BlueRidgePaperProducts_CantonMill_SWMP1999

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BLUE RIDGE PAPER PRODUCTS INC.
June 28, 2000
Mr. James Patterson
Waste Management Specialist
North Carolina Department of Environment and
Natural Resources
Division of Solid Waste
59 Woodfin Place
Asheville, North Carolina 28802
Re: 10-Year Solid Waste Management Plan Update — FY 2009/2010
Dear Mr. Patterson:
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Per North Carolina House Bill 859, Section 130A-309.09D CO, the owner of an industrial
solid waste facility must develop a 10-year waste management plan, update it every three
years, and provide a report on the implementation of the plan by August 1 of each year.
The initial plan was submitted to you July 14, 1997. A comprehensive plan update was
completed July 29, 1999.
The purpose of this report is to describe the plan implementation and to update the report
as it was submitted on July 29, 1999. The attached document has been revised to reflect
the Blue Ridge Paper Products Solid Waste Management Plan through fiscal year
2009/2010.
Should you have any questions regarding the plan, please call me at 828-646-2028.
Sincerely,
Jim Giauque
Attachment
File:lfpin00
Copy: Derric Brown -
Bob Williams
175 Main Street • P.O. Box 4000 • Canton, North Carolina 28716 • 828-646-2000

BLUE RIDGE PAPERPRODUCTS INC
CANTON MILL
JULY 1 � 1996 - JUNE 309 20ti,

Table of Contents
Page
Introduction
1
Part 1. Geographic Area and Solid Waste Stream Evaluation
2
Geographic Area
2
Waste Stream Evaluation
2
Paper and Board Production
2
Process Waste Generation
3
Asbestos -Containing Material Generation
3
Non -Process Waste Generation
4
Hazardous Waste Generation
4
Total Waste Generation
5
Part 11. Waste Reduction Initiatives 6
Source Reduction, Recycling, Reuse & Energy Recovery 6
Process Waste Management 6
Recycling, Reuse and Energy Recovery Management 6
Part 111. Summary 8

Appendix A General Location Map of Blue Ridge Paper A-1
Products Inc, Canton Mill and Landfill Number 6
Appendix B Canton Mill Non -Process Solid Waste Program B-1
File:WMPLAN.doc

Blue Ridge Paper Products Inc., Canton facility, is a pulp and paper mill that manufactures
uncoated paper and bleached paperboard. The Canton Mill was purchased form Champion
International Corporation on May 14, 1999. The Canton Mill employs approximately 1,200
people and operates three uncoated paper machines and one paperboard machine around the
clock. The four machines produce over 500,000 tons of paper and board each year.
This Solid Waste Management Plan was prepared in accordance with North Carolina General
Statute 130A-309.09D (c), as amended in 1996 by the North Carolina General Assembly in
HB859. These amendments provide for the owner of an industrial waste landfill to establish a
waste management plan with the following components:
1. A waste reduction goal established by the generator.
2. Options for the management and reduction of wastes evaluated by the generator.
3. A waste management strategy, including plans for waste reduction and waste disposal, for
the 10-year period covered by the plan.
Through implementation of this comprehensive solid waste management plan, as well as
updates that will follow every three years, the Canton Mill provides for the management of solid
waste for the next 10 years. The long-range vision of the Canton Mill is to develop and maintain
a comprehensive waste management program that provides the necessary disposal capacity,
waste collection and transport services, efficient collection and marketing of recyclable
materials, and on -going waste reduction capability. Included is improved solid waste cost
management in an on -going effort to facilitate the mill's goal of achieving financial viability as a
low-cost producer into the 21 st Century.
Since 1991, impressive strides have been met at the mill in solid waste reduction. The Canton
Mill Modernization Project (CMP), completed in 1994 at a cost of $330 million, puts the mill on
the cutting edge of pollution prevention technology in North America. As a result of this and
other mill programs since fiscal year 1989/90 (July 31, 1989 through June 30, 1990), process
solid waste generation at the mill has been reduced significantly. Process solid waste was
reduced approximately 187,000 tons from 1989/90 to 1998/99, a 43% reduction. Work continues
to further enhance in -mill process waste minimization. In -mill recycling of non -process waste
streams is dependent upon highly volatile local markets for these materials.
Specific Canton Mill goals for waste management and waste minimization include:
1. To minimize the production of process waste streams (wastewater treatment plant sludge,
lime mud, flyash and woodwaste).
2. To further develop an efficient non -process waste stream recycling program.
3. To continue to develop an informed -workplace regarding waste management issues.
4. To increase the efficiency and cost-effectiveness of the solid waste programs.
1

