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Home My WebLink AboutNC0000272_EPA Perf. Track Site Visit_20061016 Blue Ridge Paper Products Inc. Canton Mill EPA National Environmental Performance Track Site Visit October 16, 2006 Name Organization `r HS I�OQ� `"'129�/l� li�.ywo�� k7�^�jrs I¢s6oc�si.c. T,us j(s A o FK LL ` I A 5 A[C 10 0- S 10/16/06 Page 1 of 3 Blue Ridge Paper Products Inc. Canton Mill EPA National Environmental Performance Track Site Visit October 16, 2006 Name Organization (k J ` T) N z — f1 Z W AS l 10/16/06 Page 2 of 3 EPA Performance Track Site Visit BLUE•RIDGi' Blue Ridge Paper Canton Mill, 16 Oct 2006 BL BL RI D � I Introductions and Performance National Track Overview /�Environmental Canton Mill Photo Tour PerformanceTrack U S.EmlmnrnentW"ecuon Agency Environmental Aspects Environmental Perfonnan� National Is Track Elements Environmental Canton Mill is a charter member of EPA Lunch&Discussion �1ftrxe7rack Performance Track(December 2000) EMS Details Future Commitments • Plan to renew with new commitments in BLUE RIDGE ApH12007 Wrap-Up&Feedback ru•xeovc+s rxc 'i'hc Ixwt-Lwkia tt;Pu}xer tlac. (:Aaratnla Mill eanPlo c have. ever Proda.a National llil; Environmental PerformanceTrack /S.Environmental Pratecdon Agency w— EPA Overview on Performance Track and purpose of site visit RI,Ur 21111:I Blue Ridge Paper Products Inc. BLUE RIDGE Canton Mill PAPER PRODUCTS INC. Established in to produce pulp for the Champion paperr mill mill in Hamilton,Ohio THE COMPANY-Formed in May 1999 when the • Many changes over 100 year history of site employees and KPS Special Situation Funds • Current configuration: purchased the Canton Division from Champion -Oxygen Delignification(OD100)and Bleach International Filtrate Recycle(BFR) 2000 employees -Elemental Chlorine Free(ECF)process DalryPak -3 Uncoated Paper Machines $500 MM/yr sales - I Paperboard Machine V-10 Qq A('w S ego c�/ rSe- QIP o r , �12 Blue Ridge Paper Products Inc. Blue Ridge Paper Products Canton Mill Products • Printing,writing,envelope and specialty papers • FDA good grade bleached paperboard for cup stock, food packaging and liquid packaging products DairyPak Division and Products • Extrusion coating mill in Waynesville,NC • 4 liquid packaging plants—GA,OH,VA&IA • 2 and 4 color flexo and off-set printing • Printed liquid packages for milk carton,juice carton and specialty food products Challenge BLUE RIDGE Canton Mill Photo Tour PAPER "°°°"""` Environmental Working hard to build focus a successful long-term National -Environmental business- Environmental Management System 1 Perforr�yceTrack•Remain competitive -Mill Process Overview -Environmental Aspects •Preserve secure, Performance Track -Performance living wage jobs helps achieve these -Community Involvement in Western NC goals •Continue environmental improvement BLUE"RI DIG E Pigeon River Below Clydc Environmental Management Environmental Management System (EMS) System (EMS) Plan for how the $ Key Elements (Performance Track Criteria) Canton Mill • Environmental Health and Safety Policy protects the • Significant environmental aspects environment • Performance measures and goals PLAN-DO- • Procedures,training and controls CHECK-ACT Audits PLAN-DO- • Management Review CHECK-ACT 2 Environmental Management Environmental, Health & System (EMS) Safety (EHS) Policy EMS is posted Obey the law on the Int aneBRPP D .DDmu Protect workers and the community � t• d====-� •EHS Policy is Prevent pollution t. "'""'"` on the • Continually improve company external web �_ Communicate site - BLUE RIDGE •t•DIODVCtt IIK EHS-Canton Mill Environmental Awareness and - Communication - Internal • Key performance indicators -daily,monthly,quarterly and annual Management and business reviews ^-�- x Annual supervisor's environmental awareness and update Annual environmental awareness computer ,__„,• ,__- based training (Canton Mill employees) EDvirwheentsl-9salaneimfiessionsls • New hire environmental and alachnlclans awareness training wanessidar-a saianad Dnnhassmnals BLUE RIDGE and 19 houd,cap...Wis •' Environmental Management CANTON MILL System (EMS) Review • Internal assessment-Oct 2005 • 3rd party multi-media compliance audit-Nov 2005 • Management reviews-Nov 2005, Mar 2006 and Sep 2006 • 3rd party EMS assessment(ANSI-RAB accredited assessor per Performance Track) NN - scheduled Jan 2007 BLUE RIDGE 3 Canton Mill Mill Tour — Basic Process Flow • 200 acre site surrounded by Town of Canton Pull, • Fully integrated paper mill with exception of CHIPS production LIME wood yard-we purchase chips 4 KILNS Process flow SCREENING i H12 aAi(¢LNew-N:NH.Na25 Ca('03 - Chip Pile B Screening DIGESTERS CAUSTIZING - Batch Digesters-iB w/liquor recirculation&direct steam injection i cme»eyr. - Hardwood&Pine Fibedines-washing and bleaching FIBERLINES BI-&Lai— RECOVERY - Paper and board machines wanhina —► EVAPORATORS - Warehouse and distribution FURNACES BleaIching - Chemical recovery cycle kil e- n and caustidang limited ♦ Chemical- Utilities-water plant,coal yard,power boilers,generators, Paper Recovery Cycle wastewater treatment and landfill PAPER MACHINES Production Canton Mill — Unique Features EMS Required Elements Bleach Filtrate Recycling(BFRTm)-only Kraft pulp and paper mill in the world with this process Significant Environmental Aspects - Pollution prevention technology for containing Kraft pulp color Activities that if not well managed can within the process and reducing wastewater load to treatment cause environmental harm, large cost or • Elemental chlorine free bleaching with OD100T0i liability process - Cument"state of art minimum environmental impact • Formal exercise to Identify,evaluate and rank technology for fine paper pulp production • Production and environmental personnel • High-rate activated sludge wastewater treatment involved - Many pulp and paper mills use lagoons • Periodically reviewed and updated BLUE RIDGE a...ca a<n i»< Canton Mill Significant Environmental Aspects Environmental Aspects Products Top Five from Aspects&Impacts Evaluation 