Weyerhaeuser_NewBernPulpMill_SWMP1997

Southern Environmental Field Station
PO Box 1391
New Bern NC 28563-1391
Weyerhaeuser Fax [9191633 7404
September 9, 1997
Ms. Andrea Barefoot
Division of Waste Management
Solid Waste Section
P.O. Box 27687
Raleigh, NC 27611-7687
Dear Andrea:
Enclosed is the solid waste management plan for Weyerhaeuser's New Bern pulp mill.
The facility owns and operates an on -site industrial landfill. This plan is submitted to
you at the request of Mr. Bill Morris of the Washington Regional Office. A copy of this
plan was submitted to Bill at an earlier date. If you have questions regarding the plan,
please call me at [phone].
Sincerely,
Richard Gay
Integrated Waste Management
xc: Bill Morris
Dave Gardner

1 1 �, ' �
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1.0 Executive Summary
The solid waste management plan is intended to provide a comprehensive look at
waste generated by Weyerhaeuser's New Bern Mill Complex. In accordance
with House Bill 859 Sec.16 G.S. 130A-309.09D(c), this plan contains 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. The plan will be
made available to the Department of Environment, Health, and Natural
Resources. Updates of the plan will occur every three years.
The pulp mill operations has SIC code 2600 and the sawmill operates under
2400. Both facilities share a landfill owned and operated by Weyerhaeuser
Company. The landfill is expected to close in 2003. It is the intention of the mill
to maintain a landfill owned and operated by the company to prevent potential
liability from third party landfills.
The plan describes waste minimization strategies for the mill over a ten year time
line. The year of 1990 is used as the baseline for waste generation rate. The rate
in 1990 was 14,059 tons or 79,129 cubic yards per year. Waste disposed of in
the landfill in 1995 was 6,974 tons or 56,303 cubic yards.
The NC waste reduction goal of disposal in landfills is 40% by the year 2001.
The New Bern Mill has achieved a reduction of 50% through 1995 based on
weight which is the criteria specified by the state. The mill has set a target of an
additional 20% reduction in waste iandfilled by 2001. The mill's truck count
system will be utilized to measure the reduction.

1.1 Company Polio
Weyerhaeuser Company supports pollution prevention at all of its operating
facilities. This support is expressed in its Minimum Impact Mill philosophy
which says that the company may not achieve zero impact to the environment but
will work toward having as little impact as possible. Weyerhaeuser was one of
the first forest products industries to develop an environmental policy. The
policy was written in 1971 and updated in 1996.
The Weyerhaeuser Environmental Policy aligns with the company value:
Citizenship:
"We support the communities where we do business, hold ourselves to the highest
standards of ethical conduct and environmental responsibility, and communicate
openly with Weyerhaeuser employees and the public. "
Weyerhaeuser employees at all levels will work to ensure that we comply with
applicable laws and regulations and to continuously improve environmental
performance wherever we do business
• Employees are accountable for ensuring compliance with applicable laws and for
managing and operating our business to conform with the company's goals of:
Practicing sustainable forestry;
Reducing pollution; and
Conserving natural resources through recycling and waste reduction.
In conducting our business, we are committed to:
Continuously improving our processes for reducing wastes and emissions to the
environment.
Conserving energy and natural resources by maximizing recycling and by-product
reuse.
2.0 Current Situation
2.1 Mill Description
The New Bern Pulp Mill began operating in 1969 producing bleached
kraft pulp 24 hours a day, 7 days a week. The mill now has the capacity
of producing eight major grades of pulp for uses ranging from diapers to
high quality paper to paneling for automobiles.

