WashingtonStateDepartmentofEcology IndustrialFootprintProject WasteStreamReductionandReUseinthePulpandPaperSector ProjectTask5.1 By MichelleBird 1 Dr.JohnTalberth 2 CenterforSustainableEconomy 1704BLlanoStreet,Suite194 SantaFe,NewMexico87505 (505)9861163 www.sustainableeconomy.

org August2008

1 2

EnvironmentalPolicyFellow,CenterforSustainableEconomy(english@recyclenewmexico.com). PresidentandSeniorEconomist,CenterforSustainableEconomy.Director,SustainabilityIndicatorsProgram, RedefiningProgress(jtalberth@cybermesa.com).

 WasteStreamReductionandReUseinthePulpandPaperSector 1.0Background InsupportofProjectTask5fortheWashingtonStateIndustrialFootprintProject(IFP)Center forSustainableEconomyhaspreparedthisreportidentifyingmajorcomponentsofthepulp andpaperwastestreamandopportunitiesforrecyclingandreuseofthatstreaminbeneficial uses.ThepurposeofthereportistoprovideWashingtonStatesDepartmentofEcology(DOE) withanoverviewofpotentialwastestreamreductioninitiativesapplicabletothesectorin generalandformillsparticipatingintheIFP. Thereportisorganizedassuch.InSection2,weprovideadescriptionofthemajorcomponents ofthepulpandpapersectorwastestream.Wefocusourattentiononthree:wastewater treatmentplantresiduals,boilerashresidues,andcausticizingresiduals.InSection3,weprovide asummaryofstateoftheartwastereductiontechniquesemployedinthesectorworldwide, drawingfromindustrysustainabilityreportsandotherpublishedliterature.Section4providesa comprehensiveoverviewofpotentialmarketsforallmajortypesofwaste.InSection5,we reviewsomekeybarriersandchallengesforreuse,andreporttheresultsofaninternalsurvey ofmillsparticipatingintheIFP.InSection6,weconcludewithabriefoverviewofbothindustry ledandpublicprogramstoincreasethereuseofpulpandpaperresiduals. 2.0PulpandPaperMillWasteStreamDescription Papermakingproducessignificantresidualwastestreamsconsistingof: Wastewatertreatmentplant(WWTP)residuals. Boilerandfurnaceash. Causticizingresidueswhichincludelimemud,limeslakergritsandgreenliquor dregs. Woodyarddebris. Pulpingandpapermillrejects. TheUnitedStatespulpandpapermillindustryseesanannualgenerationofsolidwastesand byproductsolidsof15milliondrytons.Compositionvariesbymill,butcanbeasmuchas50 percentsolidsto50percentwater.Thesolidsaregenerally50percentfiberandasmuchas50 percentminerals.PulpspHistypicallyaround12,butmillsneutralizeresiduebeforedisposal. Residuecanalsocontainrecoverabletitaniumoxideandcalciumsulfate(WisconsinBiorefining DevelopmentInitiative). Millsgeneratethreetypesofsolidwaste:sludgefromwastewatertreatmentplants,ashfrom boilers,andmiscellaneoussolidwaste,whichincludeswoodwaste,wastefromthechemical recoverysystem,nonrecyclablepaper,rejectsfromrecyclingprocessesandgeneralmillrefuse. Mechanicalandchemicalpulpmillsgeneratethesameamountoftotalsolidwaste.Insome 2

cases,recyclingbasedpapermillsproducemoresolidwastethanvirginfibermills.Thisresidue consistsalmostentirelyofinorganicfillers,coatingsandshortpaperfibersthatarewashedout oftherecoveredpaperinthefibercleaningprocess.Printingandwritingpapermillstendto generatethemostsludge,whilepaperboardmillsproducetheleast(EnvironmentalDefense Fund). 2.1Wastewatertreatmentplant(WWTP)residuals WWTPresidualsarethelargestvolumeresidualwastestreamgeneratedbythepulpandpaper industry,producing5.5milliondrytonsannuallyindustrywideintheU.S(Thacker2007).There arefourtypesofWWTPresiduals:(1)primary(includingdeinkingresiduals)represents40%of WWTPresiduals;(2)secondary(wasteactivatedsludge)is1%;(3)combinedprimaryand secondary(54%)and,(4)dredged(5%).Mechanicaldewateringisthenormofprocessing WWTPresiduals,withasolidscontentinthe3040%rangeonaverage.Whenprocessedinthis manner,thewastedoesnotfallintothehazardouscategoryasdefinedbytheResource ConservationandRecoveryAct(RCRA).Thissolidwasteislowinmetals,withlowtomedium nutrientsandlowintraceorganics.Asmallnumberofmillsdrytheirresiduals,whichproducea 7095%solidwasterate(Thacker2007).

Waterisrecycledinpulpandpapermillstoconserveenergyandrawmaterials;however,some mustbediscardedtominimizeproblemssuchascorrosionorscaling.Excessprocesswateris eithertreatedonsitebythefacilityorbyamunicipalwastewatertreatmentplant.Onsite treatmentoftenconsistsofclarification(primary)andbiological(secondary)treatmentto removesuspendedsolidsandsolubleorganicmaterials.Thesolidmaterialsareseparatedfrom thetreatedwaterandaretypicallydewateredtoacakelikeconsistencyutilizingbeltpressesor screwpresses(RMT,Inc.2003). PrimaryWWTPresidualsmostlyconsistofprocessedwoodfiberandinorganicormineral matter(e.g.kaolinclay,CaCO3,TiO2).Theash(inorganicmaterial)producedfromthisprocess rangesbydryweightfromlessthan10%upto70%.SecondaryWWTPresidualsconsistmostly ofbacterialbiomass(nonpathogenic). Becauseofthetendencyforchlorinatedorganiccompoundstopartitionfromeffluenttosolids, wastewatertreatmentsludgeisasignificantenvironmentalconcernforthepulpandpaper industry.Itshouldbenoted,however,thatrecenttrendsawayfromelementalchlorine bleachinghavereducedthesehazards.AcontinuingconcernistheveryhighpH(>12.5)ofmost residualwastes.Whenthesewastesaredisposedofinanaqueousform,theymaymeetthe ResourceConservationandRecoveryActs(RCRAs)definitionofacorrosivehazardouswaste. Sludgegenerationratesvarywidelyamongmills.Forexample,bleachedkraftmillssurveyedas partofEPAs104MillStudyreportedsludgegenerationthatrangedfrom14140kilograms (kg)ofsludgepertonofpulp.Totalsludgegenerationforthese104millswas2.5milliondry metrictonsperyear,oranaverageofapproximately26,000drymetrictonsperyearperplant. Pulpmakingoperationsareresponsibleforthebulkofsludgewastes,althoughtreatmentof 3

papermakingeffluentsalsogeneratessignificantsludgevolumes.Forthemajorityofpulpand integratedmillsthatoperatetheirownwastewatertreatmentsystems,sludgesaregenerated onsite.Asmallnumberofpulpmills,andamuchlargerproportionofpapermaking establishments,dischargeeffluentstopubliclyownedwastewatertreatmentworks(POTWs). Landfillandsurfaceimpoundmentdisposalaremostoftenusedforwastewatertreatment sludge,butasignificantnumberofmillsdisposeofsludgethroughlandapplication.DOEand EPAconsiderproperlandapplicationofsludgeasabeneficialuse.Papermillsludgescan consumelargepercentagesoflocallandfillspaceeachyear.Whendisposedofbybeingspread oncropland,concernsareraisedabouttracecontaminantsbuildingupinsoilorrunningoff intoarealakesandstreams.Somepulpandpapercompaniesactuallyburntheirsludgein incineratorsforonsiteenergygeneration,compoundingwhatcanbecomeseriousairpollution problems(CWAC). Accordingtoa2002studybytheAmericanForestryandPaperAssociation,WWTPresiduals weremanagednationallyinthefollowingmanners: Landfill/lagoon:51.8% Landapplication:14.6% Incinerationforenergyproduction:21.9% Otherbeneficialuse:11.7% TheConfederationofEuropeanPaperIndustries(CEPI)reportedin2003thatwastewater treatmentresidualsinmembercountriesonaverageweremanagedwith33%goinginto energyrecovery,37%landapplication,19%usedinotherindustriesand11%landfilled(Barjic). 2.2.Boilerashresiduals Boilerash,anotherwasteproductfrommills,represents4milliondrytonsannuallyintheU.S. ACanadianstudyofpulpandpapermillssawamarkedincreaseinthevolumeofboilerash residualsbetween1995and2002(Camberatoetal.1997).Boilerashinmillsettingsis producedfromwood,coal,woodandcoalcombined,andacombinationofwood,coaland othersolidfuels.Ninetyninepercentofboilerashisderivedfrompowerboilersandonly1 percentofashwastecomesfromrecoveryboilers.Coalashcomprisesabout15percentofthe ashproducedbythepulpandpaperindustryeachyear,however,inWashingtonState,this percentageismuchlessbecausecoalisaninsignificantsourceofenergy.Woodfiredboilerash (woodash)comprisesabout22percentoftheash.Ofthetotalwoodashgenerated,28percent (0.8milliontons)isusedinabeneficialuseapplication,thusleavingapproximately2.0million tonsofashtobedisposedinalandfillorlagoon(RMT,Inc.2003). Woodashcanbedescribedasbeinghighinunburnedcarbon,highinMgandCa(asourceofK andP),alkaline(highpH),relativelylittleornoheavymetalcontentandcementitious. Unburnedcarboncanrangefrom1050%ofresidualsinwoodflyash(Camberatoetal.1997). Comparedtocoalash,woodashtypicallyishigherincalciumandpotassiumandlowerin 4

