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United States
Environmental Protection
Agency
EPA/600/R-93/110
Office of Research and
Development
Washington, DC 20460
Office of Pollution
Prevention and Toxics
Washington, DC 20460
August 1993
Pollution Prevention
Printed on Recycled Paper
EPA/600/R-93/110
August 1993
POLLUTION PREVENTION TECHNOLOGIES FOR THE BLEACHED
KRAFT SEGMENT OF THE U.S. PULP AND PAPER INDUSTRY
Contract No. 68-CO-0068
Work Assignment Manager
Jocelyn Woodman
Pollution Prevention Division
Office of Pollution Prevention and Toxics
Office of Pollution Prevention and Toxics
Office of Prevention, Pesticides, and Toxic Substances
U.S. Environmental Protection Agency
Washington, DC 20460
Office of Environmental Engineering and Technology Demonstration
Office of Research and Development
U.S. Environmental Protection Agency
Washington, DC 20460
Notice
This document is intended to provide technical and economic information on approaches to
pollution prevention in the pulp and paper industry. Compliance with environmental and occupational
safety and health laws is the responsibility of each individual business and is not the focus of this
document.
Mention of trade names or commercial products within this report does not constitute
endorsement or recommendation for use. Users are encouraged to duplicate this publication as needed.
Acknowledgements
This report was prepared by ERG, Inc. of Lexington, Massachusetts under EPA Office of Research
and Development Contract No. 68-CO-0068 for the EPA Office of Pollution Prevention and Toxics. The
OPPT Work Assignment Manager was Jocelyn Woodman, while Jeff Cantin managed the development
of the document for ERG.
The report has been subjected to the U.S. Environmental Protection Agency’s peer review process.
The following individuals participated in the review. Their helpful comments are greatly appreciated:
Gary A. Amendola
Amendola Engineering
1052 Kenneth Drive
Lakewood, Ohio 44107
Karl C. Ayers
Director, Env. Programs
Mead Corporation
Courthouse Plaza, N.E.
Dayton, Ohio 45463
Betsy Bicknell
Radian Corporation
2455 Horsepen Road, Suite 250
Hemdon, Virginia 22071
Danforth G. Bodien
U.S. EPA Region X
1200 Sixth Ave.
Seattle, Washington 98101
Jens Folke, Managing Director Steve Geil
European Environmental Research
U.S. EPA Office of Water
Group, Ltd.
401 M Street SW
Pinievangen 14
Washington, DC. 20460
DK-3450 Allerod, Denmark
David P. Graves
Director, Env. Management
Weyerhaeuser Paper Company
33663 Weyerhaeuser Way South
Federal Way, Washington 98003
George Heath
K.C. Hustvedt
U.S. EPA Office of Water
U.S. EPA Office of Air Quality
401 M Street, SW
Planning and Standards
Washington, D.C. 20460
RTP, North Carolina 27711
Thomas J. Holdsworth
U.S. EPA Office of Research and
Development
26 W. Martin Luther King Drive
Cincinnati. Ohio 45268
Anna Klein
U.S. EPA Office of Water
401 M Street, SW
Washington, D.C. 20460
Neil McCubbin
N. McCubbin Consultants
140 Fishers Point
Foster, Quebec
JOE 1RO Canada
Debra Nicoll
U.S. EPA Office of Water
401 M Street, SW
Washington, D.C. 20460
TABLE OF CONTENTS
SECTION ONE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION ONE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
l-5
SECTION TWO
POLLUTANTS OF CONCERN IN THE PULP AND PAPER
2.1
2.2
2.3
INDUSTRY
2- 1
Effluents
2- 1
2.1.1
Solids
2-2
2.1.2
Biological Oxygen Demand
2-4
2.1.3
Color
2-6
2.1.4
Chlorinated Organic Compounds
2-8
2.1.5
Other Toxic Compounds
2-13
Solid Wastes
2-14
2.2.1
Wastewater Treatment Sludge
2- 14
2.2.2
Boiler and Furnace Ash and Scrubber Sludge
2-16
2.2.3
Wood Processing and Other Wastes
2-17
Air Pollutants
2-17
2.3.1
Reduced Sulfur Compounds
2- 17
2.3.2
Particulates
2- 18
2.3.3
Volatile Organic Compounds
2- 18
2.3.4
Chloroform
2- 19
2.3.5
Other Hazardous Air Pollutants
2-20
SECTION TWO REFERENCES
2-22
SECTION THREE
POLLUTION PREVENTION TECHNOLOGIES IN
WOODYARD AND CHIPPING OPERATIONS . . . . . . . . . . . . . . .