Loblolly pine is the species of wood used most at the New Bern Mill.
Logs and chips are received by the woodyard as raw materials. Logs are
debarked, chipped, and screened prior to going to the digestors for
cooking. After pulping or cooking process, the brown pulp is washed to
remove pulping chemicals which are sent to the chemical recovery area
where they are burned in a high pressure recovery boiler. Inorganic
chemicals recovered are used in the chemical manufacturing process that
continues over and over. Steam produced by the boiler is used to generate
electricity from the mill's turbine generator and to dry pulp. Brown pulp
is bleached in a six -stage bleaching process that includes oxygen but no
elemental chlorine. Bleach pulp is sent to the pulp machine for sheet
formation and drying. Following drying the rolls are cut into smaller rolls
or into bales and prepared for shipping. Shipments are made by truck and
rail to domestic markets. In close proximity to the Atlantic seaboard, a
significant percentage of the mill's production is exported to European
markets. Production is about 250,000 tons per year.
2.2 Waste Stream Quantities and Current Management Practices
Waste
Wood yard bark, wood
waste, chip screen fines
Wood yard debris, grit
Grits
Dregs
Lime mud
Primary clarifier sludge
General mill waste
Asbestos
Scrap metal
Putrescible waste
Office waste
Off -specification
production
Quantity (tons/yr.) 1995 Management Practice
59,000 BDT
Sold as hog fuel to Craven
Wood Energy
1700 BDT
Sold to Parker Bark
Company for beauty bark
1300 BDT
Landfilled on -site
3000
Landfilled on -site
2000
Discharged to alkaline
sewer to WWTS
unknown
Discharged to acid sewer to
WWTS
20,000
Landfilled on -site
1500
Landfilled on -site
100 cu. ft.
Landfilled on -site
500
Recycled via Goldsboro
Iron & Metal
150
Regional Landfill
22
Recycled by ARS
100
Landfilled on -site

2.2.1
Hazardous Waste
Although the intent of this plan is to address nonhazardous waste
generation and reduction, the mill has had great success in reducing the
amount of recurring hazardous waste requiring disposal. The following
table captures the waste reduction that has been achieved between 1989
and 1995 inclusive.
Year
KG
LB
1989
5,659
12,450
1990
69025
1.3,257
1991
4,150
9,130
1992
1,440
3,169
1993
1,668
3,669
1994
928
2,042
1995
1,373
3,026
2.3 Waste Character
Twelve primary waste streams are generated by the New Bern Mill
operations. A brief description of each waste follows. With the
exception of putrescible waste, all waste is disposed on -site in the mill's
landfill. Other smaller waste streams, not delineated, contribute to the
overall solid waste generation.
logyard debris is generated as a result of Woodyard cleanup and
consists of bark, wood, soil, and rock.
bark/wood waste consists of scrap wood, chips, bark, wooden
shipping crates, and wood construction debris.
lime grits are unreacted particles of lime that settle to the
bottom of the slaker where they are raked out for
disposal.
lime mud is composed of precipitated calcium carbonate
referred to as "lime mud" and calcium oxide.

primary clarifier is composed of highly organic settled solids
sludge removed from the primary wastewater treatment
system. This sludge is landfilled with a high
moisture content.
General trash consists of maintenance, demolition, and
construction debris, packaging material, and similar
type materials. Due to the various wastes in this
category, opportunities exist for segregation to
enhance reuse and recycling of this waste stream.
asbestos includes friable and nonfriable asbestos materials
and articles containing asbestos. Asbestos becomes
a waste when removed for repair or prior to
demolition. Asbestos is typically managed in place
and removed on an as needed basis.
pulp/reject is the off -specification fibrous raw material used to
make paper.
knots are composed of unpulped compression wood or
uncooked chips that are removed prior to pulp
washing and returned to the digestor or landfilled as
waste.
demolition is material removed during demolition activities and
from construction activities.
paper/cardboard is primarily packaging materials and office waste
rock media is generated from the electro-static precipitator that
uses pea gravel as the scrubbing media. The rock is
discarded when its size becomes too small to be
effective.
putrescible waste includes food waste generated by the vending service
contractor. Because the landfill was permitted with
some variances from requirements of a sanitary
landfill, it is imperative that putrescible waste be
separated from the general mill waste. Separate
containers are provided for disposal of this waste
stream to ensure this waste is sent to the regional
landfill which is permitted as a Subtitle D facility.