PART I
GEOGRAPHIC AREA AND SOLID WASTE STREAM EVALUATION
GEOGRAPHIC
This plan provides only for the solid waste streams generated by the Canton Pulp & Paper Mill
of Blue Ridge Paper Products Inc., located in Canton, North Carolina, Haywood County. 'The
Canton Mill is located approximately 14 miles west of Asheville, North Carolina. The location of
the mill and its associated Blue Ridge Paper Products -owned landfill (Landfill No. 6, Permit No.
44-06), is shown on the map in Appendix A.
WASTE STREAM EVALUATION
Four basic types of wastes are generated at the Canton Mill:
Process Wastes, including wastewater treatment sludge, lime mud, flyash and woodwaste
(note that only process wastes are received at the Canton Mill Landfill No.6);
Hazardous Wastes, including paint waste and parts washer degreasers;
Construction and Demolition Wastes, including inert bricks, blocks, concrete and wood;
General Trash, including office waste and non-recyclables.
Note that many of the materials recycled in the mill, including paper and container board are
salvaged and sorted from the general trash waste stream. Some of these materials are recycled
through local recycling vendors, as markets allow (discussed below and in Appendix B). Other
materials such as clean, unmarketable paper (broke and trimmings), wood fines and
polyethylene from depoly, are reused in the process or burned for energy recovery. Recyclable
metals are mainly generated from construction and demolition activities, as well as mill
maintenance. When appropriate, inert construction and demolition debris have been disposed
in a Beneficial Fill in cooperation with Haywood County.
PAPER AND PAPERBOARD PRODUCTION
For this study, the basis of Canton Mill waste generation is the annual mill production of paper
and board products. Table 1 shows the rate of production by fiscal year from FY 1991-92
through FY 1998-99. The fiscal year estimates are based upon calendar year paper and board
production. It should be noted that production has remained consistent throughout the period,
with total production exceeding 500,000 tons each year. A slight decrease in production is
noticeable in FY 1992-93 due to Canton Modernization Project (CMP) construction activities.
Table 1 - Canton Mill Paper and Board Production
Fiscal Year 1991-92 Through Fiscal Year 1998-99 - Tons
Paper and Board
Fiscal Year Production - Tons
1991-92 569,583
1992-93
520,113
1993-94
514,640
1994-95
558,462
1995-96
548,357
1996-97
551,245
1997-98
567,631
1998-99
578,542

PROCESS WASTE GENERATION
The vast majority of the wastes generated at the Canton Mill are the Process Wastes listed
below. These are the waste materials generated through the wood -handling, pulp -making,
chemical -recovery and paper -making production processes. These wastes are disposed in the
Canton Mill industrial landfill, North Carolina Solid Waste Management Permit No. 44-06. The
landfill (Landfill No. 6) is wholly owned, operated and managed by Blue Ridge Paper Products.
Wastes are delivered to the landfill from the mill site by truck on a daily basis. A summary of
process waste disposal at Landfill No. 6 from FY 1989-90 through FY 1997-98 is shown in Table
2.
Table 2 - Estimated Process Waste Disposal by Type
Fiscal Year 1989-90 Through Fiscal Year 1998-99
Canton Mill Landfill No. 6 (Permit No. 44-06)
WWTP
Lime
Boiler
Boiler
Wood
Fiscal Year
Sludge
Mud
Flyash
Cinders
Waste
Total
(Tons)
(Tons)
(Tons)
(Tons)
(Tons)
(Tons)
1989-90
225,916
116,560
72,066
8,940
6,315
429,797
1990-91
230,038
93,775
68,085
7,020
5,670
404,538
1991-92
220,343
96,959
63,727
6,668
1,992
389,689
1992-93
221,599
89,326
60,052
5,475
3,447
379,899
1993-94
149,746
110,092
53,379
6,420
8,596
328,233
1994-95
135,650
88,962
60,944
9,906
7,848
303,310
1995-96
132,935
117,553
71,148
11,943
12,095
345,674
1996-97
142,866
109,810
65,636
10,195
15,428
343,935
1997-98
117,139
99,697
65,880
9,893
19,406
312,015
1998-99
99,620
73,561
60,719
5,701
2,719
242,652
ASBESTOS CONTAINING MATERIAL GENERATION
In addition to the above waste streams, Landfill No. 6 is also permitted to receive for disposal
asbestos -containing material (ACM) removed from roofing, pipe insulation, siding and related
activities at the mill. The dedicated asbestos disposal area was permitted by the Division of
Solid Waste Management on September 27, 1990. Although records are not available for ACM
disposal prior to May 1992, a summary of disposal since that time is provided in Table 3.
Increases in ACM disposed typically coincide with capital projects, such as the CMP, or work to
replace transite siding.
Table 3 - Total ACM Disposed at Canton Mill Landfill No. 6
Fiscal Year 1991-92 Through Fiscal Year 1998-99
Total Delivered
Fiscal Year Pounds
1991-92 54,100
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
379,970
230,100
79,240
339,233
488,880
88,440
86,660
Tons
27
190
115
40
170
244
44
43

