorine multiple: <0.05.
• nonintegrated mill effluents (capacity
>50,000 tons): 5 kg of chemical oxygen
demand (COD) per ton of paper and 1 kg of
total suspended solids (TSS) per ton of paper;
• secondary fiber mill effluents (capacity
>25,000 tons): 2 kg of TSS per ton of paper;
and
• newsprint mill effluents (capacity >25,000
tons): 2 kg of TSS per ton of paper.
Mills existing before 1993 must adhere to the
last two amounts by 1995, to the first two amounts
by 1996, and to the third amount by 1997.
France, Portugal, Germany, Spain, the United
Kingdom, and Norway had exceptions to the
proposal. The group agreed to analyze the problem
and to submit their comments to Sweden to draft a
new proposal (or proposals) before December 15,
1992.
Helsinki Commission
The Helsinki Commission (HELCOM) also meets
several times a year. HELCOM member nations in-
clude Denmark, Estonia, Finland, Germany, Latvia,
Lithuania, Norway, Poland, Russia, and Sweden.
The last meeting was in St. Petersburg, Russia, on
May 18-22, 1992. The commission approved a
proposal that will immediately limit the annual dis-
charge amounts allowed for each new mill to 65 kg
COD per ADt, with biological oxygen demand
(BOD) reduced in proportion to COD; and to 60 g
of phosphorus per ADt. All mills in existence in
1995 will have to limit their annual discharge
amounts to 2 kg of AOX per ADt for softwood
bleached kraft mill effluent (BKME), and to 1 kg of
AOX per air-dried ton for hardwood BKME — or, as
a total average for each country, 1.4 kg of AOX per
ADt. Pre-1990 mills have until 2000 to comply
with the HELCOM-approved amounts of
COD/BOD and phosphorus in their effluents. All
HELCOM members must comply with the
proposal.
One mill in Denmark uses salt water as its
process water, which makes chemical recovery al-
most impossible. Among the former Soviet bloc
countries, even chemical analysis may be unreli-
able; therefore, collaboration and knowledge trans-
fer from the Nordic countries and Germany to the
Eastern European countries are part of the agree-
ment. No standards have been agreed on yet for the
wood-containing paper in integrated and nonin-
tegrated mills or for chemithermomechanical pulp
(CMTP) mills. As a first step it is agreed that
• water management should aim at high recir-
culation rates;
• cooling water used for this single purpose
should be protected against contamination;
• hazardous chemicals should be replaced by
less hazardous ones;
• wastewater from wood-containing paper in
integrated and nonintegrated mills should be
treated biologically or chemically; and
• wastewater from CTMP operations should be
treated anaerobically/aerobically or by aero-
bic/chemical treatment.
EC Council Directive
In 1975, the EC Commission worked out a proposal
for a Council Directive on the reduction of water
pollution caused by wood pulp mills in the mem-
ber states. The Council never finalized this direc-
tive proposal, which was based on a French decree
from 1972 regulating total suspended solids (TSS)
and biological oxygen demand (BODs). Since
1972, many EC countries have developed their
own effluent standards (see Table 1).
Traditionally, the focus on wastewater dischar-
ges from the pulp and paper industry has been on
BOD and TSS. Occasionally, regulations have in-
cluded COD. Belgium operates with four cate-
211
-------
Government Activities
Table 1. — Current EC emission standards for pulp mills.
PARAMETER UNIT
Water m3/tso
TSS mg/L
kg/tao
COD mg/L
kgAo>
BODs mg/L
kgAso
AOX kg/tao
N-NHU+ mg/L
Tot-P mg/L
Color mg/L
Fish toxicity dilution factor
BELGIUM (1986)
120
120
525
(63)
45
(5.4)
2
2
825
FRANCE (1972) GERMANY (1989)
2.5-85
300
5-70
(20-50)
5.0-80 5
1
5
0.1
2 (DIN 3841 2)
PORTUGAL (1 988) SPAIN (PROPOSAL)
2.5-12.5 4.0-38
5-45 2.4-24.5
Source: Fotke, 1991
gories, Germany with eight Spain allows the
highest limits for secondary fiber plants.
Swedish Mill Effluent Tests
The biological effects of effluents from Swedish
pulp and paper mills using different bleaching and
external treatment concepts have been assessed
using a variety of biological test methods, ranging
from acute lethality tests (to medium-term multi-
species tests of subacute or chronic effects) to com-
plex, multispecies tests in outdoor model eco-
systems.
A series of medium-term laboratory tests for
subacute effects in zebra fish and Ceriodaphnia
were carried out in which the lowest observed ef-
fect concentration (LOEC) was determined for
reproduction and survival of embryo/larvae and for
induction of adverse effects during gametogenesis
in fish, determined as reduced stress tolerance in
the offspring (see Fig. 2). Based on data from such
tests, one can conclude the following:
• The amount of subacute toxicity, expressed
as TEFsA (where TEFSA = 11/LOEC X waste-
water flow per ton of pulp) for a mill using a
conventional bleaching sequence typical for
the years before 1980 is about 1,000 for
endpoint A and 6,000 for endpoint B. This
serves as a reference for the worst case.
• Introduction of oxygen delignification
without any other major change in the
bleaching sequence will reduce the TEFsA
values to 500 (A) and 5,000 (B). This number
represents the technology typical in Sweden
around 1985 and now becoming widespread
in the United States.
• Reduction of the washing loss and carryover
of substance from the oxygen stage to the
chlorination stage and better control of the
bleaching process, including oxygen rein-
forcement of the extraction stage (the prac-
tice in many Swedish mills at the end of the
1980s) reduces the TEFsA values for the
endpoint B to about 2,100 but does not
change the TEFsA value for the endpoint A.
The best available bleaching practice used in
Sweden at the beginning of the 1990s, with
oxygen delignification followed by a rela-
tively high chlorine charge (70 percent of the
active chlorine in the chlorination stage),
produces an effluent with TEFsA values of
170 (A) and 250 (B), respectively. Figure 2
shows the reduction of various pollutants in
pulp mill effluents as a result of external
treatment in an aerated stabilization basin.
i External treatment of the effluents in an
aerated stabilization basin with a retention
time of 8 to 9 days and operated with an
anoxic prezone for effective elimination of
chlorate in the effluents, resulted in efficient
reduction of most pollutants. Irrespective of
the sophistication levels of the washing and
bleaching technology, the treatment will
produce an effluent that has two to four times
lower TEFsA values than effluents before the
external treatment. However, the reduction
in AOX as a result of the external treatment
was normally only 30 to 40 percent as com-
pared with the drastic reduction in toxicity.
i Bleaching sequences with 100 percent sub-
stitution and AOX levels of 0.1 to 0.2 kg per
air-dried ton do not further reduce the TEFsA
values compared with the externally treated
effluents (aerated stabilization basin) from
mills using the "last-generation" cooking,
washing, and bleaching technology, but still
keeping a low degree of chlorine dioxide
substitution (about 30 percent of the active
chlorine in the chlorination stage as D),
giving an AOX in the treated effluent of 1.3
kg per air-dried ton.
212
-------
J. FOLKE
\ br
6000 -
4000 -
2000 -
0 -
(7) (6) (5)
. . •
(2)
•
(3)
(A\ •
W
•
1)
02468 AOX(kg/ADt)
(1) C95D5 Conventional bleaching (<1980X5) O C70D3o (Last generation)
(2) O(C85D15)(1985) (6) O C70D30 (Last generation) + ASB
(3) O C92D8 E(O) (End of 80s) (7) O P D (Modern fluff pulp)
(4) ° C85D15 + ASB Mills and years refer to
the Swedish situation.
Figure 2.—Relationship between AOX and TEFsA.
Adsorbable Organic Halogens
These conclusions are further substantiated by the
results of long-term experiments (about 5 months in
duration) in which sublittoral brackish-water com-
munities from the Baltic Sea were exposed to
various effluents in large (8 m3) outdoor test tanks.
Tank studies were supplemented by medium-term
exposures of rainbow trout, followed by assessment
of the physiological and biochemical status of the
fish.
The combined results from these comprehen-
sive biological tests indicated that no correlation
exists between the amount of AOX being formed
during the bleaching and the composite biological
response. The effluent from a mill producing un-
bleached kraft pulp produced a composite biologi-
cal response that was stronger than that obtained
with effluents from mills with bleaching and AOX
levels up to about 4 kg/ADt. However, the effluents
from the production of unbleached pulp are dif-
ficult to compare directly with those from bleached
production. The only comparison that is justified at
this stage is that compounds other than chlorinated
organics significantly contribute to the overall
toxicity of pulp mill effluents.
The U.N. Conference on
Human Environment
Some fundamental principles for the protection of
the environment against discharges of pollutants
from industrial and other sources were formulated
at the United Nations Conference on the Human
Environment in Stockholm in 1972. The need for
controlling sources of environmental pollutants
was reflected in Principle No. 6:
The discharge of toxic substances or of
other substances and release of heat, in
such quantities or concentrations as to
exceed the capacity of the environment
to render them harmless, must be halted
in order to ensure that serious or
irreversible damage is not inflicted upon
ecosystems.
This principle is related to "the assimilative
capacity" of the environment, which was further
developed and given detailed meaning by the
Group of Experts on the Scientific Aspects of
Marine Pollution in 1986. A clear distinction is
made between processes resulting in "contamina-
tion" and processes resulting in "pollution." "Con-
tamination" means an increase of substances in the
environment as a result of human activities, "pollu-
tion" is reserved for substances or heat increases
resulting from human activity that result (or are like-
ly to result) in harm or other deleterious effects on
living resources and ecosystems, hazards to human
health, impairment of environmental quality, and
reduction of amenities.
Best Available Technological/
Economical Options
Regulators all over the world tend to adopt the op-
tion of best available technology (BAT) or best
213
-------
Governmenf Activities
available technology economically achievable
(BATEA). Quite obviously, however, a stringent and
narrow-minded application of this policy will
(sometimes) result in suboptimizations of available
resources for environmental protection and, oc-
casionally, even in counterprotective action. In par-
ticular, the result may be detrimental on the
economy and the environment if the BAT policy is
uncritically combined with "the principle of
precautionary action." If available scientific
knowledge is not taken into account, a general and
vague fear of possible danger can be used as an ar-
gument for requiring action to control inputs of
substances to the environment.
Conventional biological wastewater treatment
uses heterotrophic microorganisms, ideally to
mineralize organics, so that plants can use the
material in their photosynthesis. Although such
degradation increases the entropy of the environ-
ment, it is hardly pollution, because it is necessary
for the anabolic activity of plants. Such a degrada-
tion process would also occur in nature without the
use of biological treatment plants.
The energy that is released through degradation
processes during biological wastewater treatment
is, in principle, available at the treatment plant. In a
very few cases, that energy is used to help drive the
process. In other cases, it substitutes more polluting
energy sources (see Table 2). However, in most
cases, this energy is lost because the capital and
maintenance costs of the complex systems that can
be used to recover energy (e.g., as gas from sludge
digesters) outweigh the costs of purchasing electri-
cal energy from a fossil fuel-burning power station.
The use of external (nonrenewable) energy for
pumps and aerators results in air pollution resulting
from fuel consumption and an overall greater en-
vironmental degradation than would be the case
without any wastewater treatment at all.
Table 2.—Examples of doubtful investments.
Chlorine dioxide (100% in the first stage)
• uses excess energy as compared to chlorine
• creates a chlor-alkali imbalance
• causes chlorate discharges
Chlorine-free, semibleached pulp (lignox-type)
• uses even more energy than chlorine dioxide
• increases chronic toxicity
Activated sludge treatment for OCI removal
• discharges persistent organics
• uses fossil fuel energy to turn water contamination into
air pollution and solid waste
Excessive substitution of virgin fibers with secondary fibers
• virgin and secondary fibers exist in different
geographical areas
• "save a tree — eliminate a forest'
• wastepaper collection and processing add to the
greenhouse gases more so than wood pulping
Critical Levels of Contamination
and Pollution
It is not easy to define the difference between con-
tamination and pollution, but, during the last five
years, environmental agencies worldwide have
tried to define "critical loads" or "critical levels."
The UN Commission for Europe issued the follow-
ing definition of critical load in relation to
transboundary air pollutants:
A quantitive estimate of an exposure to
one or more pollutants below which
significant harmful effects on specific
sensitive elements of the environment do
not occur according to present knowledge.
A similar definition may be applicable to
specific chlorinated organic substances discharged
to the aquatic environment. However, it is not
reasonable to assume that the concept of "critical
load" can ever be applied to a parameter such as
AOX, since AOX comprises a plethora of individual
substances with a vast variety of properties. It
seems much more promising to try to determine
critical loads of specific fractions of the AOX com-
plex — fractions having relatively uniform physico-
chemical and toxic properties, such as polychlor-
inated phenolics or polychlorinated dibenzo-p-
dioxins and dibenzofurans (PCDD and PCDFs).
Protection Strategies
Two useful environmental protection strategies that
have been recently developed are based on the
"Best Practicable Environmental Option" and
"Long-term Sustainability of Receiving Ecosys-
tems." The latter principle was established by the
World Commission on Environment and Develop-
ment in the Brundtland Report, which states:
States shall maintain ecosystems and
ecological processes essential to the
functioning of the biosphere, shall
preserve biological diversity, and shall
observe the principle of optimal
sustainable yield in the use of living
natural resources and ecosystems.
Both principles require a holistic view on en-
vironmental problems and imply an optimal use of
different environmental media, for example, to ac-
commodate waste with the intent to minimize the
overall loading or detrimental effects on the en-
vironment. Protection strategies based on these
principles will include site-specific environmental
quality criteria (or critical levels) with the aim of
avoiding local and regional detrimental effects on
214
-------
J. FOLKE
ecosystems. The strategies will also include peri-
odic biological field monitoring to check that ade-
quate ecosystem protection is achieved.
External effluent treatment in aerated stabiliza-
tion basins or activated sludge plants only modestly
reduces polychlorinated organics. However, reduc-
tion of high AOX emissions by means of internal
measures in the mill may represent effective protec-
tion of the environment, provided cost-effective
and energy-saving solutions are used. The question
is, however, how far do we need to go?
The weakness in using AOX as an effluent con-
trol parameter in the future is the lack of correlation
between the specific AOX discharge and effects on
the ecosystems. A modern kraft pulp mill in which
the chlorine multiple in the first C/D stage in the
bleaching process has been reduced to less than
0.15, corresponding to an AOX formation of 1.5 to
2 kg per air-dried ton, normally produces an ef-
fluent with relatively harmless chlorinated or-
ganics, which seem to be fairly similar to naturally
formed chloroorganics. Nonchlorinated substan-
ces, such as wood extractives, are responsible for
the remaining weak environmental effects of such
effluents. Therefore, a continued strong emphasis
on further reductions of AOX below levels of 1.5
kg/ADt is not the best way to provide environmen-
tal protection.
Ecological Economics
Environmental protection cannot be examined by
itself. Resource production must also be con-
sidered. The basic limiting factor in resource
production is not currency, but energy and
materials required to produce that energy. In only
300 years, humankind will have used (according to
some estimates) 80 percent of the entire amount of
fossil fuels accumulated over a period of 600 mil-
lion years. Thus, what is lacking in our current
economy is the ability to address properly our use
of resources or ecological economics; for instance,
to distinguish streams produced from wood chips
from streams produced from coal. Pulp and paper
mill operations are potentially within the frame-
work of ecological economics.
Pollution control technologies based on using
huge amounts of energy are not compatible with
ecological economics and should be omitted. The
goal is better environmental management of eco-
nomic activities (see Fig. 3). Seemingly, this is fre-
quently forgotten by environmentalist groups in
their push for a better environment.
Costs,
A$/Akg pollutant removed
Entropy
Environmental
degradation
Pollutant discharged,
kg/ADt
Figure 3.—Maximizing
economics.
Energy put into
pollutant removal
the efforts of ecological
For Further Reading
Folke, J. 1991. Regulatory requirements for pulp and paper mill
effluent control: scientific basis and consequence. Water
Sci. Technol. 24(3/4): 19-32.
Folke, J. and Commission of the European Communities, DC XI.
1989. The Technical and Economical Aspect of Measures
to Reduce Water Pollution Caused by the Discharges from
the Pulp and Paper Industry. Final Rep. Study Contract No.
B6612-551 -88. COWIconsult and the EC Commission.
Folke, J. and H. Edde. 1990. Effective and economic environ-
ment control by initiative taking rather than response.
Pages 29-35 in Proc. Int. Process Product Qua). Conf.
Tech. Ass. Pulp Pap. Indus. London, UK.
Folke, J., H. Edde, and K.-J. Lehtinen. 1991. The scientific foun-
dation of adsorbable organohalogens (AOX) as a
regulatory parameter for control of organochlorine com-
pounds. Pages 517-27 in Proc. Environ. Conf., Tech. Ass.
Pulp Pap. Indus. San Antonio, TX.
Folke, J., L. Landner, and N. McCubbin. 1992. Is AOX removal
by biological effluent treatment consistent with environ-
mental protection objectives? Pages 849-57 in Proc. En-
viron. Conf. Tech. Ass. Pulp Pap. Indus. Richmond, VA.
McCubbin, N. el al. 1992. Best Available Technology for the
Ontario Pulp and Paper Industry. Rep. Prep, for Water
Resour. Branch. Munic./lndus. Strat. Abatement. Ont.
Minis. Environ. Toronto, Ont., Can.
215
-------
Environmental Regulation of the
United States Pulp and Paper Industry
Kathleen M. Bennett
Vice President, Environmental Affairs
James River Corporation
Richmond, Virginia
Since the mid-20th century, the U.S. pulp and
paper industry has invested billions of dol-
lars in ecological enhancement to reduce
the unwanted and unintended impacts of its
manufacturing processes on the environment. This
discussion will briefly describe certain significant
regulatory programs and activities now under way,
and their implications for the industry and the en-
vironment.
Pulp and paper are made from renewable
resources, whether from wood, cotton, or other
natural fibers, and are among the most environ-
mentally benign products in existence. Paper is
recyclable, biodegradable, combustible for energy,
and safe for the user. The industry's manufacturing
processes, moreover, are in many ways models of
pollution prevention. The kraft process, for ex-
ample, recovers and reuses inorganic chemicals
and combusts the organics removed from wood to
recover energy. Several closed-loop processes
within the mill, such as chemical recovery, the lime
cycle, and many water cycles, are designed to use,
reuse, and use the same resources again and again.
The pulp and paper industry is among the most
capital-intensive industries in this country. This
means, among other things, that the industry must
respond to ever-pressing demands for major capital
improvements to remain competitive; it also means
that there is little tolerance for premature obsoles-
cence.
The pulp and paper industry has long
demonstrated its commitment to environmental
protection and enhancement. A significant event
occurred in 1943 — the paper industry's founding
of the National Council for Air and Stream Im-
provement (NCASI) to provide a source of data and
information about the environmental effects of the
industry's air and water discharges and techniques
to reduce them. These observations are very impor-
tant in considering regulation and regulatory ac-
tivity affecting the pulp and paper industry.
There are many environmental statutes that af-
fect the industry, both at the State and Federal
levels, which impact mill sitings; construction;
manufacturing; chemical product use; wastewater
discharges; gaseous emissions; solid waste genera-
tion, transportation, storage, and disposal; product
content, handling, and distribution; human resour-
ces issues such as training; and many other factors.
The most significant environmental laws affect-
ing the U.S. pulp and paper industry are the Clean
Air Act, the Clean Water Act and the Resource Con-
servation and Recovery Act. The first two are the
most specific to our industry, and are especially im-
portant because their scope and impact are not
matched by those in effect in other countries.
Clean Air Act
Since 1970, comprehensive Federal legislation and
implementing rules have been in place to protect
against air pollution's adverse health and welfare
effects and to protect aesthetic values such as
visibility and odor. The legislation affects new, ex-
isting, and modifications of existing sources. New
source standards promulgated for major industrial
categories are required to be updated every four
years. Our industry was one of the earliest to have
new source performance standards, which were
most recently updated in 1986.
In the United States, the Clean Air Act affects
stack emissions as well as fugitive and area sources.
It provides a State and Federal framework for
achieving and maintaining air quality standards
and for preventing "significant air quality deteriora-
tion."
216
-------
KM. BENNETT
Results
Major impacts on the industry's emissions of sulfur
dioxide, and particulates including metals, nitrogen
oxide (NOx), volatile organic compounds, carbon
monoxide, and total reduced sulfur have resulted.
Despite significant industry growth, reductions of
22 percent were achieved in the industry's sulfur
dioxide emissions from 1980 to 1985, through
decreases in the use of oil and other fossil fuels and
in the sulfur content of such fuels.
Control requirements kept increases in the
industry's emissions of NOX to very low amounts.
The volumes might otherwise have been large, as a
result of increased use of wood residues and coal,
for which the NOX content is slightly higher than for
other fuels. Data for 1985-1990 are now being
compiled. Paniculate controls have resulted in pol-
lution prevention as well as chemical recovery in
the industry; but industry-specific figures quantify-
ing the reductions in particulate emissions are not
available. However, capture efficiencies in excess
of 99.5 percent are typical for new sources or
retrofits of existing equipment, compared to the 80
to 90 percent capture efficiencies of the past.
The Clean Air Act, along with industry
economics, has spurred increased reliance on in-
ternally generated energy (hog fuel and other wood
residuals, capture of heat generated in chemical
recovery to meet steam requirements, and other
steps). An estimated 56 percent of the industry's
energy requirements are met through internal ener-
gy generation, reducing dependence on fossil fuel,
reusing materials, and preventing pollution.
"Air Toxics"
The 1990 Clean Air Act Amendments added
sweeping new requirements for "air toxics" regula-
tion that will affect other industry emissions:
chlorine, chloroform, hydrochloric acid, methanol,
methyl ethyl ketone, and others. The air toxics
provisions provide for technology-based emission
standards to be established for 189 hazardous air
pollutants from major industrial categories of new
and existing emitters. These requirements are to be
no less stringent than "best-performing 12 percent"
for existing sources and to represent the levels
achieved by the best performing sources for new
installations.
According to the new law's "air toxics" require-
ments, the U.S. Environmental Protection Agency
(EPA) may reduce or eliminate emissions based on
process changes, substitutions, enclosures, work
practices, operational standards, training, and other
means. Strict new rules are expected to be
proposed in October 1993, and made final in Oc-
tober 1995.
Clean Water Act
Water pollution control began in the pulp and
paper industry almost at the inception of the in-
dustry, and has been an earnest matter since the
middle part of this century (coinciding with the
founding of NCASI) and beyond. These earlier ef-
forts were prompted by local considerations for
health and aesthetic qualities.
Since 1972, the United States has implemented
comprehensive Federal clean water legislation
based on State water quality standards and Federal
wastewater discharge standards and limitations.
Federal permits are required for wastewater dis-
charges to "navigable waters of the United States,"
which limit both the content and the mass of the
discharges. Provisions have been established to
create evolving technology-based standards for
each major category of industrial discharger, and
also to establish water quality-based limitations
aimed at protecting against any potential adverse
cumulative impacts due to total loadings.
Like the Clean Air Act, the Clean Water Act
reconciles local needs and conditions with en-
vironmental protection goals. The rulemaking
forum provides the appropriate mechanism for
technical review and data compilation, involve-
ment and commentary by all interested parties, and
consideration of all relevant factors, such as en-
vironmental objectives and impacts, scientific facts
and concepts, technology, economics, and timing.
Regulations of the pulp and paper industry
under the Clean Water Act have required sig-
nificant reductions of our industry's discharges of
dissolved oxygen, total suspended solids, chemical
oxygen demand, biochemical oxygen demand, pH,
and conductivity. As a result, well-treated kraft pulp
mill effluents operating in compliance with prevail-
ing rules show little or no adverse impact on the en-
vironment.
Moreover, there has been a reduction by nearly
95 percent in the amount of biochemical oxygen
demand discharged per unit of production since
1945, and by 65 to 75 percent since 1975. There
has been a reduction by more than 40 percent of
total suspended solids in industry wastewaters per
unit of production since 1975, and of more than 80
percent since 1965. Due to water conservation ef-
forts, it required 70 percent less water to make a ton
of paper in 1988 than it did in 1959. It is now com-
mon in this industry to discharge water with less
suspended solid material than was present in the
intake water.
217
-------
Government Activities
Effluent Guidelines Revisions
"Best Available Technology" requirements for our
industry are now being updated, as required by the
Clean Water Act. Under consideration for both new
and existing sources are limitations for dioxin/
furan, chlorinated phenolics (which may be regu-
lated as individual compounds or in total), volatile
organic compounds, chlorinated organics as in ad-
sorbable organic halogens (AOX), color, and other
nonconventional pollutants. "Best Practicable
Technology/Best Conventional Technology" re-
quirements are also being updated for conventional
pollutants (dissolved oxygen, total suspended
solids, chemical oxygen demand, BOD, and pH).
Surrogate substances and measures, such as
AOX, are being investigated for use in controlling
chlorinated organic compounds. While the in-
dustry has long responded to public concern about
potential adverse impacts to health and environ-
ment attributed to chlorinated organics, the in-
dustry questions the appropriateness of a generic
regulation not linked to toxicity or other effects.
Large amounts of data support the conclusion that
few if any adverse impacts occur to the environ-
ment that are attributable to this industry's organic
chlorinated discharges at today's levels.
Further, the industry does not view the AOX test
as an appropriate measure of environmental sig-
nificance since, among other things, AOX fails to
distinguish the "wheat from the chaff' in terms of
toxicity of the various compounds that are present,
including those also found in nature. In any case, as
a result of other pollution prevention efforts
(primarily associated with dioxin reductions) a
marked reduction in AOX levels has also been
achieved. The U.S. industry continues to compare
favorably with those of other nations (for example,
Sweden, Finland, and Canada). It must be em-
phasized, however, that no health or environmen-
tal rationale justifies the establishment of AOX as a
control parameter — a view increasingly under-
stood and shared worldwide.
We would certainly not want to predict the out-
come of EPA's effluent guidelines revision, espe-
cially before the agency has even proposed the
new rules; nevertheless, it is clear that authority ex-
ists for EPA to impose stringent new requirements
on the industry, that EPA is the appropriate lead
agency, and that a proper forum exists for con-
sideration of all relevant factors.
Important Considerations
The pulp and paper industry is capital-intensive, re-
quiring tens or hundreds of millions of dollars each
year for new plants and equipment. Capital is
scarce and expensive. Effective capital manage-
ment is a crucial success factor, especially in the
United States where capital formation is not sup-
ported well by national fiscal policy. Generating
returns on investment that are competitive with the
financial returns possible in industries that are not
capital-intensive is challenging. Foreign competi-
tion for our products and investment is also increas-
ing.
Priorities must be established for allocating the
limited capital on which the industry can draw in a
given year. Constant productivity improvements
are critical to survival in a globalized industry.
There are of course competing environmental and
safety demands — the industry has pledged to ad-
vance the rate and technology of recycling; source
reduction and pollution prevention initiatives are
increasing; and process safety rules, with their
pressing goals, also require capital; and there are
many other important objectives. Elimination of
poverty, enhanced nutrition, and improved
delivery of health care cannot be forgotten as part
of our urgent national agenda. Given limited
resources, choices must be made, and time allotted
to generate the necessary capital allowed.
Under the circumstances, stability and predict-
ability in capital requirements are important. This
outlook is especially critical for existing facilities,
which cannot afford to have technology declared
obsolete early in their useful life. Replacement is
simply too expensive, and capital is not available.
Time for planning for new requirements, and for
amortization of existing capital stock, are key.
Therefore, it is imperative that environmental
regulations be soundly based, stable, and predict-
able; reflect appropriate priorities; and allow
flexibility to recognize site-specific factors. As a na-
tion, we must aim limited environmental, human,
and capital resources at improvements that will
bring the most substantial benefits to human health
and environmental protection.
Challenges Involved in Effective
Environmental Regulation
Developing and implementing effective environ-
mental regulation of this complex and richly
diverse industry is a challenge. The industry has ex-
isted for hundreds of years, and produces
thousands of products using a wide variety of
equipment, processes, and chemicals in facilities of
all ages and configurations. Establishing rules that
will keep all sources moving toward appropriate
environmental goals while recognizing their site-
specific considerations is a formidable but neces-
sary task.
218
-------
KM. BENNETT
There are of course encumbrances to com-
promise, on all sides. The need to maintain a safe,
robust, profitable, and responsive industry can
make compromise costly. Strict, unyielding legisla-
tion and the ties of precedent, coupled with the
need to maintain an aggressive profile, can make
compromise a difficult legal or political issue for
EPA. State and local governments often walk a nar-
row line, needing strong Federal backing and fund-
ing on the one hand but desperate for needed
flexibility and discretion on the other. Advocacy
groups can at times lose sight of the need for
balance, propelled by the need to galvanize public
opinion and keep the membership dollars coming.
Difficulties with congressional structure cannot
be overlooked. The proliferation of committees and
subcommittees, the lack of either a budget or a
priority-setting mechanism when it comes to the
expenditure of private funds for legislated social
goals, and incentives against an organized,
measured approach to a goal of any kind have
recently created a dizzying collection of conflict-
ing, overlapping, inefficient, and unfocused
statutes.
Our only hope of resolution lies in enhanced
comprehension among the parties of each other's
positions, reliance on scientific and technical fact,
and increased public education. Given the present
state of the economy, and the mood of the public
toward government decisionmaking, these are ur-
gent objectives.
Conclusion
Existing regulations, coupled with massive invest-
ments and industry ingenuity, have brought about
significant reductions in environmental impacts
from the pulp and paper industry. Pollution preven-
tion, spurred by concern for efficiency and
economics as well as by regulation, has resulted in
recapture and reuse of significant internal streams
in the industry's processes. Legislation already in
force and its implementing regulations will cause
continued environmental improvement as Federal
Clean Air and Clean Water Act requirements are
implemented and updated. The EPA has ample
authority to deal directly with any residual environ-
mental concerns not already addressed by more
than 10,000 pages of Federal regulation. There is
also the real and growing contribution of voluntary
pollution prevention in this industry, as cited by
EPA's current Administrator William Reilly. There is
no need to resort to distracting, indirect, and distor-
tive approaches such as market intervention to at-
tempt to influence manufacturing, when direct
means are readily at hand. The regulatory forum,
for all its foibles, remains the last, best hope of
determining appropriate environmental protection
and pollution prevention goals and the means to
achieve them. We all have an interest in improving
the process.
219
-------
U.S. Regional Pollution
Prevention Activities
Michael D. Witt
Chief, Industrial Wastewater Section
Wisconsin Department of Natural Resources
Madison, Wisconsin
The Lake Superior Agreement is a United
States-Canada program to restore and protect
the Lake Superior basin. The agreement,
signed in September 1991, established a goal of
zero discharge of nine persistent compounds. The
International joint Commission (IJC) had recom-
mended in its 5th Biennial Report that Lake Supe-
rior be established as a demonstration area.
The IJC is a six-member binational commission
established in 1909 by the Boundary Waters Treaty
between the United States and Canada. The com-
mission deals with issues of waters along the bor-
der, seeks public and scientific input into these
issues, and makes recommendations for action.
Two other groups of particular importance to the
Great Lakes are the Great Lakes Water Quality
Board (made up of State, Provincial, and Federal
representatives) and the Great Lakes Science Ad-
visory Board (made up of scientists and technical
members).
The Lake Superior Agreement identifies respon-
sibilities of the Federal Governments of Canada
and the United States; the States of Minnesota, Wis-
consin, and Michigan; and the Province of Ontario.
The agreement focuses on zero discharge or emis-
sion of nine designated persistent bioaccumulative
toxic substances and on a broader program to iden-
tify impairments to restoring and protecting the
basin's ecosystem. The nine toxics are 2,3,7,8-
tetrachlorodibenzo-p-dioxin (2,3,7,8-TCDD); oc-
tachlorostyrene; hexachlorobenzene; chlordane;
dichlorodiphenyltrichloroethane (DDT); dichloro-
diphenyldichloroethan (DDE) and other metabo-
lites; toxaphene; polychlorinated biphenyl (PCP);
and mercury.
The zero discharge language focuses on a pol-
lution prevention approach and development of a
binational plan. A partnership between cities to ex-
change ideas, strategies, and technical knowledge
has been established, and efforts are keyed to the
U.S. Environmental Protection Agency (EPA) 33/50
program. The agreement also has special protec-
tion designations, including one for enhanced anti-
degradation.
All of Lake Superior's waters are designated as
Outstanding Resource Waters, and areas are iden-
tified for no new increases of toxics. The unique
characteristics of the lake are recognized. Under
the agreement's controls and regulations, point
source controls are upgraded, a goal is set for the
virtual elimination of toxic substances, and sedi-
ment cleanup programs are examined. Consistent
standards are sought for the basin, and efforts are
made to build on the Great Lakes Initiative.
A broader program to restore and protect the
Lake Superior ecosystem is ongoing. It includes an
evaluation of the chemically induced impairments
in the basin, consistent monitoring programs, and
use of a sentinel species as an indicator of basin
health. Consistent consumption advisories have
been established. Inventory, restoration, and the
protection of existing habitats are also being
planned. A State of the Basin report is being
developed that will include a Lakewide Manage-
ment Plan.
The protection and restoration program is
building on the work performed in seven areas of
concern (AOCs) in the basin. This work identifies
ecosystem objectives and best management prac-
tices (BMPs) for nonpoint source pollution
problems.
Joint Pollution Prevention
Projects in Three States
Joint projects between Minnesota, Michigan, and
Wisconsin, funded by EPA's Great Lakes National
Program office, perform the following functions:
220
-------
M.D. WITT
m provide a public awareness campaign;
• provide a regional "clean sweep" program
for the public in the Duluth/Superior area;
and
• train municipal wastewater treatment plant
operators to recognize pollution prevention
opportunities by increasing their knowledge
of local industries.
In Wisconsin, pollution prevention efforts in-
clude joint work with the University of Wisconsin
Extension Service to provide technical assistance to
businesses in the state. A current focus is on haz-
ardous pollutants used in or produced by small-
and medium-sized businesses. The joint efforts
seek to integrate pollution prevention into existing
programs (regulatory and others) and to use all ex-
isting communications outlets — newsletters,
meetings, and enforcement actions. Permit applica-
tions can also be used to request information on
multimedia transfers and pollution prevention.
State Actions Affecting Pulp
and Paper Mills
Wisconsin's Consolidated Papers, Inc., has estab-
lished dioxin minimization activities that have im-
proved brown stock washing, expanded chlorine
dioxide substitution as much as 45 to 55 percent,
evaluated hydrogen peroxide bleaching and
oxygen delignification use, and assessed the reduc-
tion of air emissions through incineration. The goal
of these activities is focused on maintaining a con-
sistent level of dioxin discharge below the effluent
limit of 0.73 mg per day.
The Nekoosa Papers-Georgia-Pacific Corpora-
tion Dioxin Elimination Project has resulted in the
high substitution of chlorine dioxide in the first
bleaching stage and the use of hydrogen peroxide
in the second stage, substitution of low precursor
defoamers, improvement of brown stock washing
efficiency, and a stepwise addition of chlorine. The
project's goal is a consistent level of dioxin dis-
charge below the level of 0.49 mg per day.
Procter & Gamble has worked with Wisconsin
to switch from its current hypochlorite bleaching of
broke to the use of Oxone™, a proprietary process
of the Du Pont Company, by the of end of 1993,
thereby reducing chloroform emissions by 75 per-
cent.
In Minnesota, pollution prevention has focused
on the Potlatch Corporation's kraft mill expansion
and discharges to the Western Lake Superior
Sanitary District treatment plant. The company has
worked on doubling its bleached kraft production,
installing new brown stock washing systems, ad-
ding oxygen delignification systems, and convert-
ing to 100 percent chlorine dioxide processes.
These changes also include air emission controls.
The State expects to see a 46 percent reduction in
the discharge of dioxin and other chlorinated or-
ganics.
The State of Michigan is requiring minimiza-
tion of dioxin in all internal waste streams. Mich-
igan is taking a general approach similar to
Wisconsin and Minnesota that should result in
chlorine dioxide substitution, the careful selection
of other chemicals such as defoamers, and the in-
stallation of oxygen delignification systems.
For More Information
Wisconsin
• Lake Superior Agreement/Ecosystem
Charles Ledin
Wisconsin Department of Natural Resources
(608) 266-1956
» Joint Pollution Prevention Projects
Michael Witt
Wisconsin Department of Natural Resources
(608)266-1494
Minnesota
• Eric Kilberg
Minnesota Pollution Control Agency
(612)296-8643
Michigan
• William McCracken
Michigan Department of Natural Resources
(517)335-4114
221
-------
An Update on Washington State's
Hazardous Waste Reduction Act
Dee Williams
Toxics Reduction Specialist
Department of Ecology
Olympia, Washington
A statewide goal of reducing hazardous waste
generation by 50 percent by 1995 is in effect
in Washington State, based on the Hazard-
ous Waste Reduction Act of 1990, which en-
courages reduction of hazardous substance use and
hazardous waste generation whenever economi-
cally and technically practicable. Pollution preven-
tion plans are necessary to achieve the statewide
goal. Hence, planning is required by law, while im-
plementation is voluntary. Facilities can be fined for
failure to prepare a plan, but they can't be fined for
failure to meet reduction goals.
Implementing the Act
So what drives implementation? How are pollution
prevention programs adequately established at a
facility, and how is reduction really accomplished
without regulatory mandate? The answer is good
pollution prevention planning. Washington's law
establishes certain key elements to be addressed
throughout the planning process. By incorporating
these key elements, a successful waste reduction
program can be put into place. Washington's plan-
ning requirements are detailed in WAC 173-307-
030 (Wash. Dep. Ecol. 1991). For pulp and paper
mills, the plan is organized in four parts:
• Management Support/General Overview.
The first section must begin with a policy
statement that shows management and cor-
porate support for the planning effort. It
should provide the policy's scope and objec-
tives; describe the facility, products made,
and levels of production; and present an
overview of the processes used. Finally, it
should present information on total annual
pounds of hazardous waste generated and
toxic releases, and a description of current
reduction, recycling, and treatment activ-
ities.
• Opportunltles/Goals/lmplementatlon. The
second section serves to identify hazardous
substances used and hazardous waste
generated, describe each facility process,
and identify all reasonable opportunities for
further reduction, recycling, and treatment. It
should also evaluate identified pollution
prevention opportunities and select the op-
portunities to be implemented. A policy
statement that risks will not be shifted should
proceed a list of specific performance goals
and an implementation schedule (a five-year
plan).
• Rnanclal Plan Description. The third section
will identify costs and benefits from im-
plementing the selected opportunities. A
description of the accounting systems used
must also be included.
• Personnel and Employee Requirements.
The fourth section describes personnel train-
ing and employee involvement programs.
Employees are encouraged to provide input
during the planning process.
The written plan or an executive summary must
be submitted to the Washington State Department
of Ecology. Most pulp and paper mills in Washing-
ton were required to complete plans by September
1, 1992 (a few facilities must complete plans by
1993 or 1994). After this filing, progress reports
must be submitted to the Department of Ecology
annually on September 1. The progress report
should provide exact information on the quantities
of hazardous waste and hazardous substances
reduced during the prior year.
222
-------
D. WILLIAMS
Technical Assistance
Several forms of technical assistance are available
to mills preparing pollution prevention plans. The
Northwest Pulp & Paper Association, National
Council of the Pulp and Paper Industry for Air and
Stream Improvement (NCASI), and Washington
Pulp and Paper Foundation have been active in
gathering and disseminating information.
Washington's Department of Ecology has a
Waste Reduction, Recycling, and Litter Control
(WRRLC) program; this program is available to pro-
vide technical assistance for meeting the planning
requirements. WRRLC's Toxics Reduction Unit
works with facilities in completing plans. Staff iden-
tify specific pollution prevention ideas and tech-
nologies, develop environmental programs,
educate management and employees about pollu-
tion prevention, or define reduction and recycling
opportunities. The WRRLC program is nonregu-
latory — staff do not conduct inspections or en-
force waste management regulations.
WRRLC staff are available to meet with man-
agers to discuss pollution prevention issues. At
some facilities, WRRLC has been involved in kick-
off meetings to help educate employees about pol-
lution prevention and to assist in "getting everyone
on board." They have also helped evaluate unit
processes to define reduction opportunities, re-
viewed existing facility programs for implementa-
tion of proposed reduction activities, and helped
set up costs-and-benefits tracking systems.
As an integral part of WRRLC's long-term tech-
nical assistance to the pulp and paper industry, staff
are working with other regulatory programs, or-
ganizations, and community groups to define and
address pollution prevention barriers.
Regulatory Barriers and Opportunities
One of the primary pollution prevention regulatory
barriers that affects the pulp and paper industry is
an end-of-pipe, medium-specific focus. Regulatory
actions are often geared toward controlling or abat-
ing pollutants rather than prevention. Further,
regulatory policies such as Best Demonstrated
Available Technologies (BOAT) and Best Available
Control Technology (BACT) are in many cases
based on specific control and management tech-
nologies. This type of specification, while effective,
"seems to center on a single-medium approach and
can potentially reduce flexibility and innovation/'
as the Minnesota Office of Waste Management
(1991) discovered in its Report on Barriers to Pollu-
tion Prevention.
To further complicate the regulatory scene, the
sometimes adversarial nature of the mill/agency
relationship is also a primary barrier. For quite
some time, regulators have lived in a "command
and control" mode; facilities have operated in a
"compliance" mode with lawyers as intermedi-
aries. This relationship is often ineffective, and
potential advances in environmental management
are lost. To address these barriers, WRRLC has ini-
tiated a number of projects including the review of
the State's solid and hazardous waste regulations
and their administration. Regulators and industry
have been solicited to define problems. Some of
the questions being asked include the following:
• Are regulations appropriate and
understandable?
• Do they address pollution prevention?
• Are regulators appropriately interpreting
and administering the law?
• Is the administrative system working?
• How can identified barriers be addressed?
WRRLC is trying to enhance cross-program
communication and interaction, by working with
the U.S. Environmental Protection Agency (EPA)
Region X Pollution Prevention Roundtable on a
workshop for permit writers, and by working with
Department of Ecology enforcement programs to
review permit and enforcement actions for the in-
tegration of pollution prevention alternatives. Un-
der an EPA contract, WRRLC is currently partic-
ipating in a project with a local pulp and paper mill
to compile a model pollution prevention plan for
the kraft segment of the pulp and paper industry.
This plan is to be used to settle enforcement actions
creatively and to come up with a multimedia ap-
proach to pollution prevention planning.
Economic and Institutional Issues
Many mills operate on a limited time for return on
investment, and most pollution prevention alterna-
tives are costly and result in little or no added value
for the company. To address these problems,
WRRLC provides information on available grants,
loans, and credits. WRRLC has also been active in
developing economic analysis guidelines for pollu-
tion prevention, and in compiling and relaying in-
formation on total cost accounting. Liability,
compliance, and oversight costs are required to be
addressed through Washington's pollution preven-
tion planning law. WRRLC provides mills with the
tools they need to get a handle on these costs. The
Department of Ecology's Water Quality Program
Alternative Strategies Unit is investigating eco-
nomic incentives for water pollution control.
Projects are focused on determining efficiency,
equity, and feasibility of using various economic in-
223
-------
Government Activities
centives or market-oriented approaches for water
pollution control purposes.
WRRLC has also sought to determine potential
incentives for implementing pollution prevention
alternatives within the pulp and paper industry.
Washington has joined with several other States to
form the Western States Contracting Alliance. This
purchasing alliance was formed to create market
incentives for recycled products, thereby also driv-
ing potential pollution prevention activities.
The structures that support agency and mill
operation are complex, and communication is
tough. Department of Ecology staff members don't
always talk to each other and mill managers don't
always communicate well internally. The Depart-
ment and mills don't always speak the same lan-
guage. Other communication barriers exist
between the department and the public, and be-
tween mills and the public. Common ground is
often difficult to establish, and clear vision is dif-
ficult to find. WRRLC is involved in cross-program
training and educational efforts. WRRLC staff at-
tend training sessions that are hosted by other
Agency programs, and regulatory staff are en-
couraged to attend WRRLC training sessions.
WRRLC encourages cross-departmental activities
within mills — forming planning teams to address
pollution prevention issues, and modifying or en-
hancing existing structures to include pollution
prevention activities.
WRRLC is also working with pulp and paper
associations to gather and disseminate information.
For example, this fall, the Department of Ecology
and the Northwest Pulp and Paper Association will
cosponsor a workshop on boiler ash issues. Interac-
tion is critical. WRRLC understands its need to
learn more about how the industry works, how
decisions are made, and how external issues affect
business decisions so that its members, as members
of the regulatory community, can offer a more in-
formed response to regulatory issues. WRRLC inter-
action with industry associations and mills allows
for that sort of education.
Conclusion
Many issues and activities are currently being ex-
plored in the area of pollution prevention. It seems
that our interest in pollution prevention could easi-
ly be focused on one issue such as chlorine bleach-
ing vs. nonchlorine bleaching. This effort does lead
to great breakthroughs; however, focusing solely on
pollution prevention technology can be mislead-
ing. Pollution prevention deals more with the goal
of technology than its content and is rarely ad-
vanced by adding a black box to an operational
process. Instead, pollution prevention involves
finding innovative ways to look at processes and
operations. We need to move beyond our own
comfort to work in a more productive way with
mills and government agencies. We need to work
more productively to share information among the
separate worlds of industry, community, and
regulators.
References
Minnesota Office Waste Management. 1991. Report on Barriers
to Pollution Prevention. St. Paul, MN.
Washington Department of Ecology. 1991. Pollution Prevention
Plans. Off. Waste. Reduc. Olympia, WA.
Washington Hazardous Waste Reduction Act. 1990. Chap.
70.95C RCW. Olympia, WA.
224
-------
British Columbia Regulations to
Eliminate Adsorbable Organic
Halogens from Pulp Mill Effluents
Ann Hillyer
Barrister and Solicitor, Staff Counsel
West Coast Environmental Law Association
Vancouver, British Columbia, Canada
British Columbia has 24 pulp mills, which
play a significant role in its economy. Most
of the mills produce chlorine bleached kraft
pulp, from softwood, for an export market. Pollu-
tion from British Columbia's pulp mills has been
one of the province's most serious environmental
issues, and the subject of heightened public con-
cern. Recently, the British Columbia government
has received widespread attention because of its
tough new pulp mill regulation, put into effect July
1, 1992, that requires mills to eliminate adsorbable
organic halogens (AOX) that are produced in the
bleaching process by December 31, 2002.
The regulation gives each mill a choice. It can
opt to meet an interim discharge standard of 1.5 kg
AOX per air-dried metric ton (tonne) of pulp
produced on or before December 31,1995; in that
case, the mill has until the end of 2002 to eliminate
AOX entirely. Alternatively, a mill can bypass the
interim standard of 1.5 kg AOX, and choose instead
to eliminate it entirely by December 31, 2000. All
mills were required to submit plans and schedules
by June 30,1992, indicating how they would meet
the new standards. Progress reports will be required
every six months.
The new AOX limits follow the 1990 introduc-
tion of organochlorine regulations in British Colum-
bia. At that time, the British Columbia government
set a limit of 2.5 kg AOX per air-dried tonne of pulp
and also required all mills to have secondary treat-
ment facilities installed. Each mill negotiated a date
to meet these requirements, since a number of mills
needed substantial upgrading to meet the stand-
ards.
Events Leading to Regulation
In 1988, following reports linking dioxins to pulp
mills, the Canadian government conducted dioxin
analysis of shellfish collected near three coastal
pulp mills and, several months later, closed coastal
shellfisheries near those mills.
Since late 1988, the Federal Government has
closed hundreds of kilometers of British Columbia's
coastline to shellfish harvesting in nine major areas
because of dioxin and furan contamination from
pulp mills. These shellfisheries' closures were ac-
companied by a number of health advisories,
which warned people not to consume certain
species of fish over set limits, and some types of
diving ducks and waterbirds. A general advisory
was issued against eating the livers of any bottom-
fish caught near coastal mills.
The closures and the health advisories created
concern in British Columbia among industry,
government, and the public. In addition to the en-
vironmental concerns, many shellfishers lost their
source of livelihood when the shellfisheries were
closed. Aboriginal peoples, who often live close to
pulp mills, lost a major source of food.
Since 1988, mounting public pressure about
pulp mill pollution, dioxin contamination, the
shellfisheries' closures, and the continuing dis-
charge of organochlorines from pulp mills led to
two major responses from the government. Both
the Provincial and Federal governments have sig-
nificantly tightened the environmental standards
that apply to pulp mills, and the Provincial govern-
ment has started seriously prosecuting offending
225
-------
Government Activities
pulp mills. Until recently, the British Columbia pulp
and paper industry had a history of routine non-
compliance with regulatory standards. Now it is
not uncommon for a mill in violation of environ-
mental standards to be prosecuted.
The Pulp Pollution Campaign
I am a lawyer with the West Coast Environmental
Law Association (WCELA), a nonprofit public inter-
est organization in British Columbia that provides
legal advice and legal counsel to individuals and
organizations with environmental problems. Since
1988, lawyers at WCELA have acted on behalf of
54 individuals and organizations representing over
250,000 citizens, who have been concerned about
pollution from pulp and paper mills in British
Columbia. We call this the Pulp Pollution Cam-
paign.
WCELA also participates in a multisector group
called the Multi-Stakeholder Working Group
(MSWC) on Pulp Mill Regulation in British Colum-
bia. This group was formed in 1991 to provide
imput to the pulp mill regulatory process in the
Province. The MSWG includes a wide variety of
stakeholders, including individuals from environ-
mental groups, unions, native peoples, the pulp
and paper industry, shellfish associations, technol-
ogy suppliers and consulting engineers, the Federal
Government, the Provincial Government, and
universities.
Universal Aspects of British
Columbia Regulations
Pulp mills are also regulated throughout Canada by
the Federal government. The Canadian Environ-
mental Protection Act prohibits mills from discharg-
ing detectable levels of dioxins and furans after
January 1, 1994. The federal Fisheries Act governs
the discharge of the conventional pollutants — bio-
chemical oxygen demand (BOD), total suspended
solids (TSS), and toxicity. It also requires mills to
participate in an environmental effects monitoring
program, which helps determine whether or not the
current regulatory standards are adequate to pro-
tect the environment.
Most British Columbia mills have undergone
major upgrading because of the changes in pulp
mill regulations over the last two years, and be-
cause of high level public and industry concern in
the Province about pulp mill pollution. It is clear
that the most recent regulation requiring the
elimination of organochlorines by 2002 will con-
tinue to drive the development of technology
needed to meet that standard.
There are four aspects of the British Columbia
regulation requiring the elimination of organo-
chlorines that can be applied anywhere in the
prevention of pulp mill pollution. The regulation
• incorporates precautionary and preventative
approach principles;
• uses long-term planning;
• targets a goal of zero pollution; and
• takes advantage of emerging market
opportunities.
Precautionary and Preventative
Approach Principles
The precautionary principle — that action should
be taken to prevent contamination before there is
conclusive proof of harm — is receiving significant
attention in the quest for sustainability. Many scien-
tists and policymakers have pointed out the
dangers of waiting for proof of harm before taking
action to cut pollution. To quote the Great Lakes
Science Advisory Board (1989):
The current requirement for "proof" of
harm creates a situation that can resolve
itself only through costly errors. One by
one "proof of harm can never keep pace
with the rates of introduction of chemicals.