2.4 Treatment, Disposal, & Recycling Facilities and Transporters
2.4.1 Treatment facility:
Wastewater Treatment System - NPDES permit
# NC0003191 - mill site
2.4.2 Disposal facilities:
Weyerhaeuser New Bern Landfill - permit # 25-02 - mill site
BFI Medical Waste Systems - medical waste incinerator
Haw River, NC [phone]
Coastal Regional Solid Waste Management Authority - landfill
permit # 25-04
2.4.3 Recycling facilities:
Noble Oil Services
Raleigh, NC
Goldsboro Iron and Metal
Goldsboro, NC [phone]
Tire Service
Battery Service
Weyerhaeuser Forest Products
Plymouth, NC [phone]
CMS Generation Operating Co.
Craven Wood Energy Plant - 201 Executive Pkwy.
New Bern, NC [phone]
2.4.4 Transporters:
Noble Oil Service
Raleigh, NC
Goldboro Iron and Metal
Goldsboro, NC [phone]
BFI - medical waste transporter
Rocky Mount, NC [phone]
Weyerhaeuser Company
Charles Blythe Equipment Co. Inc.
Hwy. 41 E. Trenton, NC (9190 448-9181

2.5 Landfill Status
Weyerhaeuser Company owns and operates a 30 acre landfill on the New
Bern Mill site. The landfill receives waste from the pulp mill operations
and the sawmill. The landfill has an undetermined capacity but
will be limited by state law requiring unlined landfills to cease
receiving waste by January 1, 1998. A reclassification of the landfill
as an industrial landfill allowed the mill to petition the state for a closure
variance. With that variance, the site will continue receiving waste until
2003 or a maximum of five years beyond the 1998 deadline; at that
time the landfill will be closed and a lined landfill will be required to be
put in service.
A second landfill consisting of two 10-acre lined cells is also on mill
property. The lined landfill, permitted by the Division of Environmental
Management in 1984, has not received waste to date. This landfill
continues to have annual inspections by the NC Water Quality Division.
3.0 Opportunity Analysis for key Solid. Waste Streams
3.1 Waste Collection
General mill waste is deposited in five cu. yd. lugger buckets throughout
the mill. The buckets are routinely picked up and carried by truck to the
landfill for disposal. Bulk hauls to the landfill are accomplished by mill
trucks with capacities of five, eight, ten, and twelve yards. The majority
of the waste is transported by dump trucks. The driver of each truck
maintains a record for each load hauled to the landfill. No separation of
general waste collected in lugger buckets occurs on -site or at the landfill.
To ensure putrescible waste generated from the canteen areas remains
separated from general mill waste, separate containers are provided. This
waste is taken by a contractor (ARS) to the regional landfill for disposal.
3.2 Waste Tracking
Waste transported to the New Bern Mill Landfill is tracked by the
Environmental Department. Truck counts and volumes are submitted to
the department by the truck drivers. This data is entered into an Excel
data base by the environmental engineer. For mill purposes the data is
used as volumetric and not as a weight measurement. The volume
transported is converted to a weight basis for state reporting purposes. An
assumed weight of 300 lb./cu. yd. is used for the calculation. A project

has been initiated to improve waste tracking developing average bulk
densities for each waste stream. The new data will be used in place of the
average density of municipal garbage to give a better representation of
waste generation.
3.3 Special wastes
Special wastes usually require special handling, disposal, or have
particular health or environmental concerns. North Carolina law has
identified several such wastes. These items and materials are banned from
landfill disposal. To ensure these wastes are handled properly, these
special wastes are removed from the general mill waste stream prior to
disposal.
Tires for mobile equipment are purchased from suppliers that take back
used tires for recycle or proper disposal. Used tires are returned to the
suppliers when new tires are purchased. Tow motor tires are not
considered tires by the solid waste rules and therefore are landfilled.
Lead acid batteries are purchased from suppliers that accept used batteries
equal to or greater than the number of batteries purchased. Because of
this waste reduction activity, it is necessary to store only a minimal
number of used batteries on -site.
Medical waste generated through the Safety Department is shipped semi-
annually to BFI for destruction by incineration. Although considered
nonregulated medical waste by the NC Solid Waste Regulations, sharps
and other medical wastes are shipped off -site for disposal. No manifests
are required for tracking this waste; but, all shipments are tracked by a
manifest system and records are maintained by the Medical Department.
White goods requiring disposal/recycling must have their CFC refrigerant
removed by certified HVAC technicians prior to transportation to the
metal reclaimer or landfill.
Used oil is collected on -site in totes for pick-up by Noble Oil Service for
recycling.
Putrescible waste is disposed off -site in the landfill operated by Coastal
Regional Solid Waste Management Authority to ensure putrescible waste
is not disposed with industrial waste in the mill's landfill..
Aluminum cans are collected in numerous receptacles throughout the
mill and removed by interested employees for recycle.