1. Facility overall-resource consumption and Inputs efficiency Wastes 2. Wastewater permit-compliance 3. Airpermit-compliance 4. Environmental community issues _ 5. Solid and hazardous waste-compliance BLUE RIDGE 4 Environmental Aspects Canton Mill Photo Tour Hwd Fiberline-0D 100 TM-02 Delig,DI,Eo,D2 Products -Conventional Vacuum Washers Pine Fiberline-OD100 TM-02 Delig,DI,Eo,D2 Bleached Kraft pulp plus Bleach Filtrate Recycling(BFRTM) - - 1420 tons per day Compaction Battle Washers Paper and paperboard - 1620 tons per day Tall oil and turpentine BFR CONCEPT FLOWSHEET Canton Mill Photo Tour CNLORIOE REMOVAL PROCESS eta WATER WOOD PULP �. MMem REMovAL — 1 - _ No.11 d 12 PM-200 tpd each PROC@88 _ Ca 8 M9 No ZO PM-400 tpd Canton Mill Photo Tour Canton Mill Photo Tour No 19 Paper Board Machine- Warehousingand 0 F_j 'MA !j 1000 red Distribution •By truck and rail •Both domestic and export •Mix of on-site and off-site facilities near customers •2417 truck shuttle of paperboard to Depoly Plant to recover Waynesville extrusion coated broke 5 Environmental Aspects Environmental Aspects Inputs O A N E Inputs O T E " Wood Chips ® E we Wood Chips R G � Water Y s -5400 tons per day Energy CANTON MILL 30 to 40 rail cars Chemicals `'' 200 trucks La Environmental Aspects Environmental Aspects Inputs Inputs Water Energy Coal- 1100 tons per day Purchased electricity Pigeon River is source -640 MWH per day Large water fitter plant and related utilities Canton Mill Photo Tour Environmental Aspects Power Boiler& Generator Important point - Inputs Complex • Canton Mill uses large quantities of wood chips, water, energy and chemicals -Greatest direct cost of operations 4 Coal-fired boilers and 1 duel fuel coal 8 bark boll.,. 2040 —Greatest opportunity for both business and MMBtufhr max fuel input. 60 M W power generation capacity. environmental Improvement ESPs and low-NOx burners on at boilers. Wet scrubber on Bark Boiler. Power boilers fall under NOx SIP call for ozone season controls 6 Environmental Aspects Environmental Aspects Wastes W W IE H O A N E Wastewater ® jr E R Important point - Wastes R G � Air Emissions x a • Canton Mill wastewater,air emissions and solid CANTON waste must be in specification every day Solid Waste MILL_ • Violation of environmental permits can result in Stormwater shutdown of mill Environmental Aspects Environmental Aspects Wastes Wastes Wastewater Wastewater -25 million gallons Primary specifications: per day(mgd) from mill •Flow -Color - 1 mgd from Canton -pH Wastewater Permit -Oxygen demand specifies treatment •Suspended solids Heat Environmental Performance Blue Ridge Paper Canton Mill Environmental Aspects Wastewater Treatment Wastes Effluent quality is among the Air Emissions best of Kraft pulp and paper mills in the world(EKONO 2005) M 0 Air Permit specifies : Color performance is emission limits and excellent-Canton MITI is Controls recognized as an industry leader 7 Environmental Aspects Environmental Aspects Wastes Wastes Air Emissions Air Emissions Key emission limits: Key controls: -Opacity -Electrostatic precipitators -Sulfur dioxide(S02) -Wet scrubbers -Nitrogen oxides(NOx) Also limits on- •NCG and foul condensate -Particulate matter(PM) Type of fuel and fuel use collection -Total reduced sulfur(TRS) Hazardous air pollutants -Steam stripper and kilns Canton Mill Photo Tour Canton Mill Photo Tour CEMS-NOx MACTI - monitors on all power boilers NCGn are burned in kilns TRS monitors on Recovery Foul Sources condensates are steam stripped and burned in kilns m t.Room ® Generator ro Steam stripper and kiln and boiler Operdtors Environmental Aspects Environmental Aspects Wastes Wastes Solid Waste P^ Solid Waste Process waste Landfill Permit specifies requirements -Lime mud waste materials in the -Fly ash landfill -Wastewater Sludge Controls include Cost -Cinders •Landfill liner $74 per ton including hauling •Leachate collection 8 Environmental Aspects Environmental Aspects — Wastes Mills Sewers and Storm Drains Solid Waste Stormwater Permit-onlystormwatercan Non-process waste enter mill storm drains that discharge directly to -12.5 tons per day river Trash,metal,cardboard, •Chemicals,oils wood,office paper 8 -construction debris and waste materials •75%recycled in 2005 are prohibited •25%to White Oak Landfill Environmental Performance Performance Track Commitments Current term 2004 thru 2006 e..x.a.n ..a. • Performance Track 2004 Commitments • Ozone Season NOx Reductions �_ .. ". • Environmental KPIs • Beyond Compliance . • Benchmarking • Community Involvement Public Commitments made April 2004 Reduce NO.by 19%-annua1 NO.reducuon pelf..c is better dun goal Reduce depoly plastic burned by 75%-achieved I00%during 21105 Impmve hardwood chip yield by 0.5%-have improved but picked wrong metric Expand Pigeon River non-game reintroduction program to NC secu.of.i cr Ozone Season NOx Reduction from Performance - Environmental KPIs Power Boilers - 2003 base year thm 2006 aoe,m°a nnarl[l: j mow,. p.1-1 Canton Mill tracks environmental key .r«r ro eiw—. """"° "ienN. "•duc"°"- performance indicators(KPIs)on a daily twwne. a.w t° r«r ii p o.°".s...°" °"° w'""° basis for compliance: Emb.bn aNa IW I«1 t1.a NA Na 2a« 1.. rm e.2 w «x Boiler performance 1•awa 6.1 «1 «x • Recovery furnaceperforrnance 2. a.: a« ax ,., ax Wastewater performance Early reduction.also wntinuO annual benefit in non-ozone season • MACT compliance s°m rvox rreaha stet nra yee,e to panidty°n-aaf eeu.reauer,.oair°r • TRS and other permit parameters indtah,taw NOA Mene,e end SNCR • RWaling builerou+age as pan of 200fi ozone eearun NOa,eduniw 9 Performance—Environmental KPIs Performance— Beyond Compliance Canton Mill also tracks resource use and Management goals for key air and water efficiency key performance indicators indicators are significantly more stringent (KPIs)on a daily basis : than permit limits. Examples— • Water use • NCG venting • Energy use • Boiler opacity periods • Condensates return • Wastewater performance • Production • Condensates management • Fiber loss These goals are set annually and are formally reviewed on monthly and quarterly basis Performance—Beyond Compliance Continuous Improvement— Blue Ridge Paper Six Sigma Gain sharing program to reward continuous uses the six sigma improvement-includes metrics related to business resource efficiency and EHS performance. improvement process. Examples— Strength of Six Sigma Is DMAIC-Define, • Energy use—MMBtu/GT Paper Measum,Analyze, • Fiber loss—tons per day Implement and Control. • Employee safety—incident rate Process engineers and • Wastewater performance-color managers at the Canton Mill have received formal Six Sigma training and many have led teams. Performance— Beyond Compliance Project Name: Optimize NOx-2006 l'l38amII a¢lY[Y»W1xYYYntivuN0tivhYs�cne— YllbkeBPm.m LBw•tlQ••1Msw h Resource Efficiency Six Sigma Projects— • Fiber loss/wood yield «: ,.