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HomeMy WebLinkAboutChampion_CantonMill_SWMP1996t " 0! CHAMPION INTERNATIONAL CORPORATION CANTON MILL �i I I'll IN 0 V I Page Introduction I Part I. Geographic Area and Solid Waste 2 Stream Evaluation Geographic Area 2 Waste Stream Evaluation 2 Paper and Paperboard Production 2 Process Waste Generation 3 Asbestos -Containing Material 3 Generation Non -Process Waste Generation 4 Hazardous Waste Generation 5 Total Waste Generation 5 Part 11. Waste Reduction Initiatives 7 Source Reduction, Recycling, Reuse & 7 Energy Recovery Process Waste Management 7 Recycling, Reuse and Energy 7 Management Part 111. Summary 1 9 1 �, �W 0 Page Appendix A. General Location Map of Champion A-1 International Corporation Canton Mill and Landfill No. 6 Appendix B. Canton Mill Non -Process B-1 Solid Waste Program INTRODUCTION Champion International Corporation's Canton facility is a pulp and paper mill that manufactures uncoated paper and bleached paperboard. The Canton Mill employs nearly 1,400 people and operates three uncoated paper machines and one paperboard machine around the clock. The four machines annually produce over 500,000 tons of paper and board. 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 $300 million, puts the mill on the cutting edge of pollution preventive technology in North America. As a result of this and other mill programs since the 1989/90 fiscal year (July 31, 1989 through June 30, 1990), process solid waste generation at the mill has been reduced significantly by an average total of 84,000 tons per year, or approximately 20%. Work continues to further enhance in -mill waste minimization. With an in -mill recycling program, non -process waste streams have declined by approximately 90% over the period. 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 FER N_8 GEOGRAPHIC AREA AND SOLID WASTE STREAM EVALUATION This plan provides only for the solid waste streams generated by the Canton Pulp & Paper Mill of Champion International Corporation, 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 Champion -owned landfill (Landfill No. 6, Permit No. 44-06), are shown on the map in Appendix A. WASTE STREAM EVALUATION Four basic types of wastes are generated at the Canton Mill: Process Wastes, including waste water 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; and General Trash, including office waste and non-recyclables. 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 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. For this study, the basis of Canton Mill waste generation is the annual mill production of paper and paperboard products. Table 1 shows the rate of production by fiscal year from FY 1991-92 through FY 1995-96. The fiscal year estimates are based upon calendar year paper and paperboard 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. 0 Table 1 - Canton Mill Paper and Board Production Fiscal Year 1991-92 Through Fiscal Year 1995-96 - 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 The vast majority of the wastes generated at the Canton Mill are the Process Wastes described 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 Champion International Corporation. 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 1995-96 is shown in Table 2. Table 2 - Estimated Process Waste Disposal by Type Fiscal Year 1989-90 Through Fiscal Year 1995-96 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 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. 3 Increases in ACM disposed typically represent capital projects, such as the CMP, or facility siding work to replace transite. Table 3 - Total ACM[ Disposed at Canton Mill Landfill No. 6 Fiscal Year 1991-92 Through Fiscal Year 1995-96 Total Delivered Fiscal Year Founds 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 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. 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, container board, waste white paper (from the paper - making process), and office paper has been recycled. A summary of the Canton Mill recycling program is provided in Appendix B. Please note that this information is available by calendar year only. Also, during 1996, an additional 4,100 tons of metal were recycled by contract and 17,740 tons of C&D waste were disposed in a Beneficial Fill in cooperation with Haywood County, saving valuable municipal landfill space and creating usable space for future activities. Because these materials were recycled and used in the 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. 4 Table 4 - Estimated Canton Mill Total Non -process Waste Generation Fiscal Year 1991-92 Through Fiscal Year 1995-96 Fiscal Year Tons 1991-92 18,050 1992-93 22,650 1993-94 11,859 1994-95 1,938 1995-96 1,563 The significant decrease if approximately 90% 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 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 Mall Hazardous Waste Disposal Fiscal Year 1991-92 Through Fiscal Year 1995-96 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 Total waste disposed by fiscal year, including process, non -process, ACM and hazardous wastes is provided in Table 6. 