aluminumandiron.Woodashisgenerallylowinenvironmentalcontaminants.Potentially hazardousconstituentsincludetracemetalssuchasarsenic,cadmium,andselenium;however, woodashgenerallyhasmoreconsistentandlowermetalsconcentrationsascomparedtocoal ash(RMT,Inc.2003). Mixedfuelsourceashisthemostcommonashproducedbythepulpandpaperindustry, accountingfor63percentofthe2.8milliontonsofashproducedeachyear.Mixedfuelashis managedsimilarlytowoodashandcoalash.Asawhole,72percentoftheboilerashproduced bythepulpandpaperindustryisdisposedinalandfillorlagoon,and28percent(or2million tons)isemployedinbeneficialuseapplications.Mixedfuelsourceashiscomposedofthe noncombustiblematerialsderivedfromtheincinerationofmixturesinvaryingproportionsof wood,coal,WWTPresiduals,and/orothermaterialsduringenergygenerationactivities.The compositionofmixedfuelashmaybemorevariablefromfacilitytofacility,sincetherelative proportionofthedifferentfuelsisvariable(RMT,Inc.2003). Energyforthemanufacturingprocesscanbeprovidedbypublicutilitiesorgeneratedonsiteby theuseofrecoveryboilers,powerboilers,andturbines.Recoveryboilersburnliquidcalled spentliquor,whichisgeneratedduringthechemicalpulpingprocess.Powerboilerstypically burncoal,naturalgas,wood,oil,andmixedsolidfuels(e.g.,coal,woodresidues,process residues,tires,etc.).Proportionsoffuelsusedinthisindustryspowerboilershavechanged overthelastfewdecades,withadecreaseintheuseoffossilfuelsandanincreaseintheuseof woodandprocessresidues(RMT,Inc.2003). Accordingtoa2002studybytheAmericanForestryandPaperAssociation,boilerashwas managednationallyinthefollowingmanners(NCASI2007): Landfill/lagoon:65.4% Landapplication:9.3% Otherbeneficialuse:25.3% 2.3Causticizingresiduals Causticizingresiduessuchasslakergrits,greenliquordregs,andexcesslimemudareamong thesignificantbyproductsolidsfromkraftpulpmills.In1995,about1.7milliondrytonswere producedannually,withexcesslimemudrepresenting59%ofthetotal,greenliquordregs28% andslakergrit14%.Overall,81%ofthesematerialswerelandfilled.Thesematerialshave chemicalandphysicalpropertiesthatcanmakethemsuitableforanumberofbeneficialuses. Theyarealkaline,highincalcium,notRCRAhazardouswaste,andlowinmetals(NCASI2001). Aswithotherindustrialbyproducts,thetoxicityandleachabilityoftraceconstituentsinthe causticizingresidualsshouldbeassessedpriortoanybeneficialuseapplication(RMT,Inc. 2003). Greenliquordregsarecomposedofnonreactiveandinsolublematerialsremainingafter inorganicprocesschemicals(smelt)fromtherecoveryfurnacearemixedwithwater.Thedregs 5

areremovedbygravityclarification.Greenliquordregsconsistofcarbonaceousmaterial,along withcompoundsofcalcium,sodium,magnesium,andsulfur.Theytypicallycontain45to55 percentsolids. Limemud(calciumcarbonateandwater)isburnedinalimekilntoregeneratethematerialto lime(calciumoxide).Itnormallyisnotabyproduct;however,excesslimemudcanbe generatedinthosefacilitieswithlimitedlimekilncapacityandduringperiodsofkilndowntime. Limemudiscomposedprimarilyofcalciumcarbonate,butmayalsocontainunreactedcalcium hydroxide,unslakedcalciumoxide,magnesium,andsodium.Thesolidscontentoflimemudis generallybetween70and80percent. Limeslakergritsareproducedwhenlimeismixedwithgreenliquor.Theyarecomposedof overburnedand/orunderburnedlimethatisproducedinthelimekiln.Thegritsalsocontain sodium,magnesium,andaluminumsalt,andthesolidscontentrangesfromto70to80 percent. Collectively,thecausticizingmaterialscanbecharacterizedashavingapHabove11,andas containingvaryingproportionsofcalcium,aluminum,iron,sodium,potassium,sulfur, magnesium,andchlorine.Calciumisapredominantcomponent. Accordingto1995figures,causticizingresidualsweremanagednationallyinthefollowing manner(NCASI2001): LimeMud GreenLiquorDregs SlakerGrits Lagoonorlandfill 70% 95% 91% Landapplication 9% 3% 5.5% Reuseinmill 1% 0% 3% Otherbeneficialuse 21% 2% 1% 3.0StateoftheArtWasteStreamReductionTechniques Examinationofpulpandpapermillsaroundtheworldbringsexamplesofwhereindustry leadersareconvertingwasteintoaresource.Manycompaniesarenowabletolabelwhat formerlywasdesignatedaswasteintoaproductcategory.Inthissection,wefirstidentify numerouswastereductionandreuseinitiativespublishedinindustrysustainabilityplansand otherindustryreports.Forthesakeofbrevity,wehavepreparedthissectionasbulletedlists withreferencestospecificsustainabilityplans.Wethenidentifysomeoftheemergingwaste reductiontechnologiesthatmayplayanimportantroleinthenearfuture. 3.1Industryleaderswastereductionstrategies 3.1.1Examplesofwastewatertreatmentplantresidualimplementation: SludgewastesareburnedinthepowerboileratApril,Inc.mills(April2006). 6

Byproductsusedtomakecompostmixture,cementadditives,pottingsoil,landscape bark,androofingshinglesatBoisemills(Boise2006). Sludgethatsettlesinthewastetreatmentprocessisdewateredandburnedasan alternaterenewableenergysourcetocreatesteamatBoisemills(Boise2006). TheCatalystPaperRecyclingDivisionsent31,000tonsofresiduals(inertcarbonink andpaperfiber)tocustomersinsteadoflandfillsin2006.Customersusethe residualsasagrowingmediumforturf(Catalyst2006). Goalforbleachedmillsistoachieveafiberlossrateoflessthan1percentandfor unbleachedmillstoachievealossrateoflessthan12percentatInternationalPaper (InternationalPaper2006). Fibersludgefromthepaperandboardmillsandashesleftafterenergyproduction areusedforsoilimprovementassuchorcompostedatMetsliittoGroupmills (Metsliitto2006). Some5,000tonsofsludgefromallofNeenah'spaperbrandsisconvertedtosteam, electricity,andglassaggregateeveryyear.Theprimarypurposeofthisrecycling processistoreducetheloadonlandfills,whichcarriesoutacorporate environmentaldirective.Neenahthenpurchasesthesteambacktodrypaperduring manufacturingandalsotoheatitsmill.Thecompanyprojectsthatusingthisgreen steamwillreduceitsnaturalgasconsumptionby80%annually(Neenah2006). Papersludgeashwasusedeffectivelyinroadbedconstructionandsoilimprovement atNipponPaperGroup(2006). NipponPaperGrouphasfoundthatduetothetraceamountsofheavymetals containedtherein,untreatedpapersludgeashcannotmeetsoilenvironmental standards.NipponPaperIndustriesKushiromillhasbeendevelopinghydrothermal solidificationequipmentthatcrystallizesandsealsinheavymetalsthatare containedinpapersludgeash.Verificationtestingoftheequipmentbeganinfiscal 2006toprepareforactualoperation.Productsthathavegonethroughthe granulationandhydrothermalreactionarelightweight,porous,andhavegood drainageproperties.Takingadvantageoftheseproperties,suchproductsaretobe usedassoilimprovementagents(NipponPaperGroup2006). NorskeSkogsmodernmillsutilizebyproducts,suchassludgefromwastewater treatmentanddeinkingplants,andotherorganicwastefromtheproductionprocess asbiofuelforthermalenergyproduction(NorskeSkog2006). SludgeandashinAustraliaandAsiaaresometimesusedforsoilimprovementin agricultureatNorskeSkogmills(2006). StoraEnsohasworkedonimprovementsinwastewatertreatmentplantnutrient control.Nitrogenandphosphorusareaddedasnutrientsourcesforthebiological organismsinthewastewatertreatmentprocess(StoraEnso2006). StoraEnsocombustswastewatertreatmentanddeinkingsludgeinHylteMills newlyrebuiltbiofuelboiler.TheDuluthMillhasanincreaseduseofdeinkingsludge fordailycoveratmunicipallandfills(StoraEnso2006).

3.1.2Examplesofboilerashresidualimplementation: Boilerashhasbeenappliedinroadconstructionandconcretebrickmanufacture fromAPRIL,Inc.mills(2006). WoodashwastefromtheboilersattheBoiseInternationalFalls,Minnesota,paper millisspreadonlocalfarmlandtoimprovesoilpH(Boise2006). WoodashisusedasafertilizeratMetsliittoGroupmills(2006). NipponPaperCompanycontinuestodevelopvarioustechnologies,including hydrothermalsolidificationtechnology,soastofindnewusesforincineratedashat eachmill(NipponPaperCompany2006). StoraEnsousesallboilerashfromAnjalankoskiMillinroadconstructionprojects. (StoraEnso2006). 3.1.3Examplesofcaustizingresidualimplementation: Theboilerusesblackliquorrecoveredfromthemanufacturingprocess,barkand rejectchipsatAPRIL,Inc.mills(2006). Sourcesofselfgeneratedenergy,suchaswoodwastes,pulpingliquors,and hydroelectricpower,provided63percentoftotalenergyrequirementsin2005at Boisemills(2006). InpulpproductionattheMetsliittoGroupmills,thechemicalsinthecookingliquor arerecoveredforreuse,andthelignindissolvedinthecookingliquorisusedfor energyproduction(MetsliittoGroup2006). 3.1.4Examplesofwoodyarddebrisandmillrejectimplementation: Theboilerusesblackliquorrecoveredfromthemanufacturingprocess,barkand rejectchipsatAPRIL,Inc.mills(2006). UseofscreenrejectsasmaterialforsecondgradepaperproductionatAPRIL,Inc. mills(2006). Sourcesofselfgeneratedenergy,suchaswoodwastes,pulpingliquors,and hydroelectricpower,provided63percentoftotalenergyrequirementsin2005at Boisemills(2006). WoodwastefromwoodproductsplantsandpapermillsisburnedasfuelatBoise mills(2006). MostofthefiberCatalystusesconsistsofresidualsfromBritishColumbiasawmills chips,shavingsandsawdust.Thecompanyalsousespoorqualitysoftwoodlogsthat aredefectiveorotherwiseunsuitableforlumbermanufacture,anddeinkedpulp recycledfromoldnewspapersandmagazines(Catalyst2006). InternationalPaperwoodproductsmillsfrequentlysellshavingsandbarkto companiesthatusetheserawmaterialsasagreenhousegasneutralsubstitutefor naturalgasandcoal(InternationalPaper2006).

Byproducts,suchaswoodchips,sawdustandbark,areusedasrawmaterialsfor chipboardandpulpproductionorinheatgenerationatMetsliittoGroupmills (2006). Mostofthewoodthatisnotconvertedintoproductsisutilizedeitherinenergy productionatMetsliittosownproductionunitsorasbiofuelsoldoutsidethe Group(MetsliittoGroup2006).