•„ .,.,N • Boiler efficiency/condensates collection — ��: �.. • Basis weight control yam; Environmental Six Sigma Projects— • Pulp mill process factors affecting wastewater �.....�.....m,_ .a»».,........e,.... performance - _.. ----------- —� • Boiler optimization for NOx .. • Title V implementation ..... �.�. '.; 10 Performance— Beyond Compliance Performance—Beyond Compliance Operating targets for foul condensates management— MACT L Phase 2 Equivalency by Permit(EBP) — Canton Mill significantly April 2007 startup—significantly is mere More over collects&over treats greater air emission reduction than Actual 27(s reyubad_ achieved at lower cost than perfarmanu MACT 1 Standard 2005 Condensates control by rule lose Ssa Methanol 40 CFR ra subpart S Demonstration Control by Rule ESP Project- Collected 11.1 Ibs/ODTP 24.1 Lbsl ODTP Item 40 CFR 63 subpart S SLOX RTO • Treated 102 It0sl ODTP 23.5 Lbsl ODTP Methanol 192 tpy -219 tpy TRS -17 tpy .23 tpy • Stripper downtime target<5%of operating hours and vocs •286 tpy -323 tpy scheduled for annual on a when production is one-half of normal,standard allows 10%downnme Capital Cost E 11.2 Million E 8.3 mllaon Benchmarking-Wastewater Flow(tao i asrs•) Performance — Benchmarking Beat 50%of NoM Amammn Integrates Wee Mills Canton Mill environmental data compared to ,, pulp and paper industry in North America 40 61.e wdga Palms Canton Mill I —' and Europe(EKONO 2005 Report) 64mvAapaper °^ —Water use efficiency is among best 50 percents of mills in North America eo _ —Wastewater effluent quality is among best 10 10 percent of mills in world l l l as - 0 —Hazardous air emissions are well below o 10 24 30 40 so m ro as so 100 E. CpnwlAiva P:etlunien.Y. applicable standards _Kor.11" 2004 Benchmarking-Wastewater Effluent AOX(2o 4 dais, Bes110%,of NoM Rmancan Integrated Kral Mills Environmental Performance el r , 'Cif0 `,dills ^m Is LCil4 k i,l l ii iul lllcii1, a> 131.Ridge Peas" "-'--'. ° ,; Ozone Season NOx Reductions CA anion Mig T .... asCorkg(AOTeP .Y_._;.....;..._;._!... Environmental KPIs q■, ,_.* • Beyond a'03 -- "' �- " Compliance oat as -L-. ,..,. , Community e w w m ae sa so % ea sa +m Involvement Can:4are hodualon•�. B,)IhmaM Bala murw-EKONO Inc.2004 11 Community Involvement Community & Watershed Support Community Informational Meetings Non-Game Species Re-introduction Project • Cocks Co, llyoac..tic for Pigeon River,managed by University of Tennessee(since 2001) Mill Tour Program commm,ily colleges-AB Tech and Maywood T«h • Actively promoted concept and brought key • Teaehera-Bravard college(Pisgah Forest lusdnde)and Mars Hai parties together in 2000&2001 Labor �r DreayI old timers • Participate in TN and NC steering committees Other mmrested groapa • Leverage financial and technical support with others Legislative Delegation/NC General Assembly Blue Ridge Paper updates Pigeon River Recovery Project Pigeon --=— River Non-game _..� BLUE RIDGE species re- introductions TN-2001we a NC-2004 j Managed by Univ.of Tenn. Rim�9y Dept of 1 Wildlife, a Forestry and Fisheries Community & Watershed Support Homeland Security/ EPA-RMP Haywood Waterways(long-term association) Haywood County Local Emergency Planning • Donate professional time as Technical advisors Committee(LEPC) • Participate in annual Kids in Creek program • Helped establish LEPC in early days of SARA, mill was charter member Stripped Shiners Project with NC Wildlife . Donate professional time to support LEPC operations and Haywood Co Schools(2006) Mal loss prevenron manager is LEPC Ate-thair Grow interest,awareness and involvement in • Mutual aid agreement with Haywood Co.Emergency Pigeon River Management for fire,rescue and haz mat response - Millis the primary hez met responder for Cowty - Routineyart exercises and marine emergency response with local fire depm userta and rescue squads 12 Blue Ridge Paper Produ�s Canton Mill Mill & Process Security • Robust Process Safety Management system • 24-hour on-site security • Video surveillance at key entry points • Fencing and gate access throughout majority of AV, perimeter ` Identify card access program • Full contractor safety program • Background checks on new hires • Close coordination with law enforcement Fmergemy Response Team • Product safety systems September 2006 State & National Involvement National Environmental Involvement Manufacturers and Chemical Industry Council of EPA Performance Track ! North Carolina(MCIC) Carolinas Air Pollution Control Association Promote continued environmental improvement and (CAPCA) performance beyond compliance through industry partnerships with regulatory agencies,communities National Council of Air and Stream Improvement and NGOs (NCSAI) EPA National Environmental Performance Track National / ErMronmental BLUE•RIDGE f�r, ,?e�r(wmnanceTradc 13 ATTACHMENT - I Blue Ridge Paper Products Inc. Environmental, Health and Safety Policy Canton Mill Endorsement BLUE RIDGE PAPER PRODUCTS INC. BLUE RIDGE PAPER PRODUCTS INC. Environment, Health and Safety (EH&S) Policy Blue Ridge Paper Products Inc. (Blue Ridge) is committed to protecting the environment and the health and safety of its employees, customers and the citizens of communities where the Company