Likewise, Gro Bruntland, Prime Minister of
Norway and former chair of the U.N. Commission
on Environment and Development states:
/ will add my strong support to those who
say that we cannot delay action until all
scientific facts are on the table. We
already know enough to start to act — and
to act more forcefully. We know the time
it takes from decision to implementation
to practical effects. We know that it costs
more to repair environmental damage
than to prevent it. If we err in our
decisions affecting the future of our
children and our planet, let us err on the
side of caution (Cameron andAbouchar,
1991).
This precautionary approach is in contrast to
the traditional approach of allowing the release of
pollutants until it is proven that a particular pol-
lutant is harmful to humans or the environment.
Only then do governments respond by regulating
the harmful substance. This traditional approach ig-
226
-------
A. HILLYER
nores how little is really known about the multitude
of pollutants that are released into the environment
and the complex web of life that such pollutants af-
fect.
In the past when we have discovered serious
environmental consequences from members of the
organochlorine family, such as dichlorodipheny/
trichloroethane (DDT), polychlorinated biphenyls
(PCBs), and dioxins, we have gone through painful
— and expensive — environmental catch up as we
learn about the environmental damage and embark
on the slow process of implementing regulatory
standards to deal with the substances.
Using the precautionary approach rather than
the traditional one to develop regulations makes
sense if we are serious about achieving sus-
tainability. Where there are threats of serious en-
vironmental damage, lack of scientific certainty
should not be used as a rationale for postponing
measures to prevent that damage.
There has been discussion about the scientific
uncertainties associated with using AOX as a
regulatory tool. The elimination of organochlorines
is not the same as choosing a permissible discharge
level. Requiring the elim-ination of AOX indicates a
policy decision to err on the side of caution in the
face of scientific uncertainty. It also signals to in-
dustry that a process change is required to elimin-
ate the use of chlorine compounds in bleaching
pulp.
Preventing the production of organochlorines
opens up the possibility of eliminating the dis-
charge of all pulp mill effluent. Eliminating the use
of chlorine compounds will remove many of the
problems associated with recycling the effluent
fromkraftmills.
Organochlorines are not responsible for all en-
vironmental problems associated with pulp mill ef-
fluent. For example, research by scientists at
Environment Canada suggests that pulp mill ef-
fluent affects fish, even when the effluent is from a
pulp mill that does not use chlorine compounds.
The process changes needed to eliminate or-
ganochlorines could enable the pulp industry to
more easily become effluent free, solving both the
organochlorine problem and any other known —
or unknown — environmental problems associated
with pulp mill effluent.
Increasing emphasis is placed today on the
"polluter pays" principle, namely, that those who
pollute should pay the ensuing costs and damages.
In British Columbia, many parties have called for
compensation for the victims of pulp mill pollution,
particularly in light of the shellfisheries' closures. In
this context, the precautionary principle and the
preventative principle are the least expensive ap-
proaches to dealing with pulp mill pollution.
Long-term Planning
The regulatory approach taken by the British
Columbia government incorporates long-term gov-
ernment planning. Recognizing that sustainability
involves planning the future as well as cleaning up
the past, the British Columbia government has
enacted a law more than 10 years in advance of
when the requirements must be met.
The 10-year period for achieving the elimina-
tion of organochlorines allows industry a realistic
time frame for developing and implementing the
process changes that will be necessary. The AOX
regulation requires that mills report on their plans
every six months, showing progress toward achiev-
ing the long-term requirement. The government in-
tends to involve all sectors in discussing the plans
for process changes and in monitoring the progress
of the industry. Clearly, if we have a long-range
plan, we can choose process changes that will
yield the maximum environmental benefits, and we
will also have time to assess the potential environ-
mental impacts of new processes.
Goal of Zero Pollution
The government recently released an Environment-
al Action Plan for British Columbia, which states,
"Our goal is zero pollution."This standard provides
the benchmark against which all regulatory initia-
tives aimed at environmental protection can be
measured. The elimination of organochlorines goes
some distance in achieving that standard for the
pulp industry.
Market Opportunities
Given the growing global interest in purchasing
pulp bleached without chlorine compounds, the
British Columbia regulation helps its pulp and
paper industry to anticipate and meet that market
demand. The industry knows that it will be required
to produce such pulp within a time frame of 10
years. Therefore, industry is in a good position to
seek out and to cultivate the market for environ-
mentally benign products.
Sustainability in the pulp and paper sector will
involve radical shifts in approaches to pollution
and significant process changes to achieve a goal of
zero pollution. The British Columbia regulation re-
quiring the elimination of organochlorines is a step
in that direction.
227
-------
Government Activities
References
Cameron, j., and J. Abouchar. 1991. The precautionary prin-
ciple: a fundamental principle of law and policy for the
protection of the global environment. Boston Coll. Int.
Comparative Law Rev. 14(1 ):1.
Great Lakes Science Advisory Board. 1989. Page 67 in Report of
the Great Lakes Science Advisory Board. Int. Joint Comm.,
Windsor, Ontario, Can.
228
-------
Panel 4:
Government Activities
Question and Answer Session
• Phil Berry, Oregon Department of Environmental
Quality: I'd like to ask Mike Witt about some
things. One very quick question about the integra-
tion of pollution prevention into NPDES permits.
We've been working as an organization to integrate
pollution prevention into all the things that we do
that include permitting. I'm curious if Wisconsin
has found any ways to integrate specific pollution
prevention approaches into NPDES permits.
• Michael Witt, Wisconsin Department of Natural
Resources: There are several ways to approach per-
mits. One way is to put in study requirements,
which we've done in a number of permits, by as-
king people to take something like an environmen-
tal audit approach to their process. Some people
call these "waste minimization studies." Then, to
follow up, we've asked those who set specific dates
to provide submittals. That's about as far as we've
got. I could come up with a few other examples,
but they aren't really representative of the program
as a whole.
• Gayle Coyer, National Wildlife Federation: A
quick comment and then a question. My comment
is directed to Dr. Folke. I think the problem with
your regulatory framework and your designations
of contaminants and pollutants is that contaminants
turn into pojlutants. I mean, who would have
thought when we started discharging the con-
taminant DDT that it would become a devastating
pollutant. Or who would have thought that the
contaminant PCB would turn into a devastating
pollutant? I think that we need to reverse the onus:
chemicals are guilty until they're proven innocent,
instead of innocent until they're proven guilty.
• Jens Folke, Environmental Research Croup,
Denmark The ecotoxicological signs for DDT and
PCB have been developing over the last 35 years,
and are now quite advanced. I think you are per-
haps disregarding the scientific knowledge that has
been gained in these ecotoxicological signs when
you come up with these examples to indict other
chemicals.
• Gayle Coyer: My question is for Mike Witt,
regarding the Lake Superior Binational Program. I
think it represents a historic precedent that two
Federal governments, three states, and a province
have gotten together and actually committed to
protect a particular body of water. In that respect
the program represents a good example for the rest
of the nation. My concern is to make this program
mean more than just paper, particularly in the
realm of controls and regulations and permits. It
has to be a truly coordinated effort around the lake.
It is also a first chance for these governments to tell
us what their zero discharge commitment was in
the Potlatch Corporation expansion permits, and
for us to ask where Michigan and Wisconsin were
during that whole process. Where was the EPA?
Did the EPA discuss whether or not the agency
agreed with the Minnesota decisions or even if
these decisions were compatible with a commit-
ment to zero discharge?
• Michael Witt: The response, Gayle, is that we
recognized this problem early in the summer and
met a few times with representatives from the other
states to work it out. I think we have relatively bet-
ter communication on permit issues now than we
had even four or five months ago. I'm hoping that it
229
-------
Government Activities
helps. I know that you'll watch us to see that it before it's too late. As you know, once we get down
does. the road, it's tough to turn around and go a different
direction. We're looking for earlier opportunities
• Gayle Coyer: Are we going to see a coordinated and consistency in approach so that if we go one
response on the Murphy Oil Permits? direction, the state of Michigan or Minnesota won't
go off in a different direction with a permit, or
• Michael Witt: We have communicated with the ^Tt?? lik? that lt/S ^in8.to takef a 'f6 time'
other states on that issue. I hope that we will have but' think we're putt.ng the p.eces into place now
better communication and better involvement to get coordination in the future.
230
-------
The Pulp and Paper Cluster's Mission
Martha Prothro
Deputy Assistant Administrator, Office of Water
U.S. Environmental Protection Agency
Washington, D.C.
T
I he Pulp and Paper Cluster group, formed by
the U.S. Environmental Protection Agency
(EPA), has a four-part mission:
1. To coordinate development and implemen-
tation of rules, guidance, and action affect-
ing the industry, with a special emphasis on
minimizing cross-media (air, water, and soil)
impacts.
2. To conduct outreach to the industry, en-
vironmental groups, and the public general-
ly about EPA activities affecting the industry.
3. To try and improve management efficiencies
inside the agency; to share data collection
and analyses; to combine our rulemakings;
and to reduce and eliminate redundant
work among various programs.
4. To encourage the adoption of pollution
prevention techniques in the industry. This
final goal is one of EPA Administrator Wil-
liam Reilly's priorities, and the reason that
the Pulp and Paper Industry Cluster spon-
sored this conference.
The Cluster started in the summer of 1990 with
the involvement of three EPA offices — Water,
Toxic Substances, and Policy Planning and Evalua-
tion. Now eight EPA program offices are very active
in the Cluster. They include the Offices of Water,
Air, Solid Waste, General Counsel, Policy Planning
and Evaluation, Regional Operations, Research and
Development, and Enforcement.
The EPA Regions participate as needed and
many of them plug into our meetings by telecon-
ference. Some regional personnel occasionally at-
tend Cluster meetings and provide support for the
headquarters' staff.
The Cluster is now focusing on several major
regulations, including the revised Effluent Guide-
line for the water program. Another is the Maxi-
mum Achievable Control Technology (MACT) rule
that John Sietz, Office of Air Quality Planning and
Standards, will discuss. A third is the pulp and
paper mill sludge rules that are the shared respon-
sibility of Jeff Denit, Office of Solid Waste, and
Mark Greenwood, Office of Pollution Prevention
and Toxics. They will talk about that rule.
Changing hats, now, from the Cluster to the
Water Program, I will speak briefly about activities
going on in the Office of Water.
Clean Water Act
The 1987 Clean Water Act amendments spurred
many States to adopt toxic standards very quickly
— States that had not previously had ambient water
quality standards for toxic pollutants. Forty-two
States and territories have moved to adopt dioxin
standards by setting numeric criteria that span four
orders of magnitude in their degree of stringency.
The States have shown considerable flexibility in
what they can do. Of the 42 standards that have
been adopted, EPA has approved 39. A total of 48
of the 57 states and territories now have dioxin
criteria in development, proposed, or adopted, and
EPA has proposed dioxin standards for the remain-
ing States.
Information about the permitting program is
current as of June 30, 1992. Fifty-one final permits
were issued to pulp and paper mills that discharge
to streams identified as "toxic hot spots." EPA and
the States were required to address these streams
on an expedited basis under section 304(1) of the
Clean Water Act. Nineteen of the 51 final permits
were issued by EPA, 32 by the States — all with
dioxin limits. Eight more permits are in develop-
ment. At least another 51 pulp and paper mills dis-
charge waste to other waterbodies not on the list of
"toxic hot spots." These 51 mills have final permits
231
-------
EPA Activities
that include dioxin limits or dioxin-monitoring re-
quirements — three have EPA permits, 48 have
State permits. Seven additional permits are current-
ly in draft form.
Many of the final 51 permits are in the appeal
stage of the 304(1) process. In all, 39 have been ap-
pealed. Five permits not falling under section 304(1)
have been appealed. Almost all of the EPA permits
have been appealed. State laws vary, but under
Federal law when an appeal is filed, the challenged
provisions are stayed until the appeal is resolved.
Effluent Guideline
EPA is required to propose a revised Effluent
Guideline regulation by October 1993. This
revision is on schedule with the terms of a consent
decree that settled a lawsuit filed by the Environ-
mental Defense Fund and the National Wildlife
Federation against EPA. Three key Office of Water
people are working on those regulations; they are
Don Anderson, Debbie Nichol, and George Heath.
EPA has decided to develop the pulp and paper
effluent guideline and the Maximum Achievable
Control Technology (MACT) rule concurrently. We
recognize that circumstances could arise to delay
one or the other of these rules, and that we are
operating under mandated deadlines. If cir-
cumstances should arise to delay one or the other,
we will have to decide whether it makes sense to
keep the two processes concurrent. At present,
however, that is our goal, and we are on schedule.
The results should assure industry that the require-
ments for air and water will be developed together
and should improve industry's ability to plan ex-
pansions and pollution prevention, and to respond
to concerns by the public, environmentalists, and
government.
Moving the Effluent Guidelines and the MACT
rules forward simultaneously will improve our
chances for the highest net environmental gain at
the least cost and reduce EPA's cost in developing
the rule. Under the current schedule, we will meet
with EPA's Deputy Administrator in April 1993 to
discuss options on the rules, after which our offices
will complete the draft version of all analyses and
rule language by August 1993. Finally, the draft
should be in proposal form by October 1993.
The proposed regulation will reflect EPA's con-
sideration of the range of available technologies.
For bleach mills we will look at technologies rang-
ing from improved housekeeping to improved pulp
washing to chlorine dioxide substitution, oxygen
delignification, hydrogen peroxide substitution,
and combinations of these. We may also need to
look at some add-ons to meet specific water or air
regulations. The Effluent Guidelines establish per-
formance standards; they do not stipulate tech-
nologies for effluent treatment or manufacturing.
We do look at these technologies, however, to
determine appropriate limits.
Our greatest difficulty right now is keeping up
with the technological changes at U.S. pulp and
paper mills. At least half of all U.S. pulp mills have
made significant changes in the last few years. EPA
is watching these changes as closely as possible, to
make sure our final rule reflects the latest informa-
tion. We are considering whether or not to have a
public hearing sometime this fall, perhaps on the
joint process that we have undertaken. We would
be interested in your response to these ideas.
232
-------
The Pulp and Paper Sludge Rule
Mark Greenwood
Director, Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C.
Under Section 6 of the Toxic Substances Con-
trol Act (TSCA), the U.S. Environmental
Protection Agency (EPA) Office of Pollution
Prevention and Toxics (OPPT) set standards and
management practices for land spreading sludge,
and proposed a rule in May 1991. In October
1991, the EPA's risk assessment materials on the
sludge rule were peer-reviewed. The peer reviews
that came back were critical in many ways, but that
was expected because this is a precedent-setting
risk assessment that deals with many complex is-
sues, including avian risks. The comment period
closed at the end of November 1991, and we are
now in the process of deciding what to do next.
The comments we received indicate that we
need to consider new data related to Section 308 of
the Clean Water Act. We also learned to our con-
cern that EPA is having a significant impact on the
role of various State programs that manage sludge,
and that the proposed rule would affect the dis-
tribution and marketing of some products. We had
to start thinking through options for how we might
deal with the issues in this area.
The third problem (regarding marketing and
distribution) is closely related to the title of my of-
fice and this conference. We are concerned about
the way the sludge rules may play into industry in-
centives for pollution prevention. Our current
thinking is that we will need to repropose the rule,
which probably won't happen until the fall of
1993.
The time lag may be negative for us but at the
same time it represents an opportunity. By delaying
the final rule until October 1993, we will be on
track with the timelines for air and water. Thus, we
may be able to create a more integrated analysis of
how the sludge management option fits into the
technological choices that are presented in the air
and water rules. The delay will also allow more
time to look at risk reduction. One option we are
considering is whether we should approach the in-
dustry about sludge management in the short term.
The 33/50 Program
Talking about a voluntary approach is a good segue
into the 33/50 program, which is an innovative way
of approaching a pollution problem. Every year,
EPA looks at emissions on the Toxic Release Inven-
tory (TRI) and we find that some emissions are rela-
tively high in many industries. We decided to lower
the emission levels and to find an innovative way of
getting industry to do so. In 1991, EPA Ad-
ministrator William Reilly wrote letters to the CEOs
of major U.S. companies that emit high levels of
toxicants, and asked them to make commitments to
reduce their emissions of 17 key chemicals by 33
percent in 1992 and by 50 percent in 1995. There
were no sanctions associated with participation or
nonparticipation — it was totally voluntary. Over-
all, industry response has been positive. More than
850 companies made commitments to the program
to reduce their emissions by 350 million pounds by
1995. This reduction is significant. It's rare to get
850 companies to do anything in concert. EPA is
pleased with the 33/50 results.
How does the pulp and paper industry fit this
scenario? We approached 7,700 companies initial-
ly, of which 156 were paper companies (paper and
pulp manufacturers and other sectors of the paper
products industry). In 1988, pulp and paper in-
dustry plants emitted 84 million pounds of the 17
TRI chemicals, or about 6 percent of the total. By
1990, the TRI emissions from this industry had
been reduced to 65.9 million pounds — a 22 per-
cent reduction in two years.
Of the 156 paper companies, 40 joined the
33/50 program with explicit numerical commit-
233
-------
EPA Activities
ments — a commitment rate of 26 percent. That is a nificant portion of the industry. This response indi-
very high response rate. The industry should be cates that your industry is making a good-faith ef-
complimented for that. Only the pharmaceutical fort to participate in voluntary programs as well as
industry and pesticide manufacturers had a higher regulatory programs. I commend you for this effort,
rate of response. The 40 companies committed to and if any of you are interested, the 33/50 program
the 33/50 program account for 68 percent of the is still open.
industry's total waste generation — a rather sig-
234
-------
The Maximum Achievable Control
Technology Rule
John S. Seitz
Director, Office of Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina
To develop a Maximum Achievable Control
Technology (MACT) Rule, there is a process
by which we collect information. Working
with industry, we take the best 88 percent mark that
current technology can accomplish in air emission
reduction as the "MACT floor" for existing sources.
In addition, for new sources, we can take the best of
the best, and base the MACT standard on that. We
do have some options in setting a technology
standard. Most standards equate to a performance
level that is ascertained by collecting data, sharing
information, understanding that information, and
setting a target.
In the past, the U.S. Environmental Protection
Agency (EPA) set a standard in the air program that
industry felt was very rigid and provided no
flexibility. Industry also told EPA that the water
standard was in contradiction to the air standard —
causing the industry to spend many thousands of
dollars to comply with the water standard, only to
find out later that other standards made that expend-
iture premature and wasteful.
In terms of process, the MACT standard, the
Cluster activity, and the effluent guidelines address
this problem head-on. The standpoint in the Office
of Air is that the MACT rule and effluent guidelines
lead us down the regulatory path together. It would
be a tremendous disservice to the industry, to the
environmental community, to State and local agen-
cies, and to the Federal regulators to be forced to
deal with the various pollution requirements for
this industry in isolation from each other. We are
trying very hard to integrate these activities because
separate statutory mandates could pull them apart.
I feel very strongly that they need to stay together.
My office will meet the October 1993 deadline
for the effluent guideline. The Office of Air staff ex-
perts who are working on this project are Penny
Lassiter and Stephen Shedd. We are working very
hard to meet this commitment and have assigned
additional people to this project to meet the water
schedule.
On the surface, we have what appears to be a
very simple task, namely, to set a technology-based
standard, subcategorize its components, and estab-
lish the "MACT floor." But what we need to talk
about among all interested parties is how to set a
technology standard that fosters and gives industry
the flexibility and incentives it needs to follow up
on pollution prevention opportunities. How does
the EPA Office of Air assure the public and environ-
mentalists that the industry's technology standards
meet the intent of the Clean Air Act, if you choose
to go an alternative route? How do we set a stand-
ard that States are able to write into a permitting
program?
We have gone very public in implementing the
Clean Air Act, and we intend to keep the MACT
regulatory process as public as we can. To collect
up-to-date data and to share information, we want
to meet frequently with industry, environmentalists,
State and local regu-lators, and the public. If I have
a question about MACT implementation, I want to
be able to ask industry what its concerns are and
how can we work this out together.
For the past year, we have been in close contact
with industry as we implemented the Clean Air Act,
and we have been very successful. My professional
staff feels strongly that this communication process
allows us to propose better regulations than would
235
-------
EPA Activities
otherwise be possible. As we move to integrate communicate actively with all parties despite dis-
these two rules, I challenge us to continue to work agreements.
together. I was not here earlier today but I under- | hope that spirit of open-ended communica-
stand that Dee Williams (Washington State Depart- tion is kept alive, as we continue to meet on these
ment of Ecology) said she heard and felt the topics. The National Air Pollution Control Techni-
polarization in the room. The challenge in im- ques Advisory Committee will be meeting early
plementing the Clean Air Act, is to continue to next year, and we invite everyone to attend.
236
-------
Solid Waste Office Update
Jeffery Denit
Deputy Director, Office of Solid Waste
U.S. Environmental Protection Agency
Washington, D.C.
The Office of Solid Waste at the U.S. Environ-
mental Protection Agency (EPA) is substantial-
ly involved in the Cluster activities estab-
lished by Hank Habicht, U.S. EPA Deputy Ad-
ministrator. Within the past year, EPA's discussions
on sludge disposal in land-fills benefited immense-
ly from the input of the Cluster organizations. With
their help, EPA determined that the risk to human
health and the environment does not justify nation-
al regulations and that local authorities are ade-
quate to address any risks. Another activity
involving the Office of Solid Waste is the land
spreading of sludge and its effect on wildlife and
human health. Some extremely difficult issues are
associated with exposure assessments and this
sludge disposal rule. The Office of Solid Waste will
continue to be involved in this rule as necessary.
The most significant impact of the Resource
Conservation and Recovery Act (RCRA) on the pulp
and paper industry in the short term may be EPA's
Municipal Subtitle D program, which will have im-
plications for commodity recycling. Pulp and paper
products constitute 40 percent of the municipal
solid waste stream. We see it as our responsibility
to establish national leadership in designing a high
priority, solid waste management program.
Our overall approach is to stimulate the supply
of recyclable materials and the demand for re-
cycled products, including paper. The Federal
Paper Procurement Guidelines require dealing with
several complex issues, including a thorough un-
derstanding of the guidelines associated with
government procurement and their application in
private sector purchasing. How do we cope with
the general notion of recycled content — including
pre- and postconsumer materials and total recycled
content? There are many extremely complicated is-
sues involved with something as large-scale as the
Federal Government's procurement of paper and
paper products.
Later this fall, a focus group meeting will be
held to gather additional input from all interested
parties on how Federal Paper Procurement
Guidelines can be revised. We will, of course, issue
a Federal Register notice announcing the an-
ticipated establishment of the group. Other initia-
tives include partial funding for the National Office
Paper Recycling Project, directed by the U.S. Con-
ference of Mayors which recently issued a national
challenge to business and industry to increase the
collection of recovered paper and the use of
recycled paper products. EPA is an active par-
ticipant in both arenas. In the meantime, we con-
tinue to provide technical assistance to other
Federal agencies as they implement their recycling
programs. EPA is currently preparing a guidebook
on the introduction and use of recycled products.
Regarding Subtitle D nonhazardous wastes,
and the pulp and paper industry's wastes in par-
ticular, EPA is already working closely with several
key States that are essential actors in regulatory
matters affecting industrial wastes. Wisconsin and
Alabama have been included in this instance, be-
cause of the pulp and paper industry's presence in
those States. EPA is also conducting an analysis of
pulp and paper sludge to better determine whether
sludge can be a recycled product.
237
-------
Panel 5:
EPA Activities
Question and Answer Session
• Mark Floegel, Greenpeace: I just can't leave the
microphone alone. I'm like an ant in the sugar.
These remarks are not a question or a comment but
a proposal. And I'm going to make it to this panel
because it seems to be the most appropriate. I know
that one of the goals of this conference is to achieve
even-handedness among the disparate groups that
are together here, and in that light, you've put out
some beautiful conference materials. I've noticed,
however, that they're all on chlorine-bleached
paper. I propose that the proceedings for the con-
ference be done on chlorine-free paper and then
people will have some of both when they look back
on the conference. There are a number of people
here, I know, who produce or sell such papers. I'm
sure they could set you up with something that
would meet your specifications and your budget.
• Mark Greenwood: I guess we'll see how com-
petitive their prices are.
• Martha Prothro, Office of Water, U.S. Environ-
mental Protection Agency. Actually, there is a
reason behind our choices. I'm not sure if we want
to go into it now, but it did occur to us before the
conference to use both. It's not as easy as you may
think. *
Are there any other questions? Comments?
• Jessica Landman, Natural Resources Defense
Council (microphone not on): When you meet to
discuss Federal procurement guidelines, will you
be discussing the issue of chlorine-free paper?
• Mark Greenwood: No, I expect the issues of
process technology to be discussed. At this junc-
ture, I don't really know the degree to which we'll
discuss the issues of chlorine-free vs. not chlorine-
free. Our primary statutory directive is to worry
about recycled content. That's what our principal
focus will be, because it certainly represents the
main issue for us at this point.
• Jessica Landman: I respectfully suggest that in
your collective responsibilities under the Pollution
Prevention Act of 1990 you do have an opportunity
and an obligation to look at other cross media is-
sues. It would seem to me like a logical opportunity
to put such questions on the table.
• Mark Greenwood: I have no doubt they'll be put
on the table. I'm not suggesting they won't be.
• Jessica Landman: One final question about that.
To whom will the procurement guidelines be ap-
plicable? To EPA alone or to others outside EPA?
• Mark Greenwood: Federal procurement guide-
lines are broadly applicable to agencies of the
Federal government and others who may use them.
Incidentally, I don't know if most of you know this,
but I think it is fairly significant that the Congres-
sional Record will now be printed on 100 percent
recycled paper, effective May 1,1992.
* See Conference Note on page 339.
238
-------
Thursday, August 20,1992
PRODUCT PERFORMANCE
SPECIFICATIONS AND CUSTOMER DEMAND
PANEL i: Direct Customers
PANEL 2: Publishers and Printers
LUNCHEON SPEAKER: The Implications of Sustainable
Development for the Forest Product
Industry
PANEL 3: Market Pulp
CLOSING REMARKS
-------
The Market for Chlorine-free Paper
David Assmann
Vice President and Director of Information Services
Conservatree Paper Company
San Francisco, California
M
arkets for any new product are driven by
demand and supply-side considerations.
We need to look at both in order to deter-
mine the future of chlorine-free paper.
Demand Side
The pressures responsible for creating a demand for
paper produced without chlorine or chlorine
derivatives are driven by health and environmental
concerns. Dioxin was first found in paper mill
sludge in 1985, and the U.S. public first became
aware of dioxin content in paper in 1987. Since
then, public concern about organochlorines in
paper has been building steadily.
Two years ago we got one call a month asking
about chlorine-free paper — now we get calls vir-
tually every day from potential consumers of
chlorine-free paper. Whether or not the messages
that are getting through to consumers and paper
users about organochlorines are 100 percent ac-
curate isn't the issue — the very fact that they are
part of consumer perception makes them market
considerations. The concerns we hear most fre-
quently are these:
• Organochlorines and dioxins are a health
hazard at any level. From the U.S. Environ-
mental Protection Agency (EPA) report
(1985) that called dioxin "the most potent
carcinogen ever tested on laboratory
animals" to this summer's media reports call-
ing dioxin "an environmental hormone that
can disrupt the immune system and induce a
variety of cancers," consumers are getting
the message that dioxins and, by extension,
organochlorines are dangerous. Recent
media reports have even called into question
the practice of chlorinating water.
• Organochlorines pose a hazard to wildlife.
Interest in chlorine-free paper increased at
the end of last year after widespread media
coverage of a U.S. Fish and Wildlife press
report that dioxin had been discovered in the
eggshells of bald eagles nesting near the
lower Columbia River in Oregon (see also
R.G. Anthony et al. In press). On March 24,
1992, the New York Times reported that gulls
and seabirds exposed to organochlorines by
eating contaminated fish are suffering
reproductive damage that is similar to the ef-
fects of diethylstilbestrol (DES), the now-
banned drug that resulted in serious health
problems for the daughters and sons of
women who used the drug in the 1950s
(New York Times, 1992).
It has also been reported that or-
ganochlorines pose a threat to the health of
wildlife in the Great Lakes. The International
Joint Commission, a U.S.-Canadian commis-
sion charged with monitoring the health of
the Great Lakes, has recommended that the
use of chlorine and its compounds be
avoided in the manufacturing process (Int.
Joint Comm. 1992).
• Organochlorines are a hazard to the ozone
layer. James Anderson, a Harvard physicist
who headed a major atmospheric study for
the National Aeronautics and Space Ad-
ministration (NASA) has called for an end to
the production of chlorine and bromine
compounds because they have a negative ef-
fect on the global ozone layer. NASA's study
disputes a long-held notion that chlorine and
bromine play a minor role in controlling
ozone concentrations (Natl. Aero. Space
Admin. 1992).
These concerns will continue to drive con-
sumer demand for chlorine-free paper. Consumer
demand will also be augmented by public and
private policy initiatives that grow out of consumer
concerns. So far these initiatives include a decision
240
-------
D. ASSMANN
by British Columbia, Canada, to ban all or-
ganochlorine emissions by 2002. The province of
Ontario has already banned the production of
dioxins and furans in petroleum manufacturing and
is now looking at doing the same for pulp and
paper.
State preference programs for chlorine-free
paper are proliferating. For example, Oregon is
considering a 12 percent price preference for
chlorine-free paper. A number of State officials are
now on record as having called for the elimination
of chlorine bleaching. Governor Howard Dean of
Vermont has even appealed to New York state offi-
cials to force International Paper to switch from
chlorine to oxygen bleaching to eliminate or-
ganochlorine contamination.
Increasingly, municipal, State, and Federal
price requests are specifying chlorine-free paper.
The U.S. General Services Administration is cur-
rently trying to determine the availability of
chlorine-free paper, and a 17-state buying consor-
tium has included chlorine-free paper in its re-
quests for bids.
Industry is also responsive to consumer needs.
The editors of Time magazine, in a statement issued
after they had received 22,000 letters complaining
about the magazine's use of chlorine-bleached
paper, have said that Time will switch to chlorine-
free paper when it becomes available. A major
copy chain, Kinko's, will soon offer chlorine-free
papers in all its stores across the country.
Supply Side
Unfortunately, the supply of chlorine-free paper is
not keeping pace with the demand. Although the
paper industry has had patents for chlorine-free
bleaching technologies since the early 1970s —
one of these patents described chlorine bleaching
as a cause of serious pollution as early as 1970 — it
has been slow to implement any chlorine-free
processes in North America.
Twenty-six mills -are listed as producing totally
chlorine-free market pulp in the March 1992 issue
of Pulp and Paper International, and another 10 are
listed as studying totally chlorine-free processes or
carrying out trials, but none of these are mills are in
the United States (O'Reardon, 1992). As far as we
know, the only two manufacturers of chlorine-free
printing and writing paper in the United States are
Lyons Falls and Mohawk. The amount of chlorine-
free paper currently available in this country is
minuscule.
It's not that chlorine-free paper can't be
produced here. In other parts of the world,
chlorine-free paper is being made in many grades,
including lightweight coated paper. European mills
produced 500,000 tons of chlorine-free paper in
1991 and will be producing 4.5 million tons a year
by 1995.
Many North American mills have substituted
chlorine dioxide or other chlorine derivatives for
chlorine gas (also known as elemental chlorine).
This substitution can significantly reduce the emis-
sion of organochlorines, but it does not eliminate
the production of these toxins. However, their con-
tinued production hasn't stopped companies from
trying to exploit the switch to chlorine dioxide. Mr.
Coffee, for example, claims that its chlorine
dioxide-bleached coffee filters are produced using
a "chlorine-free" process. But, as Consumer
Reports (1991) notes, "chemists would be hard-
pressed to explain how a method using any
chlorinated compound can be chlorine-free."
The American Paper Institute (API) has
mounted an aggressive campaign against chlorine-
free paper. For example, when the General Services
Administration sent out a request for information
on chlorine-free papers to paper companies, the In-
stitute sent a memo (Horton, 1992) to all its mem-
bers, saying that they were not obligated to respond
to the request for information about chlorine-free
papers.
The memo, signed by API's Virgil Horton,
makes this statement:
Last week I alerted you that a questionnaire
the General Services Administration (GSA)
prepared on recycled content and bleach-
ing processes might be mailed to your
company. It is important for you to know
that you are not required to respond to this
questionnaire in total, or in part. The GSA
has no government mandate requiring this
information.
This resistance to chlorine-free paper comes
despite concrete evidence that there is consumer
demand for, and interest in, chlorine-free paper.
Five years ago, in 1987, API commissioned a
public opinion poll — one which, to this day, they
have not made public (Cambridge Reports, 1987).
According to this poll, when the public was
asked, "if dioxin is discovered in paper products at
extremely low levels, would you cut back on your
use of paper products," 59 percent said yes.
Another 10 percent said they weren't sure. In other
words, more than two-thirds of the population
would reduce their consumption of paper in order
to avoid contact with dioxins.
That same poll shows that only 10 percent of
the public would find a scientist employed by a
paper company to be credible on the dioxin issue.
241
-------
That percentage drops to 7 percent in States that
produce paper, and paper company presidents rank
even lower than company scientists.
That's the crux of the issue. The public is not
going to believe an industry that offers chlorine
dioxide as a substitute for chlorine.
Of those polled, 48 percent believed that ac-
tion should be taken to keep dioxin out of the air,
water, and soil — without any further study. Given
the negative media dioxin has received in the past
six months, that percentage is probably higher
today.
Despite industry resistance, I believe the supply
of chlorine-free paper will increase as a result of (1)
increasing consumer and corporate demand for
chlorine-free papers and (2) regulatory and legal
actions to limit the production of organochlorines.
The paper industry has already been hit with
hundreds of lawsuits over dioxin contamination,
some of which have resulted in multimillion dollar
jury awards. Insurance carriers for paper com-
panies have also stipulated that they will not cover
jury awards for dioxin contamination.
The North American paper industry needs to
recognize that chlorine-free paper is the future. In
Europe, the pulp and paper industry has already
come to that conclusion. In an article in Pulp and
Paper International last August entitled "Chlorine is
Dying: We Told You So," the publication editorial-
ized that "reports of the death of chlorine are far
from exaggerated. In the short term, that means the
death of elemental chlorine, but let's be clear, over
the next 10 years, we are talking about the removal
of the whole chlorine family of compounds from
the pulp-bleaching process" (Pearson, 1991).
In April of this year, Pulp and Paper Internation-
al ran a follow-up editorial:
There are still many companies which
would reject the Nordic rush into TCP (to-
tally chlorine-free). They argue that chlor-
ine is still innocent of any damage to
human health until such time as this can be
proven. They also believe that the invest-
ment needed to remove traces of com-
pounds which are actually harmless puts
too high a cost on a currently unprofitable
industry like market pulp. They do not en-
visage a headlong rush into TCP, but
gradual elimination of molecular chlorine
and a substitution of chlorine dioxide.
Foremost among these voices is Geor-
gia-Pacific in the USA, which told its cus-
tomers at the end of January that it had
invested heavily in fundamental research
into the chlorine issue and had reached the
conclusion that substituting chlorine by
chlorine dioxide was the way forward, not
complete chlorine removal.
It's not difficult to sympathize with
GP's view. But in our opinion it has brought
forward its argument too late. The debate
with the environmentalists put the pulp in-
dustry on the defensive three years ago and
planted some ideas about the industry in
the minds of the consumer. The clock can-
not be turned back.
What all researchers into organic
chlorine compounds can agree about is
that little is understood about how organo-
chlorines behave in the human body. All
that seems to be known is that they are dif-
ficult for the body to eliminate, and can be
accumulated in fat tissues. With the
science in this formative stage, the poten-
tial for scare stories which will disrupt the
business of the chlorine-using pulp in-
dustry is enormous. Market pulp producers
using chlorine and its compounds are in
danger of remaining on the defensive for a
long time to come.
For that reason, we believe that the tide
will sweep the market pulp industry
towards the final elimination of chlorine
bleacheries. Whether or not you believe
that organochlorine effluent from pulp
mills is harmful to humans, a failure to
respond to the rising environmental tide of
the 1990s could well lead to an ebb in your
company's fortunes (Pearson, 1992).
Chlorine is Not the Only
Pollution Issue
As important as the chlorine issue is, it is not the
only pollution issue connected with paper produc-
tion. Other issues include sulphur and other air
emissions, the use of solvents in deinking,
landspreading of paper sludge, paper incineration,
and pollution reduction through the use of recycled
paper.
Incineration, which is now being marketed as
waste-to-energy, competes directly with recycling
for the 80 percent of the waste stream that is both
burnable and recyclable. "Waste to energy" plants
recover from 1 to 10 percent of the energy value of
solid waste, while recycling typically recovers be-
tween 50 and 90 percent. According to the
American Paper Institute, 60 percent of the annual
release of dioxin comes from the incineration of
municipal solid waste. In addition, incineration
242
-------
D. ASSMANN
releases other organochlorines, nitrogen oxides,
sulfur oxides, carbon monoxide, and hydrogen
chloride.
Recycling, on the other hand, keeps pollutants
out of the air, in addition to saving energy, water,
trees, and landfill space.
Despite the industry's claims that the/re doing
everything they can to promote recycling, we lag
behind much of the rest of the world in recycling.
Our recovery rate is lower than the global average,
and lags behind countries like Chile, Colombia,
and Bulgaria. If the industry meets its target of 40
percent recovery in 1995, we'll have a wastepaper
utilization rate of 30 percent. That's still 23 percent
lower than the rate we had in 1944. If we look at
printing and writing paper — the largest single
paper component of the solid waste stream —
we're currently recycling less than 6 percent of this
paper. Less than 1 percent of postconsumer printing
and writing paper gets recycled back into printing
and writing paper.
Meanwhile our collection programs are out-
pacing demand. We'll collect 250,000 more tons of
office paper than we can use this year. No wonder
wastepaper prices have dropped by 42 percent
since 1986.
Rather than build new deinking facilities, the
industry continues to expand virgin paper capacity.
Over the past decade virgin paper capacity in the
printing and writing field has grown by 8 million
tons, while deinking capacity has actually shown a
decrease. In 1976,13 recycling mills had their own
deinking facilities producing high grade printing
and writing paper. By 1990, eight of these had
closed.
In conclusion, the industry has a long way to go
to eliminate chlorine and chlorine derivatives, to
promote the production of recycled paper, and to
reduce pollution overall.
References
Anthony, R.C., M. Carrett, and C.A. Schuler. In press. Environ-
mental contaminants in bald eagles in the Columbia River
estuary. J. Wildlife. Manage.
Cambridge Reports, Inc. 1987. Papier Industry Study of Dioxin
Issue. Am. Pap. Inst. New York, NY (not in general distribu-
tion).
Consumer's Union. 1991. Dioxin in coffee filters — is it a
hazard? Consumer Rep. 1 (1 ):47.
Morton, V. 1992. July memo to members. Am. Pap. Inst. New
York, NY (not in general distribution).
International Joint Commission. 1992. Page 30 in Sixth Biennial
Report of Great Lakes Water Quality. Windsor, Ont. Can.
National Aeronautics and Space Administration. 1992. End of
Mission Statement. Second Airborne Arctic Stratospheric
Expedition. Press Briefing. Washington, DC.
New York Times. 1992. March 24. Page C1.
O'Reardon, D. 1992. Study and justification of needs must
proceed bleach plant modification. Pulp Pap. Int.
66(3):53-56.
Pearson, J. 1991. Chlorine is dying: we told you so. Pulp Pap.
Int. 65(8):72.
-. 1992. TCP: there's no holding back the tide. Pulp Pap.
Int. 66(41:72.
U.S. Environmental Protection Agency. 1985. Health Assess-
ment Document for Polychlorinated Dibenzo-p-dioxins.
Off. Health Environ. Assess. Washington, DC.
243
-------
Life in a Medium-sized Paper Company
John F. Church, Jr.
President
The Cincinnati Cordage and Paper Company
Cincinnati, Ohio
The Cincinnati Cordage and Paper Company,
headquartered in Cincinnati, Ohio, is an in-
dependent printing and writing paper mer-
chant operating warehouses in Cincinnati, Dayton,
Columbus, and Cleveland, Ohio; Indianapolis, In-
diana; Huntington, West Virginia; Knoxville and
Nashville, Tennessee; and Pittsburgh, Pennsyl-
vania. We also have retail locations in Pittsburgh,
Youngstown, Akron, and Cleveland. We have sales
people who call coast to coast on publication and
catalog business, and we have a sales specification
program throughout the corporation. We consider
our company to be fairly representative of the in-
dustry, notwithstanding the enormous multibillion
dollar merchants and the small single location
houses among our competition.
Paper Use
In 1991, we purchased approximately $120 million
worth of paper, in the amounts listed in Table 1.
We serve 6,000 customers a year, with 130,000
orders. Today, 5 to 7 percent of our papers are
made with recycled content; 10 years ago that fig-
ure was 1 percent or less.
Our product specifications are generally ac-
cepted as industry standards. They vary slightly
from mill to mill and grade to grade but are always
competitive. We do develop special grades from
time to time to meet specific customer needs, but
these, too, fall within industry norms. Some
specialty grades that are manufactured on a regular
basis have become standards — for example, the
latex papers, Texaprint and Kimdura. The bright-
ness range on our papers is from 60 to 99 and the
opacity range is from 80 to 99, in general. Other
papers exist that are obviously translucent sheets,
and others that are less bright and opaque, but they
are generally not used by our customers.
The papers we purchase are made by a variety
of technologies. Alkaline is becoming the standard
Table 1.—Paper stocks purchased by Cordage
Papers in 1991 as a percent of total papers pur-
chased.
PAPER GRADES
Coated book
Web coated
Offset
Coated cover
Bond
Xerographic
Carbonless
Subtotal
Envelopes
Text
Opaque
Text cover
Pressure sensitive
Uncoated cover
Index
Subtotal
Other
Total
PERCENT
18.3
16.1
14.1
11.0
7.8
7.2
5.8
3.1
2.7
2.3
2.0
1.5
1.0
1.0
6.1
80.3
13.6
100.0
paper grade because of its archival qualities, cost,
and quality. Approximately 30 percent of the
papers we now purchase are alkaline, and we es-
timate that this figure will grow to 60 or 70 percent
in five years.
Traditionally, paper merchants have had a close
and critical relationship with suppliers, and
through franchise and other agreements, we repre-
sent our suppliers in the marketplace. Sometimes
this commitment goes beyond market force, but at
the end of the day, the marketplace itself decides
what products are purchased and manufactured,
and the customer reigns as king. We market,
promote, specify, and stock the papers that make
the most sense to us and help fulfill our obligation
to our customer and suppliers. We cannot stock
everything. We are driven by the needs of our
stakeholders: our customers, suppliers, employees,
stockholders, and the community in which we
work and live.
244
-------
J.F. CHURCH, JR.
Customer Description
In our market niche are commercial printers, quick
printers, in-plant printers, publishers, institutions,
nonprofit and government agencies, major cor-
porations, business forms printers, and converters.
Sensitivity to environmental issues varies dramati-
cally from group to group and within each group.
Commercial printers and business forms manufac-
turers are moderately sensitive to environmental is-
sues, in general, but very sensitive when operating
in an environmentally high impact area, where
emissions are of great concern. The industry is im-
proving the manufacturing process and developing
water-based and soy-based inks. Environmental
awareness and interest are on the rise.
Quick printers are much smaller businesses
and their interest is generally modest at best. It is
primarily driven by their customers' needs and
desires, with an occasional exception. In-plant
printers are motivated by the wishes of their cor-
porate owners and the motivation for large cor-
porations is the same. The consumer-products
companies that have a high profile are most inter-
ested in the environment. They seek to convey a
very positive corporate image to the consumer,
which includes environmental responsibility.
Publishers' paper needs vary dramatically
based on their publication's content and reader-
ship. Magazine publishers are usually more sensi-
tive, and in this group Buzzworm is the most
environmentally enlightened and committed pub-
lisher I know as far as recycled paper is concerned.
Others are extremely focused on costs. The price
gap severely restricts companies from switching to
recycled papers, especially in tough economic
conditions. Institutions have a strong interest in en-
vironmental issues, but their efforts to change are
often hampered by cost considerations. Institutions,
especially hospitals and educational institutions,
have a responsibility to all their constituents. Non-
profit and government agencies, however, seem to
have the strongest interest of all — understandably.
Converters' interest depends on their manufactur-
ing process and product line. They tend to be more
interested if they perceive a marketing advantage.
A great deal of confusion over the past several
years has centered on recycled papers — their
definition and the integrity of their fibers, quality,
and price, I would ask our industry to confirm the
objective. Is it to reduce or eliminate solid waste to
the landfill? If so, the old adage "waste not, want
not" applies.
The customer demand for alternatively
bleached paper is very low; however, confusion
about the bleaching issue is extreme. Most cus-
tomers don't understand the issue and appear not
to care. But we provide information on the issue to
customers who request it and seek alternatively
bleached products for these customers whenever
possible. Dioxin has only recently become a focus
now that newly developed testing equipment has
been able to detect low levels of the substance in
paper. Totally chlorine-free (TCP) bleaching is not
an issue at this time because there are so few mills
that offer TCP papers. A demand for TCP papers will
no doubt grow, although very slowly. Cordage
Papers will support TCP mills as they develop, and
work with them to create successful marketing
programs.
If there is one thought I would like to leave with
you, it's the need for balance. I found it best stated
in the August 17, 1992, issue of Walden's Paper
Report. Eight state co-ops have bought 15,700 tons
of recycled paper. They are going to form a stand-
ards board to set common specifications for
manufacturers, based on "a pragmatic decision
balancing the desire to achieve high percentage of
recycled content with the need to insure that the
standards can be reasonably achieved at economi-
cally feasible prices." The same balance can be
achieved with TCP.
245
-------
Pollution Prevention —
How Customers View the Issues
Donald G. Monefeldt
Manager, Supply Products Marketing
Xerox Corporation
Webster, New York
Xerox, a major reseller of xerographic paper
around the world, got into this business be-
cause the existing grades of office paper were
not well-suited for use in a xerographic copier. A
cooperative effort between Xerox and one of its
suppliers lead to the development of the xero-
graphic grade. Today, about 3 million tons of xero-
graphic grade papers are manufactured annually in
the United States.
Xerox continues in the business, however, be-
cause we believe that our quality process provides
our customers with papers that, on average, sig-
nificantly outperform the rest of the industry's
product.
Xerox is a leadership company— in terms of its
products and the way we conduct business. Such
leadership must, of course, include environmental
responsibility. As an employer, a neighbor, and a
supplier, Xerox is concerned about the environ-
ment. Part of my job assignment is to help define
and implement the company's environmental pro-
gram as a supplier of toners, developers, and paper
products.
Based on input from our customers and our
own personnel, we decided that it was critical to
assess two environmental areas concerning paper.
The first area was the health risks associated with
dioxin in the papers produced and the effluent dis-
charged by our suppliers; the second was the
feasibility of recycled content xerographic paper.
Customer Interest Level
Over the past few years in the United States, we
have only had about 100 customer inquiries about
2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD) levels
in either the paper or the effluent. A few have come
from State and local governments. Most come from
environmentally concerned individuals seeking in-
formation. We have had only a few customers ask-
ing us to supply totally chlorine-free (TCP) paper.
Our opinion is that customer interest in TCP or ele-
mental chlorine-free (ECF) products is about where
recycling was a few years ago. We think it will
grow.
The situation in Europe is quite different. Rank
Xerox markets two brands of Green paper. One is
TCP; the other is an "environmental" paper that
carries the Norwegian Foundation's "Swan" label.
The Swan label includes parameters for adsorbable
organic halogens (AOX), chemical oxygen demand
(COD), sulfur, packaging, and fiber sources. These
papers are premium-priced niche products. The
price premium is in the 15 percent range. Cus-
tomers are primarily northern European govern-
ments and government-regulated companies. The
rest of the orders are from a wide spectrum of com-
panies, including some very large companies that
also have a significant presence in the United
States.
Pappas, an international consulting firm in the
United Kingdom, predicts that by 1995 "the market
will be almost exclusively chlorine-free." Our Rank
Xerox associates expect that half the xerographic
grades will be chlorine-free by 1995.
Focus on Recycled-content Papers
In North America, we have had a substantial cus-
tomer interest in recycling. The total number of in-
quiries is well into the thousands. Most of our
callers wanted information that would help them
decide how they should structure their recycling
program — in terms of collection and procurement.
The modest but growing customer demand for
recycled content xerographic papers will grow sig-
246
-------
D. MONEFELDT
nificantly as recycled prices approach parity with
virgin paper prices.
We have chosen to focus our efforts on recy-
cling. Before we made that decision, however, we
made an attempt to understand the level of health
risk associated with TCDD. Regardless of limited
customer interest, if we had found convincing
evidence that dioxins posed a significant health
risk, we were prepared to encourage our suppliers
to invest in alternative bleaching processes.
Our environmental health and safety group
conducted a survey of the literature in late 1989
and early 1990. They concluded that available
published data does not indicate that mills dis-
charging TCDD in the 10 parts per quadrillion
(ppq) range constitute a significant health risk. The
discharge levels from our suppliers are in the non-
detect or low ppq range.
Our research and development team also sup-
ports this assessment. They also brought to my at-
tention the fact that paper mills play a very small
role in total TCDD generation. Therefore, if one
wants to make a meaningful difference in this area,
the paper industry is not a prime candidate.
Given that advice, we focused our attention on
the recycling issue, where our industry could play a
significant role. It is fair to ask, "How did our cus-
tomers feel about our choice of which issue to pur-
sue?" I think it is accurate to say that they
understood our decision but were still uneasy.
When the word "dioxin" is used, responses based
on risk assessments and detection levels do not
cause the anxiety to go away. Dioxin is an emotion-
ally charged topic. That reaction has not changed
in two years.
When we made our decision to focus on recy-
cling, our expectation was that the paper industry
would eventually move to new bleaching proces-
ses; it would just be a matter of time. If for no other
reason, customer concern would result in the
choice of new bleaching technology for new
capacity or regularly scheduled upgrades and
rebuilds of existing capacity. We did not expect that
the industry would prematurely retire existing
capacity that was operating at the nondetect level.
In 1990, we did not have a consensus in our
company about how the recycling issue would be
resolved. We needed better understanding of three
factors regarding the use of waste paper as a raw
material for xerographic copy paper. These factors
were economics, function, and appearance.
After a considerable amount of work, we con-
cluded that copy paper made from recycled fiber
can be cost-effective under certain conditions, but
the supply of waste white office paper would have
to increase and the price to the mills would have to
decrease. The capital investment would have to be
made to provide incremental pulp capacity to
supply an up-to-date and cost-effective paper
machine. Mills that consistently make good quality
xerographic paper from virgin fiber would also
learn to make good quality paper with the ap-
propriate amount of recycled fiber.
We have qualified some mills to make a
recycled content xerographic paper for us. We
need to find others.
Facing the Future
Growth in recycling has a positive role to play in
pollution prevention. Deinked white office waste
requires significantly less bleaching than virgin
fiber. One bleaching stage is sufficient in that case.
Peroxide is used in at least two U.S. bleaching in-
stallations. While I have not seen the numbers, my
expectation is that recycling will also get high
marks in terms of "eco labeling" criteria.
If I were Star Tre/r's Spock and relied entirely on
logic, I would be optimistic about the near-term fu-
ture for pollution prevention in pulp and paper be-
cause of continuing investment in recycling
capacity and periodic upgrades of the older bleach-
ing operations to new technology.