3.1.5Examplesofgeneralwastereductionaccomplishments: Aracruztreatedsolidwastewithahighdegreeofrecycling,reducingdisposalto landfillsby85%(Aracruz2006). BoisePaperlandfilled51%ofresidualsandBoiseWoodProductslandfilled5% residuals(Boise2006). Partialpaperrollsonmachines,aresultofthechangeoverfrommakingonegradeof papertoanother,iscollectedandrepulpedatBoisemills(2006). AllCatalystmillsrecyclesolidwaste,includingwood,metal,paper,fluorescentlight bulbs,andoil.31,000tonsofresidualsweredivertedtocustomersin2006asa growingmediumforturf.CatalystPaperRecyclingDivisionusesmethanefroma landfillforaportionofitsenergyneeds(Catalyst2006). Increasinglyefficientutilizationofwoodisbeingdevelopedby,forexample, collectingandharvestingresiduesandstumpsforfueluseatMetsliittoGroupmills (2006). WastehasbeenavoidedatMondiPaperGroupthroughtheintroductionofreusable plasticcoresinpaperproductionatthesitesinAustria,Israel,theSlovakRepublic andHungary(MondiPaperGroup2006). EffortsatNipponPaperGrouparemadetorecoverenergyfromcombustiblesand usewasteacidtoneutralizeeffluent(NipponPaperGroup2006). WithintheOjiPaperGroup,89%ofwastedischargeisrecycledthroughrecyclingor effectiveutilization.Ojihasagoaltoreducethevolumeoflandfilldisposaltozero throughfurtherefforts.Theyhavesetagoaltoachieveafinaldisposalratioof0.5% byMarch2011(OjiPaperGroup2006). StoraEnsohasawastetolandfillgoalof10%reductionbytheendof2009from 2004.ThemostimportantbiofuelsfortheGroupareblackliquor,bark,logging residuesandinternalresidualsincludingdeinkingsludgeandbiosludge(StoraEnso 2006). Votorantimdisposesofmanufacturingresiduesusingthefollowingmethods:47% coprocessing,29%composting,4%reuse,14%recycling,and6%landfill. Compostingistheuseofresiduesforapplicationineucalyptusplantations.100%of theindustrialresiduesaretreatedthroughthe3Rconcept(reduce,reutilize, recycle).Compostingisthedestinationof95%ofthesolidwastesproducedatthe LuizAntniounit.Throughthisprocess,theresiduesaretransformedintoorganic compostandusedintheeucalyptusplantations.Thisinitiativemakesitpossibleto eliminatetworesiduestreams(industrialandwoodyard),aswellasgenerating 9

annualsavingsof$170,107forthesubstitutionofchemicalfertilizerusedinthe forests(Votorantim2006). MetsliittoGroupreduceditstotalwastetolandfillfrom216,291tonsin2005to 176,416tonsin2006(MetsliittoGroup2006).

3.2Emergingtechnologiesinwastereduction TheU.S.DepartmentofEnergyOfficeofEnergyEfficiencyandRenewableEnergy(EERE)hasan IndustrialTechnologiesProgram(ITP)thatspecificallyworkswiththepulpandpapermill industrytoenhancetheirenergyusageefficienciesandotherindustrialenvironmental improvements. ExamplesoftheEEREprojectsrelevanttothereductionofwasteinpulpandpapermillsas outlinedintheForestProductsFY2004Portfolio: ImprovedRecoveryBoilerPerformanceThroughControlofCombustion,Sulfurand AlkaliChemistry(BrighamYoungUniversity). DevelopmentofMethanedeNOXReburningProcessforWastewood,Sludgeand BiomassFiredStokerBoiler(GasTechnologyInstitute). ParticleFormationandDepositioninRecoveryBoilers(SandiaNationalLaboratory). Agenda2020isaninitiativesupportedbytheAmericanForestryandPaperAssociation(AF&PA) thathasformedallianceswithfederalagencies(includingITP)tofundcostsharedR&Dprojects aimedatimprovingU.S.forestproductsenergyefficiency,industrycompetitiveness,and environmentalperformance.Oneexampleofwastereductiontechnologyemergingfromthese alliancesincludestheOnlineFluidicsControlledHeadbox.ITPandtheWoodruffSchoolof MechanicalEngineeringattheGeorgiaInstituteofTechnologyisinvestigatingthisnew technologytomodifyfiberorientationintheformingofpaperthatcanenhancepaperand paperboardqualityandleadtoenergysavingsfromreducedrawmaterial(fiber)requirements. Thestaticversionofthetechnology(theVortigensystem)hasbeendemonstratedinlongterm commercialpapermachinetrials.Theprojectisnowfocusingondevisingameansforonline controloftheprocess. Overthelastyear,arobustsystemsuitableforonlinepilottrialsandfinalcommercial implementationusingfourturningvanesfabricateddirectlyfromshapememoryalloy(SMA) wasdesigned,built,andtestedinlaboratoryexperiments;itisnowbeingadaptedtotwoway SMAactuation.ThetwowaySMAvanesweretestedinpilottrialsin2005.Thistechnology promisesabetterpaperproduct,reducedrejects,increasedproductivity,andsignificantly reducedfibercostsandwaterandenergyuse. AnotherexampleisthetheLateralCorrugator:AnImprovedMethodForManufacturing CorrugatedBoxes.ITPseekstodevelopacommerciallyviablelateralcorrugatingprocess.This includesdesigningandbuildingapilotlateralcorrugator,testingandevaluatingthepilot machine,anddevelopingastrategyforcommercialization.Thelateralcorrugatorwillbe 10

designedandbuiltasaretrofittoconventionalpilotcorrugatingfacilitiesattheITPIndustrial EngineeringCenter.Theconstructionofthecorrugatingrollstackforthisprojectisnearing completion.Ifsuccessful,thelateralcorrugatorcouldreducefiberconsumptionandimprove thecompressivestrengthtoweightratioofcorrugatedshippingcontainers,therebyreducing energyusageinbothmanufacturingandtransportation.Anadditionalbenefitoflateral corrugatingisthatwithcuttowidthsheeting,paperrollmanagementissimplifiedand corrugatortrimwasteisminimized,resultinginadditionalreductionsinmaterialconsumption, wastegenerationandenergyusage(U.S.DepartmentofEnergy2005). 4.0SummaryofPotentialMarketsforWasteProducts Oneofthemostpromisingwaystoreducepulpandpaperwastestreamsisgreatermill participationinemergingmarketsforuseofresiduals.Inthissection,wereviewpotential marketsforwastewatertreatmentplant(WWTP)residuals,boilerandfurnaceash,caustizing residues,woodyarddebris,andpulpingandpapermillrejects. 4.1PotentialmarketsorusesforWWTPresiduals WWTPresidualsarethelargestvolumeresidualwastestreamgeneratedbythepulpandpaper industry.Whenprocessedusingmechanicaldewatering,thewastedoesnotfallintothe hazardouscategoryasdefinedbyRCRA.ThechemicalcompositionofWWTPresidualsmakes themexcellentcandidatesforlandapplicationtosupplyorganicmatterandnutrientsin agriculturalandforestedsoil.PrimaryWWTPresidualshavethecapacitytoabsorblarge amountsofliquid,thusservingwellforabsorbentproducts. Table1:WWTPResidualMarketsandBeneficialUses ActualMarketsorBeneficialUses Description Papermakingfiberandfiller Inproductssuchasfiberboard,WWTPmaybe usedasfiller. Industrialabsorbent Oilspillandgeneralindustrialabsorbent product. Animalbedding/catlitter BeddingandlitteravailableinmajorU.S.pet storesanddepartmentstores.Consumessmall volumeofmaterial. Manufacturedsoilcomponent Manufacturedsoilsarecreatedfromavariety ofsourcestoprovideallnecessaryplantgrowth nutrients. Compostfeedstock WWTPwhencombinedwithothercomponents makesanexcellentcompostedproduct. 11

Table1,continued Landfillcoverorbarriercap

Acidminedrainage(AMD)controlcover

Buildingboard/rooffelt/tarpaper

Brickorconcreteadditive

Glassorlightweightaggregate

Finemineralproduct

Cementkilnfeedstock

Fuelpelletadditive (NCASI2001)providesanotherclassification,whichincludes:(a)plasticsadditives;(b)animal feed;(c)vermicomposting;(d)ethanolproduction;(f)levulinicacidproduction;(g)moldedpulp products;(h)celluloseinsulation;(i)mineralsrecovery,and(j)fuelsfrompyroloysis. 4.1.1LandapplicationofWWTPresiduals WWTPresidualshavebeenappliedtolandinthecapacityofasoilconditioner,fertilizer,liming agentandasanerosionandweedcontrol.Issuessurroundingresiduallandapplicationinclude thelownitrogencountoftheproduct,especiallywithprimaryresiduals.Withalackof nitrogen,vegetationmaysuffer.Managementbycompostingtheproductwithpropercarbon andnitrogenmixescanimprovetheproduct(Thacker2007b). CompositionofWWTPresidualsfromavarietyofmilltypeswasdocumentedbyaNational CouncilforAirandStreamImprovement(NCASI)54millstudy(ThackerandVriesman1984). Testingofnutrientsisrecommendedperfacilityiflandapplicationforagricultureisplanned. Mixingthesludgewithlackingcomponentsensuresproperfertilizerformulas.Thesamestudy lookedatheavymetalsandtoxicelements,findingthatsludgesdidnotcontainanyelementsin higherconcentrationsthanallowedintheFederalRegisterregulations. 12

Landfillsmustplaceadailycovertoprevent wastefromblowingaway.Alandfillbarriercap orhydraulicbarrierisusedwhenclosinga landfill. AmanufacturedsoilusingWWTPcomponents canbeusedtopreventstormwaterrunoffon minesites. Structuralandnonstructuralsolidpaneland profilebuildingproductscanbecreatedby sludgepulp. Deinkingsludgeprovidescertainchemical components(silicondioxideandaluminum oxide)beneficialtocementkilnfeedstocks. WWTPresidualsaretypicallymixedwithflyash andpelletized.Thepelletsareplacedinarotary kilnandheated,creatingalightweight aggregate. ThemineralconstituentsofWWTPresiduals, commonlyreferredtoastheashcontent,are valuable. WWTPresidualscanbeaddedasanadmixture toconcretetoserveasasourceofwoodfiber. UsesWWTPasanenergysource.