No other wastes are permitted for disposal at the Canton Mill No. 6 Landfill. All other waste
streams are disposed via the Haywood County Waste Management System, by contractor,
reused within the mill, or are recycled.
NON -PROCESS WASTE GENERATION
It is estimated that in FY 1991/92, 4% of the total waste stream (process wastes, etc.) consisted
of deliveries to the municipal (town of Canton) landfill. The Town of Canton Landfill closed in
April of 1994. Since that time, pallets/wood and constructionand demolition (C&D) waste have
been delivered to the Haywood County Wood Waste Landfill. Regular trash has beentaken to
the Haywood County Materials Recovery Facility (MRF) for subsequent processing and disposal
at the Haywood County White Oak Landfill.
In addition to the above, metal is recycled. Container board, waste white paper (from the paper -
making process), and office paper was recycled or disposed at the Haywood County Landfill in
FY 1998/99, dependent upon markets for recyclables. A summary of the Canton Mill recycling
program is provided in Appendix B. Please note that this information is available by calendar
year only. Because these materials were recycled and used in a Beneficial Fill, the tonnage is
excluded from the Non -Process Waste Generation.
Given the above, it is estimated that the following volumes of non -process wastes (wastes not
disposed in the Canton Mill No. 6 Landfill, including pallets/wood, C&D material and regular
trash) were generated by fiscal year.
Table 4 - Estimated Canton Mill Total Non -process Waste Generation
Fiscal Year 1991-92 Through Fiscal Year 1998-99
Fiscal Year
Tons
1991-92
18,050
1992-93
22,650
1993-94
11,859
1994-95
1,938
1995-96
1,563
1996-97
1,522
1997-98
1,614
1998-99
2,152
The significant decrease of approximately 88% (Base year 1991-92) in the non -process waste
landfill disposal is due to the completion of the CMP construction and demolition, and the
implementation of the recycling program within the mill in 1994.
HAZARDOUS WASTE GENERATION
Hazardous wastes are also generated at the Canton Mill and disposed in compliance with
Resource Conservation and Recovery Act (RCRA) standards. Hazardous wastes generated at
the mill include paint solvents, spent parts washer degreasers, surplus laboratory and process
chemicals, and electrical or instrument components. The amount of hazardous waste disposed
by fiscal year is shown in Table 5, below.
11

Table 5 - Canton Mill Hazard Waste Disposal
Fiscal Year 1991-92 Through Fiscal Year 1998-99
Total Disposed
Fiscal Year
Pounds
Tons
1991-92
25,426
12.7
1992-93
22,030
11.0
1993-94
22,272
11.1
1994-95
47,640
23.8
1995-96
16,665
8.3
1996-97
18,981
9.5
1997-98
24,871
12.4
1998-99
14,343
7.2
TOTAL WASTE GENERATION
Total waste disposed by fiscal year, including process, non -process, and hazardous wastes is
provided in Table 6.
Table 6 - Canton Mill Total Estimated Waste Generation
Fiscal Year 1991-92 Through 1998-99
Tons Disposed
Fiscal Year
Process
Non -Process
ACM
Hazardous
Total
1991-92
389,689
18,050
27
13
407,779
1992-93
379,879
22,650
190
11
402,730
1993-94
328,233
11,859
115
11
340,218
1994-95
303,310
1,938
40
24
305,312
1995-96
345,674
1,563
170
8
347,415
1996-97
343,935
1,664
244
10
345,711
1997-98
312,015
1,814
44
12
313,685
1998-99
242,652
2,152
43
7
244,854
When compared to the pre-CMP basis year FY 1989-90, a 43% reduction in process wastes
has been realized. The generation rate of all mill waste streams has been reduced by capital
programs where resource utilization and waste generation were integral components. For
example, the CMP (1993) resulted in the production of over 30% less wastewater treatment
plant sludge than previously generated.
These aspects of the Canton Mill waste management program will be discussed further in the
sections below.
5