But the situation could change quickly and
dramatically. The "D" word, dioxin, still generates
strong emotional responses. Public interest could
grow quickly. Last week, there were two one-hour
programs on a Rochester, New York, television sta-
tion dealing with the effects of pollution in the
Great Lakes. Programs like these do get your atten-
tion.
I am personally very grateful to the sponsors of
this symposium. It is a marvelous learning ex-
perience. Based on what I have learned, I believe
that my company and the paper industry are doing
the right thing. But I must tell you, I have some
lingering uneasiness.
I do not envy the people in our industry who
will be responding to the two TV programs I saw
last week. They need ready access to good data and
help to convey the right messages. They — and we
— need peer-reviewed data that all parties can sup-
port. With the hard data in hand, perhaps there will
be other conferences to deal with the questions
"What processes are on the right track?" and "What
processes have to be changed?"
247
-------
The Nation's Number One Paper
Purchaser Looks at Recycled
Content, Chlorine Processing
Barbara Belasco
Environmental/Recycling Spokesperson and Specification Manager
General Service Administration, Region 2
New York, New York
The Federal Government is the United States'
single largest consumer of paper products.
The General Services Administration (GSA)
Federal supply service is the procuring arm of the
Federal Government. GSA buys a wide variety of
commonly used commodities, among them paper
and paper products. GSA does the contracting, then
makes the products available to all Federal agen-
cies. Large-volume items are stored in warehouses.
GSA also advertises items in publications sent to
other agencies. New products can be introduced
into the Federal supply system by a request from a
vendor, a request from a customer, or initiated by
GSA.
In 1991, GSA purchased an estimated 323,000
tons, or $317 million worth of paper and paper
products. Estimated tonnage figures for the high
volume items were
• xerographic paper: 109,000 tons;
• computer paper: 78,000 tons;
• tissue products: 36,000 tons;
• envelopes: 11,000 tons; and
• fine and printing papers: 12,000 tons.
We also purchase other types of paper, includ-
ing bond, writing, offset, ledger, mimeo, duplicat-
ing, cover, index, computer paper, and products
such as envelopes, fax paper, file folders, paper-
board, labels, writing pads, napkins, toilet paper,
towels, shipping cartons, and wrapping paper.
The best estimate is that we have 35,000 to
40,000 customers, based on a recent survey of ac-
tivity address codes. Our biggest customer is the
Department of Defense.
More than 100 specifications apply to the
paper products purchase, and many paper cus-
tomers have detailed physical, visual, and perfor-
mance requirements. For example, the xerographic
paper specification A-A-1912 requires certain
qualities of stiffness, tear, opacity, color, smooth-
ness, and performance, among others. Almost all
specifications for paper and paper products have
been revised in recent years to include require-
ments for recycled content.
With a goal of increasing postconsumer con-
tent, GSA sent a market survey to 66 paper com-
panies who manufacture printing and writing
grades, to study the availability of high grade print-
ing and writing paper made with postconsumer
recovered materials. The results showed that each
grade was available with 10 percent postconsumer
content, in some quantity. Several grades are avail-
able with more than 10 percent postconsumer con-
tent. In 1991, recycled products accounted for
more than $100 million in purchases. The products
met or exceeded U.S. Environmental Protection
Agency (EPA) requirements for recycled products as
listed in EPA Guidelines for Paper and Paper
Products, 40 CFR Part 250.
Recently, a few customers have requested
paper made without chlorine bleaching. Accord-
ingly, we surveyed industry to determine the
availability of nonchlorine bleached paper. The
responses indicated that some nonchlorine
bleached paper is available in the marketplace.
GSA is now reviewing the possibility of adding
such products to its supply purchases, provided
that the cost is reasonable.
The government can create markets for en-
vironmentally friendly products. An Agency cus-
tomer recently requested nonchlorine bleached
248
-------
B. BELASCO
copier paper, containing 100 percent waste paper,
including 20 percent postconsumer. We responded
by putting forth a solicitation for more than 2,000
tons of paper meeting this description. Assuming
that we receive bids with reasonable prices, a con-
tract could be awarded, and the paper will be avail-
able for the customer. It will also be advertised in
government publications to other agencies in order
to stimulate demand for this product.
The Federal Government has also responded to
environmental groups. Last fall, congressional hear-
ings were held by Senators William S. Cohen (R-
Maine) and Carl Levin (D-Michigan) to review the
efforts of GSA in environmental areas. Environmen-
tal groups testified at these hearings. They were ex-
tremely critical of GSA's lack of initiative in the
purchase of chlorine-free paper. In response to
these hearings, we revised specifications for tissue
products — napkins, towels, and toilet tissue. The
new specifications require that the products con-
tain 90 to 100 percent postconsumer recovered
materials and be unbleached, or totally chlorine-
free. This requirement created a new product line
of tissue products offered to our customers as alter-
natives to the standard products. The napkins have
been in the GSA warehouse for several months and
are available for purchase by our customers. They
are included in the GSA catalog and have been ad-
vertised in MarkeTips, the government advertising
magazine that is sent to all agencies. Awards for
towels and toilet tissue will be made shortly.
Specification changes were made to allow for the
purchase of postconsumer, unbleached tissue
products.
Customers are very aware of the critical issues
surrounding solid waste. Recycling and the
procurement of recycled products have been
stimulated by the Resource Conservation and
Recovery Act (RCRA). Customers are willing and
eager to buy our recycled products. GSA publishes
a recycled products guide, a listing of all recycled
products. On the other hand, interest in non-
chlorine bleached paper is relatively new. As a pur-
chasing agency, we have to be responsive to
customer demands and know what is available in
the marketplace. As we have worked with industry
on recycled products, so will we work with in-
dustry to satisfy our customers' demands for paper
products made without chlorine bleach.
249
-------
Pollution Prevention in the
Envelope Industry
Michael J. Cousin
Mail-Well Envelope
Georgia-Pacific Corporation
Atlanta, Georgia
Georgia-Pacific's Mail-Well Envelope is
proud of its record of success in pollution
prevention. We are a leader in safe manu-
facturing processes and the efficient use of raw
materials. Pollution prevention and associated
waste reduction strategies are a fundamental com-
ponent of the way we do business. Our successes
are permanent and a building block for future im-
provements because they make economic sense.
Mail-Well produces envelopes. Paper must be
available to satisfy our customers' quality and price
demands. The availability of high volume, low cost
paper for use in the production of envelopes is req-
uisite for the long-term viability of the envelope in-
dustry. Reclaiming fiber is a sound business
approach to this long-term goal. Specifying the
composition of specific performance paper prod-
ucts is not; it raises costs and does not provide a
long-term solution to the diminishing availability of
landfill space. Reusing fiber for energy is an excit-
ing alternative for paper that cannot be economi-
cally reclaimed.
The scenario for so-called chlorine-free papers
is similar. Specifying the use of totally chlorine-free
(TCP) pulps will only add to the manufacturing cost
and limit the availability of high volume papers.
TCP is prohibitively costly as a kraft bleaching
process. The older sulfite process is a limited option
for TCP approaches; however, sulfite pulps have
lower inherent strength than kraft pulps. The trade-
off in strength is unacceptable for use in perfor-
mance papers. In addition, bleached sulfite pulp
accounts for only a small fraction of the available
bleached pulp. If a nonchlorine bleaching se-
quence is a better alternative than shutting down a
sulfite pulp mill and paying higher prices for market
pulp, then the paper price will also be higher.
A combination of effective management ap-
proaches and technological innovations that satisfy
the cost and quality criteria for world class, com-
petitive industries is a winning strategy. Progress in
the use of flexographic printing and water-based
inks is one example of a successful pollution
prevention strategy.
The envelope industry has focused on the ap-
propriate selection and efficient use of raw
materials as its most effective pollution prevention
strategy. Mail-Well remains a leader in the eyes of
its customers because it has not sacrificed quality to
any management or technological approach. We
continue to produce the products that our cus-
tomers want at the quality standard they need and
expect and at competitive prices.
Envelopes
The envelope industry purchases approximately
1.15 million tons of paper annually. Thus, envelope
papers accounted for approximately 10 percent of
the 11.5 million tons of uncoated free sheet papers
shipped in 1991 (Am. Pap. Institute, 1992a).
According to calculations from data collected
by the Envelope Manufacturers Association of
America (EMAA), approximately 50 percent of the
cost to produce envelopes is the cost of raw
materials. As much as 80 percent of this cost is for
paper; the rest is distributed among ink, adhesives,
and window film purchases. Raw materials recla-
mation for internal use or for outside sale is a criti-
cal component of the business strategy of envelope
manufacturers.
Paper
According to U.S. Postal Service (USPS) data, ap-
proximately 15.2 billion pieces of first and third
class mail were processed in 1991 (Am. Pap. In-
stitute, 1992b). This figure reflects a 2.6 percent
250
-------
M.J. COUSIN
compound annual growth rate since 1986. And ac-
cording to information provided by the U.S.
General Services Administration (GSA), envelopes
with recycled fiber account for 27 percent, or ap-
proximately $18 million of the $67 million of GSA's
annual envelope purchases. By contrast, recycled
uncoated free sheet accounted for only 6 percent of
all uncoated free sheet shipped in 1991. In today's
low demand economic climate, government pur-
chases appear to be a major force in the sale of en-
velopes made from recycled paper.
Commercial envelope purchasers require price
parity between recycled and virgin papers — a cost
parity that we are nowhere near achieving. This
discrepancy presents a barrier to the accessibility of
recycled papers for use in high volume perfor-
mance paper products. Recycled papers cost more
to produce than virgin papers, and the incentive for
papermakers to invest capital in collection, sorting,
cleaning, deinking,, and bleaching equipment will
not materialize so long as these prices do not reflect
costs.
Recycled Paper Availability
Figure 1 presents a comparison of the relative costs
to produce a ton of paper on various machines cur-
rently operating in the United States. The market
price for envelope papers reflects their manufacture
at lower cost, high volume, world-class papermak-
ing facilities. Paper is produced using pulp supplied
by on-site mills integrated with fast, wide, and effi-
cient modern paper machines. Any strategy that in-
creases the costs to produce products at these
facilities will inhibit their ability to compete
profitably in the world's markets for high volume,
price sensitive products such as envelope papers.
In fact, the costs to produce paper must continue to
go down if existing firms hope to compete against
the newer, larger machines that are added each
year. Simply maintaining costs is not good enough
to assure a manufacturer's long-term growth.
Many older U.S. papermaking facilities require
more fiber than can be produced from their on-site
pulp mills. Consequently, these partially integrated
facilities purchase market pulp to satisfy their fiber
requirements. The machines at these mills tend to
be smaller and less productive than their modern
counterparts.
The higher operating costs of these facilities re-
quire a manufacturing strategy that promotes the
production of higher priced products to generate
the returns necessary to stay in business. Although
mills with smaller machines — those in the middle
range of Figure 1 — still attempt to compete in the
envelope papers market, the manufacture of en-
velope papers, whether virgin or recycled, cannot
be considered a long-term strategy for them.
0)
o
o
0>
iS
CO
"3
DC
1
579
Cumulative Capacity (MM Tons)
11
13
Figure 1.—Production costs for uncoated free sheet.
251
-------
Direct Customers
A line has been placed through the cost curve
in Figure 1. Lower cost paper manufacturers
producing high volume papers, such as envelope,
are located to the left of the line while higher cost
producers manufacturing specialty and premium
papers are located to the right. The approximate
average annual production of the paper machines
in the lower cost facilities approaches 100,000
tons. The average production of the machines to
the right of the line is only 33,000 tons.
This demarcation line for high volume paper
producers will continue to move to the left as
newer, wider, faster paper machines are con-
structed. Today's newest machines are capable of
producing more than 350,000 tons of paper an-
nually. Partially and nonintegrated paper producers
have little choice but to continue the transition
from the production of high volume papers to low
volume, high priced premium or specialty papers
or go out of business.
The facilities at the highest end of the cost
curve generally possess small paper machines
using purchased pulp. The costs to make paper are
high, but the price for these products provides the
returns necessary to operate the facilities. These
mills also purchase expensive deinked pulp, and
recycled papers have found a solid home in this
niche.
Premium papers are purchased when the im-
pression of the message is as important as the
printed information. Approximately 40 percent of
the high priced cover and text papers sold today are
made using recycled fiber. Only 10 percent of this
paper contained recycled fiber as recently as 1990.
However, cover and text papers accounted for only
3.7 percent of the uncoated free sheet shipped in
1991, and the growth of the market should only
continue to roughly track the gross domestic
product (GDP). The high cost to manufacture paper
at these facilities keeps them out of the high volume
envelope market whether or not their products con-
tain recycled fiber.
As stated earlier, recycled papers cost more to
produce than high volume virgin papers. Sig-
nificant processing costs for sorting, cleaning,
deinking, and bleaching must be added to the cost
of any raw material used to isolate fiber for the
manufacture of recycled papers. The cost of the
raw material will determine whether a paper grade
can be manufactured profitably at competitive
market prices. The average price for waste
newsprint in the United States in December 1991
was $12.50 per ton, while selected deinkable free
sheet grade prices varied from $138.13 per ton to
$190.63 per ton for white ledger and laser-free
computer print-out paper, respectively (Miller
Freeman, Inc. 1991).
The community infrastructure to collect and
sort newsprint has been in place for years. The low
cost of this readily available raw material provides
an opportunity for papermaking facilities with
deinking plants to compete in niche markets where
the lower brightness of groundwood-containing
products is acceptable. Unfortunately, low paper
brightness from groundwood papers has not been
acceptable for envelope end-users. In fact,
groundwood and its cousins, the "alphabet pulps"
— chemithermomechanical pulp (CTMP) and
bleached chemithermomechanical pulp (BCTMP)
— are not allowed in high-volume envelope
papers. The high speed optical readers used today
by the U.S. Postal Service require high contracts
between paper and print to assure efficient mail
sorting.
Once again, the market price of free sheet high-
volume envelope papers reflects the fact that they
are manufactured on predominantly low-cost,
high-volume paper machines in facilities fully in-
tegrated with on-site pulp mills. Consequently,
nonintegrated facilities with deinking plants may
produce envelope papers, but do not offer a long-
term supply option.
Fiber Reclamation
A portion of the fiber that paper mills purchase
today is supplied by the envelope industry. Accord-
ing to EMAA data, only 72 percent of the paper for
envelope production ends up in envelopes. The
remaining amount, approximately 25 million tons,
ends up as a process by-product. Nearly all of this
paper is reclaimed. The unprinted trimmings and
cuttings are carefully collected and resold as a
premium grade of pulp substitute. Printed and
mixed waste is also collected and sold as a raw
material to the existing recycled pulp mills.
The composition of the envelope paper by-
product stream reflects the business and product
mix of the envelope manufacturer. Mail-Well's
process by-product stream is composed of ap-
proximately 70 percent unprinted, 18 percent print-
ed, 8 percent white, colors, and printed combined,
and 3 percent mixed papers. The mixed com-
ponent contains a variety of small volume items in-
cluding rejected envelopes with glue and windows.
This waste is sold for reuse or reclamation at a
market determined price, depending on color and
quality.
Collecting and selling unused paper makes
good business sense to the envelope industry. The
sale of unused fiber is an important source of
revenue for envelope producers. This does not
252
-------
M.J. COUSIN
Rank Cost
Nonintegrated Mill
Integrated
~~ Pulp And
Paper Mill
Fiber
Source
BHK BSK GWD Free Pulp
Deinkable Sub
Figure 2.—Ranked costs of fiber to a paper mill.
mean that the by-product is more valuable than the
purchased paper; envelopes generate the profit.
However, envelope manufacture is a highly com-
petitive business in which cost containment is al-
most as important as product price. Reclaiming and
selling leftover process paper provides valuable
revenue to offset the inherent design losses from
envelope preparation. This valuable fiber has not
and should never see a landfill.
Figure 2 displays a rank ordering of the cost of
fiber to a paper machine from various sources. Al-
though the price of envelope cuttings is significant-
ly greater than the cost of on-site pulp to a paper
machine, hard-whites pulp sub can be purchased
by partially integrated and nonintegrated mills for a
lower price than market pulp. Unused envelope
paper is an appropriate alternative to purchased
pulp for some higher cost mills producing higher
priced paper products.
The availability of envelope cuttings will not
improve for nonintegrated paper producers for
several reasons. First, growth in envelope produc-
tion is expected to be modest, roughly equal to the
GDP. Envelope paper use, as measured by
American Paper Institute (1992a), increased at a
compound annual rate of only 1.6 percent between
1986 and 1991, almost matching the GDP which
grew at a rate of 1.9 percent. Second, as stated ear-
lier, most of the paper by-product from envelope
manufacturing is currently being recovered. Third,
producing envelopes is a better source of income
than selling paper cuttings.
CTMP BHK
BSK Recycled
Pulp
Minimizing process waste is a high priority
among all envelope manufacturers. It should be
kept in mind that envelope manufacturing waste
seldom finds its way back to envelope paper. En-
velope cuttings are used by higher cost, partially in-
tegrated and nonintegrated paper mills. On-site
pulp manufacture is the lowest cost approach for
obtaining fiber. Specifying a waste component for
reuse in envelope papers will only add cost to the
highly competitive raw material.
Concerns About
Postconsumer Content
Envelope manufacturers are dedicated to improv-
ing the efficiencies of their operations through
reducing the amount of paper cuttings and by im-
proving the up-time of the converting equipment.
The recycled papers available today that contain
postconsumer waste tend to display highly variable
properties, for example, appearance, strength, and
performance. When paper strength is low, the
production rate of envelope equipment must be
reduced, which raises manufacturing costs. Fre-
quent breaks from poor paper properties increase
waste.
Some recycled envelope papers can be
managed to run reasonably well on envelope con-
verting equipment. The cost of set up time can be
expected to go down as experience running these
papers increases. However, it is difficult to expect
that papers containing high levels of post consumer
fiber will ever perform as well as virgin papers.
253
-------
Direct Customers
Postconsumer waste tends to be laden with
contaminants. Some of these contaminants, even
after deinking, end up in the recycled paper where
they act as defects. Defects are not only aesthetical-
ly undesirable; they also degrade paper perfor-
mance on high speed envelope converting
equipment.
Envelope production is a highly competitive in-
dustry where manufacturing efficiency dictates
profitability. Today's envelope paper by-product is
considered a premium pulp substitute. Poor per-
forming paper would affect envelope manufac-
turers negatively on two fronts. Low strength and
contamination could reduce hard-won manufac-
turing efficiencies and productivity as well as
replace a premium value by-product with a less
desirable, lower valued contaminated waste.
Fiber to Energy
In cases where the collection of fiber is not pos-
sible, such as on envelopes sent to residences, con-
verting fiber to energy makes more sense than the
costly activities to reclaim fiber for reuse in paper.
In this way, the fiber is in fact reused — but to make
energy rather than paper — and the objective of
reducing the volume of paper products going to
landfills is satisfied. The achievement of the 40 per-
cent recovered paper goal in 1995 still leaves 50
million tons of discarded paper unused. Converting
this noneconomically reclaimable fiber to energy is
an option that makes economic sense since energy
is a valuable commodity. There are more than
6,000 coal-fired boilers in operation with the
ability to use 900 million tons of coal. Pelletized
fuel would displace 5 percent of this capacity with
a cleaner burning substitute.
Georgia-Pacific has a fiber-to-energy pilot pro-
gram at its Crossett, Arkansas, operation. Non-
reclaimable waste paper from Ashley County,
Arkansas, will be pelletized and sold as sup-
plemental fuel to the Georgia-Pacific mill in .Cros-
sett. This project should reduce the waste to the
Ashley County landfill by 65 percent. Cost-effective
solutions to landfills for nonreclaimable fiber are
appearing.
Alternatively Bleached Fiber
Our customers have not requested envelopes
manufactured from so-called totally chlorine-free
paper. Of course, we will work to satisfy requests, if
they appear, as we have for requests to supply en-
velopes made from recycled paper. However,
quality paper must be available at competitive
prices. We expect to experience greater difficulties
in procuring chlorine-free envelope papers than we
experienced in procuring recycled papers. We
have learned from our recycling activities that two
key requirements must be met to satisfy any new
customer requests.
Totally Chlorine-free Papers
First, totally chlorine-free papers must be available
at prices competitive with existing envelope
papers. Customers willing to pay a premium for
chlorine-free products will most likely be the ex-
ception rather than the rule — as they are for
recycled papers.
Essentially, no price premium has been real-
ized for envelopes incorporating expensive
recycled fiber. Situations in which a price premium
has been realized that reflects the higher costs of
the recycled paper are expected to be evermore in-
frequent in the future. Similarly, we expect price
parity with existing envelope papers to be a re-
quirement for the long-term viability of any en-
velopes sold to high volume, highly competitive
end users. If a niche for chlorine-free envelope
papers evolves, it is likely to be in markets currently
satisfied by existing high-priced premium products
such as writing grades and cover and text papers.
Index of Constant ('92) $/Ton
2.1
1.9
1.6
1.3
1.0
RISI 8/92
Forecast
I
I i
j
I I I I
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005
Figure 3.—Relative industry prices for uncoated free
sheet as compiled by Resource Information Systems,
Inc., Bedford Massachusetts.
Figure 3 presents an index of the historical and
projected price of uncoated free sheet paper be-
tween 1959 and the year 2005 in relative constant
1992 dollars. As was discussed in the situation
analysis of recycled papers, the price for high
volume papers used to produce envelopes reflects
the lower competitive costs of fully integrated
modern paper-making facilities. As a result, the
constant dollar price of uncoated free sheet papers
has steadily declined and is projected to continue
to decline. Any increase in the cost to produce that
fiber will jeopardize the competitive position of the
U.S. paper industry in the world market. With
today's technology, the elimination of chlorine
254
-------
M.I. COUSIN
from the bleaching process for kraft pulps is un-
necessary, since emission targets are being satis-
fied. In addition, these changes are prohibitively
expensive.
Second, envelope stocks produced from
chlorine-free pulps must meet the quality and per-
formance standards of today's papers. Most of the
current chlorine-free pulp is produced in sulfite
mills. We do not believe that these pulps meet the
above criteria because the sulfite process is
generally more costly to operate than kraft mills at
modern facilities, and the suitability of the fiber
produced for high performance envelope grades is
questionable.
Chlorine-free Fiber Source
Sulfite pulp displays lower strength than pulp
produced using the kraft process. Long fiber is the
primary source for strength in envelope papers. The
sulfite process is seldom used in the United States
for producing the softwood pulp that is used in per-
formance papers such as envelope. In fact, the kraft
pulping process was developed to take advantage
of the strength properties of long fiber. Envelope
papers must be strong to assure cost-effective
operating efficiencies at envelope converting
facilities. Reducing the paper's strength would re-
quire a corresponding increase in the weight of the
envelope paper to assure good performance of the
converting equipment, a move that is counter to
source reduction strategy.
Sources of sulfite pulp are limited and represent
only 4.7 percent of bleached pulp production. In
the United States, available bleached pulp made
from the sulfite process has decreased at a com-
pound annual rate of 3.9 percent between 1980
and 1990. At the same time, an additional bleached
kraft capacity of 8.6 million tons has been intro-
duced (Am. Pap. Institute, 1992c). A few sulfite
mills are still producing printing and writing papers
at older, higher cost facilities, particularly in
Europe, and especially Germany. Once again,
these operations tend to produce higher priced
grades to avoid competing with the lower cost
structure of the newer U.S. world-class facilities.
Bleached pulp production costs will increase if
the use of a totally nonchlorine bleaching process
is imposed. Still, nonchlorine bleaching may be a
less expensive alternative to expending the sig-
nificant capital dollars required to replace an exist-
ing sulfite mill with a new kraft mill. Again, these
older sulfite pulp mills are already more costly to
operate than Kraft mills. "Chlorine free" technology
will further increase sulfite pulping costs..
On-site pulp production will also remain a
lower cost alternative than purchasing market pulp.
Higher cost, partially and nonintegrated papermak-
ing facilities can purchase any available market to-
tally chlorine free pulp to produce paper. Higher
cost mills are not viable long-term options for en-
velope production regardless of the bleaching tech-
nology.
Quality is a paramount concern for perfor-
mance paper grades such as envelope. The inten-
sity of the bleaching process is guided by the
acceptable trade-offs in strength and brightness.
Strength is critical for acceptable product perfor-
mance, while brightness is customer driven. We
understand that today's proposed TCP approaches
severely reduce strength as market brightness is
sought. Because strength cannot be sacrificed, we
are concerned that a decline in initial pulp bright-
ness will result from the imposition of chlorine-free
bleaching. We know that customers will not accept
lower quality whether the product is envelope or
premium grades. Costly chemical brighteners may
be needed to maintain competitive paper quality.
Summary of Alternatives to
Chlorine Bleaching
It will be difficult to find high quality chlorine-free
paper that is competitive for use in envelopes.
Some markets may evolve for chlorine-free paper,
but these niches will be in markets where volume is
relatively small and growth is limited. Only the
manufacture of higher priced products can provide
the returns required to offset the higher costs of
production. We must keep in mind that today's
bleaching processes continue to meet and exceed
both product performance and pollution guidelines
as well as offer the lowest cost approach to provid-
ing safe paper products.
The Ink Story
Envelopes are used to contain and protect docu-
ments for delivery through the mail as well as to
present information and a message. This informa-
tion can be as mundane as an address or as unique
as an advertising statement composed of multi-
color, high-coverage graphics. Quality printing is
an important and necessary component of en-
velope production.
Changing Inks
According to EMAA data, approximately 65 per-
cent of all envelopes are printed using the
flexographic process in which a flexible plate con-
taining the raised image transfers ink directly to the
envelope paper. The balance is printed using the
offset process. Envelope printing has enjoyed a
255
-------
Direct Customers
dramatic change since 1980 when 70 percent of
the printing was accomplished using solvent-based
inks. The flexographic process is almost entirely
100 percent water-based.
The industry will continue to work in partner-
ship with its ink suppliers to promote the ongoing
development and further implementation of water-
and vegetable-based ink resins in offset printing,
which will further reduce the use of solvents in the
printing environment and in the waste streams.
Source Reduction
One of the most exciting developments in the en-
velope industry can be seen in the pilot trials at
Mail-Well for on-site formulation of aqueous
flexographic ink colors. Flexs inks are a close
cousin to latex paints. Colors can be prepared on
an ''as needed" basis, like paints, to complete a
single job. Thus, the'waste and possible disposal is-
sues for unused ink colors can be avoided.
Reclamation
The reclamation of waste inks is another exciting
development. Unused ink is being recycled at
several Mail-Well locations. Excess ink colors are
collected, mixed and returned to the original ink
supplier for reformulation. The ink vendor adjusts
the mixture to produce a recycled black ink that is
sold back to Mail-Well for reuse. This successful
recycling project prevents pollution and reduces
operating costs. Lower costs assure that ink
reclamation will be a long-term management and
technological approach to pollution prevention.
Conclusions
The envelope industry is proud of its obvious suc-
cesses in pollution prevention and waste avoid-
ance. The activities discussed here and any
additional efforts are the consequence of an en-
vironmental partnership between manufacturers
and suppliers. The results are long-term solutions
because they make economic sense. Thus, for ex-
ample, envelope waste is reclaimed because it
makes economic sense.
Recycling for paper production also makes
economic sense when the fiber is a lower cost alter-
native to other fiber sources. The by-product paper
of envelope production is almost completely used
today at partially or nonintegrated papermaking
facilities producing higher priced products.
Economics must be allowed to dictate the ap-
propriate end-use for fiber. Cost-competitive, high-
volume performance grades such as envelope
paper do not provide the most effective long-term
area for use of postconsumer fiber. Postconsumer
fiber may be more effectively used in papers that
have less demanding requirements for aesthetics
than envelopes. Converting nonreclaimable fiber to
energy makes economic sense.
Chlorine-free envelope papers are not in
demand. Today, the sulfite process appears to be
the most appropriate application of nonchlorine
bleaching technology. However, these processes
either reduce the strength of paper-making fiber or
provide lower brightness paper. Kraft pulps will still
be required to maintain the demanding perfor-
mance requirements of envelope papers to avoid
increasing the weight of the paper.
Today's kraft bleaching processes continue to
meet and exceed pollution guidelines. Legislating
bleaching technology does not make economic
sense and is not a long-term solution.
The transition of envelope printing to water-
based flexography is an example of progress that is
long-term because it prevents pollution and lowers
manufacturing costs without sacrificing quality.
The envelope industry in the United States, along
with the pulp and paper industry, will remain world
class and cost-competitive as long as sound busi-
ness decisions continue to guide the introduction of
innovations.
References
American Paper Institute. 1992a. Annual Statistical Summary,
'91. Printing-Writing Pap. Div., New York.
. 1992b. Periodical Papers Marketing Information, '91.
Printing-Writing Pap. Div., New York.
-. 1992c. 1991 Statistics of Paper, Paperboard and Wood
Pulp. Printing-Writing Pap. Div., New York.
Miller Freeman, Inc. 1991. U.S. wastepaper prices by region.
Pap. Recycler2:12.
256
-------
Creating Demand for
Environmentally Preferable Paper
Lauren Blum
Staff Scientist
John Ruston
Economic Analyst
Environmental Defense Fund
New York, New York
Environmental Impacts of Paper
Manufacturing and Consumption
The United States' propensity to use ever larger
amounts of paper, especially bright white paper,
has two significant environmental impacts. First,
pulp and paper manufacturing generates significant
air and water pollution. Second, U.S. consumption
of paper — 580 pounds per person per year on
average — makes discarded paper by far the largest
component of municipal solid waste. Pollution
prevention technologies exist, however, and will
become more profitable industry investments as
consumer demand increases for environmentally
preferable paper products.
Chlorine Bleaching
Improving manufacturing processes and eliminat-
ing chlorine-containing chemicals from the delig-
nification and bleaching of pulp will practically
eliminate water pollution, significantly reduce ef-
fluent flow and lower chloroform air emissions.
Currently, organic waste from bleaching stages that
use chlorine-containing chemicals must be dis-
charged because the chloride ion in the wastewater
is very corrosive. The long-term goal is for pulp
mills to recycle most or all bleach plant effluent to
the recovery boiler, thereby obtaining additional
fuel value from the recovered organic waste.
Eliminating chlorine compounds from the
bleaching process also offers significant reductions
in water pollutants such as biological oxygen
demand (BOD) and color. The effect of these
process changes is most apparent when one com-
pares the effluent from Union Camp's traditional
bleaching sequences with that projected for its
ozone extended delignification or oxygen extended
delignification (OZED) process now in the final
stages of installation in Franklin, Virginia. Union
Camp's oxygen extended delignification process
yields an 85 ISO brightness pulp that uses 75 per-
cent less chlorine dioxide than a bleaching se-
quence with 100 percent chlorine dioxide
substitution. As shown in Table 1, this process also
produces 94 percent less BOD and 99.2 percent
less color for softwood pine bleached to 82 ISO
brightness (McCubbin etal. 1992).
By moving to nonchlorine-compound bleach-
ing processes, pulp mills can eliminate chlorinated
organic compounds, a major environmental
hazard, from water and air discharges. Most
chlorinated organic compounds (with the excep-
tion of chlorofluorocarbons) have high levels of
biological activity regardless of their therapeutic or
harmful effects (Fleming, 1992).
The detrimental effects of persistent chlorinated
organic compounds on the health of wildlife and
humans have been documented (Great Lakes Sci.
Advis. Board, 1991). Although our knowledge of
chlorinated organic compounds present in pulp
mill effluent is increasing, there is still much to
learn. Of the 313 organic compounds identified in
a study of pulp mill effluent, 205 are chlorinated or-
ganics (McKague et al. 1989). Significant amounts
of chlorinated lignins are also discharged. Jokela
and Salkinoja-Salonen (1992) have shown that the
average molecular weight (Mw) of the chlorinated
organics isolated from four bleached kraft mill ef-
fluents ranged from 330 to 550. C. Wesen (1988)
257
-------
Direct Customers
Table 1.—Comparison of conventional and chlorine-free bleaching at Union Camp, Franklin, Virginia.
Bleach plant effluent flow
Southern Pine Pulp To 82 ISO Brightness
TOX in pulp
TOX in bleach plant effluent
Chloroform generation
BOD in bleach plant effluent
Color (APHA chloroplatinate)
Breaking length
Viscosity
Tear
Bleaching chemical cost*
UNITS
m3/t pulp
kg/t pulp
kg/t pulp
kg/t pulp
kg/t pulp
kg/t pulp
km
dm2
$US/t
CEDED
47.0
0.28
6.5
0.18
16.0
185.0
13.8
17.0
111.0
50.0
OC/D(30)D
16.0
0.13
3.0
0.008
7.0
42.0
12.4
13.0
119.0
33.0
OZED
14.0
0.04
0.08**
0.002
1.0
1.5
12.3
11.0
124.0
17.0
Mixed Southern Hardwoods to 82 ISO Brightness
TOX in pulp
TOX in bleach plant effluent
Chloroform generation
BOD in bleach plant effluent
Color (APHA chloroplatinate)
kg/t pulp
kg/t pulp
kg/t pulp
kg/t pulp
kg/t pulp
0.2
3.0
0.18
8.0
55.0
0.12
2.0
0.1
4.5
12.0
0.03
0.06**
0.002
1.0
0.5
*At typical U.S. costs, assuming current dioxin control measures have been implemented.
"Depends on amount of chlorine in chlorine dioxide.
Source: McCubbin Consultants, 1992.
found that 60 percent of the substances recovered
from fish and sediment had molecular weights
above 300. Highly studied acutely toxic com-
ponents of mill effluent, such as dehydroabietic
acid, most chlorinated phenols, and guaiacols, all
have molecular weights below 300. We may also
discover new compounds with health effects as
serious as dioxin's have been. For example, one
review article discusses a chlorinated organic com-
pound that is an extremely potent bacterial
mutagen (Holmbom, 1990). Since the mix of
chlorinated organics cannot be controlled in the
pulp manufacturing process, the International Joint
Commission on Great Lakes Water Quality recom-
mends that "industry and other affected parties
develop timetables to sunset the use of chlorine
and chlorine-containing compounds as industrial
feedstocks" (Int. Joint Comm. 1992).
Solid Waste and Recycling
Solid waste is the environmental impact most wide-
ly recognized among the general public that results
from mass paper consumption. Paper and paper
packaging currently comprise about one-third of
the 162 million tons of trash disposed in landfills
and incinerators in the United States (Franklin
Assoc. 1992a). Paper is also the most widely
recycled material in municipal solid waste. As we
collect more and more paper in curbside and office
paper recycling programs, it is critical that we also
expand the markets for recovered paper.
Increasing the use of recycled fiber in printing
and writing paper products has paramount impor-
tance, especially in papers used in office applica-
tions, commercial publications, business forms,
books, and magazines. Only two producers of
recycled printing and writing paper in the United
States have the equipment to remove significant
quantities of laserjet and photocopy ink from
recovered office paper. A handful of additional
mills make recycled printing and writing paper
using recovered paper that is less contaminated as
a raw material. Paper recycling technology in this
sector is improving rapidly, but more mills need to
install it. Overall, in 1990, 22 million tons of print-
ing and writing paper were consumed in the United
States, but only 1.4 million tons of recycled fiber
were used as a raw material in printing and writing
paper manufacture; the remaining 94 percent was
virgin fiber (Franklin Assoc. 1992b).
For other paper products, for example,
newsprint, corrugated boxes and recycled folding
cartons (such as cereal boxes), the paper industry is
already making major investments to add recycling
capacity. In 1989, for example, there were nine
newsprint mills in North America that consumed
old newspapers for some or all of their fiber supply.
By 1992, 19 such mills were operating. Recycling
capacity had been added to 10 mills that had
formerly used only virgin fiber. By 1995, the total
will be about 30 (or roughly 40 percent of
newsprint mills in operation; old newspapers are
also used by mills that make recycled boxboard
packaging) (Am. Papermaker, 1992).
Currently, the availability and pricing of
recycled printing and writing paper are often not
competitive with virgin paper. Although the rela-
tively few mills that produce recycled printing and
writing paper often have lower raw material costs
258
-------
L BLUM&J. RUSTON
than nonintegrated virgin mills, the recycling mills
tend to be smaller and older, and hence have
higher overall costs than major virgin producers.
Until consumer demand is demonstrated, the
largest, most efficient producers of printing and
writing paper will remain hesitant to add recycling
capacity.
Importance of Consumer Demand
for Environmentally Preferable Paper
Change in the capital-intensive paper industry is
usually slow and incremental. Traditionally, paper
mills have been critical of investments in pollution
control technology since such investments usually
do not increase mill productivity. The paper in-
dustry is also quite competitive, however, and ul-
timately mills must meet the needs of their
customers. Major investments in recycling equip-
ment are now being planned at many paper mills.
Technology is also currently available to produce
white paper without using chlorine compounds,
but mills are generally not moving to install it. This
reluctance is caused by a combination of cost, risk
aversion, a historical commitment to marketing
brighter and whiter paper, and the accurate percep-
tion that consumer demand for chlorine-free white
paper has yet to develop.
The impact of consumer demand on the paper
industry is visible in the production and marketing
shifts of individual companies that make paper with
recycled content. The major expansion of recycling
capacity now underway in the newsprint industry is
a result of (1) an increased supply of raw materials
due to the growth of community recycling
programs and recycling by private waste haulers
seeking to avoid rising tipping fees; (2) tne ex-
panded use of flotation deinking technology; and
(3) demand for more recycled newsprint by
newspaper publishers, who are in turn responding
to their readers, state legislation (in California, Con-
necticut, and Florida), and voluntary agreements
between publishers and state officials (in Mas-
sachusetts and New York).
In the tissue industry, recycling-based com-
panies that have traditionally served the commer-
cial and institutional market have now introduced
products aimed at environmentally conscious
households. The Fort Howard Corporation, for ex-
ample, has introduced the Green Forest™ label,
and Green Bay Packaging, Inc., has introduced
recycled linerboard products in which the top liner
is made with recovered newsprint or office paper
(the Ecobrite™ and Ecowhite™ brands, respective-
ly). In order to sell their products in recycled pack-
aging, companies such as Proctor & Gamble,
Kodak, and Bristol-Myers Squibb are shifting some
of their products into recycled boxboard (the
material used to make cereal boxes). This has
revived profits and growth in a sector of the paper
industry that had otherwise been losing market
share for over a decade.
Defining Environmentally
Preferable Paper
Manufacturers generally produce what consumers
demand. In the paper industry, production methods
are changing as consumers become more aware of
the environmental issues associated with paper
use, particularly recycling. Creating consumer
demand for unbleached, reduced brightness, and
chlorine-free papers is more difficult since in-
dividuals are less aware of the environmental im-
pacts of pulp and paper manufacturing. In compar-
ison, paper procurement officials in business and
government, tend to be specialists, and are capable
of absorbing a greater amount of information on
environmental issues associated with paper
production and use.
An initial step in building demand for "environ-
mentally preferable" paper among business con-
sumers is to develop a detailed framework that
helps paper purchasers match environmentally
preferable papers to specific end uses (e.g., four-
color text books, tissue, and cosmetics packaging).
As paper users shift demand to environmentally
preferable papers, some mills will expand produc-
tion of existing products and others will develop
new products. This change will be an incremental
process, requiring cooperation among users, sup-
pliers, and manufacturers. Several types of shifts in
paper use can help reduce the environmental im-
pacts of paper production and disposal. Environ-
mentally preferable paper products fall into four
major categories. The selection of a given type of
paper from these categories will depend largely on
the performance requirements of a specific paper
product.
Recycled Paper
The oversupply of recovered paper relative to cur-
rent market demand has put a damper on com-
munity and business recycling programs. Recycling
markets can be strengthened if businesses increase
their use of paper with recycled content. In addi-
tion, because recovered office paper, for example,
has already been bleached once, producing
recycled paper does not require the heavy use of
chlorine that bleaching virgin pulp requires.
Making paper from recycled fiber substantially
reduces energy and water consumption; using
259
-------
Direct Customers
recycled fibers also reduces demand for forest
resources and the related conversion of natural
forests to monoculture pine plantations.
Unbleached Paper
Many needs, especially in packaging, can be met
without the use of bright white paper. For example,
the McDonald's Corporation in 1991 switched
from white virgin takeout bags to brown, 100 per-
cent recycled bags, and to brown wraps for its Big
Mac hamburgers (Capatosto et at. 1991). Kellogg's
Eggo™ waffles are packaged in coated unbleached
kraft paperboard, a strong, high-quality product
that is coated on one side to allow for high quality
graphics. This product is a viable alternative to
white virgin bleached paperboard (e.g., a doughnut
box). A number of office products such as file
folders and large envelopes could be made from
unbleached or semibleached paper. Of the nearly
26 million tons of bleached paper and paperboard
produced annually in the United States, we es-
timate that roughly 8 million tons are used in ap-
plications, primarily packaging, in which whiteness
and functionality are not strictly related.
High-yield Mechanical and Sulfite Papers
Because mechanical pulps are bleached with
hydrogen peroxide or sodium hydrosulfite instead
of chlorine, they are not associated with the
generation of chlorinated organic compounds. The
same is true of high-yield sulfite pulps. Sulfite pulp-
ing produces a creamy colored pulp without
bleaching, and a white pulp when bleached with
hydrogen peroxide. While not quite as strong or as
bright as bleached kraft pulp, paper made from
these pulps can be used for a number of applica-
tions, such as business forms. The McDonald's Cor-
poration is testing a chlorine-free sulfite paper for
its small french-fry bags.
Groundwood, chemithermomechanical pulps
(CTMP), bleached CTMP, and high yield sulfite
pulps should also be considered because they use
trees more efficiently. Yields of these processes
range from above 92 percent for groundwood to 75
percent for high yield sulfite, compared to yields for
kraft pulp of 45 to 55 percent (McGovern, 1985).
Chlorine-free Bleached Kraft Paper
Several new technologies are available that use
oxygen-based compounds in place of chlorine to
remove lignin and whiten paper fibers to produce a
strong, high-quality pulp. Newly constructed kraft
pulp mills in the United States and worldwide are
using these technologies because they also cut
chemical and pollution control costs. For older
mills, retrofits can be expensive, depending on the
type of the mill and the products it makes. One fac-
tor in determining the economic viability of such
retrofits is the brightness required of the pulp,
which is usually specified by the consumer. For
many types of paper, such as photocopy, ledger, or
book paper, brightness can be reduced without im-
pairing the function of the paper. A beige, cream, or
ivory paper will be easier on the eyes, and perhaps
an aesthetic improvement, but even a barely dis-
cernable reduction in brightness may significantly
improve the economics of the oxygen-based
bleaching systems. Thus, a major opportunity exists
to move customer demand toward less bright
paper, in turn making it more viable for mills to in-
stall nonchlorine bleaching technologies.
Totally chlorine-free (TCF) kraft pulp is current-
ly produced by 12 mills worldwide — 10 in
Europe, two in North America (Cox, 1992). These
mills use oxygen delignification or extended cook-
ing, or both, with enzymes or other oxygen con-
taining chemicals (ozone, hydrogen peroxide,
sodium hydrosulfite) to replace chlorine, chlorine
dioxide, and sodium hypochlorite.
Installation of prebleaching stages (oxygen
delignification and extended cooking are the most
widely used technologies) is a critical step for pulp
mills in their move toward the long-term goal of
closed recovery systems. Both technologies — a
combination is best — reduce the amount of lignin
in the prebleached pulp to a low enough level that
other nonchlorine-containing chemicals can
brighten the pulp to 80 or 85 GE brightness. Reduc-
ing the lignin in the pulp before it enters the bleach
plant also reduces the amount of chlorine and
chlorine dioxide needed to obtain high brightness
kraft pulps.
These reductions are significant — oxygen
delignification reduces the amount of chlorine used
to bleach the pulp by 50 percent. For a plant that
produces 1,000 tons of pulp per day, oxygen delig-
nification and 70 percent chlorine dioxide substitu-
tion reduces elemental chlorine requirements from
42 tons per day to 6.4 tons per day, combined with
5.7 tons per day of chlorine dioxide (Bettis, 1991).
The elimination of elemental chlorine and
sodium hypochlorite is also important since studies
show that the chlorination and first extraction
stages generate over 90 percent of the chlorinated
organics present in bleached kraft mill effluent
(Hall et al. 1989). High levels of chlorinated or-
ganics are extracted from the first extraction stage
because the alkali solution solubilizes many of the
compounds that are insoluble in the acidic filtrate
from the chlorination stage.
260
-------
L BLUM&J. RUSTON
Sodium hypochlorite is a significant concern
because it generates large amounts of chloroform, a
substance thought to be a probable human car-
cinogen, as a by-product of the bleaching process.
A CEHDED sequence results in releases of 240 to
300 grams per air-dried metric ton of pulp, al-
though the paper industry's National Council for
Air and Stream Improvement (NCASI) has reported
chloroform emissions exceeding 1,200 grams per
air-dried metric ton of pulp (McCubbin et al. 1992).
Under the U.S. Environmental Protection Agency's
Industrial Toxics Project, companies that emit
chloroform to water, land, or air are being en-
couraged to voluntarily cut those emissions by 50
percent from 1988 baseline levels by the year 1995
(Mies etal. 1992).
For bleached kraft papers, pulping processes
that use oxygen delignification and extended cook-
ing with 100 percent chlorine dioxide substitution
(no elemental chlorine or sodium hypochlorite) are
the next step down a hierarchy of environmental
preference. At the top of the hierarchy of environ-
mental preferences is paper made from totally
chlorine-free pulp, but four categories exist. They
are interchangeable and selection depends on
one's specific requirements. The categories are
• unbleached kraft,
• 100 percent recycled kraft,
• hydrogen peroxide and/or sodium
hydrosulfite paper (e.g., groundwood,
bleached and nonbleached CTMP, and high
yield sulfite,), and
• totally chlorine-free kraft.
Following TCF pulp, in order of environmental
preference, come bleaching processes that use
• no elemental chlorine or sodium
hypochlorite with oxygen delignification
and/or extended cooking for kraft pulp,
• high chlorine dioxide substitution with
oxygen delignification and/or extended
cooking for kraft pulp,
• 100 percent chlorine dioxide substitution
(no chlorine or sodium hypochlorite is used
[elementally chlorine free]), and
• chlorine with process improvements, such
as high chlorine dioxide substitution,
elimination of hypochlorite stages, and
efficient brownstock washing.
Pulping processes that have oxygen delignifica-
tion or extended cooking with high chlorine
dioxide substitution (the higher the level of sub-
stitution, the better) are preferred to processes that
use 100 percent chlorine dioxide only. Again, in-
vestment in oxygen delignification or extended
cooking systems is the first step in the conversion to
pulp manufacturing processes with the least en-
vironmental impact.
Investment in additional chlorine dioxide
capacity will solve the short-term problem of
dioxin contamination, but a significant amount of
chlorinated organics will still be produced. Mc-
Cubbin et al. (1992) estimated the adsorbable or-
ganic halogen (AOX) level for the eight kraft mills in
Ontario with different combinations of pollution
prevention technology. With 100 percent chlorine
dioxide substitution, AOX levels ranged from 0.35
to 0.75 kg AOX per air-dried metric ton of pulp. The
addition of oxygen delignification or extended
cooking reduces these levels to 0.24 to 0.60 kg
AOX per air-dried ton of pulp. Installation of
oxygen delignification and extended cooking with
100 percent chlorine dioxide substitution reduce
these levels by an additional 20 percent on
average.
If a specific paper use requires pulp bleached
with elemental chlorine, a purchaser should work
with a mill that minimizes its use. These mills
should have made process improvements such as
high chlorine dioxide substitution, efficient brown
stock washing, and elimination of sodium
hypochlorite stages.
Incorporating Environmental
Preferences into Paper
Purchasing Decisions
Large institutional users of paper make purchasing
decisions based on performance, availability, and
cost. By adding environmental preferences to this
set of criteria — with equivalent weight to other
factors — consumers can use demand to reward
mills that are making investments and products that
improve the environment.
Paper consumers, the environment, and in-
dustry can benefit from shifts to environmentally
preferable papers. In this section, we present a
framework that incorporates environmental prefer-
ences into paper specifications. The framework
(see Fig. 1) includes criteria from the following
three areas:
• performance, cost, and availability;
• environmental preferences; and
• recyclability.
Application of this framework begins with a
reevaluation of performance criteria. When iden-
tifying performance characteristics, paper users
261
-------
Direct Customers
PERFORMANCE
CHARACTERISTICS
ENVIRONMENTAL
PREFERENCES
RECYCLABILITY
SPECIFICATIONS FOR
ENVIRONMENTALLY PREFERABLE
PAPER
IMPACT ON PAPER COSTS
Large specification change - savings
Small specification change - no change
No specification change - increase
Figure 1.—A framework to incorporate environmental preferences into paper specifications.
should focus on what they actually need the paper
to do. Purchasers should consider three major
aspects of performance: functionality, brightness,
and strength.
Functionality requirements depend on the
specific use of the paper product. For four-color
textbooks (high quality printing), for example, run
ability, low dot gain, low nicking, and linting are
important properties of the paper. In the case of
brightness, a key question is How bright does the
paper really need to be to perform its function? A 5
to 10 point reduction in the brightness of photo-
copy paper, for example, will not compromise the
ability of a person to read printing on the page.
Strength requirements vary dramatically for dif-
ferent paper products. For paperboard used for
beverage carriers, wet strength and a smooth print-
ing surface are key attributes, while absorbency
and softness are important for tissue.
Since the pulp manufacturing process strongly
affects brightness and strength, users should
evaluate their requirements carefully. Where pos-
sible, reducing strength requirements will give
paper buyers a wider possible selection of currently
available papers made from totally chlorine-free
manufacturing processes. An accurate definition of
the performance characteristics facilitates the iden-
tification of environmentally preferable paper
products for a given end use.
With performance characteristics in hand, we
can determine which paper grades are actually en-
vironmentally preferable for a given use. Paper
with recycled content is preferred to virgin paper
because use of recycled paper reduces the con-
sumption of virgin materials and builds markets for
recovered paperstock.
Unbleached kraft paper is by definition totally
chlorine-free paper. One hundred percent recycled
paper may be unbleached or bleached with
hydrogen peroxide depending on the original
brightness of the recycled fiber and the use re-
quired of the paper.
Recyclability should also be considered in the
selection of environmentally preferable paper.
Recyclability depends on three factors:
• the intrinsic qualities of the sheet,
• end use requirements, and
• the local and regional recycling
infrastructure.
Coating, for example, can be an intrinsic
quality of a sheet. Coated sheet has a high percent-
age of clay or precipitated calcium carbonate add-
ed, which must be separated from the fiber during
the pulping process.
Inks, dyesA adhesives, laminates, and other
materials also affect recyclability. In some cases the
use of significant quantities of groundwood paper
(in either virgin or recycled sheet) in office settings
can downgrade the commodity value of paper
recovered from the office. Setting up stations for
262
-------
L BLUM&l. RUSTON
recovering paper of particularly high value, such as
impact-printed computer paper, is a partial means
of avoiding this problem.
hicorporating environmental specifications
may have three impacts on paper costs. In some
cases, applying this framework will result in a large
specification shift, from bleached folding cartons to
unbleached kraft or recycled boxboard, for ex-
ample, which can lead to significant cost savings.
Small specification changes, for example, switch-
ing to a totally chlorine-free copy paper with an 80
GE brightness from a virgin sheet with 84 GE bright-
ness, should result in at most a small cost increase.