Hazardous wastes are shipped off -site to RCRA permitted treatment,
storage, or disposal facilities.
Liquid wastes must be dewatered or solidified to contain no free liquids as
defined by the paint filter liquids test Method 9095 prior to
transporting to the landfill.
3.4 Disposal and Storage
Groundwater monitoring wells are installed both up gradient and down
gradient. Wells LF-01 - LF04 are sampled semiannually with results
submitted to the NC Department of Environment, Health and Natural
Resources, Division of Solid Waste, Groundwater data is also entered
into GIS Key database. Surface water samples are collected both
upstream and downstream of the landfill.
Leachate from the landfill is collected in a surface ditch and directed to a
pump station located on the southeast end of the landfill, The collected
leachate, is pumped to the mill's wastewater treatment system.
3.5 Recycling and Marketing of Waste Streams
Several materials disposed of in the landfill are being considered as
potential raw materials for other facilities. The technical and economic
feasibility as well as potential liability associated with use of these
materials must be determined before the materials are offered as reusable
materials.
Primary clarifier sludge is generated as a result of wastewater treatment.
Mill effluent entering the wastewater treatment system contains varying
amounts of residual fiber and other organics and inorganic materials that
are settled and removed in the primary clarifier as sludge. This sludge
which contains over 75% fiber is landfilled on -site. The mill reduced the
fiber loss of 2,000 BDT in 1992 by 50% in 1993. To explore the
feasibility of marketing the residual fiber found in the primary clarifier
sludge, an exhaustive search of potential users of residual fiber from the
mill was conducted. Of the approximately 130 companies contacted, 16
requested samples, the remainder expressed no interest in the material.
Only two companies expressed interest following receipt of the samples.
Follow up has not produced a prospective user or market.
A potential lime mud user survey was also conducted. Eleven utilities
were contacted to see if there was interest in the lime mud. One company,
currently in a five year contract with a pebble lime supplier, would like to

explore the potential of using this slurry form of lime. Modification of
this potential user's process would be required to handle the material. If
costs are favorable, a potential user could be available in three years. An
additional project for lime reutilization will involve certifying the lime
material through the NCDA as a soil liming material. This project has the
potential to remove all the lime from the mill's waste stream.
Scrap metal is collected on -site by the mill. Goldsboro Iron and Metal
supplies trailers for the mill to store scrap metal until full. GI&M
transports the trailers to their site in Goldsboro, NC for
recycle/reclamation.
Used crankcase oil is generated by the garage during routine mobile
equipment maintenance. Gearbox oil used to lubricate large stationary
equipment, such as the pulp machine, must be disposed of once removed
from the machines. Used oils are consolidated into totes for pick up at the
mill by Noble Oil Service. The oil is transported to Noble Oil for storage
prior to recycling. Crankcase and gearbox oils are recycled at a rate of
approximately 4200 gals. per year.
Scrap tires are returned to the supplier at the time of purchase of new tires.
Lead -acid batteries are recycled through local suppliers.
CFC's are reclaimed by on -site portable recycling units by the mill's
HVAC technicians.
3.6 Regional Waste Management Opportunities
Although wood waste is not currently utilized by the mill as boiler fuel,
any future on -site combustion of wood waste would present an
opportunity for utilizing the ash produced as a soil amendment. Land
application of ash on company land would be an alternative to landfilling.
Land application has been developed for other areas in the region for ash,
making any future ash generation a good fit within the existing program.
Reuse of lime dregs as a component in brick manufacturing presents an
opportunity for potentially combining New Bern's dregs with those of
Plymouth for utilization by Nash Brick Company. Trials began in May
1997 in a joint project between Plymouth and Nash Brick. If the trials
prove successful and economically feasible, New Bern will have the
opportunity to participate in the same project.
Wood waste generated by the mill that is not acceptable for boiler fuel by
Craven Wood Energy is transported to Plymouth's Wood Products to be
hogged and transferred to Plymouth's Pulp, Paper and Packaging Sector
for use in their power boilers.