 Table2:MacronutrientsandMicronutrientConcentrationinPulpandPaperMillWWTP Residues(ThackerandVriesman1984) Nutrient Range Median Macronutrients(g/kg): N(allmilltypes) 0.5187.5 8.98 N(combinedmills) 1.159 8.5 N(primarymills) 0.519.0 2.7 N(secondarymills) 6.287.5 23.3 P(allmilltypes) 0.0125.4 2.35 P(combinedmills) 0.125.4 .67 P(primarymills) 0.014.0 1.6 P(secondarymills) 0.4216.7 4.2 K 0.1210 2.2 Ca 0.28210 14.0 Mg 0.219.0 1.55 S 0.220.0 4.68 Micronutrients(mg/Kg) B <1491 25.0 Cl 0.068,500 383 Cu 3.91,590 52.0 Fe 97.110,800 1540 Mn 132,200 155.0 Mo 2.514.0 Zn 133,780 188 Primarysludgesaretypicallylowinplantnutrients,especiallyN,andhavehighC:Nratios. SecondarysludgeshavehigherconcentrationsofNandPandlowerC:Nratiosthanprimary sludges,becauseNandParecommonlyaddedtothewastetreatmentsystemtoenhance biologicaldegradation.Mixturesofprimaryandsecondarysludgesarealsogenerated,with propertiesdependentontheproportionofeachsludgetypeinthemix. Cropresponsestolandappliedpapermanufacturingsludgeshavebeenvariable,dependenton thesludgeNconcentration,C:Nratio,andamountapplied.Increasedcropyieldsresultingfrom applicationoflowC:Nratiosludgeshavebeenobtainedinsomestudies,whereasotherstudies haveshowndecreasedcropproductivityfromhighC:Nratiosludges.PlantNdeficienciesin highC:NratiosludgesresultfromNimmobilization,whichoccurswhentheNconcentrationof thesludgeisinsufficienttomeetthedemandsofthesoilmicrobialcommunity.Nitrogenfrom thesludgeandsoilisthenimmobilizedintomicrobialtissues,renderingitunavailableforplant uptake. Asthesludgedecomposes,CisevolvedasCO,resultinginagradualdeclineinC:Nratioandan increaseinNavailability.Strategiestoovercomethislimitationinclude;(a)applyingsludgewell 13

inadvanceofcropplantingsothattheC:Nratioofthesludgehasbeenreducedtothepoint thatimmobilizationnolongeroccurs,(b)addingadditionalNtosatisfymicrobialdemandforN necessarytodecomposethesludge,or(c)plantinglegumessothatsoilNisnotrequiredbythe crop(Camberatoetal.1997). AddingfertilizerNtosoilamendedwithhighC:Nratiosludgeisalsoaneffectivemethodof eliminatingtheeffectsofNimmobilizationoncropproductivity.Compostingresidualsmaybe analternativemethodofincreasingNavailabilityofhighC:Nratiosludges.Studiesshowthat compostingreducedtheC:Nratioofthesludgefrom23:1to10:1.Inanotherstudy,aprimary sludge,tailings,ash,andNsourcemixturewithaninitialC:Nratio>270:1wascompostedfor14 weeksandcuredfor4weeks,which,dependingontheamountoftheashinthemixture, resultedincompostC:Nratiosrangingfrom14:1to67:1.Nitrogenimmobilizationwouldbe considerablylesswiththecompostedmixturethanwiththeinitialsludgemixture. Papermanufacturingsludgesmayalsohavepositiveeffectsonsoilphysicalproperties.High applicationrates(448and672metrictonsperhectare)ofprimaryclarifiersludgetoasandy soilincreasedsoilcationexchangecapacityandavailablemoisturecontentasmuchastwoto fivefold.Inthiscase,bothorganicmatterandkaoliniteclayinthesludgewerelikely responsiblefortheincreaseintheseparameters(Camberatoetal.1997). 4.1.2Compostingwastestreamsolids Creatingcompost,whenmanagedbyapulpandpapermillfacilitythatcreatestheresidues, involvesstrongtechnicalknowledgeofthecompostprocess. Feedstocksthathavebeenaddedtopulpandpapermillresiduestocreatebalancedcomposts includeyardtrimmings,municipalbiosolids,foodprocessingresidues(dairyorpaunch), manuresoranimalbedding,pharmaceuticalsludge,andtextileresidues.Therearefour methodsofcreatingcompost:windrows,staticpiles,aeratedstaticpilesandinvesselsystems. Benefitsofcompostincludeincreasedcationexchangecapacityandorganicmattercontentof soil,additionofplantnutrients,suppressionofplantpathogens,increasedmoistureretention andreducedweedgrowthwhenusedasmulchandreducedwatererosionofsoilslopes. Qualitymeasurementsofcompostincludeorganicmattercontent,nutrientcontent(NPK), traceelements,pHvalue,moisturecontent,particlesize/texture,waterholdingcapacity, stabilityandmaturity.Themostcommonproblemsarelackofstabilityandmaturity(Thacker 2005). Compostendmarketsexpandannuallyasthepublicandprivatesectorsrecognizethevalueof theproductasareseedingagent,erosioncontrolandsoilstabilizer.Asummaryofendusers include: Nurseries(fieldandcontainerusage) Landscapingcompanies 14

Retail/homeowners Topsoilblenders Landfillcover Agriculture Silviculture Roadside/DepartmentofTransportation(DOT)developmentandreclamation(Thacker 2005) Minereclamation

Asof2005,25millswerehavingtheirbyproductscomposted(notincludingwoodresidues). Mostmillsweresmallerscale,producinglessthan10drytonsperday(dtpd)ofbyproduct,but thelargestmillproduced100dtpd.Primarily,thewastewatertreatmentanddeinkingresiduals werecomposted,butsomemillsalsosuppliedashandgritresiduesforthemix.Themedian ageofthecompostprogramswere7years,withthelongestrunningcompostprogramcoming inat23years.Inmostcases,themillcontractedwithamunicipalorprivatecomposter,paying fortransportationaswellasatipfee.Mostoperationsusedthewindrowmethodwithperiodic turningofthematerial(Thacker2005). Anotherpotentialendmarketisprovidingmillresiduesforvermicomposting,whereworms processthematerialanddeliverahighqualityendproduct.Onelargescalevermicomposting companyusedwastewatertreatmentresidualsaswellascardboardmanufacturerejectsas partoftheirfeedstock. Fordetailedinstructionsoncompostingresiduesfrompulpandpapermills,theNCASIhas developedTechnicalBulletinNo.894,availabletomembers.Anotherexcellentresourceisthe OnFarmCompostingHandbookcreatedbytheNaturalResource,Agriculture,andEngineering Science(NRAES)association. 4.1.3Erosioncontrolapplications SeveralstudiesimplementingmillWWTPresidualshaveshownthataddingthebyproductto landapplicationsforerosioncontrolpurposes,thesoilwasstabilizedwithaggregateformation andwaterinfiltrationratesincreased.A2003studybyChowinvestigatedtheeffectsof residualsongravellyloamsoilforthepurposeoferosioncontrol.Chowfoundthatafterone yearanda4%organicmatteraddition,thatthestudyareasawa23%reductioninrunoff volumeanda70%reductioninsoilloss.Residualsmayalsobeappliedtostabilizesteepslopes asameansoferosioncontrol(Thacker2007b).Otherrelevantfactsrelatedtoerosioncontrol applications: StateDOTshaveincreasinglyemployedcompostforavarietyofpurposes. Erosioncontrolhasbecomeanimportantmarketforcompost. TheAmericanAssociationofStateHighwayandTransportationOfficials(AASHTO)has publishedstandardspecificationsforcompostfilterbermsandforcompostblankets. 15

StudiesinIowaandVirginiademonstratedthatcompostsmadewithmillWWTP residualswereeffectiveincontrollingerosion. CompostfromaMichiganmillhasreceivedstateDOTapproval(Thacker2005).

4.1.4Manufacturedtopsoilsusingshortpaperfiber ShortPaperFiber(SPF)hasbeenidentifiedasanorganiccomponentformanufacturedtop soils,usingamixof1:1withsand/siltbyvolume.SPFisusedforincreasingthesoilorganic matter.SPFislowinnutrientssothatifappliedtolandwithoutcompostingthematerial,SPF canbeaddedinhighvolumeswithoutriskofnutrientexcess.SPFhasahighC:Nratioandlow concentrationsofN.PandKandissometimesasourceofCaCo3(Carpenter2005). TopsoilutilizingSPFholdsmanytimesitsweightinwater,provideserosionresistance, withstandsheavyrainstormsduetohighwaterabsorbencyrates,canmaintain3:1slope erosionbeforevegetationgrowsback,canreducemulchingrequirementsandincreaselength ofuninterruptedslopes. AnimportantfactorincreatingtopsoilsusingSPFistheC:Nratioinordertoprovidefor maximumvegetationregrowthandavoidleaching.Theoptimalratioisintherangeof25:1to 35:1C:N.Whenusingwastewatertreatmentresidualsfromprimarysources,highlevelsofN arerequiredtoachieveoptimalbalance.Areclamationprojecton10acresusingthismaterial requiredthepurchaseof$13,000ofnitrogen. Nutrientsourcesformanufacturedtopsoilscanbebiosolidsandsecondarywastewater treatmentresiduals.ThesetwoproductshavealowC:Nratio,arehighinplantavailable nitrogen,arerichinphosphorous,andprovidesuchmicronutrientsascopper,zinc,iron,and molybdenum.Bothproductsalsohelpignitesoilmicrobialactivityandhelpprovideforastrong revegetationresponse. Successfulmanufacturedtopsoiltestplotshaveused4.5partsfiberclay,4partssandand1 partbiomassash.Revegetationusingmanufacturedtopsoilapplicationscomparedtonatural topsoilseeddenservegetationregrowth.Itisrecommendedthatifproductiscreated,touse componentssuchasbiomassash,woodyardwastesorwastewatertreatmentresidualsto darkenthesoiltogiveamoreearthtonedhue,astheinitialproductisgray. 4.1.5Soilamendmentproduction Optimizingsoilchemistryisacriticalprocessinsustainingagriculturalandforestedlands.The chemicalcompositionofWWTPresidualsmakesthemexcellentcandidatesforlandapplication tosupplyorganicmatterandnutrientsinagriculturalandforestedsoil.SecondaryWWTP residualsgenerallyhavecarbontonitrogenratiosrangingfromabout5:1to20:1,thusmaking theresidualsasignificantsourceofnitrogen.Secondaryresidualsalsocanbeagoodsourceof phosphorus.TheorganicmatterinprimaryWWTPresidualscanimprovethewaterand nutrientholdingcapacityofsandysoils,andtheaerationandpermeabilityofclaysoils.Also, 16

