NC0000272_1999_Hardwood_Fiberline_Color

December 1, 1999 Report -Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFRTm
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
1.0 Introduction
This report evaluates Blue Ridge Paper Products Canton Mill's implementation of
partial Eo filtrate recycle on the hardwood fiberline and the potential for color
reduction with full BFRT-"4 implementation on the hardwood fiberline. This report is
submitted in accordance with the requirements of Part III, Paragraph E (11) of the
1997 modified Color Variance and NPDES Permit issued to Champion International
Corporation for its Canton Mill. The language of this paragraph provides that:
"The permittee shall begin implementation of that portion of
the BFR"11 technology which involves the recycling of the Eo
stage of the hardwood line by no later than January 1, 1999. The
permittee further shall provide an evaluation of that
implementation as well as the potential for full implementation of
the BFR'M technology on the mill's hardwood line to the Division
of Water Quality, the Technology Review Workgroup and the
NPDES Committee by December 1, 1999. The evaluation will
include data reflecting the color reduction benefit gained from
the partial implementation and a projection of potential color
reduction benefit to be gained from full implementation of the
BFR'technology on the hardwood line."
I

December 1, 1999 Report-Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFR"m
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
2.0 Review of Color Performance at the Canton MiH
The Canton Mi11's commitment to color reduction is illustrated in Figure 1. Since 1988,
color in the secondary effluent has been reduced by more than 89% (annual average). The
color reduction can be attributed to the Canton Modernization Project (CMP) and to
continuing mill-wide efforts to reduce color, including those detailed most recently in the
June 1, 1998 Color Technology Measures Report.
From January 1999 through August 1999, color in the secondary effluent averaged 40,791
pounds per day, well below the 60,000 pound limit specified in the NPDES Permit. For
the same period, as well as that period in 1998, monthly averages for true color at the
Hepco bridge were all below 50 standard color units (scu's) even at flows less than the
30Q2 which occurred in August 1998 and August 1999.
Using North Carolina's governing flow criteria (30Q2), historical flow records, and the
1999 January - August secondary effluent color discharge, it is expected that color in the
Pigeon River at the Hepco gage will be less than 50 scu's 100 %:of the applicable time.
Therefore, the Canton mill's actual color performance results in significant mitigation of
the occurrence and degree of color at the Hepco gage.
2

December 1, 1999 Report-Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full SFRTM
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
Figure 9:Canton.Mill Secondary Effluent Color Performance
Annual Averages.1998-1998
Monthly Averages:Jan 99-Sep 99
400000
350000
SE Color
300000 -95,000 Monthly limit-effective 1/1/98-11/31/98
a 60,000 Annual limit-effective 1211/98-present
V 250000 — —69,000 Monthly limit-effective 121/98- resent
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3.0 Hardwood Eo Recycle Evaluation
3.1 Project Description
All installation work for partial hardwood Eo.recycle was completed in mid-September
1998 for a total cost of $112,200. This project involved the installation of piping and
controls to pump Eo filtrate directly to the Decker Filtrate Tank for reuse in the process.
Prior to September 1998, Eo filtrate had been sewered and contributed to the Canton
NM's total color discharged to the Wastewater Treatment Plant. Figure 2 details the pre
and post-recycle filtrate flows.
3

December 1, 1999 Report - Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFRTM
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
Figure 2: Hardwood Eo Recycle Plan-Filtrate Flow Changes for Eo Recycle
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3.2 Canton Hardwood Eo Recycle Implementation Plan
The Hardwood Eo Recycle Implementation Plan was initiated in 1997. Projected impacts
on the hardwood fiberline as well as potential color savings from partial Eo recycle were
evaluated. Past filtrate recycling trials on the hardwood fiberline resulted in significant
washer scaling and corrosion problems. To minimize scaling and corrosion problems, and
evaluate their potential and rate of occurrence, a systematic approach to partial hardwood
Eo recycle was utilized. This systematic approach involved incrementally increasing the
recycle rate each month, beginning in October 1998. This approach also allowed the mill
to identify the optimum recycle rate for maximum color reduction.
4