operates. Accordingly,Blue Ridge is committed to: ■ At a minimum, compliance with all applicable environment, health and safety (EH&S) laws and regulations, and to the principles and sound practices of sustainable forestry as well as to any voluntary commitments. The company will strive to achieve EMS performance beyond levels established by legal requirements whenever feasible ■ Reducing workplace accidents and injuries and otherwise preserving and protecting the health and safety of its employees • Reducing releases to air, water and land; pollution prevention; the efficient use of natural resources and energy conservation • Continual improvement of our environmental performance, including periodic review of progress towards established environmental objectives ■ Developing good working relationships with regulators and members of the communities in which we operate and engaging in ongoing, open communications with our stakeholders Blue Ridge Paper Products Inc. management is committed to effectively implementing this EMS Policy. Required resources shall be dedicated to its implementation. Related programs shall be evaluated periodically to ensure their suitability and effectiveness. All employees shall be held accountable for contributing to the Policy's implementation. This policy statement shall be communicated to all employees and shall be available to the public on request. If there are any questions, comments or improvement suggestions please contact the Blue Ridge Paper Products Corporate Director of Regulatory Affairs at (828)454-0687. Rich Lozyniak CEO Blue Ridge Paper Products Inc. Revised: September 22.2006 BLUE RIDGE PAPER PRODUCTS INC. Canton Mill Endorsement- Blue Ridge Paper Products EH&S Policy The Canton Mill endorses the Blue Ridge Paper Products Inc. Environment, Health and Safety (EH&S) Policy. The Canton Mill will strive to meet all applicable commitments set forth in the Corporate EH&S Policy. In addition to the commitments set forth in the Corporate EH&S Policy, the Canton Mill specifically commits to: • Reporting on Canton Mill environmental performance to employees and members of the communities in which we operate • Designing, implementing and maintaining an Environmental Management System (EMS) that provides a disciplined framework of procedures and programs within which we fulfill our environmental responsibilities and continually improve our performance It is our responsibility to support the Corporate EH&S Policy, the Canton Mill's EMS and related EH&S programs. We invite your comments, suggestions and questions. Robert M. Shanahan R. Derric Brown Vice President Director Manufacturing and Mill Management Environmental,Health and Safety Mill Management Team cjam4Hemey -- Andy sto poul4 �zhh Eddie Plemmons [ i. az Bumg er a in Briian, Rhodes 1. 'a.ld ay Clary f Dann J e Steve Rogers 41um Froehlich Robert u rd /jeriy Smathers Paul Geoghelraff Mark Patterson September 22,2006 ATTACHMENT - 2 Reference Materials • EHS Organization Chart • Basic Mill Process Flow • Wastewater Treatment Schematic Derdc Brown Director, Environmental, Health&Safety 828-646-2318 E H S — Canton Mill Ann Riddle Administrative Assistant 646-6700 Paul Dickens Donald Messer Manager, Manager, Environmental Affairs Health&Safety 646-6141 646-2331 Louie Justus Jim Giauque Fire Control Environmental Reporting Engineer Waste Compliance& Landfill Supervisor and 646-2372 646-2028 - Emergency Response 646-2491 Brenda Goodlake Matt Upton Environmental Compliance Technician Environmental Monitoring Engineer Medical Medical 646-2834 646-6814 646-2137 Glenn Rogers David=Greene Security Water Compliance Coordinator Environmen 646-2874 646-2109 Complian646 Michael e r Department Safety Representatives Air Compliancece Coordioordi nator/ Max Bradburn-646-2767 Phil Moore-646-2240 Supervisor Danny Burnette-646-2009 Larry Mills -646-2073 646-6855 Bill Chapman CEM Maintenance Technician Environmental - 9 salaried professionals 646-6873 and 4 technicians Leroy Hannah&Weldon Clinard Environmental Technicians Wastewater — 4 salaried professionals 646-2379 and 19 hourly operators Mill Tour — Basic Process Flow Pulp CHIPS production LIME KILNS SCREENING Ca(OH)2 i White Liquor — NaOH, Na2S CaCO3 DIGESTERS CAUSTIZING Green Liquor t FIBERLINES Black Liquor RECOVERY Washing ♦ EVAPORATORS --1000- FURNACES Bleaching Chemical Paper Recovery Cycle PAPER MACHINES production TOTAL INFLUENT = LOW LIFT + ACID SEWER RETURN ACTIVATED SLUDGE ACID SEWERI"' __—__—— 0 to 3 MGD 1 1 PRIMARY INFLUENT 1 EFFLUENT OUTFALL PRIMARY AERATION SECONDARY FLOW METER FINAL CLARIFIERS BASINS CLARIFIERS CASCADE AERATION EFFLUENT PRIMARY EFFLUENT DIFFUSER 29.9 MGD CANTON EFFLUENT WW 0.9 MGD 1 SECONDARY EFFLUENT LOW LIFT MILL GRRCHAMBER AEROBIC .....� SEWER BAR SCREENS .......... 1 ....... ........................ . DIGESTER(S) 26 to 29 MGD PUMPS.4 X 15 MGD WASTE SLUDGE 1 FILTRATE SLUDGE DEWATERING COMPLIANCE SAMPLE LOCATIONS 1 . LOW LIFT-TIME PACED ACID SEWER-TIME PACED DEWATERED SLUDGE FINAL EFFLUENT-FLOW PACED TO LANDFILL FINAL EFFLUENT-GRAB(pH,temp,cond,DO&fecal) PRIMARY CLARIFIERS AERATION BASINS/AEROBIC DIGESTERS SECONDARY CLARIFIERS 2- 200 FT DIA X 14.75 FT SWD 2-2.3 MGAL(ONE OR BOTH USED FOR AEROBIC DIGESTION) 2- 200 FT DIA X 12 FT SWD 3.47 MGAL,EACH 2-3.4 MGAL USED FOR ACTIVATED SLUDGE 2.82 MGAL,EACH 11.4 MGAL TOTAL AVAILABLE VOLUME 1-125 FT DIA X 11 FT SWD 1 -150 FT DIA X 14 FT SWD 1.01 MGAL 20 SURFACE AERATORS 1.85 MGAL SPARE CLARIFIER USED FOR SPILL COLLECTION 125/56 HP, 1.3 LBS 02 PER HP-HR SPARE CLARIFIER USED FOR SEASONAL USE RETURN SLUDGE 50 TO 100 WASTE SLUDGE 2 TO 5 TREATMENT CHEMICALS Primary Influent pH control-carbon dioxide Primary Effluent pH control-sulfuric acid Primary Settling-polymer as required ATTACHMENT IV-SIMPLIFIED WASTEWATER FLOW DIAGRAM Activated Sludge-supplemental ammonia and phosphate nutrients as required Sludge Dewatering-polymer Blue Ridge Paper Products,Inc. Effluent Aeration-oxygen Canton Mill Defoamer-as required in primary effluent and final effluent NPDES NC 0000272 5/22/06 DWQ Canton