WASTE REDUCTION INITIATIVES
As discussed in the Introduction and detailed in Part I, above, it is the Canton Mill's goal to
continue to incorporate into its process the means to reduce the generation of waste at the
source. Further waste generation reduction will come from diversions from the various waste
streams as a result of recycling efforts, beneficial fills, and by-product use.
Waste reduction rates are calculated for the baseline year 1991-92through fiscal year 1998-99
as shown in Table 7, below.
Table 7 - Waste Disposal Rates
FY 1991-92 Through FY 1998-99
Disposal Rate
Fiscal Year
Paper and Board
Total Waste
Per Ton of
Production - Tons
Disposal - Tons
Production
Baseline year
1991-92
569,583
407,752
0.716
1992-93
520,113
402,540
0.774
1993-94
514,640
340,103
0.661
1994-95
558,462
305,272
0.547
1995-96
548-357
347,245
0.633
1996-97
551,245
345,711
0.627
1997-98
567,631
313,685
0.553
1998-99
578,542
244,854
0.423
Process Waste Management
At present, greater than 99% of the total waste generated in the Canton Mill consists of process
wastes. To date, only major changes to the production process involving capital investment or
system retirement have significantly affected the Canton Mill disposal rate. Beyond the source
reduction benefits of the Canton Modernization Project, multiple process waste reduction
projects have been evaluated, although, to date, none have progressed beyond the conceptual
phase. Improvements to the No.19 Paper Machine in the Fall of 1997 resulted in significant
reductions to the mill sewer fiber losses, which are reflected in the lower WWTP sludge tonnage
in 1997-98 and thereafter.
Recycling, Reuse and Energy Recovery Management
It is evident from the Canton Mill waste generation history detailed above that continuous source
reduction progress is being made with both, process and non -process waste streams. Although
not significant by comparison to the tonnage of process wastes disposed at Landfill No. 6, the
social and practical importance of the recycling program cannot be overstated. A large portion
of in -mill non -process waste is now recycled, reused in the process, or used for energy
production, and as a result, a great deal of landfill space, as well as natural resources, is saved.
Included are paper broke and trim, wood dust, screen rejects, cores and deploy materials, and
mixed metals. Office paper and other materials are recycled as markets allow. Soft markets
have reduced the volume of materials recycled since 1997. By weight, 17% of non -process
wastes were recycled in 1999.
C

Further, efficiency and source reduction is planned for the recycling program as the system is
expanded throughout the mill and more recyclables captured. Table 8, below, shows the
estimated tonnage of waste materials reused in the Canton Mill paper production process,
burned for energy recovery, recycled, or used for beneficial fill.
Table 8 - Total Estimated Tons of Waste Materials Reused in the Canton Mill Process for
Paper Production and Energy Recovery, Commercially Recycled, or
Used for Beneficial Fill
Calcarb Broke & Wood Dust/ Mixed Container Paper Office Beneficial
1-1 Trimti Screen Rejects Metal Board Broke Paper Fill
Cores &
Depoly 31
1991
0
72,200
23,360
NA
---
--- --- ---
1992
0
85,402
22,265
NA
---
--- --- ---
1993
0
78,564
23,360
NA
---
--- --- ---
1994
0
83,595
22,265
874
33
1,002 4 ---
1995
1,757
70,423
22,265
1,724
58
728 83 ---
1996
2,727
73,031
22,265
5,3584'
63
918 50 17,740
1997
2,289
82,294
22,265
1,277
7
103 9 503
1998
1,364
82,852
22,265
673
---
--- --- ---
1999
0
74,280
22,265
498
---
--- --- ---
-1 Marketed agricultural liming product
21 Paper reused in the paper making process
3' Burned for energy recovery — Dry Tons. Department Estimate.
4' Recycled via local recycling firms or by contractor. In 1996, 4,100 tons of metal were recycled
by contractor, and 1,258 tons recycled through a local recycler.
NA — Not available
Although not available on a fiscal year basis, the totals in Table 8, above, represent the annual
volume of wastes that are diverted from the BRPP landfill or the Haywood County White Oak
Landfill. In addition, these materials have maintained a useful life as agricultural lime, fill
material, recycling raw material, or energy. No materials are burned without energy recovery,
thus lessening our dependence on coal.
Opportunities exist to further reduce the in -mill, non -process waste streams, including the
recycling of paper baling wire and additional wooden pallets. In addition, project -based wastes
handled by contractors represent an opportunity for increased sorting and recycling prior to
disposal.
7