Incorporating environmental preferences, for ex-
ample, a shift to high brightness (90 GE brightness)
and totally chlorine-free printing paper, may in-
crease paper costs. Ideally, the net cost effect of a
package of shifts to environmentally preferable
paper within a firm will be zero or negative.
Examples
Paper consumers can use this framework to identify
the environmentally preferable options for a given
end use. Two brief examples of how to identify en-
vironmentally preferable paper follow. These ex-
amples are simplified and present options for a
range of end uses. The actual selection process will
require a careful consideration of detailed speci-
fications for a product and how they could change
to incorporate environmental preferences.
Folding boxboard cartons are used to package
many consumer products ranging from cereal and
dog biscuits to cosmetics and pharmaceuticals.
Folding boxboard is usually printed with graphics
that promote and identify the product. Three types
of folding boxboard are available today (see Fig. 2).
Clay-coated recycled boxboard has 100 percent
recycled content and is coated with clay to provide
a smooth white printing surface. The inside of the
box is gray, brown, or white, depending on the type
of fiber used in the liner. Coated unbleached kraft
paperboard is a virgin, unbleached boxboard. It has
a clay-coated surface but a brown interior. Solid
bleached sulfate paperboard is bleached using
chlorine-containing chemicals. It has the smoothest
printing surface, and its white interior is preferred
by marketers who believe that this packaging
promotes an image of hygiene or high quality.
When applying the hierarchy of environmental
preferences to a product that could be packaged in
any of the materials, we prefer using recycled box-
board because it is unbleached and uses no virgin
materials. Coated unbleached kraft would be the
second best choice since it is made from un-
bleached virgin materials. Use of solid bleached
sulfate would be the least environmentally prefer-
able choice.
The performance requirements of the end use,
however, may require the use of a different
material. Coated unbleached kraft boxboard has
penetrated the frozen food packaging market, once
dominated by solid bleached sulfate, because its
superior wet strength results in better performance
of the package in freeze/thaw cycles. Cosmetics
and pharmaceutical packaging offer an opportunity
to switch to an environmentally preferable package
SOLID BLEACHED
SULFATE
Preferred Shift
Bleaching "required" for use
e.g., ice cream carton
CLAY-COATED
RECYCLED BOXBOARD
TOTALLY CHLORINE FREE
SOLID BLEACHED SULFATE
Strength/density
Product requirements
- Wet strength
- Tear strength
COATED UNBLEACHED
KRAFT
Figure 2.—Application of the framework: folding boxboard.
Available today
— - To be developed
263
-------
Direct Customers
— they have no functional characteristics that re-
quire the solid bleached sulfate packaging.
Direct contact food packaging is another area
where solid bleached sulfate packaging currently
dominates the market. Both bleached and un-
bleached kraft boxboard producers can certify to
the satisfaction of the U.S. Food and Drug Ad-
ministration (FDA) that the level of metals and toxic
compounds in their raw materials meet the require-
ments for food contact.
Recycled boxboard producers cannot make
this claim because they cannot completely control,
and thus guarantee, the content of their raw
materials. Recycled boxboard manufacturers, how-
ever, are performing the extractive tests required for
FDA approval for direct food contact applications.
If this packaging must be bleached, the consumer
products companies that sell food products can
work with solid bleached sulfate producers to cre-
ate a product that is totally chlorine-free. This pack-
aging will not be available in the short-term, but
consumer demand can provide a strong incentive
for these boxboard manufacturers to make the
necessary investments.
Environmentally preferable options can also
replace high brightness printing papers (see Fig. 3).
Several possibilities exist for printing jobs that re-
quire 85 GE brightness paper. If strength is not a
critical issue, printers can use paper that contains
BCTMP — for example, the aspen pulp produced
by Millar Western's new mil' in Meadow Lake, Sas-
katchewan. Not only is this pulp produced without
any chlorine compounds, it produces a strong opa-
que sheet (McCready, 1992).
Many mills can produce elementally chlorine-
free kraft paper using 100 percent chlorine dioxide
in the bleaching process. They have not produced
much, however, because there has been little
demand. Union Camp will also produce elemental-
ly chlorine-free paper using oxygen delignification
and ozone bleaching. The Franklin, Virginia, mill
will produce pulp with comparatively low environ-
mental impact. Mills, including the one in Franklin,
Virginia, can produce totally chlorine-free paper,
but purchasers and manufacturers will have to
work together to see that these products find a
market.
Conclusion
To make the market for environmentally preferable
papers more efficient, consumers need to under-
stand the importance of and learn how to incor-
porate environmental preferences into their paper
purchasing decisions. Educated consumers will re-
quest environmentally preferable papers from their
suppliers and will work with their suppliers to ob-
tain them. The Environmental Defense Fund seeks
to work with paper users and purchasers to deter-
mine specifications for environmentally preferable
paper for specific end uses.
The process, however, does not stop with the
creation of demand for these products. Buyers, sup-
pliers, and manufacturers must work together to en-
sure that supply develops to meet the demand for
environmentally preferable paper. Creating a
market for new paper is an ongoing process — both
specifications and products will evolve as mills in-
stall new technologies to meet the demand for en-
vironmentally preferable products. As mills reap
market rewards for making investments in environ-
mental protection, we will see a stream of new
products. Thus, creating demand for environmen-
tally preferable products benefits consumers, the
environmental community, and the pulp and paper
industry,
References
American Papermaker. 1992. Recycled newsprint production
grows as more deinking plants come on line. 55(2):48.
High brightness
white paper
Strength is not
critical
Bleached Chemi-
Thermo-Mechanical Pulp
(BCTMP)
Result of a cooperative
„ development effort
important
Elementally Chlorine
Free Kraft
Totally Chlorine Free
Kraft
Figure 3.—Application of the framework: printing paper.
264
-------
L BLUM &{. RUSTON
Bettis, J. 1991. Bleach plant modifications, controls help in-
dustry limit dioxin formation. Pages 19-25 in K.L. Patrick,
ed. Bleaching Technologies. Miller Freeman, Inc. San
Francisco, CA.
Capatosto, T. et al. 1991. Page 94 in Waste Reduction Task
Force Final Report. Environ. Defense Fund, McDonald's
Corp. New York, NY.
Cox, J. 1992. North American pulp producers move into
chlorine-free bleaching. Am. Papermaker 55:20-21.
Fleming, B.J. 1992. The organochlorine spectrum: mills, public
must discern toxic, nontoxic. Pulp Pap. 66(4):59-62.
Franklin Associates. 1992a. Characterization of municipal solid
waste in the United States: 1992 update. Pages ES-6, Table
ES-1 in Solid Waste Emergency Response. EPA/530-R-019.
U.S. Environ. Prot Agency. Washington, DC.
-. 1992b. Evaluation of Proposed New Recycled Paper
Standards and Definitions. Rep. Recycling Ad vis. Counc.,
Washington, DC.
Great Lakes Science Advisory Board. 1991. Rep. Int. joint
Comm. Windsor, Ont., Can.
Hall, E.R., J. Fraser, S. Garden, and L.-A. Cornacchio. 1989. Or-
ganochlorine discharges in wastewaters from kraft mill
bleach plants. Pulp Paper Can. 90( 11 ):T421-25.
Holmbom, B. 1990. Mulagenic compounds in chlorinated pulp
bleaching waters and drinking waters. Pages 333-39 in H.
Vainio et al. eds. Complex Mixtures and Cancer Risk. Int.
Agency Res. Cancer. Lyon, France.
International joint Commission. 1992. Sixth Biennial Report
Under the Great Lakes Water Quality Agreement of 1978
to the Governments of the United Stales and Canada and
the State and Provincial Governments of the Great Lakes
Basin. Washington, DC.
jokela, j.K. and M. Salkinoja-Salonen. 1992. Molecular weight
distributions of organic halogens in bleached kraft mill ef-
fluents. Environ. Sci. Tech. 26(6): 1190-97.
McCready, M. 1992. Millar Western-Meadow Lake: making
quality APP/BCTMP that's environmentally correct. Pap.
Age108(l):11-l3.
McGovem, J.N. 1985. Changes in U.S. papermaking fibers:
1690-1985. Forestry Res. Notes. No. 262. Dep. Forestry,
Univ. Wisconsin at Madison.
McCubbin, N. et al. 1992. Best Available Technology for the
Ontario Pulp and Paper Industry. Rep. ISBN 7729-9261 -4.
Ontario Ministry Environ. Toronto, Ont., Can.
McKague, A.B., j. jar I, and K.P. Krmgstad. 1988. An up-to-date
list of compounds identified in bleaching effluent. Pres.
Swed. Forest Indus. Water Air Pollut. Res. Found. Wood
Pulp Chem. Conf. AF-IFK. Stockholm, Sweden.
Mies, W. et al. 1992. U.S. paper industry will benefit from
economic revival this year. Pulp Paper Int. 66(l):52-72.
Wesen, C. 1988. Chemical characterization of chlorinated lig-
nin derivatives in organisms. Water Sci. Tech. 20(2): 185-
88.
-------
Panel 1:
Direct Customers
Question and Answer Session
m Marqulta Mill, University of Maine: I've been lis-
tening to discussions about totally chlorine-free
paper for three days now and I find myself coming
up with a cross between a request and wishful
thinking. There are a number of ways, obviously, to
produce TCF paper and each has environmental
trade-offs that may relate to the subject of pollution
prevention. My short-term request is that more
precise definitions relative to TCF papers be used;
my longer-term desire is that the environmental
trade-offs involved in their production be dis-
cussed, studied, and better defined vis-a-vis various
production methods and vis-a-vis chlorine-
bleached paper.
• Kathie Emmett, State of Washington, Depart-
ment of Ecology: I work in procurement programs. I
also work with a western states' contracting al-
liance that represents 17 states who are thinking
about collectively purchasing recycled content
papers and other environmentally sound papers.
State governments are demanding chlorine-free
papers; the problem has been availability. We've
been looking for chlorine-free papers for two years.
It has not been available in the United States, with
the possible exception of the mill in New York. But
I come from Washington state and I represent states
located west of the Mississippi, and we're not will-
ing to go very far from the west coast to buy our
paper. We've also been looking for a paper that is
bleached without chlorine or only with
hypochloride. This paper has not been available
either.
I'm beginning to think that requesting chlorine-
free paper does not go far enough. I think that by it-
self this request attempts to satisfy a very complex
environmental problem with a very simple solu-
tion. The fact is that chlorine is only one of many
toxic chemicals used in paper and pulp production.
Most procurement people are not chemical en-
gineers, so simply telling us to request chlorine-free
paper does not seem to be an adequate or easy
solution. I suggest that a better solution would be to
look at pollution prevention planning overall and
request that more mills become proactive in their
programs. They need to develop pollution preven-
tion measures that flow from a comprehensive mul-
timedia approach to their own pulp and paper
production.
• Peter Radeckl, Michigan Technological Univer-
sity: My question is directed primarily at Mr.
Church and Ms. Belasco. However, I'm not speak-
ing as a representative of Michigan Tech or
anybody else but as a former small business owner
with a sales staff, and as a former employee of a
major oil company, a role in which I often had
salespeople coming in to see me. In both instances,
I was often able to influence the products that were
purchased by my customers through the education-
al process that occurs between a potential cus-
tomer and a trusted salesperson. We've heard a
great deal today and throughout this conference
with regard to the notion that the supplier or mill
will sell what a customer demands. But I think that
the educational process is probably the key point in
determining how a market is distributed and the
types of products that enter it. If I'm an end-user, for
example, I may think that I want a certain product.
The first thing I'm going to do is get on the phone
and call my sales rep, and say, "How about such
and such a product; what's the deal on how that
product, or process, is viewed within your or-
ganisation?" My business was in structural
fabrication, so it's a completely different ball game.
But I'm curious to know if that same type of rule ap-
plies in the pulp and paper Industry, Are you — or
266
-------
QUESTION * ANSWEK SESSION
can you — work proactively at pollution preven-
tion through your safes and marketing?
• John Church, The Cincinnati Cordage and Paper
Company, Thanks for the question, I think. I really
do appreciate the opportunity to respond, and I'd
like to take the liberty of making an observation.
We all came to this meeting with different expecta-
tions and from our own personal or business
perspectives. I've heard a couple of times now —
and this idea is going to reinforce my response to
your question — that the perception in the
marketplace, either by customers or by media, is
that there's a responsibility for organizations and for
all of us to educate the customers.
It has also been said that we are not here to
debate or to ask why but to discuss how. I find that
interesting and fascinating. Again, because we all
come here with our own expectations and from our
own hill, so to speak, we're standing on our own
hill, From our hill, we're the good guys, because
we'll do whatever our customers want and
whatever our suppliers want. We're the conduit.
But I think your question is very pertinent and I
don't think I have an answer that you'll like be-
cause I don't have one that I like. I do think that we,
as an industry, the paper industry — and I'm talking
about both the manufacturers and the distributors
— are lax in obtaining and at least disseminating
information. As my distinguished colleague Don
Monefeldt pleaded at the end of his presentation,
we must have more accurate data. All of us,
manufacturers and consumers, need more and bet-
ter data.
As a consumer, when I go to the store and buy a
recycled product, I'm doing it primarily because it
satisfies my personal need. It's an emotional
decision, and I don't know when I buy it whether or
not I'm really doing something good for the en-
vironment. I feel that I am, and that's the way most
of us buy things. It's all a matter of perception and
we've heard that word before. Perception is every-
thing; perception is reality. But that being true, we
do have a responsibility to understand the issues
and to disseminate information in the marketplace
so that people like me and companies like mine
can have the right data and information.
Frankly, we do a lot with recycled paper. We
have seminars. We bring manufacturers and other
people in to talk about the value and benefits of
recycled paper. There are hundreds of misconcep-
tions about the quality, price, performance, and
availability of recycled paper. In fact, it's becoming
more and more available, more and more competi-
tive, and better and better in quality. And the recy-
cling process is also Improving. I suspect something
similar may happen with TCF papers. We have be-
come very proactive and have developed some
private branded and recycled papers that were the
first of their kind in the marketplace. When it comes
to recycling, we've educated our sales force, had
meetings, and had Pat Dollar on the agenda —
she's going to be here later. When she was working
for another company, she came in and spoke to us
on the advantages and benefits of their recycled
papers.
But I have to admit that we're behind the curve
on chlorine. And frankly, I would like to know more
about the chlorine problem myself before we
develop a program in our company to educate the
marketplace. And we're talking education now,
we're not talking marketing or everyone coming
from his or her own needs and developing the data
that's available into a marketing program. I don't
think that's ethically right. I think we have to look at
both sides of the question. We have to get as much
empirical data as possible and determine whether
the product is right or not, necessary or not, to the
best of our ability. Then we can be proactive in the
marketplace. Did I answer the question, I'm not
sure?
• Barbara Belasco, General Services Administra-
tion: I can tell you want some answers or guidance
from the Federal government. First, I'm almost
repeating what John has said. In recycled products,
there is a law, the RCRA, that mandates the Federal
Government to buy recycled products with as
much postconsumer content as possible. And GAO
has been actively doing that. We promote it, we ad-
vertise it, we have internal magazines that go out to
all Federal agencies every month or every other
month and every single magazine has an article
about recycled copier paper or some other
recycled item that we're promoting and encourag-
ing the agencies to buy. Sometimes we run special
price sales to the agencies, lowering the price of the
recycled product to encourage clients to use it.
Only so will they understand that the quality and
the performance of these products are no different
from regular virgin products.
Our quality inspectors go all over the country.
First, they go to mills before the shipments are
made; then, if any customer complains about a
product, the quality inspector goes on site to the
client, reviews the complaint, and writes a report
on what they saw and found. We also test the
product in the testing laboratory in San Francisco
and keep a running account of quality problems. So
far, very few of them have been justified. Most
problems have been in the machine or its con-
ditioning; — either the paper dried out or the paper
was too wet or otherwise misused.
16?
-------
Direct Customers
So we're tracking quality. We also promote all
the successes that we've had with recycled
products. We have a recycled products guide, a
special catalog that all the agencies have so that
when they want to buy something they can look
there first to see if they can use a recycled product.
We're very enthusiastic about recycling.
We don't do this at all with chlorine-free paper.
Here, we can't take a position pro or con. We've
been flooded with information from both sides
saying that TCP is bad, that TCF is good. We have
this information, but we're a procuring agency. We
depend on the EPA to look at the data and to review
it technically. They're still working in the laboratory
on this issue, so they haven't come up with an
answer yet on which way to go. That is why we
aren't advertising chlorine-free papers. However,
we're getting requests from customers all over the
United States for nonchlorine bleached paper.
They're coming in without any prompting on our
part.
So that's where we are. So far, nonchlorine
bleached paper is a new product, and we haven't
reached any decision about its worth. But if a cus-
tomer wants it, we will get it. We're industrially
funded, which means that our funds come from
sales to the agencies. We're just like a business. If a
customer wants something, it's to our benefit to get
it for them.
The unbleached napkins, towels, and tissue
products that we now have we found in response to
congressional hearings. We were asked to make
this move; it did not come from customer requests.
These products are just sitting in our warehouse.
No one ever asks for them. Therefore we have been
doing active marketing in this respect and trying to
promote the unbleached products. In this case cus-
tomers have to change their perceptions to realize
that a brown napkin is just as a good as a white
napkin. That's where our advertising efforts are
going right now.
• David Bailey, Environmental Defense Fund: Most
of my questions and concerns were just addressed.
I applaud the remarks of Mr. Church. I think he is
right on target and I also applaud the Xerox Cor-
poration. Your conclusions based on your inde-
pendent research on the dioxin issue may not agree
with those of the Environmental Defense Fund or
my own. But that's not important. The fact that your
companies have engaged in making your own as-
sessment is critically important in determining what
the public perception will be.
I think that many potential direct customers are
likely to come to you rather than rely on comments
from environmental organizations or the paper in-
dustry. The responsibility you show and your will-
ingness to be a player is admirable, and I en-
courage you to continue to do that, i also believe
that when EPA finishes its dioxin reassessment, it
will provide everyone with scientifically developed
data by some of the best people in the world. I
would encourage you to reevaluate your position
on dioxin when that assessment is available.
• Steve Levltas, Environmental Defense Fund: I
have a question for Ms. Belasco and Mr. Cousin.
Ms. Belasco, you talked about consumer awareness
about unbleached towels and other tissue products
in terms of the lack of relationship between white-
ness or brightness and functionality. To what extent
is the Federal government looking at specification
changes dealing with brightness in the printing and
writing grades? I just got a letter from my Con-
gressman, actually a newsletter, in a brilliantly
white envelope. The materials on the table here
also have a fairly high brightness level. As there's
really no functional reason to continue this cult of
whiteness, I wonder what the Federal government
is doing in that regard. Similarly, in the private sec-
tor, I didn't hear any discussion about reduced
brightness specifications for envelopes. It seems to
me that this issue is a tremendously productive,
constructive, and promising way to help reduce en-
vironmental impacts and chemical use and to do
that in a way that has economic advantage for the
producers.
• Barbara Belasco: We have many envelopes
now that are completely unbleached; we also use
white envelopes. If a customer requests an en-
velope of a lower brightness, or if a customer re-
quests a totally chlorine-free envelope that we
discover we can only obtain with a lower bright-
ness, then if those customers are willing to accept
the lower brightness, we will certainly change the
specification.
• Steve Levltas: Well, but I'm suggesting that we
need more leadership from GSA — from the top —
on these issues rather than relying on the cus-
tomers. You need to do the same thing in the print-
ing and writing grades that you're already doing in
a very commendable way in tissues. So I hope that
bringing the whiteness or brightness down will be
included in some of your revisions of the specifica-
tions.
• Barbara Belasco: Yes, as part of the solicitation
that we're going after now, we may have to con-
sider doing something like that,
• Steve Levltas: That would be great,
• Rebecca Todd, Sierra Club Legal Defense Fund:
I have a few questions. First, Mr. Cousin, I think that
268
-------
QUESTION & ANSWER SESSION
if your perspective in this debate is that chlorine-
free products are not a viable solution, then it
should come as no surprise if your customers do
not request chlorine-free products. Second, I would
like a clarification from you as to why you think
chlorine-free products are not a viable solution?
• Michael Cousin, Georgia-Pacific Corporation:
I'm speaking in terms of availability. As I said, we
looked at the question, where, if our customers re-
quested it, we would get the paper. We looked at
the structure of the industry, and the only chlorine-
free option seems to be in sulfite. Sulfite really isn't
an option in the United States for commodity
papers and envelope papers because a sufficient
amount can't be found. The second possibility or
source was the conversion of the kraft process to
eliminate all chlorine products, but we saw that this
source adds cost. The cost structure that we're deal-
ing with, in today's terms, does not justify TCP
products as a viable option for us — even to satisfy
a demand should it arise.
• Rebecca Todd: Then haven't you also precluded
your customers from requesting chlorine-free paper
from you even if they are willing to pay the addi-
tional costs? You're saying that it's not a viable solu-
tion because we say it's not. But if you were willing,
because of customer demand, to look at chlorine-
free options, then perforce, it would become an op-
tion.
I have a question also for Ms. Belasco. I believe
you mentioned that you were thinking of adding
other chlorine-free products to your lists and I'm
curious to leam what other chlorine-free products
you have considered, and also what the source is of
the chlorine-free products that you currently carry.
• Barbara Belasco: We're looking at writing
papers. The one solicitation we have made is for
copier paper. Now we're looking at some grades of
writing papers such as bond writing papers, writing
pads, note pads, things like that. We really do not
have anything now that's totally chlorine-free. Ven-
dors bid to the government; paper mills do not. The
vendors can go to whatever sources they want to
get the supplies that they then bid to the govern-
ment. So I really can't tell you what paper mills will
be bidding, We will probably know by the end of
September who bid on the first solicitation for
chlorine-free paper. Then I could let you know, if
you give me your name.
• Mark Floegel, Greenpeace: I have a short ques-
tion for Mr, Cousin. I've heard you say that Geor-
gia-Pacific has decided against chlorine-free
technology and they've also decided against sulfite
technology. But it's my understanding that in your
Bellingham, Washington, mill you make a
chlorine-free, sulfite market pulp. Can you com-
ment on that?
• Michael Cousin: 1 don't have a comment. My
talk concerned commodity envelope papers and
that's what I'm aware of. Bellingham is a tissue mill.
• Mark Floegel: I believe it's somewhat integrated
and somewhat pulp.
• Nick Lardlerl, Scott Paper Company: After hear-
ing these comments about whiteness and GSA's
specifications for toilet tissues, unbleached with no
dirt specks, I really wonder where the supposed
cult is.
• Hlllel Gray, National Environmental Law Center:
My question is for Mr. Cousin but anyone else may
respond. Can you tell me what kind of forecast you
used in your cost analysis for increased regulatory
costs or potential liability associated with the use of
chlorine? How did you factor that into your
analysis?
• Michael Cousin: That was a cost... you're talk-
ing about the relationship for paper machines
making uncoated free sheet? That cost analysis?
• Hlllel Gray: I'm thinking about your analysis for
the year 2000, and whether you expect liability or
regulatory costs to increase if you don't move to
chlorine-free?
• Michael Cousin: No, as I said, those costs were
generated using what it costs today to make a ton of
paper on those paper machines. The same ap-
proach was used for each machine included in that
analysis.
• Hlllel Gray: So are you doing any forecasting?
• Michael Cousin: I'm sure we are. I just got the
costs, the estimated industry study.
• Hlllel Gray: Would you be willing to provide
later, in the proceedings of this conference, some
information on the company's forecasts on the in-
direct costs associated with chlorine?
• Michael Cousin: I think I'd have to check with
the company. I honestly do not know that informa-
tion.
• John Church: I think you invited other members
of the panel to respond to your question. And my
answer is no, we have not done any forecasts as-
sociated with the liability of purchasing and selling
TCF papers to the year 2000. Or for that matter
even to next year. But I think that reinforces my re-
269
-------
Direct Customers
quest and my plea for more empirical data. I don't
think we have.enough information to make a
reasonable and intelligent decision. And as far as
trying to forecast the cost of legislation I assume it
applies to TCP as well as to using chlorine. For that
matter, trying to forecast the cost of any legislation
is, if not impossible, extremely difficult.
• Nell McCubbln, N. McCubbin Consultants, Inc.:
I found Don Monefeldt's comments very interest-
ing, particularly coming from an organization like
the Xerox Corporation. You mentioned that your
TCP products are currently limited in geographic
region to Northern Europe and that they are about
15 percent more expensive. According to my arith-
metic, that corresponds to just a little more than the
actual cost of making the lignin-like pulp that I
presume they're based on, which is all you can buy
in TCP today. When Sodra Cell AB starts its ozone
system next month and Union Camp's is running
(starting up now), then according to my arithmetic,
when kraft pulp is reduced, they'll all be about the
same price as regular pulp. So if the pulps are about
the same price, perhaps TCP xerographic paper will
also be at the same price as traditional. What do
you think will happen to the market then?
• Don Monefeldt, Xerox: Well, we'll find out. I
think I have a reading on what you're after. As I in-
dicated, our friends in Europe believe that about
half the market will be TCP by the middle of the
decade. It's hard for me to imagine that this could
occur if it required appreciable price premiums. So
it's implicit in their estimate that TCP will become a
regular commodity — produced cost-effectively on
high-speed equipment. The only way they can get
half the market is if their prices are comparable. If I
were a salesperson and had access to chlorine-free
at no price premium, I'd much rather sell it than
deal with the questions that might arise from
people who are concerned about the other
product.
• Med Byrd, North Carolina State University: You
talk about creating a demand for totally chlorine-
free papers and paper products. It's important to
realize that we need to make the consumer aware
that these products are an available option. What
we really need is to give the consumers complete
information and let them make a totally informed
choice about the overall effect TCP will have on the
environment. And we should do that before we run
helter-skelter into creating a huge demand for sul-
fite mills and abandon the kraft process for a totally
chlorine-free process. We don't have the answers
yet. There's an incredible amount of research going
on, especially at the university level. Research in-
stitutions will soon be able to see what the overall
effect of this fundamental shift in our industry's
going to be. So before we sit here and send the con-
sumer rushing off to meet some new technology,
we need to give them the information they need to
make an informed, total decision. Let's not meet
some short-term, high profile, high publicity goal
and throw the baby out with the bathwater. We
need to know the complete implications of the
changes we're talking about.
• Norman LJebergott, DuPont Canada, Inc.: I'm
very, very interested in all you have to say about
using TCP pulps and recycled paper. But you
haven't gone far enough. Because once you have
this paper, once you use it, you'll want to recycle it
again. And this is where some of the problems
come in. This is why we need foresight. Some U.S.
secondary fiber mills are still using hypochlorite
and hypochlorate. We're trying to get them to use
other nonchlorine bleaching chemicals. Now
you're giving them another fiber that can be darker
and have a little more specks and a bit more kraft in
it. Certainly you can use oxygen peroxide and
hydrosulfates, but think about it. When you recycle
something and you're already using recycled con-
tent, you've got to go one step further. So wash
things, wash the inks, wash the dyes, wash the en-
capsulated things, things that are forgotten as you
go toward this new product.
• Jens Folke, European Environmental Research
Croup: Those things are beginning to flower, I
think. I agree with many of your perspectives. But I
am also looking at and coming from a different part
of the world. I mean, in North America and Europe,
you have 10 percent of the world's population
using about two-thirds of the world's pulp and
paper products and 70 percent of the world's total
energy. My perspective is that if you're willing, you
can reduce the absorbable organic halogens down
to about 1.5 to 2 ppq, and then it's only speculation
that there is any toxicity remaining in that fraction.
Now, we know that there is toxicity in un-
chlorinated compounds, so as I see it, you are wise
to continue kraft operations — at least until these
ozone plants come into operation. I think you're
losing the perspective. I would like to see environ-
mentalists in this part of the world go into energy
conservation programs that will really do some-
thing for the environment rather than speculate on
what will happen if we remove these compounds.
If you take the discussion we had yesterday about
the principle of precautionary action, what you're
saying is that now you have 250,000 people in an
organization who believe that this compound or
this type of material may be dangerous. And then
next year you have another 250,000 saying, okay,
270
-------
QUESTION & ANSWER SESSION
maybe this compound should be removed because
maybe it's dangerous. It's like you have to talk to
the pope about this. I think we have to go for a
deeper perspective, and say, hey, we have
developed the ecotoxicological signs on top of all
those environmental problems that we discovered
during the 70s and now this arch of the last 15-25
years is on its back and we have the tools to deal
with it. Otherwise, we are just disregarding
knowledge and being willing to pump and burn oil
on the speculation that something else may be
dangerous. But that's irreversible; once we've
burned the oil, we can't put it down in the ground
again.
• Lauren Blum, Environmental Defense Fund: May
I respond, just briefly. I think that what we're really
interested in is not to shift from kraft to sulfite, as
though that were the way to go forever. We're inter-
ested in trying to make consumers aware that there
are many different kinds of paper, including papers
of reduced brightness. We're trying to make people
question whether they really need bright, strong
paper for every use. We're not endorsing sulfite, or
still less, saying kraft is the only way to go, or that
we have to have chlorine-free processes or it won't
work. We do realize it will happen over time. So I
don't think that is the issue. I think one of the things
I've seen as a chemist is that even though science
has improved, there's much we don't know and,
therefore, reasons to move toward more preventive
strategies. On the other hand, energy conservation
also matters. Our challenge, and what we have to
work on, is balancing all these needs, incorporating
them, and including recycling and the need for
chlorine-free paper in the equation, so that it's not
just one or the other.
• James Austin, MoDoCell, Inc.: As most of you
are aware, MoDoCell is one of the largest
producers of chlorine-free pulp in the world. The
largest sulfite mill, yes, is chlorine-free. One of the
things we'll be addressing this afternoon is the tech-
nology of high-yield pulp, bleached chemical ther-
momolecular pulp (BCTMP), and Aspen BCTMP in
particular. It's a perfect replacement for hardwood
kraft. The specification changes that need to be
made will be coming out of the EPA group. These
changes in the specification standards will begin to
allow new technology for high-yield nonchlorine
bleached pulps to be used in this country. They are
also the biggest hurdles that we have to address in
the next couple of years.
271
-------
The Environment Is Good for Business
— A Publishing Company's View
Kit Taylor
Vice President Manufacturing
Times Mirror Magazines
New York, New York
As the nation's leading publisher of spe-
cial-interest, leisure-oriented magazines,
Times Mirror Magazines reaches more
people actively involved in the outdoors than any
other media company. Every month, some 30 mil-
lion readers across the United States read our nine
magazines — Field & Stream, Golf Magazine,
Home Mechanix, Outdoor Life, Popular Science,
Salt Water Sportsman, Ski Magazine, Skiing
Magazine, and Yachting. Therefore, Times Mirror
Magazines has a responsibility and a unique oppor-
tunity to communicate with its readers on key en-
vironmental issues.
Two years ago, Times Mirror Magazines trans-
lated this commitment into action with the estab-
lishment of the Times Mirror Magazines Con-
servation Council. The Conservation Council's goal
is to increase our readers' awareness of important
environmental issues and to initiate conservation
programs. We use two specific approaches to
achieve our goals. We have established an office in
Washington, D.C., to work with Capitol Hill,
government agencies, and conservation organiza-
tions on regulations and legislation affecting
natural resources. We also write corporate
editorials addressing specific conservation issues
and calling on our readers to take action to resolve
any problems. These editorials appear quarterly in
all our magazines.
To further demonstrate Times Mirror Magazines
environmental concerns, we conducted a survey of
1,200 adult Americans with the guidance of the
Roper Organization. The poll revealed a surprising
sense of awareness among the U.S. public that
problems can be solved by balancing environmen-
tal protection with economic development. The
survey reveals the following important facts about
our readers:
• 65 percent disagree with the premise that
economic security and well-being have
priority over environmental problems;
• 92 percent are optimistic that a good balance
between economic progress and environ-
mental protection can be found; and
• 63 percent believe that environmental pro-
tection laws and regulations have not gone
far enough.
Only 10 percent of our readers believes that regula-
tions have gone too far.
Obviously, our readers have leisure-time pas-
sions that are closely linked with outdoor activities.
Paper Purchasing, Processing,
and Perceptions
Times Mirror Magazines prints an average of 11.5
million magazines a month. We buy 30,000 tons of
paper annually. The basic weight and quality
specifications vary within this tonnage depending
on its end use:
• 2,200 tons (or 7 percent) of this paper is 70-
pound and 90-pound coated cover stock —
the brightness specification for this quality of
paper is 82 points;
• 24,000 tons (or 80 percent) is lightweight,
No. 5, coated groundwood — No. 5 coated
groundwood has a brightness specification of
71; and
• 3,800 tons (or 13 percent) of the paper we
purchase is 40-pound and 50-pound news-
print stock made of 100 percent recycled
magazines.
272
-------
K. TAYLOR
Times Mirror Magazines made the switch to
recycled stock about four years ago, based on en-
vironmental and economic reasons. Our readers
appreciate the fact that we try to use recycled paper
wherever possible.
As the primary paper purchasing agent at Times
Mirror Magazines, I make an effort to be as in-
formed as possible on the environmental positions
of our suppliers. At the present time, about half of
our paper is produced without chlorine bleaching.
The 3,800 tons of recycled newsprint stock
referred to earlier is made from 100 percent
recycled pulp, which is produced using the flota-
tion process. This method does not require any
bleaches in the deinking process, creating a 100
percent chlorine-free product.
One of our large coated-paper suppliers and a
major North American mill has cut back from a
five-stage bleaching process to three stages. This
change reduced effluent dioxin content by 92 per-
cent, demonstrating a significant effort to reduce
the impact of chlorine compounds on the environ-
ment.
The U.S. paper industry has already invested
more than $1 billion over the last three years in im-
proved environmental technologies. The industry
has also spent $6.6 billion on pollution control
since the 1970s.
The alternatives to chlorine bleaches vary from
mill to mill. Most of the mills we buy from believe
the demand for elemental chlorine-free paper will
increase and satisfy most consumers' environmen-
tal expectations. Some mills are making plans to
fulfill that demand; others are not prepared to make
such a commitment.
Publishing Industry Current and
Future Concerns
Today, Times Mirror Magazines' readers have not
expressed much anxiety about dioxin and the
manufacture of magazine paper. They are still
struggling with questions related to recycling. Just
as the publishing industry had to learn the terminol-
ogy relating to recycled paper, now we must learn
the vocabulary that relates to dioxin concerns. As
our readers become more aware of the effects of
dioxin on the environment, the demand for its con-
trol will naturally be affected.
Publishers will have to pressure paper suppliers
to manufacture paper having as little negative effect
on the environment as possible. This requirement
may eventually produce totally chlorine-free (TCP)
paper. A recent assessment made by National Eco-
nomic Research Associates concluded that produc-
tion costs of paper in the United States would
increase by approximately $60 per ton as a result of
extraordinary capital expenditures to develop TCP
processes. These increased costs would obviously
be reflected in the prices charged to paper buyers
and would, most likely, pass on to readers.
At this particular time in the publishing
industry's struggling economic climate, we would
have great difficulty meeting any paper cost in-
creases. Paper costs comprise about 35 percent of
the total cost of magazine production and any in-
crease on that portion of our costs would be dif-
ficult to bear. In many cases, publishers' position
with their readers is not strong enough to charge
them for additional costs. We need to preserve
every reader we have in order to insure our long-
term health.
Perhaps Times Mirror Magazines, more than
some publishing companies, will have the oppor-
tunity to develop a marketing plan that promotes us
to our readers as an environmentally conscientious
firm that uses TCP paper in its magazine produc-
tion. I am certain that many readers would be im-
pressed; however, the question that remains is this:
Does the publisher have to absorb all the expense,
or will readers also be willing to support the en-
vironment financially through a higher subscription
price?
It is very difficult to survey readers accurately
on this subject. If we raise their consciousness fur-
ther about the issue and then determine that they
won't financially support it, we won't have any
choice but to incur the expense ourselves — an ex-
pense that could be impossible to absorb. It could
be very expensive if the issue turns out to interest
only a small percentage of our readers.
Nevertheless, to date we have discovered,
through the Conservation Council and through our
Partnership for Environmental Education with the
U.S. Environmental Protection Agency (EPA), that
being environmentally aware is smart business. We
have indeed positively affected our bottom line
with our position on conservation issues that are
near and dear to our readers' and advertisers'
hearts. However, a huge commitment to increased
publication costs would be a very complicated
decision.
Times Mirror Magazines is determined to stay
informed on all the environmental issues related to
publishing. We feel we are making some positive
contributions to the environment by our continued
research on, and use of, recycled paper; our experi-
ments with vegetable oil inks; our awareness of and
influence on the use of chlorine bleaching; and
through our Conservation Council efforts. Our
company policy is to be environmentally respon-
sible. We believe it is ultimately good business.
273
-------
Alternatively Bleached Papers and
Other Impossibilities
Roger Telschow
President, Ecoprint
Silver Spring, Maryland
I will speak on two interrelated topics this morn-
ing. The first topic concerns the demand for al-
ternatively bleached papers; the second, the
experience that printers have had working on alter-
natively bleached papers. I work for a commercial
printing company in metropolitan Washington,
D.C., called Ecoprint, which, as the name implies,
is a very environmentally aware company. I am
also something of a conference junkie, so perhaps I
can give you a slightly different perspective on al-
ternative technologies.
For years, Ecoprint has used recycled papers.
We have also worked with eight or nine different
ink manufacturers to find the best, environmentally
safe inks. We have also done some research to
reduce the volatility of solvents, and we have at-
tempted to eliminate chlorinated hydrocarbons
throughout the shop. In general, we have sought
ways to prevent pollution and minimize hazardous
waste. We use about 350,000 pounds of paper per
year, and we do printing for associations, nonprofit
organizations, and small publishing companies,
among others. Therefore, our papers are primarily
coated and uncoated, bond, text, offset grades of
paper, and some cover stock.
Current Demands for
Alternatively Bleached Paper
Recently, we have seen an increased demand for
alternatively bleached papers. This demand has
been rising over the years, and, of course, bleach-
ing chemicals have been a concern as far back as I
can remember for some people. But I think in the
last 24 months, the trend has surged upward sig-
nificantly. All kinds of people are now asking us if
we have a chlorine-free paper, a hydrogen
peroxide bleached paper, or an oxygen bleached
paper. As awareness of the alternatives to chlorine
bleach increase, so will the demand for these alter-
natively bleached papers.
The price differential — or how much people
are willing to pay for these technologies — is dif-
ficult for me to say. One of our alternatively
bleached sheets is the least expensive sheet that we
offer; no one has to pay a premium for it. For some
of our other sheets, I think people may pay a
premium in the range of 5 to 10 percent. Although
I am basing this on a seat-of-the-pants analysis
rather than statistics, I would say that this difference
is similar to the difference that people are paying
for recycled papers. I don't think they would be
willing to pay much more at this time, nor is it
necessary.
We have imported a German sheet through
Canuset Corporation in Baltimore, a firm that im-
ports the Steinbeiss-Hemming Sheet, and we have
had some decent market acceptance on that sheet.
It is not a super-white sheet, either, but rather gray.
It contains 50 to 90 percent postconsumer content,
and it is hydrogen peroxide bleached. Essentially,
the biggest challenge for us has been to find these
sheets that we can take to a market niche. We ask
that they be bright, inexpensive, and high in
postconsumer content. Right now, as an offset
printer, we are probably using 20 percent non-
chlorine bleached paper and 40 percent that is
bleached using small amounts of sodium
hypochlorite but no elemental chlorine or chlorine
dioxide. We are also running about 95 percent
recycled paper.
Future trends will show a continued increase in
nonchlorine bleached papers. I think we are going
to see more technologies come on board, perhaps
especially in the recycled sector, and more
hydrogen peroxide bleaching. So long as we have
some groundwood content in the pulp, we really
can't rely on chlorine or chlorine dioxide. I think
274
-------
R. TELSCHOW
we will see some real improvements very soon. We
have seen improvements even in the last 18 months
or so. I am thinking particularly about the Patriot
Mill in Boston, which is producing a very
marketable product that in some instances has up
to 80 percent postconsumer content and the mill is
using alternative bleaching. These events will also
bring the cost down.
Looking toward the Future
On the observations and suggestions side of things,
I think the common goal for many of us is that we
want to reduce the impact of papermaking on the
environment in all senses. I hear this over and over
again, but I also hear of obstacles and costs that
lead some to the conclusion, frankly, that these en-
vironmentally better technologies are impossible
— you just can't do this stuff, or so I hear repeated-
ly. The caution reminds me of the history we have
been through in the last 10 years as a printing com-
pany. Ecoprint has been told repeatedly that
postconsumer content and alternative bleaching
technologies are impossible or uneconomical, or
that the alternative is worse for the environment
than what we have now.
My observation is that we are too often blinded
by the obstacles that face us, When you look at
some of the improvements in the printing industry
that Ecoprint has experienced, you know that new
ideas are possible. We were told, for example, that
it was impossible to get recycled papers that were
clean, that ran on the presses well, that were avail-
able and economical. Today, Ecoprint has paper
that meets precisely those specifications. We were
also told that it is impossible to run your press
without using alcohol. We have been doing that
for some time.
Not too long ago, we were warned that it is im-
possible to get good quality printing without using
highly volatile solvents and that we wouldn't be
able to find substitutes for the chlorinated
hydrocarbons in our cleaning agents. "You won't,"
they said, "find a substitute for this ozone depleting
compound." But we did.
So when we were told at another conference
that we would not be able to remove the heavy
metal pigments from inks and still have a good
quality product, we didn't believe it. We wrote a
proposal on the subject to the U.S. Environmental
Protection Agency, and they have helped fund our
current research in this area. We have made some
progress, and I hope we will have a commercially
usable product in the next six months.
Ecoprint, I should remind you, is a printing
company. We are not a research firm. We are not a
pigment or an ink manufacturer. But, we've sought
out some help and some subcontractors and some
other people in the industry. I'm certainly not here
to tell you what heros we are, but to remind you
that what we are frequently told is impossible or
undoable or uneconomical turns out in a very short
time to be the standard of excellence. I think that it
is a good idea to keep our minds open to pos-
sibilities and accept new projects even if they will
only make progress in fits and starts.
We are initially going to have some set-backs
and some increase in costs. But I think you are like-
ly to see, as more technologies come on board in
the future, that demands will increase, and the right
alternatives will be found. Whatever the alterna-
tives are, they are going to reduce dramatically the
environmental impact of printing. My appeal
would be that we look at change positively and
embrace it, rather than see it as an enemy; realize
that change in papermaking, printing, chemical
technology, or whatever is really what renews us as
a graphic arts and papermaking industry.
Remember, too, that papermaking has not been
a static process over the years. Needless to say it is
only in this century that wood has been paper's
primary ingredient. Other ingredients have been
everything from rice to cloth to goat skins. One of
my favorite examples of how we shouldn't be too
resistant to change involves the goats. Imagine
printing the Sunday New York Times and having to
wait while someone rounded up 100,000 goatskins
every weekend to print the paper on. Not a pretty
sight!
So who is to say what the future will hold? If
we can keep our minds open, we can stand at the
leading edge of this thing. Maybe. Take a deep
breath. We will also need to acknowledge our fear
of the unknown, our tendency to say that the devil
we know today is better than the devil we don't
know yet — to say, "Okay, we are scared of that,
but we are going to do it anyway." Make the com-
mitment as an organization, not to wait until your
subscribers or members sound the alarm and say,
"Hey, why aren't you running environmentally
sound paper?"
I am beginning to hear from manufacturers and
producers of magazines and other writing papers,
who are trying to stay on the leading edge of this.
Well, thinking creatively about alternatives is the
leading edge, in my opinion. We don't want to get
caught with our pants down when Sweden is way
ahead of us and has already cleaned-up its sulfite
process, for example.
Let's stay at the leading edge and start talking
about alternatives now. It will probably take years
to accomplish, but it can begin with a few well-
275
-------
Publishers and Printers
placed phone calls to suppliers from people who
buy thousands of tons of paper each year. The
buyers are beginning to ask about the papermaking
process: "How clean is it? How can we partner
with you to clean it up, to make it better?"
This conference is a testament, I would think,
to the fact that many of those phone calls have al-
ready been made. I see many people here,
whereas five years ago, there wouldn't have been
so many. I say, "Right on!" I think that we are
moving in the right direction — for the sake of the
industry and the environment.
276
-------
Evolving Paper Product
Specifications and Market Demand
— A Publisher's Viewpoint
Donald W. Hopkins
Vice President and General Manager
Hearst Enterprises Division
The Hearst Corporation
New York, New York
Hearst Enterprises is a major consumer of
paper for newspapers, magazines, and
books. The grades range from colored un-
coated groundwood products of 50 brightness
(BRT) to coated No. 2 papers at 85 BRT. In-between
are newsprint, at 57 to 60 BRT; directory, at 60 to
64 BRT; uncoated groundwood, at 63 to 70 BRT;
uncoated free sheet, at 80 BRT; lightweight coated
groundwood No. 5, at 67 to 71 BRT; and coated
No. 4, at 75 to 79 BRT, to mention the major
products. Newsprint is primarily produced from
mechanical pulps bleached with nonchlorine
chemicals. All the other products are produced by
the sulphate kraft process containing hardwood,
softwood, and groundwood pulps.
Most of our suppliers have both chlorine and
chlorine dioxide stages in their mill processes. All
have either converted the process to eliminate
dioxin formation or announced their intention to
do so. We base our paper purchases on quality
characteristics and economic factors. Long-term
availability is essential.'Our divisions have not ex-
pressed an interest in switching to alternatively
bleached paper. Alternatively bleached paper is not
currently available in any quantity that we think
would meet the quality and cost criteria for paper
products produced by Hearst Enterprises.
Customer Description
The newspaper and magazine divisions of The
Hearst Corporation sell to advertisers and con-
sumers through subscriptions and newsstands.
Books are purchased primarily by consumers. The
books and business publishing division publishes
the William Morrow line of hardcover books, Avon
Books in paperback, and business publications
under Motor Professional Books, Floor Covering
Weekly, American Druggist, Diversion Magazine,
Electronic Engineering technical publications, and
others.
Hearst is the largest U.S. publisher of monthly
consumer magazines with 13 major titles including
Colonial Homes
Cosmopolitan
Country Living
Esquire
Sports Afield
Harper's Bazaar
House Beautiful
Motor Boating & Sailing
Popular Mechanics
Redbook
Good Housekeeping
Town & Country
Victoria
Hearst is also a major magazine publisher in
the United Kingdom. The newspaper division is the
lOth-largest publisher in the United States with a
daily circulation exceeding 1,000,000 copies in 12
cities. Hearst newspapers include
Houston Chronicle 407,000 Daily/603,000 Sunday
Seattle Post Intelligencer 250,000 Daily/521,000 Sunday
San Antonio Light 155,000 Daily/227,000 Sunday
San Francisco Examiner 131,000 Daily/705,000 Sunday
Albany Times Union 110,000 Dai ly/107,000 Sunday
277
-------
Publishers and Printers
Future Action regulations in force in the regions in which they
operate. In addition, most are modifying their
Hearst relies on the scientific community to con- processes to reduce any potentially harmful ele-
tinue to monitor the papermaking process to deter- ments below detectable levels. Based on their
mine the need for fundamental change. Our reports, I see no need for an alternatively bleached
suppliers have informed us, however, that they are paper.
in full compliance with all water, air, and land use
278
-------
Printing the IKEA Catalog Entirely
on Totally Chlorine-free Paper
Michael J. O'Rourke
Catalog Manager
IKEA U.S., Inc.
Plymouth Meeting, Pennsylvania
Earlier this year, IKEA released its 1993
catalog. As noted in the press release that ac-
companied its distribution, the catalog is
printed on a totally chlorine-free paper (TCP) con-
taining no old-growth forest fibers. The significance
of this achievement is clear. The IKEA catalog is one
of the largest color printing jobs in the world. It is
read by millions of people each year in 25
countries.
To be involved in the environment is part of
what IKEA is and flows from its philosophy. Many
years ago, IKEA founder Ingvar Kamprad vowed "to
create a better everyday life for the majority of
people" by offering a wide variety of home furnish-
ing items of good design and function at low prices.
IKEA has set out to accomplish this goal in every
dimension of its business activities. Ingvar
Kamprad, like Sam Walton of Wal-Mart, imbued
IKEA with his own personal philosophy about life
and doing business.
Established over 40 years ago in Sweden, IKEA
is the world's largest home furnishings retailer with
110 stores in 25 countries. Last year, 90 million
people visited IKEA stores around the world,
generating a total sales turnover of almost U.S. $4
billion.
Caring about the environment is a natural con-
sequence of the IKEA ambition to improve our
customers' quality of life. The IKEA spirit of daring
to be different created a corporate environmental
policy that strives to minimize any possible adverse
affects that may result as a consequence of its ac-
tivities. IKEA is consistently looking at many en-
vironmental issues, not just the environmental
impact of its catalog.
The IKEA Customer
In the United States, IKEA has 11 stores located in
and around such large cities as New York, Los An-
geles, Philadelphia, Washington, Baltimore, Pitts-
burgh, and Houston. IKEA customers in the United
States represent a wide demographic profile, as do
IKEA customers in 24 other countries. The IKEA
customer represents a cross-section of the popula-
tion in each of the company's retail markets
worldwide.
As a result, awareness of environmental issues,
specifically the bleaching process and alternatives
to bleaching, varies from market to market. Califor-
nia, New York, Canada, and many northern Euro-
pean countries are more environmentally aware
than others and have placed more demands on
government and industry to deal with environmen-
tal issues. On an international scale, public de-
mands for greener products will increase with time
as environmental awareness develops and spreads
to other countries.
In general, IKEA customers may not be well in-
formed about the bleaching process issue, but a
majority react negatively to the word "chlorine"
and positively to the term "chlorine-free." IKEA cus-
tomers in Scandinavia are more knowledgeable
than customers in other countries because of a na-
tional awareness of the environmental impact of
the bleaching process. But corporate philosophy
dictates that IKEA should be aware of how its
operations affect the environment, and we must be
responsible about activities identified as having a
negative impact. IKEA strives to meet its own volun-
tary standards, and since it is an international com-
pany, it imposes the strictest local standards on a
global basis.
Creating a Totally
Chlorine-free Catalog
As noted before, more than 90 million people
visited IKEA in 1991. The annual IKEA catalog,
produced in more than 15 languages, is the most
279
-------
Publishers and Printers
important catalyst for attracting customers to its
stores. Inter IKEA Systems BV in Holland is respon-
sible for centrally coordinating the total purchase of
print capacity and paper for the different versions of
the annual IKEA catalog. To meet the total needs for
all versions, Inter IKEA purchases 40,000 metric
tons of paper annually.
Over a year ago, an Inter IKEA project group
met with a paper expert from Greenpeace to de-
velop common environmental goals for the 1993
IKEA catalog. The goals were to prohibit the use of
old-growth forest fiber in the paper, to demand a
minimum amount of bleaching in the manufactur-
ing process, and to promote catalog recycling.
With these goals in mind, IKEA set about fulfill-
ing its paper needs. Three major European paper
suppliers were chosen who could provide a TCP
paper without using old-growth forest fibers: Italy's
Burgo, Finland's Finpap, and Kymmene. The paper
used in the body of the different versions of the
1993 IKEA catalog was lightweight coated TCF
paper, with weights ranging from 51 to 61 grams.
The cover stock was a TCF board, ranging in weight
from 175-200 grams. It was purchased from Finn-
board in Finland and Stora Billerud in Sweden. The
paper used for inserts was also TCF.