December 1, 1999 Report - Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFR"
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
3.3 Net Color Reduction
Partial hardwood Eo recycle was instituted in mid-September 1998. Due to process
control issues, the Eo recycle flow varied more than expected. A reliable control system
was developed and implemented prior to January 1999 that allowed the recycle flow to be
set by the hardwood bleach plant operator. The average measured Eo recycle rate for
1999 was approximately 140 gpm with a net measured Eo filtrate color reduction of
approximately 1,940 lbs/day.
Recycle rates during this trial period ranged from 100 gpm to 200 gpm. Eo recycle rates
were increased/decreased incrementally each month in order to determine the optimum
recycle rate for Eo filtrate color reduction with minimum scaling and corrosion problems.
A recycle rate of 150 gpm resulted in the optimum net color reduction with minimal
impact thus far from carryover(increased carryover could result in increasing bleach plant
color thereby offsetting decreased color from Eo recycle). The mill will continue to
monitor the hardwood fiberline for scaling and corrosion problems that could result from
the recycle of Eo filtrate. The average net Eo filtrate color reduction was approximately
2,200 lbs/day during the months when the recycle rate was 150 gpm. At recycle rates
greater than 150 gpm, washing efficiency declined and the net Eo filtrate color increased.
In addition to the color reduction benefit, the pumping of Eo filtrate and pre-bleach filtrate
to the decker filtrate tank reduced the need for fresh water make-up in the decker tank by
approximately 225 gpm.
5

December 1, 1999 Report-Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFRTM
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
4.0 Potential for Full BFRTM on Hardwood Fiberline
4.1 Projected Color Reduction
Full implementation of BFRTM technology on the hardwood fiberline would involve D-100
stage filtrate being recycled to the brownstock washing and oxygen delignification
systems, similar to the pine fiberline.
The 1998 average color removal rate from recycling D-100 filtrate via BFRTM on the pine
fiberline was applied to the 1998 average D-100 filtrate color load to the mill sewer. A
potential primary influent color reduction of approximately 3,872 lbs/day could result from
installing the full BFRTM technology on the hardwood fiberline. Assumptions made to
achieve this color reduction include: I)The color removal rate for the hardwood fiberline
would be consistent with the color removal rate seen on the pine fiberline, 2)Carryover of
recycled material into the D2 stage and paper machines would be manageable, 3)Increased
chloride recycled would be managed by the CRP additions to the recovery cycle, and 4)No
operational problems would occur in the brownstock washing system_
4.2 Feasibility of Installing Full BFRTM on the Hardwood Fiberline
It has been estimated that full installation of BFRTM technology on the hardwood fiberline
would have a capital cost similar to the capital cost of $25,000,000 (± 25%) for
installation of BFRTM on the Pine fiberline (based on 1994 dollars). Capital cost includes
construction of another Metals Removal Process (MRP), additions to the existing
Chlorides Removal Process (CRP), various piping modifications, provisions for additional
6

December 1, 1999 Report-Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFRTM
Implementation on the Hardwood Line
BLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
white liquor oxidation and increased black liquor evaporation capacity. The increased
operational costs have not been included.
Implementation of the full BFRm technology on the hardwood fiberline is considered cost
prohibitive and is not warranted.
7

December 1, 1999 Report -Hardwood Fiberline Color Management:
Eo Recycle Evaluation and Potential for Full BFRTM
Implementation on the Hardwood Line
SLUE RIDGE PAPER PRODUCTS,INC.
CANTON,NC
5.0 Conclusion
The mill's January 1999 - August 1999 average secondary effluent color discharge of
40,791 lbs/day has been achieved through successful implementation of extensive color
reduction projects and measures detailed in the June 1, 1998 Color Technology Measures
Report, BFRTm on the pine fiberline and partial hardwood Eo Recycle.
Partial recycling of the Eo filtrate on the hardwood fiberline at the optimum rate resulted
in a color reduction of approximately 2,200 pounds per day. The Canton Mill will
continue partial hardwood Eo recycle and will continue to evaluate potential impacts to
the process.
This level of performance demonstrates the Canton mill's commitment toward brown
colored material management and fulfilling the requirements of the 1997 modified Color
Variance and NPDES Permit. The mill's commitment to continue partial hardwood Eo
recycle will result in additional color reduction and mitigation of the occurrence and
degree of color during periods of lowest river flow. Full BFRrm on the hardwood
fiberline, due to the potential for minimal color reductions, approximately 3,872 lbs/day,
and the excessive cost, estimated to be $25,000,000 in 1994 dollars, is considered cost
prohibitive and is not warranted.
This completes implementation of the technologies coIIectively referred to as the "Near-
Term Package." Full analysis of seasonal fluctuations in the "Near-Term Package"
process operations will be completed by June 1, 2000 and a report submitted by January 1,
2001 on the feasibility of achieving a color loading limit within the range of 48,000 -
52,000 pounds per day.
8