4.0 Criteria and Schedule for Prioritizing Wastes for Minimization
Proigcts
Based on information collected from truck counts, minimization priority
will be given to the waste streams contributing the largest volume to the
landfill. Weight will not be used as the primary a criterion as landfill
space is consumed based on volume rather than weight. Projects that can
be implemented without capital expenditures and still make a significant
contribution to waste reduction will be given a higher priority.
Scheduling of capital projects will be based on the mill's available capital
budget. Waste minimization activities will compete for capital dollars
along with production projects.
Key Waste Management Strategies:
Landfill closure
Primary sludge dewatering
Wood waste burned as Hog Fuel on -site
Primary sludge burning
Land application of boiler ash
Land application of lime mud
Project
Landfill closure
Primary sludge dewatering
Wood waste burned in hog
fuel boiler
Primary sludge burned in
hog fuel boiler
Land application of boiler
ash
Land application of lime
mud
Benefits
regulatory compliance
volume reduction
volume reduction
volume reduction
beneficial use
beneficial use
Estimated completion date
2003
2000
2001
2001
2002
1998

5.0 Ten -Year Implementation Plan
5.1 Mill Contact
The mill contact for the solid waste management program is Dave
Gardner, Environmental Manager for the New Bern Mill. Brad Chesson,
Environmental Engineer, has responsibility for solid waste records
including data entry, internal reporting, and Industrial Waste Landfill
Annual Reports. The Environmental Manager is responsible for the
landfill operations and compliance with the state rules governing landfills.

NC Annual LandfillReport
17

Solid Waste Yearly Monitoring Reports
for New Bern Mill
18

Waste
Quantity
Density
#
tons
Chips
500
560
280000
140
Demolition
315
800
252000
126
Dirt
605
2600
1573000
786.5
G. Trash
5064
300
1519200
759.6
Grit
8050
1080
8694000
4347
Knots
315
650
204750
102.375
Lime Grits
405
2190
886950
443.475
Lime Mud
69
2500
172500
86.25
Paper
101
300
30300
15.15
Pulp/rejects
546
500
273000
136.5
Sludge
21670
1685
36513950
18256.97
Wood residue
1495
875
1308125
654.0625
total1996
25853.88
Waste
Quantity
Density
#
tons
Chips
100
560
56000
28
Demolition
1284
800
1027200
513.6
Dirt
1550
2600
4030000
2015
G. Trash
5706
300
1711800
855.9
Grit
10133
1080
10943640
5471.82
Knots
440
650
286000
143
Lime Grits
1193
2190
2612670
1306,335
Lime Mud
53
2500
132500
66.25
Paper
499
300
149700
74.85
Pulp/rejects
874
500
437000
218.5
Sludge
22920
1685
38620200
19310.1
Wood residue
1635
875
1430625
715.3125
Total
30718.66
1995
Waste
Quantity
Density
#
tons
Chips
40
560
22400
11.2
Demolition
265
800
212000
106
Dirt
730
2600
1898000
949
G. Trash
5797
300
1739100
869.55
Grit
1060
1080
1144800
572.4
Knots
685
650
445250
222.625
Lime Grits
1338
2190
2930220
1465.11
Lime Mud
18611
2500
46527500
23263.75
Paper
363
300
108900
54.45
Pulp/rejects
1415
500
707500
353.75
Sludge
21400
1685
36059000
18029.5
Wood residue
4465
875
3906875
1953.437
total1994
47850.77

