BlueRidgePaperProducts_CantonMill_SWMP2008

ever reenf
packaging
Blue Ridge Paper Products Inc. - Canton Mill
July 28, 2008
Ms. Andrea Keller
Waste Management Specialist
North Carolina Department of Environment and
Natural Resources
Division of Solid Waste
2090 US Highway 70
Swannanoa, North Carolina 28778
Re: 10-Year Solid Waste Management Plan Implementation Update — FY 2008-2018
Dear Ms. Keller:
Attached is a copy of the 10-Year Solid Waste Management Plan update for the Blue Ridge
Paper Products Inc, Canton Mill. The purpose of this report is to describe plan implementation
and to update the report since it was submitted in 2007. The attached document has been revised
to reflect the Blue Ridge Paper Products Solid Waste Management Plan through fiscal year
2017-2018.
Should you have any questions regarding the plan, please call me at the number listed below.
Sincerely,
Jame�sr�A—�Gii`auque
Waste Compliance & Landfill Supervisor
Blue Ridge Paper Products Inc.
giauai @blueridaepaper.com
828-646-2028 Fax [phone]
Attachment
Filelfpin08
Copy: Derric Brown
Paul Dickens
Manager Environmental Affairs
Blue Ridge Paper Products Inc.
dickep@blueridaer)aper.com
828-646-6141 Fax [phone]
Blue Ridge Paper Products Inc. — Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
RECEIVED
JUL 3 1 2008
Division of Evergreen Packaging
SOLID WASTE SECTION
ASHEVILLE REGIONAL OFFICE

BLUE RIDGE PAPER PRODUCTS INC
CANTON MILL
SOLID WASTE MANAGEMENT PLAN
AUGUST 1, 2007--DUNE 309 2018

Table of Contents
Page
Introduction
1
Part I. Geographic Area and Solid Waste Stream Evaluation
3
Geographic Area
3
Waste Stream Evaluation
3
Paper and Board Production
3
Process Waste Generation
4
Asbestos -Containing Material Generation
5
Non -Process Waste Generation
6
Hazardous Waste Generation
7
Total Waste Generation
8
Part II. Waste Reduction Initiatives 9
Source Reduction, Recycling, Reuse & Energy Recovery 9
Process Waste Management 9
Recycling, Reuse and Energy Recovery Management 10
Part III. Summary 12

APPENDIX
PAGE
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:I Oyearplan2007.doc

INTRODUCTION
Blue Ridge Paper Products Inc's, (BRPP) 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. On July 31, 2007, BRPP was purchased
by Rank Corporation, and is presently a division of Evergreen Packaging, doing business as
Evergreen Packaging. The parent company of the Canton Mill remains Blue Ridge Holding
Corporation, based in Memphis, Tennessee. The Canton Mill employs approximately 941
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
H13859. 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 (owner).
2. Evaluation of options for the management and reduction of wastes.
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 generation was
reduced by approximately 125,000 tons from 1989/90 to 2006/07, a 26.4% reduction. This is
due primarily to capital improvements that have improved the efficiency of the pulp and paper
making process. 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.
Several studies were initiated in 2008 to evaluate the feasibility of process waste alternative
uses, including the land application of wastewater treatment plant sludge, and the use of lime
as an agricultural liming product. It was concluded that the land application of sludge was not
feasible due to insufficient availability of land meeting regulatory criteria within an economic
haul distance. The agricultural use of lime was also limited by land availability and the
economies of hauling to regional markets.
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, 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.
2

PART
GEOGRAPHIC AREA AND SOLID WASTE STREAM EVALUATION
GEOGRAPHIC AREA
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) are shown on the map in Appendix A.
WASTE STREAM EVALUATION
Five basic types of wastes are generated at the Canton Mill:
Process Wastes, including wastewater treatment sludge, lime mud, flyash, cinders and
woodwaste (note that only process wastes and asbestos containing material (ACM) are
permitted to be received at the Canton Mill Landfill No.6);
Hazardous Wastes, including paint waste and laboratory waste;
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-recyciables.
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 or national recycling vendors, as markets allow (discussed below and in
Appendix B). Other materials such as clean, unmarketable paper (broke and trimmings), and
wood fines, are reused in the process or burned for energy recovery. Polyethylene generated in
the Depoly process, is also recycled through a national vendor. For the purpose of this report,
other materials such as turpentine, and some "broke" paper (paper not sellable for its intended
end use due to defects or damage) are considered by-products of the process, sold to outside
markets, and not reported as waste materials. 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, or with private individuals.
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 1989-90
through FY 2006-07. 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 can
be seen in FY 1992-93 and FY 1993-94 due to Canton Modernization Project (CMP)
construction activities.

