Best available technology for the Ontario pulp and paper industry

614 Pages·1992·28.7 MB·English

by  Ontario. Water Resources Branch

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BEST AVAILABLE TECHNOLOGY
FOR THE
ONTARIO PULP AND PAPER INDUSTRY
(2 Environment
Environnement
Ontario

BEST AVAILABLE TECHNOLOGY
FOR THE
ONTARIO PULP AND PAPER INDUSTRY
Report Prepared By:
Neil McCubbin
Howard Edde
Ed Barnes
Jens Folke
Eva Bergman
Dennis Owen
Individual authors can be contacted as follows:
Neil McCubbin N. McCubbin Consultants Inc.
140 Fisher's Point
Foster, Quebec JOE 1RO
Phone: [phone] FAX: [phone]
Ed Barnes E.T.Barnes and Associates Inc.
1206-4134 Maywood Street
Burnaby, B.C. V5H 4C9
Phone: [phone] FAX: [phone]
Eva Bergman Pacific Simulation Inc.
121 Sweet Ave.
Moscow, Idaho 83843 USA
Phone: [phone] FAX: [phone]
Howard Edde Howard Edde Inc.
Sherwood Forest Office Park, Suite 201
2661 Bellevue, Washington, 98008 USA
Phone: [phone] FAX: [phone]
Jens Folke MFG, European Environmental Research Group
14 Pinievangen DK-3450
Allerod DENMARK
Phone: [phone] FAX: [phone]
Dennis Owen Dennis Owen and Associates Ltd.
225 Bagot Street
Kingston, Ontario K7L 3G3
Phone: [phone] FAX: [phone]
The above authors would like to thank the many individuals who contributed to the preparation of
this report. Information and assistance was provided by many people from industry, consulting,
governmental, academic and manufacturing organizations as well as mill staff in Ontario, many
parts of Canada, US and Europe. Particular recognition is due to Alistair Stewart and Kirsten Vice
of the Ministry of the Environment for their efforts to provide the extensive Ministry data in a limited
time frame. We would also like to thank the members of the BAT Subcommittee who provided
comments and criticism throughout the project.
Proprietary and registered trade names are used in this report where appropriate to improve the
clarity of explanations or to define sources of information. This should not be construed as
approval or recommendation for use in Ontario, either on the part of the report’s authors or the
Ministry of the Environment. The authors recognise that the registered trade names remain the
property of their registered owners.
N. McCubbin Consultants Inc. BAT Definition Study, Pulp and Paper Sector
Summary Table of Contents
EXECUTIVE SUMMARY
1 SUMMARY REPORT
2 INTRODUCTION
3 MANUFACTURING PROCESSES
4 EFFLUENT CHARACTERISTICS in 1990
5 DEMONSTRATED CONTROL TECHNOLOGY 155
6 EMERGING TECHNOLOGIES 225
7 ALTERNATIVE TECHNOLOGY TRAINS 241
8 COSTS of APPLICATION of TECHNOLOGY TRAINS 257
REFERENCES
Appendices
Appendix A Mill Descriptions
Appendix B Ontario Mill Effluents in 1990
Appendix C Mill Contact Reports
Appendix D Notes on Regulatory Issues
Appendix E Zero Effluent TMP Mill Analysis
Appendix F Use of Municipal Sewage as Mill Water Supply
Appendix G Other Effluent Control Technologies
Appendix H Terms of Reference
Glossary and SI Conversion Table
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(Notes)
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N. McCubbin Consultants Inc. BAT Definition Study, Pulp and Paper Sector
Detailed Table of Contents
EXECUTIVE SUMMARY
Attainable Effluent Characteristics
Conventional pollutants
Organochlorines
Ontario effluent monitoring priority pollutants list
Costs of Implementing BAT in Ontario mills
Capital costs
Operating costs
Costs and attainable effluent discharges for individual mills OOOO=BF1111 WD
1 SUMMARY REPORT