Waste
Quantity
Density
#
tons
Chips
300
560
168000
84
Demolition
810
800
648000
324
Dirt
170
2600
442000
221
G. Trash
14510
300
4353000
2176.5
Grit
1040
1080
1123200
561.6
Knots
1130
650
734500
367.25
Lime Grits
1170
2190
2562300
1281.15
Lime Mud
13870
2500
34675000
17337.5
Paper
540
300
162000
81
Pulp/rejects
6690
500
3345000
1672.5
Sludge
23850
1685
40187250
20093.62
Wood residue
5760
875
5040000
2520
total1993
46720.12
Waste
Quantity
Density
#
tons
Chips
1350
560
756000
378
Demolition
240
800
192000
96
Dirt
4820
2600
12532000
6266
G. Trash
7820
300
2346000
1173
Grit
1940
1080
2095200
1047.6
Knots
1950
650
12.67500
633.75
Lime Grits
2310
2190
5058900
2529.45
Lime Mud
5810
2500
14525000
7262.5
Paper
1060
300
318000
159
Pulp/rejects
1440
500
720000
360
Sludge
24210
1685
40793850
20396.92
Wood residue
4000
875
3500000
1750
total1992
42052.22
Waste
Quantity
Density
#
tons
Flyash
8864
750
6648000
3324
Demolition
10440
800
8352000
4176
Dirt
4820
2600
12532000
6266
G. Trash
9784
300
2935200
1467.6
Grit
736
1080
794880
397.44
Knots
1360
650
884000
442
Lime Grits
1280
2190
2803200
1401.6
Lime Mud
3488
2500
8720000
4360
Paper
1825
300
547500
273.75
Pulp/rejects
1440
500
720000
360
Sludge
43040
1685
72522400
36261.2
Wood residue
5920
875
5180000
2590
total1990
61319.59

Solid Waste Streams Comparisons
to Base Year99

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Paint filter Liquids
Method 909
20

PAINT FILTER LIQUIDS TEST
1.0 SCOPE AND APPLICATION
1.1 This method is used to determine the presence of free liquids in a representative
sample of waste.
1.2 The method is used to determine compliance with 40 CFR 264.314 and 265.314.
2.0 SUMMARY OF METHOD
2.1 A predetermined amount of material is placed in a paint filter. If any portion of
the material passes through and drops from the filter within the 5-min. test period, the
material is deemed to contain free liquids.
3.0 INTERFERENCES
3.1 Filter media were observed to separate from the filter cone on exposure to
alkaline materials. This development causes no problem if the sample is not disturbed.
4.0 APPARATUS AND MATERIALS
4.1 Conical paint filter: Mesh number 60 (fine meshed size). Available at local paint
stores such as Sherwin-Williams and Glidden for an approximate cost of $0.07 each.
4.2 Glass funnel: If the paint filter, with the waste, cannot sustain its weight on the
ring stand, then a fluted glass funnel or glass funnel with a mouth large enough to allow at
least 1 in. of the filter mesh to protrude should be used to support the filter. The funnel is
to be fluted or have a large open mouth I order to support the paint filter yet not interfere
with the movement, to the graduated cylinder, of the liquid that passes through the filter
mesh.
4.3 Ring stand and ring, or tripod.
4.4 Graduated cylinder or beaker: 100-ml.
5.0 REAGENTS
5.1 None.
9095-1
Revision 0
Date September 1986

6.0 SAMPLE COLLECTION, PRESERVATION, AND HANDLING
6.1 All samples must be collected according to the directions in Chapter Nine of this
manual.
6.2 A 100-ml or 100-g representative sample is required for the test. If it is not
possible to obtain a sample of 100-ml or 100-g that is sufficiently representative of the
waste, the analyst may use larger samples in multiples of 100 ml or 100 g, i.e. 200, 300,
400 ml or g. However, when larger samples are used, analysts shall divide the sample into
100-ml or 100-g portions and test each portion separately. If any portion contains free
liquids, the entire sample is considered to have free liquids.
7.0 PROCEDURE
7.1 Assemble test apparatus as shown in Figure 1.
7.2 place sample in the filter. A funnel may be used to provide support for the paint
filter.
7.3 Allow sample to drain for 5 min. into the graduated cylinder.
7.4 If any portion of the test material collects in the graduated cylinder in the 5-min.
period, then the material is deemed to contain free liquids for purposes of 40 CFR 264.314
and 265.314.
8.0 QUALITY CONTROL
8.1 Duplicate samples should be analyzed on a routine basis.
9.1 No data provided.
10.0 REFERENCES
10.1 None required.
9095-2
Revision 0
Date September 1986

Method 9095
Paint Filter Liquids Test
Yes
Material is deemed to
contain free liquids:
see 40 CFR 264.314 o
265.314
Stop
Revision - 0
-Date _September 1966
Kx 3 x