Mill Tour •Introductions •Mill Overview and Photo Tour •Permit Renewal •Van Tour •Questions BLUE RIDGE PAPER PRODUCTS INC. Pigeon River Below Clyde BLUE RIDGE PAPER PRODUCTS INC. DairyPak A DIVISION OF BLUE RIDGE PAPER PRODUCTS INC. I Blue Ridge Paper Products Inc. Canton Mill Established in 1908 to produce pulp for the Champion paper mill in Hamilton, Ohio • Many changes over 100 year history of site • Current configuration: — Oxygen Delignification (OD100) and Bleach Filtrate Recycle (BFR) — Elemental Chlorine Free (ECF) process — 3 Uncoated Paper Machines — 1 Paperboard Machine Blue Ridge Paper Products Inc. Canton Mill Products • Printing, writing, envelope and specialty papers • FDA good grade bleached paperboard for cup stock, food packaging and liquid packaging products DairyPak Division and Products • Extrusion coating mill in Waynesville, NC • 4 liquid packaging plants — GA, OH, VA & IA • 2 and 4 color flexo and off-set printing • Printed liquid packages for milk carton,juice carton and specialty food products 2 Blue Ridge Paper Products H! Sr F7oridas Mat Canton Mill Tour oo� c� Canton Mill Location J Canton Mill, 6U " RM 63.3 Pigeon River tributary to French Broad River Wev Frrk Lug RA Canton Mill Tour 175 acre site surrounded by Town of Canton • Process flow — Chip Pile & Screening — Batch Digesters— 18 w/liquor recirculation &direct steam injection — Hardwood&Pine Fiberlines—OD 100 and BFR — Paper and board machines — Warehouse and distribution — Chemical recovery cycle—kiln and causticizing limited — Utilities—water plant, coal yard, power boilers, generators, wastewater treatment and landfill Canton Mill Tour Digester Building Hardwood Blow Tower and Accumulator Hardwood Brownstock Washing Canton Mill Tour Hardwood Fiberline —OD100 TM - 02 Delig, D1, Eo, D2 — Conventional Vacuum Washers Pine Fiberline— OD100 TM - 02 Delig, D1, Eo, D2 plus Bleach Filtrate Recycling (BFRTM) - Compaction Baffle Washers BFR CONCEPT FLOWSHEET BLACK CHLORIDE LIQUOR RECOVERY ESP —)o- REMOVAL EVAPS BOILER �PROCESS CAUSTICRING IW�II � WATER WOOD COOKING/ I PULP WASHING/ OXYGEN SCREENING DELIG. D EO D MINERAL ...._ _ .. .. REMOVAL PROCESS G��otir.e.T:oK:a.e. Pine Fiberline Filtrate Recycling 0 000 kW TO DECKER I FILTRATE TANK T � C �A WATER WHITE- WATER *rNERAL EDP D2 REMOVAL TO PROCESS DECKER MINERALS TO BLEACHED SHOWERS PURGE—Divalent Cations HIGH DENSITY that scale washers STORAGE Canton Mill Tour ' Pine 02 Delig( � Bleachand -: Towers Pine Brown HD Storage Both Pine and Hwd fiberlines have extensive counter-current filtrate flow for water conservation and color prevention Both filberlines have filtrate collection sumps and storage to contain color materials for recovery Canton Mill Sump System Fiberlines gAgE ister(HWasher(HW) wnnkPine Blow Tower HardwoodI F—HV—VDBl.e.h—L HWPrimary BleachPI Spill Tank Scm Feed Tk Pine West Brownstock pnd Pre-% Feed Tank(Pn) Pine East Pine Brown Brownstock Spill Tank Pine Knotter Hardwood Sump BlowTower 7 Canton Mill Sewers Color, Conductivity, Flow and Fiber Loss Ovaewers "in 6rc i "Flows-CGlor-Fiber .Jxm- o saom rv.sw nu M11EI frwE e.N.YYY 119 PY FII RrivY ee•/ ENwY 9wc6 B O daG 160 tomibve CM � 6cYn Mrx a "$ GO S V I aY Iz F11Ymne 1.9 q W i E iC8 •iempneWx s rim m ex r'excG .0 PM E.,M. G Pwr,�rer. RNzs LM/IO I11 PNE r /\\ 6Y51{m.pl !8! TeneiWa ].5]tom �a x.oq aw. \\ \ MF ,No r `.1.. 6M91 C.O.YYF vX v CO O O O Roan zsez Yaax n..mrarl +meaur row. s6 n< xnmeo" >>�y xG0 P ver F av rNeY i99 Canton Mill Tour Recovery furnaces and Causticizing Lime kilns ESPs & scrubbers P Two recovery furnaces Recovery area has extensive spill containment and storage system to contain color materials for recovery 8 Canton Mill Sump System -Recovery East Heavy uquo EWp.Wash #10 Recovery Wafer Tenk Baller pt1 Recovery Boller Baca Liquor WaB Foul Ewporebrc Condensate Swenson Foul Condensab E.P.Boll out Ewporabr Boll Sump Out Tank Ewoorsbr Tank Farm Ewporebr 'U'Nor10 Ewporabr 'U'Saufa sewer Vwm 6frlppe.Sump Q`LIWr/Wm sewer WM Camp Branca Werabr Alarm Tank Fenn Neery Bleck TeII OiI Save NI Tell ql IJquor Tank Compountl Canton Mill Tour oils �I, li 5fs rA., No. 11 & 12 PM 11 No. 20 PM y Canton Mill Tour No 19 Paper Board Machine Depoly Plant to recover extrusion coated broke Canton Mill Tour Power Boiler & I - Generator x Complex _ 5 We 4 Coal-fired boilers and 1 dual fuel coal & bark boiler ESPs and low-NOx burners on coal boilers io Canton Mill Tour " t. h Water plant, cooling � towers, coal yard, bark boiler and pine Hwd Bleached HD storage Cooling towers recycle water Canton Mill Tour Activated sludge wastewater plant with excellent BOD performance *Permitted wastewater treatment capacity of 29.9 mgd -Effluent Standards — 40 CFR 430, Subpart B - Bleached Papergrade Kraft and Soda (aka Cluster Rule) *Mill wastewater plant also serves Town of Canton •Offline Clarifier Used As A Contingency II TOTAL INFLUENT = LOW LIFT + ACID SEWER RETURN ACTIVATED SLUDGE ACID SEWER r_____________________i 0 to 3 MGD I PRIMARYINFLUENT EFFLUENT OUTFACE PRIMARY AERATION SECONDARY FLOW METER FINAL CLARIFIERS BASINS CLARIFIERS CASCADE AERATION EFFLUENT PRIMARY EFFLUENT DIFFUSER 29.9 MGD CANTON EFFLUENT WW 0.9 MGD I SECONDARY EFFLUENT LOW LIFT � MILL GRTTCHAMeER AEROBIC SEWER BAR SCREENS .......... I ............................... .....r DIGESTER(S) 26 to 29 MGD PUMPS-4X 15 MGD WASTE SLUDGE I FILTRATE SLUDGE UEWATERING I DEWATERED SLUDGE TO LANDFILL PRIMARY CLARIFIERS AERATION BASINS/AEROBIC DIGESTERS SECONDARY CLARIFIERS 2- 200 FT DIA X 14.75 FT SWD 2-2.3 MGAL(ONE OR BOTH USED FOR AEROBIC DIGESTION) 2- 200 FT DIA X 12 FT SWD 3.47 MGAL,EACH 2-3.4 MGAL USED FOR ACTIVATED SLUDGE 2.82 MGAL,EACH 11.4 MGAL TOTAL AVAILABLE VOLUME 1 -125FFDIAX11 FTSWD 1-15OFTDIAXI4FTSWD 1.01 MGAL 20 SURFACE AERATORS 1.85 MGAL SPARE CLARIFIER USED FOR SPILL COLLECTION 125/56 HP, 1.3 LBS 02 PER HP-HR SPARE CLARIFIER USED FOR SEASONAL USE RETURN SLUDGE SO TO 100 WASTE SLUDGE 2 TO 5 TREATMENT CHEMICALS Primary Influent pH control.carbon dioxide Primary Effluent pH control-sulfuric acid Primary Settling-polymer as required ATTACHMENT IV-SIMPLIFIED WASTEWATER FLOW DIAGRAM Activated Sludge-supplemental ammonia and phosphate nutrients as required Sludge Dewatering-polymer Blue Ridge Paper Products, Inc. Effluent Aeration-oxygen Canton Mill Defoamer-as required in primary effluent and final effluent NPDES INC 0000272 M MiAP..,M�.