Community Advisory Committee
Larry Blazer
Superintendent of Schools
Cocke County Schools
305 Hedrick Drive
Newport, TN 37821
423/623-7821 (0)
423/625-3947 (F)
[e-mail].k 12.tn.us
Bradley Davis
Pigeon River Manager
USA Raft
P.O. Box 16
Hartford,TN 37753
[phone]
[phone]
[e-mail]
Diane Keys
Cocke County Tourism
360 East Main Street
Newport,TN 37821
423/625-9675 (0)
423/625-9677 (F)
[e-mail]
Roland Dykes
Mayor of Newport
P.O. Box 370
Newport,TN 37821
423/623-7323 (0)
423/623-7098 (F)
423/623-7180 (H)
[e-mail]
Terry Huskey
Vice-President,
General Manager Paper Division
Blue Ridge Paper /J —
P.O. Box 4000
Canton NC 28716 v
s
828/646-2840 (0)
828/646-2166 (F)

Alton Higgins
Union Representative
BIue Ridge Paper
P.O. Box 4000
Canton,NC 28716 ✓✓✓
828/646-2294 (0)
828/648-7599 (F)
[e-mail]
Jay Hinson
Executive Director
Economic Development Commission '�JAI e�j
100 Industrial Park Drive
Waynesville,NC 28786 04 r
828/456-3737 (0) A0
828/452-1352 (F)
[e-mail]
Jack Horton
Haywood County Manager
Court House Annex
Waynesville,NC 28786
8281452-6625 (0)
828/452-6715 (F)
[e-mail]
Jonathan Key
Publisher
The Enterprise Mountaineer
220 North Main Street
Waynesville,NC 28786
828/452-0661 ( )
8281452-0665 (FF)
[e-mail]
Charles Lewis Moore
YV
County Executive - Cocke County
360 Main Street East
Newport, TN 37821
423/623-8791 (0)
423/623-8792 (F)

Dave Popiel
Publisher
Newport Plain Talk
P.O. Box 279
Newport, TN 37822
423/623-6171 (0)
423/625-1995 (F)
[e-mail]
Pat Smathers
Mayor of Canton
2 Church Street
Canton,NC 28716
828/648-8240 (0)
828/648-3869 (F)
[e-mail]
Ray Snader
377 Graham Street
Newport, TN 37821
423/623/8743 (0)
423/623/0545 (F)
[e-mail]
Bill Upton
Superintendent of Schools
Haywood County Schools
1615 North Main Street
Waynesville,NC 28786
828/456-2400 (0)
828/456-2438 (F)
[e-mail]
Gay Webb
303 Wilton Springs Road
Newport,TN 37821
423/623-9777 (0)
423/623-3660 (F)
[e-mail]

I I
Bob Williams
Director EHS
Blue Ridge Paper
P.O. Box 4000
Canton,NC 28716
828/646-2033 (0)
828/646-6892(F)
[e-mail]
Dean Williams
Executive Director
Economic Development Commission
433 Prospect Avenue
Newport,TN 37821
423/623-3008 (0)
423/625-1846 (F)
[e-mail]
Patsy Williams
Chairperson, Cocke County
Tourism Council
P.O. Box 709
Newport, TN 37822
423/623-2855 (H)
423/623-2324 (0)
423/625-0356 (F)
manes(@,xtn.net
Tennessee Joint Watershed Committee Members
Tim Dockery
402 South Washington Avenue r
Newport, TN 37821
[phone] (0)
[phone] (F)
Jerry Wilde I
1330 North Highway 107
Newport,TN 37821
423/623.5131 (H)
"0
'-Ft4
no fax# available el—
Charles Lewis Moore
(see above)
kie
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