bothprimaryandsecondaryWWTPtreatmentresidualscanprovideasignificantsourceof othermacroandmicronutrients.Inadditiontoprovidingnutrientsandorganicmattertosoil, someWWTPresidualshighinmineralcontenthavebeensuccessfullyappliedaslimingagents toraisethepHofacidicsoil(RMTInc.2003). BrowningFerrisIndustrieshascreatedapatentedformulautilizingWWTPresidualstocreatea productcalledBioMixsoils.Thesoilmixhasprohibitedrainwatercontaminationrunofffrom refusepilesandmaintainedwaterqualityrequirements.Wastesludgeiscombinedwithnative soils,fertilizersandpHadjustingcompoundstocreatetheagronomicsoil.Themixhasbeen marketedtolandfillsforclosures,dailycover,intermediatecover,gradingmaterialandbaseof serviceroads.Ithasbeensoldtocoal,bauxiteandphosphateminereclamationsites.The producthasalsobeenusedforgolfcoursesandcityparks(NCASI2001). Inaparticularacidminedrainagereclamationproject,700,000tonsoftheBiomixproductwas usedtoregainpositivewaterquality.BioMixsoilshavemoistureholdingcapacitiesexceeding 200%to300%comparedtonativesoils.Themoistureholdingcapacityisduetotheproperties ofthefiber.Oncetherainwatercomesintocontactwiththefiberitisimmediatelydrawninto thefiber.Asthewaterenters,thefiberswellsgivingittheabilitytohold10to20timesits weightinwater.Ithasbeenshownthata12inchlayerofaproperlyblendedmixofBioMixsoil canhold16inchesofwaterbeforereleasingwatertothelayerbelow. 4.1.6Alternativedailycoverforlandfills WWTPresidualsaresuccessfullyusedasanalternativecovermaterialtothetraditional6 inchesofdailysoilcoverusedforactivefacesofalandfill.Analternativedailycovercanalso helpcontrolblowinglitter,animals,andinsectsatthelandfill.Dependinguponphysical characteristics,someWWTPresidualsmayrequiremodificationforconsistencyandworkability beforeuseasdailycovermaterial(RMTInc.2003). 4.1.7Hydraulicbarrierlayerforlandfillsandminereclamation Since1990,morethan29industrialandmunicipallandfillsand8minereclamationsiteshave beenclosedusingresidualsasthehydraulicbarrierlayer.Landfillsizerangedfroma1.6acre municipallandfilltoa30acreindustriallandfill.Combinedresidualswerereportedtocontain approximately5to15%secondarysludge.Barrierthicknessrangedfrom18to49incheswitha medianvalueof30.Asignificantnumberofthefullscaleclosureapplicationsusedablendof wastewatertreatmentresiduals(aswellasflyash)andlocalsoilstoconstructtheoverburden, frostprotection,andvegetativelayers.Thesesyntheticsoils(sometimesreferredtoas engineeredsoils),whilenotdesignedforlowhydraulicconductivity,weredeterminedtohave otherdesirableproperties,makingthemsuperiortolocalsoilsforuseascappingmaterials. Usingresidualsinthebarrierlayerofthecapwasconsideredbeneficialintworespects.First,at arelativelylowunitweight,thecapwouldplacelimitedbearingpressureonthewaste material.Also,theresidualswereconsiderablymoreflexiblethancompactedclay(NCASI2005). 17

AnAmericanSocietyforTestingandMaterials(ASTM)StandardGuideisbeingdevelopedto defineappropriatehydraulicconductivitytestingprotocolsforpaperindustryresidualsutilized asbarriermaterialinlandfillcovers.Moreinformationonthisspecificationisprovidedin Appendix1. TheStandardGuidewillproscribethefollowing: Measurestocontrolgasshouldbeusedwhentestingresidualsthatproducegas.Gas productioncanbecontrolledeffectivelyby(a)testingat4C,(b)spikingpermeantwith DBNPAbiocideatmaximumrecommendedconcentration,and(c)applyinghigh backpressure(>330kPa)whiletesting.Flushinglinesalsoworksbutislaborintensive. Thehydraulicgradientshouldbeaslowaspracticaltosimulatefieldconditions. Hydraulicgradientsmorethan10shouldnotbeused. Residualsspecimensshouldbetestedattheeffectivestresslikelytoexistinthefield. Testingresidualswithtapwaterisacceptable;however,somestatesmayhave regulationsthatspecifyotherpermeants. TheterminationcriteriaofASTMD5084arereasonableforresidualsexceptthatthe rangeofacceptableoutflowinflowratioshouldbeincreasedto0.70to1.3inches (NCASI2005). 4.1.8Absorbentandanimalbedding PrimaryWWTPresidualshavethecapacitytoabsorblargeamountsofliquid.Thisdesirable characteristichasbeenexploitedbytheanimalbedding/litterandindustrialsorbentindustries. WWTPresidualshavebeensuccessfullyusedasthebaserawmaterialinmanyindustrial sorbentandanimalbeddingproducts,whichareavailableonthemarkettoday.Twoexamples ofcompaniesthatuseWWTPresidualsintheirabsorbentproductsareInternational Absorbents,Inc.,andCompleteSpillSolutions(RMTInc.2003). 4.1.9Lightweightglassaggregate ThemineralconstituentsofWWTPresiduals,commonlyreferredtoastheashcontent,canbe convertedtoaggregatematerialthroughaheatfusingprocess.Intheproductionoflightweight aggregate,theWWTPresidualsaretypicallymixedwithflyashandpelletized.Thepelletsare placedinarotarykilnandheated.Oncecooled,theresultingproductisalightweightaggregate thattypicallymeetsASTMstandards,andwhichcanbeusedinconcretemasonry,landscaping, andgeotechnicalapplications.Intheproductionofglassaggregate,themineralconstituentsof theWWTPresidualsaremeltedbyhightemperaturesandtappedoff.Themoltenliquidisthen cooledrapidlyinawaterquenchingsystem,andtheresultingproductisglassaggregate.The glassaggregatecanbeusedinfloortiles,abrasives,roofingshingles,asphaltandchipseal aggregates,anddecorativelandscaping.Intheproductionofbothlightweightaggregateand glassaggregate,theheatfusingprocessdestroysanydioxins,furans,andotherorganicsand encapsulatesheavymetalconstituents,suchthattheleachedextractsoftheresulting aggregatespassdrinkingwaterstandards(RMTInc.2003). 18

 4.1.10Portlandcementconcreteadditive WWTPresidualscanbeaddedasanadmixturetoconcretetoserveasasourceofwoodfiber. Woodfibershavebeenshowntoincreasethedurabilityandpumpability,whilereducing shrinkrelatedcrackinginconcrete.Theadditionofresidualsalsomayprovidegreaterfreeze thawcrackingresistanceandgreatersaltscalingresistancethanplainconcrete.However,care mustbetakentonotreducecompressivestrength,andahigherdoseofhighrangewater reducingadmixturemaybeneededtoavoidahighwaterdemandintheconcrete(RMTInc. 2003). 4.1.11Cementkilnmanufacture ThoseWWTPresidualswithahighinorganiccontentcanserveasfeedstockintheproduction ofcement.Thebasicrawmaterialsrequiredtomakecementincludelimestone,clay,sand,and ironore,whichprovidecalcium,silicon,aluminum,andiron.WWTPresidualshighininorganics cancontainsignificantquantitiesofthesebasematerials. 4.1.12Buildingboard PulpextrusionisaprocessforconvertingWWTPresidualsintobothstructuraland nonstructuralsolidpanelandprofileproducts.TheWWTPresidualsrequiretheadditionofa watersolublepolymertoalterrheologicalproperties,suchthatahomogeneouspulppastecan beformedandextruded.Followingextrusion,theresidualsareconsolidatedbypressdrying. Theresultingphysicalandmechanicalpropertiesofthebuildingboardaredependentuponthe typeoffiberusedasthefeedmaterial;however,themechanicalpropertiesofbuildingboard manufacturedfromWWTPresidualshavebeenshowntobesimilartothemechanical propertiesoftraditionalwetprocesshardboard(Scottetal.,2000).Residualsfromadeinking millintheNetherlandshavebeenusedtomanufacturecommercialbuildingboard;however, theboardmakingfacilityhasclosed. 4.1.13Regulationsandguidelines Appendix1outlinesWWTPbyproductstandardsforsoilamendments,compost,alternative dailycoveratlandfills,hydraulicbarrierlayers,industrialsorbents/animalbeddingand lightweightglassaggregate. 4.2Potentialmarketsorusesforboilerashwaste Boilerashwasteresidueshaveincreasedsincethe1990s.Opportunitiesforbeneficialuseof thismaterialtyperangefromlargescalelandapplicationsandconstructionuse,tosmaller scaleapplicationswiththewastewatertreatmentindustryandpapermakingprocess.Residual useofboilerashwastecanbemanagedbywatchingashchemistryandboileroperation.Itis importanttonotethatthesourceofthewoodfuelcreatesamarkeddifferenceinboilerash 19

