NC0000272_Annual Report_20190329

ever reen .. Canton Office
175 Main Street• Canton, NC 28716
packaging
March 29, 2019
CERTIFIED MAIL
Return Receipt Requested
7008 3230 0002 2595 8040
}
North Carolina Department of Environment
and Natural Resources
Division of Environmental Quality
Water Quality Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh,NC 27699-1617
Re: NPDES NO. NC0000272
Best Management Practices 2018 Annual Report
Blue Ridge Paper Products Inc. d/b/a Evergreen Packaging
Canton,NC
This letter report(two copies) is the 2018 summary of Best Management Practices (BMP) daily
monitoring for the Canton Mill. The report is required on or before March 31'of each year by
Special Condition A.(6.) Best Management Practices, Section E.4 and Section F.1, of the mill's
NPDES Permit No. NC0000272.
The BMP action levels established in accordance with permit requirements and in effect for 2018
are as follows:
Effective Dates: 1 Jan 2018 —31 Dec 2018
Action Level Total Influent(TI) Color — Action Required
daily monitoring result
1-Day Upper Action Immediate investigation and documented
> 72,500 lbs/day for one day
Level (UAL) corrective action
2-dayUpper Action > 59,400 lbs/dayfor two Investigation and documented corrective
pp 9
Level (UAL) consecutive days action
2-day Lower Action > 55,400 lbs/day for two
Level (LAL) consecutive days Investigation and documentation
Blue Ridge Paper Products Inc dba Evergreen Packaging'.,,cantonyilf m
175 Main Street • PO Box 4000
—Canton,—North-Carolina-28716—•-828=646=2000--
Dang Business ui Cai orn!a as Evergreen Beverage Packaging
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29 Mar 2019,Page 2
Daily records of total influent color are maintained at the mill. These daily color data are
compared to BMP action levels every morning. Total influent color exceeded BMP action levels
on the dates outlined in the following table. A brief summary of information for these dates are
included as required by permit Condition A.(6.), Section E.4. The permit-required BMP
investigation reports are maintained at the mill. None of the BMP action level days resulted in
disruption to the wastewater treatment plant. The Canton Mill met all NPDES annual average
effluent limits for the period July 1, 2017 to June 30, 2018.
Date(s) Total Influent Action Level and Summary
(TI) Color
10 - 11 Feb 72,448 lbs/day 2-day LAL— Investigation and documented corrective
2018 58,488 lbs/day action
Cause and Corrective Action(s)— BMP event. The pulp mill
was pumping excess foam from their filtrate tanks to the
east black liquor compound and over flowed the compound
walls. Once over the walls the material made its way into
the sewer. The pulp mill has been instructed to go back to
pumping foam from the filtrate tanks only twice a shift to
mitigate this problem.
20 —21 March 97,937 lbs/day 2-day UAL— Investigation and documented corrective
2018 74,886 lbs/day action
Cause and Corrective Action(s)—Non-BMP event. Annual
outage on #10 recovery furnace and hardwood pulp mill.
High color material was sent over the past few days in
preparation for the annual outage. Color was monitored
closely and color reducing polymer was added to mitigate
drop the color before entering the secondary system.
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
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29 Mar 2019,Page 3
Date(s) Total Influent Action Level and Summary
(TI) Color
24—26 Mar 94,371 lbs/day 1-day UAL/ 1-day UAL/ 2-day LAL— Investigation and
2018 57,069 lbs/day documented corrective action
76,793 lbs/day
Cause and Corrective Action(s) — Non-BMP event. The
annual outage continued on longer than planned due to
unforeseen maintenance issues. This caused weak wash
inventory to grow beyond what we could hold. The weak
wash overflowed into the sewer. That high pH material
mixes with the bleach plant filtrate causing higher than
normal color in the secondary system.