�._ -------------------- � a 6LMYES G.E® ,,.�,.aw..E,ME��E �sWiq ATTACHMENT IV-SIMPLIFIEO WASTEWATER FLOW DIAGRAM mM.a.gsia.f ammampvgvetiae..rymef 9rM0auYg-[Wv 01�PLL}FRRe1u[O.Irc. OMome-nroybPonWm[i.4vosM HppEdllCOpN$T$ Wastewater Treatment Performance Blue Ridge Paper Canton Mill > Effluent quality is among the best of Kraft pulp and paper mills in the world(EKONO 2005) > Color performance is excellent > Effluent AOX and bleach plant chloroform are all less than 20% of Cluster Rule limits U Chlorophenols and Dioxin in bleach plant effluents are all non- detect Effluent toxicity passes at 90 to 100% effluent concentration Effluent Color Management Blue Ridge Paper Canton Mill • Mill Commitment To Excellent Color Performance - 2001 permit includes color reduction tiers - 48k lbs/day in 2001 -) 40 to 42k lbs/day by 2004 4 32 to 39k lbs/day by 2006 • Pollution Prevention approach to achieve color limits - Bleach Filtrate Recycling TM - Water conservation and reuse - Tight mill operations - Spill collection and recovery facilities - BMP program focus on color Effluent Color Performance 1988 -2006 Figure 2 - Annual Average Effluent Color Blue Ridge Paper Canton Mill, 1988 thru Mar 2006 m 400 380 __ - 333 301 307 300 z4s _- `0 200 o i2o f.1 100 76 76 89 62 43 4T W9 4 ¢5 -JO 3e 3e 0 ,Q ti Greater than 90 percent reduction in effluent color since 1988. Color reductions have continued during current permit term. 13 Figure 1 - Color Reduction Initiatives Under 2001 NPDES Permit, Blue Ridge Paper Products Inc. - Canton Mill Color Reduction Initiative/Project 2002 2004 2006 Cost$ 1 2-Hour color testing,frequency .........._.................................... ......._...__..........._........................_._.................................._..._.._...................._...._.......................................................... ..... .....__.._ . ................_.._.............._..._.._........_.._._...__..........._................ 2 Liebetott.Recommendations Implemented (2001.BEPER.Report) incl in#8 ...._............_...... ......_.........................................................._..__...__._........._......_...........- --._...___......_.... _ 3 Use of Off Ime Clarifier for Spill Diversion ......... ..............._.................._._ ......... ._...... . . . ._.._...—.___....___---'--...................................................................._.. ...._.__................_ ..._...._...._._...._.... _..._._.........._.._....... 6.6......_�—....... ... Hw Brown Recovery,Tank Line to Pine Blow,Tower 135,000 ......... .___. ... ......................_. . .............. . ..._............. __...._.................._.. .............................. .. ..._..........................._...__—..._............ .._..__._................ ........................._.... ...............135,......... 5 I Hour color testin fre uene dorm maintenance outa es - ----- ..............._..............................8.._.....9..........Y......._......g............_.._......_...................P_......................................................._....................._.......................................... ............................._ ............._..._ ........................_...._................................. G Installation of Mechanical Seals(clean water segregation).........................._....................._................_......._.............................................................................. ......................_''�azn +twua ' 180,000 .............................................._....................._......._........... .................. ..... ............._...._........__..... ..-.................................................._.......... 7 Im rovement of a ui ment used for handlin Pine and Hardwood Kno[Re'ects ��-- °-..v.wwaurt�, 125,500 .._.._.............................a....I............................_......................... ...................................................._.... _...._._.1.................................................................................................................. ....................................................._........._..........................-.............._............................. ................_......_........ 8 Bleach.Filtrate,Recycle.Improvements.._..........................................__.............------._...................._....._.................................._......_._.......-..... .........................................................:.........:otwavta.�aem zit .....,;.,fry..�..._..__............................ 1,550,000 9 Installed Ftberlme control logic improvements isx t'z 1,080,000 ....... .. ......... ....... ........_.._........___........................ ............. ............ ..... ...._....... ...................... . .................. •....................................... ........................:......0 10 Determined multiple contributors and.interaction effects causing Sewer.Generated.Color .: tsrrua o, y,�; .. ......._......... ._...... . . ............---.. enc sc a sewervgenerated color work 5 000 12 HardwoodFiberline Six,Sigma,Team,forprocess.optimization,and color improvements......._.............................................._...._._.................. ,,,,, ......._-,,,,,,--_..,..,,,,,,-_..108,000 ............... 13 Improvements made........................................................to Pine Brownstock sumps for better recovery 200 800 .. ....... .............. __................_...... .......... ...... ............ ... ..............................................................................._............. 14 White Rot Fungus,Trial,(See note.below)* 30,000................................