nutrients.Ashesfromwoodandbarkfuelsourcesvarygreatlyfromashescreatedfrompulp andpapermillresiduals(hogfuelandwastewatertreatmentresidue). Thereisalsoasignificantdifferenceindioxinandfuranlevelswhenyoucompareashcreated frominlandmills(whichhaveverylowrates)tothesaltladencoastalmillfuels(whichinmost caseshavehigherrates).Dioxinandfuranconcentrationsmaybereducedbyonlyusingthe bottomashfromcoastalmills,butthisisasmallpercentageofmaterialwhencomparedtofly ash.Ifchloridelevelscanbereducedinthehogfuelbeforeincineration,thentheflyashcanbe beneficiallyused.Completecombustionofthehogfuelalsogreatlyreducesthedioxideand furanconcentrations.Thereductioncanbecompletedbyburningthefuelat850degrees Celsiusfortwoseconds,ensuringthewoodiscompletelydry,andallowingonlysmallfuel particlesizes.Posttreatmentofashwithexposuretosunlight,ultravioletlightandbiological processescanreduceconcentrationsaswell.AndcompostingtheashwithWWTPresidualshas showna50%decreaseindioxideandfuranconcentrations(ElliottandMahmood2006). Woodfiredboilerashhasfewermetalsatlowerconcentrations(exceptcadmium)thancoal firedash.Thesequalitiesmakewoodashbettersuitedforlandapplication.Bottomasheshave higherbulkdensity,lowercarboncontentandtraceamountsofdioxinsandfurans.Ashesfrom hogfuel,whicharehighinsaltcontent,usedprimarilyincoastalpulpandpapermillsare regulatedfordioxidesandfurans.Butareductionintheuseofchlorinatedorganicscanmake thisashtypesatisfactoryforlandapplications(ElliottandMahmood2006). Table3:BoilerAshWasteMarketsorBeneficialUses MarketorBeneficialUses Description Compostfeedstock Thewoodashsuppliesnutrients,reducesmoisture, actsasabulkingagentandimpartsdarkcolor,as wellasreducingodor. Manufacturedsoilcomponent Woodashismoreappropriateforlandapplication. Ashesprovidealkalinitytosoil. Cementandbrickfeedstock BoilerashfromwoodandWWTPresiduesis suitableforcementandbrickmanufacture. Concreteadditive Coalflyashusedasadditiveinconcretefor highwaysandotherapplications.AstateDOT approveduseofcoalwoodflyashforusein concreteaftershortandlongtermevaluationof product.Withwoodflyashadded,concreteis stronger,moredurable,moreresistanttowater erosioninsaltwaterconditions,andisless expensive.Coalwoodbottomashisusedas aggregateinconcreteblocks(Thacker2007a) 20

Table3,continued FlowablefillControlledLow StrengthMaterial(CLSM)

Wastestabilization

Soilstabilization Earthenconstruction Asphaltaggregate/roadbuilding component Landfilldailycover Activatedcarbonmanufacture

CLSMisaplasticsoilcementandhasbecomea popularmaterialforprojectssuchasstructuralfill, foundationsupport,pavementbase,andconduit bedding. Woodashneutralizestheacidicwastematerialto preventleachingofcontaminantsandtobind contaminantswithinthewaste. Canbeusedaspottingorlimingagent. Boilerashmayincreasethestrengthofthe structureifitiscementitious. Coalwoodbottomashisusedasaggregatein asphaltmixes. WhenmixedwithWWTPresiduals,canprovide dailycoverforlandfills. Flyash,withunburnedcarboninrangesof2732%, hasbeenfoundtobeaneffectiveabsorbentof certainodorsandcolors.

4.2.1Landapplication Usingwoodashhasbecomemorecommoninreforestationsettings,usingthepremisethat theashhelpstoreturnnutrientstothesoils.Theuseofcoalashisnotbeneficialinthis instance,asthecomponentsofthatparticularasharenotcompatiblewithforestedsoils.When addingwoodashtosoils,attentionmustbepaidtoaddNandwatersolublePforpropersoil balance. ANorthCarolinaWeyerhaeusermillappliedbottomashfromahogfuelfiredboileratarateof 27tons/haonaloblollypineplantationtofindincreasedratesofK,MgandCacomparedto testplots.AnewsprintmillinOregonappliedpowerboilerashasalimingagentasa replacementofcommercialagriculturallime.Theprogramwassuccessfulenoughtocreatea productcalledProLimePlus,utilizingtheash.Weyerhaeuserhasmarketedasimilarproduct calledCarolinaSilviAshforyearrounduseontimberlands.ThegovernmentofAlberta,Canada in2002developedspecificationsfortheuseofenergyrecoverysystemwoodashesasaliming agentforcultivatedagriculturallands(ElliottandMahmood2006). 4.2.2Soilamendment Thisiscurrentlyoneofthemostcommonbeneficialuseapplicationsforwoodash.Optimizing soilchemistryisacriticalprocessinagriculture.WoodashneutralizesthepHofacidicsoilina mannersimilartotheuseofagriculturallimeandservesasanutrientsource(fertilizer)to agriculturalsoil.Thesmallparticlesizeofwoodashmaypromoteamorerapidchangeinthe pHofthesoilascomparedtotraditionalagriculturallime.Woodashhasalsobeensuccessfully 21

appliedasaforestsoilamendment.WoodashhasbeenproventoraisethepHofacidicsoiland servesasanutrientsourcetopromotethegrowthoftrees(RMTInc.2003). 4.2.3Soilstabilization Woodashisaneffectiveagentforthechemicaland/ormechanicalstabilizationofsoil.Soil stabilizationisthealterationofsoilpropertiestoimproveitschemicalorengineering performance.Woodashisusedtoneutralizeacidicsoiltopreventtheleachingof contaminants,andtobindcontaminantswithinthesoil.Woodashisalsousedinthesame mannertostabilizewastematerials,suchassludgeswhenmanagedinlanddisposalunits.The woodashneutralizesacidicwastematerialtopreventleachingofcontaminantsandtobind contaminantswithinthewaste(RMTInc.2003). 4.2.4Buildingproducts Carboncontentof6%intheashisthehighesttoleratedamountforconcreteandcement production.AmidwestU.S.millhasproducedstructuralgradeconcretewithwoodashasan additive.BoilerashfromwoodandWWTPresiduesatanothermillwassuitableforcementand brickmanufacture.Atanewsprintmill,thebottomashisseparatedoutandusedasanadditive forbrick,andtheflyashisusedinPortlandcementproduction(ElliottandMahmood2006). MajorcomponentsofPortlandcementarevariousoxidesofcalcium,silicon,aluminum,and iron,withcalciumbeingthepredominantelement.Dependingonitschemicalcomposition, boilerashcanbedesirableincementmanufactureasasourceofcalcium,aluminumorsilicon. Ashcanimprovethestrengthanddurabilityofconcrete,butthisusenormallyislimitedtocoal flyashbecauseASTMstandardsspecifythismaterial,andhighlevelsofunburnedcarboninash canbedetrimental(Thacker2005). Astoearthenconstructionapplications,boilerashmayincreasethestrengthofthestructureif itiscementitious.Otherwise,itissimplyfillmaterial.Apulpmillsashfromthecombustionof barkandWWTPresidualsisamajoringredientinaconstructionmaterialtermedAshcrete.It isemployedinthemodificationofawastewaterlagoon,inalandfillclosure,andasabasefora concretepad.Mentionismadethattwoothermillsutilizeasimilarmaterialtoconstructberms andtocloselagoons(Thacker2005). 4.2.5Roadbuildingmaterials Forashtobeconsideredinsuchapplicationsasaggregateformillsiteroadsorpubliclyowned roads,specificationsinmoisturecontent,drydensity,degreeofcontaminationandleachability mustbemet.Anoptimumadditionrateis10%woodashinreplacementofthetraditionalroad buildingmaterial.Manymillshavebeenabletousetheashintheirownroadbuildingorforsale tolocalcommunities,allowingthosemillstoreclassifythematerialfromawasteproducttoa product.18TheFloridaDepartmentofTransportationhasapprovedacombinationcoalwood ashfromapapermilltobeemployedinconcreteroadconstruction(Thacker2005). 22

4.2.6Compostfeedstock Woodashhaswidelybeenidentifiedasacompostproductionfeedstock.Thewoodash suppliesnutrients,reducesmoisture,actsasabulkingagentandimpartsdarkcolor.Another keycomponentofwoodashthatisvaluedbyindustryworkingwithcompostproductionisthe abilityofwoodashtoreduceodor(Thacker2007b) TheUPMKymmeneNewBrunswickmillsendsitswood(primarilyfromclarifieragents)andoil biomassburnerashtoacompostingcompany.Inturn,thecompanyaddstheashata1015% byweighttoproduceorganictopsoil,blackearthandlawnandgardenmix.Theashservesto addanearthyblackcolor,stabilizepH,andcontrolodorandpathogens. Amixtureofcertaintypesofwoodashwithmillwastewatertreatmentresidualswillprovidean excellentsoilconditioner.Blendingashesfromapowerboilerthatprimarilyuseshogfuelwith somewastewatertreatmentresidualsandaminorsupplementofcoal,withwastewater treatmentresidualsresultsinaproductrichinnutrients(K,Ca,Mg)andalkalinity(fromthe ash)andNandP(fromtheresiduals). AnintegratedkraftmillinMaineproducing650tons/dayhasbeenabletorecycle63%ofits wastewatertreatmentresidualsand86%ofitsgeneratedboilerashesforuseonagricultural landsasasoilconditioner.AnintegratedBritishColumbia(BC)coastalbleachedkraftmillused a1:1compostingratioofboilerashtowastewatertreatmentresidualstoproduceasoil conditionermeetingallsafetyregulationsoftheBCMinistryofGovernment.Thecomposting cutinhalfthedioxinandfuranconcentrations(ElliottandMahmood2006).Finlandhasalso usedwastewatertreatmentresiduestogranulatetheboilerashbeforelandapplications,in ordertominimizetheairborneparticulatelevelsoftheash. 4.2.7Activatedcarbon Flyashtraditionallyhashighlevelsofunburnedcarbon,whichhassimilarpropertiesof activatedcarbon.Thusash,withunburnedcarboninrangesof2732%,hasbeenfoundtobean effectiveabsorbentofcertainodorsandcolors. 4.2.8Regulationsandguidelines Appendix2outlineswoodashbyproductstandardsforsoilamendments. 4.3Potentialmarketsandusesforcausticizingresidues Causticizingresiduessuchasslakergrits,greenliquordregs,andexcesslimemudareamong thesignificantbyproductsolidsfromkraftpulpmills.Thesematerialshavechemicaland physicalpropertiesthatcanmakethemsuitableforanumberofbeneficialuses(NCASI2007). 23