5 - 6 Apr 2018 61,640 lbs/day 1-day UAL/2-day UAL— Immediate Corrective Action
111,343 lbs/day
Cause and Corrective Action(s) — BMP event. During an
outage on the Swensons evaporators, startup did not go as
planned and a small amount of black liquor was sent to the
sewer. A berm was constructed by Recovery personnel to
help divert the flow away from the sewer and into the sump
area so the material could be sent to boil out. The following
day it was discovered that the berm had collapsed and
more liquor was going to the sewer. Supervision will now
oversee the construction of any berms used to divert high
color material and frequent checks will be conducted.
16 Jun 2018 112,043 lbs/day Immediate investigation and documented corrective
action
Cause and Corrective Action(s)— BMP Event. The lime
kiln was dumping dregs because of high torque on
clarifiers, during this time the sump at#11 recovery boiler
was left open to aide in clean up. During this time, one of
the oxidized black liquor pumps blew a seal and sent black
liquor right into the sewer. WTP operators captured most of
the black liquor material in #1 clarifier and treated it with our
color reducing coagulant. The pump was taken out of
service and the seal was repaired.
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
Z.WEW FOLDER DIRECTORYIEnvironmentallWATERWew folderrBMPIBMP Events12018 Annual BMP Summary.doc

29 Mar 2019,Page 4
Date(s) Total Influent Action Level and Summary
(TI) Color
Jun 27—Jul 1 59,017 lbs/day 2-day UAL/2-day UAL/ 1-day UAL— Investigation and
2018 60,568 lbs/day documented corrective action
65,485 lbs/day
53,915 lbs/day Cause and Corrective Action(s) — BMP Event. The pulp mill
82,026 lbs/day began acid washing digesters on Jun 26th. The wash sent a
steady stream of high color material to the WTP for 5 days.
Color reducing polymer was added and the secondary
effluent color numbers were kept under control. Acid
washing digesters usually occurs more often. The washes
had been put off for a while due to the run ability of the pulp
mill. Pulp mill personnel will work to keep washes on
schedule.
4 —5 Jul 2018 58,822 lbs/day 2-day LAL/ 1-day UAL - Investigation and documented
81,657 lbs/day corrective action
Cause and Corrective Action(s)— BMP Event. During an
acid wash of#10 digester in the pulp mill, the contents of
the digester were dumped and the gate on the sump to the
sewer was left open. WTP received very high color material
which they attempted to capture in #1 clarifier. That
material was then slowly fed back into the system and
treated with our color reducing polymer. More frequent
checks of area sewers and sump pumps to ensure gates
are closed and sumps are pumping where they are
supposed to be.
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
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29 Mar 2019,Page 5
Date(s) Total Influent Action Level and Summary
(TI) Color
5—8 Aug 2018 55,981 lbs/day 2-day UAL/ 2-day UAL/ 1-day UAL - Investigation and
67,269 lbs/day documented corrective action
61,609 lbs/day
80,339 lbs/day Cause and Corrective Action(s)—BMP Event. On 8/5 3
digester liquor heat exchangers in the lower end were
identified as possible color contributors, all 3 had significant
leaks. They were scheduled to be repaired during the pulp
mill outage on 8/8. The WTP continued to see color on 8/7
and 8/8. The MRP was down from 8/3 thru 8/9. This had a
negative impact on pine bleach plant closure. On Tuesday
night 8/7 the recovery area overflowed weak wash to the
sewer, this high pH material when mixed with bleach plant
filtrate causes high color. On 8/7 a sump on#10 recovery
failed to kick on due to a stuck ball float. This resulted in
black liquor going over the berm and into the sewer. During
this time the black liquor mix tank on the 2nd floor of#10
recovery overflowed to the sewer. During the outage the 5th
and 6th effect of the Swenson's evaporators were steamed
to reduce color.
23—24 Aug 62.806 lbs/day 2-day UAL - Investigation and documented corrective
2018 67.155 lbs/day action
Cause and Corrective Action(s)—BMP Event. On
Thursday 8/23 an unplanned outage took place on #11
recovery boiler and the pine pulp mill. A combination of
black liquor cyclone instability and leaking digesters led to
the outage taking place. At the same time a boil out of the
West GB evaporator set took place. During the boil out
color in the corresponding sewer was very high. It appears
high color material made it out of the evaps and into the
sewer. We continued to see high color material through the
next 24 hours. Color reducing coagulant was added at the
WTP. Secondary effluent color on the following days was
elevated but still well below our limit.
