HomeMy WebLinkAboutNC0000272_Annual Report_20170703I
evergreen'.0
packaging
July 3, 2017
Canton Office
175 Main Street • Canton, NC 28716
Landon Davidson
Regional Supervisor
Division of Water Resources
North Carolina Department of Environmental Quality
Asheville Regional Office
2090 U.S. Highway 70
Swannanoa, North Carolina 28778
NMM #36-17
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
7099 3220 0007 0371 4828
Re: Annual Progress Report on Color
NPDES Permit No. NC0000272
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton Mill
Dear Mr. Davidson —
RECEIVEMCDENWR
JUL 112017
Water (duality
Porrnitting Section
Enclosed is the Annual Progress Report on Color required by Part I A.(8.) item 8 of the May 26, 2010
NPDES permit. This report covers the seventh year of the permit (July 2016 through June 2017).
Very truly yours,
BLUE RIDGE PAPER PRODUCTS INC.
DOING BUSINESS AS EVERGREEN PACKAGING
By:
Nick McCracken
EHS Water Supervisor
828-646-2874
mck.mccracken(a)everpack com
Enclosure: July 2017 Annual Progress Report on Color
cc* NC DWR — Complex NPDES Permitting Unit, Raleigh
Doing Business in California as Evergreen Beverage Packaging
EOHS\Share\Water\NPDES\Permits\2010 NPDES Permit\Permit Reports\Color Reports 2010 Print
I
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
I. Introduction
Part I A.(8.) item 8 of the May 2010 NPDES permit states — The facility will provide annual
progress reports to the Division on the color reduction efforts. This report fulfills the
requirement of Part I A.(8.) item 8 for the sixth year of the permit, July 2016 through June
2017, with emphasis on the mill's Best Management Practices (BMP) program
refinements.
Color -related reports previously submitted to the NC Division of Water Resources (DWR)
under terms of the May 2010 NPDES permit include the following:
o July 2011 Annual Progress Report on Color [Evergreen 2011 ]
o February 2012 Update to the Color Reduction Implementation Plan [Evergreen
2012a]
o July 2012 Annual Progress Report on Color [Evergreen 2012d]
o July 2013 Annual Progress Report on Color [Evergreen 2013]
o July 2014 Annual Progress Report on Color [Evergreen 2014]
o July 2015 Annual Progress Report on Color [Evergreen 2015]
o July 2016 Annual Progress Report on Color [Evergreen 2016]
These reports are incorporated by reference.
I
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
II. Background
Levels of color in the wastewater effluent from the Canton Mill are among the best of Kraft
pulp and paper mills in the world [EKONO 2005, NCASI 2006]. This high level of color
performance is achieved by in -process controls and BMP's. The Canton Mill continues to
operate the controls and practices proven successful for color prevention. These controls
and practices go well beyond the requirements of the EPA Cluster Rule for Pulp and Paper
(40 CFR 430, Subpart B). Many, such as the Bleach Filtrate Recycling ProcessTM, are
unique to the Canton Mill.
The May 2010 NPDES permit includes a daily maximum effluent true color limit of
105,250 lbs per day. The permit also specifies a monthly average true color limit of 52,000
lbs per day and a current annual average (calendar year) true color limit of 36,000 lbs per
day. t Compliance with these effluent limits requires significant management of mill
operations related to color. Prevention of wastewater effluent color is a priority for mill
operations every day.
III. Color Performance
Figure 1 illustrates the color performance of the Canton Mill since 1997. Annual average
effluent true color in Figure 1 is presented in units of 1000 lbs per day. The calculation of
1 The initial effluent limit was 38,020 lbs per day (annual average) Effective July 1, 20014, and in
accordance with Section A. (8.) paragraph 2., the effluent lumt for color was reduced to 36, 000 lbs per
day (annual average).
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
effluent color as a daily mass (lbs) is defined in Part I A.(8.) items 2 & 3 of the permit.
color (lbs/day) = effluent flow (mgd) x effluent true color (platinum cobalt units) x 8.34.
Effluent true color is measured using NCASI method 253 (1971).
Figure 1 - Annual Average Effluent Color
Blue Ridge Paper Canton Mill, 1997 thru 2017
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The best color performance for the Canton Mill occurs during normal, or full, production.