_.... ............._.........._......_..—._._...................................................._.._.........................................................................._......_......_.._..._......................................................................................................................................................___.0 15 C1O2/_Ozone Bleaching.of.CRP,wastes[ream(See note below)* 15,000 ........... .. _ ....................._... ............_._l_...._..__._...................................._.............._.........................................._..............._......._. ...._...-____.._.................._._._........................................_..................................._. ............_.............___. 16 Ozone/C1O2(ZD)Stage,for Hardwood bleach.line -lab study,(See note below)* 30,000 17 2nd Stage.O2.delignification on.Pine. lab,study(See note below)* incl in# 15 18 Ozone Bleaching of effluents:tab pilotstudies(See note below)* 35,000 ......._........_..._............ ........................................._..........__...............................__....._._._....._.._............................................................................................._.._................................. ..............................._.. ..........................................................._....... 19 Pine Brown Recovery Tank,Line to.Hwd,Blow Tower _ incl. in#13 ___........_......__..____...... ....... .................................-----.................._____.._.........__..._...._................................................................................_....................... ....... ... . . ..........................................._.............................__... 20 Milk of Lime Trial(See note below)* ��"" "' 25,000 ......................._.._._........._......................................._..........._.._...._................................__...................._.._......._._......................._.__.................._.... _................. ............................................. ................................... ...........-".._.._........................_.................................................. ..........._...................... 21 Land Application,of CRP wastestream(See note below)* _................ ..........._............._._........_....___....--'-'--.__..._........._........................._._...................................._................................................ .........................._........._._...._..............................-----.._.._....................._..._........................................................_............._ 22 Commercial Incineration of CRP waste stream(See note below)* _......................................................................................_-.___._._._........................._...................._._..._._..................................................................................................................._............................................................................._............._.... ................._...................................._........... 23 Coapulation/Precipitation,of,CRP wastestream(See note below)* 12,000 ........................._....-"--"-............................_........_......................___..._....._............................................................................................ ......................_........... ...........I--.._......_................................ ................_._..........................................._... 24 Solidification for Land,Disposal of.CRP wastestream(See note below)* ._.._..-----.._...._............ ..........._.._........_........_..................................._....._._.._...._.._.._.._.__...._...... ...........................................__.................................---.....__. ........................ ......_......_............._........................................................... .'..__.... 25 Pine and Hardwood gyat !pary.Screen.Re ec[s.Press 151,000 ..................._......._........... ......... .. ............._ ................. ......._..__...................................._..._.._._.._ .. .............................................................................4...._._...._._._. 26 Catalytic peroxide,treatment.of Eo stream.(See note below)* 15,000 27 Trial to confirm and size system for 002 de-colorization of CRP/evaluate full-scale application(trials wmpleted.after.Sep 04 floods,see note below)* 60,000..................................._.._........... ................._...._...._............_...__.............._..............................................._......................................................__._....................._...__............................................................ ............................._......................................._..................._...._..0 28 Peroxide Trials on Hardwood Eo(See note below)* 30,000 ................................_............................................................................._............................................................._.............................................__._..... ........._. ......... . _ ....................__.. ................................_...............................__.............................._... ................................................. ........... 29 Green Liquor,Sump.ar recovery furnaces 100 000 30 CRP on Lime Precoat Filter See note below)* """""' ..............................i'a"I.......................................__............................._............................................................._..........__............._.._........................................................................................ ._.................................._.._....................... ......._.__'__................._..._....................... ................