BlueRidgePaperProducts_CantonMill_SWMP2002

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BLUE RIDGE
PAPER PRODUCTS INC.
June 17, 2002
Mr. James Patterson
Waste Management Specialist
North Carolina Department of Environment and
Natural Resources
Division of Solid Waste
852 Merriman Avenue
Asheville, North Carolina 28804
Re: 10-Year Solid Waste Management Plan Update — FY 2011/2012
Dear Mr. Patterson:
Per North Carolina House Bill 859, Section 130A-309.09D(c), 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 July 14, 1997.
The purpose of this report is to describe plan implementation and to update the report as
it was submitted on June 20, 2001. The attached document has been revised to reflect the
Blue Ridge Paper Products Solid Waste Management Plan through fiscal year 2011/2012.
Since June 30, 2001, significant strides have been made to reduce the volume of
hazardous waste generation, and increase the in -mill recycling rate. This progress will be
detailed in the fiscal year 2001/2002 plan.
Should you have any questions regarding the plan, please call me at 828-646-2028.
Sincerely,
Jim Giauque
Attachment
File:lfpin02
Copy: ferric Brown
Bob Williams
175 Main Street - P0. Box 4000
Canton, North Carolina 28716
Phone: [phone] a Fax: [phone]
reaigii`rfj Y<>tar Expectations

m jJ;wjlrAT'jW :11:1ZIS] 11[1��

Table of Contents
Introduction
1
Part I. 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 4
Non -Process Waste Generation 4
Hazardous Waste Generation 5
Total Waste Generation 6
Part II. Waste Reduction Initiatives 7
Source Reduction, Recycling, Reuse & Energy Recovery 7
Process Waste Management 7
Recycling, Reuse and Energy Recovery Management 7
Part III. Summary g

UaUAD11104
Appendix B
File: 1 Oyearplan2002.doc
General Location Map of Blue Ridge Paper
Products Inc, Canton Mill and Landfill Number 6
Canton Mill Non -Process Solid Waste Program
us
W5

Blue Ridge Paper Products Inc.'s, Canton facility, is a pulp and paper mill that manufactures
uncoated paper and bleached paperboard. The Canton Mill was purchased from Champion
International Corporation on May 14, 1999. The Canton Mill employs approximately 1,100
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 paperboard 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.
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 175,000 tons from 1989/90 to 2000/01, a 40.7% 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 and regional 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,,,'
ud, flyash, cinders, 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.

E7,Tr_1W
GEOGRAPHIC AREA AND SOLID WASTE STREAM EVALUATION
GEOGRAPHIC AREA
This p/8O provides only for the solid VVaOtS Str88DlS g8O8[8tSd by the C@OtOD PU|o & Paper K8iU
of Blue Ridge Paper Products Inc., located in C8OtOD. North C8[U|iO8, Haywood County. The
C8DhDO Mill is located 8ppn]Xi[D8t8|y 14 Dli|8S VY83t of Asheville, North C8nD|iO8. The location of
the mill and its associated B|U8 Ridge Paper Products -owned landfill (Landfill NO. 8, Permit No.
44-O8)'i3shown OOthe map iOAppendix /\.
WASTE STREAM EVALUATION
Five basic types of wastes are generated at the Canton Mill:
Process Wamtee, including vv8Sbevvater treatment a|udQ8. |irna nnud, flynah. cinders 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;
Recyclable Materials, including metal, various grades of paper, wood, cardboard, etc.;
General Trash, including office waste and non-recyclables.
Note that nl8Oy of the Dl8Leh8|S recycled in the DliU, including paper and COOt8in8[ board are
salvaged and sorted from the general trash waste stream. Some Ofthese materials are recycled
through |OC8| recycling vendors, as markets allow (discussed below and in Appendix B). Other
nl8ter|3|S such as C|e8n. unmarketable paper (broke and t[irnmingS), wood fines and
polyethylene from depO|y. are reused in the process or burned for energy recovery. F<eCyC|8b|e
rnSt@|s are mainly generated frOrn construction and demolition activities, as well as [ni||
maintenance, When appropriate, inert construction and demolition debris have been disposed
in a Beneficial Fill in cooperation with HeyvvOOd County,
PAPER AND PAPERBOARD PRODUCTION
For this 8tUdy, the b8Sk5 of Canton K4iU waste generation is the ennU8/ rniU production Of paper
and b0]Rj products. Table 1 Sh0vvs the rate Of production by fi8C8! year from FY 1889-90
through FY2O0O-01 The fiscal year estimates are based upon calendar year paper and board
production. It should be noted that production has remained consistent throughout the p8riOd,
with b]t8| production exceeding 500,000 tons each year. A slight decrease in production is
noticeable in FY 1992-93 due to Canton Modernization Project (CK4P) construction activities.
2