At full production, the internal recycling and recovery of process filtrates, pulping liquors
and other process wastewaters is balanced. Color materials are contained within the Kraft
pulping process at an efficiency of greater than 99 percent. Color performance is affected
by process variability. Color materials can be lost during startup and shutdown associated
with a process upset, production curtailment or unplanned outage. The Canton Mill has an
environmental and economic incentive to maintain process reliability and operate at full
production.
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Effluent color performance improved over the previous year's performance. The increased
outage schedule for the lower end of the mill continues to improve process reliability. This
operational strategy with improvements to operating systems and control strategies
contributed to color performance in 2016 & 2017.
IV. Color Proiects and Refinements to Best Management Practices
The Canton Mill has a standing Color Team that meets regularly to review color
performance. Color Team members include managers, supervisors and engineers involved
with production, maintenance, wastewater treatment and regulatory affairs. The Color
Team's scope includes:
• Monitoring color performance and the effectiveness of mill systems to prevent
effluent color
• Identifying and tracking corrective actions related to Cluster Rule BMP color
events
• Planning and reviewing process trials related to effluent color
• Planning and reviewing the effectiveness of capital and expense projects related
to effluent color
• Reviewing production and wastewater treatment issues that may affect operating
reliability and effluent color.
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
The Color Team evaluates projects, trials and process initiatives. Not all are successful.
The July 2011 Color Progress Report [Evergreen 2011 ] documented significant Color
Team activities between May 2006 and May 2011. Significant activities since 2010 are
outlined in Tables 1 and 2. Capital projects in Table 1 are identified by Capital
Improvement Project (CIP) number. Other projects were completed on operations and
maintenance expense. Direct spending on Color Team related projects, trials and initiatives
identified in Tables 1 and 2 during the period May 2010 through May 2017 exceeded $3.95
MM. These costs are in addition to the on-going cost to operate and maintain color
prevention systems at the Canton Mill.
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2010
East Heavy / Tall Oil Sump transfer line repair. This was a proactive
measure to prevent color material losses from this transfer line. BMP
sustaining measure.
o Completed August 2010, cnsd *
Replaced decant line from Turpentine loading to 4A manhole. This was a
proactive measure to prevent losses from this transfer line. BMP
sustaining measure.
o Completed 2010
o CIP —315223 m
o Cost - $275,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2010
Repair and recoating of west side of Camp Branch compound. Project to
maintain integrity of spill containment. BMP sustaining measure.
o Completed 2010
o CIP —315588
o Cost - $235,000
Several black liquor transfer line replacements including East Heavy
storage tank and West GB Discharge BMP sustaining measure.
o Completed 2010, cnsd*
Replaced conductivity and level switches in East Heavy compound with
new, more reliable type. BMP improvement.
o Completed 3Q 2010, cnsd*
Relocation of sewer conductivity meter below Digester Area sumps. BMP
optimization in this area.
o Completed November 2010, cnsd*
West Heavy Liquor (former Red Liquor Tank) shell replacement / repairs.
BMP sustaining measure.
o Completed May 2010
o CIP — 266446
o Cost — $265,000
Mini -Hoods on No. 11 Smelt Dissolving Tank (SMDT). Allows
substitution of weak wash for clean water in SMDT demister creating
more process demand for weak wash and reducing high pH material
discharged to sewer. Related to the weak wash purge strategy (Table 2)
and TRW Recommendations regarding prevention of sewer -generated
color — high pH.
o Completed 3Q 2010, cnsd*
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2010
Installation of spray bar on the 5fl' effect of the Swenson evaporator set.
Spray allows the 5' effect chevrons to be cleaned on the run reducing the
amount of carryover color in the condensate system during normal
operation between evaporator outages. Color material carry over from
evaporators into condensates is related to TRW Recommendations to
prevent sewer -generated color.
o Completed October 2010, cnsd *
North White Liquor Tank shell replacement/ repairs. BMP sustaining
measure and project related to TRW Recommendations regarding
prevention of sewer -generated color — high pH white liquor.
o Completed Dec 2010
o CIP —322435
o Cost — $724,000
2011
Process lines to allow front-end boil out of West GB evaporator set.