Table4:CaustizingResidualMarketsorBeneficialUses MarketorBeneficialUses Description Limingagentonagriculturaland Anincreaseincropyieldwasdocumentedtobesimilar forestlandapplication tothecomplimentarycommerciallyavailablelimestone. Cementandbrickfeedstock Thebasicrawmaterialsrequiredtomakecementare calcium,silicon,aluminum,andiron.Causticizing materialshavehighpercentagesofcalcium,aluminum, andiron. Compostfeedstock Provideslimetocompostmixture. Manufacturedsoilingredient Causticizingresidualsprovidelimetosoil. Soilstabilization/earthen Soilstabilizationisthealterationofsoilpropertiesto construction improvethechemicalorengineeringperformanceof thesoil.Limeslakergritshavebeenusedasanadditive. Surfacemineandacidmine ManufacturedsoilusingcausticizingandWWTP reclamation componentscanbeusedtopreventstormwaterrunoff onminesites. Gaseoussulfurcompound Canassistintheremovalofasulfurcompoundthat treatment containsgas,particularlyanindustrialgaseouseffluent. Alternativedailycoverand Limeslakergritshavebeensuccessfullyusedasan hydraulicbarrierforlandfills alternativecovermaterialtothetraditional6inchesof dailysoilcoverusedforactivefacesofalandfill. Wastewaterneutralization ResidualsprovidepotentialalternativesforadjustingpH inwastewatertoneutrallevels. pHadjustmentofprocesswater ResidualsprovidepotentialalternativesforadjustingpH inprocesswater. WastewaterAOXremoval Theremovaloforganichalogens(AOX)from wastewatercanbeassistedbyusingcaustizing residuals. Roaddustcontrol Limeslakergritshasalsobeenshowntobeeffectiveas adustsuppressantonunpavedroads. Sludgebulkingcontrol Assistsinthebiologicaltreatmentofsludgeand providingbulkingcontrol. Asphaltadditive Limemud,limeslakergrits,andgreenliquordregshave beenusedsuccessfullyasasubstituteforfineaggregate inroads. 4.3.1Landapplication Landapplicationisthemostcommonlypracticedbeneficialuseforcausticizingmaterials,with limemudbeingthematerialthatismostcommonlyusedasasoilamendment.Causticizing residualsareutilizedasareplacementforagriculturallimestonetoincreasesoilpH.SoilpHis animportantchemicalcharacteristicbecauseitaffectstheavailabilityofmanyplantnutrients andtoxicelements.ThesoilpHdesirableforcropproductionisdependentbothonthesoiltype 24

andthecropspecies,butingeneralisintherangeof5.8to7.0.SoilpHlevelsbeloworabove theoptimumrangecanbedetrimentaltocropgrowth(Camberatoetal.1997). Instudiesoflandapplicationsutilizingcausticizingresiduals,anincreaseincropyieldwas documentedtobesimilartothecomplimentarycommerciallyavailablelimestone.Inmany soils,periodiclimingisrequiredsothatconditionsarefavorableforplantrootingandnutrient acquisitionandtocountertheeffectsofagriculturallandacidification.Recentestimates indicate11millionMgofagriculturallimestonearesoldannuallyintheUSAatacostof$58 million.Industrialresiduals,particularlythosefromthepapermanufacturingindustry,provide potentialalternativesforadjustingsoilpH.Particlesizeisthemainfactordeterminingreaction rate.Causticizingresidualsgenerallyhavesmallerparticlesizesthanagriculturallimestoneand thereforetendtoreactfaster.Therapidrateofreactionofthesematerialscomparedto limestonemaybeanadvantageifsoilsareplantedshortlyfollowingamendmentapplication (Camberatoetal.1997). Basedonlimingneeds,typicalapplicationratesareabout2.5tons/acreforgritsanddregs (mixedtogether)andaboutoneton/acreforlimemud(Thacker2005). 4.3.2Alternativedailycover Limeslakergritshavebeensuccessfullyusedasanalternativecovermaterialtothetraditional 6inchesofdailysoilcoverusedforactivefacesofalandfill.Theuseofgritsasanalternative dailycoverhelpstocontrolblowinglitter,animals,andinsectsatthelandfill(RMT,Inc.2003). 4.3.3.Cementmanufacturing Causticizingmaterialsareutilizedasfeedstocksintheproductionofcement.Thebasicraw materialsrequiredtomakecementarecalcium,silicon,aluminum,andiron.Causticizing materialshavehighpercentagesofcalcium,aluminum,andiron,andifproperlywashed(asis thenorm),theygenerallyarelowinconstituentsthatcannegativelyimpacttheproductionand qualityofcement,suchassulfurandsodium(RMT,Inc.2003). 4.3.4Soilstabilization Soilstabilizationisthealterationofsoilpropertiestoimprovethechemicalorengineering performanceofthesoil.Limeslakergritshavegenerallybeenusedinthisapplication.Lime slakergrits,whenmixedwithsandandcompactedinlifts,havebeenshowntohandleheavy trucktrafficbetterthantypicalsoilsurfaces.Limeslakergritshasalsobeenshowntobe effectiveasadustsuppressantonunpavedroads.Whilethedustfromthegrit/sandroadsis finerthanthatproducedfromnativesoilroads,thegrithasabetterliquidholdingcapacity, whichimprovesefficiencyfordustsuppressiontechniques(RMT,Inc.2003).

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 4.3.5Aggregateinasphaltpaving Limemud,limeslakergrits,andgreenliquordregshavebeenusedsuccessfullyasasubstitute forfineaggregateinroads. 4.3.6Regulationsandguidelines Appendix3outlinescaustizingbyproductstandardsforsoilamendmentsandalternativedaily coveratlandfills. 4.4Woodyarddebrisandpulping/papermillrejects Themajorityofwoodwastes,alsoknownashogfuel,comingfrompulpandpapermillsare usedtofuelpowerboilerstogenerateelectricity,steamorboth.Millsalsousecoal,oil,and naturalgastosupplement(Camberatoetal.1997).Woodchips,sawdustandbarkresidualsare alsousedasrawmaterialsforchipboardandpulpproduction. Woodyarddebrisandpulp/papermillrejectshavelongestablishedusefulnessasaninputfor energyandstraightbackintothepapermakingprocess.Thesematerialsalsomaybeaddedto compostmixturessatisfactorily. Table5:DebrisandRejectsMarketsorBeneficialUses MarketorBeneficialUses Description Boilerfuel(energyinput) Debrisandrejectsusefulasanenergysource. Secondgradepaperproduction Rejectscommonlyareplacedbackintoserviceforlower gradepapers. Compostfeedstock Bothwooddebrisandmillrejectsaresuitableasa compostadditive. 5.0BarriersandChallengestoBeneficialUseofProducts Despitetheemergenceandgrowthofmarketsforpulpandpapermillwastebyproducts,there remainmanybarriersandchallengestomorewidespreaduseofthesematerials.Onecommon barrierisamismatchbetweenbyproductquantityandprocessor/marketdemand.Toomuch materialcandrivepricessolowthatitbecomeseconomicallyinfeasibleformillstoincurthe transactioncostsofgettingtheirwastematerialstomarkets.Toolittle,ontheotherhand, makesitinfeasibleforbuyerssincethereareminimumthresholdsinhowmuchmaterialis neededtobeuseful.Anotherbarrierisapessimisticbeenthere,donethatattitudeamong millsfromexposuretoanumberofbeneficialuseprogramsthatneverdevelopedorwere shortlived,resultinginreducedmotivationtopursueopportunities. 26

Inaddition,millsandendusersarefocusedtypicallyonnormalbusinessactivities,andthere maybealackoftimetothoroughlyinvestigatepotentialbeneficialuses.Nonetheless,waste brokers/facilitatorshavebeneficialuseasanareaoffocusandcanbecriticaltothesuccessofa project.Inaddition,Statemarketdevelopmentagenciescanhelppromotebeneficialusesof industrialresiduals(NCASI2001). Thedecisionmakingprocessformostmillsislocal,butwiththeneedforexpertcorporatelevel support.Beforeenteringintoanewapproach,fullexplorationofalternativesmustoccur beforeallocatingcapital.Beneficialusedecisionsmustmeetcorporateenvironmentalhealth andsafetyexpectations,regulatoryrequirements,andreturnoninvestment/financialcriteria. Driversforbeneficialuseprogramsincluderesourceconservationinitiatives,economicforces andregulatoryforces. AnexampleisMeadWestvaco,whichhadalandfillrateof52.6%,witha16.7%reuserate,8.2% recyclingrateand22.5%energyrecoveryrate.Thecompanysetawastehierarchytoguideits wastemanagement: MeadWestvacosWasteHierarchy: ImprovedResourceUtilization WasteSourceReduction OnsiteRecycling/Reuse OffsiteRecycling/Reuse OnsiteTreatment Treatment/Disposal Thecompanysresidualsmanagementbeneficialuseprogramelementsinclude: Utilizecompanyprojectreviewguidelines. Allprojectsreviewedandapprovedbylegal,environmental,productstewardshippeer review. Allprojectsmustbesupportedbygoodtechnical,economic,legal,andbusiness analyses. Allresidualsrequirerigoroustesting/characterizationpriortoutilization. Residualsmustgothrougharigorousproductstewardshipscreening. Residualsbeneficialuseshouldtypicallyincludeautilizationplan. Allproposedbeneficialuseprojectsrequirearigorouslegalreviewincluding contracts/agreements. Allresiduals/beneficialuseprojectsrequirecommunication/notificationtolocal regulatoryagencies. Allprojectsrequirefollowupmonitoringtoinsuretheprojectcontinuestomeetits originalmeritsandisusedfollowinggoodmanagementpractices. 27

Thecompanysbeneficialuseprojectreviewprocessincludes: Ideacollection Enduseapplication/screening Testing/characterization(includeagronomicvalue) Gatekeeperpeerreviewbyresidualsgroup,andcorporateenvironmental/legal Productinformation Utilizationplans Statenotification:permitting/approval Publicnotice Publicrelations Followupprogram(McCormickandBryer2002). Inaddition,allbyproductusageprojectsmustalsocompleteafeasibilityanalysiswithcosts andbenefitsproperlyweighed.Feasibilityconsiderationsinclude: Distancetomarket/processor:Costofhaulingmustbeconsidered,aswellasweightof byproduct. Technicalexperienceatmill:Isthemillcapableofproducingthebyproductasspecified bytheendmarket? Costtoproduceandcostsavings:benefitsofbyproductusemustincludecost avoidanceoflandfilling,butcanalsoincludeenvironmentalbenefitsavings.Allprojects mustevaluateadditionalcoststopreparematerialforbyproductuseaswell. Volumeconsumption:willtheendmarketbeabletoconsumetheamountofmaterial produced? Potentialliability:byproductsmustbeproperlymatchedforuse,ensuringcorrect chemicalandpHrequirementsforenduse(Wiegand). Theseconsiderationsmustalsoaccountformilltype,milllocation,wastetypeandcompany businessstrategy.Forexample,alternativeusesforsludgeash,suchasbricksandcement,are anexcellentoptionifausercanbefoundnearthemillandiflongtermcontractscanbe acquired.Newproductsdevelopedfrompulpandpapermillsludge,however,needtohavea markettomakethemeconomicallyfeasible.Itdoesnotmakesensetodevelopandcreate productsforwhichthereisnomarket(Scott). Inthecaseoflandspreading,thiscanbeaccomplishedwitheitherdewateredornondewatered sludge.Whenthesludgeisnotdewatered,itisfluidenoughtoallowsprayapplication. Transportationcostscanbecomeprohibitive,however,iftheunderwateredsludgeneedstobe transportedagreatdistancefromthemill.Withdewateredsludge,theapplicationareascanbe fartherfromthemill.Whilesprayapplicationcanalsobeusedbyredilutingthesludge,other applicationmethodscanalsobeused.Anotherfeasibilityissuewithlandspreadingislocating enoughlandonwhichtospreadthesludge(Scott).