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
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29 Mar 2019,Page 6
Date(s) Total Influent Action Level and Summary
(TI) Color
14— 16 Sept 67,269 lbs/day 2-day UAL/ 1-day UAL - Investigation and documented
2018 61,609 lbs/day corrective action
80,339 lbs/day
Cause and Corrective Action(s)—Non-BMP Event.
During a scheduled cyclone wash on number 11 recovery
boiler, the Swenson's black liquor evaporators were taken
down for a boil out of the system. During the boil out it was
discovered that the system was very dirty and required
more cleaning and dumping than usual. The WTP was
notified of the high color material coming our way. The
WTP operators opened the gate to #1 clarifier to catch the
high color material. #1 clarifier was filled to about 75%
capacity. Further cleaning of the Swenson's revealed fiber
in the system this instigated another boil out and thus more
black liquor color to the WTP. #1 clarifier was then filled to
nearly 100% of its capacity. Over the next two days
problems with the Swenson's continued. And a similar
process was carried out. The evaporators were restored to
full working order on 9-17.
12 — 16 Oct 70,611 lbs/day 2-day UAL/ 2-day UAL / 1-day UAL - Investigation and
2018 86,356 lbs/day documented corrective action
58,060 lbs/day
105,203 lbs/day Cause and Corrective Action(s) — Non-BMP Event. Both
73,947 lbs/day evaporator were taken down for a planned boil out. While
offline, maintenance personnel identified several issues
which prevented startup. Several attempts were made to
start up throughout the week with no success. Each time
the evaporators were started up, they had to go down and
flush the system, Communication was excellent during this
time and the high color material was all dealt with at the
WTP.
Blue Ridge Paper Products Inc dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
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29 Mar 2019,Page 7
r
Date(s) Total Influent Action Level and Summary
(TI) Color
9 — 10 Nov 79,096 lbs/day 1-day UAL/ 2-day UAL - Investigation and documented
2019 70,362 lbs/day corrective action
Cause and Corrective Action(s)— BMP Event. The mud
filter filtrate sump in the causticizing area overflowed to the
sewer causing high color material to come to the WTP.
Additionally on both the 9th and 10th weak wash overflowed
to the sewer and mixed with the bleach plant material which
produced higher color material once in the sewer. The
filtrate sump was cleaned out to support higher flow and
prevent that area from flooding.
20 —21 Dec 57,754 lbs/day 2-day LAL - Investigation and documented corrective
2019 56,724 lbs/day action
Cause and Corrective Action(s)— BMP Event. On 12/20
a leak developed in the east un oxidized black liquor
storage tank. It was discovered during the daily BMP
inspection of the area. While most of the leak was being
picked up by the area sump, some of the material made its
way into the sewer and into the WTP. A barrier was
constructed to divert the leak entirely into the sump area.
The tank was taken out of service and repaired on the next
outage. On 12/21 #10 recovery furnace tripped off and the
black liquor cyclones over ran into the sewer. The recovery
area crew notified the WTP in a timely manner and that
high color material was captured and treated. Maintenance
worked on cyclone level indicators to prevent another trip
from occurring.
Please contact us if you have questions regarding this information.
Sincerely,
Jacob Trantham
WWTP Lab Supervisor
Evergreen Packaging—Canton Mill
[e-mail]
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
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. , Y
29 Mar 2019, Page 8
cc:
Mr. Landon Davidson
DWQ Regional Supervisor, Asheville Regional Office
North Carolina Department of Environmental Quality
2090 U.S. Highway 70
Swannanoa, NC 28778
Blue Ridge Paper Products Inc. dba Evergreen Packaging—Canton Mill
175 Main Street • PO Box 4000
Canton, North Carolina 28716 • 828-646-2000
Z.WEW FOLDER DIRECTORYIEnv ronmental1WATERINew folderIBMP1BMP Events12018 Annual BMP Summary.doc