Allows more frequent, less intense evaporator cleaning BMP
improvement for process reliability to avoid carryover of color material
into condensate systems. Reduces the volume of color material generated
by evaporator boil out during outages. Color material carry over from
evaporators into condensates is related to TRW Recommendations to
prevent sewer -generated color.
o Completed May 2011, cnsd *
Repaired drain valves on No. 2 and 3 Primary Clarifiers. Allows reliable
isolation of one of these larger volume clarifiers as the spare clarifier for
high color material diversion during semi-annual outages. BMP sustaining
measure.
o Completed March 2011, cnsd*
Pme Weak Liquor Tank shell replacement / repairs. BMP sustaining
measure.
o Completed May 2011
o CIP —331985
o Cost — $349,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2011
Installed soft start on motors for the hardwood weak black liquor transfer
pumps and hardwood blow tower dilution pumps. Project reduces pump
start water hammer in pipes containing black liquor and reduces risk of
gasket failure, valve failure and/or pipe hanger failure from water hammer
pipe movement. Project was identified by a water hammer valve failure in
May 2011 that was contained within the process and did not reach the
wastewater plant.
o Completed May 2011 on hardwood blow tower dilution pumps
o Completed Jul 2011 on hardwood weak black transfer pumps
o 4 soft starts at $7540 each, project cost of $30,160 plus installation
cost on maintenance expense
2012
Installation of new Oramac shower bars on the East Decker at the
Hardwood Fiberline. These shower bars help improve washing efficiency
and reduced carry-over of sodium compounds into the bleach plant, which
in turn, will reduce D1 stage CIOz demand and effluent color from the
bleach plant.
o Completed April 2012
o Cost - —$40,000
Replaced shower bars on hardwood East Decker with improved design
matching shower bars previously installed on hardwood brownstock
washers. These shower bars improve washing and reduce carryover of
color materials into the bleach plant. Liebergott Recommendation.
o Completed during May 2012 hardwood semi-annual outage as part
of larger East Decker vat repair project
o CIP — 358168
o Cost — $32,000 for shower bar portion of project
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2012
Replaced level controls on condensate flash tanks on the West GB
evaporator set. The new controls are more reliable and less prone to
plugging and false level indication that can cause color material carryover
into the combined condensate system, which contributes to sewer
generated color. Related to TRW Recommendations regarding prevention
of sewer generated color.
o Completed during May 2012 semi-annual outage
0 2 capillary level elements and isolation valves at $9500 each,
project cost of $ 29,000 including installation on maintenance
expense
West GB Skim Tank cleaning and repair of leaks. BMP sustaining
measures.
o Completed July 2012
o Cost - $125,000
West Heavy Liquor Tank compound sealing and lining. BMP sustaining
measure.
o Completed August 2012
o Cost - $150,000
Replacement of floor drain piping in Hardwood fiberline. Floor drains
carry spill material directly to the Hardwood Spill Tank. This replacement
minimized losses to the mill sewer system.
o Completed Fall 2012, ensd *
Sealing and lining of the West Unoxidized Black Liquor compound. BMP
sustaining measure to reduce potential leakage of high pH material and to
reinstate the integrity of the containment and sump
o Completed August 2012
Cost - $150,000
West GB Feed Tank cleaning and repair of leaks. BMP sustaining
measures.
o Completed September 2012
o Cost - $75,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2012
Replacement of floor drains on #10 Recovery Boiler. BMP sustaining
measure.
o Completed October 2012
o Cost - $150,000
Wash Water line replacement (phase II). Project identified to improve line
integrity and prevent potential elevated color losses from reaching the mill
sewer system.
o Completed December 2012
o CIP - 371577
o Cost - $99,333
2013
Relocation of #5B Sewer conductivity meter and sampler. BMP
improvement measure related to TRW Recommendations to further
improve leak detection and process monitoring.
o Completed January 2013, cnsd *
South Green Liquor Clarifier shell replacement / repairs. BMP sustaining
measure and project related to TRW Recommendations regarding
prevention of sewer -generated color — high pH green liquor.
o Completed February 2013
o CIP - 370243
o Cost - $581,442
Installation of an additional u -drain located on the north side of the
Hardwood Blow Tower. This drain will allow the capture and redirection
of weak black liquor material from around the blow tower to the mill sump
system.
o Completed March 2013
o Cost - $36,641
West Green Liquor Clarifier shell replacement / repairs. BMP sustaining
measure and project related to TRW Recommendations regarding
prevention of sewer -generated color — high pH green liquor.
