NC0000272_1998 Color Tech Measures Report_19980601

Canton Mill
Box C-10
Canton.North Carolina 28716
UChampion
Champion International Corporation
May 27, 1998
�iqy� Od
Mr. Forrest Westall Asti�9rFq 9
NC Department of ��FgGOIi 0
Environment and Natural Resources FpoN rFC
Division of Water Quality a�oFoy
59 Woodfm Place cF
Asheville,NC 28801
RE: NPDES Permit Modification - Permit No. NC0000272
Dear Mr. Westall:
In accordance with the above referenced permit, we are forwarding herewith the report to
meet the requirements of Part III-E, Paragraphs 7, 8 and 9. Included with this is a
progress report on Champion's Bleach Filtrate Recycling (BFRTm) technology
demonstration.
If you have any questions regarding this submittal, please contact me at(828)646-2033.
Sincerely, _
Robert V. Williams
Manager
Environmental, Occupational Health& Safety
Enclosure
xc: EPA Technology Review Workgroup (Please see attached list)
data\bobw\n pdes\mod it\west598

1998 COLOR TECHNOLOGY MEASURES REPORT
PREPARED FOR
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA
AND
TECHNOLOGY REVIEW WORKGROUP
■
Champion
Champion International Corporation
MAIN STREET
CANTON, NC 28716
JUNE 1 , 1998

1998 COLOR TECHNOLOGY MEASURES REPORT
PREPARED FOR
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA
AND
TECHNOLOGY REVIEW WORKGROUP
■
Champion
Champion International Corporation
MAIN STREET
CANTON, NC 28716
JUNE 1 , 1998

Table of Contents
Executive Summary i
1.0 Introduction I
1.1 Purpose 1
1.2 Historical Background 2
2.0 1997 NPDES Permit Part III, Paragraph E 8 Requirements - 5
June 1, 1998 Report Submittal
3.0 1997 NPDES Permit Part III,Paragraph E 9 Requirements - 6
BMPs
3.1 Part III, Paragraph E 9-Best Management Practices(BMP) Required Projects 6
3.2 General Discussion 6
3.3 Replacement of Digester Recirculation Pumps 6
3.4 Double-Chambered Pine Courtyard Spill Collection Sump 7
3.4.1 Project Description 7
3.4.2 Project Justification 9
3.5 Weak Black Liquor Tank Containment Project 9
3.6 Additional Operational Measures 11
3.6.1 Correction of Evaporator Demister Set Clogging 11
3.6.2 Installation of Condensate Instrumentation and Sampling Ports for 12
Evaporator Set
3.6.3 Assurance of Continued Dry Conveying of Knot Rejects 12
4.01997 NPDES Permit Part 111,Paragraph E 7 Requirements - 14
Additional Color Reduction Measures
4.1 Part III,Paragraph E 7-Additional Color Reduction Measures 14
4.2 General Discussion 14
4.3 Further Upgrading and Integrating of Sewer Monitoring 16
4.3.1 Sewered Condensates 16
4.3.2 Chloride Removal Process (CRP) 17
4.3.3 Pine Bleach Plant Automatic Flow Meters 18

4.4 Automated Mill Process Control Systems ... 19
Is 4.4.1 Electrical and Instrumentation (E&I) 19
4.4.2 Fiberline Spill Tank Level Management Plan 20
4.5 Continued Operator Training 22
4.5.1 Pulp Mill 22
a) Operator Skills Training(OST)Program 22
b) On-the-Job Training(OJT)Program 23
4.5.2 Recovery 25
a) Operator Skills Training(OSI) Program 25
b) On-the-Job Training(OJT) Program 25
4.6 Additional Controls for Unmeasured Sources of Liquor Losses 27
4.6.1 Hardwood Secondary Knotter Accepts Tank Overflow 27
4.6.2 Miscellaneous Field Work 28
4.7 Diverting Clean Water Discharges 29
4.7.1 Digester Area Project 29
4.7.2 Oxidation Blower Coolers Project 29
4.8 Capturing&Recycling Liquors During Fiberline Disruptions 30
4.8.1 Detailed Scheduling of Planned Outages 30
4.8.2 Contingency Planning for Unplanned Outages 32
4.9 Primary Influent Turbidity Interference Study 33
4.10 Sewer Generated Color 35
4.10.1 General Discussion 35
4.10.2 Previous Research&Findings 36
4.10.3 Research Plan for 1998 37
5.0 Bleached Filtrate Recycling(BFRTm) Process on Pine Fiberline 39
6.0 Conclusion 41

LIST OF APPENDICES
Appendix A: Pine-Courtyard Spill Collection Sump
Appendix A-1: Engineering Drawing
Appendix A-2: NPDES Permit Modification Letter
Appendix B: Weak Black Liquor Containment Engineering Drawing
Appendix C: E &I Critical Equipment PM Plan
Appendix D: Pulp Mill Training
Appendix D-1: OST Manual Summary
Appendix D-2: OJT Training Session
Appendix E: Recovery Operations Training
Appendix E-1: OST Manual Summary
Appendix E-2: OJT Training Session
Appendix F: NCASI Turbidity Study Document
Appendix G: Sewer Generated Color 1998 Study Plan
Appendix H: Bleached Filtrate Recycling (BFRTm) Process
Appendix H-1: "Initial Leamings from the BFR Demonstration'
Appendix H-2: "Progress Report on the BFRTm Technology Demo: Dec 1996"
t

t
June 1, 1998 NPDES Report
1.0 Introduction
1.1 Purpose
This report on in-mill color reduction measures at Champion International
Corporation's Canton, North Carolina integrated pulp and paper mill is submitted in
accordance with the requirements of Part III, Section E, Paragraph 7, 8 and 9 of the
mill's 1997 NPDES Permit (the 1997 Permit). Following a brief historical background of
the 1997 modification of the NPDES permit and associated Color Variance, Sections 2.0,
3.0 and 4.0 of this report cover the specific requirements listed in Part III, Section E,
Paragraphs 7, 8 and 9 of the 1997 Permit. All four Best Management Practices (BMP)
projects required by Paragraph 9 of the 1997 Permit have been completed and are
discussed in Section 3.0. Each of the projects listed in Paragraph 7 have been completed
by the mill and are discussed in Section 4.0 of this report. The status of the Bleached
Filtrate Recycling (BFRTm) process on the mill's pine fiber line is discussed in Section
5.0. Finally, the report concludes in Section 6.0, with a summary of the mill's overall
color reduction efforts.
The report identifies a strategy and timeline for each project to further reduce
color discharges from the Canton Mill. Color reduction projects completed include:
gathering more extensive and detailed data on sources of color within the Mill to
substantially improve the accuracy of measurements; improvements in the Mill's existing
Best Management Practices (BMP) program and completion of efforts to identify,
quantify and improve the accuracy of a mass balance of sources of process black liquor
losses, including unmeasured sources and discharges during periods of fiber line
disruption. Each section includes an explanation of and rationale for the strategy being
implemented. Although the BFRTM demonstration is not complete, the mill is currently
meeting the effluent limitations set forth in Part III, Section E, Paragraph 10 of the 1997
Permit.
1

1.2 Historical Background
Champion's Canton Mill discharges treated wastewater from pulp and paper
production processes at the Mill to the Pigeon River about 37 miles upstream from the
North Carolina-Tennessee border. In the mid-1980s, the State of Tennessee objected to
the issuance of an NPDES permit for the Mill because of color in the effluent. As a result
of Tennessee's objections, EPA withdrew permitting authority from North Carolina and
proposed a true color limit of 50 platinum cobalt units at the point of discharge. Because
there was no demonstrated and cost-effective technology capable of meeting such a limit
at the point of discharge, Champion sought variances from the North Carolina and
Tennessee water quality standards for color, both of which are narrative rather than
numerical standards. North Carolina granted a variance in July 1988 (the 1988 Variance),
but Tennessee did not. The North Carolina variance required the Canton Mill to meet the
Tennessee water quality standard for color at the Tennessee border, using a predictive
model. EPA approved the North Carolina variance in August 1988, and incorporated it
into the federal NPDES permit issued to Champion in October 1989 (the 1989 Permit).
Following administrative appeals filed by third parties representing a citizen group in
Tennessee, the 1989 permit was upheld in 1992.
In March 1990, prior to final approval of the 1989 permit, Champion began the
Canton Modernization Project (CMP), a $330 million effort to dramatically improve the
mill's effluent quality and meet the stringent new requirements of the variance and
permit. The project, among other improvements, involved the elimination of elemental
chlorine in the bleaching process with the complete substitution of chlorine dioxide and
oxygen delignifrcation. Additional process changes were implemented to "tighten up" the
Mill with regard to losses of colored process waters. Once completed in 1994, the CMP
reduced the mill's wastewater discharge from an average of 45 Million gallons per day
(mgd) to an average of less than 29 mgd, as well as reducing color in the Mill's effluent
by almost 80 percent. Figure One illustrates the reduction in color discharges to the
Pigeon River since 1988. Of particular note are the more recent reductions following
successful implementation of the CMP in 1994.
2

Under the terms of the 1988 Variance, Champion was required to submit an
annual review of developments in color reduction technologies to the North Carolina
Department of Environmental Management (NCDEM). The 1988 Variance called for the
establishment of a Variance Review Committee (VRC), consisting of water quality staff
and experts in the pulp and paper industry, after startup and completion of the CMP. The
VRC was charged with reviewing the variance and reporting to the North Carolina
NPDES Committee regarding adequacy of the existing variance. The NPDES Committee
reviewed the variance in 1993 and made no changes to it.
In May 1995, in conjunction with the first triennial review of water quality
standards following the completion of CMP, the NPDES Committee appointed the VRC
to review the adequacy of the variance. After reviewing the variance in late 1995 and
early 1996, the VRC recommended in March 1996 that the effluent limit for color at the
point of discharge be reduced by 23 percent from the variance and 1989 Permit.
Following public hearings on the recommended changes to the variance and draft NPDES
-� permit, the NPDES Committee adopted the hearing officer's recommendations and
modified the variance, establishing new limits for color discharge of 124,933 pounds per
day (daily average on annual basis) and 132,341 pounds per day (monthly average)
decreasing from 172,368 and 258,945 pounds, respectively. The modification of the
variance was transmitted to EPA on October 17, 1996 and EPA advised the State of
North Carolina that the agency would approve the variance modification. On December
11, 1996, following further discussions between Champion, EPA and the States of North
Carolina and Tennessee, the NPDES Committee adopted an amended order for
modification of the color variance, further reducing the discharge limit for color to 98,168
pounds per day (daily average on annual basis) and 125,434 pounds per day (monthly
average). The amended order included numerous additional requirements for further
color reduction. The Division of Water Quality issued the NPDES permit the next day,
incorporating the variance as modified and amended. On December 26, 1996, EPA
finally approved the changes to the variance.
On January 13, 1997,the State of Tennessee filed a petition for a contested case in
the North Carolina Office of Administrative Hearings challenging the NPDES permit and
3

the variance. Tennessee's objections, and those of other intervenors were resolved by
issuance of the February 20, 1998, Settlement Agreement in State of Tennessee et al. v.
North Carolina Dept of Environment and Natural Resources et al. Pursuant to that
agreement, the 1996 permit was further modified providing for, beginning December 1,
1998, an annual average true color not to exceed 60,000 pounds per day and a monthly
average not to exceed 69,000 pounds per day, unless Champion's patented Bleached
Filtrate Recycling (BFRT") technology is not successful, with an ultimate target annual
average true color loading within the range of 48,000 - 52,000 pounds per day.
Additional study and reporting requirements, as stated in the Settlement Agreement and
1997 modified NPDES permit, are covered in Sections 2.0, 3.0 and 4.0 of this report.
4

2.0 1997 NPDES Permit Part III, Paragraph E 8 Requirements -
June 1, 1998 Report Submittal
The language of this paragraph of the 1997 Permit provides that:
"The permittee shall provide a report to the Division of Water Quality,
the Technology Review Workgroup and the NPDES Committee no later than
June 1, 1998. This report will identify a strategy and time line for implementing
those color reduction measures identified in Paragraph E 7 until the target
effluent limitations in Paragraph E 12 [48-52,0001bs/day annual average] are
met or all measures in Paragraph E 7 have been fully implemented. The report
will include an explanation of and rationale for both the implementation strategy
and the proposed time line. The report will also identify those measures which
will be implemented in the event that the effluent limitations set out in Paragraph
E 10 [60,000 Ibs/day annual, 69,000 Ibs/day monthly] are not achieved by the
color reduction measures specified in that paragraph."
This report fulfills the requirements of Part III, Paragraph E 8. Each of the
projects listed in Paragraph E 7 has been completed or is currently under study.
Although the BFRTm demonstration is not yet complete, the mill is currently achieving
the effluent limitations set forth in Part 171, Section E, Paragraph 10 of the 1997 Permit.
The requirement listed in Paragraph E 11 of the 1997 Permit [Hardwood Eo Recycle]
will be completed in 1999 as a part of the continuing effort to meet the target effluent
limitations established in Paragraph E 12.
f
5