Table 1 - Canton Mill Paper and Board Production
Fiscal Year 1989-90 Through Fiscal Year 2006.07 - 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
2001-02
561,271
2002-03
577,219
2003-04
566,646
2004-05
573,285
2005-06
598,426
2006-07
599,206
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. Each of these materials 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 history at Landfill No. 6 from FY 1989-90 through FY
2006-07 is shown in Table 2.
Table 2 - Estimated Process Waste Disposal by Type
Fiscal Year 1989-90 Through Fiscal Year 2006-07
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
4

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
641
258,731
2000-01
110,707
82,931
53,620
6,344
1,224
254,826
2001-02
101,603
79,090
51,812
5,756
0
237,261
2002-03
103,972
96,772
40,434
6,753
192
248,123
2003-04
106,346
104,516
42,504
6,382
2,476
262,224
2004-05
109,992
109,065
50,509
5,599
3,016
278,181
2005-06
115,281
120,492
62,110
6,274
357
304,514
2006-07
119,448
136,924
51,769
7,030
1,154
316,325
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, and siding derived
from 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 roofing, pipe insulation, or transite siding.
Table 3 - Total ACM Disposed at Canton Mill Landfill No. 6
Fiscal Year 1991-92 Through Fiscal Year 2006-07
Total Delivered
Fiscal Year
Pounds
Tons
1991-92
54,100
27
1992-93
379,970
190
1993-94
230,100
115
1994-95
79,240
40
1995-96
339,233
170
1996-97
488,880
244
1997-98
88,440
44
1998-99
86,660
43
1999-00
155,560
78
2000-01
17,240
9
2001-02
67,540
34
2002-03
16,120
8
2003-04
87,060
44
2004-05
86,126
43
2005-06
272,840
136
2006-07
6,020
3
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.
11

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. After that time, pallets/wood and construction and demolition (C&D) waste were
delivered to the Haywood County Wood Waste Landfill. The Haywood County Wood Waste
Landfill closed in late 2002, at which time non -recyclable wood, pallets, and C & D waste were
delivered to the Haywood County White Oak Landfill. Regular trash is 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. Containerboard, waste white paper (from the paper -
making process), and office paper were primarily recycled, or disposed at the Haywood County
Landfill in FY 2006-07, dependent upon the condition of the material. The total volume of non -
process wastes delivered to the White Oak Landfill has continued to decline, due primarily to an
increase in the volume of paper products removed from the general mill waste stream and
recycled, or re -used in the mill papermaking process.
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.
Table 4 - Estimated Canton Mill Total Non -process Waste Generation
Fiscal Year 1991-92 Through Fiscal Year 2006-07
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
1998-99
2,348
1999-00
2,096
2000-01
1,422
2001-02
1,329
2002-03
1,134
2003-04
1,129
2004-05
2,308
2005-06
1,328
2006-07
1,126
FY 2006-07 non -process waste volume generated is only 6.2% of the amount generated in
base year 1991-92 due to the continued implementation of the recycling program begun in the
mill in 1994.
f

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 primarily include paint solvents, paint waste solids, 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 2006-07
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
1999-00
13,611
6.8
2000-01
12,828
6.4
2001-02
9,651
4.8
2002-03
1,029
0.5
2003-04
1,958
1.0
2004-05
1,048
0.5
2005-06
860
0.4
2006-07
1,055
0.5
The generation of hazardous waste declined significantly in 2002-03 due to the implementation
in 2002 of a new parts washer system that utilizes filtered bioremediation fluid reclaiming. It is
anticipated that paint wastes will be the largest component of hazardous waste in the future, the
volume of which will be driven by architectural painting/coating requirements.
7

TOTAL WASTE GENERATION
Total waste disposed by fiscal year, including process, non-process,'and hazardous wastes, are
provided in Table 6.
Table 6 - Canton Mill Total Estimated Waste Generation
Fiscal Year 1991-92 Through 2006-07
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
2001-02
237,261
1,329
34
5
238,629
2002-03
248,123
1,134
8
1
249,266
2003-04
262,224
1,110
44
1
263,396
2004-05
278,181
2,308
43
1
280,533
2005-06
304,514
1,328
136
1
305,979
2006-07
316,325
1,126
3
1
317,455
When compared to the pre-CMP basis year FY 1991-92, a 22% reduction in Canton Mill waste
generation has been realized in FY 2005-06. Capital programs have reduced the generation
rate of all mill waste streams where resource utilization and waste generation were integral
components. For example, the CMP (1993) resulted in a greater than 30% reduction in the
production of wastewater treatment plant sludge than previously generated, and significant fiber
loss reductions were realized by the Number 19 Paper Machine rebuild in 1999, as reflected in
the lower WWTP sludge tonnage in 1997-98 and thereafter.
These aspects of the Canton Mill waste management program will be discussed further in the
sections below.
E:1