Table 1 - Canton Mill Paper and Board Production
Fiscal Year 1989-90 Through Fiscal Year 2000-01 - Tons
Paper and Board
Fiscal Year
Production - Tons
1989-90
579,935
1990-91
572,696
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
1999-00
562,807
2000-01
540,030
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 2000-01 is shown in Table
2.
Table 2 - Estimated Process Waste Disposal by Type
Fiscal Year 1989-90 Through Fiscal Year 2000-01
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
1999-00
106,188
86,036
59,806
6,060
6411,
258,731
2000-01
110,707
82,931
53,620
6,344
224
254,826
iI

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
operations and maintenance 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 2000-01
Total Delivered
Fiscal Year Pounds
1991-92 54,100
1992-93 379,970
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
230,100
79,240
339,233
488,880
88,440
86,660
155,560
17,240
Tons
27
190
115
40
170
244
44
43
78
9
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 construction and demolition (C&D) waste have
been delivered to the Haywood County Wood Waste Landfill. Regular trash has been taken 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 were recycled or disposed at the Haywood County Landfill in
FY 2000-01, 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. Based on the above information, 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.
In.

Table 4 - Estimated Canton Mill Total Non -process Waste Generation
Fiscal Year 1991-92 Through Fiscal Year 2000-01
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
1,608
1997-98
1,756
1998-9��,
2,348
1999-00
2,096
2000-01
1,422
The significant decrease of approximately 92% (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.
Table 5 - Canton Mill Hazardous Waste Disposal
Fiscal Year 1991-92 Through Fiscal Year 2000-01
Total Disposed
Fiscal Year
Founds
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
1999-00
13,611
6.8
2000-01
12,828
6A
5

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 2000-01
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
1,608
244
10
345,747
1997-98
312,015
1,756
44
12
313,827
1998-99
242,652
2,348
43
7
245,050
1999-00
258,731
2,096
78
7
260,912
2000-01
254,826,,
1,422
9
6
256,263
When compared to the pre-CMP basis year FY 1989-90, a 40.7% 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.
6

WASTE REDUCTION INITIATIVES
As discussed in the Introduction 8 i|ed in Part | ab0ve, it is the Canton MiU'ogoo| to
CODtiDUe to iODOrpOn3t8 into its pnJCSSS the Dl98OS to reduce the generation of waste at the
SOUFCe. Further waste generation F8dUCtiDO will CODl8 from diVe[SiODS from the V8hOUS VV8St8
streams 8G8result Ofrecycling efforts, beneficial fills, and by-product use.
VV@Ste [8dUCtk]O rates are CQ|CU|at8d for the b8SeUO8 year 1981-92thn]ugh fiscal year 2OOO-01
as ShoVvO in Table 7. b8|OVV.
Table 7~Waste Disposal Rates
FY1991-92Through FY 2000'01
Disposal Rate
Fiscal Year
Paper and Board
Total Waste
Per Ton mf
Production ~Tons
Disposal ~Tons
Production
Baseline year
1891-92
589.583
407.752
0.718
1982-93
520.113
402.540
0774
1993-94
514'840
340,103
0.881
1994-95
558.462
305.272
0.547
1995-86
548'357
347.245
0.033
1996-87
551,245
345,797
0.627
1997-98
567'831
313.827
0.554
1998-99
578.542
245.050
0.423
1898-00
562.807
200'912
0.484
2000-01
540.030
250.203
0.475
Process Waste Management
At present, greater than QS% of the total Vv3Ste generated in the Canton Mill CODSiSts Of process
vv@SteS. To date, only major changes to the production process involving C8piL8| investment or
system retirement have significantly affected the Canton Mill disposal rate, Beyond the source
reduction benefits Of the Canton Modernization Project, multiple process vv@Ste reduction
projects have been evaluated, B|thOugh, to date, none have progressed beyond the conceptual
phase. Improvements to the No,19 Paper K4@Ch|D8 in the Fall Of1S97resulted in significant
reductions to the mill sewer fiber losses, which are reflected in the lowerWWTP sludge tonnage
in 1gQ7-9Oand thereafter.
Recycling, Reuse and Energy Recovery Management
It is evident from the Canton Mill waste generation history detailed above that continuous source
n9dU[tiOD pr0gF8SS is being made with bDth, process and non -process waste 3tr88nOS. Although
riot significant by comparison to the tonnage ofprocess wastes disposed at Landfill No. 0. the
SOCi8| and practical irDpOrt8OC8 of the recycling pn]Q[8rn cannot be overstated, A large portion
Df in-rniU non -process vv8Gha is now naoyC|8d, reused in the prooess, or used for energy
production, and as o reSU|t, o great deal of landfill space, as well as n@tVn3| resOUrCSS. is saved.
|OC|Uded are paper broke and trim, wood dUst. screen rejects, cores and deploy materials, arid
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, 40% of non -process
wastes were recycled in 2001.
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/
Trim2'
Screen Rejects
Cores &
Depoly3'
1991
---
72,200
20,259
1992
---
85,402
21,516
1993
---
78,564
55,158
1994
---
83,595
38,779
1995
1,757
70,423
42,942
1996
2,727
73,031
72,687
1997
2,289
82,294
139,911
1998
1,364
82,852
143,684
1999
---
74,280
79,991
2000
--
86,782
49,195
2001
---
84,460
31,589
Marketed agricultural liming product
21 Paper reused in the paper making process
31 Burned for energy recovery - Dry Tons.
NA -- Not available
Mixed Container Paper Office Beneficial
Metal Board Broke Paper Fill
NA
---
---
--- ---
NA---
---
--- ---
NA---
---
--- ---
874
33
1,002
4 ---
1,724
58
728
83 ---
5,358
63
918
50 17,740
1,277
7
103
9 503
673
---
---
--- ---
498
---
---
--- ---
587
46
378
--- ---
429
---
551
--- ---
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 beneficial purpose 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.
8