3.0 1997 NPDES Permit Part III,Paragraph E 9 Requirements - BMPs
3.1 Part III, Paragraph E 9 -Best Management Practices (BMP) Required Projects
The language of this paragraph of the 1997 Permit provides that:
"Four BMPs which have already been identified as having both a high
potential for achieving color reduction and a high level of implement ability are:
(a) installation of replacement digester recirculation pumps and a spill collection
sump;" (b) [installation of a double-chambered courtyard sump]* ; "(c)
installation of weak black liquor tank containment, and; (d) correction of
evaporate set demister clogging , installation of condensate instrumentation and
sampling ports for the evaporator set, and assurance of continued dry conveying
of knot rejects. The permittee shall fully implement all four of these BMPs by
June 1, 1998."
3.2 General Discussion
Part III, Paragraph E 7 of the 1997 Permit requires the implementation of four
Best Management Practices (BMP) projects by June 1, 1998. All four of the BMP's
listed above were completed before June 1'. The digester spill collection sump and pine
courtyard Parshall flume slide gate were combined into a single project involving the
installation of a double-chambered sump in the pine courtyard and is discussed in Section
3.4. The color reduction benefits from these projects will be evaluated after collection of
sufficient operational data.
3.3 Replacement of Digester Recirculation Pumps
Approval to replace the black liquor recirculation pumps for all 18 batch digesters
was received in early March 1996. Installation of these pumps began in April 1996 and
took place during the annual inspection for each digester. All 18 recirculation pumps
were installed and operating by February 1997 for a total cost of$537,000. The previous
recirculation pumps were 1950's vintage centrifugal units unique to the Canton Mill. The
* Justification and Technology Review Workgroup approval of this project are provided in Appendix A2.
6

replacement of these pumps has reduced the quantity of concentrated colored material
from the digester area as shown in the secondary effluent trend in Figure 1.
3.4 Double-Chambered Pine Courtyard Spill Collection Sump
3.4.1 Project Description
The pine courtyard and digester area of the mill did not have spill collection
systems; such systems were incorporated as a BMP requirement of the 1997 Permit. The
pine courtyard and digester area (2B area) includes the following source areas: the
digester building including portions of the hardwood blow tank and accumulator, the
hardwood brownstock building including the hardwood oxygen delignifrcation area and
the pine blow tank and accumulator area. Based on a short-term color contribution mass
balance performed within this area in April 1997, the digester area and hardwood
brownstock area each contribute approximately 25% of the color while the remaining
50% of the color comes from the courtyard area. Therefore, two BMP projects for the
digester and courtyard area were included in the 1997 Permit as covered in Section 3.1 of
this report. The two projects were to install a digester spill collection sump and install a
pine courtyard Parshall flume slide gate. In early 1998, with the approval of EPA, North
Carolina and Tennessee, these two projects were combined into one project, a double-
chambered courtyard sump. The justification for this project is discussed in the following
section.
Funding for the two-chambered pine courtyard sump was approved in February
1998 at a total cost of $275,000. The sump provides a system to detect, collect and
reclaim colored materials from the digester building and pine courtyard area based on
7

conductivity control. The completed sump is located in the pine courtyard area. The
sump is 8 ft. square x 10 ft. deep and constructed of reinforced concrete. The sump is
divided into three sub-compartments. Two of the three sub-compartments are designed
as pump compartments with the third serving as a discharge weir into the U-drain flowing
to the 2B Parshall flume. The two pump compartments are the collection points for the
two sources of flow in this area. One compartment receives flow from the digester
building and the other compartment receives flow from the courtyard and hardwood
brownstock area. Engineering drawings of this sump and U-drain system can be found in
Appendix Al.
The digester compartment and the pine courtyard compartment have independent
conductivity monitoring. The digester area is typically a low volume, high concentration
color contributor whereas the courtyard area is typically a low concentration, high
volume contributor. Each compartment is designed to pump a maximum of 400 gallons
per minute. Manual slide gates were installed which allow cross-connection of the sumps
to facilitate maintenance activity in one of the compartments. In the event of upset
conditions the manual gates may also be configured to briefly increase the total sump
collection capacity to 800 gallons per minute. However, total typical flow from both the
digester and courtyard area is approximately 425 gallons/minute. The sump is covered
with a steel plate to allow maintenance traffic to pass over the sump area.
The sump pumps for each of the two compartments are equipped with
independent conductivity probes which are connected to the Distributive Control System
(DCS). The conductivity set points trigger the sump pumps to turn on to minimize the
loss of detected colored material. Collected material from the sump is pumped to the
8

hardwood brownstock spill collection tank. The sump compartments will normally
overflow the third compartment's discharge weir to a U-drain flowing to the 213 Parshall
flume. It is important to note that 50-100 gallons of clean, non-contact cooling (NCC)
water no longer flow through the courtyard due to the diversion project discussed in
Section 4.7.1. Details on this sump project are located in Appendix A.
3.4.2 Project Justification
As stated in the 1997 modified NPDES Permit, the mill was required to install a
digester spill collection sump and a pine courtyard Parshall flume slide gate by June 1,
1998. The mill concluded the above design was an improvement to the sump and
Parshall flume slide gate conceptual design and submitted this design to the Technology
Review Workgroup for approval. A copy of the documentation sent to NCDWQ and
TRW in February 1998 for approval of the new sump design is located in Appendix A2.
While this sump configuration cost more than the original conceptual design, it offers
better operational performance and maintenance reliability.
3.5 Weak Black Liquor Tank Containment Project
With the completion of the Canton Modernization Project in 1994, all of the
black liquor storage tanks are contained and have reclaim sumps on conductivity control,
with the exception of the hardwood weak liquor storage tank. Due to the potential for
colored losses from this tank, a containment system was identified as a BMP during the
1997 Permit discussions.
Funding to construct the hardwood weak black liquor(WBL) containment system
r
was approved in January 1998 at a total cost of $96,500. Work on this project
9

commenced immediately following project approval and was completed in May 1998.
The containment volume is sufficient to contain most losses based on historical events.
Additional containment capacity is constrained by existing process equipment in this area
and maintenance of the WBL tank.
This project provides a concrete containment wall for the WBL storage tank as
well as the associated Soap tank. Within the containment area a new stainless steel sump
was installed as a designed low point. Additional concrete work was required on the
existing slab to control the direction of flow toward the new sump. A four inch Stainless
Steel pipe connects the sump to the mill sewer. A manual valve and an automatic valve
were installed in the sewer overflow connection to prevent released material from
entering the mill sewer.
The control systems for this project are a sump level switch, sump conductivity
probe and tank overflow temperature switch. A level switch is installed on the
containment wall above the sump in order to detect any fluid level within the area above
the top of the sump and alarm the operators. The conductivity probe was installed in the
sump to determine the presence of black liquor and initiate an operator alarm. A
temperature switch was installed in the tank overflow line as an early warning of tank
overflow. The operator alarms for all of the instrumentation are sent by the DCS to the
Evaporator Control Room as well as the Hardwood Fiber Line Brownstock Operator's
Station. The DCS simultaneously closes the sewer connection automatic control valve.
The manual valve is a backup to the automatic valve and allows for maintenance of the
automatic valve.
10

A piping connection for a portable sump pump was installed from the sump to the
top of the WBL tank. This project provides detection, operator alarm(s), containment and
reclaim capability to manage the infrequent colored losses from the weak black liquor
storage tank. The engineering drawings for this BMP project are located in Appendix B.
3.6 Additional Operational Measures
3.6.1 Correction of Evaporator Demister Set Clogging
Evaporator condensates are generated as a result of"boiling" the water out of the
black liquor entering the evaporator set. Periodically, color is carried over into the
evaporator condensates as a result of entrained black liquor in the water vapor
(condensate) driven off the evaporator in the vapor dome. The primary source of the
entrained black liquor is fouling of the leading-edge of the evaporator set demisters.
When the demisters were washed, the evaporator condensate color concentration
decreased.
Operations determined that the black liquor fiber filter performance was
important to prevent demister leading edge fouling. The recovery area operations staff
addressed this issue and corrected the problem during the last quarter of 1997. Due to
improved management of fiber filter up-time, communication and monitoring of the fiber
filters, condensate color has decreased as demonstrated by the reduction in secondary
effluent color. In addition, manways were installed in the evaporator vapor domes to
provide access to wash the evaporator demisters.
II

3.6.2 Installation of Condensate Instrumentation &Sampling Ports for Evaporator Set
As discussed above, evaporator condensates can periodically carry over colored
material as a result of entrained black liquor in the water vapor (condensate) driven off
the evaporator in the vapor dome. The individual contributions of color from the sewered
combined and contaminated condensates were previously unmeasured. To quantify the
daily color contribution from these sources, automated solenoid valve samplers were
installed on both the combined and contaminated evaporator condensate sewered streams
in January 1998. These samplers collect a 24-hour composite which is analyzed for color
concentration and incorporated into the mill's Plant Information (PIT") System for data
analysis and trending.
There are also eight conductivity probes within the evaporator condensate
collection and segregation s stem that
y provide operations notification of any change in
operation that can cause an increase in sewered color. Corrective action to minimize the
loss of colored material is initiated based on these internal conductivity readings.
However, these probes cannot necessarily indicate gradual increases in sewered color
from evaporator condensates. To identify such problems requires the information
generated via the continuous samplers discussed above. The conductivity probes support
the daily sewered condensate color data by providing the mill with information to
respond to the performance of the evaporator systems and manage color for this source.
3.6.3 Assurance of Continued Dry Conveying of Knot Rejects
Sealed pressure knotters were installed during the CMP in 1993 to minimize color
losses from the knot system. The knotter is not designed to use water to transport knots
12

to the rejects bin. The cause of a stream of discolored water from the Hardwood fiber
line Secondary Knotter into the rejects bin was identified and corrected in early 1998.
Occasionally, a piece of foreign material would hang in the throat of the valve and
damage the valve seat. A spare valve is maintained on-site for the Hardwood fiber line
secondary knotter and the knotter is inspected during each shift in order to assure the
valve is properly closing and sealing completely. In addition, flow from this area is
discharged to the new double-chambered pine courtyard spill collection sump.
13

4.0 1997 NPDES Permit Part III, Paragraph E 7 Requirements -
Additional Color Reduction Measures
4.1 Part I11, Paragraph E 7 -Additional Color Reduction Measures
The language of this paragraph of the 1997 Permit provides that:
"Working with the Technology Review Workgroup, Champion has
already begun the process of identifying and implementing possible prevention
and control measures which can be taken to further reduce color discharges from
the mill. The permittee is directed to further evaluate mill operation so as to fully
identify opportunities for preventing and controlling measurable black liquor
leaks and spills (best management practices - BMPs). This evaluation will
include gathering more extensive and detailed data on sources of color within the
mill to substantially improve the accuracy of measurements, to improve the
mill's existing BMP program, and to complete efforts to identify, quantify and
substantially improve the accuracy of a mass balance of sources of leaks and
spills of black liquors, including unmeasured sources and discharges during
periods of fiber line disruption. Such BMPs include: further upgrading and
integrating of sewer monitoring(e.g., additional flow measurement and sampling
stations to facilitate more comprehensive and daily monitoring of sources) and
automated mill process control systems with operational procedures and
management oversight to reduce black liquor leaks and spills; continuing
operator training; identifying and implementing additional controls for known
but unmeasured sources (e.g., evaporator set, knot rejects bin, etc.) of liquor
losses; modifying the digester area to facilitate capturing leaks and spills;
diverting clean water discharges; and capturing and recycling liquors during fiber
line disruptions through detailed scheduling of planned outages and contingency
planning for unplanned outages. The permittee also is directed to thoroughly
evaluate additional measures to modify its process operations and controls to
remove or reduce sewer generated color."
4.2 General Discussion
The Canton Mill has one of the most extensive sewer monitoring programs for
color in the industry. The mill monitors, on a daily basis, the color load (lbs/day)
contributions from the following sewer areas: 2B (Hardwood Brownstock washing,
Digesters and Pine Blow Heat Recovery area), 3A (Pine and Hardwood Eo filtrate and
Pine Brownstock washing and Oxygen Delignification), 5B (Recovery, Black Liquor
Oxidation and Chloride Removal Process (CRP)),No. 1 (No 11 and 12 Paper Machines),
Hardwood and Pine Acid and Alkaline bleach plant filtrates and Combined and
14

Contaminated Condensates. Other areas of the mill are measured on a concentration
basis.
The "unquantified" fraction of Primary Influent color was a focal point during the
1997 Permit discussions. The mill defines unquantified color as a component of primary
influent color resulting from turbidity, sewer generated color and minor contributions
from unmeasured areas of the mill. The discussions focused on quantifying
"unquantified" color in order to evaluate the potential for additional color reduction
activities. This "unquantified" portion accounts for approximately 40% of the mill's
primary influent color. The "unquantified" fraction is attributed to three independent
reasons; 1) turbidity (color test method interference which is a false-positive
representation of true color), 2) sewer generated color and 3) color from unmeasured
areas of the mill.
In order to quantify this fraction, the mill increased its color monitoring program.
Automated samplers were installed on the black liquor evaporator combined and
contaminated condensates. Samples also are collected from the CRP purge stream.
Automated flow meters were installed on the Pine Dl and Eo stages to provide sewered
flow measurements for calculating bleach plant color loads to the wastewater treatment
plant rather than using a mass balance approach. This new color data has reduced
unquantified color. All major process areas now have daily color monitoring. The four
BMPs discussed in Section 3.0 have addressed the evaporator set, knot rejects bin and
digester area requirements. Current data indicates that the majority of the remaining
"unquantified" primary influent color is due to the effects of turbidity and sewer
generated color. Plans to further quantify and characterize turbidity
q fy interference and
15

�- sewer generated color are discussed in Sections 4.9 and 4.10. Turbidity interference and
sewer generated color research projects are scheduled for the summer of 1998. In
addition, the mill is currently working in cooperation with NCASI on an industry
sponsored turbidity interference study.
4.3 Further Upgrading and Integrating of Sewer Monitoring
4.3.1 Sewered Condensates
Evaporator condensates are generated as a result of"boiling" the water out of the
black liquor entering the evaporator set. Periodically, color is carried over into the
evaporator condensates as a result of entrained black liquor in the water vapor
(condensate) driven off the evaporator in the vapor dome. Historically, sewered
combined and contaminated condensate were discharged to the main No. 4 sewer line
where only the color concentration was measured. Therefore the color contribution from
these condensate streams was not independently quantified. To quantify the daily color
loadings from these streams, continuous samplers were installed on both the combined
and contaminated condensate streams.
Automated solenoid valve samplers were installed on both the combined and
contaminated condensate sewered streams in the black liquor evaporator area in January
1998. These samplers collect a 24-hour composite which is analyzed for color
concentration on a daily basis.
The samples are analyzed for color concentration by wastewater treatment plant
personnel, recorded in the laboratory data files and entered into the mill's PITH System.
The color concentration is then multiplied by the calculated daily average sewer flow in
16

order to generate the daily combined and contaminated condensate color contribution in
pounds per day. This value is monitored daily by both Operations and Environmental
personnel. Data trends are available on the PITM System.
4.3.2 Chloride Removal Process (CRP)
The Chloride Removal Process (CRP) is an integral component of the Bleached
Filtrate Recycle (BFRTM) process at the Mill. Details of the BFRTM process, including
CRP, are included in Appendix H. The Chloride Removal Process is designed to separate
chlorides and potassium from the recovery boiler ash solution that contains primarily
saltcake and black liquor. Colored material from the recovery boiler ash carries over into
the salt cake filtrate which is then sewered to purge chloride and potassium. The salt
cake is returned to the recovery boilers as a make-up chemical for the kraft process. In
order to meet the required process levels of potassium and chlorides while maintaining an
overall low level of process equilibrium, up to 15 gallons per minute of this filtrate is
sewered. Since the amount of color from the CRP is variable, it is important to monitor
the amount of color that enters the sewer from the CRP process.
Color monitoring of this purge is accomplished in two ways. The first method
looks at the amount of color in the 5B sewer before and after the CRP U-drain and uses
the difference to calculate CRP color. The second method is to collect a grab sample
from the"purge stream" daily and measure both the color concentration and sewered flow
rate. A daily color mass (lbs/day) is calculated, trended and monitored.
The CRP samples are analyzed for color concentration by wastewater treatment
plant personnel, recorded in the laboratory data files and entered into the PITM System.
17