IKEA is very happy with the final result of using
TCF papers for the entire catalog. TCF is slightly less
expensive than the papers used in earlier years.
Compared to the lightweight coated paper used in
the past, the TCF paper had a brightness that was 2
percent lower — a percentage that is hardly notice-
able. There is a visible improvement in its opacity
compared to papers with similar weight that were
used previously.
All of the rotogravure printers IKEA used,
reported that both runability and printability were
as good as or better than in previous years. This
year, IKEA printed the different European versions
of its catalog at major printers such as Gruner &
Jahr, Burda and Broschek in Germany, Ringier in
Switzerland, and ILte in Italy. In North America,
IKEA printed its American and Canadian versions at
Donnelley in Casa Grande, Arizona, and Brown in
Franklin, Kentucky.
Looking into the Future
IKEA founder Kamprad once said, "Most things still
remain to be done — a glorious future!" Although
an important step has been taken by switching the
entire catalog to a TCF paper, there are still other
challenges to be met to make the catalog even
more environmentally friendly.
The inks, glue, and lacquer used in the catalog
printing and binding process do not pose any
obstacle to recycling printed catalogs. IKEA has
finalized an arrangement to recycle printed
catalogs in the United States and Switzerland.
Many IKEA retail organizations in other countries
are in the process of looking for means to recycle
printed catalogs. The most natural step now will be
to promote the development of an equivalent TCF
paper that contains a greater amount of postcon-
sumer recycled fiber. IKEA hopes to reach that goal
within two years.
280
-------
Panel 2:
Publishers and Printers
Question and Answer Session
m Kathle Emmett, State of Washington, Depart-
ment of Ecology: I have a question to which any of
the panelists may respond. Do any of you, as
buyers, have requirements in your contractual
agreements concerning your suppliers' adherence
to State and Federal environmental regulations or
pollution prevention activity?
• Unidentified Speaker: The answer is yes.
• Kathle Emmett: Can you specify these, or do
you just ask them if they are in compliance with
State and Federal regulations? How do you phrase
the question?
• Roger Telschow, Ecoprint: The general contract
clause provides for the supplier to be in full com-
pliance with all Federal and State laws. We call that
the boilerplate clause. On a personal note, having
been brought up in a paper mill, though not literal-
ly, of course, I perhaps have a little better under-
standing of how you comply with some of these
rules and regulations. I was responsible for dealing
with the regulatory agencies in one company I
worked for. Now I go on regular mill tours, peri-
odically. I go where I want to go, not where the
managers want me to go. And we ask the resident
managers questions; for example, what is your his-
tory? What type of violations have you had? We
know that everything is fallible; only the things a
god makes are infallible. So they do have accidents
and upsets. If they don't tell me about it, I'll read it
in the paper the next day, anyway. I think that our
companies, our suppliers are doing an excellent
job. If we all managed our daily lives and homes
the same way some of these mills are managed we
would not be talking about environmental pollu-
tion today.
• Michael O'Rourke, IKEA, North America: The
same applies to IKEA. Although I'm not specifically
involved in the procurement of printing capacity or
the purchase of paper, I do know that IKEA requires
that all its suppliers adhere to all legislation regard-
ing the issue.
• Pete Radeckl, Michigan Technological Univer-
sity: I have questions for Ms. Taylor and Mr. Hop-
kins, and an open-ended question for Mr.
O'Rourke. First, Ms. Taylor, I think some of the
things that you've done with recycled products are
very commendable, but I did detect something that
concerned me. With regard to procuring materials
that may enhance pollution prevention, if they in-
crease the cost of your raw materials, you ex-
plained that it may be difficult for you to raise
subscription rates to satisfy those costs. Can you tell
us what percentage of your revenues come from
subscription rates and whether or not it would be
possible to satisfy those costs by increased costs of
advertising in your magazines?
• Kit Taylor: I can't tell you specifically what our
revenue is from subscription rates, but it's slightly
under 50 percent, ! believe. Not slightly under, it is
below 50 percent, somewhere between 20 and 50
percent. What we want is for subscribers to rein-
force our commitment to the extra expense. Since
our advertising dollars have been going down over
the last few years it's not going to come from there.
The cost of paper's going up; the cost of goods in
general is going up. So we need to recover that
money somewhere. Publishing is not an incredibly
profitable industry.
• Pete Radeckl: Thank you. Mr. Hopkins, you
mentioned that you hadn't received any formal re-
quests from readers for information about chlorine-
281
-------
Publishers and Printers
free products. I'm not that familiar with your busi-
ness, but if I were to pick up a copy of Popular
Mechanics, for example, and I wanted to find out
something about the TCP products used in that par-
ticular magazine, would I see Hearst in there some-
where or would I write to Popular Mechanics under
some other letterhead?
• Don Hopkins, Hearst Enterprises: Yes, in both in-
stances. You could address the letter to Popular
Mechanics, or — on the masthead, as we call it in
the business — you would find that it's published
by the Hearst Magazine Division of the Hearst Cor-
poration and any inquiry of that nature would
come through our system, whether by telephone or
letter. It would eventually get to the people I talked
to in preparation for this meeting. They tell me,
however, that they do not remember any call or
query of that type. Now whether or not some editor
may have received a written question and didn't
think it was important enough to bark up the sys-
tem, I wouldn't know. But, in fact, this is not an
issue among some 300 million readers of our
magazines.
• Pete Radeckl: Mr. O'Rourke, I think IKEA's
catalog is fantastic and I'm not saying I'm on the
chlorine side or the nonchlorine side. But the fact
that you are out there making an honest effort to do
things environmentally sound is excellent. I'm
curious; do you have similar types of aggressive
measures that you're pursuing with regard to the
products that you sell in the catalog — as to how
they're produced? I know that's a bit outside this
conference, but maybe just a few comments that
you might want to share with us.
• Michael O'Rourke: As I stated earlier, the catalog
is just one of many environmental issues that IKEA
is working on. I can refer to Margaret Rainey of
Greenpeace and the long cooperation that we've
had with them on a number of other matters. PCB,
for example, was a subject that we looked at very
closely. I'd be happy to refer you to the officer in
the company who is involved with environmental
policy who can fill you in on more details.
• Gayle Coyer, National Wildlife Federation: I
have a question for Mr. Hopkins. You made the
point that a lot of your decisions are based on
scientific information. I'd like to know if you and
your company are monitoring the dioxin reassess-
ment that is currently underway, and if you and
your company are prepared to change your paper
procurement specifications based on the outcome
of that reassessment.
• Don Hopkins: First of all, I said I rely on the
scientific information that is provided to me
primarily through trade publications and the
media. I read some of the same journals that the
gentleman from Conservatree talked about earlier
this morning. I am aware that there is a reassess-
ment of the impact of dioxin in mill effluents taking
place. I'm not aware of how extensive it is or
whether it's before or after the many changes in the
cooking and bleaching processes that have been
described here. I'm familiar with one study that
measured dioxin going into Lake Superior in a
stream before the stream was affected by paper-
making facilities. At one point, the dioxin level was
higher there than in that same stream below the
chemical pulp-mills. So, we're trying to keep
abreast of the information and the art that's out
there. We will, as always, do what's best. We are
environmentally conscious citizens. But more im-
portant, I think our suppliers will address the issue
so it will not become a factor for us.
• Gayle Coyer: Is there going to be a decision for
your company at some point that will reflect the
outcome of the dioxin reassessment that is current-
ly underway?
• Don Hopkins: You're suggesting that the study
will conclude in black and white. I frankly doubt
that will happen. I suspect that a conclusion will be
reached that may or may not be different from prior
assessments. The people who are responsible for
making the changes will see that we cannot stop
publishing magazines and newspapers — well,
newspapers aren't a factor — but magazines and
books because somebody says that the paper we're
using may have a problem. We can't just stop
publishing. So what we need to do is wait for that
day to happen, work with our suppliers, and come
up with a logical and sound solution. The emotion-
al issue cannot control the publishing business.
Otherwise, we would go into something else. You
know, we could make furniture or something. I
think you're asking me to come to a conclusion that
is truly impossible.
• Gayle Coyer: No, I raised this issue because you
made quite a point of saying that you believe your
papers are environmentally friendly. If new infor-
mation comes to light, such that your papers may
not be environmentally friendly, are you prepared
to make changes? That is the issue I was trying to
explore.
• Don Hopkins: We will always use the best avail-
able paper for our products.
282
-------
QUESTION & ANSWER SESSION
• Tim Martin, Greenpeace: I have a question and a
comment for Mr. Hopkins. The question is very
brief. Are you the person to write to in the Hearst
Corporation?
• Don Hopkins: Yes.
• Tim Martin: The comment is this: I think you
raise a false dilemma in terms of unbleached paper.
No fashion magazine, no high-color printing job
wants to be on unbleached kraft. That's not the
dilemma that exists; it's not the dilemma that
Greenpeace or any other environmental group
raises. Obviously, the quality of the IKEA catalog
and many other publications exemplifies that. So
I'd just like to warn you that I think you should be
careful about how you raise the issue. Because I
think you're rather purposely misleading.
• Richard Phillips, International Paper: Mr. Hop-
kins, I don't think you intended to say this, but you
indicated that the EPA dioxin reassessment was
aimed at the paper industry. It's not. It's an overall
scientific reassessment of the potential human
health hazards from dioxin. The paper industry ac-
counts for less than 1 percent of all the toxic
equivalents of dioxin that are produced in the
United States annually. There's a draft document
out now on exposure to dioxin in the environment;
it's about 600 pages long and the paper industry oc-
cupies less than a page in it. I just wanted to set the
record straight, in case you're confused on that
issue.
283
-------
The Implications of Sustainable
Development for the Forest
Product Industry
Peter E. Wrist
President and Chief Executive Officer
Pulp and Paper Research Institute of Canada
Pointe Claire, Quebec, Canada
A major change has taken place over the past
few years in the public's attitude toward the
forest products industry in general, and the
pulp and paper industry in particular. Until very
recently, the public praised the industry's products
for their versatility, low cost, cleanliness, and for
being made from a renewable raw material. Steady
progress was also being made in reducing the
known environmental impacts of our industries' ef-
fluents.
This sudden change in public opinion is largely
the result of a major campaign — global in nature,
well financed, and skillfully managed — that has
capitalized on a heightened environmental con-
cern among an affluent generation in the
developed countries. The effects of this change in
some of our industry's markets and operations have
been dramatic. Market pulp specifications in Ger-
many are no longer limited to properties of the pulp
required to satisfy its intended use; they now re-
quire certification that strict environmental perfor-
mance standards have been implemented at the
mill that produces it, and assurance that sustainable
management practices are being followed in the
forests from which the fiber comes. Now it is
proposed that the pulp supplier be required to fund
the collection and recycling of the products after
customer use. To paraphrase Germany's Environ-
ment Minister, "You no longer sell pulp in Germany
— you merely lease its use."
Restoring a positive public image requires not
only maintaining our product quality, but also as-
surances that we are managing forests and operat-
ing manufacturing processes in an environmentally
sustainable manner. Above all, we must do a better
job of communicating our processes and improve-
ments to the public, so that it can be more
knowledgeable about our industry.
Sustainable Development
Sustainable development gained worldwide
prominence in the 1987 report, "Our Common Fu-
ture" by the United Nations World Commission on
Environment and Development. Chaired by Gro
Harlem Brundtland, the Norwegian Prime Minister,
this international committee found that unchecked
endemic poverty and population growth in the un-
derdeveloped nations is as much a long-term threat
to the global environment as economic develop-
ment.
Technology and social organizations, the Com-
mission argued, can and must be managed and im-
proved so that a sustainable environment can
coexist with the economic growth required to pro-
vide the world's basic needs of food, clothing, and
shelter, and to extend to all peoples an opportunity
to fulfill their aspirations for a better life. The Com-
mission did not underestimate the magnitude of the
world's problems; it issued an urgent plea for
prompt action by governments and individuals to
make the necessary changes in technologies and
social systems that would make sustainable devel-
opment a reality.
Sustainable development is defined in the
report as development that meets the needs of the
present generation without compromising the
ability of future generations to meet their own
needs. The concept, therefore, implies a limitation
on the nature and direction of development: the ac-
284
-------
P.E. WRIST
tivity must be sustainable. It rejects, however, the
concept of finite limits to growth (Meadows et al.
1972), believing that today's limits can be ex-
panded as our technology and environmental and
social understanding increase. This improved un-
derstanding will undoubtedly lead to changes in
current lifestyles. But changing the lifestyles of
people in the developed countries will not be suffi-
cient to raise the living standard in the developing
countries; we must also increase the productive
capacity of the world's ecosystems.
Although the sustainable development concept
has been adopted by many countries and organiza-
tions as a basis for future action, support has not
been unanimous. Some groups have dismissed sus-
tainable development as a contradiction in terms.
For them, the only acceptable policy focuses on the
preservation of the environment and rejects
economic development. Their political agenda
calls for a permanent reduction in the current
worldwide consumption of natural resources, and a
more equitable distribution of the residual (Kroesa,
1991). They appear to reject the possibility of en-
larging the pie through prudent resource manage-
ment and technological innovation.
At the other end of the spectrum are those who
continue to seek economic growth without con-
cern for environmental sustainability. They have
not accepted the change that has occurred in the
public's values, and they react with surprise and
anger when their behavior is challenged. Today's
battles over environmental issues arise primarily
from the incompatibility of these two extreme
points of view.
A wide divergence of views still exists on the
full implications of the sustainable development
concept and on how we can best develop policies
and actions to achieve it. Not withstanding the May
11, 1992, cover of Business Week proclaiming
"Growth vs. Environment," a recognition on all
sides is growing that sustainable development is
not an exercise in tradeoffs between economic
development and environmental protection, where
a gain on one side is a loss on the other, but a
cooperative endeavor in which both the environ-
ment and the economy are beneficiaries (Smith et
al. 1992). Decisions based on maximizing eco-
nomic efficiency without concern for long-term in-
dustrial environmental effects or vice-versa by
some environmentalists and regulators is no longer
appropriate.
Process and Recognition
Today's complex environmental and economic
problems cannot be solved by changing our ac-
counting procedures to include additional values
for a variety of environmental costs and benefits.
Though this suggestion could improve the
economic efficiency of our decisionmaking, it fails
to deal with two fundamental issues that are part of
the Brundtland vision (U.N. World Comm. Environ.
Dev. 1987). The first is that development today
should not compromise the ability of future genera-
tions to make their own choices, the intergenera-
tional equity issue. The interests of future gener-
ations cannot be taken care of by simply changing
accounting practices.
The second issue is the public demand to in-
clude a large number of noneconomic factors in the
environmental decisionmaking process — factors
such as maintaining the diversity of plant and
animal species, public recreation, preservation of
ecosystems, and the wide range of social goals, cul-
tures, and religious beliefs that exist concerning the
use of forest systems. In a democratic system,
resolving the conflict among societal goals is the
task we delegate to politicians and bureaucrats
rather than economists or scientists.
How does this political process work? And is
there a role for good science in the process? Eric
Ashby (1992) described a useful but simplified
model of the process. He observes that during an
issue's first phase, politicians usually ignore it until
it reaches emotional proportions triggered either by
the persistent actions of a crusader, for example, in
the case of pesticides, by Rachel Carson's The
Silent Spring (1962); or by a life-threatening acci-
dent, for example, by persons eating food con-
taminated by a toxic chemical spill (Kuratsune and
Shapiro, 1984).
While these crusaders or "initiators," as Ashby
calls them, may dress their arguments in scientific
terms, it is the sensational element in their message,
not its scientific accuracy, that grabs the attention of
the public and eventually the politicians. Ashby, a
renowned biological scientist himself, reluctantly
admits that a crusader who "stretches" science a lit-
tle may even be excused at this stage for his or her
efforts to gain the public's attention.
Issues and Challenges
Once the issue gains public attention, it enters a
second phase, as Ashby points out. Advocates on
either side of the issue present their arguments: one
side emphasizes the threats to the environment; the
other, the costs of making the proposed changes.
Both sides will use, and occasionally misuse,
"science" to support their arguments. During this
public debate, the scientist and the economist have
an important role to play. If they can avoid the role
285
-------
The Implications of Sustainable Development...
or the appearance of advocacy, they will inform the
public and provide politicians and bureaucrats
(who must eventually make and implement public
policy) with the best information available. That is,
they help the policymakers better understand the
issues involved before they have to reach a final
decision.
Even with good scientific and economic input,
some information is always lacking and the even-
tual political decision will involve as much political
instinct as logical analysis of the scientific and
economic facts. If, however, the scientists or
economists have done their job effectively, the
decision is less likely to be in conflict with available
scientific knowledge. Once the political policy and
goals have been established, a further opportunity
arises in a third phase for technical input to guide
the development of regulations that will achieve
political goals in the most economical manner pos-
sible.
Pollution prevention is the preferred and, in the
long run, the most economical solution, and closed
industrial systems are an optimum goal. But pollu-
tion prevention technology is not available to solve
every problem, so pollution control processes (end-
of-the-pipe treatment) are an essential part of effec-
tive, timely, and responsible environmental protec-
tion. And economic technology is not the only
limiting factor. Limited resources and other com-
peting economic demands also prevent quick solu-
tions to environmental issues.
A sustainable development strategy must there-
fore include setting priorities so that the most im-
portant issues can be tackled first. If resources are
applied to issues of low priority, they are unavail-
able to address more critical problems. Continuing
research and development must be used to fill im-
portant factual gaps and improve future priority set-
ting and resource allocation. Good science has a
role to play in both these areas.
The Forest Products Industry
and Sustainable Development
Recycled fibers do not grow in garbage dumps;
they start their lives in forests as virgin fiber. The
Brundtland vision of sustainable development in-
volves more than the management of forests for
sustained yield. Sustained yield is a harvesting
policy that limits the annual allowable cut in a
forest at a level below its estimated average annual
incremental growth. This practice, already widely
used in the major pulp producing countries, is a
necessary but insufficient requirement for main-
taining sustainable development in the forest.
Sustained yield prevents the overexploitation of
the forest resource through timber harvesting, but it
does not address the need for improved forest
management practices to protect biodiversity. It
cannot deal with the issues of uneven age distribu-
tions and overmature stands, or with ways to im-
prove the productivity and quality of the resource.
Sustained yield gives no answer to the question of
how society's new demands for multiple uses of
forest resources can be made compatible with in-
creasing fiber demands and with periodical har-
vesting of the resource. Sustainable forestry must
deal with all these issues.
The public's shopping list of services to be
provided by the forest continues to increase. In ad-
dition to providing the raw material for timber uses,
today's forest managers must also meet demands
for
• watershed management and soil
conservation,
• recreation of various kinds,
• preservation of wildlife habitat on land and
in rivers and lakes,
• preservation of genetic diversity,
• moderation of global climates and rainfall
patterns,
• achieving global management over
greenhouse gases such as carbon dioxide,
and
• remediation of impoverished farmland and
cut-over areas that have not been
successfully regenerated.
And the list continues to grow. Satisfying these
demands will require new forest management
policy and practices. One such technique being
developed is the "ecological planning method" in
which clearcutting, a practice required for the
regeneration of many commercially valuable
species, is limited to small acreages that follow the
natural contours of the landscape (Hagglund,
1992).
This practice reduces the possibility of soil
erosion and runoff of nutrients into the streams and
lakes. The clearcut areas are interspersed with is-
lands and corridors of older trees that provide cover
for wildlife and help restore biodiversity to the
forest after replanting. Clearcutting is an issue that
raises powerful images and emotions. Perception
often overrules understanding on both sides of the
debate, and the need exists to promote better un-
derstanding and communication on why and when
this forest management technique is appropriate
and environmentally sound.
286
-------
P.E. WRIST
An alternate approach, the practice of "soft
forestry," is often advocated by environmentalists
as the only acceptable sustainable system. Soft
forestry involves selective harvesting, natural
regeneration, and the use of soft-footed harvesting
equipment. From an economic viewpoint, soft
forestry's disadvantage is that timber productivity
per hectare is low and costly using this method. It
may, however, be an appropriate alternative for
some public forests and private wooded lots where
policy has decided that nontimber uses are to be
given highest priority. In many areas, knowledge
necessary for the optimum application of these im-
proved forest management programs for different
forest types is still lacking and must be developed
by ongoing research.
Intensively Managed Plantations
Do intensively managed plantations have a
legitimate place in a sustainable forest policy? This
is an issue of much disagreement between some
foresters and environmentalists. Plantation pro-
ponents believe that timber production on a limited
number of small sites close to the manufacturing
mills allows diversity of use and species to be better
maintained over wide areas remote from the mill
that may then be managed less intensively for mul-
tiple use. Proponents cite the examples of intensive
management of eucalypt plantations in Brazil
(Campinhos, 1992), or the Pinus radiata plantations
of Chile (Delmastro, 1992) and New Zealand
(Dyck, 1992).
Their opponents insist that all forests must be
managed to retain their "natural" state. Plantations
of limited species, even with a wide diversity of
provenances to maintain a large genetic pool, they
claim, are not sustainable in the long run (Hogarth,
1991). This "natural forest" approach limits the op-
portunities to enhance the stock genetically or to
raise the productivity of the forest significantly
above that of the natural forest.
In the absence of sufficient research to resolve
these issues, we need a mix of forest management
strategies so that good data can be collected and
analyzed for each different approach. In a mixed
approach, sites of outstanding ecological diversity
could be set aside as permanent preserves. The ex-
tent of the areas set aside — whether 5, 10, or 15
percent of the total forest — is a matter of public
policy. Indeed, the ratio should probably vary from
one region to another depending on the uniqueness
of the individual forests.
Other sites with suitable soil conditions and
topography would become plantations, intensively
managed primarily for timber supply, but with
some multiple uses possible in the periods between
harvesting. In many cases, these sites could be
abandoned or be marginally economic farmland.
The largest proportion of the forest, however, could
then be managed less intensively for multiple use
including an emphasis on maintaining the biodi-
versity characteristic of the natural forest.
Indeed, developing a diversity of management
practices tailored to specific sites and uses may
prove to be as important an objective for ensuring
the future sustainability of our forests, and the
ability of our forest systems to adapt to potential
long range problems such as acid rain and global
warming, as the goal of preserving the diversity of
species and their genetic pools.
Maintaining the Genetic Pool
Fortunately, a start has been made to generate bet-
ter information on forest genetics for future deci-
sionmaking. Of particular importance is Gene
Namkoong's pioneering work at North Carolina
State University. He has developed breeding strat-
egies that will not only enhance the quality of the
forest stock, but also maintain its genetic diversity
and resilience under changing climatic conditions
(Namkoong, 1991).
The contents of a forest's genetic pool do not
remain static over time. As environmental condi-
tions change, so does the relative competitiveness
of specific species or gene combinations. As a
result, the frequency of different genes present in a
forest ecosystem changes from one generation to
the next. Namkoong stresses that we must not only
maintain the gene pools that produce superior trees
on fertile forestry sites; we also need to protect the
genes that allow trees to survive in poor soils. Their
ability to survive under stressful conditions may
well make them the "future winners," if and when
major environmental changes occur, for example,
as a result of global warming.
The significance of this concept is illustrated in
the work of last year's Wallenberg Prize winner,
Donald H. Marx. Marx (1991) discovered a new
way of restoring forest productivity to areas that
have been badly degraded. The symbiotic role of
mycorrhiza in tree nutrition and early life survival
has been known for some time. Marx's contribution
arose from a serendipitous observation that the
mycorrhiza, Pisolithus tinctorius, which is normally
a very poor competitor in good soil conditions, is
able to tolerate high temperatures. He also found it
does well in poor acidic soils, and tolerates high
heavy metal concentrations. Today, seedlings in-
oculated with Pisolithus tinctorius are being suc-
cessfully used to rehabilitate sites that had
previously resisted reforestation.
287
-------
The Implications of Sustainable Development...
The close interdependence of the entire forest
ecology with soil and climate has been recognized
by James P. Kimmins et al. at the University of
British Columbia (1990), who are using ecological
site type classification and indicator plant species
to monitor the impact and long-term trends caused
by management practices and climate change.
Their research is already beginning to have its im-
pact on British Columbia forest management and
reforestation practices.
Fertilization Research
Fertilization, combined with hybrid breeding, has
been the key to productivity gains in agriculture but
has found only limited use in commercial forestry.
Unfortunately, fertilizer and chemical use by
farmers is a major source of water pollution in
many places. Research on plantation fertilization
by Torsten Ingestad, an earlier Wallenberg prize
winner, has demonstrated that these adverse en-
vironmental problems can be avoided, and timber
yields improved if application rates are carefully
matched to the nutritional requirements of the trees
at different stages of their growth (Ingestad, 1989).
This practice has undergone field trials in Sweden
and Iberia on forest plantation sites and promises to
achieve greater productivity with lower chemical
use and minimized environmental impact.
In another field, the recent studies of J.R. Sedell
et al. (1988) on streams in the Pacific Northwest
have drawn attention to the role played by large
pieces of woody debris in streams, in determining
the abundance and quality of fish habitat. Their
findings illustrate the interdependence of sus-
tainable forestry and sustainable fisheries and can
help improve management practices for both
resources. It is now recognized that during harvest-
ing operations in the proximity of still or running
water, not only must borders of trees be left to pro-
vide shade and a passage for wildlife but also
woody debris must be left in the streams and ma-
ture trees and snags on the banks. Such debris
provides fish and other aquatic organisms with the
ecosystems and nutrients they need to propagate
and prosper while the harvested forest is being
regenerated. These examples of forestry research
are representative of the kinds of knowledge that
will make our forest management practices more
compatible with the goal of sustainable develop-
ment.
The Attack on Effluents
Pulp and paper mill effluents have recently come
under heavy attack from environmental groups. As
a result, my own Institute's research program has
undergone a major shift over the past few years,
from a focus on process modifications to reduce
manufacturing costs and improve quality to a focus
dominated by environmental issues. The Canadian
pulp and paper industry is committed to the virtual
elimination of persistent bioaccumulable toxics
from its effluents. The Pulp and Paper Research In-
stitute of Canada (PAPRICAN) has been assigned
the responsibility for developing the technology to
accomplish this goal and has entered into a jointly
funded cooperative program with the Canadian
government to do so. Although pollution preven-
tion and system closure are the long-term goals,
pollution treatment measures will also be needed
in the interim.
Laboratory and field studies on environmental
impact are being carried out to help guide the
work. In addition to evaluating the effect of ef-
fluents on early fish larvae growth rates and
ceriodaphnia reproduction, we are now including
fish liver enzyme assays and studies offish matura-
tion and reproduction after lifetime exposure to ef-
fluents.
Process modifications, proposed by PAPRICAN
and others (Luthe et al. 1992), have already al-
lowed mills to reduce the previously low traces of
dioxins found in their products and effluents below
the background levels that are ubiquitous in an in-
dustrial society (Berry et al. 1992). As a result,
chlorine use by the Canadian pulp industry has al-
ready been reduced by over 50 percent; oxidizing
chemicals, such as chlorine dioxide, oxygen,
ozone, peroxide, and activated oxygen, are being
used as chlorine substitutions. Extended cooking
and enzyme treatment are also being used com-
mercially in some bleached pulp mills to reduce
the quantity of bleaching chemicals required (Scott
etal. 1992).
Recent research has shown that dioxins are
present on most of the exposed surfaces we come
in contact with in our daily lives, including
recycled papers and containers. This contamina-
tion is most likely the result of atmospheric deposi-
tion from combustion sources such as incinerators
and automobiles. Bleached kraft pulp made ac-
cording to recommended technologies to eliminate
dioxin formation typically contains less dioxin and
furan than pulp made from unbleached and
recycled papers. I believe that the issue of back-
ground levels will emerge as the determinant of
achievable regulatory levels of dioxin in paper
products and production effluents rather than
changing levels of analytical detection. Airborne
contamination from extraneous sources raises
questions of how far one industry can be held ac-
countable for removing a contaminant that is
288
-------
RE. WRIST
caused by society at large, particularly a con-
taminant that eventually may require modifications
in transportation systems to overcome.
Recycling Research
Goals are being set in most major developed
countries for increased levels of product recycling,
including grades of paper that previously had not
been considered suitable candidates for incorporat-
ing recycled fibers. Over time, increased rates of
recycling will moderate the demand for pulpwood
significantly, and lessen demands on the forest. The
industry is increasing recycling aggressively. The
question remains whether recycling levels should
be set by regulations or by market and economic
forces.
Recycling is not simply an issue of fiber conser-
vation but also involves fiber quality, energy use,
health, sludge disposal, and other issues that argue
against adopting a single uniform solution for all
grades and locations. Research on recycling at
PAPRICAN is focusing on better deinking processes
and on ways to overcome the strength deficiencies
of recycled fiber. Recycled fibers have lost some of
virgin fibers' elasticity. This elasticity may lead to
increased breaks on high-speed presses.
PAPRICAN is also tackling the challenges in-
volved in finding ways to reuse or dispose of deink-
ing sludges in an environmentally acceptable
manner. Public acceptance of reduced product
quality in papers made from recycled fiber is con-
sidered a transient situation and for most uses the
market push for improved quality will return.
New technologies, including some based on
recently developed membrane materials, are lead-
ing to novel ways to clarify and reuse process
water. If these efforts prove commercially success-
ful, environmental benefits will accrue through
lower effluent loads and reduced energy consump-
tion. The ultimate goal of all process research is a
manufacturing operation that does not discharge
any harmful wastes into the environment.
Pulp Producers' Opposing Positions
As mentioned earlier, sustainable development is-
sues can rarely be solved by economic or scientific
reasoning alone, although good science has a
legitimate role to play. Two examples of ongoing
debates concern the future use of chlorine com-
pound bleaching and the pros and cons of incinera-
tion as an environmentally friendly way of
managing the disposal of residual low grade waste-
papers.
Two opposing positions have been taken by
pulp producers in response to demands by some
market segments for chlorine-free pulp. Such dif-
ferences of response are healthy signs that we have
a highly competitive industry and one in which the
free market system is working well. Competition
stimulates technological innovation, and this in
turn may benefit both the customer and the en-
vironment. However, the danger exists that the
development of technology by one company to
meet the demands of one segment of the market
may be indirectly imposed later by regulators on
the whole market under the guise of best available
technology economically achievable (BATEA)
regulations solely because it is available.
The balancing of environmental benefits and
the economic efficiency requirement embodied in
sustainable development and the BATEA concept
must be strictly followed in such cases. Regulations
should respond to scientific evidence of environ-
mental benefit rather than to perceptions,
philosophy, or the availability of new technology
developed to satisfy a niche market. Regulations
must provide significant environmental benefits or
they can lead to serious misuse of scarce resources.
Conclusion
The changed public perception of our industry is
not a passing cloud that will disappear with the
passage of time. Rather, it is a reflection of a major
and lasting shift in public expectations and values
concerning the environment. The actions needed
to regain public confidence in our industry and to
achieve the goal of sustainable development go
hand-in-hand. Significant changes in forest man-
agement and manufacturing operations have al-
ready occurred. Much progress has already been
made, and a commitment exists to continue re-
search and development toward the long-range
goal of sustainable development. The role of good
science in sustainable development is to provide
the signposts and tools to define problems and to
set priorities for their solution. Although political
judgment remains an important part of the
decisionmaking process, good science can help en-
sure that we use limited resources for solving the
important problems first.
References
Ashby, E. 1977. Reconciling Man with the Environment. Stan-
ford Univ. Press. Stanford, CA.
Berry, R.M., C.E. Luthe, and R.H. Voss. 1992. The ubiquitous
nature of dioxins: a comparison of the dioxins content of
common everyday materials with that of pulps and papers.
PPR 934. Pulp Paper Res. Insl. Canada. Pointe Claire,
Que., Can.
Campinhos, E. 1992. Tropical/subtropical forest policies and
practices: the Brazilian example. Pres. GLOBE '92 Symp.
Vancouver, BC, Can.
289
-------
The Implications of Sustainable Development...
Carson, R. 1962. The Silent Spring. Houghton Mifflin. Boston,
MA.
Delmastro, R.J. 1992. Planting monospecies for fiber produc-
tion in Chile. Pres. U.N. Food Agric. Organ. Advisory
Committee of Experts on Pulp and Paper, Rome, Italy.
Dyck, W.J. 1992. Current and future technologies in forestry: a
New Zealand perspective. Pres. GLOBE '92 Symp., Van-
couver, BC, Can.
Hagglund, B. 1992. Forestry and the environment — the in-
dustrial outlook. Pres. GLOBE '92 Symp., Vancouver, BC,
Can.
Hogarth, D. 1991. Greenpeace's $3 billion threat to forestry.
Financial Post. June 10,1991. Sec. 1, pg. 1.
Ingestad, T. 1989. Defined Nutrient Additions to Plants — A
Theory and Its Applications. Swedish Univ. Agric. Sci. Up-
psala, Sweden.
Kimmins, J.P. et al. 1990. Monitoring the condition of the
Canadian forest environment. Environ. Monitor. Assess.
15(3):231-40.
Kroesa, R. 1991. Sustainable paper production: specific actions
for environmental compatibility. Pres. U.N. Food Agri.
Org. Advisory Committee on Pulp and Paper Symp. Rome,
Italy.
Kuratsune, M. and R. Shapiro, eds. 1984. PCB Poisoning in
Japan and Taiwan. Alan R. Liss. New York, NY.
Luthe, C.E., P.E. Wrist, and R.M. Berry. 1992. An evaluation of
the effectiveness of dioxins control strategies on or-
ganochlorine effluent discharges from the Canadian
bleached chemical pulp industry. Pulp Paper Can.
93(9):239-48.
Marx, D.H. 1991. Forest application of the ectomycorrhizal
fungus Pisolithus tinctorius. Lecture, 1991 Marcus Wallen-
berg Prize Winner. Stockholm, Sweden.
Meadows, D.H., D.L. Meadows, J. Randers, and W.W. Behrens.
1972. The Limits to Growth. Univ. Books, New York, NY.
Namkoong, G. 1991. Forest trees. Comm. Managing Global
Genetic Resour.: Agric. Imperatives. Board Agric., Natl.
Res. Counc., Natl. Acad. Press. Washington, DC.
Scott, B.P., F. Young, and M.G. Paice. 1992. Enzyme pretreat-
ment of unbleached softwood pulp effectively reduces ac-
tive chlorine multiple and AOX generation. Pres. 1992
Pacific Western Spring Conf. Can. Pulp Paper Ass. Jasper,
Alberta, Can.
Sedell, J.R., P.A. Bisson, F.J. Swanson, and S.V. Gregory. 1988.
What we know about large trees that fall into streams and
rivers. Pages 47-81 in From the Forest to the Sea: A Story of
Fallen Trees. Gen. Tech. Rep. PNW-GTR-229. Forest Serv.,
U.S. Dep. Agric., Bur. Land Manage., U.S. Dep. Interior.
Washington, DC.
Smith, E.T., D. Woodruff, and F. Templeton. 1992. Growth vs.
environment: the push for sustainable development. Bus.
Week. Issue 3265, May 11,1992: 66-75.
United Nations World Commission on Environment and
Development. 1987. Our Common Future. Oxford Univ.
Press. New York, NY.
290
-------
Market Pulp and the Environment
— Issues in Perspective
Dean W. Decrease
Director of Technical Service, Pulp Division
Weyerhaeuser Company
Tacoma, Washington
M
arket pulp is used in a vast array of
products and places, and the consumers
of market pulp products have specific
quality and performance needs. These facts com-
bine to create a very complex market situation. No
single formula describes all the needs that cus-
tomers of market pulp have. However, some com-
mon trends can be discerned, and these will be the
subject of this presentation. My objective is
threefold: first, to describe the market pulp business
in general and how it relates to demands for en-
vironmental quality; second, to delineate customer
needs, and what customers really want in the en-
vironmental arena; and third, to present
Weyerhaeuser's response to these issues, including
our view of the future as it relates to environmen-
talism.
The Market Pulp Business
Market pulp represents 20 percent of the world's
total bleached paper grade pulp capacity (Fig. 1).
Thus, 80 percent (or 140 million metric tons
[tonnes]) of paper grade pulp produced today is
only indirectly influenced by market forces. On the
capacity side, bleached kraft represents about 82
percent of the total market pulp capacity (Fig. 2).
Not surprisingly, most of my comments will focus
on the environmental requirements of bleached
kraft market pulp.
Incidentally, the size of the paper grade pulp
market is about 25 million tonnes, nearly half of
which is sold to Europe (see Fig. 3). Events in
Europe are therefore critically important to the en-
tire pulp market. However, as shown in Figure 4,
more than half of the paper grade market pulp
produced today comes from North America.
177.63 Million Tonnes
Figure 1.—Market pulp portion of total global capacity of
bleached paper grade pulp (1992).
Weyerhaeuser's Role in the Market
Weyerhaeuser's market pulp division produces ap-
proximately 2.1 million tonnes of fluff, papermak-
ing, specialty, and dissolving pulp. Approximately
65 percent of these products are exported to Europe
and the Pacific Rim. With the recent acquisition of
the Grande Prairie and Flint River operations,
Weyerhaeuser is the world's largest supplier of
market pulp, serving more than 75 countries. Our
facilities are distributed throughout North America,
spanning most of the major commercial forest
regions. Thus, we have a wide variety of fibers that
291
-------
Market Pulp
Mechanical
Sulfite 5%
Unbleached Kraft
4.5%
34.8 Million Tonnes
Figure 2.—Global paper grade market pulp capacity
(1992).
Latin America 5%
Other Pacific Rim
& Africa
Japan
North America
25 Million Tonnes
Figure 3.—Global markets for bleached chemical grade
pulp (1991).
Other 7%
Latin America
W. Europe 13%
Nordic
Figure 4.—Global sources of bleached chemical paper
garde — market pulp capacity (excludes former Soviet
Union and PRC).
find their way into a large number of applications
— an unparalleled breadth of market exposure.
We also have a significant division that was
responsible for collecting 1.8 million tonnes of
recycled fiber in 1991, from 23 recycling centers in
20 States. This division is growing rapidly.
What Do Customers Really Want?
Fiber suppliers, papermakers, publishers, and dis-
tributors share concern and some confusion about
customers' environmental needs and demands.
We're all in this together, and none of us can claim
to fully understand where the environmental
demands are going. Nevertheless, we have been
working together for some time to anticipate the
needs of consumers and to develop strategies to ad-
dress their concerns. Some of the factors involved
in this complex situation include recycling, forest
management, and chlorine bleaching. These are
the "big three" issues for market pulp customers.
Recycling and forest management are perhaps the
most familiar; I'll discuss them briefly before dwell-
ing somewhat longer on the details of chlorine
bleaching.
Recycling Is Working
What is the market message on recycling? "Just do
it!" Recycling is a global ethic. It has tremendous
appeal to individuals because recycling is some-
thing that people can do personally to benefit the
environment. This appeal explains the rapid expan-
sion of recycling practices; it also ensures that the
issue is not going to fade away. Of course, there are
environmental questions associated with recycling
that are simply not considered in this global thrust
to increase recovery rates. For example, "life cycle"
issues need to be resolved, such as the cost to
transport recycled material over long distances, the
fate of sludges that come from deinking processes,
and the safety of recycled food containers.
Notwithstanding these concerns, recycling
continues to grow. Figure 5 shows a steady decline
in the ratio of pulp to paper and paperboard
capacity from the early 1970s to the present, largely
as a result of recycling, combined with increases in
paper filler content. This figure is an excellent ex-
ample of source reduction in action. Paper contains
substantially less virgin fiber today than it did 20
years ago.
How has this trend influenced Weyerhaeuser's
business? Figure 6 shows the rapid increase in
recycled fiber sales volume that we experienced
from 1975 to 1991 and project through 1995. We
expect our recycled fiber sales to double between
1990 and 1995.
I can also report a dramatic increase in the use
of recycled fiber within the company. By 1998 we
anticipate using recycled fiber in amounts
292
-------
D.W. DeCREASE
85
80
Percent 75
70
65
70 72 74 76 78 80 82 84 86 88 90 92 94
Figure 5.—Ratio of paper pulp to paper and paperboard capacity.
Tonnes (Millions/Yr)
3.0
2.5
2.0
1.5
1.0
0.5
0
1975 1980 1985 1990 91 92 93 94 95
Figure 6.—Weyerhaeuser recycled fiber sales.
equivalent to the output of eight kraft pulp mills,
each producing 800 tonnes a day (see Fig. 7).
The pulp and paper industry is moving rapidly
toward its goal of a 40 percent recovery rate in-
dustrywide by 1995. The voluntary, market-driven
actions that are being taken are working well. We
are concerned, however, that mandated recycling
legislation could hamper this positive trend. With
the market working well, we feel it would be a mis-
take to disrupt this positive trend.
Forest Management Issues
Forest management is another issue currently in the
minds of many consumers. Let me review the key
market messages we are receiving from the public
on this issue.
First, we are being asked to practice sustainable
forestry. That concept, however, is not well defined.
We are also being asked to maintain the biodiver-
sity of the forest. Again, the meaning or definition of
293
-------
Market Pulp
Tonnes /Yr (Millions)
CD Projects currently under study
• Approved projects
2.35
0.52
0
1989 1991 92 93
Figure 7.—Weyerhaeuser recycle fiber usage.
biodiversity is not clear. A final important message
that we are receiving from the market is that we
should protect "virgin" forests, though no one has
clearly defined what a virgin forest is. These are
serious issues that we are actively addressing, but
much work needs to be done to better articulate
their significance.
To summarize Weyerhaeuser's view, we
believe that commercial forests can be managed on
a sustainable basis to provide
• clean water,
• wildlife and fisheries habitats,
• recreational opportunities, and the
• aesthetic value of the forest.
We also recognize the importance of maintain-
ing biodiversity in managed forests. We see
managed forests as an important complement to
the biodiversity being sought in wilderness areas,
national parks, and other reserved federal lands.
Well-managed commercial forests will enable
society to reserve more public forestlands for non-
commercial uses. We need to focus our efforts on
deriving maximum benefit from the forests that we
use as a way of protecting the forests that we set
aside.
Without doubt, wood is a renewable raw
material that can be used to meet the basic needs of
a growing world population. If not wood, what? Of
course, we have much to learn about forest
management issues stemming from the market, but
we're well on the way to defining the issues.
Chlorine Bleaching, an Evolving Issue
The market message on chlorine is clear: "don't use
chlorine for bleaching." Right now, this message
Equivalent to 8
Kraft Milles Each
Producing 800
Tonnes/Day
95 96 97 98
has reached maturity primarily in Europe. The issue
is mostly driven by events in Germany; however,
those of you who know the European market real-
ize that no major market in Europe is independent
of the others. What happens in Germany essentially
happens in the rest of Europe. There are no major
European producers of paper or other consumer
products that do not have significant customers in
Germany.
The evolution of this issue began in Europe. A
brochure emerged from Sweden in the late 1980s.
Its title was "Paper and the Environment"; its
primary author was Goran Bryntse. This brochure
detailed the deteriorating quality of the Baltic Sea.
Bryntse proposed in this pamphlet a three-
tiered rating system designed to evaluate the "en-
vironmental friendliness" of papers manufactured
in Sweden. He assigned an "A" rating to "chlorine-
free" paper from manufacturers with effluent bear-
ing less than 0.1 kg of adsorbable organic halogens
(AOX) per tonne of pulp, and a "B" rating to "low
chlorine paper," containing less than 0.5 kg AOX
per tonne. Anything above 0.5 kg per tonne was
referred to as chlorine paper. Note that dioxin is not
mentioned in this rating system. To this day, dioxin
is not a major issue in Europe.
It is also interesting to note that the brochure
represents a paradigm shift from concern about
product quality to a more global concern about en-
vironmental protection in the place where the
product is manufactured. This shift represents an
important development.
With this evolution, a nomenclature emerged
to describe the various bleaching options now
being used in Europe. At the first level is an elemen-
tal chlorine-free (ECF) option. In this option, no
chlorine gas is added to the bleaching process;
however, other chlorine compounds may be used.
294
-------
D.W. DeCREASE
The next, more stringent level is referred to as
low AOX pulp. This pulp may contain anywhere
from 0.1 to 0.7 kg AOX per tonne of pulp depend-
ing on the individual customer's needs. The highest
designation, the ultimate goal for some is a totally
chlorine-free (TCP) pulp in which no chlorine com-
pounds at all are used for bleaching.
Although the ultimate goal may be TCP for
some European markets, the industry currently
does not have the capability to make TCP pulp at
acceptable brightness, strength, and cost levels.
This incapability has created tension in the
marketplace and fostered a search for alternatives.
Going back to Bryntse's alphabetical rating
criteria, papermakers are seeking a bridge to TCP
by researching a low chlorine option that allows
them to achieve a gradient chlorine-free status
along the way to TCP. Their approach is to create
formulations combining kraft pulp having some
low level of chlorine and other TCP components
such as chemithermomechanical pulp (CTMP) and
filler, giving a net 0.1 kg AOX per tonne in the
paper sheet. With this kind of formula, the kraft
pulp itself may vary as required to provide this tar-
get level in the paper. This may sound like hocus
pocus — clearly it is marketing and not science —
but it is real and represents a true reduction in
chlorinated organics along the way to TCP.
Chlorine Bleaching Today
Customers in North America and Japan are show-
ing growing interest in the chlorine issue and par-
ticularly in ECF products, but as yet this market is
not widespread. In Europe, ECF is required in most
places; however, demand for low AOX pulp is
rapidly emerging as the next step. This option arises
out of the industry's inability to meet TCP demand.
With this in mind, we need to consider the
availability of totally chlorine-free bleached market
pulps. Table 1 illustrates that while some volume of
bleached CTMP and sulfite pulp is available in a to-
tally chlorine-free form, only a small proportion of
kraft pulp (the majority of pulp on the market) is
available as TCP. This number is growing, but it will
take some years to reach a supply level sufficient to
meet the demand.
Table 1.—Availability of totally chlorine-free bleached
market pulps (May 1992).
GRADE
BCTMP
Sulfite
Kraft
GLOBAL MARKET
CAPACrTY** (1992)
2.10
1.88
28.40
TCP
PROPORTON
Virtually all
At least one third
2.5%
•Excludes former Soviet Union and Peoples Republic of China
"Millions of tonnes
The first constraint on the achievement of TCP
is product quality. Do not underestimate the impor-
tance of this factor. Brightness and strength are
primary barriers to TCP today. For most mills, it i:>
not possible to use TCP processes and achieve
mandated brightness targets. Of equal importance
is our inability to maintain acceptable strength
levels at economical production speeds. Thus,
product cost becomes a constraint. Only ex-
perience and technology can help us overcome the
production factors affecting these key product char-
acteristics.
The second major constraint to achieving TCP
is technology. Most mills do not have the
capability, and those that do require further tech-
nological advancements to overcome the bright-
ness and strength issue.
Third, even as the technology emerges, is
refined, and becomes widely available, significant
capital is needed to convert from traditional
bleaching and pulping processes. A pulp mill is a
closely linked network of interrelated, highly com-
plex systems, and major changes to any portion of
the system affect the entire mill. Those impacts
must be thoroughly understood and accom-
modated before TCP production can become
routine. Understanding, experimentation, and ac-
commodation take time, our fourth constraint.
Despite those constraints, our manufacturing
processes are evolving toward TCP. Figure 8 traces
the evolution of kraft pulp mills over the last 30
years. Note how the state of the art has changed in
terms of bleaching sequences and the resulting ac-
ceptable AOX levels. Advancements in technology
and processes have already made vast decreases in
AOX levels while retaining full brightness and
strength levels, yet market concern for AOX did not
arise much before 1990. No doubt the added im-
petus of those market concerns, combined with fur-
ther exploration of such alternatives as extended
delignification and ozone, will continue this trend
into the next decade.
This progress will not be easy, quick, or inex-
pensive. Table 2 shows the magnitude of the quality
reductions and cost increases we must manage and
overcome to follow that trend. As we move along
the spectrum from conventional bleaching proces-
ses to ECF and low AOX pulp to TCP, the quality
decreases by about 10 percent at each step beyond
ECF, and the costs increase in far greater incre-
ments. Nor do capital expenditures alone suffice;
chemical costs increase significantly, leading to
higher overall manufacturing costs. (This is but one
example; depending on specific product and
manufacturing processes, the case can be much
worse than depicted here.) The result, as I've men-
295
-------
Market Pulp
AOX* (kg/t pulp - in effluent)
8
0
Conv-CEDED
1960's
Late
1970's
Conv-0-D/CEQDEpD
MCC-O-DE0DED
Mid
1980's
1990
1995?
Evolution of Technology
*These AOX levels assume full pulp brightness and strength
Note: AOX does not correlate with toxicity
Figure 8.—The state-of-the-art kraft mill.
tioned before, is that TCP requires an enormous
capital investment and does not yet meet customer
quality needs. We still don't know either the capital
or the manufacturing costs of producing TCP at the
brightness and strength levels that customers will
require.
Right now there are some European customers
who want TCP, but only at acceptable product
quality and cost levels, neither of which we can
currently deliver. To get there, pulp manufacturers
will need to build a bridge, an intermediate step. Ef-
forts are already underway, and it appears that
chlorine dioxide will play a vital role in that transi-
tion.
Even chlorine dioxide, however, is likely to be
transitory. The demand for TCP in the European
market is driving the elimination of bleaching done
with chlorine and assorted chlorine compounds
though the pace of change is currently determined
by the limitations of technology and the economics
of quality and cost. As we make headway against
those limitations, TCP demand is likely to spread to
Table 2.—A mill example.
the rest of the world, where chlorine bleaching is
not yet a major market issue. It appears to be only a
matter of time.
To recap the major market issues:
• Recycling is moving rapidly and successfully,
and we feel it can be best continued without
mandates.
• Forest management is an emerging issue that
involves a positive story about renewable
resources. There is no doubt, though, that we
must better understand the issues surround-
ing biodiversity and resource management.
We must examine our management practices
closely and continuously improve them.
• Chlorine bleaching, primarily a European
concern, is an area in which we have made
tremendous strides but have a long way to go
before technological and quality limitations
allow us to fully meet demands for TCP. In
the meantime, ECF should be recognized for
the huge positive step that it provides.
CONVENTIONAL
Brightness
Strength
Cost of bleaching chemicals
Capital requirement
90
100%
base
base
ECF
90
100%
+20%
$6 million
LOW AOX
97
93%
+50%
$14 million
TCP
75*
88%*
+50%
$14 million
TCP
85+
100%
?
>$1 00 million
•This TCP quality does not meet customer needs
296
-------
D.W.DeCREASE
Issues to Anticipate
Additional issues on the horizon include energy
use, odor, and water use. The first is energy use. As
life cycle analysis becomes better understood,
energy will play a larger role in critiques of environ-
mental performance. The second is odor. Despite
our increasingly sensitive measurement and
recovery systems, this long-standing community
concern won't go away soon. Finally, water use,
like energy use, is an additional area of concern as
the availability of clean and plentiful water be-
comes more constrained in many communities.
These issues require our consideration now if we
are to understand and address them properly as
they arise.
The Forest Products Cycle
The answers to these issues lie within the forest
products cycle that begins with the harvesting and
replanting of trees and progresses through produc-
tion to consumer use, recycling, composting, con-
version to energy, and appropriate use of landfills
before starting all over again. We are fortunate to
be working within an industry that uses a renew-
able resource in a myriad of ways and efficiently
satisfies both customer needs and the environmen-
tal and social concerns engendered by our
manufacturing and disposal methods. We should
be proud of our record and our accomplishments
within this cycle — proud, but not satisfied. As the
cycle keeps coming, we can always do more to im-
prove our performance in every arena, including
environmental performance.