o Completed March 2013
o CIP - 370243
o Cost - $122,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2013
Installation of new Oramac shower bars on the West Decker at the
Hardwood Fiberline. These shower bars help improve washing efficiency
and reduced carry-over of sodium compounds into the bleach plant, which
in turn, will reduce D1 stage C102 demand and effluent color from the
bleach plant.
o Completed April 2013
o Cost - —$40,000
West White Liquor Storage Tank shell replacement / repairs. BMP
sustaining measure and project related to TRW Recommendations
regarding prevention of sewer -generated color — high pH white liquor.
o Completed April 2013
o Cost - $122,000
West GB 2nd Effect pump upgrade. Obsolete pump replaced with different
style to increase reliability and reduce downtime which in some cases can
be attributed to increase color loading to the mill sewer system.
o Completed April 2013
o Cost - $72,869
Mini -Hoods on No. 10 Smelt Dissolving Tank (SMDT). Allows
substitution of Weak Wash for clean water in SMDT demister creating
more process demand for weak wash and reducing high pH material
discharged to sewer. Related to the weak wash purge strategy (Table 2)
and TRW Recommendations regarding prevention of sewer -generated
color — high pH.
o Completed May 2013, cnsd *
2014
Curbing at #10 Recovery Boiler sewer sump gate. BMP measure designed
to prevent black liquor material from going around sewer gate and to be
directed to sump.
o Completed March 2014
o Cost - $15,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2014
West GB Evaporator capillary level elements and isolation valves.
Reduces the amount of carryover to the combined condensate tank and
potential sewer generated color.
o Completed April 2014
o Cost - $29,000
West GB Evaporator black liquor piping replacement from product liquor
flash tank back to the 3' effect. BMP sustaining measure.
o Completed April 2014, csnd *
North Oxidizer feed piping upgrade to stainless steel. BMP sustaining
measure.
o Completed April 2014, csnd *
Floor drain replacement and material upgrade on #11 Recovery Boiler.
This piping carries spill material to the mill sump system minimizing
losses. BMP sustaining measure.
o Completed April 2014
o Cost - $150,000
Causticizing Sample Box piping upgrade. Reduced frequency of plugging
and for white and green liquors to enter the mill sewer system causing
sewer generated color.
o Completed May 2014, cnsd *
Black liquor transfer piping replacements around West Unoxidized and
East Unoxidized storage tanks. BMP sustaining measure.
o Completed June 2014, cnsd *
2015
Acid cleaning of the filtrate line from Pine Eo to Decker filtrate tank. This
allows operations to refine the filtrate balance cycle inside the bleach plant
preventing colored filtrate material from overflowing to the mill sewer
system.
o Completed April 2015
0 Cost - $10,000
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2015
Installation of automatic valve on Pine D1 washer sewer drain. Remove
potential for colored filtrate losses to mill sewer. BMP sustaining
measure.
o Completed May 2015
o Cost - $6,000
Pine D2 washer drum replacement. Old drum created a situation where
the Acid Sewer filtrates were being piped to the influent side of the
WWTP. This created opportunities for sewer generated color to occur.
Once installed those filtrates were then piped back to the effluent side of
the clarifiers.
o Completed May 2015
o Cost - $225,000
Dome replacement for the 2nd effect on the West GB Evaporator set. BMP
sustaining measure.
o Completed May 2015
o Cost - $135,000
East Unoxidized Black Liquor storage tank repair & replacement items.
Replaced suction side spool coming out of tank, suction side isolation hand
valve, suction side expansion joint, suction side tee to pumps and replaced
hand valve on feed side to the tank. BMP sustaining measure.
o Completed July 2015
o Cost - $15,000
Green Liquor piping and hand valve replacement to the Causticizers. BMP
sustaining measure.
o Completed July 2015
o Cost - $8,000
Black liquor solids meter installation on Hardwood Brownstock fiberline.
Assisted mill in developing operating strategy that minimizes color
carryover to bleach plant stages that reach the sewer.
o Completed September 2015
o Cost - $8,300
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2016
White Liquor pump tank repairs. Reinforcement of outer shell to prevent
leaks. BMP sustaining measure
o Completed April 2016
o Cost - $45,000
Improvement to Weak Wash overflow monitoring. Installation of
temperature probe on overflow line and level cell in weir box to sewer.