As with the condensates, an automated solenoid valve sampler was installed on the purge
stream within the CRP building in September 1997. The sampler collected a 24-hour
composite which was analyzed for color concentration on a daily basis. However, due to
the nature of the purge stream the sampler became plugged and difficult to maintain after
several months of operation. Based on insignificant differences between single grab and
24-hour composite sample color data, it was concluded that grab samples adequately
characterized the color contributions from CRP. Thus, the use of the automated sampler
was discontinued in March 1998. The concentration is then multiplied by the daily
average CRP purge rate within the PITM System in order to generate a daily loading value
in pounds of true color per day. This value is monitored and trended daily by both
Operations and Environmental personnel.
4.3.3 Pine Bleach Plant Automatic Flow Meters
Automatic flow meters were installed on the D100 and Eo stages of the Pine fiber
line in June 1997. The flow meters measure the sewered flows from the pine fiber line
D 100 and Eo filtrates. Data collection from the flow meters began in July 1997 and was
integrated into the Pine fiber line's DCS. The flow data allows the Pulp Mill to control
the degree of BFRTM closure by selecting the sewered flow of both D100 and Eo stage
filtrates. Previously, the D100 and Eo sewered daily average flow rates were calculated
based on filtrate mass flow balances. Direct measurement provides an accurate daily
average flow rate to calculate the Pine bleach plant color loading.
The BFRTM control strategy adjusts these flows through process operation and
control in order to achieve a target closure on the Pine fiber line and simultaneously
18

prevent filtrate tank overflow during normal operation. The mill currently targets for
80% closure of the first two bleaching filtrate stages in the Pine fiber line. Higher closure
rates introduce process variability which have resulted in an overall increased level of
bleach plant color. The configuration of controlling the ratio of sewered DIN to Eo
filtrate, and associated filtrate tank level override control, allows the mill to change the
closure target and prevent filtrate tank overflow. The benefit to the mill is improved
accountability of color discharge from the Pine bleach plant and the operation of a much
more stable bleach plant and fiber line filtrate system.
4.4 Automated Mill Process Control Systems ...
4.4.1 Electrical and Instrumentation (E & 1) Preventative Maintenance Plan
The Electrical and Instrumentation (E & 1) Section of the Canton Mill's
Maintenance and Engineering Department is responsible for the maintenance and
calibration of all control instrumentation within the mill such as conductivity probes,
flow meters, temperature probes, level transmitters, etc. Some of these instruments are
important for management of the process to minimize mill color losses. In order to
assure this instrumentation is operating properly, the Canton Mill E & I Section
developed a preventative maintenance program which is located in Appendix C. The
program addresses two key elements: 1) the identification of equipment to minimize
color losses and 2) a specific preventative maintenance program for such equipment.
For the program the E & I, Environmental, Pulp Mill and Recovery Operations
Departments developed a list of color control instrumentation including: conductivity
transmitters, level transmitters, temperature probes and overflow alarms. The program
19

consists of a computerized instrument calibration system and routine check sheets for
routine calibration which should increase the reliability of the instrumentation. The
computerized instrument calibration system will store calibration specifications for each
instrument, including calibration range and acceptable tolerance. Routine calibration
schedules and manufacturer's specifications allow the technicians to determine the drift
in each instrument and re-calibrate if necessary. The check lists will be used to schedule
and document E & I preventative maintenance tasks and will be kept on file by the area
maintenance planner. This program will be implemented by July 1, 1998.
4.4.2 Fiberline Spill Tank Level Management Plan
Over the past two years the reduction in brown color losses from the pine fiber
line has contributed to decreased effluent color as illustrated in Figure 1. Pulp Mill
Operations and Environmental personnel worked on two projects to further minimize and
control brown color losses from the pine fiber line. These projects are a spill tank level
management plan and reconfiguration of the pine fiber line's spill collection sump. The
final configuration of the spill collection sump was completed and operational during
mid-November 1997 while the Spill Tank Level Management Plan went into effect in
early December 1997. Both projects have resulted in reduced brown color losses from
the pine fiber line.
Data collected on color losses from the pine fiber line indicate that some of the
mill's losses occur during mechanical failures (i.e. the primary knotter). Therefore, the
availability of brownstock spill tank capacity is important to spill recovery and recycle.
20

As of December 1997, a spill tank management plan was implemented for the pine fiber
line operators.
The Spill Tank Level Management Plan requires the brownstock operators, at the
first of each shift, to log the spill tank level on their daily logsheet. If the level is high,
the operators will start slowly lowering the level in the tank by pumping its contents back
into the process. This daily task was automated in March 1998. The operators are
alarmed at the beginning of each shift by the DCS if the spill tank level exceeds the alarm
level. The DCS checks the operator response three hours later by rechecking the tank
level to assure that the tank level was addressed. By maintaining low spill collection tank
levels, there should be adequate collection capacity in the tank. This management plan
was incorporated into the Operator Training Program (Section 4.5.1) for the pine
brownstock operators.
As mentioned above, the success of the Spill Tank Level Management Plan is
closely related to the performance of the sump pump as well as operator awareness. The
east brownstock sump pump for the pine fiber line was reconfigured in mid-November
1997. Pulp Mill Operations felt the performance of the pump was critical prior to
initiating the Spill Tank Level Management Plan. The redesigned sump pump now runs
continuously so pump priming is no longer an inherent problem to reliable pump
operation. The control system logic provides for recovery of material based on
conductivity control. The conductivity probe is mounted within a newly installed
recirculation line to improve the performance of the probe and reduce the potential for
fiber to "blind" the probe. When the conductivity in the sump is low the pump
recirculates flow back into the sump through the newly installed recirculation line. When
21 '

conductivity is above the set point, a newly installed automatic valve within the
recirculation line will close and divert the material to the brownstock spill collection tank
for recycle and recovery.
Overall, the mill has seen a decrease in the daily brownstock color from the pine
fiber line contributing to reduced secondary effluent color as shown in Figure 1. The new
sump design and management plan have resulted in a reduction of color losses from the
pine fiber line.
4.5 Continued Operator Training
4.5.1 Pulp Mill
4.5.1 a) Operator Skills Training(OST)Program
The Pulp Mill Operator Skills Training (OST) Program has been updated to
reflect the activities in this report. This program typically involves the operators studying
and self-checking written material contained in manuals which cover specific components
of Pulp Mill Operations. The pulp mill is currently revising the manuals covering
processes which may contribute color to the sewer. The revisions will incorporate both
general color reduction information as well as any new systems or procedures. Systems
and procedures include, for example, the pine fiber line spill tank level management plan,
new 3A sewer sump configuration and a new multi-chambered pine courtyard sump.
Each process manual will discuss the implications of the specific process operation on
colored discharges. The operators train on how to effectively minimize their area's
impact on color discharges. Examples of such manuals include:
22

• Digester Contingency Operations
• Explain and Operate Hardwood Brownstock Spill Collection System
• Explain Hardwood Brownstock System Operating Concepts
• Explain Hardwood Bleaching Operating Concepts
• Explain and Operate Bleach Plant Spill Collection System
• Explain Blow Heat System
• Explain Pine Brownstock System
In addition to updating the individual process manuals, the pulp mill is creating two new
OST manuals for operator training. A learning guide was developed to explain the
operation and logic for the multi-chambered pine courtyard sump system discussed in
Section 3.4. Another learning guide was developed to outline the color impacts from the
operation of the pulp mill in general. The "Explain Pulp Mill Area Compliance and
Color Control' learning guide summary is located in Appendix D1. The learning guide
covers the pulp mill's operating plan regarding color losses during normal operations as
well as managing non-routine events. This learning guide provides training on the impact
of the pulp mill on color variance compliance. This overall OST effort provides a
foundation for color control and awareness which will be reinforced during the Pulp
Mill's On-the-Job Training Program discussed below.
4.5.1 b) On-the-Job Training (OJT) Program
Pulp Mill Operations developed an operator On-the-Job Training (OJT) Program
which began in April 1998. The OJT operator program expands upon the new OST
information to communicate the environmental impact of their operations in addition to
the training programs currently in place. A training session was developed by the Pulp
23

Manufacturing and Environmental Departments to transfer general knowledge from the
1997 Permit and operational color impacts to the Pulp operators. The training session
program is found in Appendix D2. Throughout the month of April 1998 each operating
crew received this training.
The training session begins with an overview of the 1997 Permit including the
compliance limits and dates. This provides a timeline for the operators to understand mill
effluent color limitations and future requirements. A performance history on brown and
bleach plant color losses from each fiber line is compared to the current level of
performance. This provides a benchmark for operating performance and the performance
level required to maintain compliance. The current BMP projects are discussed to update
the operators on progress, environmental impact and operational impact.
The training session continues with a discussion of the potential sources of color
in the pulp mill such as pump packing in the brownstock and digesters, screen rejects,
bleach plant color (i.e. MRP operability), etc. The purpose of this is to stress the
importance of day-to-day awareness of operations and maintenance issues which have the
potential to result in colored discharges. The session covers the sources of color which
contribute the greatest color loading to the treatment plant and the difference in
wastewater treatment of bleach vs. brown color. Shift managers will periodically review
new plans and procedures with their operators. This training allows the operators to
understand the regulatory implications of the permit and their roles in managing and
minimizing colored losses.
24

4.5.2 Recovery
4.5.2 a) Operator Skills Training(OST) Program
The Recovery Area Operator Skills Training Program (OST) has been updated to
reflect the activities in this report. This program typically involves the operators studying
and self-checking on materials contained in manuals which cover specific components of
Recovery Operations. In order to incorporate the color reduction activities discussed in
this report, a learning guide was developed which covers recovery area processes which
can contribute color to the sewer. The "Explain Recovery Area Compliance and Color
Control" learning guide summary is located in Appendix El. The learning guide covers
the recovery area's color sources, monitoring and control systems, preventative
maintenance measures, spill collection systems and operating plans regarding color losses
during normal operations and non-routine events. This learning guide provides an overall
lesson on the impact of the recovery area on color variance compliance. This overall OST
effort provides a sound environmental foundation which will be further enhanced in the
Recovery Operations On-the-Job Training Program covered below.
4.5.2 b) On-the-Job Training (OJT) Program
Recovery Operations developed an operator On-the-Job Training Program (OJT)
which began in May 1998. The program expands upon the new OST guide information
to communicate the environmental impact of their operations in addition to the traditional
training programs currently in place. A training session was developed by the Recovery
and Environmental Departments to transfer general knowledge from the 1997 Permit and
operational color impacts to the recovery operators. The training session program can be
25

r found in Appendix E2. Throughout the month of May each operating crew received this
training.
The training session begins with an overview of the 1997 Permit including the
compliance limits and dates. This provides a timeline for the operators to understand the
mill effluent color limitations and future requirements. A performance history on
Recovery, CRP and condensate color is compared to the current level of performance.
This provides a benchmark for operating performance and the performance level required
to maintain compliance. The current BMP projects are discussed to update the operators
on progress, environmental impact and operational impact. This training allows the
operators to understand the regulatory implications of the permit and their role to
minimize color losses.
The training session continues with a discussion of the potential sources of color
in the recovery area such as pump packing, CRP and evaporator boilouts, sump operation,
etc. The purpose of this is to stress the importance of day-to-day awareness of operations
and maintenance issues which have the potential to result in colored discharges. The
session covers the sources of color that have the potential to contribute the greatest color
loading to the wastewater treatment plant. Shift managers will periodically review new
plans and procedures with their operators. This training allows the operators to
understand the regulatory implications of the permit and their role to manage and
minimize color losses.
26

�- 4.6 Additional Controls for Unmeasured Sources of Liquor Losses
4.6.1 Hardwood Secondary Knotter Accepts Tank Overflow
The Secondary Knotter Accepts Tank for the hardwood fiber line overflowed to
the sewer twice in the past several years resulting in elevated color discharges. The
overflows occurred when the tank level transmitter failed. In addition to the level
transmitter preventative maintenance discussed in Section 4.4.1, the mill has installed a
temperature probe with operator alarm for direct indication of tank overflow.
The Secondary Knotter Accepts Tank overflow line runs from the tank, which is
inside the hardwood fiber line brownstock washing building, to the sewer discharge point
just upstream of the 2B Parshall flume. Due to its piping configuration this potential
color source will not be collected by the new courtyard sump discussed in Section 3.4.
An engineering solution to this potential color source was identified in early
January 1998 and incorporated into the pine courtyard sump BMP project. The solution
was to install a temperature probe in the overflow line. Output from the temperature
probe is tied into the DCS. Under normal tank level conditions the temperature probe
will read the ambient temperature indicating no tank overflow. If a tank overflow occurs,
the increase in temperature will be detected by the temperature probe and the DCS will
trigger an alarm at the hardwood brownstock operator station. This will give the
operators notification to react to the situation and minimize process losses. This project
was completed at the end of May 1998.
27