3-l
3.1
Raw Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-l
3.2
Recycle of Log Flume Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3.3
Dry Debarking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
vii
TABLE OF CONTENTS (cont.)
Page
SECTION THREE
POLLUTION PREVENTION TECHNOLOGIES IN
WOODYARD AND CHIPPING OPERATIONS (cont.)
3.4
Improved Chipping and Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3.5
Storm Water Management
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
SECTION THREE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
SECTION FOUR
POLLUTION PREVENTION TECHNOLOGIES IN
4.0
4.1
4.2
4.3
4.4
PULPING OPERATIONS
4- 1
Introduction
4- 1
Conventional Kraft Pulping
4-4
4.1 .l
Batch Pulping
4-4
4.1.2
Continuous Pulping
4-8
4.1.3 The Kraft Recovery Cycle
4-8
Extended Delignification
4- 10
4.2.1
Number of Installations
4-16
4.2.2
Costs and Economics
4-20
4.2.3
Pollution Prevention Potential
4-21
4.2.4
Compatibility with Downstream Bleaching Stages
4-23
4.2.5
Impacts oti Other Aspects of Mill Operations
4-28
Oxygen Delignification
4-32
4.3.1
Number of Installations
4-39
4.3.2
Costs and Economics
4-42
4.3.3
Pollution Prevention Potential
4-47
4.3.4
Compatibility With Downstream Bleaching Stages
4-47
4.3.5
Impacts on Other Aspects of Mill Operations
4-51
Ozone Delignification
4-52
4.4.1
Number of Installations
4-57
4.4.2
Costs and Economics
4-60
4.4.3
Pollution Prevention Potential
4-62
4.4.4
Impacts on Other Aspects of Mill Operations
4-64
Vlll
TABLE OF CONTENTS (cont.)
SECTION FOUR
POLLUTION PREVENTION TECHNOLOGIES IN
4.5
4.6
4.7
4.8
4.9
4.10
PULPING OPERATIONS (cont.)
Anthraquinone Catalysis
4-69
4.5.1
Number of Installations
4-69
4.5.2
Costs and Economics
4-70
4.5.3
Pollution Prevention Potential
4-70
4.5.4
Impacts on Other Aspects of Mill Operations
4-72
4.5.5
Environmental Effects
4-72
Black Liquor Spill Control and Prevention
4-73
4.6.1
Number of Installations
4-75
4.6.2
Costs and Economics
4-75
4.6.3
Pollution Prevention Potential
4-75
4.6.4
Impacts on Other Aspects of Mill Operations
4-76
Enzyme Treatment of Pulp
4-76
4.7.1
Number of Installations
4-78
4.7.2
Costs and Economics
4-80
4.7.3
Pollution Prevention Potential
4-8 1
4.7.4
Compatibility With Other Aspects of Mill Operations
4-81
Improved Brownstock Washing
4-81
4.8.1
Number of Installations
4-83
4.8.2
Costs and Economics
4-84
4.8.3
Pollution Prevention Potential
4-84
4.8.4
Impacts on Other Aspects of Mill Operations
4-87
Closed Screen Room
4-89
Miscellaneous Pulping Technologies
4-89
4.10.1
The Lignox Process
4-90
4.10.2
Solvent Pulping
4-90
4.10.3
Polysulfide Cooking
4-93
4.10.4
Demethylation
4-94
SECTION FOUR REFERENCES
4-96
ix
TABLE OF CONTENTS (cont.)
SECTION FIVE
POLLUTION PREVENTION TECHNOLOGIES IN
5.1
5.2
5.3
5.4
5.5
5.6
BLEACHING OPERATIONS
5-I
Conventional Kraft Pulp Bleaching
5-l
Chlorine Dioxide Substitution
5-5
5.2.1
Number of Installations
5-10
5.2.2
Costs and Economics
5- 14
5.2.3
Pollution Prevention Potential
5-20
5.2.4
Other Impacts
5-24
Split Addition of Chlorine Charge/Improved pH Control
5-25
5.3.1
Number of Installations
5-26
5.3.2
Costs and Economics
5-26
5.3.4
Pollution Prevention Potential
5-26
Oxygen-Reinforced Extraction
5-26
5.4.1
Number of Installations
5-28
5.4.2
Costs and Economics
5-28
5.4.3
Pollution Prevention Potential
5-29
Peroxide Extraction
5-30
5.5.1
Number of-Installations.