Our goal should be to maximize the forest
products cycle, with "no-effect" manufacturing as
the ultimate goal. We don't claim to have all the
answers, but among the answers are the following:
• sustainable forestry, providing fiber from
manufacturing residuals and trees grown for
the purpose of making pulp;
• energy self-sufficiency in closed-cycle
processes, manufacturing methods with low
water use and the recovery of chemicals for
reuse;
• recycling after use and clean conversion to
energy or compost of those fibers that cannot
be recycled; and finally
• the return of ash or compost to the land to
become part of the next forest cycle.
This ongoing, sustainable, and successful cycle
will, if properly managed, result in environmental
responsibility, economic sustainability, and suc-
cess. The environmental issues that we face today
— recycling, forest management, and chlorine
bleaching — are integral to the cycle and will help
determine the evolution of the pulp and paper in-
dustries over the next decades. With an ultimate
goal of "no-effect" manufacturing, and a perspec-
tive that encompasses these issues within the
framework of the whole forest products cycle, we
can manage the pulp and paper industry's evolu-
tion into an improved and improving future.
297
-------
Market Barriers for Aspen
Bleached Chemithermomechanical
Pulp Products in the United States
Patricia J. Dollar
Consultant
Slave Lake Pulp Corporation
McLean, Virginia
Slave Lake Pulp Corporation is the result of a
partnership formed by Alberta Energy Com-
pany of Canada and MoDo of Sweden, to
construct a 350 tons per day bleached chemither-
momechanical pulp (BCTMP) mill using state-of-
the-art equipment and technology. The mill is
located in Slave Lake, Alberta, Canada, surrounded
by vast reserves of aspen timber. Scandinavian
paper manufacturers have long had an unparal-
leled worldwide reputation for being on the leading
edge of environmental risk assessment and risk
management.
The Slave Lake pulp mill uses self-regenerating
aspen forests in northern Canada. From initial
manufacturing processes to the finished pulp, all
details are selected for minimum environmental
impact. The process does not use chorine or
chlorine dioxide but a two-stage peroxide bleach-
ing process.
The aspen species used in the BCTMP
manufacturing process has a low lignin content
fiber, which is highly suitable for use by the high-
grade paper manufacturers who are the mill's tar-
geted customers.
The BCTMP process results in a high-yield pulp
(trade name: Ranger), with an 88 percent average
yield that is almost twice that achieved by a con-
ventional kraft process. The aspen fiber also has a
brightness level of 85 ISO, which makes it suitable
for use in coated and uncoated free sheet paper
grades.
Aspen BCTMP Fiber Replaces
Hardwood Kraft Pulp
Aspen BCTMP fiber is designed as a replacement
for hardwood kraft pulp in the manufacture of com-
modity and high-grade printing and writing papers.
Aspen BCTMP has a zero purity rating of 82 per-
cent, freeness ranges of 75 to 350 Canadian Stand-
ard Freeness, and consistently meets brightness
ranges of 85 to 86 percent ISO.
BCTMP processing technology provides the
paper manufacturer with a pulp that produces sur-
face smoothness, good bulk characteristics, and ex-
cel lent opacity. In addition, in coated paper grades,
the surface coating eliminates potential color rever-
sion. The results of many tests and end-user feed-
back confirm that brightness reversion is no longer
the issue that was originally associated with early
generation high-yield pulps.
Adding aspen BCTMP enhances the bulk and
stiffness of recycled grades, which are usually
notorious for their limpness. Copier papers in par-
ticular benefit from the enhanced performance and
stability that comes from the addition of aspen
BCTMP to the furnish. BCTMP also helps to offset
reduced brightness levels in deinked fiber, which
levels have long been a complaint in copier papers.
Some possible cost advantages are also gained by
adding BCTMP to recycled furnish. Depending on
the amount of virgin kraft or recycled fiber
replaced, cost savings on the manufacturing side
298
-------
P.). DOLLAR
can help to reduce the current disparity in price be-
tween virgin and recycled papers.
Demand for Aspen BCTMP
in the United States
Aspen BCTMP is marketed mostly in Europe, the
Far East and North America for a variety of end-use
applications such as copier papers, forms, bond,
and high-grade coated papers. Some of the demand
in Europe and japan result from the fact that
BCTMP is totally chlorine-free — those markets
also have a much greater familiarity with high yield
pulp in general. However, despite successes in
Europe and the Far East, to date, there has been
surprisingly limited market penetration for aspen
BCTMP in North America.
Papermakers cite wood-free definitions as their
primary reason for not using this product. They
refer to existing definitions used by the government
and adopted by the pulp and paper industry. As
most of us know, these definitions limit the use of
"mechanical pulp," "groundwood," or lignin. Now,
aspen BCTMP does contain lignin — albeit only 17
percent versus the nearly 28 percent that is found in
groundwood pulp — but according to harmonized
tariff definitions, it is not a "mechanical pulp." In
fact, in these definitions, nonbleached chemither-
momechanical pulp (CTMP) is included as a "semi-
chemical pulp."
The industry needs, I think, to rewrite some
definitions and to be more specific about others.
For example, the Joint Committee on Printing (JCP)
specification used by the U.S. Government Printing
Office (GPO) limits the groundwood content in cer-
tain grades (to a maximum of either 10 or 1 per-
cent). Clearly, BCTMP is not groundwood.
However, GPO uses the phloroglucinol test to
detect groundwood, yet this test identifies lignin
and can therefore be used to exclude BCTMP from
inclusion in government procurement. My under-
standing is that the JCP specifications do not define
"groundwood" or mention BCTMP as a nonaccep-
table pulp. Many U.S. specifications and standards
are written around old technology and are prevent-
ing the adoption and use of pulps from newer tech-
nologies.
Canada is Adopting New
Standards for BCTMP
The Canadian General Standards Board (a federal
committee) is in the process of adopting new stand-
ards that have no limits on the amount of BCTMP in
wood-free grades bought through government
procurement. In comparison, the U.S. government,
by default, is creating real but unnecessary trade
barriers to the advancement of sound environmen-
tal pulp and papermaking technology by not help-
ing to create procurement opportunities for
BCTMP. Slave Lake Pulp Corporation has ap-
proached many U.S. paper manufacturers, but
mills are reluctant to purchase BCTMP as long as
their products will be considered as groundwood-
containing papers that do not meet Federal
procurement standards.
Lignin-free Permanent
Papers Controversy
Several organizations in their zeal to set standards
and insure the permanence of papers have chosen
to adopt or propose standards demanding that per-
manent papers be lignin-free. While I am squarely
in their corner regarding the deterioration of paper,
we must not forget that we are in an industry of
constantly evolving technology (otherwise paper-
makers would still be down by the river pounding
papyrus on rocks). Part of technological advance
involves changes in pulping and bleaching proces-
ses. By today's standards and testing procedures,
lignin is an unwanted label. But this notion is based
on outdated information and makes no allowances
for new processes. The end-use performance of
BCTMP-containing papers has not been closely ex-
amined. Currently laboratory testing methods
merely detect lignin, which is clearly not an ac-
curate measure of the potential value of BCTMP
pulps.
Those who are involved in the permanent
papers issue would probably agree that the
paramount objective is to avoid the physical
degradation of the paper. BCTMP papers have been
shown to meet this need. In the United Kingdom,
for example, papers containing up to 15 percent
BCTMP have recently been approved by a commit-
tee for buyers of archival papers. This approval will
become part of a long-term test on the performance
of BCTMP-containing papers. Independent tests
have shown that alkaline coated and uncoated
papers with up to 60 percent BCTMP (of the fiber)
are equal to free sheet for retention of physical
characteristics in accelerated aging tests. As pre-
viously mentioned, interest in BCTMP outside the
United States is growing because buyers are con-
cerned about chlorine use in traditional chemical
pulps. Consequently, we need to do all that we can
to encourage the growth and development of new
technologies that produce better papers in an en-
vironmentally friendly manner and provide cost
savings.
Incentives should begin with changing the free-
sheet and groundwood standards as presently writ-
ten, or with the creation of a third standard for
299
-------
Market Pulp
BCTMP pulps. It is imperative that we eliminate the promoting the use and procurement of recycled
"guilt by association" attitude that currently has papers. Now, the Federal Government needs to
BCTMP and semichemical pulps categorized with provide additional incentives, including the cre-
newsprint and other groundwood grades. Evidence ation of specifications for grades of paper that will
from many test runs and commercially produced allow the use of BCTMP pulp in federally procured
papers dictate otherwise. In the past decade, the finished goods.
Federal Government has become a leader in
300
-------
One Company's Experience
with Chlorine-free Bleached Pulp
(a Cautionary Tale)
Ladd T. Seton
Export Sales
Fraser Paper, Limited
Stamford, Connecticut
Requests for chlorine-free pulp and paper ap-
peared in the European markets from about
1986 on, as a consequence of suggestions
by some environmental groups that dioxins and
other chlorinated organics, present in minute quan-
tities in paper and pulp mill effluent, might be
harmful to users of bleached paper and to con-
sumers of fish, living in bodies of water receiving
such effluents.
This notion found strong resonance, principally
in Germany and Scandinavia, for reasons best
analyzed by political scientists and students of eth-
nic psychology. Significant segments of the pulp
and paper industry in those countries, and in
countries pursuing trade in Scandinavia and Ger-
many responded positively. They made the neces-
sary investments to offer elemental chlorine-free
(ECF) and totally chlorine-free (TCP) pulps for the
manufacture of so-called chlorine-free papers.
Fraser Paper, which owns a magnesium bisul-
fite market pulp mill in New Brunswick, Canada,
was one of the early producers to have 100 percent
TCP capability and was, I believe, the first in North
America to produce TCP chemical pulp. Today, that
mill is shut down and being offered for sale.
Given the "clamor" for TCP pulps and chlorine-
free papers, many ask, "what happened?"
Fraser Paper's TCP Experience
Our experience may be useful to others who are
trying to respond to changing market trends and so-
called market opportunities. Market pulp is an in-
dustrial intermediate product, sold by pulp pro-
ducers to paper manufacturers. These producers
are typically companies of significant size; they are
also technically competent and commercially as-
tute. Ordinary transactions are quite large. As a
consequence, when pulp buyers speak, pulp sales-
people listen!
As we look down the product chain, market
complexity increases, with more options and play-
ers involved. For example, printing and writing
paper passes through several stages of conversion
and distribution, which are often independently
managed or owned.
I mention this complexity to show the difficulty
one has when faced with an evolving situation. Ini-
tially, the demand was made for chlorine-free
papers, then chlorine-free pulps, then for pulps
bleached without chlorine, then pulps bleached
without chlorine compounds (see Table 1).
Table 1.—Common environmental acronyms.
ACRONYM
DEFINITION
"Green" "Environmentally correct" white pulp
ECF Elemental chlorine-free
CGF Chlorine gas-free
CCF Chlorine compound-free
CCF (again) Chemical chlorine-free
NCC Nonchlorine compound
MCF Molecular chlorine-free — technically the
most accurate term to use for pulps that
have nevertheless been bleached with
chlorine dioxide
ACF Active chlorine-free
ACF (again) Absolutely chlorine-free
ACF (yet again!) Almost chlorine-free
TCF Totally chlorine-free — now the accepted
term to characterize pulps that have
involved no chlorine compounds at all
in their bleaching processes
301
-------
Market Pulp
Now, oxygen, ozone, peroxide, enzymes, and
other methods are being considered for pulp
bleaching. But is this what the market really wants?
Understanding the Market
What is the market? Is it the ordinary consumer
buying a roll of toilet paper; the secretary making a
xerographic copy; the owner of a small print shop
printing menus for the neighborhood restaurant;
the purchasing manager of a large publishing house
buying tens of thousands of tons of paper per year;
or the environmental activists' vision of what
"ought to be"? I don't know — probably all of
them!
As noted earlier, certain segments of the world
paper industry responded quickly to the chlorine-
free bleaching issue, especially Germany, which
has no kraft pulp mills, only sulfite mills; and some
Scandinavian countries, where there are a number
of older sulfite mills. In all cases, the countries had
strong environmental movements.
The sulfite pulping process has not maintained
its share of the total chemical pulp produced and in
those terms has been in decline for some time. The
technologically, economically, and environmental-
ly more advantageous kraft pulping process domi-
nates the world industry today. Sulfite pulps are
best used in special applications that make good
use of sulfite's unique fiber properties.
Sulfite pulp is easier to bleach than kraft pulp.
Therefore, the conversion of a sulfite bleach plant
to an ECF or TCP bleaching process is relatively
simple, not too costly, and results in product quality
approaching that of conventional chlorine-
bleached sulfite pulps. Many in the sulfite industry
saw an opportunity to enhance their market posi-
tion and improve their future prospects by convert-
ing or building plants to produce ECF and TCP
pulp.
Two things happened. First, most of the
European sulfite producers reached the same con-
clusion. Today virtually all of the Western world's
sulfite market pulp capacity has ECF potential, and I
estimate that probably half, if not more, has TCP
capability, for a total capacity of nearly 1.8 million
metric tons.
Second, they expected that the one, clear, un-
questioned virtue of having truly chlorine-free pulp
would neutralize the technical differences between
sulfite and kraft, thus permitting sulfite pulp to
recapture market segments lost to kraft pulps. Well,
where are we now?
In Germany and the surrounding countries,
pulp buyers have accepted TCP sulfite pulps for ap-
plications in which sulfite fiber performance com-
pares to that of kraft — primarily tissue and some
printing and writing applications. Pulp import
statistics for 1990 and 1991 bear this out, reflecting
an increase of sulfite pulp imports to Germany (see
Fig.D
Many buyers, however, continue to demand
kraft fiber properties, principally strength, without
sacrificing brightness and cleanliness. In a market
Thousands of Metric Tons
3000-.
2500j
500*
400
300
200
100
0
2452
2752
2614 —- —
211
223
214
2830
2992
2865
2900 (E)
Kraft
294
214
211
85
86
87
88
Year
89
90
91
Figure 1.—German imports of bleached chemical pulp.
Source: PP1 Fact Book 92
302
-------
in which paper specifiers are unwilling and unable
to compromise on product quality, the pulp buyers
have no choice. The economic status of the pulp
market during the last two years has contributed
commercial elements to this competitive situation.
In other parts of the world, the market for chlorine-
free pulps is very small and limited to some very
specialized applications.
Conclusion
Some people say, "the market is always right." I say
"be sure you really understand the market." Leader-
ship, or being ahead of the crowd, does have its ad-
vantages and, sometimes, disadvantages.
LT. SETON
Seemingly interchangeable, similar products
can have nuances both subtle and important. In
some applications, substitution of sulfite for kraft
fibers and vice versa is possible and practical. In
others, only a strong economic incentive will cre-
ate a change. In still others, substitution is not a
realistic expectation. It is vital to understand the
economic and technical implications of each situa-
tion.
Given the broad spectrum of fibers required by
the paper industry, a market does exist for sulfite
pulps. But whatever bleaching process is selected
by each mill to respond to changing needs, the
basic fiber properties defined by the wood species
and cooking process will continue to count.
303
-------
Market and Technical Aspects of
Totally Chlorine-free Bleached
Kraft Pulp in Europe
Steve Moldenius
Technical Director and Manager
Research and Development
Sodra Cell
Morrum, Sweden
The European pulp and paper industry is in the
middle of the fastest and most dramatic
quality change it has experienced in the past
few decades — the move from chlorine bleached
to totally chlorine-free (TCP) bleached products.
The change is driven by environmental pressure
groups and political decisions. Market demand has
also forced this technical evolution and, today,
most suifite pulps are totally chlorine-free at high
brightness levels. During the past year, even totally
chorine-free kraft pulps at high brightness estab-
lished a market segment.
Sodra Cell has three mills in southern Sweden
— in Morrum, Monsteras, and Varo — with a total
production capacity of 1 million tons of bleached
kraft pulp. Approximately 40 percent of the produc-
tion is hardwood (birch); the other 60 percent is
softwood (spruce and pine). This year about 15 to
20 percent of our production was in TCP grades,
bleached without chlorine or chlorine dioxide. All
our production is market pulp, and 75 percent of it
is exported. Our customers are mainly located in
central Europe. Today we produce softwood pulp at
80 percent ISO and hardwood pulp at more than
80 percent ISO. In September 1992, Sodra Cell
started the production of kraft hardwood pulp at
full brightness (88 to 90 percent ISO) and totally
chlorine-free. Ozone, peroxide, and oxygen
bleaches are used instead.
The Evolution of Totally
Chlorine-free Pulp
Long before environmental marketing was a reality,
environmental protection was a top priority for the
pulp industry. Chlorine bleaching produced toxic
and heavily colored effluents that resulted in a large
consumption of oxygen in the receiving waters.
In Sweden, earnest environmental protection
work began in 1974 to minimize the negative effect
of pulp bleaching. Before then, chlorine gas con-
sumption had increased in tandem with increased
pulp production. The first oxygen bleaching plant
was installed in 1973; from 1974 to 1991, chlorine
gas consumption decreased from 270,000 tons per
year to less than 35,000 tons per year. Today all
Swedish kraft pulp mills have installed oxygen
delignification equipment. I doubt whether any
chlorine gas will be used in Sweden after 1993 for
bleaching pulp.
International Agreements
The public's "chlorophobia" has, of course, had an
impact on the politicians. In 1988, the Swedish Par-
liament decided that "discharges of stable organic
chlorine compounds from pulp and paper mills are
to cease entirely." In 1990, the Nordic Ministers of
the Environment came to a similar agreement.
The Third International Conference on the
Protection of the North Sea agreed that "all sub-
stances that are persistent, toxicant, and liable to
bioaccumulate should be reduced to levels that are
not harmful to man or nature before the year
2000." In 1990, Sweden, Norway, Denmark, Ger-
many, the United Kingdom, Switzerland, France,
Belgium, the Netherlands, and the Commission of
the European Communities signed the agreement.
When environmental pressure groups, govern-
ments and the general public demand that pulp and
paper be produced totally chlorine-free, the in-
dustry must certainly try to change production
304
-------
S. MOLDENIUS
methods. Environmental arguments in marketing
are here to stay. New quality criteria have been in-
troduced with arguments that do not affect the
product but the production process. These criteria
have initiated dramatic technical development that
has never before been seen in the history of pulp
production. Initially development work was
focused on the reduction of adsorbable organic
halogens (AOX) to low levels; today a zero AOX is
the ultimate goal.
Totally Chlorine-free Bleaching
Chlorine-free chemicals are used in large quantities
for the bleaching of mechanical pulps. For ex-
ample, chemithermomechanical pulp (CTMP) is
bleached with peroxide. In recent years, peroxide
has been used for bleaching sulfite pulps to high
brightness levels. Peroxide is also the chemical
used for producing TCP bleached kraft pulps. The
peroxide bleaching process, similar to CTMP
bleaching, consists of two stages: the first is
pretreatment with a chelating agent or an acid
wash; the second is the actual bleaching stage in
which the peroxide is charged.
All TCP kraft pulps are similarly bleached with
peroxide. Commercial production started in 1990.
Although production is small so far, it's steadily in-
creasing; many mills have already announced that
they are going to start production of TCP pulp.
Today's brightness level is about 80 percent
ISO. For example, Sodra Cell has both a hardwood
and a softwood at 80 percent ISO brightness.
Hardwood is relatively easy to bleach to more than
80 percent brightness; softwood is more difficult
because its strength is an important consideration.
Too high a peroxide charge will decrease the pulp
strength. That's why we use the technique of ex-
tended cooking before the peroxide bleaching. Ex-
tended cooking yields approximately five units
higher brightness with retained strength properties.
Strength properties for TCP pulps are the same as
for standard pulps.
The Ozone Alternative
The next challenge is to reach full brightness with
chemicals that do not contain chlorine. On a
laboratory scale, different sequences have been
shown to give high or full brightness. The key factor
in these sequences consists of at least one stage
with ozone. Sodra Cell's MonsterSs mill started
ozone bleaching on a full scale in September. The
pulp bleached with ozone, oxygen, and peroxide is
totally chlorine-free. The hardwood pulp will reach
full brightness, 88 to 90 percent ISO, and the
softwood will achieve a high brightness. The
bleaching system consists of peroxide and ozone at
medium consistency at a production rate of 1,100
tons per day.
Entering the TCP era is another step taken for
environmental reasons. In the 1960s, we closed
down old sulfite mills. In the 1970s, we started
oxygen delignification. In the 1980s, we began to
abandon chlorine gas. Now, — in the 1990s — we
shall eliminate all chlorine containing chemicals
and produce TCP pulps. There's no reason to be
threatened by development. Make it an opportunity
instead!
Conclusion
Environmental pressure groups, governments, and
the general public are demanding TCP products.
This demand has led to the development of bright
TCP pulps. It began with TCP sulfite pulps, but now
kraft pulps are also available on the market. Today's
TCP kraft pulps have a brightness level of 80 per-
cent ISO. That brightness is sufficient for wood-
containing papers; however, it is too low for many
wood-free papers. It is necessary to increase the
brightness to full brightness for the TCP grades.
Many paper companies have said that they will
produce TCP papers when pulps are available with
the same brightness as chlorine-bleached pulps.
Sodra Cell started to produce hardwood TCP
pulp at full brightness in September. Later, we will
also have softwood TCP at full brightness. I am con-
vinced that within the next few years substantial
amounts of TCP kraft pulps will be available at full
brightness and strength from several companies.
The only drawback to such TCP pulps will be the
price. Production costs for TCP pulps are higher be-
cause the bleaching chemicals are expensive, and
the investment cost is high. In the end, the general
public must — and will — accept a slightly higher
price for TCP products.
305
-------
Panel 3:
Market Pulp
Question and Answer Session
m Med Byrd, North Carolina State University: For
Dr. Moldenius, could you comment on the cost dif-
ferential between a TCP pulp and a standard pulp?
• Steve Moldenius, Sodra Cell AB: I can't give you
the actual prices since they are changing from day
to day. The TCP market is its own market in the
same way that hardwood and softwood are their
own markets. But today, the price is about 15 per-
cent higher for TCP grades, both hardwood and
softwood.
• Med Byrd: I just want to comment, I was travel-
ing abroad recently and I saw an ad for your com-
pany in an airline magazine. It was very amusing; it
said, "You're the customer, you're always right. You
told us you wanted chlorine-free pulp. We don't
think it's required, but we're going to do it." A pretty
unique, pretty funny attitude, I think. I also have a
comment for Ms. Dollar. I appreciate your com-
ments about CTMP. Those of us at North Carolina
State University believe that it plays a strong role in
future market and future pulping operations. We
just put in a 3.5 tons per day pilot plant, so we're
hoping that you're right. But also, I think it's fair that
if you look at everything in a systematic way, you
always need to consider the energy input into a
mechanical pulp and compare that to an
equivalent electrical or electrochemical energy for
chemical and other pulping demands. In some ap-
plications, that energy ultimately depends on your
location and can really make a difference in how
well a TMP or CTMP is received.
• Sherl Tonn, Citizens for a Healthy Bay: Mr. De-
Crease, I was really interested to hear you say that
Weyerhaeuser was planning a pulp expansion. Can
you elaborate on specifically what technology
you're planning, where you're planning the expan-
sion, and what you're going to do about pollution
prevention?
• Dean Decrease, Weyerhaeuser Company:
That's not really the reason I am here. I was ex-
plaining why Carl Geist isn't here. It's not an expan-
sion; it's a purchase of two mills that are already in
place.
• Sherl Tonn: Which two mills?
• Dean Decrease: We can talk about the details
later.
• Mary McKlel, U.S. Environmental Protection
Agency: Ms. Dollar, I wanted to thank you for your
perception and your vote of confidence. Not
everybody realizes that when a Federal bureaucrat
is away from his or her desk, it actually decreases
efficiency. But more important, in your talk you ad-
dressed the area of Federal procurement that is near
and dear to my heart. Perhaps not everyone real-
izes that the GPO system of specifications and the
Federal specification system are two different sys-
tems. There are overlapping areas of respon-
sibilities, but GSA's area is much broader. If Barbara
were here, I'm sure she would invite you to talk to
the group in New York about some possibilities. I
am not familiar with each of their 115 specifica-
tions to know whether our requirements preclude
the use of the pulp you mentioned but I encourage
you to talk with the New York people.
• Patricia Dollar, Slave Lake Pulp Corporation:
Yes, I'd like to make a comment on that. In my at-
tempts to understand what is happening in govern-
ment procurement we have come across the most
interesting things and one is that we have a major
problem in terminology and semantics on this
issue. It seems that everyone from NISO, ASTM,
GSA, and GPO have a mandate to help create
306
-------
QUESTION & ANSWER SESSION
markets for environmentally friendly products, but
how can we do that if there's a catch-22 in the
procurement guidelines? If you're a procurement
officer, you can only do what your guidelines allow
you to do. So you're shackled by language that
really needs to be looked into to allow a new con-
sensus to form. And this problem is not only within
the government; it's also within the commercial
sector.
• Susan Poniatowskl, University of Massachu-
setts at Lowell: Ms. Dollar, I have not kept up with
all the various conjugations in the area of mechani-
cal pulping, but correct me if I'm wrong. Is BCTMP,
Bleached Chemical Thermal Mechanical Pulp?
• Patricia Dollar: Yes.
• Susan Ponlatowski: Can you tell us what the
chemical treatment is and is it a prechemical or a
postchemical treatment after the thermal mechani-
cal?
• Patricia Dollar: Well, may I defer that question to
the gentleman next to me? I am not a chemist, or
even a person who payed attention in her college
chemistry class. Everyone here the first day spoke a
language I don't understand. I can get through the
alphabet, but when it comes to chemistry I defer to
the man on my left.
• Unidentified Speaker: You bleach after the refin-
ing.
• Susan Poniatowski: Yes, I understand that the
bleaching occurs afterwards, but I understand also
that there is usually an application of some sulphur
compounds either prior to or immediately after the
actual refining?
• Unidentified Speaker: That is sulfite, the "C" of
CTMP. The chemical treatment with sulfite is a
pretreatment.
• Susan Poniatowskl: Okay, exactly. My second
understanding of the process is that there is no
recovery cycle yet developed for this particular
process. Is that correct also in the Slave Lake
facility?
• Patricia Dollar: I have to refer this question, also.
We have a gentleman in the audience who is the
technical director at the mill. I think he might know
better than I what they're doing there. If you would
stand up, Ben, please.
• Ben Gromberg, Slave Lake Pulp Corporation:
You are, I believe, correct. There is no recovery
cycle today. One reason is that we use much
weaker solutions of chemicals than was formerly
possible in the chemical pulp industry.
• Susan Poniatowskl: If you're getting an 80 per-
cent yield, what is happening to the 20 percent lig-
nin, waste, and lost fiber coming off the pulp? How
are you dealing with that environmentally, and
what about the chemical that you cannot recover,
which I assume goes out in the same waste flow?
• Ben Gromberg: First, our yield is 88 percent, so
we're talking about 12 percent and in our case, we
use an activator sludge system to take care of the ef-
fluents.
• Susan Poniatowski: And the sludge is ...
• Ben Gromberg: . . . dried and later on incin-
erated.
• Mark Roegel, Greenpeace: I'd like to ask for two
clarifications from Mr. Seton. I was delighted when
your paper came on the market and sad to see it go.
One of your sales reps told me you had a $120 mil-
lion conversion cost. The figure he gave me to
move from chlorine-based chemicals to non-
chlorine based chemicals was $9 million. I was
hoping that you could clarify that. The other thing I
hope you will clarify is that during the entire time
your pulp was on the market your sales rep was
never able to give me any sales literature that said it
was chlorine-free. So, to my consumer perception,
you never marketed it as chlorine-free pulp or
never discussed the chemical make-up of the pulp,
which seems to me one of the reasons it failed, that
you hid your light under a bushel. I was wondering
if you could clarify this.
• Ladd Seton, Fraser Paper, Limited: Number one,
I did not mention any number at all in my talk
about a conversion cost so I don't know where the
$120 million came from, maybe from your conver-
sations with somebody else. The second point, the
$9 million, I can, in fact, confirm. That was the ap-
proximate amount of the investment necessary for
us to go from ECF to TCP in our specific case.
• Mark Floegel: Is that Canadian?
• Ladd Seton: Yes.
• Mark Floegel: Did you have sales material to in-
dicate that it was chlorine-free?
• Ladd Seton: Of course. Now, once again, let me
clarify. The product of our mill was market pulp. It
was not paper. I also happen to know the sales rep
that you talked to. He was in fact helping you buy
chlorine-free paper, which ultimately I think you
307
-------
Market Pulp
purchased from Lyons-Falls and I'm happy to tell
you that Lyons-Falls used our TCF pulp to make
some of your production. The only thing that I
regret is that your orders were so modest and small;
had you provided Lyons-Falls with bigger orders,
they would have provided us with bigger orders for
our pulp.
• Mark Floegel: For that we need more Green-
peace members.
• Peter Radeckl, Michigan Technological Univer-
sity: This is directed to Dr. Moldenius. Regarding
the creation of a plant that sounds rather flexible for
both chlorinated and nonchlorinated products, and
regarding the rest of the movement that you men-
tioned in Sweden and elsewhere in Europe — were
any significant incentives provided by the Swedish
government in the way of product specs, price sup-
ports, tax incentives, or anything along those lines
to assist you in the design, development, and even-
tual entrance into the marketplace of TCF products?
• Steve Moldenius: Nothing.
• Nell McCubbln, N. McCubbin Consultants, Inc.:
I wonder if Steve Moldenius would be willing to tell
us how much ozone and how much hydrogen
peroxide he expects to require to bleach to full
brightness. Or is that a trade secret?
• Steve Moldenius: So far, I don't know. We are
starting September 1.
• Nell McCubbln: You've obviously done pilot and
lab work.
• Steve Moldenius: Yes, we have used pilot
programs, but I'd rather wait to see the full-scale
operation.
• Nell McCubbln: Okay, fair enough. Thank you.
308
-------
Closing Remarks
Mary Ellen Weber
Director, Economics, Exposure, and Technology Division
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C.
want to thank Administrator William Reilly and
Deputy Administrator Hank Habicht for their
uninterrupted commitment to this symposium
and for their personal and much appreciated sup-
port of me and my staff during the past 15 months. I
also want to congratulate John McGlennon for his
terrific management of the sessions; Libby Parker
and Project Manager, Susan Krueger; Lisa Harris,
who assisted them; and Abt Associates; Eastern Re-
search Group (ERG); and JT&A. Thank you for a su-
perb job.
Most of all, I want to thank the 60 or so
speakers and the participants from industry and the
environmental community who helped us recruit
them. We have had a wonderful group here, and as
your reward, I will not try to recap all 60 presenta-
tions! The proceedings will do that. But I am grate-
ful to all participants and most especially to the
speakers for their graciousness and dedication.
As you know, the U.S. Environmental Protec-
tion Agency (EPA) is reassessing the status of dioxin
and other toxins, and we are committed to basing
our decisions on the best publicly available peer-
reviewed science. William Reilly has spoken many
times about his belief in the compatibility between
sustained economic development and environ-
mental protection — with an emphasis on preven-
tion.
This conference has addressed a small but a
very crucial piece of the chlorine equation. We
have talked about the technical and economic
aspects of alternative bleaching technologies. We
do not leave here with a simple one-size-fits-all
answer. We do, however, now share a common ex-
perience and the same basic information.
I hope that this symposium will be the begin-
ning of a habit of communicating with, instead of
at, one another. In the future, we should be able to
address scientific issues and the inevitable differen-
ces in our evaluations of scientific data with the
same professionalism that we have demonstrated
during this symposium in discussing technology
and economics.
309
-------
INTERNATIONAL SYMPOSIUM ON
POLLUTION PREVENTION IN THE MANUFACTURE OF
PULP AND PAPER — OPPORTUNITIES & BARRIERS
August 18-20, 1992 • Washington, D.C.
ATTENDEE LIST
(FINAL LIST, 8/20/92)
Said Abubakr
Professor
University of Wisconsin
Department of Paper Science
Stevens Point, Wl 54481 USA
TEL: 715-346-4817
FAX: 715-346-3624
Michael Affleck
International Coordinator of the Pulp and
Paper Project
Greenpeace
1017 West Jackson Boulevard
Chicago, IL 60607 USA
TEL: 312-666-3305
FAX: 312-226-2714
Donald Albert
Civil Engineer
Maine Department of Environmental
Protection
State House Station 17
Augusta, ME 04333 USA
TEL: 207-289-7767
FAX: 207-289-7939
Clark Allen
Chemical Engineer
Research Triangle Institute
P.O. Box12194
Research Triangle Park, NC 27709 USA
TEL: 919-541-5826
FAX: 919-541-5945
Donald F. Anderson
Chief, Commodities Branch
Engineering and Analysis Division, OST
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-7189
FAX: 202-260-7185
J.R. (Ross) Anderson
Market Development Manager
Du Pont Canada
P.O. Box 2200, Streetsville
Mississauga, Ontario L5M 2M3 Canada
TEL: 416-821-5237
FAX: 416-821-5945
SPEAKER
Norman Anderson
Director of Environmental Health
American Lung Association of Maine
128Sewall Street
Augusta, ME 04330 USA
TEL: 207-622-6394
FAX: 207-626-2919
• Rune Anderson
Director
Frovifors Bruk AB
Jarnvagsgatan 34
Frovi, Sweden S-71040
FAX: 46-581-31765
Frank Antonucci
Department Leader, Environmental
Technology
Champion International Corporation
Technical Center, Environmental Technology
West Nyack, NY 10094 USA
TEL: 914-578-7212
FAX: 914-578-7175
Folke Arbin
Project Engineer
Potlatch Corporation
P.O. Box 510
Cloquet, MN 55720 USA
TEL: 218-879-1025
FAX: 218-879-1905
A. Douglas Armstrong
Manager Pulp and Paper Feasibility
Georgia-Pacific Corporation
133 Peachtree Street, NE
Atlanta, GA 30303 USA
TEL: 404-521-4613
FAX: 404-521-5093
R. Bruce Arnold
President
R.B. Arnold Associates, Inc.
130 West Lancaster Avenue, Suite 301
Wayne, PA 19087-4079 USA
TEL: 215-964-9757
FAX: 215-687-7739
• David Assmann
Vice President and Director, Conservatree
Information Services
Conservatree Paper Company
10 Lombard Street, Suite 250
San Francisco, CA 94111 USA
TEL: 415-433-1000
FAX: 415-391-7890
iri
Robert Atkinson
Analyst, Office of Technology Assessment
U.S. Congress
OTA U.S. Congress - WDC
Washington, DC 20510-8025 USA
TEL: 202-228-6362
FAX: 202-228-6344
James L. Austin
President
MoDoCell, Inc.
One Selleck Street, Suite 460
Norwalk, CT 06855 USA
TEL: 203-854-9447
FAX: 203-854-9522
• Peter Axegard
Research Director, Pulp Department
Swedish Pulp and Paper Research Institute
P.O. Box 5604
Stockholm, Sweden S-11485
TEL: 011-468-676700
FAX: 011-468-115518
David S. Bailey
Senior Attorney
Environmental Defense Fund
1875 Connecticut Avenue, NW
Washington, DC 20009 USA
TEL: 202-387-3500
FAX: 202-234-6049
Andrew M. Bollard
Editor
Bureau of National Affairs, Inc.
1231 25th Street, NW
Washington, DC 20037 USA
TEL: 202-452-6366
FAX: 202-452-4150
Kevin Bank
Attorney
Federal Trade Commission
601 Pennsylvania Avenue, NW
Washington, DC 20580 USA
TEL: 202-326-2675
FAX: 202-326-2050
Melanie S. Barger
Chemical Engineer
Office of Research and Development
U.S. Environmental Protection Agency
401 M Street, SW (MC-7904)
Washington, DC 20460 USA
TEL: 202-260-7676
FAX: 202-260-4524
-------
Richard M. Bauer
Senior Staff Engineer
Stone and Webster Engineering Corporation
245 Summer Street
Boston, MA 02107 USA
TEL: 617-589-2242
FAX: 617-589-2156
Harry Baumann
Special Advisor on Economic Adjustment
Ministry of Industry, Trade and Technology
101 Bloor Street West
Suite 503
Toronto, Ontario M5S 1P7 Canada
TEL: 416-314-3760
FAX: 416-314-3757
Dave Beal
Vice President, Quality and Technical
Lake Superior Paper Industries
100 North Central Avenue
Duluth, MN 55807 USA
TEL: 218-628-5332
FAX: 218-628-5327
• Archie Beaton
Speciality Papers
Lyons Falls Pulp and Paper
77 East Crystal Lake Avenue
Crystal Lake, IL 60014 USA
TEL: 815-455-0981
FAX: 815-455-0997
Albert-Remy Beaudiy
Senior Staff Chemist
Hoechst Celanese
4331 Chesapeake Drive
Charlotte, NC 28216 USA
TEL: 704-559-6742
FAX: 704-559-6701
• Monica M. Becker
Center for Technology, Policy and
Development
MIT
Room E-40—242
Cambridge, MA 02139 USA
TEL: 617-253-1667
FAX: 617-253-7140
• Barbara Belasco
Specification Manager
General Services Administration
26 Federal Plaza - Room 20-130 (2FYEE)
New York, NY 10278 USA
TEL: 212-264-8725
FAX: 212-264-8731
• Kathleen M. Bennett
Vice President of Corporate
Environmental Affairs
James River Corporation
P.O. Box2218
Richmond, VA 23217 USA
TEL: 804-644-5411
FAX: 804-644-4369
Howard Keith Berry
Manager, Marketing
EKA Nobel
1519 Johnson Ferry Road
Marietta, GA 30062 USA
TEL: 404-578-0858
FAX: 404-578-1359
• SPEAKER
Phil Berry
Environmental Specialist
Department of Environmental Quality
811 SW 6th Avenue
Portland, OR 07204 USA
TEL: 503-229-5913
FAX: 503-229-6977
Lynne Blake-Hedges
Economist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-779)
Washington, DC 20460 USA
TEL: 202-260-7241
FAX: 202-260-0981
Mary Blake
European Coordinator, Pulp & Paper Project
Greenpeace International
Canonbury Villas
London, N1 2PN England
TEL: 44-071-354-5100
FAX: 44-071-359-4372
Peter Blanchard
Environmental Specialist
Maine Department of Environmental
Protection
State House Station 17
Augusta, ME 04333-0017 USA
TEL: 207-289-2651
FAX: 207-289-7826
Bengt E. Blomberg
Technical Director
Slave Lake Pulp Corporation
1200, 10707 - 100 Avenue
Edmonton, AB T5J 3M1 Canada
TEL: 403-423-8492
FAX: 403-423-7550
• Lauren Blum
Consultant
Environmental Defense Fund
257 Park Avenue South
New York, NY 10010 USA
TEL: 212-505-2100
FAX: 212-505-0892
Danforth G. Bodien
Senior Technology Advisor
U.S. Environmental Protection Agency,
Region X
1200 Sixth Avenue
Seattle, WA 98101 USA
TEL: 206-553-1491
FAX: 206-553-0119
Marianne Bohren
Environmental Supervisor
Potlatch Corporation
Industrial Avenue and Avenue B
Cloquet, MN 55720 USA
TEL: 218-879-0637
FAX: 218-879-0602
R. Jerry Bollen
Director, Environmental Affairs
Weyerhaeuser Company
(CH1L28)
Tacoma, WA 98023 USA
TEL: 206-924-2747
FAX: 206-924-2013
312
David Brackins
Account Manager
Du Pont Company
8477 Kings Trail Drive
Cordova, TN 38018 USA
TEL: 901-753-7530
FAX: 901-757-1146
Rosemary F. Bradley
Senior Consultant
SRI International
333 Ravenswood
Menlo Park, CA 94025 USA
TEL: 415-859-4153
FAX: 415-859-6484
Amy 8. Brockman
Statistician
Science Applications International
Corporation
7600-A Leesburg Pike
Falls Church, VA 22043 USA
TEL: 703-734-3174
FAX: 703-821-4784
Walter J. Brodtman
Environmental Engineer
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (EN-338)
Washington, DC 20460 USA
TEL: 202-260-5798
FAX: 202-260-5282
Robert T. Brooker
Manager, Charleston Technology Center
Olin Corporation
P.O. Box 248
Charleston, TN 37310 USA
TEL: 615-336-4000
FAX: 615-336-4554
Arthur W. Brownell
Associate Director, Federal Corporate Affairs
International Paper
1620 I Street, NW, Suite 700
Washington, DC 20006 USA
TEL: 202-785-3666
FAX: 202-785-1464
Barbara J. Burns
Senior Research Engineer
Scott Paper Company
Scott Plaza III
Philadelphia, PA 19113 USA
TEL: 215-522-6367
FAX: 215-522-6502
Medwick V. Byrd, Jr.
Director of Applied Research
Department of Wood and Paper Science
North Carolina State University
Box 8005
Raleigh, NC 27695-8005 USA
TEL: 9T9-515-5790
FAX: 919-515-6302
Jeff Cantin
Eastern Research Croup
110 Hartwell Avenue
Lexington, MA 02173 USA
TEL: 617-674-7315
FAX: 617-674-2851
-------
Larry W. Carriker
Marketing Manager
Olin Corporation
120 Long Ridge Road
Stamford, CT 06904 USA
TEL: 203-356-3085
FAX: 203-356-2064
David Case
Project Manager
World Environment Center
419 Park Avenue South
New York, NY 10016 USA
TEL: 101-683-4700
FAX: 101-683-5053
Sharie Centilla
Environmental Protection Specialist
U.S. Environmental Protection Agency
401 M Street, SW (EN-336)
Washington, DC 20460 USA
TEL: 202-260-6052
FAX: 202-260-1460
Ray Chalk
Senior Engineer
World Bank
1818 H Street
Washington, DC 20433 USA
TEL: 202-473-2423
FAX: 202-477-0686
James S. Chandler, Jr.
Director/Attorney
South Carolina Environmental Law Project
P.O. Box 279
Pawleys Island, SC 29585 USA
TEL: 803-527-0078
FAX: 803-546-0351
Joyce A. Chandler
Chemical Engineer
Stationary Source Compliance Division
U.S. Environmental Protection Agency
401 M Street, SW (EN-341 W)
Washington, DC 20460 USA
TEL: 703-308-8713
FAX: 703-308-8739
Archie D. Chelseth
Director of Public Affairs
Potlatch Corporation
207 Avenue C, Box 510
Cloquet, MN 55720 USA
TEL: 218-879-1059
FAX: 218-879-1005
Mau-Yin Chow
4025 Miller Drive
Glenview, IL 60625
TEL: 708-679-1151
* John F. Church, Jr.
President
The Cincinnati Cordage and Paper Company
Box 17125
Cincinnati, OH 45217 USA
TEL: 513-242-3600
FAX: 513-242-4307
SPEAKER
Donald A. Clarey
American Paper Institute
1001 G Street, NW
7th Floor East
Washington, DC 20001 USA
TEL: 202-783-5270
FAX: 202-783-1014
Fredrick Clark
Eka Nobel
1519 Johnson Ferry Road
Marietta, GA 30062 USA
TEL: 404-578-0858
FAX: 404-973-9688
David Clarke
Managing Editor
Inside EPA Weekly Report
1225 Jefferson Davis Highway
Suite 1400
Arlington, VA 22202 USA
TEL: 703-892-1012
FAX: 703-685-8908
• John L. Clement
Manager, Pulp and Paper Industry Marketing
Babcock & Wilcox Power Generation Group
20 S. Van Buren Avenue
P.O. Box 351
Barberton, OH 44203-0351 USA
TEL: 216-753-4511
FAX: 216-860-6590
David H. Cleverly
Environmental Scientist
Office of Research and Development
U.S. Environmental Protection Agency
401 M Street, SW (H-8105)
Washington, DC 20460 USA
TEL: 202-260-7891
FAX: 202-260-6932
• Gerard P. Closset
Vice President, Corporate Technology
Champion International Corporation
Tech Center, West Nyack Road
West Nyack, NY 10994 USA
TEL: 914-578-7000
FAX: 914-578-7272
Susan Cohen
Economist
Environmental Defense Fund
257 Park Avenue South
New York, NY 10010 USA
TEL: 212-505-2100
FAX: 212-505-2375
Bob Collins
Director of Marketing
Kamyr, Inc.
Ridge Center
Glens Falls, NY 12801 USA
TEL: 518-793-5111
FAX: 518-793-5267
• Richard N. Congreve
Group Vice President
Potlatch Corporation
P.O. Box193591
San Francisco, CA 94119-3591 USA
TEL: 415-576-8814
FAX: 415-576-8840
313
• Frank Consoli
Manager of Packaging Technology
Scott Paper Company
Scott Plaza II
Philadelphia, PA 19113 USA
TEL: 215-522-5467
FAX: 215-522-5236
• C. Roger Cook
Vice President, Environment
E.B. Eddy Forest Products Ltd.
1 Station Road
Espanola, Ontario POP ICO Canada
TEL: 705-869-2020
FAX: 705-869-1802
Stacey A. Cook
Assistant Conference Coordinator
JT&A, inc.
1000 Connecticut Avenue, NW, Suite 802
Washington, DC 20036 USA
TEL: 202-833-3380
FAX: 202-466-8554
Jo Cooper
vice President, Environment and
Health Program
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2420
FAX: 202-463-2423
Simon J. Cordery
Senior Environmental Analyst
Advanced Aquatic Technology
Associates, Inc.
1155 Connecticut Avenue, NW, Suite 300
Washington, DC 20036 USA
TEL: 202-467-8525
FAX: 202-296-7533
• Michael J. Cousin
Director, Quality Processes
Georgia-Pacific Corporation, representing
Mail Well fnve/ope
55 Park Place
Atlanta, GA 30303 USA
TEL: 404-521-5174
FAX: 404-230-1659
Carolyn Cox
Economist
Federal Trade Commission
6th and Pennsylvania Avenue, N.W.
Washington, DC 20580 USA
TEL: 202-326-3434
FAX: 202-326-2050
Gayle Coyer
Manager, Lake Superior Project
National Wildlife Federation
802 Monroe
Ann Arbor, Ml 48104 USA
TEL: 313-769-3351
FAX: 313-769-1449
• Erin Craig
Corporate Environmental Programs Manager
Apple Computer Inc.
10260 Bubb Road
Mailstop 56A
Cupertino, CA 95014 USA
TEL: 408-974-7392
FAX: 408-974-1950
-------
Randi Currier
Policy Analyst
Abt Associates
55 Wheeler Street
Cambridge, MA 02138-1168 USA
TEL: 617-349-2767
FAX: 617-349-2660
Richard Damberg
Environmental Protection Specialist
Office of Air Quality Planning and Standards
U.S. Environmental Protection Agency
(MD-13)
Research Triangle Park, NC 27711 USA
TEL: 919-541-5376
FAX: 909-541-0072
Vivian Daub
Pollution Prevention Coordinator
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-556)
Washington, DC 20460 USA
TEL: 202-260-6790
FAX: 202-260-5711
Brian A. Day
Director
National Office Paper Recycling Project
The U.S. Conference of Mayors
1620 Eye Street, NW
Washington, DC 20006 USA
TEL: 202-293-7330
FAX: 202-293-2352
Jonathan D. De'Ath
Chemist
Radian Corporation
2455 Horsepen Road
Suite 250
Herndon, VA 22071 USA
TEL: 703-713-1500
FAX: 703-713-1512
• Dean DeCrease
Technical Service MaHager
WeyerhaeuseY Company
33663 Weyethdeuser Way South, CH3E24
Federal Way, WA 98003 USA
TEL: 206-924-2590
FAX: 206-9Z4-2550
Patrick Demers
Industry Relations Coordinator
University of Massachusetts - Lowell
One University Avenue
Lowell, MA 01821 USA
TEL: 508-934-3294
FAX: 508-453-2332
• Jeffery D. Denit
Deputy Director, Office of Solid Waste
U.S. Environmental Protection Agency
401 M Street, SW (OS-300)
Washington, DC 20460 USA
TEL: 202-260-4627
FAX: 202-260-9355
• SPEAKER
Lois Dicker
Supervisory Biologist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-778)
Washington, DC 20460 USA
TEL: 202-260-3387
FAX: 202-260-8168
• Richard J. Diforio, Jr.
Vice President, Environment, Health
and Safety
Champion International Corporation
One Champion Plaza
Stamford, CT 06291 USA
TEL: 203-358-7900
FAX: 203-358-7407
Bjorn Dillner
Manager, Process Development Department
Kamyr AB
Box 1033
Karlstad, Sweden 65115
TEL: 46-54-194600
FAX: 46-54-194641
• Patricia J. Dollar
Consultant
Slave Lake Pulp Corporation
7950 Old Falls Road
McLean, VA 22102 USA
TEL: 703-506-1822
FAX: 703-506-1826
Anita Doepke
Environmental Affairs Director
Menominee Paper Company, Inc.
P.O. Box 300
Menominee, Ml 49858 USA
TEL: 906-863-5595
Mary Lou Dopart
Program Manager
Digital Equipment Corporation
10 Tara Boulevard
TTB1-3/D5
Nashua, NH 03062 USA
TEL: 603-884-3731
FAX: 603-884-2253
Robert Dunkel
Legal Assistant
Times Mirror
1875 Eye Street, NW
Suite 1110
Washington, DC 20006 USA
TEL: 202-293-3126
FAX: 202-659-1484
Joseph L. Ebersole
Attorney
2101 Connecticut Avenue
Suite 63
Washington, DC 20008 USA
TEL: 202-265-9447
FAX: 202-265-7126
Gert Ekdahl
Tetra Pak
Ruben Rausings Gata
Lund, Sweden 225186
TEL: 46-46-361541
FAX: 46-46-362477
314
Barbara Elkus
Deputy Director, Engineering and Analysis
Division
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-7120
FAX: 202-260-7185
Stanley W. Eller
Staff Attorney
Natural Resources Council of Maine
271 State Street
Augusta, ME 04330 USA
TEL: 207-622-3101
FAX: 207-622-4343
Kathie Emmett
Environmental Planner
State of Washington, Department of Ecology
P.O. Box 47600
Olympia, WA 98504-7600 USA
TEL: 206-438-7541
FAX: 706-438-7789
Mary Engle
Attorney
Federal Trade Commission
601 Pennsylvania Avenue, NW
Washington, DC 20580 USA
TEL: 202-326-3161
FAX: 202-326-2050
• Richard L. Erlckson
Vice President, Environment and Technology
Weyerhaeuser Company
(CH3EZ5)
Tacoma, WA 98477 USA
TEL: 206-924-2030
FAX: 206-924-2223
Steven L. Erickson
Director, Environmental Affairs
Boise Cascade Corporation
P.O. Box 50
One Jefferson Square
Boise, ID 83728 USA
TEL: 208-384-7693
FAX: 208-384-4841
Cindy Evans
Associate Environmental Counsel
National Forest Products
1250 Connecticut Avenue
Washington, DC 20036 USA
TEL: 202-463-2582
FAX: Not Available
Valerie Evans
Assistant Product Manager
Triangle Laboratories/RTP
801 Capitola Drive
Durham, NC 27713 USA
TEL: 919-554-5729
FAX: 919-544-5491
Kathy Fahnline
Economist
Federal Trade Commission
601 Pennsylvania Avenue, NW
Washington, DC 20580 USA
TEL: 202-326-3611
FAX: 202-326-2050
-------
Laura Felx-Baker
Technical Divisions Administrator
Technical Association for the Pulp and
Paper Industry
P.O. Box 105113
Atlanta, GA 30348 USA
TEL: 404-446-1400
FAX: 404-446-6947
Ruth Felland
Manager/Chemistry
Newspaper Association of America
11600 Sunrise Valley Drive
Reston, VA 22091 USA
TEL: 703-648-1279
FAX: 703-648-1333
Bruce Ferguson
Environmental Scientist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (6405J)
Washington, DC 20460 USA
TEL: 202-260-2726
FAX: 202-260-0575
Kelly H. Ferguson
Deputy Editor
Pulp and Paper Magazine
2000 Powers Ferry Center, Suite 450
Marietta, GA 30067 USA
TEL: 404-952-1303
FAX: 404-933-0666
John L. Festa
Director, Chemical and Health Programs
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2587
FAX: 202-463-2423
Margaret Fiester
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2598
FAX: 202-463-2423
• Linda Fisher
Assistant Administrator
Office of Prevention, Pesticides, and Toxic
Substances
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-2902
FAX: 202-260-1847
• Bruce I. Fleming
Senior Research Advisor
Boise Cascade Corporation
4435 North Channel Avenue
Portland, OR 97217 USA
TEL: 503-285-3811
FAX: 503-286-7467
Charles Fletcher
Environmental Engineer
OWEC
U.S. Environmental Protection Agency
401 M Street, SW (EN-336)
Washington, DC 20460 USA
TEL: 202-260-0108
FAX: 202-260-1460
• SPEAKER
Mark Floegel
Campaigner
Greenpeace
1436 U Street, NW
Washington, DC 20009
TEL: 202-319-2480
FAX: 202-462-4507
USA
PaulFlynn
Manager, Forest Products
Department of Industry, Technology, and
Commerce
51 Allara Street
Canberra, ACT 2600 Australia
TEL: 61-6-276-1918
FAX: 61-6-276-2291
Celso Foelkel
Director of Technology and Environment
Riocell S.A.