4.6.2 Miscellaneous Field Work
Miscellaneous field work was conducted to improve the quantification of color
contributions from several known color sources within the mill which flow to the sewer
unmeasured. Between February 1997 and April 1997 flow measurements and color
concentrations were collected to provide estimates of colored material from several areas
of the mill including the Hardwood Bleach Plant overflow to the No. 4 sewer, 2B sewer
constituents (which are measured in total by the 2B sampler), sewered black liquor
condensates, Hardwood Accumulator losses to No. 4 sewer and both fiber line secondary
knotters. The sewered condensates are now measured daily (Section 4.3.1) and the
digester sump project provides for recovery of the 2B courtyard contributions (Section
3.4). Color contributions from the remaining color sources tested are minimal.
The pine secondary knotter contribution can be picked up by the redesigned
brown spill collection system (Section 4.4.2). The hardwood secondary knotter color
contributions have been reduced by the project discussed in Section 3.6.3 and are diverted
into the new courtyard sump discussed in Section 3.4. The hardwood bleach plant
contribution is typically less than 100 pounds of true color per day. The hardwood
accumulator losses are typically less than 100 pounds of true color per day, but can at
times be greater. However, most of the flow from the hardwood accumulator area is
either diverted into the new digester reclaim sump or the existing weak liquor storage
reclaim sump.
28

4.7 Diverting Clean Water Discharges
4.7.1 Digester Area Project
As part of the two-chambered Pine Courtyard Sump Project discussed in Section
3.4, a new U-drain was installed to divert 50-100 gallons per minute (gpm) of clean, non-
contact cooling (NCC) water away from the new courtyard sump. This clean cooling
water would have previously diluted any colored material flowing from the digester area.
The new U-drain was installed to connect the existing clean cooling water U-drain
outside of the digester building to the existing U-drain in the courtyard area downstream
of the new digester sump. This connection eliminates 50-100 gpm of clean cooling water
from diluting any colored material entering the digester area and the new sump. A
permanent plug was installed to prevent the clean cooling water flow from entering the
digester building. The diversion of this clean water source reduces the dilution of colored
material from the digester area resulting in a higher concentration, lower volume of
colored material for reclaim by the new digester sump. Therefore the amount of material
to be reclaimed by the sump and recycled into the process as well as additional load to the
black liquor evaporators are reduced.
4.7.2 Oxidation Blower Coolers Project
A second clean water segregation project will soon be complete in the recovery
boiler area. The Black Liquor Oxidation blowers each have an associated oil cooling
system. These oil coolers together contribute approximately 50 gpm of clean, non-contact
cooling water to the recovery boiler sump system. This source of dilution water will be
hard-piped from each cooler into a common header downstream of the recovery boiler
29

sumps. Completion of this project will eliminate approximately 50 gpm of clean water
from the reclaim sump and recovery systems. This segregation project will be installed
and operational in June 1998. ,
4.8 Capturing& Recycling Liquors During Fiberline Disruptions
4.8.1 Detailed Scheduling of Planned Outages
Scheduled outages are standard industry practice for maintaining the performance
of the pulp mill and recovery area operations. Fiber line outages occur about once every
four weeks. Detailed and extensive outages are periodically scheduled whereby one-half
of the pulping and recovery area is shut down for up to one week. Planning occurs prior
to each outage regardless of the duration or complexity of the outage. Maintenance work
schedules are prepared and flow-charts are prepared which illustrate when equipment is
to be shut down, repaired and started back up. Semi-annual outage information and lists
of personnel involved are generated and distributed throughout the mill. Key
Performance Indicators (KPI) targets for Safety, Environmental, Planning, Execution and
Cost are established before the outage, tracked to monitor outage performance and
reviewed after the outage in order to identify key learnings. Colored losses are a focus of
the outage planning.
A tank draining schedule is generated prior to the start of any outage and includes
the tank(s) to be drained including volume(s). Tanks and associated piping must be
periodically cleaned for inspection and maintenance. Provisions are made to reduce the
tank level as low as possible before shut down. Piping is emptied as much as possible
prior to cleaning.
30

- Tank level and inventory management is a key tool the mill uses to minimize
colored losses during outages. The color impact of various sources of colored losses has
been estimated and incorporated into the OST learning guides for Pulp Mill and Recovery
Operations areas as discussed in Sections 4.5.1 (a) and 4.5.2 (a). These color loss
estimates are combined with the planned outage tank draining schedule to estimate the
total outage color loss. The mill is currently developing a procedure to evaluate the color
loss estimate based on the actual tank level(s) prior to the outage. This information is
then communicated to the operations areas and wastewater treatment. Adherence to the
established schedule and detailed communication of any schedule changes are important
to minimize outage color.
The mill is incorporating the existing kraft pulping chemical inventory
management strategy as a component of the overall color management philosophy. The
E & I preventative maintenance plan discussed in Section 4.4.1 addresses the reliability
of critical color control instrumentation for outages. This equipment is inspected,
calibrated and cleaned a week prior to each major annual or semi-annual outage. The
mill began collecting hourly primary influent color measurements during specific outage
periods in September 1997. The color concentration values are entered into the mill's
PIT"' System and verbally communicated to the recovery and pulp mill shift supervisors.
Currently, a tiered/triggered response procedure is under development to determine color
levels of concern based on the measured values with associated response actions. This
will focus mill resources on detecting and identifying sources of color to minimize
colored losses.
31

The above mentioned efforts are incorporated into .the Pulp Mill and Recovery
area On-the-Job Training Program covered in Sections 4.5.1 (b) and 4.5.2 (b). These
efforts are being incorporated into the outage planning process and will be refined with
experience. Many of the above procedures and strategies are also integral to address non-
routine events and unplanned outages.
4.8.2 Contingency Planning for Unplanned Outages
A variety of non-routine events can occur which require an unscheduled outage
for repair. Events such as power and steam supply problems and mechanical issues are
examples of such occurrences. Tank level and inventory management is a key tool the
mill uses to minimize the color losses from such unplanned events. Minimizing tank
r levels reduces the loss of colored material and increases the capacity for capturing '
colored material. The Fiber Line Spill Tank Level Management Plan discussed in
Section 4.4.2 addresses this by controlling the level in the spill collection tanks. Tank
levels are controlled by the management of chemical inventories between the pulp mill
and recovery area operations. Targets are set for the weak liquor inventory for operators
to adjust the feed rates to the black liquor evaporators to maintain recovery operations
during upset conditions. Together, these two operational tools maintain the flow of black
liquor through the recovery system to minimize the loss of colored material during non-
routine events.
In order to successfully manage color through an unplanned outage, clear and
concise communication must be maintained between the pulp mill, recovery and the
wastewater treatment plant. A release of colored material may require hourly monitoring
32

of the primary influent for color in order to enhance management of the situation. The
wastewater treatment plant operators must remain aware of primary influent color and
respond to elevated color. The operator must be able to respond to the situation at the
treatment plant as well as notify supervision and operations of the problem via radio
communication. Utilization of the DCS and PITH System in addition to radio
communication with operations are important to minimize colored losses.
4.9 Primary Influent Color Turbidity Interference Study
The Canton Mill has an intensive color monitoring program both within the mill
and at the wastewater treatment plant. The in-mill sewer monitoring program provides
color data used to break down the mill's process contributions to the primary influent.
Primary influent color consists of contributions from 2B (Hardwood Brownstock
washing, Digesters and Pine Blow Heat Recovery area), 3A (Pine and Hardwood Eo
filtrate and Pine Brownstock washing), 5B (Recovery, Black Liquor Oxidation and CRP),
No. 1 (No 11 and 12 Paper Machines), Acid Filtrate and Combined and Contaminated
Condensates. As previously discussed, the remaining fraction of primary influent color is
"Unquantified" color and consists of contributions from turbidity interference and sewer
generated color.
The turbidity interference occurs while measuring primary influent color
concentration in the laboratory. The EPA approved standard NCASI test method for true
color measurement requires sample filtration. There are various materials present in the
mill environment that, when present in the primary influent, are suspended in the filtered
33

solution and scatter light. This scattered light is not read by the spectrophotometer and is
interpreted as true color by the test method. These particles do not contribute to effluent
color due to the fact that most of the turbidity interference is removed across the
wastewater treatment plant. Therefore, the true color concentration of the primary
influent is high biased by the turbidity interference effects and is not representative of the
actual true color in the sample. Material such as Precipitated Calcium Carbonate (PCC),
lime mud, dregs, Titanium Dioxide (Ti02)1 paper machine fillers, etc. contribute to this
turbidity interference.
A study will be conducted throughout the summer of 1998 to quantify the impact
of various turbidity levels on primary influent color. The ultimate goal of this study is to
account for the impact of turbidity interference on primary influent color in order to
quantify a portion of the unquantifed color. In addition to this mill study, the mill
participated in an industry sponsored turbidity study with NCASI from February 1998
through April 1998. The goal of the study is to modify the current test procedure to
reduce and/or eliminate the current turbidity interference present in the test. A draft
synopsis of the purpose, objectives, approach and outcomes of this work is included in
Appendix F of this report. NCASI's final assessment will be published as a technical
bulletin by late 1998 or early 1999.
During the summer of 1998, the Canton Mill will conduct an independent
turbidity study. The purpose of this study will be to evaluate:
1) The turbidity contributions from each of the individual in-mill sewers;
2) The turbidity contributions from various in-mill materials (i.e. dregs, Ti02, PCC,
lime mud, etc.); and
34

3) The portion of primary influent color attributed to primary influent turbidity.
Baseline in-mill sewer turbidity data is currently being collected and analyzed.
The project will consist of laboratory bench-scale studies to determine the influence of
turbidity on the color test method using known turbid materials such as dregs, TiO2,
PCC, lime mud and paper machine headbox feed solutions. The collected data will be
evaluated to quantify the effect of turbidity on primary influent color. A final turbidity
report will be generated combining Champion's and NCASI's research.
4.10 Sewer Generated Color
4.10.1 General Discussion
Sewer Generated Color (SGC) is a phenomenon which occurs due to wastewater
interactions in the mill sewer system. SGC results in a higher color than is accounted for
by the color contributions of all the individual wastewater streams. This phenomenon is
attributed to chemical reactions that occur as the mill's acid sewer(Pine D1, Pine D2 and
Hardwood D1 bleach plant filtrates) is introduced to the main mill sewer system. These
acid filtrates react under elevated pH(10-11) and elevated temperature (120°F) within the
sewer system prior to the wastewater treatment plant. The quantity of this "unmeasured"
SGC color source is an issue for closure of the mill color balance. The Canton Mill has
done most of the research on this relatively unknown color phenomenon within the
industry. Canton's research efforts have included both mill and Corporate Technical
engineers, summer interns and two Graduate students from Duke University's Nicholas
School of the Environment. During the summer of 1998 additional research will be
35

i
conducted at the Canton Mill. The study plan is outlined in Section 4.10.3. A brief
discussion of past SGC research is presented in the following section.
4.10.2 Previous Research & Findings
Champion's research into the SGC phenomenon began in the early 1990's.
Champion showed that when acid filtrates from the bleach plant mix with the alkaline
sewer effluent, the color of the resultant effluent was greater than expected based on a
mass balance. Further work showed that irreversible color is created in the acid stream
by raising the pH and temperature. Simultaneously, Canton Mill environmental engineer
Susanne Koelsch began a series of experiments to analyze the impact of the wastewater
treatment plant on color removal as well as probing into the phenomenon of SGC. These
two concepts were brought together in the summers of 1994, 1995 and 1997 for further
experimentation.
Research during the summer of 1994 was conducted by Aimee McCord while the
1995 research was conducted by Chad Salisbury. Both research efforts covered a variety
of color issues beyond SGC, however only the findings relevant to SGC are discussed. A
McCord's work determined that the color removal mechanism across the wastewater 4LS
treatment plant acts primarily on brown color sources, not on bleach plant color.
<��
Salisbury's research was designed to address two questions: GG�
1) What is the maximum potential impact of sewer generated color on color loads to the Jv/
wastewater treatment plant?
2) Is sewer generated bleach color removed at the wastewater treatment plant?
A small portion of SGC for all bleach plant filtrate combinations was found to be
removed at the wastewater treatment plant. However pine, hardwood and total bleach
36

plant effluent flows experienced a net color increase across the sewer and wastewater
treatment plant system. An undergraduate summer intern project during the summer of
1997 began the process of assessing the impact of SGC on primary influent color loads
to the wastewater treatment plant and how to minimize SGC. The objective of this work
was to determine if pH adjustment of the acid sewer prior to mixing with the alkaline
sewer would:
1) minimize the effect of the sewer generated color phenomenon on primary influent
color; and
2) result in an equivalent decrease in secondary effluent color after wastewater
treatment.
The operation of the BFRTm process at the Canton Mill was highly variable during this
project. Limited laboratory data suggested possible color reduction benefits at both the
primary influent and secondary effluent by specific wastewater stream pH adjustment.
However, more laboratory work needs to be conducted, especially since the BFRTm
process is currently stabilized at 80% bleach plant closure. The impacts of current, and
possible increased, operational levels require further study. A graduate student began
conducting additional research on sewer generated color in May 1998.
4.10.3 Research Plan for 1998
As stated in previous sections, the Canton Mill has conducted experimental bench
scale work on the sewer generated color mechanism for three summers with the aid of
summer college interns. This cooperative effort continues this summer with another
graduate degree candidate conducting the research. The student will spend the summer
37

conducting laboratory experiments to evaluate two questions raised through previous
research:
1) What effect does the color removal mechanism across the wastewater treatment
facility have on sewer generated color?
2) What is the potential impact on sewer generated color of pH adjustment of the acid
sewer prior to mixing with the mill's main alkaline sewer?
The goal of this project is to quantify the percentage, if any, of sewer generated color
which is removed across the wastewater treatment facility and to understand better if pH
adjustment is a feasible option to reduce this color source. A description of the 1998
summer study plan is listed in Appendix G.
1
38