1.1 Terms of Reference
1.1.1 Objectives
1.2 Background
1.2.1 MISA effluent monitoring program
1.3 Methodology
1.3.1 Development of this report
1.3.2 Alternative technology trains
1.3.3 Sources of information
1.4 Profile of Ontario Pulp and Paper Industry
1.5 Pulp and Paper Manufacturing Processes
1.5.1 Kraft pulp
1.5.2 Chlorine-free bleaching of kraft pulp
1.5.3 Environmental significance of the brightness of kraft pulps
1.5.4 Sulphite pulp
1.5.5 Mechanical pulp
1.5.6 Paper mills
1.5.7 Solvent pulping
1.5.8 Zero effluent
1.6 Current Effluent Characteristics
1.6.1 Effluent flows
1.6.2 Priority pollutants
1.6.3 Candidate parameters for control
1.7 Attainable Effluent Characteristics
1.7.1 Conventional pollutants
1.7.2 Discharges of nutrients
1.7.3 Adsorbable organic halogen (AOX)
1.7.4 Polychlorinated dioxins and furans from kraft mills
1.7.5 Polychlorinated dioxins and furans from non-kraft mills
1.7.6 Equivalent toxicity of dioxins
1.7.7 Metals
1.7.8 Sub-lethal toxicity
1.8 Effluent Discharge Control Technologies
1.8.1 Control at source vs external effluent treatment
1.8.2 Basis for selection of technology
1.8.3 Discharge prevention at source
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N. McCubbin Consultants Inc. BAT Definition Study, Pulp and Paper Sector
1.8.4 External treatment technologies 37
1.9 Alternative Technology Trains 40
1.9.1 Kraft sub-sector 41
1.9.2 Sulphite/mechanical sub-sector 43
1.9.3 Corrugating sub-sector 44
1.9.4 Deinking/board/fine papers/tissue sub-sector 45
1.10 Economic Achievability 45
2 INTRODUCTION 47
2.1 Background 47
2.2 Objectives 48
2.3 Sources of Ontario Mill Data 48
2.4 Pulp and Paper Sector Profile 49
2.5 Mills Included in Scope 51
2.6 Scientific Versus Industrial Practices 52
2.6.1 Science 52
2.6.2 Technology 52
2.6.3 Scientific and technical literature 53
2.6.4 Decision-making practices in the pulp and paper industry 53
2.7 Approach to Selection of Relevant Technology 53
2.7.1 Available technologies 53
2.7.2 Demonstrated technologies 54
2.7.3 BAT selection 55
2.7.4 Product modifications 56
3 MANUFACTURING PROCESSES 57
3.1 Various Categories of Pulp and Paper Mills 57
3.2 Wood Preparation 58
3.3 Principles of Pulping Wood 58
3.4 Chemical vs Mechanical Pulping Processes 59
3.5 Kraft Pulp 60
3.5.1 Debarking and chipping 60
3.5.2 Kraft process description 60
3.5.3 Digesters 61
3.5.4 Anthraquinone 62
3.5.5 Pulp washing and screening 64
3.5.6 Traditional washing equipment 67
3.5.7 Diffusion washing equipment 68
3.6 Extended Delignification 69
3.7 Bleaching of Kraft Pulp 70
3.7.1 Bleaching terminology 71
3.7.2 Pulp quality 72
3.7.3 Chlorine-based bleaching sequences 76
3.7.4 Chemical requirements for bleaching 77
3.7.5 Alkali/oxygen extraction 78
3.7.6 Effluent flow 78
3.7.7 Effluent BOD 79
3.7.8 Organic substances in bleach plant effluents 80
3.7.9 Toxicity 81
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N. McCubbin Consultants Inc. BAT Definition Study, Pulp and Paper Sector
3.7.10 Colour 81
3.7.11 Organochlorine compounds 83
3.7.12 Brightness targets and effluent characteristics 84
3.8 Sources of Chemicals 87
3.8.1 Molecular chlorine and sodium hydroxide 87
3.8.2 Sodium chlorate 87
3.8.3 Oxygen
3.8.4 Ozone
3.8.5 Hydrogen peroxide
3.8.6 Chlorine dioxide manufacture
3.8.7 Enzymes
3.9 Recovery of Pulping Chemicals
3.9.1 Process description
3.9.2 Evaporators
3.9.3 Evaporator and digester condensates
3.9.4 Soap recovery
3.9.5 White liquor production
3.9.6 Recovery cycle effluents
3.10 Recovery Boiler Capacity
