NC0005321_Fax_19990326

AN 1? '95 12:19PM
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1 199
ENV, MANAG5MENT
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management,
P.O. Box 29535
Raleigh, North Carolina 27626-0535
i
TRAINING AND CERTIFICATION DNYT
FROM. 1
FAX # [phone]
PHONE
NUMBER OF PAGES, INCLUDING THE COVER SHEET:
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...IF 10 V COR PC R A r ION
Mr. Ron Hilbelinlc
Asst. Vice President Manufacturing
Alpha Cellulose Corp.
P.O. Box 1305
Lumberton, NC 28358
Copy: Ivir, Wayland MacAllister
President and CEO
Mr. Jim Isrealson
Engineering Manager
Dear Ron.,
WATER TREATMENTPRCDUCTS
PAPER CHEMICALS
SURFACE TREATMENT PRODUCTS
COSMETIC INGREDIENTS
SPECIALTY 9IQQIDES
November 21 vll.AS.n
JAN 1 7 1995
ENV. MANAGEMENT
FAYETTEVILLE REG. OFFICE
Ron Radford
Supervisor Waste Treatment
Attached is a report by .Howard .Flock based on both his most recent visit to the plant in
October, as well as his previous visit to the plant in March, 1993. As you can see, the report is detailed
and thorough regarding the waste treatment area,
Calgon appreciates the opportunity to offer this level Of consulting to Alpha Cellulose as a part
of our commitment to you and your company. We have and will coniinue to provide you with
whatever services we haw at our disposal, to insure increased efficiency inl the operation of'the waste
treatment facility.
I trust you will find the assessment of the; plant and Howards reco►nmenclations accurate and
helpful. Should you have anv questions at all,regarding the attached report,jplease feel free to contact
me at any time. I will be happy to arrange for turthcr discussions on this subject between yourself and
Howard Flock should the need arise.
Respectfully,
72
George Flolowaty
$08 CHURCH STREET ■ WILMINGTON, NC 28A01 . PHONE [phone]
INNOVATIVE TECHNCLOGIE3, CREATIvE SOLUTION$ ...SINCE 1IQ18

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• a o'' C Fi POFAT I ❑ N
MEMO
TO: George Holowaty
FROM: Howard Flock
DATE: November 14, 1994
SUBJECT: Alpha Cellulose - Lumberton; NC
This memo summarizes the results of the subject audit conducted at this facility on October 25 to
27. Also, included is a summary of a previous audit conducted in March, 1993 since it contains
pertinent background information.
Summary of March, 1993 Audit
A. Problem - Waste treatment plant experiencing severe filamentous growth/bulking in
the activated sludge process that was causing higher final effluent discharge levels
of TSS and BOD.
B. Wastewater - Mill processing about 120 ton/day of paper, which is generating a 1.6
MGD waste stream containing a high pH (11,0i), high TSS loading (800' mg/1) and
high organic loading (BOD - 1300* mg/I and COD - 4500 mg/I).
C. Secondary Waste Treatment Plant - Employs the following treatment processes for
solids removal and degrading the organic loading of the `waste stream.
1. Primary (1 °) Treatment - DAF unit (PCE design)
2. Secondary (2°) Treatment - Activated sludge process (aeration basin with
mechanical aerators and three final clarifiers)
D. Waste Treatment Plant Operating Parameters - Actual vs. Design
Unit
1. 1 ° DAF TSS Removal
Actual Design
10% 50%
2. 2° Aeration Basin (Volume 5 x 10" gal.)
a. F/M (low)
b. MCRT (high)
c. Detention Time (long)
d. Volume Org. Loading
e. D.O. (low zones in basin)
f. Nutrients N+P (deficiency)
g. Temp C°
h. pH (high) influent/effluent
i. MLSS (high)
I. SVI (high - bulking)
0.1
30 to 40 days
3 days
28 Ibs BOD5/1000 ft3
<1.0 mg/I
<1.0 mg/I in effluent
27°
11.0`/8.7'
4000 mg/1
225 - 250 mUg
0.2 to 0.4
6 to 25 days
8' hours
20 - 40 lbs BODE/1000 ft3
1.0 - 3.0 mg/I
1.0 - 1.5 mg/I in effluent
25" - 35'
9.0/7.0
1000 - 3000 m
<150 mUg
T
INNOVATIVE TECHNOLOGIES. CREATIVE SOLUTIONS ...SINCE 1918
c,KnoK AND