5.0 Bleach Filtrate Recycling(BFRTM)Process on Pine Fiberline
A full scale demonstration of Champion's Bleach Filtrate Recycling (BFRTM)
process was begun at the Canton Mill in 1995. Details of the BFRTM demonstration
project are in Appendix H. The process has two major new components, the Chloride
Removal Process (CRP) and Metals Removal Process (MRP). For the BFRTM
demonstration the CRP and MRP become integral parts of the bleached kraft pulping and
recovery process. Both processes are integral in the overall goal of BFRTM to achieve
and sustain closure of the DIN and Eor bleach stages of the Pine fiber line at Canton.
The CRP provides a system to purge chloride and potassium from the recovery boiler
precipitator ash while the MRP removes minerals such as calcium, magnesium, etc. from
the DI00 stage filtrate. The CRP is utilized to keep the liquor cycle chloride
concentrations similar to or less than pre-BFRTM levels. The MRP is designed to
reduce/control scale forming minerals while recycling bleach plant filtrates. The BFRTM
process components were brought on-line and independently demonstrated by the mill
prior to full BFRTM implementation. The various stages included:
1) Start-up of CRP in August 1995;
2) Initial start-up of MRP in November 1995 -D100 filtrate treated and sewered;
3) EoP filtrate recycle commenced in March 1996;
4) MRP-treated D 100 filtrate bleach plant recycle began in August 1996.
Throughout the remainder of 1996 and through 1998 the mill continues the
BFRTM demonstration process. Mechanical and process issues encountered continue to be
addressed. The mill operated for several months at various closure levels while
39

attempting to attain full closure. To stabilize the BFRTM process, the mill currently
targets for 80% closure of the first two bleaching filtrate stages of the pine fiber line.
Two papers on the BFRTM process demonstration are located in Appendix H. One
article is written by Bob Caron of Champion's Applied Technologies while the other
article, written by Stratton (Champion AT) and Ferguson (Canton Mill Pulp Operations),
received the Canadian Pulp and Paper Association's 1997 Douglas Jones Award. These
articles cover the BFRTM process mechanics, operational history and environmental
performance.
40

6.0 Conclusion
The contents of this June 1, 1998 report fulfill all of the requirements of Part III,
Section E, Paragraphs 7, 8 and 9 of the mill's modified 1997 Water Quality Color
Variance and 1997 NPDES Permit effective December 31, 1997. All four of the Best
Management Practices (BMP) Projects required by Paragraph 9 were completed by the
mill before June I" and are discussed in Section 3.0. A list of projects, discussed in
Section 4.0, was developed and implemented by the mill to satisfy all in-mill color
reduction measures identified in Paragraph 7. Together with the continued
demonstration of the Bleached Filtrate Recycling (BFRTm) Process on the mill's pine
fiber line, these color reduction measures have resulted in color reductions in the
secondary effluent as illustrated in Figure 1.
41

: 6 » § °
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APPEND IX A - 7 A

z } a
APPENDIX "A — A
�
/ �

'Jt L
V 'Chami- ion
February 10. 1998
Mr. Forrest Westall
Regional Water Quality Supervisor
North Carolina Department of Environment
and Natural Resources
59 Woodfrn Place
Asheville. NC 28801
RE: NPDE4 PERMIT Mniitit~rreTI 1
PERMIT No. N(' 000 272
Dear Mr. Westall:
Per the modified permit. Part III - Special Conditions, Section E. - Requirements for
Compliance and Analysis, Paragraph 9, Champion International's Canton Mill is required
to implement four BMPs which have a high potential for achieving color reduction and a
high level of implementability.
Items (a) and (b) of that paragraph specify:
(a) installation of replacement digester recirculation pumps and a spill collection
sump
(b) installation of a pine courtyard Parshall flume slide gate
These BMPs were reviewed with you and other members of EPA's Technology Review
Team and submitted to Mr. Don Anderson, Team Leader, in May 1997. For reference,
Attachment I is that portion of the submittal that addressed these specific BMPs.
At the time of the review, all information was submitted as being in the "conceptual"
phase of project engineering. Detailed engineering is now complete and an improved
design is submitted for your approval as Attachment II.
The improved design allows for a new sump with two (2) automatic pumps and new U-
drains which will provide a reliable means of detecting any flow with elevated color
content and reduce the possibility of release by pumping the fluid to the brownstock spill
tank. Manual slide gates will also be installed to assure containment of this area.
datalwinword\bobw\n pdeskmodifielwest2-10

cn"r S_ -a:ional "C orat.c-
Forrest Westall
February 10. 1998 .
/ Page 2
1 This design is a more reliable system than what was originally conceived with t
he
Parshall flume slide gate. comparison of the two attachments reflects that Champion,
with this improved design, is prepared to commit approximately two times the
expenditure of the original conceptual phase design.
Please be advised that Champion has completed that portion of Item (a), requiring the
replacement of the digester recirculation pumps.
In order to meet the June 1, 1998 implementation deadline, we are requesting that this
improved design satisfy Items (a) and(b) by February 23, 1998.
If you have any questions, please call me at [phone].
Sincerely, ,/ In/
V •
Robert V. Williams
Manager
Environmental, Occupational Health& Safety
datalwinword lbobwln pd eslmodif iclwest2-10

State of North Carolina
Department of Environment •
and Natural Resources
Asheville Regional Office
Division of Water Quality NCDENR
James B. Hunt, Jr., Governor NOR,,,CAROLIWI DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Wayne McDevitt, Secretary
WATER QUALITY SECTION
February 23 , 1998
.Mr. Robert V. Williams, Manager
Environmental, Occupational Health & Safety
Champion' International Corporation
Canton Mill
Box C-10-
Canton, North Carolina 28716
Subject : NPDES Permit Settlement,
Installation of BMPs
Dear Mr. Williams :
In response` to'your February 10, 1998 letter on this subject,
the Division has reviewed your- request in consultation with the
Technology Review Workgroup (TRW) . A copy of the material provided
with the February 10 letter was sent to Mr. Don Anderson, Chair of
the TRW. Champion provided a phone briefing ( February 11, 1998) to
Mr. Anderson, Ms. Karrie-Jo Shell and myself about the current
status of activities at the mill, including the Company' s proposed
solution to comply with Parts (a) and (b) of Paragraph 21 of the
Settlement Agreement (a portion of the BMP installation process) .
Based on this information, Mr. Anderson and I concurred that
the proposed two-chambered:•sump requested by Champion -is .actually a
much better approach to minimizing the potential impacts of color
losses in the digester and pine courtyard areas of the mill than -
would be offered by a lone sump for the digester area and a Parshall
flume slide gate to serve the pine courtyard area (as described in
the Agreement) . It is also understood that the projected
installation costs of the two-chambered sump is actually
significantly higher than the projection made for the original
proposal . The proposed system along with a summary analysis of the
alternative was made available to the other members of the TRW by
Mr. Anderson. He received from them their concurrence that the
alternate BMP installation would more than meet the intent and..
objective of the Agreement language in Paragraph 21 that deals with
BMPs in these two mill areas .
As a result of these evaluations and the findings of the TRW,
Champion should proceed with the installation of the proposed,
59 Woodfin Place, Asheville, North Carolina 28801
Telephone [phone] Fax [phone] _
An Equal Opportunity Affirmative Action Employer

ATTACHMENT I

One ChamOlon Plaza
Slamtoro.Connecticut 06921 Ecwartl O.Clem
203 358.7847 vice Presiaent—Environmental Oualiry
i r ,
U Champion
Cnammon in,ernanc,i Ccroo,ancr•.
May 0, 1997
Mr. Don Anderson
U,S. Environmental Protection Agency
Mail Code 4303
Room 195A, East Tower
401 M Street, SW
Washington, D.C. 20460
RE: Section 308 request dated Feb. 6, 1997
Dear Mr. Anderson:
Attached are copies of the information we shared with you, an Technology Review team, on d other members of EPA's
May 8, 1997. I believe this material provides answers to all
of the questions covered in the referenced Section 308 request, but if that is not the case,
Please advise me at your earliest opportunity. It is my understanding that much of this
material will be used to support the findings of the Technology team, and some of it may
wind up in the public domain. With that understanding, you should consider that the
information covering the expected operating costs (not the capital costs) for the BFR
demonstration project on the pine line at the Canton mill is deemed by Champion to be
Business Confidential, and should be protected by this designation: Champion's stated
intention is to demonstrate whether this technology can be commercially proven to be
viable at this location, and we are required to provide proof under existing provisions of
the North Carolina color variance if this technology should prove not to be feasible.
Since the cost numbers provided are tentative(reflecting only three months of operation,
and not at full closure), the release of this information would be premature. Therefore,
we are requiring that it not be released. None of the other information enclosed is
claimed under this provision.
Sincerely,
CC: Dick Diforio
Bill Manzer

Canton Color Technology
Assessment
PRESENTED BY:
Champion International Corporation
Canton, North Carolina
May 8, 1997

Spill COntrol/Collection
Systems
■ Digester House Sump
— Collect Black Liquor Losses from:
» Digester House
» Hardwood Blow Tank & Accumulator Area
■ Parshall Flume Slide Gate
■ Weak Black Liquor Tank Containment

Project I : Digester Sump
M mum"
■ Scope of Work:
— Installation of:
» 3 foot square, reinforced, lined concrete sump pit
» Conductivity probe connected to automatic valve
» Automatic sump pump with piping to:
■ Hardwood brown spill collection system
■ Pine blow tank
— Collection and Diversion of Seal Water within
Digester Building

1
Project I: DigesterSump (cont)
■ Cost of Project (+/. 25%) :
— Labor — $41 ,000
— Equipment/Materials — $37,000
— Electrical/Instrument = 7 000
— TOTAL PROJECT COST — $855000
» Multiply by 2 to include Indirect Cost

Project II: Parshall Flume
■ Scope of Work:
— Installation of.-
One 316 SS automatic slide gate valve:
■ at entrance of No. 2B Sewer Parshall flume
■ connected to existing conductivity probe
— Relocation of existing piping
— Modification of existing cover grating

l
Project II : Parshall Flume cont
■ Cost of Project (+/_ 25%) :
— Labor = $251000
— Equipment/Materials = 20 000
— TOTAL PROJECT COST — $451000
» Multiply by 2 to include Indirect Cost

ATTACHMENT II

Chamcicr :r;?ma; --al CIrocranon
CHAMPION INTERNATIONAL CORPORATION
CANTON MILL
PROJECT INSTALL SUMP SYSTEM FOR COLOR CONTROL IN
DIGESTER/PINE COURTYARD
ARA No. 5573
This appropriation for funding of$270,000 in capital and $5,000 in expense is submitted
for the installation of a sump system in the digester and pine courtyard area to provide
best management practices color control.
The digester building and courtyard area adjacent to the pine blow tower was identified
by the EPA technical review work group as a site in need of a process loss collection
system. This area is a converging point for pine blow tower courtyard U-drains and the
digester sewer. which are the two main flow sources in this area. Any unintended process
loss generated in this area is primarily composed of black liquor and will flow directly to
the mill sewer system.
This project will provide the following equipment and facilities required to improve the
process loss detection, collection, and removal in the digester building and pine courtyard
areas:
1. A new U-drain will be installed to connect the existing U-drain which enters on the
southwest side of the digester building to the existing U-drain in the #4 Boiler
courtyard. A permanent plug will be installed to prevent the flow from entering the
sewer which exists on the southeast end of the digester building. The flow in this
existing U-drain is normally not a source of color and diverting it away from the new
sump is necessary to eliminate a source of dilution.
2. A new sump will be installed in the open area in the pine courtyard west of the
existing reject dumpsters. This pit will be 8' square x 10' deep in reinforced concrete
construction, and will have three compartments, two of which will be pump chambers
and one designed as a discharge weir. This sump will be the collecting point for the
two main sources of flow in this area-- the digester sewer and the pine courtyard U-
drain. These two sources will be routed into separate compartments in the sump to
allow individual monitoring. Each compartment will be capable of handling flows up
to 400 gal./min. in capacity and will be installed with three manual gates to allow
cross flow between the compartments and isolation of each compartment from the
discharge weir. These gates will increase the flow handling capability to 800
gals/min. (Normal flow into this area is 425 gal/min.) The manual gates will allow
for the total isolation of this sump from the mill sewer. The sump will be designed to
be covered with steel plate to allow vehicle traffic to pass over portions of the sump.
data\winwo rdlbo bw%n pd eslmodificlwest2-10

Cha=c- - _ - _
.....,-ai Corc•zucn
The manual gate operators will extend above the sump cover plate and block some
areas from passage.
r J. Two Goulds submersible sump pumps will be purchased and installed. These pumps
will require 20 HP and have 400 GPM capacity, and will handle solids up to 3" in
diameter. The pumps will be furnished in HC 600 (high chrome iron) construction,
which will provide good corrosion resistance for a pH range of 5-12 and excellent
abrasion resistance in a slum application. Three types of sump pumps were
considered for this project: self-priming, submersible and vertical. The submersible
Pump was selected for this project due to its superior reliability over the self-priming
model and lower cost when compared to the vertical pump.
4. New 6"diameter 316, Sch. 10 stainless steel piping and valves will be installed to
provide a common header from the two new vertical pumps. The combined flow will
be discharged into the top of the brownstock spill tank(Eq#38S323011).
5. Painting services will be provided for all structural steel pipe supports installed on
this project. Since the existing sump system in service (Ref. Eq. #648760020) does
not have electric tracing or insulation installed on the discharge piping, this project
will not provide electric tracing or insulation.
6. Electrical and instrumentation for this project will include new drives for the sump
PUMPS, two float switches, two conductivity probes, a new temperature probe in the
knotter reject line. and DCS control. The pumps will be installed to operate
independently based on the conductivity of the flow entering either compartment of
the sump.
7. All work on this project will be performed on a straight time basis by off-site
contractors. Subsurface soil conditions in the location proposed for the sump have
not been tested. These unknown conditions may or may not affect the construction of
the sump.
datalwinwordlb o bwln pdes\mod ificlwest2_10

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APPENDIX
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Electrical and Instrumentation Preventive Maintenance Plan For Color Control Enhancements
While standard instrumentation preventive maintenance practices are adequate for most processes in the
Canton Mill,the following enhancements shall be implemented to insure that all instrumentation associated
with color control remains properly calibrated and reliable:
1. Instrumentation critical to color control shall be identified.
2. Preventive maintenance tasks shall be developed for each type of instrument.
3. Preventive maintenance tasks shall be scheduled using the Canton Mill computerized instrument
calibration system or the Basic Care check sheets.
4. Calibration specifications shall be established in the computerized instrument calibration system for
each instrument.
5. Calibration test results and routine checks shall be documented using the computerized instrument
calibration system and the Basic Care check sheets,respectively.
6. Test results shall be reviewed periodically to refine calibration frequencies and required tasks to insure
instrumentation remains within specification between calibration intervals.
The following table contains instrumentation that is critical to color control in the Canton Mill. The
preventive maintenance tasks and frequencies listed shall be established as the initial preventive
maintenance routine. These tasks and frequencies shall be modified,based on test history,to insure that
the instrumentation remains within specification during the calibration interval.
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LT-)GB(-JGGB( 1p Raomm hh NcyT Leelhmames :YaueII,'WPea naNmnn atl MNoedviN waa �]mms pa'ae� iWeeky Bnk Cae ChedtSheb
LT-%%%-xyGIX t1G ReareIYGOM Lytlae LeM TmumEa �YauaP/WPed kMmsk aq MN ce9viNww ]Nlo pawedl WaelddBukca chJ she
LT-10G4xy0G( i/1l Rearwry NON CyTbw bat TrmankaaYiauedytupep kebrnva aw MN mawN was ]Enm I pav,edt WmMyBnk Cam CMASheea
LT-AIX-%100t If1l Remlay SaM CyTJale Lead TmamOa IYnuap/WPed kaNmava a4MNrtl wN ceder ]Ivlm
AT-)MG 170 !Ca Bn SeaaC �Y:ey{ WmtlW Bmk Caa CherA 5lreb
mOc4x!/Tmamna iBnermaal' a. eJEa 2We WeekdBok Cav Oiay Shea
Computerized Instrument Calibration System
The computerized instrument calibration system will store calibration specifications for each instrument,
including calibration range and acceptable tolerance. The system will schedule routine calibrations based
on manufacturer's recommendations,technical experience,or analysis of previous test results. When an
instrument is due for calibration,the technician shall download calibration information to a hand-held
calibrator. The calibrator shall be used to record"as-found"calibration test data. If the test results are not
within tolerance,the instrument shall be re-calibrated. After re-calibration,an"as-left"test shall be
performed. If the"as-left"test is within tolerance,the test results shall be stored and the instrument
rescheduled for calibration based on the predetermined interval. "As-found"calibration results shall be
reviewed periodically to determine if the calibration interval should be revised to assure the instrument
remains within tolerance between calibration checks.
Basic Care Check Sheet
The Basic Care check sheet will be used to schedule and document electrical and instrumentation
preventive maintenance tasks. Each check sheet contains task descriptions and a weekly schedule of tasks
to be completed. At the end of each week,the sheets shall be tiled by the area maintenance planner for
historical record and work requests shall be initiated for any exceptions.
Implementation Schedule
The preventive maintenance enhancements described above shall be implemented by July 1, 1998.