m
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 92%, 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,
2012 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 timeto reduce process solid
waste generation.
The following table (Table 9) summarizes Canton Mill waste reduction through fiscal year
20011-12.
Table 9 - Targeted Waste Reduction, FY 2002-06 and FY 2007-12
Base Year
FY 1991-92 FY 2000-01 FY 2002-06 FY 2007-12
Actual Tons Actual Tons Targeted Tons Targeted Tons
Production or Anticipated
Production of Paper & 569,583 540,030 565,000 565,000
Board
Targeted Disposal Rate Per 0.716 0.475 0.500 0.500
Ton of Production
Total Waste Disposed, 407,752 256,263 282,500 282,500
Waste Disposal Goal
% Reduction from Baseline --- -37.2% -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 2002-201.2
will be represented in future waste reduction goal annual updates.
9

m

FMa
m

SOLID WASTE
MANAGEMENT
r1 9
aal�lffi 40441,01
BLUE, IUD GE.PA PER PROD UC. TS INC
CA NTON MILL

• ,WASTE PROGRAM
1992-2001
TRASH
TRASH
TRASH
TRASH
TRASH
TRASH
TRASH
TRASH
TRASH
TRASH
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
Compacted
Compacted
Compacted
Compacted
Compacted
Compacted
Compacted
Compacted
Compacted
Compacted
&
&
&
&
&
&
&
&
&
&
Uncompacted
Uncompacted
1 Uncompacted
1 Uncompacted
Uncompacted
Uncompacted
Uncompacted
Uncompacted
Uncompacted
Uncompacted
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Flatbed
Packer
Packer
Packer
Packer
Packer
Packer
Packer
Packer
Packer
Packer
Truck
Truck
Truck
Truck
Truck
Truck
Truck
Truck
Truck
Truck
CANTON
CANTON
CANTON
CANTON
HAYWOOD
HAYWOOD
HAYWOOD
HAYWOOD
HAYWOOD
HAYWOOD
MUNICIPAL
MUNICIPAL
MUNICIPAL
MUNICIPALS
COUNTY
COUNTY
COUNTY
COUNTY
COUNTY
COUNTY
LANDFILL
LANDFILL
&
&
LANDFILL
LANDFILL
LANDFILL
LANDFILL
LANDFILL
LANDFILL
HAYWOOD
HAYWOOD
& MRF
& MRF
& MRF
& MRF
& MRF
& MRF
LANDFILL,
LANDFILL
& MRF
& MRF
4,413
3,280
2,318
1,557
1,569
1,481
1,747
2,556
1,225
1,345
TONS/YR
i
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR
TONS/YR

BLUE RIDGE PAPER PRODUCTS, INC. - CANTON MILL
WOOD
Red
A_Tons
WOOD
Salvage
Yard
ULLonsj
METAL
Orange
429 Tons
1AM,
2001 ACTUAL
County ( ) (ZD
C7ounty
-'- �'l ��an iL,
r-- ----
CB/SP/OP
Direct
Haul
ELTonjs
Rock T 3en i i
TRASH
White
Packer
897 Tons
------------- IN
C&D
Direct
Haul
LIILTons j
Contract
Rolloff
U!ifj
Tones County Waste
Cove C& D Management
County
oultyWM
Landfill 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.
Jones Cove is the Haywood County Materials Recycling Facility (MRF).

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