SUMMARY
For the purpose of this report, it has been assumed that mill production levels for pulp, paper,
paper board, chemical recovery, and energy generation remain relatively constant through the
next decade. Likewise, the resultant waste generation and associated waste management
described in this document, including recycled materials, beneficial fill disposal, source reduction
of process and non -process wastes, and the on -going investigation for further process waste
reduction and beneficial reuse, will continue.
To date, greater than 40% of the mass of in -process waste streams has been reduced, and non -
process waste streams have been reduced by 88%, illustrating Blue Ridge Paper Product's
commitment to solid waste reduction. Given the waste -handling and minimization programs
defined herein, the Canton Mill anticipates that the rate of waste generation through June 30,
2010 will remain relatively constant. Waste generation at the Canton mill is heavily dependent
upon process waste volume. Further significant decreases to the rate of process waste
generation will be dependent upon capital investment at the mill or from other projects. Given
the May 1999 acquisition of the Canton Mill by Blue Ridge Paper Products, and the uncertainty
of future capital investment, no particular plans are in place at this time to reduce solid waste
generation.
The following table (Table 9) summarizes Canton Mill waste reduction through fiscal year 2005-
10.
Base Year
FY 1991-92 FY 1998-99 FY 2000-04 FY 2005-10
Production or Anticipated
Production of Paper & 569,583 578,542 565,000 565,000
Board
Targeted Disposal Rate Per 0.716 0.423 0.500 0.500
Ton of Production
Total Waste Disposed, 407,752 244,854 282,500 282,500
Waste Disposal Goal
% Reduction from Baseline --- -40.0% -30.7% -30.7%
Waste generation is monitored regularly so that annual updates to the waste management
system are possible. An updated plan will be completed every three years and made available
to the Solid Waste Section, with reports outlining the plan implementation completed by August
1 of each year. Any significant revisions to the Canton Mill capital plan for the years 2000-2010
will be represented in future waste reduction goal annual updates.

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SOLID WA STE
MANAGEMENT
111
BL UE RID GE PA PER PR OD UC TS, INC.
CANTON MILL

IN -MILL SOLID WASTE PROGRAM -TRASH
1992 - 1999
TRASH
TRASH
1992
1993
Compacted &
Compacted &
Uncompacted
Uncompacted
TRASH
TRASH
TRASH
1994
1995
1996
Compacted &
Compacted &
Compacted &
Uncompacted
Uncompacted
Uncompacted
TRASH
TRASH
TRASH
1997
1998
1999
Compacted &
Compacted &
Compacted &
Uncompacted
Uncompacted
Uncompacted
17771
F;;
0 4 4 0 ' 4
Flatbed Flatbed Flatbed Flatbed Flatbed Flatbed Flatbed Flatbed
& Packer & Packer & Packer & Packer & Packer & Packer & Packer & Packer
Truck Truck Truck Truck Truck Truck Truck Truck
CANTON
CANTON
CANTON
CANTON
HAYWOOD
HAYWOOD
HAYWOOD
HAYWOOD
MUNICIPAL
MUNICIPAL
MUNICIPAL
MUNICIPAL
COUNTY
COUNTY
COUNTY
COUNTY
LANDFILL
LANDFILL
&
&
LANDFILL
LANDFILL
LANDFILL
LANDFILL
HAYWOOD
HAYWOOD
& MRF
& MRF
& MRF
& MRF
LANDFILL
LANDFILL
& MRF
& MRF
4,413
3,280
2,316
1,557
1,569
1,481
1,747
2,556
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR

BLItE RIDGE PAPER PRODUCTS,
0 NON -PROCESS SOLID WASTE PROGRAM
WOOD
Red
414 Tons
METAL
Orange
498 Tons
Xx/
CB
Yellow
0 Tons
SP
Direct
Haul
0 Tons*
OP
Wire Bins
0 Tons
TRASH
White
Packer
1,964 Tons
C&D
Direct
Haul
178 Tons
(.
C1C Salvag
County �,�,d Jones Jones. Jones Jones County
C& D Schulhofers Cove Cove Cove Cove C & D
County Q�:)
Q�0
Q�0
Q�D
CountyLan Landfill
C & D = Construction and Demolition Waste
OP = Office Paper
CB = Cardboard
SP = Scrap Paper
Wood = Pallets + Clean Wood
Red, Orange, Yellow and White represent the color of each bin by material type.
Schulhofers and Jones Cove are recycling destinations.
Paper waste products, including cardboard, office paper and other scrap paper, were
disposed in county landfill due to lack of recycling markets in the region.

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