BMP improvement measure designed to assist operators in monitoring
Weak Wash releases to sewer.
o Completed April 2016
o Cost - $10,600
Installation of a temperature probe on the #11 Recovery Boiler dissolving
tank overflow. BMP sustaining measure and project related to TRW
Recommendations regarding prevention of sewer -generated color — high
pH green liquor.
o Completed October 2016
o Cost - $2500
Installation of a temperature probe in the #10 Recovery Boiler cyclone
overflow. BMP improvement measure designed to alert operators of color
material reaching the mill sewer.
o Completed December 2016
o Cost - $2500
2017
Installation of a temperature probe on the #10 Recovery Boiler dissolving
tank overflow. BMP sustaining measure and project related to TRW
Recommendations regarding prevention of sewer -generated color — high
pH green liquor.
o Completed January 2017
o Cost - $2500
Installation of a temperature probe in the #11 Recovery Boiler cyclone
overflow. BMP improvement measure designed to alert operators of color
material reaching the mill sewer.
o Completed May 2017
o Cost - $2500
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 1
Color Team Capital and Maintenance Projects
2010 - Forward
Year
Project Description and Cost Information for Capital Projects
2017
Black liquor solids meter installation on Pine Brownstock fiberline.
on-going
Assisted mill in developing operating strategy that mimmizes color
carryover to bleach plant stages that reach the sewer.
2011
o Completed June 2017
o Cost - $3,000
* cnsd — cost not separately determined, completed on operations and
maintenance expense
Table 2
Color Team BMP Refinements, Trials and Process Improvements
2010 forward
Years
Refinement,Trial and/or Improvement
2010
Weak wash purge strategy to minimize potential sewer -generated color
on-going
during process upset, outage or reduced pulp mill production when
demand for weak wash is out of balance with supply in causticizing.
2011
When both fiberlmes are down, process contents of one of the spill tanks
through the evaporators to free up spill tank volume before starting up.
Was used successfully during and after the May 2011 cold mill outage to
minimize loss of dilute color material to the WWTP.
2011
Alternative polymer study by Chemtreat at WWTP. Compared against
current polyamine polymer in use for batch treatment of black color
materials. No difference in color performance. Existing batch treatment
polyamine polymer was retained.
2011
West GB Evaporator partial boil out strategy. Ability to clean process
on-going
during short outages as opportunity arises. Improves process reliability
and reduces volume of color material to recover during outages
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Table 2
Color Team BMP Refinements, Trials and Process Improvements
2010 forward
Years
Refinement Trial and/or Improvement
2012
Reliability focus - 7 to 8 week planned maintenance outage cycle for
on-going
recovery furnaces and fiberlines. Prior to 2012, planned outage cycle was
10 to 12 weeks and additional unplanned outages were often necessary.
Mill experience is that more frequent planned outages result in more
reliable process operation between outages and lower color. Color
associated with planned outages is also generally lower than color
associated with an unplanned outage.
2012
Color prevention MOC / pre -task review process for outage and
on-going
maintenance tasks associated with black liquor. This is in addition to the
permit -required review of modifications to systems managing black liquor,
turpentine and soap.
2014
Polymer study of the Acid Sewer stream at the WWTP. Polymer had the
ability to reduce the amount of color, however once introduced back into
the treatment system the sewer generated color phenomena occurred
negating all positive effects of the polymer addition. Trial deemed
unsuccessful and was not put into use.
2016
CRP purge reduction strategy to reduce color loading to the WWTP.
White liquor is being tested for chloride content. Based on the results, if
the chloride content is low the purge stream can be reduced resulting in
less volume of color material to the mill sewers stem.
2016
New mechanical seal technology on the batch digester recirculation pumps
on-going
will reduce losses of color material to the sewer. It also allows a reduction
in seal water; traditionally used on these pumps. Less tramp water reduces
dilution of color material in the sewer and improves sump performance.
2016
During cyclone washes the cyclone target level was lowered from 9.5 ft to
8.5 ft. This measure was instituted to prevent potential overflows during
washes. A standard practice was added that brought in additional staff
during these washes for the purpose of monitoring color.
2016
Color control procedure refinement to include putting both Recovery
Boiler sumps in automatic during cyclone washes and when mitigating
known black liquor losses.
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Since 2013, the Color Team has focused on the reliability of the Recovery Furnaces and
Fiberlines. When the mill experiences a process upset, and in particular an upset
requiring an unplanned outage to correct, effluent color is not as good. The mill targets
planned maintenance outages every eight to ten weeks. This frequency of outages has
been proven successful and is maintained as a part of the color management strategy.