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APPE }DIX " D ƒ

Task FL20: Explain. Fiberline Area
Compliance and Color Control
Purpose:
Understand mill effluent compliance as it pertains to color and explain the
management and process tools to control color from the fiberline area.
Performance Objective:
Given the information on effluent compliance, You will explain discharge
concerns and the actions taken to maintain compliance while completing the
performance check without error.
Learning Guide Contents: Page
Terms and Definitions 2
Sub-Objectives:
01 Explain What Is Color and What Causes Color 3
02 Explain Routine Monitoring for Color Control 9
03 Explain Fiberline Area Monitoring and Controlling
of Color Losses 13
04. Explain How To Manage Nonroutine Events 17
05. Prepare To Explain Fiberline Area Compliance and
Color Control 20
Performance Check:
Explain Fiberline Area Compliance and Color Control 21
Task Competency Form 24
Directions for Using This Learning Guide:
If you can already perform this task, notify your trainer. If you cannot perform
this task, complete the following items:
01. Study the terms and definitions.
02. Read the information for each sub-objective.
03. Complete the activities for each sub-objective.
04. Complete the self-checks.
05. Complete the performance check.
06. Consult with your trainer to review your performance check.
5113198 4710-PMG-FL20 Page I

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APPENDIX "T 492

PulpMill CTraining
olor Impact
?'FP9t ' 'ale rr
17'f¢g'`i✓rz'l"'F�d''�+n* '�7n—n�d171'�'t + r5�,1' n a
NPDE
■ 'S Permit Overview '
■ Pulp Mill Color Performance
■ Pulp Mill Color Sources
f�
r
i
k �t

1997 NP
� DES Permit Overview
A
,.r
;rr-
T;R
4.1 WIT
771
Dates and Effluent Limitations
a.
Mill Compliance Timeline
June 1 1998 Report
ecember 1 1998 Report
! � Hardwood Eo Recycle

1
1997
NPDES Permit Overview
i .—.�..��'Yi tom..��.�I�A'h 9f�P�1ek7JtFRlFFci °AT�A iI"fiRR7ta`�'llf7A f a 1 ml e..`i`ymSELt'.1"'seF;l LY I-� fl i4,_,F kt ' y
�3 _. JJ _ �'71j� ,:PYQl+�+J'+'E Pn 1�!"r•"�4"71�Y�'�`E$�' q{��rl..wv.R�`J Y7 1 �A`7 Y
'p h � J C "9'LIW.I��'� $7tt+1 `.rnE .0�.!`• t� :'� + sY. ,�'g
■ Effective December 31 , 1997
1 ■ Submit Re port on June 1 , 2001 for Permit
y ri
p Renewal recommendations
■ Expires November 30, 2001
az ■ GENERAL PROVISION:Z�. ON.
X' {M
— Mill Pulp Production capacity will not be
increased unless done in a way to reduce color.
Y
e: 'a
fR tci.
ytri!
A

}' Dates and Effluent Limitations
z.
0 Currently Monthly Avg = 95,000 lbs/day
N As of December 1 , 1998 :
— Monthly Avg = 69,000 lbs/day
IP
I — Annual Avg = 60,000 lbs/day
Color at Hepco < 50 scu when flow > 214 mgd
m As of May 1 , 2001 :
Target Annual Avg = 48-52,000 lbs/day

tfi� �� June lst Color Reduction Report
ditional Color Reduction Measures :
Enhanced Monitoring
OST and E&I PM
OJT
Controls for Unmeasured Sources
Digester Area
Clean Water Segregation
Outages

.4 � �M June 1st Col
or Reduction Report
------—----
N 9.tl:: "4'P"-
0 BMP Projects :
Digester Recirculation Pumps
r pile
Pine Courtyard Sump
WBL Tank Containment
Additional Items
Evaporator Set Demister Clogging
it
Condensate Instrumentation
Dry Convey Hwd Knot Rejects
■ Sewer Generated Color Research

V
Dec 1 Low Flow Contingency Report
N Plan to achieve additional color reduction at
Hepco during low flow periods < 214 mgd
z.
Maintenance Scheduling
Intermittent Treatment
I A Production Curtailment '
Other Temporary Measures
Stored & Timed Release
Lake Logan

Champion International Corporation - Canton, NC
Annual Average Secondary Effluent Color Discharge (lbs/day)
400,000 Historical Database from 1987 through 1998 YTD
350,000
300,000
0
250,000
0
0
U
E 200,000
w
a
$ 150,000
0
U
N
(/1
100,000
50,000
1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998
Section I: Figure 3
CMS 4/6/98

Champion International Corporation
Color Discharged at the Canton Mill as Compared to Other Mills in the
Fully Bleached Kraft Category
Source: National Council for the Pulp and Paper Industry
100
90% ---- —
v -
80%
70%
f0
p, 60%
U -
C 50%
y _
40% --- ----- —
30% — m —
20%
10%
C- U -
0%
O � O O
�('] 'a' O 00 ip p O O O
h7 u'] O
O O I C7 C7 .a. ��, O
Ln
Ln O O O O p V'
^ O !JCDO CD
Final Effluent Color (pounds per ton of pulp produced)
Section III: Figure 1
SKK/CMS 10/23/97

UIP Mill Color Sources
122'12
Pump Packing
Brownstock Area
Digesters
creen Room Rejects
■ Operational Parameters
■ Bleach Plant Impact
MRP

APPE ƒD IX 'E - 7 A

4310-REC-ENVOV01
CJ Champion v -_
Champion internationai Corooranon
Canton Mill •
Recovery, Utilities, and Resource Utilization Department
EXPLAIN RECOVERY AREA
COMPLIANCE AND
COLOR CONTROL
or� Dare' APsil 6, 1998 Revised Date
I i
Too�'s

U Champion
Champion International Corporation
98
Champion Inteernatioona9 lCo
Stamford. Connecticut
maright,reserved,including n tyow of ttatulation. No part of this work
reproduced b Y cans or used m any form without the written
Permission of Champion International Corporation. w contents of this
document must be used only in associanon with a training�o��
approved by Champion International Corporation.
Printed in the United States of America

Task ENVOVOI Explain Recovery Area
Compliance and Color
Control
Purpose:
Understand mill effluent compliance as it pertains to color and explain the management
and process tools to control color from the recovery area
Performance Objective:
Given the information on effluent compliance.explain discharge concerns and the actions
taken to maintain compliance while completing the performance check with 100%mastery.
Learning Guide Contents:
Terms and Definitions
Sub-Objectives:
01 Explain What is Color and What Causes Color
02 Explain Routine Monitoring for Color Control
03 Explain Recovery Boiler Area Monitoring and Controlling of Color es
04. Explain Evaporator Area Monitoring and Controlling of Color Losses Loss
05. Explain How To Manage Nonroutine Events
06• Prepare To Explain Recovery Area Compliance and Color Control
Performance Check:
Explain Recovery Area Compliance and Color Control
Task Competency Form
April 6.1998

K
�
r
�
�
�
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�
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<
� � .

p
Recove Color ImpactrY Training
k F ■ NPDES Permit Overview
■ Recovery Color Performance
■ Recovery Color Sources
y
•� NI �
6Y
v'
4k
rj a�
M
E
k
ggi

1997 NPDES Pertuit Overview
MIMM
{4 ry qf
■ Dates and Effluent Limitations
■ Mill Compliance Timeline
G` ■ June 1 , 1998 Report
■ December 1 , 1998 Report
■ Hardwood Eo Recycle

,
1997 NPDES Pen-nit 'Overview
gyp!L +
9. '97"�?Si' �.ifp.+xi�Cif
s" e
' 2:7 apl+•�4 g o;i�t . +�,;a:,^^Rra±T`4 '�'':S,q'f.ip""i
µ tF
q ■ Effective December 31 , 1997
A
u ■ Submit Report on June 1 , 2001 for Permit
Renewal recommendations
i
■ Expires November 30, 2001
■ GENERAL PROVISION:
Mill Pulp Production capacity will not be
increased unless done in a way to reduce color.

Dates and Effluent Limitations
0 Currently Monthly Avg = 95,000 lbs/day
0 As of December 1 ., 1998 :
— Monthly Avg = 69,000 lbs/day
— Annual Avg = 60,000 lbs/day
— Color at HePco < 50 scu when flow > 214 mgd
N As of May 1 , 2,00 1 :
Target Annual Avg = 48-52,000 lbs/day

Mill ComplianceTimeline
I� rr •'�Pi!'�kP'�'.9pyF�jj �:�-vr.�oonr _ nil rri
y r ➢
!I
■ June 1 , 1998 Color Reduction Report
■ Dec 1 , 1998 Low Flow Contingency Plan
F
r
■ Jan 1 , 1999 Hwd Eo Recycle Begins
■ Dec 1 , 1999 Report:
— Hwd Eo Recycle
�r..
f — Potential for full BFR on Hwd
t
■ Jan 1 , 2001 48-52,000 lbs/day Report
s
■ Mar 1 , 2001 End-of-Pipe Color Report

June 1 st Color
Reduction Report
n
„r...IIF 11G I,
i!
■ Additional Color Reduction Measures :
x
— Enhanced Monitoring
— OST and E&I PM
— OJT
— Controls for Unmeasured Sources
— Digester Area
1
— Clean Water Segregation
— Outages
- b

R June 1 st Color Reduction Report
tRv t?+tf-'��, ^gp jar 77l:p:!i? k'�'F�f,S,:.li�""F+�"W'�:!'•'�1
■ BMP Projects :
s — Digester Recirculation Pumps
— Pine Courtyard Sump
— WBL Tank Containment
— Additional Items
» Evaporator Set Demister Clogging
w
Condensate Instrumentation
» Dry Convey Hwd Knot Rejects
■ Sewer Generated Color Research

7 Dec 1 Low Flow Contingency genc
y Report
il
r
■ Plan to achieve additional color reduction at
a
Hepco duringlow flow periods <
rc� p ods 214 mgd
t=
— Maintenance Scheduling
f — Intermittent Treatment
— Production Curtailment
a
— Other Temporary Measures
» Stored & Timed Release
» Lake Logan

Champion Internationa, t;orporation - Canton, NC
Annual Average Secondary Effluent Color Discharge (lbs/day)
400,000 Historical Database from 1987 through 1998 YTD
350,000
300,000
T
O
"O
N
250,000
0
0
U
Z 200,000
150,000
0
U
V)
100,000
50,000
1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998
Section I: Figure 3
CMS 4/6/98

Cumulative Percent of Mills in the Bleached Kraft Category
27 O O O O O O O O O O O
CD
0-50
47 Canton Mill-BFR °
c
� C
e° y
50-100 V
`d• I m o. ,
22 100-150 n
0 150-200
b x
a
0 200-250 n o
a 250-300 b CL o
b 300-350
350-400
400-450
i
I
450+
I I I I I I i l
0
N
W ,
J

RecovervColor Sources
`-�S!'N�'^1 � 'S�I�r�jS1'I`4'�'Y�il •�1'r�•Y
101
i '�'' wK' 1�'Ri"�+@�C4fl�WAf+�'�tRF�rn'c--' .:_��•';�sYS Trn '�r97°:^^�'il`�i;9
$C'24 Ri°d n g n
g p
■ Pump Packing
— Evaporator Area
g k — Recovery Boilers
■ Combined & Contaminated Condensates
■ Operational Parameters
■ CRP
�f.
■ Turbidity

����
B ( '
a��s
��f
APPENDIX

NCASI Projects 97.0124 and 98.0132
Brief Summary
1.0 Introduction
The NCASI color method was initially proposed in the 1960s for the measurement of true
color in pulp and paper mill effluents. Since then, the processes utilized to treat effluents and
make pulp and paper have changed considerably. In recent years, new delignification and
bleaching methods have resulted in significantly reduced color loads in mill effluents. Studies
by a NCASI member company suggest that the NCASI color measurement method may be
prone to interferences when used on influents from mills employing these new technologies.
These interferences are thought to be caused by particulate matter suspended in the samples,
which scatter fight and may affect the measurement of absorbance utilized to determine the
true color value. NCASI is currently conducting studies to evaluate the performance of, and
possible improvements to, NCASI Method 253 for the determination of true color in
biologically treated mill effluents. These improvements include development of an effective
procedure for stabilizing the sample pH and optimizing the process used to remove turbidity in
the samples. An investigation into the effects of different sources of turbidity in pulp and
paper mill treatment system influents and secondary biologically treated effluents and their
effect on true color using the modifications developed during this study is also being
conducted.
2.0 Objectives
The NCASI research will address the following study objectives:
• An evaluation of the performance of NCASI Method 253 for the measurement of color
when used on influent and effluent samples from mills equipped with new delignification
and bleaching methods that have resulted in significantly reduced color loads.
• The development of techniques suitable to stabilizing sample pH during filtration and color
measurement.
• An investigation of the potential interferences in the color test method, including different
sources of turbidity.
• The development and evaluation of various approaches to overcome the interferences.
In addition to these objectives, NCASI is working to provide a well-defined and documented
method for the measurement of color that is consistent with EPA's method development
guidelines and the current NPDES requirements of member companies by integrating the
findings of this study into the existing color measurement procedure. The revised procedure
will also incorporate appropriate quality control and quality assurance procedures into the
NCASI method. Upon completion of the final modifications, NCASI may conduct a multi-
laboratory precision and ruggedness evaluation of the final procedure.