Caixa Postal 108
Guaiba, RS 92500-000 Brazil
TEL: 55-51^80-2301
FAX: 55-51-480-2878
• Jens Folke
Director
European Environmental Research Group
Pinievangen 14
Allerod, DK-3450 Denmark
TEL: 45-4814-1661
FAX: 45-4814-1660
Joseph R. Fordham
Director, Regulatory Affairs
Novo Nordisk Bioindustrials, Inc.
33 Turner Road
Danbury, CT 06813-1907 USA
TEL: 203-790-2768
FAX: 203-790-2748
James J. Foster
Senior Technical Engineer
Westvaco Corporation
104 East Riverside Avenue
Covington, VA 24426 USA
TEL: 703-969-5583
FAX: 703-969-5486
Tyler J. Fox
Economist
Research Triangle Institute
3040 Cornwallis Road
Hobbs Building
Research Triangle Park, NC 27709 USA
TEL: 919-541-6955
FAX: 919-541-5945
Gary Frank
Manager, Pulp and Utilities
Mead Corporation
P.O. Box 2500
Chillicothe, OH 45601 USA
TEL: 614-772-3837
FAX: 614-772-3278
Sara Freund
Manager
American Paper Institute
260 Madison Avenue
New York, NY 10016 USA
TEL: 212-340-0600
FAX: Not Available
Clark Gallagher
Commonwealth Environment Protection
Agency
P.O. Box E305
Queen Vil Tee
Canberra, ACT 2600 Australia
TEL: 06-274-1450
FAX: 06-274-1666
James Gallup
Environmental Engineer
U.S. Agency International Development
SA-18, Room 503
Washington, DC 20523-1811 USA
TEL: 703-875^518
FAX: 703-875-4639
Steven P. Geil
Chemical Engineer
Office of Wastewater Enforcement and
Compliance
U.S. Environmental Protection Agency
401 M Street, SW (EN-336)
Washington, DC 20460 USA
TEL: 202-260-9545
FAX: 202-260-1460
Sherri GUI
Environmental Protection Specialist
OPPE/OPA
U.S. Environmental Protection Agency
401 M Street, SW (PM-220)
Washington, DC 20460 USA
TEL: 202-260-8669
FAX: 202-260-7883
David Graves
Director, Environmental Management
Weyerhaeuser Company (CHIL28)
Tacoma, WA 98477 USA
TEL: 206-924-2812
FAX: 206-924-3866
Hillel Gray
Policy Analyst
National Environmental Law Center
29 Temple Place
Boston, MA 02111 USA
TEL: 617-422-0880
FAX: 617-422-0881
• Brian Greenwood
Manager of Research and Development
Kamyr, Inc.
Ridge Center
Glens Falls, NY 12801-3686 USA
TEL: 518-745-2759
FAX: 518-745-2971
• Mark A. Greenwood
Director, Office of Pollution Prevention and
Toxics
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-3810
FAX: 202-260-0575
Guy R. Griffin
Manager, Corporate Environmental Services
Potlatch Corporation
244 California Street, Suite 610
San Francisco, CA 94111 USA
TEL: 415-956-2472
FAX: 415-956-2971
315
-------
Thomas G. Groxne
Program Manager
Radian Corporation
2455 Horsepen Road
Suite 250
Herndon, VA 22071 USA
TEL: 703-713-1500
FAX: 703-713-1512
Douglas Hall
Supervisor, Industrial Permit Program
Minnesota Pollution Control Agency
520 Lafayette Road
St. Paul, MN 55155 USA
TEL: 612-297-1832
FAX: 612-297-8683
David Halliburton
Chief, Renewable Resources
Pulp and Paper Division
Environment Canada
351 St. Joseph, 13th floor
Hull, Quebec K1AOH3 Canada
TEL: 819-953-1128
FAX: 819-994-7762
Deborah Hanlon
Environmental Scientist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (MC-7409)
Washington, DC 20460 USA
TEL: 202-260-2726
FAX: 202-260-0575
Lisa M. Harris
Regulatory Impact Analyst
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street (TS-779)
Washington, DC 20460 USA
TEL: 202-260-168,7
FAX: 202-260-0981
Valerie Harris
Senior Environmental Engineer
Midwest Research Institute
401 Harrison Oaks Boulevard
Suite 350
Gary, NC 27513 USA
TEL: 919-677-0249
FAX: 919-677-0065
Betsy Haskin
Advisory Board Member
South Carolina Environmental Law Project
218 Cannon Street
Georgetown, SC 29442 USA
TEL: 803-546-3623
FAX: 803-546-1632
Paul Hassett
Product Manager
Miles Inc.
Mobay Road
Pittsburgh, PA 15205 USA
TEL: 412-777-4787
FAX: 412-777-4109
SPEAKER
Richard Healy
Chief, Environmental Assessment Section
Standards and Applied Science Division
U.S. Environmental Protection Agency
401 M Street, SW (WH-585)
Washington, DC 20460 USA
TEL: 202-260-7812
FAX: 202-260-9830
George A. Heath
Chemical Engineer
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-7165
FAX: 202-260-7185
Clifford Henry
Environmental Control Manager
Procter and Gamble
Route 3, Box 260
Perry, FL 32347 USA
TEL: 904-584-0347
FAX: 904-584-9517
Kimberly A. Hibbard
Licensing Engineer, Air Bureau
Maine Department of Environmental
Protection
State House Station #17
Augusta, ME 04333 USA
TEL: 207-289-2437
FAX: 207-289-7641
Marquita Hill
Director, Chemical Information Center
University of Maine
jenness Hall
Orono, ME 04469 USA
TEL: 207-581-2301
FAX: 207-581-2323
Pat Hill
Director, Water Quality Programs
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2420
FAX: 202-463-2423
Tanya Hillier
Conference Coordinator
JT&A, inc.
1000 Connecticut Avenue, NW, Suite 802
Washington, DC 20036 USA
TEL: 202-833-3380
FAX: 202-466-8554
• Ann Hillyer
Barrister and Solicitor
West Coast Environmental Law Association
1001 -207 West Hastings Street
Vancouver, BC V6B 1H7 Canada
TEL: 604-684-7378
FAX: 604-684-1312
• Harold L. Hintz
Technical Assistant to Vice President and
Corporate Research Director
Westvaco Corporation
299 Park Avenue
New York, NY 10171-0102 USA
TEL: 212-318-5412
FAX: 212-318-5090
William Hodgins
Environmental Specialist
Union Camp Corporation
P.O. Box 1391
Savannah, GA 31402 USA
TEL: 912-238-7470
FAX: 912-238-7631
Kenneth J. Hood
Ecologist
Office of Processes and Effects Research
U.S. Environmental Protection Agency
401 M Street SW (RD-682)
Washington, DC 20460 USA
TEL: 202-260-5976
FAX: 202-260-6370
• Donald W. Hopkins
Vice President and General Manager
Hearst Enterprises Division
The Hearst Corporation
224 West 57th Street
New York, NY 10019 USA
TEL: 212-649-3610
FAX: 212-649-3655
• Virgil K. Horton, Jr.
Vice President of the Paper Group
American Paper Institute
260 Madison Avenue
New York, NY 10016-2483 USA
TEL: 212-340-0600
FAX: 212-689-2628
Joy A. (Jamie) Horwitz
Program Associate
The Pew Charitable Trusts
2005 Market Street, Suite 1700
Philadelphia, PA 19103-7017 USA
TEL: 215-575-4748
FAX: 215-575-4924
• Clifford T. Howlett Jr.
Vice President, Government Affairs
Georgia-Pacific Corporation
133 Peachtree Street, NE
9th Floor
Atlanta, GA 30303 USA
TEL: 404-521-4000
FAX: 404-230-5642
Steven A. Hudson
Region Manager, Environmental Affairs
Boise Cascade Corporation
1615 M Street, NW, Suite 570
Washington, DC 20036 USA
TEL: 202-293-9066
FAX: 202-293-9070
Ron Hutchinson
Vice President, Marketing
Ciba-Geigy
P.O. Box 18300
Greensboro, NC 27419 USA
TEL: 919-632-2994
FAX: 919-632-7008
Lennart Igerud
Technical Marketing Manager
Eka Nobel AB
Bohus, Sweden 44580
TEL: 46-315-87000
FAX: 46-315-87732
316
-------
Arlen R. Isham
Vice President
Trenton Sales, Inc.
2646 South Loop West
Suite 445
Houston, TX 77054 USA
TEL: 713-666-1130
FAX: 713-668-4289
Allan Jamieson
Process Manager
North Broken Hill Ltd.
Box 201
Burnie, Tasmania 7320 Australia
TEL: 61-04-237115
FAX: 61-04-237274
Douglas Jamieson
Chemical Engineer
U.S. Environmental Protection Agency
401 M Street, SW (EN-341-W)
Washington, DC 20460 USA
TEL: 703-308-8731
FAX: 703-308-8739
Richard J. Jendrucko
Professor
University of Tennessee
310 Perkins Hall
Knoxville, TN 37996-2030 USA
TEL: 615-974-2171
FAX: 615-974-2669
• Lubomir Jurasek
Head, Biological Chemistry Section
PAPRICAN
570 St. Johns Boulevard
Point Claire, Quebec H9R 3J9 Canada
TEL: 514-630-4100
FAX: 514-630-4134
Henry D. Kahn
Supervisory Statistician
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-5406
FAX: 202-260-5394
Maureen F. Kaplan
Project Manager
Eastern Research Group, Inc.
110 Hartwell Avenue
Lexington, MA 02173 USA
TEL: 617-674-7337
FAX: 617-674-2851
DanKapral
Manager, Advanced Technologies and
Manufacturing
Harris Group Inc.
P.O. Box 5819
Portland, OR 97228 USA
TEL: 503-228-7200
FAX: 503-228-0422
Gerald Katz
Technical Manager, Paper Chemicals
Westvaco
Box 70848
Charleston, SC 29415 USA
TEL: 803-740-2272
fAX: 803-747-2272
^ SPEAKER
Kenneth R. Keegan
Technology Manager
Henkel Corporation
P.O. Box 410206
Charlotte, NC 28241-0206 USA
TEL: 704-587-3340
FAX: 704-587-3311
Thomas E. Kemeny
Environmental Program Manager
Georgia-Pacific Corporation
133 Peachtree Street
Atlanta, GA 30303 USA
TEL; 404-527-8937
FAX: 404-230-5678
Laxmi Kesari
Special Assistant to B.C.
SSCD
U.S. Environmental Protection Agency
2800 Crystal Drive
Arlington, VA 22207 USA
TEL: 703-308-8718
FAX: 703-308-8578
Eric J. Kilberg
Pollution Prevention Program Coordinator
Minnesota Pollution Control Agency
520 Lafayette Road
St. Paul, MN 55155 USA
TEL: 612-296-8643
FAX: Not Available
Tom Kllleen
Environmental Engineer
New York Department of Environmental
Conservation
50 Wolf Road
Albany, NY 12233-3505 USA
TEL: 518-457-6716
FAX: 518-457-1088
Michael A. King
Toxics Reduction Coordinator
Maine Department of Environmental
Protection
State House Station #17
Augusta, ME 04333 USA
TEL: 207-287-7859
FAX: 207-289-7826
Mark Kirby
Marketing Manager
Praxair, Inc. — Linde
39 Old Ridgebury Road
Danbury, CT 06817 USA
TEL: 203-794-2997
FAX: 203-794-6056
Gudolf Kjaerheim
Research Manager
Ostfold Foundation for Applied Research
Freorikstad, Norway N-1601
TEL: 47-9-341900
FAX: 47-9-342494
Anna Klein
Chemical Engineer
Engineering and Analysis Division, OST
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-7127
FAX: 202-260-7185
Michael R. KUpper
Vice President, Legal and Governmental
Affairs
Association of American Publishers
1718 Connecticut Avenue, NW
Suite 700
Washington, DC 20009 USA
TEL: 202-232-3335
FAX: 202-745-0694
Stephen H. Korzeniowski
Development and Technical Service
Manager
Du Pont Company - Du Pont Chemicals
CRP-709
Wilmington, DE 19880-0708 USA
TEL: 302-999-2408
FAX: 302-999-4396
Gopal A. Krishnagopalan
Associate Professor
Auburn University
236 Ross Hall
Auburn, AL 36849 USA
TEL: 205-844-2011
FAX: 205-844-2063
• Russell E. Kross
Vice President, Human and Environmental
Protection
The Mead Corporation
Courthouse Plaza Northeast
Dayton, OH 45463 USA
TEL: 513-495-9221
FAX: 513-495-9228
Susan Krueger
Chemical Engineer
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street (TS-779)
Washington, DC 20460 USA
TEL: 202-260-1713
FAX: 202-260-0981
Ilkka Kruus
Director, Large Scale Process
Genencor International
1700 Lexington Avenue
Rochester, NY 14606-3140 USA
TEL: 716-277-4337
FAX: 716-277-4331
James Kwait
Biologist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-778)
Washington, DC 20460 USA
TEL: 202-260-3479
FAX: 202-260-8168
Snehal Lakhani
Project Engineer
Environment Canada
25 St. Clair Avenue East
7th Floor
Toronto, Ontario M4T 1M2 Canada
TEL: 416-973-5842
FAX: 416-973-7509
317
-------
Jessica C. Landman
Senior Attorney
Natural Resources Defense Council
1350 New York Avenue, NW
Suite 300
Washington, DC 20005 USA
TEL: 202-783-7800
FAX: 202-783-5917
Nick Lardieri
Staff Vice President, Environmental and
Human Protection
Scott Paper Company
Scott Plaza
Philadelphia, PA 19113 USA
TEL: 215-522-5373
FAX: 215-522-5515
Penny E. Lassiter
Environmental Engineer
Air Quality Planning and Standards
U.S. Environmental Protection Agency
(MD-13)
Research Triangle Park, NC 27711 USA
TEL: 919-541-5396
FAX: 919-541-3470
Don J. Lee
Certified Environmental Inspector
6 Mad River C4
Sacramento, CA 98831 USA
TEL: 916-428-5756
FAX: Not Available
Steven Levitas
Senior Attorney
Environmental Defense Fund
128 East Hargett Street
Raleigh, NC 27601 USA
TEL: 919-821-7793
FAX: 919-821-5093
• Norman Liebergott
Special Consultant
DuPont Canada Inc.
4298 9th Street
Laval, Quebec H7W1Y7 Canada
TEL: 514-681-1481
FAX: 514-681-1481
• Lars-Ake Lindstrom
Vice President, Research and Development
Sunds Defibrator Industries AB
Sundsval I, Sweden S-85194
TEL: 46-6016-5095
FAX: 46-6056-8324
George Lombardo
Project Manager
World Environment Center
419 Park Avenue South
New York, NY 10016 USA
TEL: 101-683-4700
FAX: 101-683-5053
Jack Luskin
Associate Director
Toxics Use Reduction Institute
University of Massachusetts
Lowell, MA 01854 USA
TEL: 508-934-3275
FAX: 508-453-2332
• SPEAKER
Mark Luttner
Special Assistant to the Assistant
Administrator
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-556)
Washington, DC 20460 USA
TEL: 202-260-9454
FAX: 202-260-5711
Julie W. Lynch
Senior Staff, Pollution Prevention Division
U.S. Environmental Protection Agency
401 M Street, SW (MC-7409)
Washington, DC 20460 USA
TEL: 202-260-4000
James J.L. Ma
Senior Consultant
SRI International
333 Ravenswood Avenue
Menlo Park, CA 94025 USA
TEL: 415-859-3584
FAX: 915-859-5134
• David Mager
Director of Environmental Standards
Green Seal
1250 23d Street, NW
Washington, DC 20037 USA
TEL: 202-331-7337
FAX: 202-331-7533
Vince Magnotta
Research Associate, Pulp and Paper
Air Products and Chemicals, Inc.
7201 Hamilton Boulevard
Allentown, PA 18195 USA
TEL: 215-481-5633
FAX: 215-481-5136
N. Lynn Martenstein
Vice President, Communications
American Paper Institute, Inc.
1250 Connecticut Avenue, NW
Suite 360
Washington, DC 20036 USA
TEL: 202-463-5161
FAX: 202-463-5180
Tim Martin
International Pulp and Paper Campaign
Greenpeace
1017 West Jackson
Chicago, IL 60607 USA
TEL: 312-666-3305
FAX: 312-226-2714
Eliberto Martinez
Environmental Engineer
U.S. Environmental Protection Agency
77 West Jackson Street (HRM-75)
Chicago, IL 60604 USA
TEL: 312-886-4023
FAX: 312-353-6775
Burkhard Mausberg
Researcher
Pollution Probe Foundation
12 Madison Avenue
Toronto, Ontario M5R 2S1 Canada
TEL 416-926-1907
FAX: 416-926-1601
Alec McBride
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-4761
FAX: 202-260-0225
• Neil McCubbin
President
N. McCubbin Consultants Inc.
140 Fisher's Point
Foster, Quebec JOE 1RO Canada
TEL: 514-242-3333
FAX: 514-242-3294
• Thomas J. McDonough
Professor of Engineering and Group Leader
for Pulping and Bleaching
Institute of Paper Science and Technology
5 75 14th Street, NW
P.O. Box 93366
Atlanta, GA 30318-3366 USA
TEL: 404-853-9707
FAX: 404-853-9510
• John McGlennon
President
E R M Group of New England, Inc.
205 Portland Street
Boston, MA 02114 USA
TEL: 617-742-8228
FAX: 617-720-5742
Mary C. McKiel
Special Assistant
U.S. Environmental Protection Agency
401 M Street, SW (MC-7904)
Washington, DC 20460 USA
TEL: 202-260-4418
FAX: 202-260-0178
Sudhir K. Mendiratta
Senior Associate Development Engineer
Olin Corporation
P.O. Box 248
Charleston, TN 37310 USA
TEL: 615-336-4000
FAX: 615-336-4554
Ossi Meyn
Environmental Scientist
HERD/OPPTS
U.S. Environmental Protection Agency
401 M Street, SW (TS-796)
Washington, DC 20460 USA
TEL: 202-260-1264
FAX: 202-260-8168
Marcia Mia
Chemical Engineer
Air and Radiation Standards
U.S. Environmental Protection Agency
401 M Street, SW (EN-341 W)
Washington, DC 20460 USA
TEL: 703-308-8714
FAX: 703-308-8739
Roger Miller
Contributing Editor
Pesticides and Toxic Chemical News
1101 Pennsylvania Avenue, SE
Washington, DC 20003 USA
TEL: 202-544-1980
FAX: 202-546-3890
318
-------
William G. Miller
Attorney
Multinational Legal Services, P.C.
11 Dupont Circle
Washington, DC 20036 USA
TEL: 202-797-7124
FAX: 202-939-6969
Susan A. Mills
Marketing Analyst
Champion International Corporation
One Champion Plaza
Stamford, CT 06921 USA
TEL: 203-358-7631
FAX: 203-358-2730
Kim Mitchell
Research Assistant
Abt Associates
55 Wheeler Street
Cambridge, MA 02138-1168 USA
TEL: 617-349-2785
FAX: 617-349-2660
Cletis Mixon
EPS, Stationary Source Compliance Division
U.S. Environmental Protection Agency
2040 South 4th Street, Apt. 2
Arlington, VA 22204 USA
TEL: 703-308-8693
FAX: 703-308-8739
• Steve Moldenius
Technical Director
Sodra Cell AB
Technical Department
Morrum, Sweden S-375 22
TEL: 46-4545-5000
FAX: 46-4545-1651
• Donald G. Monefeldt
Manager, Supply Products Marketing
Xerox
800PhillipsRoad(218-08S)
Webster, NY 14580 USA
TEL: 716-422-2205
FAX: 716-422-9358
Karen Morehouse
Director, Centers and Special Programs Staff
Office of Exploratory Research
U.S. Environmental Protection Agency
401 M Street, SW (RD-675)
Washington, DC 20460 USA
TEL: 202-260-5750
FAX: 202-260-0450
C. Philip Morse
Staff Engineer
Waste Reduction Resource Center
3825 Barrett Drive
Raleigh, NC 22609 USA
TEL: 800-476-8686
FAX: 919-571-4135
Charles Moses
U.S. Technical Sales Service Manager
Albright & Wilson Americas
41 lOWoodway Drive
Monroe, LA 71201 USA
TEL: 318-387-4491
FAX: 318-387-8255
SPEAKER
Mark Murguia
Research Chemist
ITT Rayonier Inc.
409 East Harvard Avenue
Shelton, WA 98584 USA
TEL: 206-426-4461
FAX: 206^26-7537
John P. Murphy
Branch Manager, Washington, DC
Environmental Quality Management, Inc.
1950 Old Callows Road, Suite 430
Vienna, VA 22182 USA
TEL: 703-749-9060
FAX: 703-506-0596
W. Donald Murray
District Manager
Ontario Ministry of the Environment
435 James Street "S"/P.O. Box 5000
Thunder Bay, Ontario PTC 566 Canada
TEL: 807-475-1690
FAX: 807-475-1754
Scott D. Nelson
Environmental Protection Specialist
Stationary Source Compliance Division
U.S. Environmental Protection Agency
401 M Street, SW (EN-341 W)
Washington, DC 20460 USA
TEL: 703-308-8707
FAX: 703-308-8739
Harold L. Newman
Region Manager, Environmental Affairs
Boise Cascade Corporation
2237 South Acadian Thruway
Baton Rouge, LA 70808 USA
TEL: 504-927-5001
FAX: 504-926-0739
Joseph C. Nicolello
Manager, Pulp
American Paper Institute
260 Madison Avenue
New York, NY 10016 USA
TEL: 212-340-0672
FAX: 212-689-2628
Debra Nicoll
Economist
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-5386
FAX: 202-260-5394
Richard B. Norment
President
Norment & Associates, Inc.
7297 Lee Highway
Suite N
Falls Church, VA 22042 USA
TEL: 703-532-2151
FAX: 703-241-5603
Terry R. O'Bryan
Environmental Scientist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-778)
Washington, DC 20460 USA
TEL: 202-260-5408
FAX: 202-260-5711
Margaret O'Dell
Program Officer
The Joyce Foundation
135 South LaSalle
Chicago, IL 60603 USA
TEL: 312-782-2464
FAX: 312-782-4160
John O'Keefe
Tech Sales Representative
Miles Inc.
Mobay Road
Pittsburgh, PA 15205 USA
TEL: 412-777-2858
FAX: 412-777-4109
John O'Neal
Director, Technical Services
YWC Technologies, Inc.
210GaloLane
Kennetts, PA 19348 USA
TEL: 215-444-5288
FAX: 215^44-5238
Maureen O'Neill
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-556)
Washington, DC 20460 USA
TEL: 202-260-7818
FAX: 202-260-5711
Dara O'Rourke
Research Director
Pacific Northwest Pollution Prevention
Research Center
1218 3rd Avenue
Suite 1205
Seattle, WA 98101 USA
TEL: 206-223-1151
FAX: 206-223-1165
• Michael J. O'Rourke
Catalog Manager, IKEA North America
IKEA US, Inc.
Plymouth Commons
Plymouth Meeting, PA 19462 USA
TEL: 215-834-1520
FAX: 215-834-0439
Jim O'Shaughnessy
Professor
Department of Civil Engineering
Worcester Polytechnic Institute
Worcester, MA 01609 USA
TEL: 508-831-5309
FAX: 508-831-5808
Christopher S. Oh
Environmental Engineer
Air and Radiation Standards
U.S. Environmental Protection Agency
401 M Street, SW (EN-341 W)
Washington, DC 20460 USA
TEL: 703-308-8732
FAX: 703-308-8739
Andrew Otis
Regulatory Impact Analyst
OPPE/OPA
U.S. Environmental Protection Agency
401 M Street, SW(PM-221)
Washington, DC 20460 USA
319
-------
Bob Packwood
Manager, Pulping Research and
Development
Potlatch Corporation
P.O. Box 503
Cloquet, MN 55720-0503 USA
TEL: 218-879-2385
FAX: 218-879-2375
Louis R. Paley
Air and Radiation Standards
U.S. Environmental Protection Agency
401 M Street, SW (EN-341W)
Washington, DC 20460 USA
TEL: 703-308-8723
FAX: 703-308-8739
David Park
Industry Manager, Pulp and Paper
Air Products and Chemicals, Inc.
7201 Hamilton Boulevard
Allentown, PA 18195 USA
TEL: 215-481-5633
FAX: 215-481-5136
Jean (Libby) E. Parker
Section Chief
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-779)
Washington, DC 20460 USA
TEL: 202-260-0686-
FAX: 202-260-0981
Perry Parthasarathy
Research Specialist
Mead Central Research
P.O. Box 1700
Chillicothe, OH 45001 USA
TEL: 614-772-3689
FAX: 614-772-3595
Barry A. Patrie
Environmental Manager
Stone and Webster
500 Southborough Drive
South Portland, ME 04106 USA
TEL: 207-879-7800
FAX: 207-879-7815
W. Harvey Persinger
Project Manager, EF
Weyerhaeuser Company
WTC IC39
Tacoma, WA 98477 USA
TEL: 206-924-6509
FAX: 206-924-6592
• Richard B. Phillips
Staff Vice President and Director of Process
Technology
International Paper
P.O. Box 16070
Mobile, AL 36616 USA
TEL: 205-470-4694
FAX: 205-470-4512
Jeff Pinson
Senior Engineer
Liquid Carbonic
3740 West 74th Street
Chicago, IL 60629 USA
TEL: 312-838-6892
FAX: 312-838-6308
• SPEAKER
Harold E. Podall
Chemist
DPPT - ETD - ICB
U.S. Environmental Protection Agency
401 M Street, SW (TS-779)
Washington, DC 20460 USA
TEL: 202-260-1682
FAX: 202-260-0981
Mahesh Podar
Supervisory Economist
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-5387
FAX: 202-260-5394
Susan Poniatowski
University of Massachusetts at Lowell
91 Depot Road
Westford, MA 01886-1314 USA
TEL: 508-692-3274
Janet H. Price
Manager, Water Quality Programs
Champion International Corporation -
Pensacola Mill
P.O. Box 87
Cantonment, FL 32533 USA
TEL: 904-968-2121
FAX: 904-968-3077
John Pritchard
Technical/Quality Assurance Manager
Weyerhaeuser Company
P.O. Box 787
Plymouth, NC 27962 USA
TEL: 919-793-8186
FAX: 919-793-8164
• Martha Prothro
Deputy Assistant Administrator
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-5700
FAX: 202-260-5711
Bob Prough
Vice President-Sales
Kamyr, Inc.
Ridge Center
Glens Falls, NY 12801 USA
TEL: 518-793-5111
FAX: 518-793-5267
Douglas C. Pryke
Private Consultant
Rural Route 1
Erin, Ontario NOB 1 TO Canada
TEL: 519-855-4978
FAX: 519-855-4313
Kendall E. Pye
President
Repap Technologies Inc.
2650 Eisenhower Avenue
Valley Forge, PA 19482 USA
TEL: 215-630-9630
FAX: 215-630-0966
Peter P. Radecki
Coordinator, Center for Clean Industrial and
Treatment Technology
Michigan Technological University
1400 Towsend
Houghton, Ml 49931 USA
TEL: 906-487-3143
FAX: 906-487-2943
• Margaret Rainey
Paper Campaign
Greenpeace Sweden
Box 8913
Goteborg, Sweden S-40273
TEL: 031-222255
FAX: 031-232429
Jacqueline M. Rams
Director, Business Development
AIG Consultants, Inc.
1200 19th Street, NW
Suite 605
Washington, DC 20036 USA
TEL: 202-861-8675
FAX: 202-775-0137
Michelle Ramsey
Assistant Environmental Engineer
Midwest Research Institute
401 Harrison Oaks Boulevard
Suite 350
Cary, NC 27513 USA
TEL: 919-677-0249
FAX: 919-677-0065
• Douglas Reeve
Director, Pulp and Paper Centre
University of Toronto
200 College Street
Toronto, Ontario M5S 1A4 Canada
TEL: 416-978-3062
FAX: 416-971-2106
• David J. Refkin
Director of Environmental Affairs and
Assistant Director of Paper Purchasers
The Time Inc. Magazine Company
1271 Avenue of the Americas
New York, NY 10020-1393 USA
TEL: 212-522-1212
FAX: 212-522-0619
Janet Remmers
Biologist
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-798)
Washington, DC 20460 USA
TEL: 202-260-1583
Otto Rentz
Professor
University of Karlsruhe/IIP
Hertz Street 16
Karlsruhe, FRG 7500
TEL: 49-721-608-4460
FAX: 49-721-758-909
Agnes Reverz
Environmental Protection Specialist
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
320
-------
Rip G. Rice
President
Ozone News
1331 Patuxent Drive
Suite B
Ashton, MD 20861 USA
TEL: 301-924-4224
FAX: 301-774-4493
Nancy A. Risser
President
Risser and Associates
40 River Road
New York, NY 10044 USA
TEL: 212-753-1202
FAX: 212-752-2803
Ray Rivers
Chief, Pollution Prevention Branch
Environment Canada
25 St. Clair Avenue East
6th Floor
Toronto, Ontario M4T1M2 Canada
TEL: 416-973-1098
FAX: 416-973-7438
Rosalina M. Rodriguez
Environmental Engineer
U.S. Environmental Protection Agency
(MD-12)
Research Triangle Park, NC 27711 USA
TEL: 919-541-5298
FAX: 919-541-0237
Keith Romig
Environmental Officer
United Paper Workers International Union
P.O. Box 1475
Nashville, TN 37202 USA
TEL: 615-834-8590
FAX: 615-333-6G67
Jacqueline Romney
Environmental Scientist
Office of Waste Water Enforcement and
Compliance
U.S. Environmental Protection Agency
401 M Street, SW (EN-336)
Washington, DC 20460 USA
TEL: 202-260-9528
FAX: 202-260-1460
Alexander Ross
Senior Scientist
Office of Research and Development
U.S. Environmental Protection Agency
401 M Street, SW(RD-681)
Washington, DC 20460 USA
TEL: 202-260-2617
FAX: 202-260-3861
Wendy Rovansek
Staff Chemical Engineer
Radian Corporation
2455 Horsepen Road, Suite 250
Herndon,VA 22071 USA
TEL: 703-713-1500
FAX: 703-713-1512
SPEAKER
Nikki Roy
Pollution Prevention Specialist
Environmental Defense Fund
1875 Connecticut Avenue, Suite 1016
Washington, DC 20009 USA
TEL: 202-387-3500
FAX: 202-234-6049
Peter H. Salmon-Cox
Director, Office of Industrial Processes
Department of Energy
1000 Independence Avenue (CE-23)
Washington, DC 20585 USA
TEL: 202-586-2380
FAX: 202-586-7114
David Sandalow
Attorney
Office of General Counsel, Water Division
U.S. Environmental Protection Agency
401 M Street, SW (LE132-W)
Washington, DC 20460 USA
TEL: 202-260-7700
FAX: 202-260-7702
Dennis R. Sasseville
Associate Vice President
Environmental Science and
Engineering, Inc.
5 Overlook Drive
Amherst, NH 03031 USA
TEL: 603-672-2511
FAX: 603-672-2014
Amy Schaffer
Director, Industrial Waste Programs
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2420
FAX: 202-463-2423
Tom H. Schmidt
President
Wisconsin Paper Council
P.O. Box 718
Neenah, Wl 54957-0718 USA
TEL: 414-722-1500
FAX: 414-722-7541
Tom Schruben
AVP Environmental Products
Reliance Reinsurance Corporation
One Penn Center, 12th Floor
Philadelphia, PA 19103 USA
TEL: 215-864-6435
FAX: 215-864-6499
Roy Seidenstein
Attorney-Advisor
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-794)
Washington, DC 20460 USA
TEL: 202-260-2252
FAX: 202-260-0118
• John S. Seitz
Director
Office of Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency (MD-10)
411 West Chapel Hill Street
Durham, NC 27711 USA
TEL: 919-541-5616
FAX: 919-541-2464
• Ladd T. Seton
Export Sales
Fraser Paper, Limited
9 West Broad Street
P.O. Box1055
Stanford, CT 06904 USA
TEL: 203-359-2544
FAX: 203-358-2235
Julie Shannon
Analyst
OPPT/PPD
U.S. Environmental Protection Agency
401 M Street SW (MC-7409)
Washington, DC 20460 USA
TEL: 202-260-2736
FAX: 202-260-0178
Paul Shapiro
Program Manager
Office of Research and Development
U.S. Environmental Protection Agency
401 M Street, SW(RD-681)
Washington, DC 20460 USA
TEL: 202-260-5747
FAX: 202-260-3861
Patricia A. Shatynski
Process Engineer
Du Pont Chemicals
Jackson Lab, Chambers Works
Deepwater, NJ 08023 USA
TEL: 609-540-3705
FAX: 609-540-2344
Stephen A. Shedd
Office of Air Quality Planning and Standard
U.S. Environmental Protection Agency
(MD-13)
Research Triangle Park, NC 27711 USA
TEL: 919-541-5397
FAX: 919-541-3470
Jonathan W. Shelfer
Scientist
Kimberly-Clark Corporation
P.O. Box 0559
Coosa Pines, AL 35044-0559 USA
TEL: 205-378-2402
FAX: 205-378-2164
Paul W. Shepperd m
Group Leader
Hoechst Celanese Corporation
4331 Chesapeake Drive
Charlotte, NC 28216 USA
TEL: 704-559-6706
FAX: 704-559-6701
Robert Smerko
President
Chlorine Institute, Inc.
2001 L Street, NW, Suite 506
Washington, DC 20036 USA
TEL: 202-775-2790
FAX: 202-223-7225
Kathryn Smith
Environmental Protection Specialist
OW/OWEC/Enforcement Division
U.S. Environmental Protection Agency
401 M Street, SW (EN-338)
Washington, DC 20460 USA
TEL: 202-260-0252
FAX: 202-260-5282
321
-------
Maria D. Smith
Statistician
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-8639
FAX: 202-260-5394
Linda Smith-Vargo
Editor
Environmental Projects
P.O. Box 1117
Evanston, IL 60204-1117 USA
TEL: 708-635-7250
FAX: 708-299-1879
Susan Snider
Environmental Specialist
American Paper Institute
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2589
FAX: 202-463-2423
Stan Sobczynski
Program Manager
U.S. DOE Office of Industrial Processes
1000 Independence Avenue, SW
Washington, DC 20585 USA
TEL: 202-586-1878
FAX: 202-586-8134 or 2235
Lucy Sonnenberg
Assistant Professor
Institute of Paper Science and Technology
575 14th Street, NW
Atlanta, GA 30318 USA
TEL: 404-853-9712
FAX: 404-853-9510
Doug Spengel
Chemical Engineer
Radian Corporation
2455 Horsepen Road, Suite 250
Herndon, VA 22071 USA
TEL: 703-713-1500
FAX: 703-713-1512
• Howard E. Sproull, HI
President
Eco Paper Source
2402 West Lunt Avenue
Chicago, IL 60645 USA
TEL: 312-720-1943
FAX: 312-465-1885
Naki Stevens
Policy Director
People for Puget Sound
1326 Fifth Avenue, Suite 450
Seattle, WA 98101 USA
TEL: 206-382-7007
FAX: 206-382-7006
Alistair Stewart
Misa Pulp and Paper Sector
Ontario Ministry of Environment
135 St. Clair Avenue West
Toronto, Ontario M4V1P5 Canada
TEL: 416-323-4832
FAX: 416-323-2785
SPEAKER
Jim Stimson
Editor
Bureau of National Affairs, Inc.
1231 25th Street, NW
Washington, DC 20037 USA
TEL: 202-452-6366
FAX: 202-452-4150
Alan F. Stinchfield
Director, Pulping and Bleaching
Environmental Programs
James River Corporation
P.O. Box 2218
Richmond, VA 23217 USA
TEL: 804-649-4480
FAX: 804-649-4369
• Richard E. Storat
Vice President, Economic and Financial
Services
American Paper Institute
260 Madison Avenue
New York, NY 10016 USA
TEL: 212-340-0600
FAX: 212-689-2628
Eric Strassler
Senior Policy Analyst
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-552)
Washington, DC 20460 USA
TEL: 202-260-7150
FAX: 202-260-7185
Paul R. Stuart
Process Engineer (Manager)
Beak Consultants Ltd.
3285 Caverdish
Suite 610
Montreal, Quebec H4B 2L9 Canada
TEL: 514-487-9922
FAX: 514-487-5519
Paul Sullivan
Program Assistant
World Environment Center
419 Park Avenue South
New York, NY 10016 USA
TEL: 101-683-4700
FAX: 101-683-5053
Brita Swan
Stora Teknik AB
Box 601
Saffle, Sweden S-661 00
TEL: 46-533-821-00
FAX: 46-533-821-99
Christopher Swan
Environmental Engineer
Virginia Water Control Board
P.O. Box 7017
Peters Creek Road
Roanoke,VA 24019 USA
TEL: 703-857-7432
FAX: 703-857-7338
Patricia M. Szarek
Senior Associate
DRI/McGraw-Hill
1200 G Street, NW
Suite 1000
Washington, DC 20005 USA
TEL: 202-383-3656
FAX: 202-383-2005
Melissa A. Tancredi
Legislative Assistant
Association of American Publishers
1718 Connecticut Avenue, NW, Suite 700
Washington, DC 20009 USA
TEL: 202-232-3335
FAX: 202-745-0694
Alexandra Tarnay
Environmental Engineer
OW/OST/SASD
U.S. Environmental Protection Agency
401 M Street SW (WH-585)
Washington, DC 20460 USA
TEL: 202-260-7036
FAX: 202-260-9830
• Kit Taylor
Vice President, Manufacturing
Times Mirror Magazines
2 Park Avenue
New York, NY 10016 USA
TEL: 212-779-5000
FAX: 212-689-5408
• Roger Telschow
President
Ecoprint
9335 Fraser Avenue
Silver Spring, MD 20910 USA
TEL: 301-585-7077
FAX: 301-585-4899
• Luigi Terziotti
Vice President, Pulp and Paper Operations
Parsons & Whittemore
P.O. Box 100
Perdue Hill
Claiborne, AL 36470 USA
TEL: 205-743-8200
FAX: 205-743-8464
James R. Thompson
Managing Partner/CEO
Thompson Avant International
8521 Six Forks Road, Suite 140
Raleigh, NC 27615 USA
TEL: 919-848-2266
FAX: 919-846-1250
Rebecca Todd
Attorney
Sierra Club Legal Defense Fund
705 2nd Avenue, Suite 203
Seattle, WA 98103-1711 USA
TEL: 206-343-7340
FAX: 206-343-1526
Sheri J. Tonn
President
Citizens for a Healthy Bay
771 Broadway
Tacoma, WA 98402-3700 USA
TEL: 206-383-2429
FAX: 206-383-2446
Carlos Gustavo Tornquist
Consultant
AGAPAN
R. cel.camig90
Porto Alegre, RS 80540-050 Brazil
TEL: 0055-51-342-5714
FAX: 0055-51-342-5714
322
-------
Maria Luz L. Torre
Program Coordinator
Haribon Foundation
Room 901, Richbelt Towers
17 Annapolis Street
Creenhills, San Juan, Metro Manila
Phillippines
TEL: 62-722-7180
FAX: 62-722-6357
• William H. Trice
Executive Vice President
Union Camp Corporation
1600 Valley Road
Wayne, NJ 07470 USA
TEL: 201-628-2629
FAX: 201-628-2628
Maurice A. Tyler
Principal
Beak Consultants Ltd.
3285 Caverdish, Suite 610
Montreal, Quebec H4B2L9 Canada
TEL: 514-487-9922
FAX: 514-487-5519
Alan Ulbrecht
Environmental Research Scientist
New Jersey Technical Assistance Program
323 Martin Luther King, Jr. Boulevard
HSMRC Building
Newark, NJ 07102 USA
TEL: 201-596-5872
FAX: 201-804-1962
Judith A. Usherson
Associate Editor
Recycled Paper News
5528 Hempstead Way
Springfield, VA 22032 USA
TEL: 703-750-1158
FAX: 503-642-1258
Richard B. Valley
President
Michigan Pulp and Paper Corporation
5243 West Q Avenue
Kalamazoo, Ml 49009-9766 USA
TEL: 616-375-5112
FAX: 616-372-4690
Matthew B. Van Hook
Senior Environmental Counsel
American Paper Institute, Inc.
1250 Connecticut Avenue, NW, Suite 210
Washington, DC 20036 USA
TEL: 202-463-2420
FAX: 202-463-5180
Katherine Van Sickle
Professional Staff Member
House Science, Space, and Technology
Committee
Room 388, House Annex II
Washington, DC 20515 USA
TEL: 202-226-6980
FAX: 202-226-6983
Lynn Vendinello
Policy Analyst
U.S. Environmental Protection Agency
401 M Street, SW (1102)
Washington, DC 20460 USA
TEL: 202-260-8612
FAX: 202-260-8511
• SPEAKER
Pertti Visuri
Vice President, Technology
Ahlstrom USA Inc.
8925 Rehco Road
San Diego, CA 92104 USA
TEL: 619-458-3174
FAX: 619^58-0159
John Walkinshaw
Professor
University of Massachusetts at Lowell
91 Depot Road
Westford, MA 01886-1314 USA
TEL: 508-692-3274
Tom Wall
Special Assistant
Office of Water
U.S. Environmental Protection Agency
401 M Street, SW (WH-556)
Washington, DC 20460 USA
TEL: 202-260-5691
FAX: 202-260-5711
Peter C. Washburn
Staff Scientist
Natural Resources Council of Maine
271 State Street
Augusta, ME 04330 USA
TEL: 207-622-3101
FAX: 207-622-4343
• Mary Ellen Weber
Director, Economics, Exposure and
Technology Division
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW
Washington, DC 20460 USA
TEL: 202-260-0667
FAX: 202-260-0981
John R. Webster
Technical Service
Du Pont Company - Du Pont Chemicals
CRP-709
Wilmington, DE 19880-0709 USA
TEL: 302-999-4977
FAX: 302-999-4396
Eric Weltman
Staff Associate
Government Purchasing Project
P.O. Box 19367
Washington, DC 20036 USA
TEL: 202-387-8030
FAX: 202-234-5176
Grace Wever
President
Council of Great Lakes Industries
c/o Kodak Research Building 83
1669 Lake Avenue
Rochester, NY 14650-2215 USA
TEL: 716-722-3348
FAX: 716-722-6525
Paul Wiegand
Research Engineer
NCASI
Western Michigan University
Kalamazoo, Ml 49008-3844 USA
TEL: 616-387-5128
FAX: 616-387-5522
Ken Wiesner
Director, Office of Pollution Prevention
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, Wl 53707 USA
TEL: 608-267-9700
FAX: 608-267-2768
• Dee Williams
Toxics Reduction Specialist
Washington State Department of Ecology,
Waste Reduction Program
P.O. Box 47775
Olympia, WA 98504-4775 USA
TEL: 206-586-3518
FAX: 206-664-0478
• Michael D. Witt
Chief, Industrial Wastewater Section
Wisconsin Department of Natural Resources
101 South Webster Street, P.O. Box 7921
Madison, Wl 53707-7921 USA
TEL: 608-266-1494
FAX: 608-267-7664
Kenneth E. Woodard
Director, Charleston Technology Center
Olin Corporation
P.O. Box 248
Charleston, TN 37310 USA
TEL: 615-336-4000
FAX: 615-336-4554
Jocelyn Woodman
Environmental Engineer
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (MC-7409)
Washington, DC 20460 USA
TEL: 202-260-4418
FAX: 202-260-0178
• Peter E. Wrist
President and Chief Executive Officer
Pulp and Paper Research Institute of Canada
570 St. John's Boulevard
Pointe Claire, Quebec H9R 3J9 Canada
TEL: 514-630-4101
FAX: 514-630-9444
DanWrye
Water Quality Supervisor
Washington State Department of Ecology
P.O. Box 47600
Olympia, WA 98504 USA
TEL: 206-493-9132
FAX: 206-438-7490
Andrew J. Young
Market Development Manager
Nalco Chemical Company
One Nalco Center
Naperville, IL 60563 USA
TEL: 708-305-1444
FAX: 708-305-2931
Maurice Zeeman
Chief, Environmental Effects Branch
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
401 M Street, SW (TS-796)
Washington, DC 20460 USA
TEL: 202-260-1237
FAX: 202-260-1283
323
-------
Index of Presenters
Rune Anderson
Director
FrOvifors Bruk AB
FrOvi, Sweden
Mr. Anderson joined FrOvifors Bruk AB in 1979 as a Mill
Manager. He previously worked for Korsnas AB in re-
search and management positions. Mr. Anderson
received his M.S. from the Royal Institute of Technology
in Stockholm, Sweden.
David Assmann
Vice President and Director, Conservatree
Information Services
Conservatree Paper Company
San Francisco, California
As Director of Information Services for Conservatree
Paper Company, Mr. Assmann is responsible for public
education and legislative liaison for the nation's largest
exclusive wholesaler of recycled paper. He also oversees
the Greenline Membership Program and Conservatree
Consultants. Mr. Assmann was previously the publisher
of Mother Jones Magazine, San Francisco, California. He
is a member of numerous committees, boards, and
professional groups, including the Market Development
Committee; the National Recycling Coalition; the Legis-
lative Committee of the California Resource Recovery
Association; the Editorial Advisory Board of the Paper
Stock Report; and the Station Advisory Board of KPFA-
FM, Berkeley, California.
Peter Axegard
Research Director
Pulp Department
Swedish Pulp and Paper Research Institute (STFI)
Stockholm, Sweden
Dr. Axegard first joined STFI in Stockholm as a Research
Engineer in 1974 and remained as a Project and Group
Leader for eight years. Between 1982 and 1988 he held
administrative marketing positions at EKA Nobel, before
rejoining STFI in 1988 as Research Director of the Pulp
Department. In 1982 Dr. Axegard was Assistant Profes-
sor, Pulping Technology, at the Royal Institute. He
received an M.S. in Chemical Engineering from the
Royal Institute of Technology in Stockholm, Sweden,
and earned a doctorate in Pulping Technology from the
same institution in 1979.
Archie Beaton
Specialty Papers
Lyons Falls Pulp & Paper
Crystal Lake, Illinois
Archie Beaton, an experienced sales-graphic consultant,
is presently responsible for developing new markets and
applications for Lyons Falls specialty products, especial-
ly chlorine-free products. He is also the lead member of
the Lyons Falls Product Development Team. Mr. Beaton
has worked on environmental issues such as water-
based ink; solid bleached sulfate (SBS) cartons; the
elimination of metal pour spouts and overwraps; and
recycled materials. He has made presentations on his
approaches and technology to diverse groups, including
printers' sales meetings, the National Association of
Professional Environmental Communicators, and
manufacturers. Mr. Beaton received his B.S. in Print
Marketing from the University of Kalamazoo, Michigan.
Monica M. Becker
Research Associate
Tellus Institute
Boston, Massachusetts
Monica M. Becker joined the Tellus Institute in 1989 as a
Research Associate after several years of experience as
an industrial process and environmental engineer. Her
work includes chemical performance evaluations at
paper mills throughout the U.S., design of a recycling
program for spent chemicals, management of a
statewide PCB public facilities compliance program and
analysis of pollution prevention investments in the paper
and metal fabrications industries. Currently she is assess-
ing the financial incentives and barriers to adoption of
pollution prevention investments in industry for the New
Jersey Department of Environmental Protection and the
U.S. EPA Office of Pollution Prevention. Prior to joining
Tellus, Ms. Becker was a Project Engineer for the Com-
monwealth of Massachusetts, where she developed a
program to bring state-owned facilities into compliance
with Federal and state regulations governing the use of
PCP-filled electrical equipment and cleanup of PCP con-
tamination. She has also worked for Dynamics Research
Corporation, Wilmington, Massachusetts, and Procomp,
in Marietta, Georgia. Ms. Becker received her B.S. from
the College of Environmental Science and Forestry at the
State University of New York-Syracuse.
Barbara Belasco
Environmental/Recycling Spokesperson and
Specification Manager
General Services Administration, Region 2
New York, New York
Barbara Belasco is Environmental/Recycling Spokesper-
son for the General Services Administration, Region 2.
She is also a Specification Manager for paper and paper
products. Ms. Belasco recently came to the federal
government from the city of New York, where she was a
Recycled Products Specialist. Prior to that, Ms. Belasco
had worked for 18 years in the private sector as a
materials engineer for paper and pulp in the manufac-
ture of telephone cable; a manager for product planning
in the telecommunications industry; and an environ-
mental consultant to chemical companies. Ms. Belasco
325
-------
served as Trustee for the Bergen County Society of
Professional Engineers from 1984 to 1986, and has been
active in ASTM as Chair of the Electrical Pulp Commit-
tee. She holds an M.S. in chemistry and attended the
Pulp and Paper Course at the University of Maine.
Kathleen M. Bennett
Vice President of Corporate Environmental Affairs
James River Corporation
Richmond, Virginia
As Vice President of Corporate Environmental Affairs for
the James River Corporation, Kathleen M. Bennett over-
sees environmental, product, industrial hygiene, and
analytical services. Prior to joining James River, Ms. Ben-
nett was Director of Regulatory Affairs for Champion In-
ternational in Stamford, Connecticut. She has been
employed at the American Paper Institute and at other
paper companies for 20 years. In addition, Ms. Bennett
was appointed by President Reagan in 1980 to head the
Office of Air, Noise and Radiation at the U.S Environ-
mental Protection Agency (EPA), where she developed
an administration policy on such issues as the Clean Air
Act Amendments and acid rain. Upon leaving EPA in
1984, Ms. Bennett was appointed to the National Acid
Precipitation Task Force to help conduct a ten-year study
of acid rain. Ms. Bennett is a graduate of Manhattanville
College in Purchase, New York.