This work allows mill operations to stay ahead of potential issues that could necessitate
an unplanned outage. Fewer unplanned outages and shorter periods of downtime help the
mill maintain steady operations leading to better color performance.
V. TRW Recommendations
The Canton Mill continues to review the listed items under Section A.(8.)10. for
opportunities and refinements to our color management strategy. For this period that
includes improvements, refinements and sustaining measures to our BMP program.
BMP sustaining measures allow the mill to strengthen and enhance its color prevention
program. Temperature probes were added to the dissolving tanks on both #10 & #11
Recovery Boilers. These probes allow operators to observe and track when losses of
weak green liquor are lost to the sewer. This is an effort to better understand how these
losses impact sewer generated color within the mill sewer system. Another temperature
probe was installed on the overflow line of the #10 Recovery Boiler cyclone. Along with
a procedural change to cyclone level during washes, this improvement gives operators the
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
opportunity to stop releases of elevated color material to the sewer sooner. Under the
previous color control plan elevated color material would be observed when the
conductivity spiked in the area sump.
Additions to the fiberlines will provide improvements to the BMP program. The Pine
Brownstock fiberline added a black liquor solids meter to the process. This gives
operators better control during washing stages. It reduces the amount of carryover into
the bleach stages reducing color to the mill sewer. An improvement to the digester area
has also been identified. A trial on the #18 digester replaced the current recirculation
pump mechanical seal design with an improved technology. Initial results have shown
the new design is reducing color material losses to the sewer and reducing the need for
seal water in the area. Seal water, although necessary, can cause dilution within the mill
u -drains. Once diluted it is more difficult to collect in the mill sump system because of a
lower conductivity. Reducing tramp water is also a focus. Depending on future results
from extended run times, the mill will explore options to replace the old mechanical seals
with the new design.
Vl. Summary
Prevention of effluent color is a priority for Canton Mill operations every day. The Canton
Mill's focus on process reliability and uptime has resulted in excellent annual color
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
performance. The Canton Mill will continue to utilize the processes and practices proven
successful for wastewater effluent color prevention.
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
REFERENCES
EKONO 2005 — Environmental Performance, Regulations and Technologies in the Pulp
and Paper Industry, EKONO Inc, August 2005.
Evergreen 2011 — Annual Progress Report on Color, submitted to NC DWQ to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2011.
Evergreen 2012a — February 2012 Update to the Color Reduction Implementation Plan,
submitted to NC DWQ to meet requirements of Part I A.(8) item 11 of the May 2010
NPDES Permit, Evergreen Packaging, February 20, 2012.
Evergreen 2012b — Response to EPA Comments dated 22 March 2012 concerning
February 2012 Update to the Color Reduction Implementation Plan, letter to NC DWQ
Complex NPDES Permitting Unit from Evergreen Packaging dated April 10, 2012.
Evergreen 2012c — April 2012 Color Perception Study Plan and Response to EPA
Comments dated 28 March 2012 concerning the March 2012 Revised Color Perception
Study Plan, submitted to NC DWQ Complex NPDES Permitting Unit by Evergreen
Packaging on April 17, 2012.
Evergreen 2012d — Annual Progress Report on Color, submitted to NC DWQ to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2012.
Evergreen 2013 — Annual Progress Report on Color, submitted to NC DWR to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2013.
Evergreen 2014 — Annual Progress Report on Color, submitted to NC DWR to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2014.
Evergreen 2015 — Annual Progress Report on Color, submitted to NC DWR to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2015.
July 2017 — Annual Progress Report on Color
Blue Ridge Paper Products Inc. dba Evergreen Packaging
Canton, North Carolina
NPDES Permit No. NC0000272
Evergreen 2016 — Annual Progress Report on Color, submitted to NC DWR to meet
requirements of Part I A.(8) item 8 of the May 2010 NPDES Permit, Evergreen Packaging,
July 1, 2016.
NC OAH 2012 — Partial Settlement Agreement and Joint Stipulation to Stay, 10 EHR 4341
and 10 EHR 4982, North Carolina Office of Administrative Hearings, April 24, 2012.
NCASI 2006 — Technical Bulletin No. 919 — Review of Color Control Technologies and
Their Applicability to Modern Kraft Pulp and Paper Mill, National Council for Air and
Stream Improvement, August 2006.