PART II
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 waste generation 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 1991-92 through fiscal year 2006-07
as shown in Table 7, below.
Table 7 - Waste Disposal Rates
FY 1991-92 Through FY 2006-07
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
345,797
0.627
1997-98
567,631
313,827
0.554
1998-99
578,542
245,050
0.423
1999-00
562,807
260,912
0.464
2000-01
540,030
256,263
0.475
2001-02
561,271
238,603
0.425
2002-03
577,219
249,266
0.432
2003-04
566,646
263,396
0.465
2004-05
573,285
280,533
0.489
2005-06
598,426
305,979
0.511
2006-07
599,206
317,455
0.530
SOURCE REDUCTION RECYCLING REUSE AND ENERGY RECOVERY
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 Canton Mill capital improvement programs discussed above, multiple
process waste reduction projects have been evaluated, although, to date, none have
progressed beyond the conceptual phase.
M

Recycling, Reuse and Energy Recovery Management
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 large volume of landfill space, as well as natural resource
use, is saved. lncluded are paper broke and trim, wood dust, screen rejects, cores and deploy
materials, and mixed metals. Capital improvements in the Depoly process have helped reclaim
fiber for reuse in paper production, as is evidenced by the Broke & Trim total for 2003 through
2007 (Table 8). Office paper and other materials are recycled through a contract agreement
with a recycler. By weight, 57% of non -process wastes were recycled in 2007.
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
V Trimu Screen Rejects Metal Board Broke Paper Fill
Cores &
Depoly31
1991
---
72,200
20,259
NA
---
---
---
-""
1992
---
85,402
21,516
NA
---'"-
1993
---
78,564
55,158
NA
---
---
`--
---
1994
---
83,595
38,779
874
33
1,002
4
---
1995
1,757
70,423
42,942
1,724
58
728
83
---
1996
2,727
73,031
72,687
5,358
63
918
50
17,740
1997
2,289
82,294
139,911
1,277
7
103
9
503
1998
1,364
82,852
143,684
673
---
---
---
""-
1999
---
74,280
79,991
498
---
---
---
---
2000
---
86,782
49,195
587
46
378
---
---
2001
---
84,460
31,589
429
---
551
---
---
2002
---
99,479
30,895
518
31
766
59
---
2003
---
96,851
47,371
532
---
748
---
136
2004
---
90,526
46,525
679
47
873
10
68
2005
---
103,200
42,955
590
212
2,064
---
84
2006
---
101,136
47,602
370
---
913
---
63
2007
---
110,163
47,918
547
---
560
---
89
1 Marketed agricultural liming product
10

ti Paper reused in the paper making process as apposed to being sold outside or landfilled.
Burned for energy recovery — Dry Tons. Excludes depoly after 2001, which is now sold to
outside vendors.
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 on site 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 market pulp baling wire and additional wooden pallets. In addition, project -based
wastes handled by contractors represent an opportunity for increased sorting and recycling and
less co -mingling of waste prior to disposal.
11

PART III
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, the annual generation of in -process waste streams has been reduced by
approximately 25%, and non -process waste streams have been reduced by approximately 92%
since FY 1991-92, 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, 2017 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 July 2007
acquisition of Blue Ridge Paper Products by Rank Corporation, and the uncertainty of future
capital investment, no particular plans are in place at this time to further reduce process solid
waste generation.
The following table (Table 9) summarizes Canton Mill waste reduction through fiscal year 2016-
17.
Table 9 - Targeted Waste Reduction, FY 2008-12 and FY 2013-18
Base Year
FY 1991-92
FY 2006-07
FY 2008-12
FY 2013-18
Actual Tons
Actual Tons
Targeted Tons
Targeted Tons
Production or Anticipated
Production of Paper &
569,583
598,426
575,000
575,000
Board
Targeted Disposal Rate Per
0.716
0.511
0.500
0.500
Ton of Production
Total Waste Disposed,
407,752
305,979
287,500
287,500
Waste Disposal Goal
% Reduction from Baseline
---
-25.0%
-29.5%
-29.5%
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 2008-2018
will be represented in future waste reduction goal annual updates.
12

APPENDIX A
A-1

APPENDIX B
B-1

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