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Alpha Cellulose - Lumberton, NC
November 14, 1994
Page 2
Unit
Actual
3. Final Clarifiers (estimated design parameters)
a. Effluent Overflow Rate
b. Solids Loading Rate
300 gal/day/ft`
0.5 lb/ft2/hr.
Design
750 gal/day/ft2
0.5 Ib/ft2/hr.
The low F/M, low D.O. (inlet and outlet zones of basin), high MCRT, nutrient
deficiency, and high pH in the aeration basin are favorable factors to influence and
enhance filamentous growth. The long detention in the aeration basin is conducive
to nitrification, which has a high oxygen up -take demand, in the outlet zone rapidly
depleting the available D.O. The higher MLSS reduces mixing, lowers 02 gas
transfer rates and D.0., besides causing nutrient deficiencies.
E. Corrective Action - To control the filamento.us growth in the activated sludge
process, the f=/M and D,O. levels had to be increased while the MLSS and MCRT
had to be discussed. This was accomplished by:
1. Converting the 1 " DAF to a 1" clarifier which increased the TSS removal
from 10% to 55+%. This reduced the solids loadiing to the activated sludge
process. Assists in reducing MLSS and MCRT, besides raising the F/M.
2. installing a new, two meter belt press so that more WAS solids could be
removed from the activated sludge process. This also reduced the MLSS
and MCRT while raising the F/M.
3. Installing three new (40 hp) surface aerators and repositioning them with the
existing surface aerators throughout the aeration basin; especially at the
inlet of the aeration basin where the 1 `' influent and RAS are applied.
Partition curtains were installed at intervals from each side of the basin to
prevent channeling through it. The resulting serpentine (plug) flow was
routed through the network of surface aerators to 'maximize 0.0. efficiency
and BOD5 reduction.
F. Future Concerns - The above corrective measures will only control filamentous
growths but never eliminate it. High pH's, N and P nutrient deficiency and/or low
F/M values, especially during mill shutdown periods (2 days) every two weeks, will
continue to influence filamentous growths. Need to investigate the following:
1, pH adjustment of wastewater with acid to 9.0.
2. Increase ammonia and phosphoric acid addition td maintain a N and P
value of 1.0 to 1.5 mg/l in the final effluent.
3. Supplement an organic food source to maintain the required F/M value
during periods of shutdown.

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Alpha Cellulose - Lumberton, NC
November 14, 1994
Page 3
II. Summary of October 25.27, 1994 Audit
A. Problem - Waste treatment plant is again experiencing evere filamentous
growth/bulking in the activated sludge: process which is causing higher final effluent
discharge levels of TSS and BOD.
B. Wastewater - Mill processing about 140+ ton/day of paper, which is generating a
2.0 MGD waste stream containing a high pH (11.0'), high TSS loading (1000' mg/I)
and high organic loading (BOO -1600+ rng/I and COD - 5500+1 mg/I).
C. Secondary Waste Treatment Plant - Employs the following treatment processes for
solids removal and degrading the organic loading of the waste stream.
1. Primary (1 °) Treatment - 1 ° Clarifier. (converted I ° OAF)
2, Secondary (2°) Treatment - Activated sludge process '(aeration basin with
'diffused aerators and three final clarifiers)
Waste Treatment Plant Operating Parameters - Actual vs. Design
Desi n,
Unit
1. 1° Clarifier TSS Removal.
Actual
67%
2, 2° Aeration Basin (Volume 5 x 105 gal.)
a. F/M
b. MCRT
c. Detention Time (long)
d. Volume Org. Loading (high)
e. D.O. (low zones in basin)
f. Nutrients N+P (deficiency)
g. Temp C° (high)
h. pH (high) influent/effluent
i. MLSS
j. SVI (high - bulking)_
0.38"
20 days
2 days
40 Ibs BOD5/1000 ft3
<1.0.mg/I
.<1.0 mg/I in effluent
35°-41°
11.0'/8.7`
1650 mg/I
350 - 400 mL/g
3. Final Clarifiers (estimated design parameters)
50'
0,2to0.4
6to25days
8'! hours
20 - 40 Ibs BOD5/1000 ft3
1.0-3:0mg/I
1.0 - 1.5 mg/I in effluent
25° - 35°
9.0/7.0
1000 - 3000 mg/I
<150 mllg,
a. Effluent Overflow Rate 375 gal/day/ft2 750 gallday/ft2
b. Solids Loading Rate : 0.26 Ib/ft2/hr. 0.5 Ib/ft2/hr.
The newly installed, tapered -diffused air system has lost several sleeves and/or lateral
hoses off all the main air headers in the basin. This is causing, large air bubbles with lower
°2 gas transfer rates resulting in very low D.O. levels throughout the basin. The low D.O.,
possible nutrient deficiency, high pH and low F/M values especially during the two day
shutdown periods every two weeks continue to influence and enhance, filamentous
growths. Microscopic examination of the MLSS indicated more than one strain of
filamentous organisms. A sample of MLSS sent to Or. Michael Richard (RBD, Inc) for