Lauren Blum
Consultant
Environmental Defense Fund
New York, New York
Lauren Blum is a consultant to the Environmental
Defense Fund's (EOF) Pulp and Paper Project, where she
specializes in mill technology. Before joining EOF, she
was an Associate in the Energy and Chemicals Croup at
Booz Allen & Hamilton, Inc., in New York. There, Dr.
Blum worked on a range of strategy projects for senior
management of chemical, pharmaceutical, and con-
sumer products companies. She also worked as a Project
Leader in the Microelectric Products Research and
Development Group at the Shipley Company in New-
ton, Massachusetts, where she developed advance
products for use by integrated circuit manufacturers and
successfully introduced a new product to the market. Dr.
Blum received a B.A. in Chemistry from Harvard Univer-
sity and a Ph.D. in Inorganic Chemistry from the Mas-
sachusetts Institute of Technology. She also holds an
M.A. in Public and Private Management from Yale
University.
John F. Church, Jr.
President
The Cincinnati Cordage and Paper Company
Cincinnati, Ohio
John F. Church, Jr., is currently President of The Cincin-
nati Cordage and Paper Company. He received an A.B.
degree from Colby College in 1959 and a B.S. from Car-
negie Institute of Technology in 1961. Employed by Cor-
dage Papers in 1964 as a salesperson, Mr. Church was
elected Executive Vice President of the corporation in
1974, and President in 1976, which post he holds today.
He is a member of the National Paper Trade Association,
Inc. (currently representing 675 to 700 companies with
annual sales of $425 billion), served as its Chairman/Past
Chairman from 1981 to 1983, and has been a member of
the Advisory Council since 1984. He served as Chair-
man of the PAPER Foundation from 1985 to 1990. Mr.
Church was elected Chairman of the prestigious Paper
Distribution Council (the largest in the industry, compris-
ing one-half mill and one-half merchant representation)
in 1990. Mr. Church is a member, PDC Executive Com-
mittee (1991 to present); elected to Board of Directors,
Distribution Research and Education Foundation (1990
to present); and is a Leadership Cincinnati Alumnus
(1979); Quality of Life Steering Committee Chairman
(1987). Mr. Church served as Chairman of Junior
Achievement of Greater Cincinnati (1983 to 1985); has
been on the Board of Trustees, Cincinnati Council on
World Affairs, since 1981; is a member of the National
Association of Wholesaler-Distributors (NAW); and was
elected Secretary of that association in 1987, 2nd Vice
Chairman in 1988, 1st Vice Chairman in 1989, Chair-
man Elect in 1990, and is currently serving as 1991
Chairman of NAW.
John L. Clement
Manager, Pulp and Paper Industry Marketing
Babcock & Wilcox Company
Barberton, Ohio
John C. Clement joined Babcock & Wilcox (B&W) in
1956; he is presently B&W's Marketing Manager for
original equipment and turnkey projects for the pulp and
paper industry, having previously held positions in
design engineering, sales, and marketing. His career
with B&W has largely been involved with the pulp and
paper industry. He is a member of the Technical Associa-
tion of the Pulp and Paper Industry (TAPPI) and serves on
its Steam and Power Committee. Mr. Clement graduated
from the University of Florida with a B.S. in Chemical
Engineering and subsequently received an M.S. in
Mechanical Engineering from the University of Akron.
Gerard P. Closset
Vice President-Corporate Technology
Champion International Corporation
West Nyack, New York
Gerard P. Closset joined St. Regis Corporation (later ac-
quired by Champion International) as a Senior Staff En-
gineer in 1977. He subsequently became Manager of
Coating and Printing, then Director of Materials and
Process Technology, and was named to his current posi-
tion in 1987. Dr. Closset is a member of the Board of
Directors of the Technical Association of the Pulp and
Paper Industry (TAPPI) and serves on the Board Re-
search, Research Management, Finance, and Executive
Committees. He has participated in national meetings,
and his articles have appeared in the TAPPI journal. He
is also a member of the American Institute of Chemical
Engineers, serves on the Research Advisory Committee
of the Institute of Paper Chemistry, and is a judge for
American Paper Institutes's George Olmsted Award. In
addition, Dr. Closset holds a patent on a method for ad-
ding moisture to a moving web. Dr. Closset previously
conducted research at the School of Public Health at the
University of Pittsburgh, Pennsylvania, and worked as a
326
-------
INDEX OF PRESENTERS
Research Engineer at Westvaco. He received his B.S.,
M.S., and Ph.D. in Chemical Engineering from the
University of Pittsburgh.
Richard N. Congreve
Croup Vice President
Potlatch Corporation
San Francisco, California
Richard N. Congreve has been employed in the paper
industry for 45 years. He joined Potlatch in 1962, serv-
ing in numerous management positions involving pulp,
paperboard, and packaging. From 1975 to 1980, he was
Vice President and General Manager of the company's
Minnesota operations and the Northwest Paper Division,
headquartered in Cloquet, Minnesota. Group Vice Presi-
dent since 1980, he is presently involved in areas of en-
gineering, energy, and environment. Before joining
Potlatch, Mr. Congreve spent 15 years with Container
Corporation in Chicago. He left that company as
General Manager of the Lake Shore recycled boxboard
plant. Mr. Congreve is a member of the Paper Industry
Management Association of the Pulp and Paper Industry,
and serves on the boards of the National Council of Air
and Stream Improvement and the Foodservice and Pack-
aging Institute. Mr. Congreve received a B.S. in Chemi-
cal Engineering from Northwestern University. He is a
registered engineer in Illinois, Idaho, Washington,
California, Minnesota, and Arkansas.
Frank j. Consoli
Manager of Packaging Technology
SCOTT Paper Company
Philadelphia, Pennsylvania
Frank J. Consoli is Manager of Packaging Technology for
SCOTT Paper Company. In this capacity, he is respon-
sible for worldwide packaging development. Dr. Consoli
is a member of SCOTT's Corporate Environmental Steer-
ing Committee, which has overall responsibility for cor-
porate environmental strategies and policies. He also
serves as SCOTT's representative to the Coalition of
Northeastern Governors (CONEG) Source Reduction
Task Force and to the recently formed Southern States
Waste Management Coalition (SSWMC). He is SCOTT's
principle contact for Life-Cycle Assessments, and par-
ticipated in the August 1990 and February 1992 LCA
workshops sponsored by the Society of Environmental
Toxicology and Chemistry (SETAC). He currently serves
on the SETAC LCA Advisory Group. Prior to joining
SCOTT, Dr. Consoli was employed by the Procter &
Gamble Company, where he held a variety of product
and packaging development positions in the deodorant,
hair care, laundry additive and paper divisions. He holds
a B.S. degree in Chemical Engineering from the Univer-
sity of Massachusetts and a Ph.D. in Chemical Engineer-
ing from the University of Florida.
C. Roger Cook
Vice President, Environment
E.B. Eddy Forest Products Ltd.
Espanola, Ontario, Canada
A native of England, C. Roger Cook emigrated to Canada
to join E.B. Eddy Forest Products as a Process Engineer.
He has worked for the E.B. Eddy company for 16 years
and currently holds the position of Vice President, En-
vironment. Prior to joining E.B. Eddy, Mr. Cook worked
in England as a Fisheries Officer and Chemist for the
Lancashire and Western Sea Fisheries Committee. One
of his early assignments was to carry out the environ-
mental evaluation of North America's first oxygen delig-
nification system that began operation in the E.B. Eddy
Mill in Espanola in 1977. Mr. Cook has a Bachelor of
Technology degree in Polymer Technology from Brunei
University and obtained an M.S. in Environmental Pollu-
tion Control from Leeds University.
Michael J. Cousin
Director, Quality Processes
Georgia-Pacific Corporation
Atlanta, Georgia
As Director of Quality Processes for the Communication
Papers Division of the Georgia-Pacific Corporation,
Michael J. Cousin is responsible for the translation of
customer needs and expectations, especially to the con-
verting industries, such as envelope. Dr. Cousin joined
Georgia-Pacific in 1989 as Manager, Paper Projects for
G-P Chemicals - Research and Development, where he
worked with paper producers to enhance the efficiency
of chemicals used in the papermaking process. Recently
he has held both marketing and technical positions in
the Communication Papers Division of Georgia-Pacific
and is actively involved with the introduction of
recycled papers. Dr. Cousin began his career with Bat-
telle Memorial Institute as a research scientist, develop-
ing both natural and synthetic polymer systems and
evaluating emerging pulping technologies and their by-
products. He then spent several years with Mead Cor-
poration, where he was involved in the evaluation and
development of new product and process technology for
a variety of paper and board products and directed the
technical activities of a manufacturing operation. Dr.
Cousin received his Ph.D. from the College of Forestry,
University of Washington, where his research focused
on the production and evaluation of degradable polymer
systems for use in reforestation.
Erin Craig
Corporate Environmental Programs Manager
Apple Computer, Inc.
Cupertino, California
Erin Craig is a Corporate Environmental Programs
Manager for Apple Computer, Inc., in Cupertino, Califor-
nia. At Apple, she facilitates corporate environmental
improvements, provides technical guidance to environ-
mental efforts, and coordinates environmental
regulatory and legislative tracking. Prior to joining Apple
in 1990, she worked as a regulator of onshore and off-
shore oil developments; she was also an environmental
consultant and researcher in air quality and hazardous
waste.
Dean Decrease
Director of Technical Service, Pulp Division
Weyerhaeuser Company
Tacoma, Washington
Dean DeCrease is Director of Technical Service, Pulp
Divison, Weyerhaeuser Company. A graduate of Penn
327
-------
State and Northwestern University, he has been involved
in design and production of fine and specialty papers
since 1976. Mr. Decrease joined Weyerhaeuser's Pulp
Division in 1988 as Product Development Manager and
in his present position also has responsibility for overall
coordination of customer technical service.
Jeffery D. Denit
Deputy Director
Office of Solid Waste
U.S. Environmental Protection Agency
Washington, D.C.
Jeffery D. Denit is Deputy Director, Office of Solid
Waste, at the U.S. Environmental Protection Agency. In
addition to supporting the Director in managing this
diverse operation, Mr. Denit has senior management
responsib ility in areas of hazardous air releases from
treatment systems, large volume wastes such as from
mining activities, and the Subtitle D Nonhazardous
Waste Program. Mr. Denit joined EPA in 1970, holding
managerial positions in ORI and the Office of Water.
During this period he managed all major areas of ef-
fluent guidelines for industrial water pollution control
regulations. Previously Mr. Denit was a Civil Engineer
and Economist with the U.S. Department of Agriculture
and a Sanitary Engineer at the Federal Water Pollution
Control Administration, U.S. Department of the Interior.
From 1968 to 1970, he was a Captain in the U.S. Army,
and Post Sanitary Engineer at Fort Ord, California. Mr.
Denit has received many awards for outstanding perfor-
mance, including the EPA Bronze and Silver Medals. He
is listed in Marquis Who's Who and is a member of
Gamma Sigma Delta. He has published numerous ar-
ticles and reports on industrial pollution and public
policy and administration, and is coauthor of the Water
Pollution Control Federation Pretreatment Manual. Mr.
Denit is a member o.f the Water Pollution Control
Federation/ the American Water Works Association, and
the American Chemical Society. He received a B.S. in
Agricultural Engineering and an M.S. in Agricultural
Economics, both from Clemson University, South
Carolina. He also holds an M.S. in Sanitary Engineering
from the University of North Carolina.
Richard J. Diforio, jr.
V7ce President, Environment, Health and Safety
Champion International Corporation
Stamford, Connecticut
Richard J. Diforio, Jr., is Vice President, Environment,
Health and Safety for Champion International Corpora-
tion, a manufacturer of paper for business and industry
as well as plywood and lumber. In this position he
directs corporate loss prevention and environmental af-
fairs. Mr. Diforio joined Champion in 1965 as a Sales
Representative for Fine Papers based in New York City.
He was named Market Manager for fine papers in 1971,
Coated Paper Sales Manager in 1972, and District
Manager for Fine Papers in 1977. During the 1980s, he
served as vice president of several divisions, including
Sales and Order Services for Packaging Products, Plan-
ning and Development for Sales and Converting Opera-
tions, Business Management for Fine Papers, and
Environmental. Prior to joining Champion, Mr. Diforio
was a sales representative with the A.B. Dick Company
and was also employed as an underwriter with Chubb,
Inc. Mr. Diforio received a B.A. degree from Williams
College.
Patricia j. Dollar
Consultant
Slave Lake Pulp Corporation
McLean, Virginia
Patricia Dollar is an independent consultant specializing
in the area of recycled and environmentally friendly
manufacturing processes. Ms. Dollar has 18 years of ex-
perience in sales and marketing within the paper in-
dustry. She has worked for several Paper Corporation of
America merchant houses, most recently Conservatree
Paper Company, where she did policy research on
recycled paper issues. She also worked as Sales Manager
of Silver Leaf Paper Corporation, a recycled paper
manufacturer. Ms. Dollar has testified on paper issues
before the Senate Subcommittee on Energy Regulation
and Conservation and the Joint Committee on Printing,
and frequently consults with congressional and EPA staff
on paper issues. She has been active with several paper
recycling groups, including the Recycling Advisory
Council, ASTM, and the Environmental Action Paper
Definitions Working Croup; she also works closely with
Greenpeace, NRCD, and EOF.
Dick Erickson
Vice President, Environmental and Technology
Weyerhaeuser Company
Tacoma, Washington
Dick Erickson has worked for the Weyerhaeuser Com-
pany for over 21 years, serving in a variety of positions
including Research Scientist, Technical Service Manager
for Market Pulp, Pulp Mill Superintendent, Assistant to
Senior Vice President for Operations, Mill Manager, and
Vice President for Manufacturing and Technology. Dr.
Erikson earned a B.S. in Chemical Engineering from
Washington State University and a Ph.D. from the In-
stitute of Paper Chemistry in 1969.
Linda J. Fisher
Assistant Administrator, Office of Prevention, Pesticides
and Toxic Substances
U.S. Environmental Protection Agency
Washington, D.C.
Linda J. Fisher is EPA's Assistant Administrator for
Prevention, Pesticides and Toxic Substances. In this posi-
tion, she oversees the Agency's pollution prevention,
pesticide and toxic programs. She previously served as
EPA's Assistant Administrator of Policy, Planning and
Evaluation, where she had primary responsibility for
developing the Agency's position on global climate
change and establishing the Office of Pollution Preven-
tion. Ms. Fisher first joined the Agency in 1983 as Spe-
cial Assistant to the Assistant Administrator for Solid
Waste and Emergency Response. From 1985 to 1988,
she served as Chief of Staff for Administrator Lee M.
Thomas. She was the principal policy liaison with Con-
gress and the White House during the rewriting of the
Superfund law in 1986. Prior to joining EPA, Ms. Fisher
worked as a legislative assistant to Ohio Congressmen
328
-------
INDEX OF PRESENTERS
Clarence J. Brown and Ralph Regula. She also served as
Associate Staff Member to the House Appropriations
Committee. Ms. Fisher received her undergraduate de-
gree from Miami University of Ohio, and completed an
M.B.A. in Business Administration at George
Washington University. She received her J.D. from Ohio
State University's College of Law.
Bruce I. Fleming
Senior Research Advisor
Boise Cascade
Portland, Oregon
Bruce I. Fleming recently joined Boise Cascade as Senior
Research Advisor for the Portland, Oregon, laboratory.
Until recently, he was with the Pulp and Paper Research
Institute of Canada (Paprican), where he was Director of
Paprican's Chemical Pulping and Bleaching Division.
Along with four coauthors, he was awarded the Weldon
Medal by the Canadian Pulp and Paper Association in
1990 for a paper on dioxin abatement; he was recently
elected a Technical Association of the Pulp and Paper In-
dustry (TAPPI) Fellow.
Jens Folke
Director
European Environmental Research Croup (MFC)
Allerod, Denmark
A native of Denmark, Jens Folke is currently Director, En-
vironmental Research Croup Ltd., in Allerod. Dr. Folke
specializes in low-waste technology, environmental im-
pact assessment, resource management, and wastewater
treatment technologies, especially in regard to the pulp
and paper industry. Clients include the Danish National
Agency for Environmental Protection, the Nordic Coun-
cil of Ministers, the EC-Commission, the Ministry of En-
vironments in Ontario and Alberta, and the U.S.
Environmental Protection Agency. During 1990 Dr.
Folke was a visiting scholar on the Faculty of Environ-
mental Engineering at the University of Washington,
Seattle. He has traveled and worked internationally in
Canada, Cuba, Egypt, Finland, Great Britain, the Far
East, Eastern Europe, and the United States. Dr. Folke is
active in professional associations, including the Techni-
cal Association of the Pulp and Paper Industry (TAPPI),
where he received a certificate for the "Best Technical
Paper" in the General Category for the 1991 TAPPI En-
vironmental Conference. He also belongs to the Interna-
tional Association on Water Pollution Research and
Control (IAWPRC), and the Danish Society of Profes-
sional Engineers (DIF). In 1984 he won the Hede-Niel-
son Prize for research on environmental impact
assessment of industrial effluents. Dr. Folke received a
M.S. in Organic Chemistry and Biochemistry at the
University of Copenhagen, Denmark. He earned a Ph.D.
in Environmental Chemistry at the Technical University
of Chalmers and the University of Gothenburg, Sweden.
Mark Greenwood
Director, Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C.
As Director for the Office of Pollution Prevention and
Toxics, Mark Greenwood is responsible for implement-
ing the Toxic Substances Control Act, the Asbestos
School Hazard Abatement Act, the Asbestos Hazard
Emergency Response Act, the Pollution Prevention Act,
and certain sections of the Comprehensive Environmen-
tal Response, Compensation, and Liability Act and the
Community Right-to-Know Act. As Director, Mr. Green-
wood has led initiatives such as the 33/50 Program and
Design for the Environment. He is also charged with the
maintenance and dissemination of the Toxics Release In-
ventory. In 1978 he joined EPA's Office of General
Counsel, for whom he worked on a variety of issues
under the Clean Water Act and on solid waste legisla-
tion. He was named the first Assistant General Counsel
for RCRA in 1983, and in 1987 he assumed the duties of
Assistant General Counsel for the Superfund Program. In
1988, he became the Associate General Counsel for the
Office of Pesticides and Toxic Substances. Mr. Green-
wood is a graduate of the University of Michigan Law
School. He also received a graduate degree in Public
Policy Studies from the same institution.
Ann Hillyer
Barrister and Solicitor
West Coast Environmental Law Association
Vancouver, B.C., Canada
Ann Hillyer is a staff lawyer with West Coast Environ-
mental Law Association, a nonprofit public interest or-
ganization in Vancouver, British Columbia, providing
legal advice and counsel to individuals and organiza-
tions with environmental problems. Ms. Hillyer has
practiced law in British Columbia since 1986 and has
worked with the West Coast Environmental Law As-
sociation since 1989. Currently Ms. Hillyer is working
on a number of environmental issues, including pollu-
tion from pulp mills and problems related to atmos-
pheric change. She represents individuals and 54
organizations, with over 250,000 members, who are
concerned about pollution from pulp and paper mills in
British Columbia.
Harold L. Hintz
Technical Assistant to Vice President and Corporate
Research Director
Westvaco Corporation
New York, New York
Harold L. Hintz joined Westvaco in 1966 and has served
as Technical Assistant to the Vice President and Cor-
porate Research Director since 1981. Over the course of
his career he has held a variety of positions, including
Research Scientist, Technical Director, and Group
Leader, Charleston Research. Dr. Hintz received a B.A.
in Chemistry from Wesleyan University and an M.S. and
Ph.D. in Paper Science from The Institute of Paper
Science and Technology. His thesis won the Westbrook
Steele Gold Medal.
Donald W. Hopkins
Vice President and General Manager
Hearst Enterprises Division,
The Hearst Corporation
New York, New York
As vice President and General Manager of the Hearst
Enterprise Division, The Hearst Corporation, Donald W.
329
-------
Hopkins is responsible for paper supply and quality to
Hearst newspapers, magazines, and books. Prior to as-
suming his present position, Mr. Hopkins was with
Hearst's Pejepscot Paper Division, where he was respon-
sible for operations, sales and marketing, and wood-
lands. During the 1960s and 1970s, Mr. Hopkins worked
in various accounting and administrative positions at
Oxford Paper Company and Boise Cascade Corporation.
He is active in numerous professional associations, in-
cluding the Technical Association for the Pulp and Paper
Industry (TAPPI), PIMA, NPMA, and MPA, and is a past
President of the Paper Industry Information Office, State
of Maine. He attended Northeastern Business College in
Accounting/Business Administration.
Virgil K. Morton, Jr.
VJce President, Paper Croup
American Paper Institute
New York, New York
Virgil K. Horton, Jr., joined the American Paper Institute
(API) in January 1990 as Vice President of the Paper
Group. He is responsible for the group's four divisions
and represents the paper segment of the industry to
public, Federal, and State regulators, customer associa-
tions, and ad hoc groups. Mr. Horton worked for
Westvaco Corporation for 25 years in senior sales and
marketing management positions before joining API. He
has had extensive experience in electronic communica-
tion, specifically bar coding and electronic data ex-
change. Active in professional groups, Mr. Horton was a
founding member of the Interassociation Council on
Paper Waste Management, which serves as a forum for
members of the print communications industry to share
information and educate the public about recycling. He
has served on the board of the Graphic Communications
Association and currently serves on the United States
Postal Service's Mailer's Technical Advisory Committee.
Mr. Horton received a B.B.A. from Georgia State Univer-
sity in Marketing/Management, and holds an M.B.A. in
Marketing/Finance from St. Louis University.
Clifford T. "Kip" Hewlett, Jr.
V7ce President, Government Affairs
Georgia-Pacific Corporation
Atlanta, Georgia
As Georgia-Pacific's Vice President for Government Af-
fairs, C. T. "Kip" Hewlett, Jr., is responsible for the
development and implementation of corporate policy.
Mr. Hewlett has published numerous articles and books
on such diverse subjects as the production and utiliza-
tion of biomass energy, federal timber land-use planning
policies, and the economic effects of land-use controls.
His publications also include several papers on the
regulation of toxic chemicals, including formaldehyde.
Mr. Hewlett currently serves as Chairman of the Coali-
tion for Fair Lumber Imports and the American Paper
Institute's (API) Health Committee. He was previously
Chairman of the National Association of Manufacturers
OSHA Policy Committee, the National Forest Products
Associations Inter-industry Wood Dust Committee, and
several API committees. Mr. Hewlett is a graduate of the
Johns Hopkins University in Baltimore and Willamette
University College of Law, Salem, Oregon.
Lubomir Jurasek
Head, Biological Chemistry Section
Pulp and Paper Research Institute of Canada
St. Claire, Quebec, Canada
Lube Jurasek joined the Pulp and Paper Institute of
Canada (Paprican) in 1975, and is now Head, Biological
Chemistry Section, Process Chemistry Division. His re-
search interests are in mechanisms of biological
modification of lignocellulosic materials. Before joining
Paprican, Dr. Jurasek was on the staff of the Forest
Products Research Institute, Bratislava, Czechoslovakia
(1954-68); he was also a National Research Council of
Canada Postdoctoral Fellow (1964-66) and a Research
Associate and Lecturer at the University of Alberts (1968-
74). Dr. Jurasek is a member of the BIOFOR Steering
Committee, the Society for Industrial Microbiology, the
American Chemical Society, and the American Society
for Microbiology. Dr. Jurasek received an R.N. Dr. and a
C.Sc. from the University of Brno, Czechoslovakia.
Russell E. Kross
Vice President, Human and Environmental
Protection
The Mead Corporation
Dayton, Ohio
Russell E. Kross has been with the Mead Corporation for
24 years. He has directed Mead's corporate programs for
employee health and safety, environmental control, and
product safety since the early 1970s. He was named an
officer and Vice President of Mead in 1990. Prior to join-
ing Mead, Mr. Kross spent four years at the Iowa Health
Department. He holds an M.S. in Environmental En-
gineering from the University of Iowa.
Norman Liebergott
Special Consultant
DuPont Canada Inc.
Laval, Quebec, Canada
Norman Liebergott is a Consultant to DuPont Canada,
Inc. He is also an adjunct professor in the Department of
Chemical Engineering at McGill University. Dr. Lieber-
gott was formerly a Senior Scientist at the Pulp and Paper
Research Institute of Canada (Paprican). His research in
the area of pulp bleaching processes and environmental
control has earned 26 patents, and he has published
over 90 scientific articles. He has reported his work at
over 100 scientific meetings and been invited to
numerous plants in Canada and the United States to pro-
vide technical assistance. Dr. Liebergott has won two
Weldon medals from the Canadian Pulp and Paper As-
sociation and Best Paper Awards from the Environmental
Conferences of the Technical Associations of Pulp and
Paper Industry and the Pulp Manufacturers. He also
received a C.F.C. Ritter Prize and Paprican's Presidential
Citation for his work. Dr. Liebergott was named a Tech-
nical Association of the Pulp and Paper Industry (TAPPI)
Fellow in 1991. Dr. Liebergott received a diploma in tex-
tile chemistry, an A.B.Sc. Degree in mathematics, and a
D.Sc. in Chemistry from Sir George Williams University.
330
-------
INDEX OF PRESENTERS
Lars-Ake Lindstrom
Vice President, Research and Development
Sunds Defibrator Industries AB
Sundsvall, Sweden
Lars-Ake LindstrOm joined Sunds Defibrator AB in 1984
and worked in several management positions before be-
coming Vice President for Research and Development in
1986. Prior to joining Sunds, Dr. Lindstrom was Manager
of Pulp Bleaching at SCA Research. Dr. Lindstrdm
earned both an M.S. and Ph.D. in Chemical Engineering
from Chalmers University of Technology, Sweden.
Neil McCubbin
President
N. McCubbin Consultants, Inc.
Foster, Quebec, Canada
Since immigrating to Canada in 1965, Neil McCubbin
has worked almost entirely in the pulp and paper in-
dustry, initially in mills and later as a consultant in North
America and overseas. In earlier years his work involved
detailed engineering for mill installations, including one
of the first effluent treatment systems installed in a
Canadian pulp mill, while more recent work has con-
centrated on process aspects of environmental protec-
tion systems in the industry. He has been retained by
regulatory authorities as well as industry and industrial
associations. Mr. McCubbin is author of over one
hundred technical publications.
Thomas J. McDonough
Professor of Engineering and Croup Leader for Pulping
and Bleaching
The Institute of Paper Science and Technology
Atlanta, Georgia
Thomas J. McDonough is Professor of Engineering and
Group Leader for Pulping and Bleaching at The Institute
of Paper Science and Technology (IPST) in Atlanta, Geor-
gia. His responsibilities include the direction of aca-
demic and industrial research in the science and
technology of pulp manufacture. Mr. McDonough has a
record of extensive professional involvement and
numerous publications in areas related to the practice
and fundamentals of pulp bleaching, pulping, and lignin
reactions. Before joining IPST, he held research positions
at Canadian International Paper Company and the
Canadian Industries Limited. He earned his Ph.D. in
Chemical Engineering at the University of Toronto.
David Mager
Director of Environmental Standards
Green Seal
Washington, D.C.
David Mager is Director of Environmental Standards at
Green Seal, an independent, nonprofit organization that
encourages the manufacture and purchase of environ-
mentally responsible products through standard setting
and product certification. Mr. Mager has a long history of
expertise in product design and process, including
numerous patents and inventions. Prior to joining Green
Seal, Mr. Mager wrote Growing Green Plants: the En-
vironmental Component of Manufacturing Process and
Product Development, which was presented to General
Motors, IBM, General Electric, McDonald's, Nestle-Car-
nation, Coca Cola, Hallmark, Anheuser-Busch and
Citibank, among others, to help these companies design
environmentally superior products and redesign com-
pany operations to incorporate environmental proces-
ses. He was one of five U.S. delegates to the
International Standards Organization and one of 50 ex-
perts asked to participate in the Society of Environmental
Toxicologists and Chemists' Data Quality Workshop
focused on advancing the science of Life Cycle Analysis.
Mr. Mager also wrote the criteria for and was a judge in
Inc. magazine's Environmental Design Award.
Steve Moldenius
Technical Director and Manager, Research and
Development
Sodra Cell
Morrum, Sweden
Steve Moldenius is Technical Director and Manager, Re-
search and Development, at Sodra Cell, Morrum,
Sweden, where he is currently working to develop
chlorine-free kraft pulps. Dr. Moldenius previously
worked for Sunds Defibrator and STFI. He holds a doc-
torate in Cellulose and Paper Technology from the Royal
Institute of Technology, Stockholm, Sweden.
Donald G. Monefeldt
Manager, Supply Products Marketing
Xerox
Webster, New York
Donald Monefeldt has worked for Xerox for 29 years and
is currently Manager of Supply Products Marketing.
During his career at Xerox, he has worked in supplies
manufacturing, development, and program manage-
ment; machine product planning and program manage-
ment; and supplies marketing. Mr. Monefeldt has
pursued several environmental efforts on behalf of
Xerox, including initiating the National Office Paper
Recycling Project, which is chaired by the U.S. Con-
ference of Mayors. In addition, he conceived and imple-
mented the Eco White corrugated container (outer ply
made from repulped waste white office paper) for Xerox
Supply Products and the Mixed Waste Paper Brown con-
tainer for Xerox parts. He also developed an educational
brochure about paper recycling for Xerox customers and
initiated a project to use recycled plastic in Xerox con-
sumables packaging.
Michael J. O'Rourke
Catalog Manager, IKEA North America
IKEA U.S., Inc.
Plymouth Common, Pennsylvania
Michael J. O'Rourke, Catalog Manager for IKEA North
America (the world's largest furnishings retailer) since
1989, formerly worked in Sweden, where he accumu-
lated experience in many areas of the publishing busi-
ness, from catalog production to periodicals. Mr.
O'Rourke received a degree in Urban Affairs from Vir-
ginia Polytechnical Institute and State University.
331
-------
Richard B. Phillips
Staff Vice President and Director of Process
Technology
International Paper
Mobile, Alabama
Richard B. Phillips is Staff Vice President and Director of
Process Technology at International Paper. His dual
responsibilities include corporate environmental affairs
and development and application of process technology
for the company's pulp and paper manufacturing
facilities worldwide. Dr. Phillips joined International
Paper in 1971 and has held a variety of technical and en-
gineering positions, including Manager of Chemical
Process Technology, Manager of Manufacturing Techni-
cal Service for the pulp and paper business groups, and
Associate Director of Process Innovation. He has
authored over 20 publications and holds five U.S.
patents on oxygen and ozone bleaching. A graduate of
North Carolina State University with a Ph.D. in Chemi-
cal Engineering, Dr. Phillips also attended the Centre
Technique du Papier, University of Grenoble, France, for
postgraduate research.
Martha G. Prothro
Deputy Assistant Administrator, Office of Water
U.S. Environmental Protection Agency
Washington, D.C.
Martha Prothro is Deputy Assistant Administrator for
Water at the U.S. Environmental Protection Agency
(EPA). In this capacity, she serves as the senior career ad-
visor to the Assistant Administrator and is responsible for
the national water quality management program, which
includes water quality criteria and standards, drinking
water criteria and standards, NPDES permits for point
sources of water pollution, nonpoint source controls, the
State Revolving Fund program for constructing
municipal wastewater treatment plans, and shared
responsibility with the U.S. Army Corps of Engineers for
regulating wetlands and the disposal of 250 million
cubic yards of dredged material each year. A career
public servant with over 25 years of government service,
Ms. Prothro joined EPA in 1973 as an enforcement attor-
ney in the air pollution control program and eventually
rose through the ranks to direct the Noise and Radiation
Enforcement Division. In 1981, she moved to the Water
Division, where she was responsible for the NPDES Per-
mits Program and the national pretreatment program. In
1988, she was named Director of the Office of Water
Regulations and Standards. In April 1991, she moved to
her current position. Ms. Prothro has a B.A. degree from
the University of North Carolina and a J.D. from George
Washington University'5 National Law Center. She has
received numerous awards, including the Presidential
award for meritorious service as a senior executive.
Margaret Rainey
Greenpeace Paper Campaign
Gdteborg, Sweden
Margaret Rainey has been working with environmental
problems related to paper production and consumption
since 1986, when she started working for Greenpeace.
She is the Swedish representative of the Greenpeace In-
ternational Paper Campaign working to end chlorine-
bleaching, increase recycling, reduce overconsumption
of paper and protect forest biodiversity. She has spoken
on a wide range of environmental aspects of the pulp
and paper industry at international conferences arranged
by the European Community, the United Nations, the
pulp and paper industry, etc. Her education includes
studies in natural science ecology and human ecology.
Douglas Reeve
Director, Pulp and Paper Centre
University of Toronto
Toronto, Ontario, Canada
Douglas Reeve is Professor of Chemical Engineering and
Applied Chemistry, and Director of the Pulp and Paper
Centre at the University of Toronto. Dr. Reeve has long
been a consultant in new process technology for the
pulp and paper industry; he is widely known for his
many publications and patents on the closed-cycle
bleached Kraft pulp mill, pulp bleaching and the en-
vironment, and kraft recovery boiler fireside chemistry.
Dr. Reeve has been very active in the technical section
of the Canadian Pulp and Paper Association and Techni-
cal Association of the Pulp and Paper Industry (TAPPI),
where he is a Fellow and a recipient of the 1988 TAPPI
Pulping Division Medal. Dr. Reeve, a member of both
the TAPPI and CPPA Bleaching Committees, is Chairman
of the TAPPI Bleach Plant Operations Short Course, the
TAPPI Kraft Recovery Operations Short Course and
Leader of the CPPA Kraft Pulp Bleaching Course. Dr.
Reeve earned a B.S. (Honors Chemistry) from the
University of British Columbia and a Ph.D. in Chemical
Engineering at the University of Toronto.
David J. Refkin
Director of Environmental Affairs and Assistant Director
of Paper Purchasing
The Time Inc. Magazine Company
New York, New York
David J. serves as Time Inc.'s Director of Environmental
Affairs and Assistant Director of Paper Purchasing. In his
current position, Mr. Refkin has two major areas of
responsibility. He is responsible for environmental and
recycling activities for the company. He also plays a
major role in the purchasing of all the paper stock for the
company's magazine. Mr. Refkin is a member of the
Recycling Advisory Council's Paper Committee. In addi-
tion, he is a member of the Magazine Publishers of
America Waste Reduction Task Force and the Print Com-
munications Industry Council on Waste Management.
Following a short career in public accounting, Mr. Ref-
kin first joined Time Inc. in 1982 in Corporate Finance.
Mr. Refkin joined the Magazine, Manufacturing and Dis-
tribution division in 1986 as its Business Manager. He
became the Assistant Director of Paper Purchasing in
May 1989 and added the title of Director of Environmen-
tal Affairs in May 1992. A native of New York City, Mr.
Refkin, a C.P.A., has a B.S. degree in Accounting from
the State University of New York at Albany and a M.B.A.
degree from lona College.
332
-------
INDEX OF PRESENTERS
John S. Seitz
Director, Office of Air Quality Planning and Standards
Office of Air and Programs
U.S. Environmental Protection Agency
Washington, D.C.
Since 1990, John Seitz has been responsible for the overall
policy, management, engineering, and scientific direction
of the U.S. Environmental Protection Agency's (EPA's) Of-
fice of Air Quality Planning and Standards. He joined EPA
in 1971 as a Case Development Officer and has also served
as Chief, Regional Operations, Office of Enforcement,
where he was responsible for directing and managing EPA's
regional implementation of the Toxic Substances Control
Act and the Resource Conservation and Recovery Act. In
1980, Mr. Seitz was named Chief, Compliance Monitoring
Unit, Office of Pesticides, where he managed and directed
all operational aspects of implementing compliance
monitoring programs. From 1984 to 1987, he was Chief Ex-
ecutive Officer, Office of Compliance Monitoring, Office of
Pesticides and Toxic Substances. In this capacity, Mr. Seitz
managed and helped implement EPA's pesticides and toxic
substances compliance/enforcement programs. In 1987, he
became Director, Stationary Source Compliance Division,
where he focused on the overall implementation of the sta-
tionary compliance provisions of the Clean Air Act. Mr.
Seitz has a B.S. degree from the University of Delaware.
Ladd T. Seton
Export Sales
Fraser Paper, Limited
Stamford, Connecticut
Ladd T. Seton has held a variety of technical customer
service and marketing positions in the paper industry for
over 30 years. He recently joined Fraser Paper, Limited,
as General Manager, Market Pulp, with responsibility for
worldwide sales of sulphite market pulp. He is now
heading the export sales effort. Before joining Fraser
Paper, Mr. Seton worked for other producers of market
pulp, including International Paper Co., Weyerhaeuser,
and Louisiana Pacific Company. His experience encom-
passes manufacturing, customer technical services, and
marketing. Mr. Seton is a graduate of Oklahoma State
University with a B.S. in Chemical Engineering.
Howard Sproull III
President
ECO Paper Source
Chicago, Illinois
Howard E. Sproull III, is a consultant for paper manufac-
turers, and markets chlorine-free papers across the
United States. He provides consulting services to both
domestic and offshore manufacturers, developing
product introduction, and marketing strategies for sup-
plying chlorine-free papers. Customers currently utiliz-
ing chlorine-free papers from ECO Paper Source are
end-users, corporations, printers, and merchants. Mr.
Sproull previously worked in marketing and sales with a
domestic coated paper manufacturer and a regional
paper merchant. He completed his B.S. in Wood and
Paper Science at North Carolina State University, and
received an M.B.A. in International Business from De-
Paul University.
Richard E. Storat
Vice President, Economic & Financial Services
American Paper Institute
New York, New York
Richard E. Storat is Vice President, Economic and Finan-
cial Services of the American Paper Institute (API), the
national trade association serving the pulp, paper, and
paperboard industry. He joined the Institute in 1987.
Prior to joining API, Mr. Storat served in a series of cor-
porate management positions, including strategic plan-
ning, energy policy, and engineering assignments. In
Washington, D.C., in the early 1980s, Mr. Storat served
as the key staff assistant for synthetic fuels on the Fossil
and Synthetic Fuels Subcommittee of the House Energy
and Commerce Committee. Mr. Storat concluded ten
years of service in the U.S. Army as an Assistant Profes-
sor of Physics at the U.S. Military Academy, West Point.
He is a member of several professional associations, in-
cluding the National Association of Business
Economists. He earned his B.S. at West Point, an M.S. at
the Massachusetts Institute of Technology, and an M.B.A.
with an emphasis on economics at Lehigh University.
C. Bertil Stromberg
Director, Research and Development Laboratory
Kamyr, Inc.
Glens Falls, New York
Mr. Stromberg, a native of Sweden, joined Kamyr in
1979 as a Process Engineer. Since then he has held a
number of positions at the Glens Falls, New York,
laboratory, and became Director of the lab in 1990. Prior
to joining Kamyr, Mr. Stromberg was an Engineer in
Karlstad, Sweden. He is the holder of two patents, one
for reducing contamination in pulp processing, and the
other on washing for low bleach chemical consumption;
three additional patents are pending. In addition, Mr.
Stromberg has published scholarly articles. He is a mem-
ber of the Technical Association for the Pulp and Paper
Industry (TAPPI), CPPA, the Swedish Pulp and Paper En-
gineers Association, AlChE, and Swedish Chemical En-
gineers Association. Mr. Stromberg received his M.S. in
Chemical Engineering, Pulp and Paper Specialization,
from the Royal Institute of Technology, Stockholm.
Kit Taylor
Wee President Manufacturing
Times Mirror Magazines
New York, New York
As Vice President of Manufacturing for Times Mirror
Magazines, Kit Taylor is the manufacturing and distribu-
tion supplier liaison for Times Mirror Magazines' ten na-
tional special-interest magazines, including Field and
Stream, Popular Mechanic, and Outdoor Life, as well as
for the magazines published by Sports Marketing Group,
the company's custom publishing division. Ms. Taylor's
26-person department handles the purchasing of all
paper and coordinates prepress and printing operations.
She also supervises the company's Creative Service
Department, which produces all corporate promotional
materials. Before joining Times Mirror Magazines in
1987, Ms. Taylor was at Esquire Magazine Group, Inc.,
where she was responsible for the print, buying,
manufacturing, and distribution of five divisions, includ-
333
-------
ing Esquire and New York World; the Esquire Health &
Fitness Clinic; a wall media publication; and Club Pack,
a sampling program. Ms. Taylor began her career in
magazine publishing with the Texas Monthly in 1973.
She joined the Austin Sun as production coordinator in
1975 and later became production manager of "D"
Magazine and Texas Homes. She relocated to New York
in 1981. Ms. Taylor received a B.S. from the University
of Texas.
Roger Telschow
President
Ecoprint
Silver Spring, Maryland
Roger Telschow is President and founder of Ecoprint, a
Silver Spring, Maryland, sheetfed printing company.
Ecoprint has extensive experience in printing on
recycled papers, using nonpetroleum, vegetable oil-
based inks, and "environment-friendly" pressroom
chemicals. A recognized innovator in the area of en-
vironmental "super-compliance," Mr. Telschow also
speaks on the subject of "total quality," as his company
has won two awards for excellence in quality and ser-
vice. Ecoprint, which is dedicated to environmental and
product quality, is currently working on the reformula-
tion of printing inks to remove heavy metal-based pig-
ments, funded in part by an EPA pollution prevention
grant.
Luigi Terziotti
Wee President, Pulp and Paper Operations
Parsons & Whittemore
Claiborne, Alabama
A native of Italy, Luigi Terziotti is presently Corporate
Vice President, Pulp and Paper Operations, Parsons &
Whittemore. He is also responsible for the operation of
all manufacturing divisions, including the St. Anne Pulp
Company, Nackawic, New Brunswick, Canada, as well
as the Alabama River Newsprint Company and the
Alabama Pine Company, which are located at Claiborne
alongside the Alabama River Pulp. Dr. Terziotti joined
the Black Clawson Company—then a Parsons & Whit-
temore affiliate—as a Project Engineer in 1961, working
first in London, then in Middletown, Ohio. In 1973, he
was transferred to Parsons & Whittemore's main office in
New York; in 1977, he moved to the Claiborne plant as
Project Manager, and subsequently became Executive
Vice President/General Manager. Dr. Terziotti serves on
the boards of Auburn University's Pulp and Paper Foun-
dation and the Alabama Southern Community College
Foundation. He received a Doctor of Industrial
Chemistry degree from Bologna University.
William H. Trice
Executive Vice President
Union Camp Corporation
Wayne, New Jersey
As Executive Vice President of Union Camp Corpora-
tion, Dr. Trice is responsible for research and develop-
ment, environmental affairs, and profit and loss
responsibility for the world-wide chemical business of
Union Camp. He has had extensive experience in tech-
nology development in the pulp and paper industry,
having worked as a Research Scientist Group Leader and
Section Leader in research and development and having
held senior technical management responsibilities at the
division and corporate levels. Dr. Trice is active in
education and research organizations of the pulp and
paper industry and is currently a member of the
American Paper Institute's Environmental Steering Com-
mittee. He completed his undergraduate work at the
College of Environmental Science and Forestry at
Syracuse University, and received his M.S. and Ph.D.
from the Institute of Paper Science and Technology.
Mary Ellen Weber
Director, Economics, Exposure and Technology Division
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C
Mary Ellen Weber is Director of the Economics, Ex-
posure and Technology Division (EETD) in the Office of
Toxic Substances at the U.S. Environmental Protection
Agency. EETD is responsible for all engineering, in-
dustrial chemistry, environmental exposure, and
economic analyses of toxic substances. In the 1980s, Dr.
Weber cofounded a computer software company
specializing in designing and marketing databases for
occupational and employee medical records. Prior to
that, Dr. Weber was the Director of the Office of
Regulatory Analysis at the United States Department of
Labor — Occupational Safety and Health Administration
(OSHA). In this position she directed engineering and
economic analyses for all health and safety regulations.
Prior to joining government, Dr. Weber worked as a
Country Economist at the World Bank and at the Interna-
tional Research and Technology Corporation (IR&T). At
IR&T, she conducted a variety of regulatory impact
studies for EPA, the Department of Energy, and the
private sector, focusing on the impact of various public
policies on the environment. Dr. Weber has a B.A. in
Economics from Dominican College and a Ph.D. in
Economics from the University of Utah. She has done
postgraduate work at Stanford University, the University
of Chile, and the Universidad Nacional Autonoma de
Mexico. She completed her international education by
serving in Chile on a Foreign Area Fellowship under the
auspices of the Social Science Research Council and by
working as an Production Assistant at CBS Television
News. On her return to the United States, Dr. Weber
joined the faculty of Smith College, where she taught
economics.
Dee Williams
Toxics Reduction Specialist
Washington State Department of Ecology, Waste
Reduction Program
Olympia, Washington
Dee Williams is a Toxics Reduction Specialist with the
Washington State Department of Ecology, Office of
Waste Reduction, Recycling and Litter Control (WRRLQ.
She provides technical assistance to businesses for
developing and implementing pollution prevention
programs focusing on hazardous substance use and
waste reduction. Ms. Williams has worked with various
pulp and paper mills in Washington State and with EPA
334
-------
INDEX OF PRESENTERS
Region 10 and a local pulp mill to compile a "Model
Pollution Prevention Plan for the Pulp and Paper In-
dustry." She has participated in regional meetings of the
National Council of the Pulp and Paper Industry for Air
and Stream Improvement, the Northwest Pulp and Paper
Association, and the Washington Pulp and Paper Foun-
dation.
Michael D. Witt
Chief, Industrial Wastewater Section
Wisconsin Department of Natural Resource
Madison, Wisconsin
As Section Chief for Industrial Wastewater at the Wis-
consin Department of Natural Resources, Michael D.
Witt coordinates and supervises the issuance of NPDES
permits to 1,500 industries in Wisconsin, including dis-
charges to surface and groundwaters from pulp and
paper mills. He also supervises the animal waste
regulatory program, oversees plans for treatment systems
for industries, and develops administrative codes in
response to statutory requirements. Mr. Witt joined the
Wisconsin environmental agency in 1974, and has coor-
dinated areawide water quality management plans and
developed training courses on U.S. EPA municipal
facility plans. He has also designed programs dealing
with wasteload allocation of pulp and paper mill dis-
charges along the Fox and Wisconsin Rivers. Mr. Witt
received a B.S. in Civil Engineering from the University
of Wisconsin-Madison, and an M.S. in Civil and En-
vironmental Engineering, also from the University of
Wisconsin-Madison.
Peter E. Wrist
President and Chief Executive Officer
Pulp and Paper Research Institute of Canada
Pointe-Claire, Quebec, Canada
Peter E. Wrist joined the Pulp and Paper Research In-
stitute of Canada (Paprican) in 1983 and was elected
Chief Executive Officer in 1986. Before joining
Paprican, he was Vice President of Mead Corporation,
where he had held a number of management and re-
search positions from 1956 to 1983. From 1949 to 1952,
he worked as a Research Physicist for the British Paper
and Board Makers Research Association, and held a
similar position with the Quebec North Shore Paper
Company from 1952 to 1956. Mr. Wrist is a pioneer in
papermaking research and development. His work in
head box design, forming fabrics, and drainage on the
fourdrinier paper machine helped to develop the new
technology responsible for today's significantly in-
creased production rates. He also played a key leader-
ship role on behalf of the pulp and paper industry in
obtaining responsible environmental legislation in the
United States. Mr. Wrist is a member of the Technical
Section, CPPA; the New York Academy of Sciences; and
the Marcus Wallenberg Foundation Selection Commit-
tee. He is also a past President of the Technical Associa-
tion of the Pulp and Paper Industry (TAPPI), and past
Chairman of NCASI and The Institute of Paper
Chemistry's Research Advisory Committee. For his
professional achievements, Mr. Wrist has received the
Canadian Pulp and Paper Association Howard Smith
and Weldon Gold Medals, and the TAPPI Engineering
Division and Gold Medal Awards. He was designated a
TAPPI Fellow in 1974. Mr. Wrist received a B.A. in
Physics and an M.A. in Mathematics from Cambridge
University, England, and a M.S. degree in crystal-
lography from London University, Birbeck College. He
also attended the Advanced Management Program of the
Harvard Business School.
335
-------
Index of Authors
Anderson, Rune 126
Assmann, David 240
Axegard, Peter 84
Beaton, Archie 140
Becker, Monica M 21
Belasco, Barbara 248
Bennett, Kathleen M 216
Blum, Lauren 257
Church, Jr., John F. 244
Clement, John L 66
Closset, Gerard P. 120
Congreve, Richard N 166
Consoli, Frank J 12
Cook, C. Roger 190
Cousin, Michael J 250
Craig, Erin 145
DeCrease, Dean W 291
Denit, Jeffery 237
Diforio, Jr., Richard J 18
Dollar, Patricia J 298
Erickson, Dick 27
Fisher, Linda J 3
Fleming, Bruce 1 76
Folkejens 209
Greenwood, Mark 2,233
Hillyer,Ann 225
Hintz, Harold L 44
Hopkins, Donald W 277
Horton, Jr., Virgil K 134
Hewlett, Jr., Clifford!. 155
Jacobsson, Birgit 84
Jurasek, Lubomir 105
Kovasin, Kari 61
Kross, Russell E 41
Lancaster, Lindsay M 194
Liebergott, Norman 112
Lindstrom, Lars-Ake 61
Ljunggren, Sten 84
McCubbin, Neil 172
McDonough, Thomas J 35
Mager, David 49
Moldenius, Steve 304
Monefeldt, Donald G 246
Nilvebrant, Nils-Olof 84
O'Rourke, Michael J 279
Paice, Michael G 105
Phillips, Richard B 194
Prothro, Martha G 5,231
Rainey, Margaret 161
Reeve, Douglas W 96
Refkin, David J 143
Renard, JeanJ 194
Ruston, John 257
Seitz, JohnS 235
Seton, Ladd T. 301
Sjodin, Lars 61
Sproull III, Howard 138
Storat, Richard E 7
Stromberg, C. Bertil 54
Taylor, Kit 272
Telschow, Roger 274
Terziotti, Luigi 185
Trice, William H 100
Weber, Mary Ellen 309
White, Allen L 21
Williams, Dee 222
Witt, Michael D 220
Wrist, Peter E 284
Yin,Caifang 194
337
-------
Conference Note
One of the objectives of the Symposium was to explore the availability and acceptability of
chlorine-free and unrebleached recycled paper products. The EPA had planned to print
these Proceedings on 100 percent postconsumer unrebleached paper to give the readers an
opportunity to observe one use of an alternative paper. The Joint Committee on Printing (JCP) of the
U.S. Congress specifies the products and services the Government Printing Office may provide.
(Federal government publications must be printed in federal printing facilities.)
A price competitive U.S. manufacturer of 100% postconsumer unrebleached paper was iden-
tified for the JCP. The JCP was unwilling to add this paper to its approved list of paper. The JCP
noted that the approved paper list currently contains recycled (chlorine-bleached) paper and ob-
jected to the fact that there was at that time only one U.S. manufacturer of the paper type EPA had
requested.
Recently, JCP has received requests for permission to use chlorine-free and unrebleached
recycled paper from a number of sources and is reviewing the policy forbidding use of these alter-
native papers in federal printing facilities.
339
------- |