3.0 Approach
A list of mill candidates, from which four were selected, was reviewed to determine which
mills would best fit the criteria of low color generating mills. Grab effluent samples and
composite influent samples will be collected from the selected bleached and unbleached kraft
mills and utilized in the studies.
During the course of this research project, NCASI will conduct an evaluation of the
performance of NCASI Method 253 for the determination of true color in the samples
described above. The work will be initiated by performing replicate tests on effluents and
influents, using NCASI Method 253 to determine the components of the method that may
require further optimization in the low color value effluents. In addition to these initial
evaluations, experiments will be conducted to determine the optimum spectrophotometer
wavelength for the measurement of pulp and paper influent and effluent sample color, effects
of pre-filtration of samples, filter porosity size for optimum removal of turbidity and minimal
removal of true color, sample centrifugation versus filtration for the removal of turbidity,
effects of sample volume, and procedures for the stabilization of sample pH.
Initial research suggested the need to investigate suitable techniques to stabilize the pH of the
sample before, during, and after filtration. To address pH stability, several different buffering
systems will be investigated, including mono and dibasic sodium phosphate buffer solutions,
commercially available pHydrion buffer capsules (Metrepak), and Piperazine-N,N"-
bis[2-hydroxypropane-sulfonic acid] (POPSO) buffering solutions.
Another objective is to investigate potential interferences in the color method and to develop
and evaluate various approaches to overcome the interferences. One such interference is
turbidity. Centrifugation will be investigated as an alternative to filtration with a 0.8 µm
membrane filter to determine if the turbidity can be removed without removing true color.
Additional experiments will be conducted using successively smaller pore size filters to assess
the optimum filter size for removing particulate matter with minimum removal of true color.
To investigate the potential sources of turbidity in influent and effluent samples, solutions of
known turbidity-contributing substances such as titanium dioxide, lime, dregs, pulp fibers with
water, and precipitated calcium carbonate (PCC) will be added to solutions of known color
value. Experiments to determine the effects of various filter porosities or centrifugation on
turbidity and true color will be conducted. The investigation into the effects of different
materials that can contribute particulate matter and interfere with the measurement of true
color will be performed on influent and effluent samples.
4.0 Study Outcomes
One of the goals of the NCASI project is to provide a well-defined and documented method
for the measurement of true color that is consistent with EPA method development guidelines
and the current NPDES requirements of NCASI member companies. This method will
provide recommendations for stabilizing sample pH and reducing interferences due to
particulate matter in pulp and paper mill influent and effluent samples. The NCASI color

measurement procedure will be updated to incorporate quality control and quality assurance
procedures consistent with current analytical methods. In addition, an understanding of the
relationship between the assessment of true color and different particulate matter that may be
found in pulp and paper mill influent and effluent samples will be considered.

`
�&
APPENDIX � �

EOHS Summer Intern Program & Duke Universitv Masters Project
Water Quality- 1998
Supervised by: Chad Salisbury
I. Introduction
A) Canton Mill Orientation
1) Environmental Group Orientation
2) Standard Safety Orientation(I hour)
3) General Mill Tour
a) Paper and Board Mill
b) Pulp Mill
c) Recovery and Utilities
4) Project Specific Tour
a) Wastewater Treatment Plant(WTp)
b) Mill Sewer System
c) Bleach Plants
d) Bleach Filtrate Recycline(131711W)Process
B) Canton Mill Water Quality Issues
1) NPDES Permit and Color Variance
a) History of Issue
b) Read Permit and Variance(approved 12/97)
c) 1995 RUST color technology report
2) Canton Color Reduction Efforts
a) Bleach Filtrate Recycling(BFRTn Process on Pine Fiberline
b) Spill Control
c) Unaccounted Color Sources
[I. Summer Project-Sewer Generated Color(SGC)
A) Project Objective: The two objectives for this research are as follows:
1) Determine the effect of the color removal mechanism across the wastewater
treatment facility on sewer generated color;and
2) Determine the impact of pH adjustment of the acid sewer prior to mixing with the
mill's main alkaline sewer(see Keith's work).
A) Preliminary Literature Review
1) Read Aimee McCord's Masters Project - With focus on Introduction through page
37, 62-71
2) Read Chad Salisbury's Masters Project- With focus on Sections 1.0(all), 2.0(2.1.1,
2.1.2,2.2(pages 8-10),2.4,2.5,3.3,3.41 4.0,5.0 and 6.0)
3) Read Keith Brook's 1997 Summer Intern Project
4) 1997 Color Pie Chart and"Unaccounted"chart
5) Color Test Procedure
6) Various Sewer Generated Color Research
C) Preliminary Experimental Work:
1) Perfect Color Test Procedure-side-by-side analysis with operators at WTP
2) Set up laboratory work area at WTP-with support of Chad and John Pryately
3) Perform a couple of trials of SGC effect on acid filtrates using shaker water baths
4) Learn how to collect(ISCO sampler)and prepare(centrifugation) biosolids for
bench-scale WTP simulation
5) Repeat jar testing color adsorption experiment-only biosolids and black liquor color

D) Experimental Research-Objective I:
I) Water bath experiments on individual filtrates,hardwood vs. pine, total SGC.
2) Bench-top jar tests
F) Experimental Research-Objective 2:
1) Simulate Primary Influent at bench scale to determine how much SGC is controlled
by pH adjustment- utilize operators, extra sewer samples collected and sewer flows
from Datastream(WTP database)
2) Determine if the effect of pH adjustment on SGC is carried through the WTP
resulting in equivalent color reduction in secondary effluent.
G) Data Analysis,Results and Conclusions
1) Develop Tables and Figures to summarize collected data
2) Results may lead intern in new directions for additional experiments to answer
questions as they arise.
3) What do these results mean for the Canton mill's efforts to reduce color loads to the
Pigeon River?
III. Final Report of Findings:
A) Written Report - This document will be utilized as a technical document for the mill in
support of its NPDES permit and serve as the intem's Duke Masters Project
B) 15-20 minute Oral Presentation-Suggest the use of Powerpoint for ease of presentation
1V. Project Timeline:
The summer intern is expected to complete all necessary literature and experimental research,data
analysis and projectsummary one week prior to the individual's last day with a presentation to
take place on the last working day of the summer. The presentation will be given to interested
members of EOHS, Recovery(WTP), Pulp Mill, etc. A final report will be submitted to the mill
when the final Masters Project is submitted to Duke University. As the report is written over th course of the student's final academic year, mill representatives will edit the report and providee
necessary feedback.
NOTE: Data analysis and literature research can be done throughout summer while experiments
are running. Therefore at the end of the summer the intern should only need to compile and
Polish the work into a final product and present it to EOHS.
V. Additionalltems:
A) One-day"River Run"with WTP operator to collect Pigeon River samples
B) Attend Environmental Staff meetings
C) Attend staff Safety training
D) Participate in Canton Color Team meetings(once per month)

�
> ) :
2 & : e
,y
APPENDIX

INITIAL LEARNINGS FROM bleaching stage filtrates from an ECF sequence as
THE BFR DEMONSTRATION these contain the majority of the waste material
produced in bleaching. The BFR process and
J. Robert Caron Gerald Delaney associated laboratory and pilot studies have been
Senior Engineer BFR Product Manager thoroughly described in many recent papers [1,2,3,4].
Champion International Corp. U.S. FILTER/HPD The process is comprised of three major elements (see
375 Muscogee Road 55 Shuman Blvd. Figure 0. These are: 1) bleach filtrate recycle via
Cantonment, FL 32533 Naperville, IL 60565 counter current washing, 2) removal and control of
scale forming metals in the filtrate from the fast
acidic bleach stage, and, 3) removal of chloride to
ABSTRACT keep the liquor cycle chloride concentrations similar
to pre-BFR levels.
A full scale demonstration plant of Champion's
Bleach Filtrate Recycle (BFRSM) process was Many lessons were leamed from the closure
constructed in 1995 and started up in 1996 at the experiences of others, and no lesson was better taken
Canton,North Carolina,bleached kraft pulp.In 1997, to heart than to expect the unexpected. Ibis is the
the mill has achieved several months of operation main reason for the rigorous analytical testing
with substantial closure of the first two stages of pine program employed immediately prior to, and during
pulp bleaching (>80% closure). Several mechanical the BFR process evaluation. There are over 150 mill
and process issues were encountered during the start- variables being routinely gathered including operating
up phase, and most have since been corrected. As parameters, process chemistry, effluent data,
part of the demonstration phase. Champion will equipment performance,as well as corrosion surveys.
continue to resolve any additional process and This data collection and analysis will continue for
mechanical issues as they arise. another several months.
INTRODUCTION After several months of operation at a high degree of
closure(>80%of D 100+EOP filtrates) in 1997, the
Much of our industry is already aware that goal of the results look favorable for long-term success. Most of
BFR process is to recycle the majority of the bleach the impacts on mill operation were anticipated,
plant effluent into a mill's existing recovery cycle. although some were not. Champion has been able to
BFR is primarily focused on recovery of the first two manage all impacts to date through process or
equipment modifications as needed.
Figure 1
BFR PROCESS FLOWSHEET
BLACK CHLORIDE
LIQUOR RECOVERY ESP REMOVAL
EVAPS BOILER PROCESS
CI&K
CAUSTICIZING
WATER
COOKING/ OXYGEN
WOOD WASHING/ DELIG. D EO D IDS
SCREENING
METALS
REMOVAL Ca&
PROCESS _ Mg

RESULTS ' degree of closure has consistent) been
Y greater than
80%, and has intermittently reacted 90-100%a.Degree of Filtrate Recycle However,at present a hydraulic bottleneck in the pulp
washer train and/or water infiltration appear be
Figure 2 shows the calculated degree of closure of the limiting our ability to sustain 100% of D100 + EOP
D 100+ EOP stages. filtrate recycle. We expect this issue to be resolved
soon.
Fire 2
DEGREE OF D10000 a EDP CLOSURE
Metals Management
rF
The key process component of the metals
3 management strategy with BFR is the metals removal
44 praeess,'or MRP, as shown in Figure 3. The MRP
r ,
was started up in November, 1995, and since that
time,several mechanical and process issues have been
encountered that have limited the trill's ability to
A.r s.F on N.. D. a. F6 Mr Ap Mq J. rr
IM• IFfr utilize the MRP (utilization is a function of metals
removal efficiency,throughput,and availability of the
As can be seen in the graph, the Cost efforts to equipment). The time involved in discovering and
substantially close the D100 + EOP stages began in correcting these problems accounts for most of the
August of 1996. During the fall of 1996, some Periods of lower (i.e.<80%)closure between August
significant mechanical and process issues associated 1996 and July 1997. Most of these issues have been
the MRP were identified and resolved, allowing a resolved,although some are still outstanding.
high degree of closure to be resumed within a few
months. Figure 4 shows data that reflect the capability of the
MRP, rather than the overall average for the key
i In 1997, with the exception of the month of June, the performance indicators shown.
BLEACH FILTRATE
FROM DI STAGE
F®ER
RETURN r 1 lN•CB
MEDIA
FIBER FILTERS 1
STRAINER
•
• REGENFEANT
WASTE
SOFTENERS - ----
UNTREATED FILTERED TREATED TREATED DI
FI MTETO
BLEACH PLANT
Figure 3. Schematic of Metals Removal Process(MRP)

As can be seen, the MRP is capable of achieving a the D100 and EOP washer mats, however, is larger
hardness removal efficiency, throughput and %r than anticipated, and probably due to mill efforts to
uptime close to the design targets, maintain a high degree of closure while the MRP was
experiencing throughput or uptime difficulties. The
Figure.4 concentrations of aluminum and silicon in the weak
IN
Remits From Metals Removal Proem black liquor have not been impacted by BFR.
I a at a v{at
'0 - Bleach Chemical Requirement and Organic
b N ........ .......... Carryover
.. ........ ..........
a ........ -......-.. .. The original BFR laboratory work showed that with
e full recycle of the D100 and EOP stages, the
1121tam TW-War x upra carryover of dissolved organic material into the 13100.
and EOP stages would increase dramatically; by a
factor of approximately 2-3'times. However, due to
During the research and design phase of the BFR the degree to which much of this material would
project. it was predicted that the amount of non- already be oxidized, and due also to the high
process metals(NPMs,comprised mainly of calcium; selectivity of CIO, toward pulp relative to the
magnesium, manganese) tarried over'into the EOP dissolved organics, only a small increase in bleach
and D2 stages would increase with the BFR process, chemical requirement would be expected (1-4 kg
This increase, however, was expected to be small C102/odt).
enough not to cause any negative effects (i.e. no
impact on scaling, EOP H2O2 efficiency, or pulp Figures 6a and 6b show the increase in the amount of
quality). Figures 5a and 5b show the.profiles of carryover from each of the washers listed, for total
calcium and manganese across the bleach stages ofganic carbon (TOC) and chemical oxygen demand
involved with the BFR process. (COD),respectively.
Figure sa Figure 6a
Calcium in Pulp Washer Mat Impact of HER on TOC Carryover
isu
F�_ It
g 2N6_. ..... .-.....tff t ch.. o Ir' -:, ......... ............. iTiF7Pf^
e — e ...... ...........
L a 6
su:.._. .... .....:... I a
rR.elm .... -....
DIM EO
0
P 111 Bh Dlea rD
Figure 5b Figure 6b
ree Maagaume in Pulp Washer Mal Impact of BFR on COD Carryover
ie
' € ...... ........... i
e SN; ............ ....... ...:.:...:_ aaa�t04 O�oave. iS
a 30 ...... :...... .}wx Ovm_
Iso- - a
Ylei ....._ -........- ie .:.... ...
E ........... ...-._ ......... ......_-.
o is _.... .. ........
........... .......... i
............ EO.......
s
OOOMO
O u
1 ..._
Re Bk� ......-. ..._.
DIM e
Pia-Blaaan Dial DO
Virtually all of the increase in NPMs in the pre-
bleach washer pulp. mat arises from the use of tow As can be seen, the magnitude of the increase in
D 100 filtrate on the pre-bleach washer upper pond, as carryover from the pre-bleach washer into the 13100
expected. The increase in calcium and manganese in stage is within the range of that predicted(from 2.4 to