3.10.1 Defining capacity
3.10.2 Upgrading existing boilers
3.10.3 Reducing boiler load 99
3.10.4 Recovery boiler replacement 100
3.10.5 Status of Ontario recovery boiler loading 101
3.11 Mechanical-sulphite Spectrum of Pulping 102
3.11.1 Groundwood pulping 102
3.11.2 Thermomechanical pulping 103
3.11.3 Sulphite pulping 103
3.11.4 BOD generation by mechanical-sulphite mills 103
3.11.5 Summary of pulping processes 104
3.11.6 Discharge prevention at source 105
3.12 Semichemical Pulp 106
3.13 Secondary Fibre Pulping 106
3.14 Deinking 107
3.15 Brightening of Mechanical Pulp 108
3.16 Paper Mills 110
3.16.1 Stock preparation 110
3.16.2 Paper machines 111
3.16.3 Water balance 112
4 EFFLUENT CHARACTERISTICS in 1990 113
113
4.1 General Wastewater Variables
114
4.1.1 Biochemical oxygen demand
114
4.1.2 Chemical oxygen demand
115
4.1.3 Dissolved organic carbon (DOC)
115
4.1.4 Total Suspended Solids (TSS) / Volatile Suspended Solids (VSS)
117
4.1.5 Nitrogen and ammonia
118
4.1.6 Phosphorus
118
4.1.7 Sulphur
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4.1.8 Colour and turbidity 118
4.1.9 Specific conductivity 119
4.1.10 Toxicity 119
4.2 Resin Acids 120
4.3 Neutral, Non-chlorinated Compounds 122
4.4 Adsorbable Organic Halogen (AOX) 123
4.4.1 Calculation of AOX content of effluents 126
4.5 Formation of Organochlorine Compounds 129
4.5.1 Chlorophenolics 129
4.6 Lipophilic, Neutral Organochlorines 131
4.7 Polychlorinated Dioxins and Furans (PCDD/PCDF) 133
4.8 Chlorinated Lipophilics 137
4.9 Metals 137
4.10 Monitoring Data from the First 6 Months MISA Program 140
4.10.1 Background 141
4.11 Kraft Mill Discharges 142
4.11.1 Boise Cascade Canada Ltd., Fort Frances (Mill 06) 143
4.11.2 Canadian Pacific Forest Products Ltd., Dryden (Mill 08) 143
4.11.3 Canadian Pacific Forest Products Ltd., Thunder Bay (Mill 09) 144
4.11.4 Domtar Inc., Fine Papers Div., Cornwall (Mill 10) 145
4.11.5 Domtar Inc., Containerboard Division, Red Rock (Mill 11) 146
4.11.6 E.B. Eddy Forest Products Ltd., Espanola (Mill 14) 146
4.11.7 James River-Marathon Ltd. (Mill 16) 147
4.11.8 Kimberly-Clark Canada Inc., Terrace Bay (Mill 19) 148
4.11.9 Malette Kraft Pulp and Paper Co., Smooth Rock Falls (Mill 21) 148
4.12 Sulphite-Mechanical Mills 149
4.12.1 Abitibi-Price Inc., Thunder Bay Div. (Mill 04) 149
4.12.2 Abitibi-Price Inc., Fort William Div. (Mill 02) 149
4.12.3 Abitibi-Price Inc., Iroquois Falls Div. (Mill 01) 149
4.12.4 Abitibi-Price Inc., Provincial Papers Div. (Mill 03) 150
4.12.5 Boise Cascade Canada Ltd., Kenora (Mill 07) 150
4.12.6 Quebec and Ontario Paper Company Ltd. (Mill 23) 150
4.12.7 St. Marys Paper Inc., Sault Ste Marie (Mill 24) 151
4.12.8 Spruce Falls Power and Paper Company Ltd., Kapuskasing (Mill 25) 151
4.13 Corrugating Mills 151
4.13.1 Domtar Inc., Containerboard Division, Trenton (Mill 13) 151
4.13.2 MacMillan Bloedel Ltd., Sturgeon Falls (Mill 20) 152
4.14 Deinking-Board-Fine Papers-Tissue Mills 152
4.14.1 Beaver Wood Fibre Company Ltd., Thorold (Mill 05) 152
4.14.2 Domtar Inc., Fine Papers Div., St Catharines (Mill 12) 152
4.14.3 E.B. Eddy Forest Products Ltd., Ottawa (Mill 15) 152
4.14.4 Noranda Forest Inc., Recycled Papers, Thorold (Mill 22) 153
4.14.5 Kimberly-Clark Canada Inc., St. Catharines (Mill 18) 153
4.14.6 Kimberly-Clark Canada Inc., Huntsville (Mill 17) 154
4.14.7 Trent Valley, Paperboard Industries Corporation, Trenton (Mill 27) 154
4.14.8 Strathcona Paper Company, Napanee (Mill 26) 154
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