_...........00' 31 Peroxide Trials on Pine Eo(See note below)* � 15 000 32 Acid Sewer Rerouting L535,000 .............................................. n ......_........................................_................................................._...._......_. 33 Pall Filtration(See note below)* 15,000 34 Color Process Improvement Six Sigma Team to examine operating conditions associated 1*1 with ood color rformance . ........_g........_..._-_....... .._.._......................................................................................_..................._—....—......_._......_.__......................_..._...................._..-- -._..—__....... ......_...._.._..........._..........___.....---__.....__........_......................_....................._. ...................._........... Color Reliablity Projects-process and monitoring focus to reduce variablity of color 35 performance 446,000 Completed Process Change/Evaluation Process Evaluation or Change \\\MMO Total $ 5,898,300 Continued Performance Improvement Expected Performance Improvement - -- *Intitiative determined not to be technically,operationally, or economically feasible P'1Soa1.CWavemdlm ueu.MxI)FNBr P001 nines PYrmY,RNr Mdge Paprr Preaueh -CSnrwA SMI1 300E 2W SN( COrtf I Hweeb.rt..W B°RwY Y .ax..�a..v.w.aw 14Mgm Bcavuntlmw�N(3MI BFPPA Rryen d � • aN bv¢e4eonq irtlae Px BM iewn nnnna `ape 13JAtl S 18vveµckpy8equxPivgwi ,e euyn I a� .. 6 dWhm[dSUL(baave¢pyW� IA�OW t deq psmd&eYwi_�iMnd8e4aed Kwt ReFd 3R5 8 FHtrIHeRnk _. —... ....__...... .. ..... 10 oMpkvv68va�atlr¢4eraeae�sySaaa Qeetivd Cvbr ___._ „ _.__._ -... sl c_m'R�ldeahM J.W I] FY_sYe 3¢ it e�vuaaR Pea HmwvMvap faNtrm^vvf __.. ._... 300.1 ._.. _... 30.W ,s r __... __ ia:'ooi IS Oa[s/VJ3 WHVMx<WFeSY W .. .. . n Imaeoldrlea[rmmeke u-r91 .wwX .... _- _ _. .aoi li 0 Oxsavv[Y�P.RArY Ib PL1.Yyv$v v.4J°.. ...... __. __ _ j�µ� 9 BmnAso„y Sat Lu 4¢dL¢i I aripol A dime ed(9 GbX ._— ... Y� ISBN 33 Caa®redle®runlgp _[Sp ssObL' .. . SJ rd WNwoe.QlvemYSu®Pe3rw Aar ................._..... _ vyNParovee eemuwefb ma®16'ee.u¢dwj. ........._.... . T p[mfiumd m¢9�k¢Fx QJta.[xvrdCRP.FWM86aW mm(m6[wVleud tiv H4Meei4[a.r wr .. � . A Treb on HudwoodEa{Sa, 6-MJ. A �Lqu�SWga au�Hv® W CBP mime PeewuF — I;OD? A lNSemHerewy - ---- ! 5350W ^ a Axwi6pevmae5¢gey'ieen®mevq[wJsw emmC 35 ReitlYSRoMm�-Ov°doMmylavpnlrtrvaldYS a(roler ... -. <mpkud Rvcva Cmvpel Evdmav ! Rxea HVOwmxC1¢8e. NOW I"slB _ommee PnFwmai.elmrwemen F.pe[uf PeTmm[elq{aawr 'IVMiNve Eda�®�N nM to be lnlade.e0y.opee4ampy,maonmiiv'rR'fiN Color at Fiberville (Just Below Mill) 1997 - 2006 Figure 5-Monthly Average True Color In the Pigeon River M Fiberville January 1997 Mrough Mareh 2005 zxs Poo ns IN j 125 s` V 1W 2 s so Ps 0 p ? & $ gb $ ga � E � ayb ; YY & ; < � k � a § & gYYEaa � & � Monthly average color at Fiberville last three years = 31 color units. Elevated color corresponds to periods of low stream flow. 14 Pigeon River at Fiberville, RM 63 —May 2006 Pigeon River Above Clyde, RM 58 — May 2006 Pigeon River Below Richland Cr, RM 52 —May 2006 Below • RM 482006 a_. Color at HEPCO (20.3 Miles Down Stream) 1988 - 2006 Figure 6-Morghty Average True Color In the Pigeon Rlver M Hepco January 1988 through March 26g6 am se ew 27e aso 200 tte � >$ 1 U 15 13e W R L M a Monthly average color at HEPCO last five years = 24 color units. HEPCO / Start of Waterville Lake, RM 43 — May 2006 Color at TN / NC Line 1998 - 2006 Figure]-Monthly Average True Color In the Pigeon River at the North Carolina/Tennessee Luce January 1999 through March 2996 22s 200 +m — +w U 2 1s so u a . gma $ "gi $ 'g § ? $ ; £ 'g `s8 "sg" "s $ $ 6 Monthly avg color at NC/TN Line last five years = 17 color units. All color measurements at NC/TN line during current permit term are less than 35 color units. Near TN / NC Line, RM 25 —May 2006 Pigeon River at Newport, RM 5 -May 2006 Flood Impacts and Recovery Canton Mill Wastewater Plant September 2004 Floods • Back-to-back historic floods - Frances 9/8/04 & Ivan 9/17/04 — overtopped mill dikes and flooded the wastewater plant • Restored secondary treatment within 4 days of Frances and within 5 days of Ivan • Restored full wastewater lab within 90 days 19 Flood Projects Blue Ridge Paper Products Canton Mill Flood Strengthening • Raised critical electrical supply and control systems at wastewater plant to above elevation of Sep 2004 floods — New DCS control system at WTP • Emergency generator and flood wall for low lift pumps keep mill and critical systems at wastewater plant dry in event of mill power failure (under construction May 2006) • Focus is on protection of critical systems to minimize damage and expedite future flood recovery 2006 NPDES Permitting - Canton Mill Due to DWQ by 5/31/06: • Signed Permit Application, EPA Forms 1 &2C — A letter will accompany the application requesting changes to monitoring frequency for effluent AOX and for bleach plant effluent chloroform, chlorophenols and dioxin • Color Compliance Report[Part I, Condition A.(8.) Paragraph 10 of 2001 Permit] • 316a Thermal Variance Report [Part I, Condition A.(13). Of 2001 Permit] — 2005 Biological Assessment Report — 2005 Thermal Modeling Report 20 2006 NPDES Permitting — Canton Mill Steps towards re-issued permit with effective date of December 2006 • 5/31/06 Permit Application and Reports • Technology Review Workgroup (TRW) review of Color Compliance Report and concurrence with 39,000 lb/day effluent limit • Coordination of request to end Color Variance for Canton Mill with NPDES Committee and NC Triennial Review 2006 NPDES Permitting — Canton Mill Steps towards re-issued permit, continued • Preliminary draft permit to Blue Ridge Paper and interested parties — TDEC Water Pollution Control — EPA Region IV — Cocke County Community, TN • Draft permit and public hearing notice • Public hearing • Nov 2006 - Final draft permit 21 Van Tour of Canton Mill Personal Protective EcLuinment • Ear Plugs • Hard Hat • Safety Shoes • Safety Glasses • Escape Respirator Stay with Tour Leader when we stop When do you need to leave for home ? 22