JHN 1 'fib 1e:15PM
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Alpha Cellulose - Lumberton, NC
November 14, 1994
Page 4
filamentous identification confirmed that there were four different strains rather than the
usual one or two strains found in paper mill waste treatment plants. Besides low D.O., the
blower diffused air system is releasing its air temperature energy into the wastewater
raising the temperature in the basin from 35° to 41PC. Prior to the diffused air installation,
the surface aerators provided evaporative cooling to keep the basin temperature at or
below 35°C. The existing Mesophilic bacteria (251C - 35°C), including the filamentous
strains, start to die above 35°C. The filamentous sheaths start to break up resulting in a
large amount of light, small pin flocs. In addition, the Thermophilic bacteria have just
started "their growth cycle resulting in a large amount of small pin flocs with a.young sludge
age. When the plant shuts down for two days after two weeks of operation, the
temperature drops below 35° and the Thermophilic bacterial growths (start to die off,
prompting the existing filamentous growths to proliferate again.
E. Corrective Measures
1. .Immediate Action
a. Increased D.O. Level in Aeration Basin
1) Repair all of the damaged lateral hoses'and sleeves off all
the main air headers of the newly nstailed tapered -diffused
air system.
2} Insure sufficient D.O. Is achieved at the inlet of the aeration
basin where the waste stream is first mixed with the RAS.
Without an "effective: D.O. level at this stlage, the use of
partitioning curtains in the aeration basin to provide a
serpentine (plug) flow would be irrelevant.
b: Increase F/M Level in the,:Aeration Basin
1) During shutdown periods, apply supplemental BOD food
source to the.wastestream to support and maintain non -
filamentous biological growths.
2) ' During production runs, hold MLSS at 2250 mg/I ± 250 mg/I
or MLVSS at 1800 mg/l ± 200 mg/I to maintain an F/M of 0.3
to 0.4. "
c. Determine N and P Deficiency
1) Since the final effluent contains color, it will interfere with_
non -digestive color test kits. Use ohiy digestive test
procedures to determine final effluent N and P values.
2) Per the above, adjust N and P treatmentiaccordingly to
maintain a 1.0 to 1.5 mg/I of each i f the final effluent.

JAI 17 '95 12:15PM
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Alpha Cellulose - Lumberton, NC
November 14, 1994
Page 5
d. Chemical Treatment
1) Continued high levels of TSS/BOD carrying over into the final
effluent as a result of filamentous land/or thermophilic
growths can be controlled by applying polymer treatment to
the final clarifiers. Laboratory jar tests show that two high
molecular weight, cationic polymers (PEZ-2466 and 3466)
will increase the settling rate of the MLSS and reduce the
effluent TSS.
2) The existing CA-250/WT-24561 sludge dewatering program is
effective; however, the pH of the 1,° sludge should be
adjusted with acid or CO2 to a pH below 8.0 prior to blending
the WAS, this will significantly decrease polymer dosages
and treatment costs. Besides lowering the polymer dosages,
the acid and/or CO2 will lower the 'viscosity of the sludge
allowing for better dewatering/drainage rates, increased
production and/or drier cake solids', Since CO, is available,
start application and determine pH'that provides best
polymer treatment costs.
It should be noted that the above corrective actions (increasing nutrients', D.O., and F/M) still may
not prevent filamentous and/or thermophilic growths related to the carryover of TSS and BOD in
the final effluent, since the secondary portion of the waste treatment plant is operating at or near
capacity with no margin for error.
2. Near Term Action
a. Reduce the influent waste stream temperature to offset the rise in
temperature employed by the new diffused lair system to control the
mesophiiic bacterial growths and eliminate, the thermophilic bacterial
growths in the activated sludge process. Irk addition, the reduced
temperature allows for higher 02 gas transfer rates and maximum
D.O. levels. Successful methods employed to reduce temperature
follow.
1) Blending additional cold water to the 1" effluent waste
stream, provided the aeration basin and final clarifiers can
take the increase in hydraulic loading.
2) Passing the 1 ° effluent waste stream over a cooling tower,
provided maintenance of solids is performed to prevent
plugging and fouling problems.
3) Passing the 1* effluent waste stream through a heat
exchanger, provided there is a good source of cold water
available.