5-32
5.5.2
Costs and Economics
5-34
5.5.3
Pollution Prevention Potential
5-35
Additional Technology Options in the Bleaching Area
5-36
5.6.1
Improved Chemical Controls
5-37
5.6.2
Improved Chemical Mixing
5-37
5.6.3
Jump-Stage, Counter Current Washing
5-37
SECTION FIVE REFERENCES
5-38
[...]... objective, and in an attempt to develop and provide information on the benefits of source reduction, EPA has produced this report which examines: (1) the current state of the art, (2) the economics of adoption, and (3) the level of adoption, of selected pollution prevention technologies in the U.S pulp and paper industry The focus of this report is on the bleached kraft segment of the pulp and paper industry, ... Agency, Office of Pollution Prevention and Toxics EPA-744R-93-002 February 1993 Page l-5 Section Two - Pollutants of Concern Pollution Prevention in Pulp & Paper SECTION TWO POLLUTANTS OF CONCERN IN THE PULP AND PAPER INDUSTRY This section discusses the sources, types, and quantities of pollutants found in the waste streams of bleached kraft pulp and paper mills, and the methods currently in use for their... explains the high level of attention directed toward this segment of the industry The bleached kraft segment accounts for approximately 35 percent of the pulp mills and 47 percent of the pulp production capacity in the U.S industry (API, 1992a) The removal or destruction of chlorinated pollutants from the bleached kraft process through endof-pipe treatment is difficult due to their persistence and low... Study Office of Water Regulations and Standards, Washington, D.C., March 1988 EPA 440-l-88-025 EPA, 1992 U.S Environmental Protection Agency Model Pollution Prevention Plan for the Kraft Segment of the Pulp and Paper Industry U.S EPA Region 10, Seattle, WA, September 1992 EPA 910/9-92-30 EPA, 1993 International Symposium on Pollution Prevention in the Manufacture of Pulp and Paper Opportunities and Barriers,... Page l-3 Pollution Prevention in Pulp & Paper Section One - Introduction Much of the information contained in this report is by necessity very recent Many of the current concerns over the environmental problems of the U.S pulp and paper industry have arisen only since 1985, with the discovery of dioxin in bleached kraft mill effluents and solid wastes (EPA, 1988) Although prior to 1985 some of these alternative... This increases the bulk of the waste and Page 2-16 Section Two - Pollutants of Concern Pollution Prevention in Pulp & Paper increases the cost of their disposal Fly ash from hog fuel burners is also a concern due to the presence of dioxins and furans in the ash at some mills 2.2.3 Wood Processing and Other Wastes A number of other minor solid waste streams are associated with pulp and paper operations... Pollution Prevention in Pulp & Paper future direction of environmental regulations in their industry and the possible implications on the processes they use Market forces are equally important In particular, mills that sell pulp or paper into certain environmentally discerning international markets may be forced to adopt further pollution prevention measures in order to comply with the demands of their... alternative and emerging technologies were in use elsewhere in the world (and were under active investigation in North America), only lately has there been a move by U.S producers to adopt them Since the discovery of dioxins in pulp mill effluent, however, the U.S and international research and development effort has been impressive, and the rate of adoption of many of these in-process pollution prevention technologies. .. concern in the pulp and paper industry This section provides background for discussion in further sections on technologies that reduce these pollutants Sections Three, Four, and Five cover pollution prevention technologies that are available to reduce or minimize the generation of some of these pollutants Section Three covers technologies that can be applied in the woodyard and chipping areas of the mill... attention has generally focused on technologies that prevent the formation of dioxins and furans during bleaching, and not on biological or chemical effluent treatment The U.S industry has also recognized the role of pollution prevention techniques in reducing dioxin and furan formation According to estimates from the National Council of the Paper Industry for Air and Stream Improvement (NCASI),11more . section discusses the sources, types, and quantities of pollutants found in the waste streams
of bleached kraft pulp and paper mills, and the methods currently. compounds. Section 2.2 discusses the solid wastes, while Section
2.3 discusses air emissions.
2.1
EFFLUENTS
Pulp and paper mills require large quantities of
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