5 Table 6 - Canton Mill Total Estimated Waste Generation Fiscal Year 1991-92 Through 1995-96 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 When compared to the pre-CMP basis year FY 1989-90, a 20% 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 waste water treatment plant sludge than previously generated. These aspects of the Canton Mill waste management program will be discussed further in the sections below. Col PART II WASTE REDUCTION INITIATIVES As discussed in the Introduction and detailed in Part 1, 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 result from diversions from the various waste streams as a result of recycling efforts, beneficial fills, and by-product use. Waste disposal rates are calculated for fiscal year 1991-92 through fiscal year 1996-97 as shown in Table 7, below. Table 7 - Waste Disposal Rates, FY 1991-92 Through FY 1995-96 Fiscal Year Baseline year 1991-92 1992-93 1993-94 1994-95 1995-96 Process Waste Management Paper and hoard Production - Tons 569,583 520,113 514,640 558,462 548,357 Total Waste Disposal - Tons 407,752 402,540 340,103 305,272 347,245 Disposal Rate Per Ton of Production 0.716 0.774 0.661 0.547 0.633 At present, greater than 98% of the total waste generated in the Canton Mill consists of process wastes. To date, only major changes to the 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 are under evaluation at the present time, although, to date, none have progressed beyond the conceptual phase. Recycling, Reuse and Energy Recovery Management It is evident from the Canton Mill waste generation history detailed above that continuos 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. Over 90% (by weight) of in -mill non -process waste is now recycled annually, and a great deal of landfill space, as well as natural resources, saved. 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 7 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 ___________________Recycled4/ .................. Broke Wood Dust/ & Screen Rejects, Mixed Container Paper Office Beneficial Calcarb1 Trim2l Cores & Depoly3l Metal Board Broke Paper Fill 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 5,358 63 918 50 17,740 —� Champion marketed agricultural liming product 2i Paper reused in the paper -making process Burned for energy recovery -- Dry Tons. Department Estimate. ai Recycled via local recycling firms or by contractor. In 1996, 4,100 tons of metal were recycled by contractor, and 1,256 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 Champion 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 wooden pallets. In addition, project -based wastes handled by contractors represent an opportunity for increased sorting and recycling prior to disposal. 11 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. Several solid waste source reduction and beneficial reuse projects are being evaluated, and market analysis continues. To date, greater than 20% of the mass of in -process waste streams has been reduced, and non -process waste streams have been reduced by 90%, illustrating Champion's commitment to solid waste reduction. In addition, market development for calcarb, the waste lime product, continues with approximately 4,484 tons used for agricultural purposes to date. Given the waste -handling and minimization programs as presently defined herein, the Canton Mill anticipates reducing the rate of waste generation through June 30, 2006. 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. jim\landfill\wmplan.doc �1 A-1 11 /Y ell C < L2u z ca LU J LU (Z CL T4k! I-J jim\landfill\wmplatit METAL �WOOp � 1�9ETAi_ CB SPTRASHContract ®P C& D C& D ed Orange 9 Yellow Direct Wire Bins White Direct Beneficial Haul Packer Haul Fill 4,100 TONS 569 TONS ! ! 1,256 TONS 63 TONS 918 TONS 50 TONS 766 TONS 234 TONS 17,740 TONS Recycled (:funD Schulhofers Coburn Coburn Asheniie CC'O ® e® eficial Contractor Waste Paper Cove Fitt County Landfill t- County County 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. Schulhofers, Coburn, and Jones Cove are recycling destinations. • f Packer Truck CANTON MUNICIPAL LANDFILL 4,413 TONSNR Compacted & Uncompacted Flatbed M Packer Truck CANTON MUNICIPAL LANDFILL 3,280 TONSNR) Compacted Uncompacted Flatbed & Packer Truck CANTON MUNICIPAL & HAYWOOD LANDFILL & MRF 2,316 TONSNR Compacted. Unc• •r ^• Flatbed & Packer Truck CANTON MUNICIPAL & HAYWOOD LANDFILL & MRF 1,557 TONS/YR ) Flatbed t Packer Truck HAYWOOD LANDFILL & MRF 1,569 TONSNR ) f UJ C) o LLJ r;; F-z 0 r, LL • LO CY) CAI r LO U II I L7 0 4 I uanwri ivun Box C-10 Canton, North Carolina 28716 Champion Champion International Corporation July 14, 1997 Mr. James Patterson Waste Management Specialist North Carolina Department of Environment, Health, and Natural Resources Division of Solid Waste 59 Woodfin Place Asheville, North Carolina 28802 Dear Mr. Patterson: Per your telephone request of this date, attached is a copy of the Champion International Corporation, Canton Mill, 10-Year Solid Waste Management Plan, as required by House Bill 859, Solid Waste Amendments, Section 130A- 309.09D(c). Should you have questions regarding the document, please call me at 704-646- 2028. Sincerely, Jim Giauque i Attachment Copy: Derric Brown (letter only) John Bengel (letter only) Bob Williams (letter only) file: plan97_1.doc (CC) "Olhampion amo.cn interr�,;onai �'crnoration c: Cate: 10-Year Solid Waste July 1, 1997 Management Plan From: Suoiect: Jim Giauque 10-Year Solid Waste Management Plan Enclosed is the above plan for the Champion International Corporation Canton Mill in compliance with House Bill 859, Solid Waste Amendments, as detailed in Section 130A-309.09D(c). As determined by the above regulations, a copy of the plan shall be available upon request by the North Carolina Department of Environment, Health and Natural Resources, Solid Waste Section, by July 1, 1997, and shall be updated every three years. Additionally, a report regarding the plan's implementation shall be filed by August 1, 1998, and annually thereafter. Questions regarding this plan should be directed to the Canton Mill, Environmental Occupational Health and Natural Resources Department (EONS), Solid and Hazardous Waste Coordinator (704-646-2028), or the EOHS Department Supervisor (704-646-2318). Jim , 5 Giauque EOHS Solid & azardous Waste Coordinator Enclosures file:plan1997.doc Copy: John Bengel Derric Brown.