JAN 17 '95 12:16PM
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Alpha Cellulose - Lumberton, NC
November 14, 1994
Page 6
b. The existing aeration, basin is now at the maximum volumetric
organic loading for a tapered -aeration activated sludge system - 40
lbs. SOD5/1000 fta . Any increase in higher organic loadings which
will require the following changes to meet exiting effluent discharge
limits.
1) Investigate converting tapered -aeration system to step -
aeration system so that higher organic loadings can be
processed with only minor modii'icatio'hs. See my enclosed
highlight of the step -aeration activated sludge process.
2) Investigate.the installation of a new, small, first stage
aeration basin or high rate 02 or air enclosed reactor basin,
to remove a desired amount of arganips from the wastewater
(rougher). This would allow the existing aeration basin (2nd
stage) to successfully degrade the remaining organic loading
in the wastewater.
Finally, I have enclosed a copy of Michael' Richard's report on the results of his microscopic
examination of the Alpha Cellulose activated sludge sample. The causes he lists for filamentous
growth substantiates part of my initial findings - low F/M and D.O.
If the plant personnel have any questions concerning this memo, let i e know and I will arrange my
schedule to meet and review it with them.
411
Howard Flock
Regards,
HF/sf
cc: Roger Sigler
Nick Alfar►o
Robert Gephart

JAN 17 '95 12:15FM
IV, Step - Aeration Activated Sludge Process
P.9
Seconder Influent
Final Clarifier
Waste
Sludge
Final
Effluent
- - - - Alternate Waste Sludge Point
The step -aeration process is a modification of the conventional process in
which the secondary influent is introduced at several points in the aeration
reactor to equalize the food to microorganism ratio, thus lowering the peak
oxygen demand,
In step -aeration, the oxygen demand is more uniformly spread over the length
of the aeration reactor, resulting in better utilization of the oxygen sup-
plied. The multiple -point introduction of secondary ,influent maintains an
activated sludge with high adsorptive properties, so that the soluble organics
are removed within a relatively short contact period. Therefore, higher vol-
umetric organic loadings are possible.
Process Characteristics
1. General application to a wide range of wastes.
2. Employs plug flow.
3. Utilizes diffused -air.
4. BOD removal efficiency is 85 to 95%.
Design Parameters
1. Food to microorganism ratio (F:M) is 0.2 to,0.4.
2. Mean cell residence time (0c) is 5 to 15 days.
3. Volumetric organic loading �VOL) for the aeration reactor
is 40 to 60 lb BOD5/1000 ft .
4. MLSS is 2000 to 3500 mgll.
5. Detention time (DT avg.) of aeration reactor is 3_,to 5 hours.
6. Sludge Recycle ratio (Rr) is 25 to 75%.

JAN 17 '95 12 : 17PM
P.10
,NC
Engineering Consultants
209 5, Meldrum
Fort Collins. Colorado 80521
303/482•5922
PAX 1031482-e36e
November 5, 1994
MEMO TO: Mr. Robert J. Gephart, DSM
Calgou Corporation
120 West Bay street
Savannah, GA 31401
FROM: Michael Richard, Ph.D.
RE: Microscopic Examination Results tor an Activated sludge Sample from Alpha
Cellulose, Lumberton, NC Dated 11/3/94.
Enclosed please find microscopic examination results for an activated
sludge sample from Alpha Cellulose, Lumberton, NC dated 11/3/94. Photos
(slides) for this sample are enclosed. Following is a summary of findings
(also see the enclosed filament ID sheet).
Filament were present. at ABUNDANT amounts, causing sludge bulking by
inter -floc bridging. The activated sludge flocs were tirm and rounded in
shape and in the size range 150 to 800 um in diameter (large). Polysaccharide
in the flocs, determined by negative staining with India ink, was normal
(common). Higher life forms present were cotntncn amounts of tree ciliates and
a few testate amoebae. Filaments present were:
RANK FII.AMENTOIJS ORGANISM
1
2
3
4
Nostocoida limicola iI
Haliscomenabacterdrossis
type 1851
type 05A1
ABUNDANCE
abundant
very common
common
some
significance of F'ind7.nga
Significant filamentous bulking is occurring, caused by our filaments.
N. litaiCOla IT and H. hydrossis, were most significant, with lesser amounts of
types 1851 and 0581. The activated sludge itself was very large in size and
healthy and higher life forms were common and healthy.
These filaments have several causes, All tour filaments occur at lower
F/M operation thigh MLSS concentration) , and this may be their cause. N.
1imirola II also is caused by high conce;alrations of organic acids (at lower
F/M). H. hydrossis may also indicate low oxygen concentration.
Omer Ottire, 0anver a03b158,5320

JPM 17 '95 12:17PM
P.11
R, Gephart
11/5/94
page 2
In summary, the filaments found indicate low F/M and maybe low oxygen and
high organic acids as the cause of current bulking.
Please give me a call at 303-482-5922 if you have any questions about
these findings or wish to discuss them.
Sincere v ,
copy to Howard Flock Michael Richard, F'n.D,
Calgon/Denver