6.4 kg TOC/ton, and from 10 to 20 kg COD/ton). chloride concentration dropped from 3.4 g/I to 1.6 g/1
Additionally,the increase in carryover from the EOP shortly after starting up the CRP system.
washer into the final D2 stage is relatively low (from
3.5 to 4.1 kg TOC/odi, and from 9.1 to 12 kg
COD/ton); this is also within the magnitude of the
increase predicted. Figure 8. Chloride Removal Process
The average bleach chemical application rates are
Figure 7.The " Condenser in Fi
g pre-BFR" values correspond
to a period immediately prior to substantial closure
efforts.
Figure 7 Precipitator
Impact of BFR on Bleach Chemical Usage Ash
u
= .nr.ela
I 1rJ raJ . aa11►❑tun
v: ......
i °aa 2tl
201 ..... ...... ..... ......
< 1
is ......
S
o Strong wash
ao° awl woo eaol Black Liquor .
tftbh mKc w: r,oem.16J:efa.I
re.l tso a.yam: ty.-ara.1u;aIx. Ica SaltrJke
Saltcake
The total CIO, requirement increased by 3.4 kg Filter
CIO,/odt under conditions of >80% closure of the To Recovery
D 100 and EOP stages.NaOH usage has also increased armlet
slightly, although H2O,use is not affected and H,SO,
usage has decreased slightly. So far, it appears that
the bleach chemical costs have increased about 10-
15%a during periods of substantial closure.
Chloride Management v .
Chloride&Potassium
Under BFR process conditions, the chloride recovered to Disposal
with the bleach plant filtrates must be thatched in
magnitude with the chloride purged, in order to This figure also shows that with a high degree of
prevent elevation of chloride concentrations in the filtrate recycle, the chloride levels have risen but
recovery cycle.. The Chloride Removal Process remain below pre-BFR levels.The BFR process was
(CRP),shown in Figure 8, was developed by Sterling
Pulp Chemicals Ltd, to provide this purge using Figure 9
selective crystallization of the electrostatic Results .From Chloride Removal Process
precipitator ash. 1go aA.lm: ET
e CRP was started up in August of 1995, and has ....._. .....
i
m 61':..... :. ... ..... .....
met the performance expectations for chloride removal
(see Figure 9), although the utilization of existing I0
process equipment has limited the actual throughput. r'
r Sulfate recovery has been less than expected, due to 1
utilization of the CRP also for liquor inventory
control. Figure 10 illustrates how the white liquor

originally designed to achieve an equilibrium white or no recycle, the amount of COD discharged from
liquor chloride concentration only slightly greater the pine bleach plant corresponds to approximately 20
than for pre-BFR levels,for 100%recycle of the to 25 thousand pounds per day. During periods of
Figure 10 Figure 11
Impact of BFR on Chloride in While Liquor Impact of BFR on Bleach Plant COD
S Jt
6 .. �9IDr.RecrdbtI I
....... _. up. ... Tt 25
< '1 ......... _ a29 . ..
i ........... .�s.. ais
CUP
IAS S/f! e93 12M UM t/96 12J% 4/99 1M 6 DW
DATE Jal A9t!, od N9r Dee J- Pe! Ma Apr May 10 is,
1996.199'r '
D100 and EOP stages for all pulp mill production(1).
However, in the case of.the BFR demonstration as Figure 12
implemented at the Canton mill. where D100 and Impact or BFR on Bleach,plant color
EOP filtrates ffon: only one of the rwo pulp 39
berlines are bein :2s ...... ........_..
h g recycled(about 45% of total pulp a 29 "_"""-'
production), the equilibrium chloride concentration
was predicted to be slightly less than pre-BFR levels. v u . ._ ..... ...._ ._
-- ..
it ... .. ... ...
Consequently,the white liquor chloride concentration ° .............. .............. '
S ... .. ... ... ........1
currently being achieved is within the range of that
9
predicted. Jr Art Sep Od Nee Dec to FA Mn AM My Jus J91
1996-1991
The potassium removal efficiency of the CRP is very
similar to that for chloride. Since starting the CRP substantial recycle,the bleach plant COD discharge is
system at Canton, the virgin black liquor potassium reduced to approximately 5 thousand pounds per day,
concentration has decreased from 1.6% to less than or about 75-80%.The color discharged from the pine
0.8% (as is basis). bleach plant decreases from about 20 to about 5
thousand pounds per day. However, the treated, final
The operation of the two recovery boilers has mill effluent may not realize all of this color benefit,
improved since implementing the CRP. This is the due to the elusive behavior of a portion of bleach
result of reduced chloide levels coupled with reduced plant color during biological effluent treatment.
potassium levels in the liquor cycle, in addition to
two other operational improvements made over the Pulp Quality
course of the BFR demonstration: 1) installation of
PLC-based control of sootblowing, and, 2) nxh,, i Pulp production on the Canton mill's softwood line
variability of% solids in the firing liquor. Prior to has continued at normal operating rates with no
CRP start-up and the above improvements, the steam decline in pulp quality.In the course of start-up of the
superheater temperances would decline due to BFR process, bleaching control and filtrate
pluggage requiring"chill and blow" cleaning every 2- management strategies had to be changed significantly
3 months. Today there is no detectable decline in to accommodate the effects of carryover and recycle
superheater temperatures and the boiler is no longer of bleach filtrates. Without incorporating these
subjected to "chill and blow" cleaning between changes, pulp quality would likely have suffered.
normal outages. Since we have not seen any negative impact on pulp
quality,we have concluded that our approach on this
Effluent Benefits issue has been a successful one.
Figures II and 12 show the total COD and color CONCLUSIONS
discharged from the pine bleach plant, respectively.
As one would expect. the reductions in COD and The main objective of the BFR project is to achieve
color mirror the degree of D100 + EOP closure in and sustain 100% closure of the D100 and EOP
Figure 2. The data show that during periods of little bleach stages of the Canton pine bleach plant, and to

evaluate the impact of BFR on mill operations and 2. Caron, J. R., and Fleck, J. A., "Metals
costs. This has not yet been achieved, but a high Management in a Closed Kraft Mill Bleach Plant",
degree of D100 and EOP closure (>80%) has been proceedings from the 1994 Tappi Pulping
maintained for most of 1997. At high levels of Conference, San Diego,California.
closure, we have maintained pre-BFR levels of pulp
production rate, fiberline equipment uptime, and 3. Caron, J. R.. and Williams, L. D., "Design and
product quality. Positive impacts so far include a Integration of the Bleach Filtrate Recycle Process",
reduced degree of recovery boiler generator bank proceedings from the 1996 Tappi Minimum Effluent
pluggage, and substantial reductions in the discharge Mills Symposium, Atlanta, Georgia.
of color and COD from the bleach plant.
4. Fleck, J. A., Earl, P. F., Fagan, M. J., "Kraft
In order to achieve this, it was necessary to install Mill Bleach Filtrate Recycle and the Commercial
new equipment (CRP, MRP, bleach filtrate Demonstration of Chloride and Potassium Removal',
piping/controls), and to make process and mechanical proceedings from the 1996 Tappi Environment
modifications to the new equipment based on first- Conference,Orlando,Florida.
time learnings. All of this has been managed well,
but nevertheless represents a net increase in mill costs
relative to pre-BFR conditions.
Some of the more significant BFR-related issues that
are currently outstanding,include:
•Improvement of MRP performance
(throughput, reliability,and efficiency)
•An accurate assessment of the costs to
mill operation
•An assessment of the impact on recovery
boiler emissions (although no impact is
expected)
•An assessment of the impact of BFR on
paper machine performance(none expected),
and on corrosion and scaling potential
throughout the pulp mill
ACKNOWLEDGMENTS
The authors are grateful to the many Champions that
provided input to this paper, especially those at the
Canton mill.
BFR is a trademark of the Champion International
Corporation. CRP is a trademark of Sterling Pulp
Chemicals Ltd. The BFR and CRP trademarks ate
licensed by Champion International Corporation and
Sterling Pulp Chemicals Ltd. exclusively to U.S.
Filter/HPD.
References
1. Maples, G., Ambady, R., Caron, J. R.. Stratton,
S. C., and Vega Canovas, R. E.. 'BFR: A New
` Process Toward Bleach Plant Closure", Tappi
Journal, 77(11),pp. 71-80(1994).

-
��
APPENDIX "T 4&A

'-Progress report CHLORINE FREE BLEACHING
�
on the BFRTM tee ooU�L� IfInner —1
hnology -- AW oJ0MES I demonstration: December 1996
Partial recycling of Filtrates has been achieved on an intermittent basis
By S.C.STRATrON AND M.FERGUSO.N
CHAMPION INTERNATIONAL CORPORATIO 'Inc,Oxa en
is currently demonstrating a patented s g dehgntficaoon stage followed by three
technologvwhose purpose is to recrner tages of post•oxagen washing a 350.ton brownstock
waste materials from high density storage tower, and a medium consis-
tpulps.The demonstration pit j e blehoungrof tenev D(EOP)D bleach plant followed jn•a 75pton
pose is to show that the BFR process is a commer- bleached storage tower.All of the washers except
ciallv viable method for re�LngECF.bleaztLn the screen decker arecom
trates. is underway at Ch gfil filters. The new line Paction-baffle pressure
in Champion's Canton. NC. ISO brightness produces 600 admvdav of 85
integrated bleached kraft mill.Facilities have been The old Pine pulp'
installed that enable the reading of filtrates a have
from Pine bleach line was rebuilt and an
the first two bleaching stages of the 600 oxygen deh9ni ication stage
pine bleach lanL admridav admt/day of ECF added ro provide 695
have been stoned u All of the component systems hard hardwood pulp capacity. The
p.As of December 1996, gems hardwood configuration includes twostage knot-
recvcling of the DI00 and EO s P ring, four brownstock
been lachieved ing of the
an 0 and EOintermitte stag,
filtrates has tents.ory washers. medium of fin-
'¢en eeli¢nifi xyg n. four stages of fine
PROCESS 0 screening, three a lower.a washers, a 150.ton
OVERVIEW brownstock storage tower.a medium consistence �
T'te BFR Process is the result of some five years of D(EO)D bleach Plan, and
tensive develnnme pulp storage tower. All the washers in bleached
hard-
_ )m Sterkn rat b`•Champion,with suerricpport wood tine are vacuum drum type.
drew from the Iearuin ��e The development One of the nvo e
operation at he le g Effluent Free Nlill installed in 1965 and the o recovery boilers was
The baste to der Bay,,ON.in the 1970s and Bp,. have ceclone- they in yaP Both units
rant upon which the process was d wet bottom n'Pe direct contact evaporators and
oped is to avoid the buildup of non-process elements a Precipitators.As part of the mill uip mod-
knawn to adversely effect mill o miution project.both boilers were BFR adds two new peraoons' tertian•air and the lower furnace se tionsa wwith
ere
mill:A chloride removal process
to a bleached krah rebuilt with composite tubes to provide enhanced
a purge of chloride and P ocess (CRP) Provides corrosion resistance.Additional screen and super.
em boiler precipitator ash. and a mretals remrnal treater tubes were installed in the older boiler r
Process iMRP) enables removal of scale-formmg The environmentally-d
wood minerals, predominantly calcium, 'Deluded rebuildingof_ raven project also
Filtrates from the DI00 and EO s sets and an odor aatement syst black eem.Aor ttmill waater OD(EO)D bleach sequence are used tages of an distribution and cooling system was installed to
in the Pulp uence as wash water d
P P washers following oxvgen deli ifica- ramatically reduce the water cue in the mill.The
lion.In this way, gn chlorine dioxide
bleachingbecome dissolved wute materials from additional ca generator way rebuilt to provide
part of the black liquor. The was modifiedptoi ccom and the waste treatment plant
organic fraction is destroved in the recover,fur- [ions in modate the major reciu,
pace.and the usable chemicals are recovered.Fie- effluent flow and o S.C.MA ore 1 shows schematically These modifications achievedia 75%d decrease in TTON.
of relevance to the BFR the major process flows mill color disch Senior engineer.
process. Maples et al(I) effluent flow fro1.88 to j 27msthird reduction in Cantonment,Championint'l Corp.,
Provide a more detailed description of the process /s(43 to 29 MGD).
and the associated development effort
MILL DESCRIPTION NEW FACILITIES
The BFR process equipment installed during
The Canton mill manufactures 1994 includes a Chloride removal r
rev 1360 admt/day of a9 removal process new, Process.a met-
bleached board and printing and writing papers.In recycling filtrates as Piping and controls for
hie the mill completed a major capital project tram well u
which assured coine
in fiance with P water from Provisions to remrne
P th state and federal The chloride removal pro
quality limits.The project replaced two old three-effect evaporative cnstallizer, and vacuum
roes.which had(C+D process consists of a
l ten one new,pulp 1EFID bleach sequences filter. Water replaced black liquor in the reel i.
p p line,that incudes two stages of tator bottoms,and black liquor now flows d mecci p��I ERGUSON,
knotting, three stages of brownstock washing, a from the oxidation system to P
lourstage fine screening system a medium mnsis. P R process supt..
eva ntors to the direct contact Chain ion Int•I Corp.,
P° the recovery boiler.
Canton,NC
1'alP 6 Paper Canada T 82