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5.1Challengesandconsiderationswithlandapplicationofresiduals Therehavebeenconcernsabouttheenvironmentalimplicationsoftraceconcentrationsof dioxinsandfuransinsludgesfrommillsusingchlorinebleachingprocesses.Studiesofwildlife exposedtolandappliedsludgesfrommillsusingchlorinebleachinghaveshownnoadverse effects,however.Aspreviouslynoted,concentrationsofdioxinsandfuransinbleachingmill sludgeshavebeenreduceddramaticallyinrecentyearsduetotheimplementationofnew bleachingtechnologies.Theseandotherchlorinatedcompoundsshouldcontinuetodecreasein significance.Studieshavealsoshownthatchlorolignincompoundsformedduringchlorine bleachingprocessesarerapidlyimmobilizedinsoilandareslowlymineralizedtoinorganic chloride.Accordingtothesestudies,lowmolecularweightchlorinateddepradationproducts appeartorapidlydecomposeinsoil,anddonotaccumulate,leachorcreateatoxic environmentforsoilbacteria(Camberatoetal.1997). 5.2Federalandstateregulationoflandapplicationofpapermanufacturingresiduals Landapplicationofpapermillsludgesandotherresidualsareregulatedprimarilyatthestate level,althoughtheyarepotentiallysubjecttoregulationunderseveralfederalstatutes.Since millresidualsarenotdefinedashazardouswastes,theyarenotregulatedundertheResource ConservationandRecoveryAct(RCRA).AnalysesoforganiccompoundsusingTCLP characterization,heavymetalconcentrationsandpHaregenerallyneededtoconfirmthisfact. Aswithanysoilamendment,waterqualitystandardsfornutrientsandheavymetalsdeveloped undertheCleanWaterActmustnotbeexceeded. InMarch1994,aMemorandumofUnderstandingbetweentheU.S.EPAandtheAmerican ForestandPaperAssociationestablishedvoluntarydioxin/furanconcentrationlimits, applicationrates,sitemanagementpractices,monitoring,recordkeeping,andreporting requirementsforthelandapplication,distributionandmarketingofresidualsfromkraftand sulfitepulpandpapermillsusingchlorineandchlorinederivativebleachingprocesses.The MOUappliestoresidualswithdioxin/furanconcentrationsgreaterthanorequalto10pptTEQ. Residualswithconcentrationsbelow10pptTEQareexcludedfromtheMemorandum,except formonitoring,testing,distributionandreportingrequirements.Maximumresiduals dioxin/furanconcentrationsof50pptTEQ(ortemporarilyupto75pptTEQ)andmaximumsoil concentrationsupto10pptTEQarepermitted.Foragriculturalapplication,sludgemaybe appliedatratesupto68drymetrictonsperhectare,unlessgreaterapplicationratesare permittedbytheindividualstate. Currentstateregulationsforlandapplicationofpapermillsludgesandotherresidualsvary widely.Onlyafewstates,includingMaine,Ohio,andWisconsin,haveprovisionswhich specificallyregulatepapermillresidualssuchassludges.Aslongasanalyses(t.g.TCLP)show thematerialstobeappliedarenothazardous,theyaremostoftenregulatedundergeneral statesolidwasterequirementsorunder"BeneficialUse"provisions.Inthelattercase, regulatoryburdensandpermittingrequirementsmaybereducedifthebenefitsofthe materialstothesitecanbedemonstrated.Manystatesusetheguidelinesforheavymetalsand 29

managementpracticesdefinedinU.S.EPA503standardsforlandapplicationofmunicipal sewagesludgebiosolidsasabaselineforlandapplicationofpapermillresiduals.Papermill residualseasilymeettheU.S.EPA503compositionstandardsinmostcases.Samestateshave morestringentstandards,however,whichcanlimitlandapplicationinsomesituations.Typical requirementsincludeinformationonsiteandsoilcharacteristics,setbackdistancesfrom surfacewaterandwells,depthtogroundwater,slope,vegetativecover,andproximityto floodplainsorwetlands.Amajorregulatoryissueforthegeneratorsandusersofmillresiduals iswhetherageneralpermitforresiduals,siterequirementsandmanagementpracticesis sufficient,orwhethereachsiteandpracticemustbeindividuallypermitted(Camberatoetal. 1997). DetailsonspecificguidelinesandregulationsforWWTP,woodashandcaustizingresiduesare outlinedinAppendices1,2and3respectively. 5.3Wastestreamrecyclingandreuseatparticipatingmills ToinvestigatetheextenttowhichmillsparticipatingintheIFPwereengaginginthevarious wastestreamreduction,reuse,andrecyclinginitiativesoutlinedhere,weconductedan informalsurvey.Thesurvey,whichappearsasAppendix4,wasdistributedinJune2008toall fivemills.Thesurveybeginsbyaskingmillsabouttheannualamountofwastegenerated,its destinationandanywastereductioninitiativesmillsmayhaveundertaken,including cooperativearrangementswithotherentities. Then,foreachmajortypeofwaste,thesurveyidentifiesthebeneficialuseorendusemarkets discussedbythisreportandasksmillstoindicatewhichoffouroptionsapplies:(1)themill alreadyuseswasteinthisway;(2)themillplanstousewastethisway;(3)themillhas determinedthatusingwasteinthismanneriseconomicallyinfeasible,or(4)themillhas determinedthatusingwasteinthismannerisinfeasibleforotherreasons.Thereasonfor separatingouteconomicinfeasibilityistoidentifywhichwasteutilizationoptionsmaywarrant furtherinvestigationassubjectsofstateincentiveprograms. Threeresponseswerereceived.Toprotectconfidentialityofthemills,theresultshavebeen aggregated.ResultsforeachquestionaresummarizedinAppendix4beneatheachquestion. Althoughthesurveyneedstoberefinedtoclarifyunresolvedquestionsfromtherespondents andsenttootherWashingtonStatemills,thereareseveralimportantconclusionsthatcanbe gleanedfromthethreeresponseswereceived: Millsalreadyareengaginginanumberofimportantwastestreamrecyclingandreuse initiatives. ForWWTPresiduals,theseincludepapermakingfiberandfiller,manufacturedsoil components,andcompostfeedstock. Forboilerashresiduals,theseincludecompostfeedstock,manufacturedsoil components,cementkilnfeedstock,soilstabilization,andlandfilldailycover. Forcausticizingresiduals,theseincludemanufacturedsoilingredients. 30

Forwoodyarddebrisorpulpingandpaperrejects,theseincludeboilerfuelandsecond gradepaperproduction. Anumberofwastestreamrecyclingandreuseinitiativesarebeingexplored,suchas acidminedrainagecontrolcover,animalbedding,roofingpaper,hydroseed,engineered seedpellets,concreteadditive,asphaltaggregate,materialsforsurfacemine reclamation,andpHadjustmentofprocesswater. Fourteenbeneficialorendmarketusesforwastewerenotundertakenbymillsdueto economicinfeasibility.Thesemaybeappropriatetargetsforeconomicincentive programs.

6.0IncreasingtheUseofWasteResiduals 6.1Industryeffortstofosterincreaseduseofwasteproducts Oneoftheleadersinpromotingthebeneficialuseofbyproductsofthepulpandpaper industryistheNationalCouncilforAirandStreamImprovement(NCASI,www.ncasi.org).NCASI servesasanenvironmentalresourcefortheforestproductsindustryinitsbroadestdefinition, addressingawiderangeofissuesofimportancetothisindustry,includingthepromotionofthe beneficialuseoftheindustrysbyproducts. Inanefforttopromotebeneficialuseapplicationsamongitsmembers,NCASIpublishes technicalreportsandbulletinsthataddressthepotentialbeneficialuseapplicationsofpulpand paperindustrybyproducts.Inaddition,NCASIhasrecentlyworkedwiththeU.S.EPAin sponsoringtheIndustrialByProductsBeneficialUseSummitthatbringstogetherregulators andindustryrepresentatives,tobetterunderstandthebeneficialuseofindustrialbyproducts (www.byproductsummit.com) InadditiontoNCASI,theTechnicalAssociationofthePulpandPaperIndustry(TAPPI, www.tappi.org)providesresourcestothepulpandpaperindustryrelatingtobeneficialuseof pulpandpaperbyproducts.TAPPIistheleadingtechnicalassociationfortheworldwidepulp, paper,andconvertingindustriesprovidinginformation,education,andknowledgesharing opportunities.TAPPIsEnvironmentalDivisionactivelysupportsbeneficialusethroughits ResidualsManagementCommittee.Activeinformationexchange,andtrainingandeducation arepromotedatitsannualmeetingheldinthespringeachyear.Inaddition,TAPPIhostsan activediscussionboardandAsktheExperts,whichareelectronicforumsthatallowthose interestedinbeneficialusealternativestonetworkwitheachotherandindustryexperts(RMT Inc.2003). 6.2Publicsectorincentivesandresearchprogramstoreduceindustrywaste 6.2.1FocusonEnergy WisconsinprovidesastatelevelprogramcalledFocusonEnergy,whichbringssupporttothe statesmillswithprojectevaluationassistanceandmonetaryincentives.Grantscanbeusedto 31

examineaprojectsfeasibility.Thisprogramisrelevanttoenergywastestreamreductionin thatfossilfuelsonaverageaccountfor75%ofamillsenergyinput.Findingincreasedwaysto usethewastestreamforenergyprovidesatwolevelbenefitwithdecreasedpurchaseoffuels anddecreasedwaste(WisconsinPaperCouncil). TheFocusonEnergyprogramhasidentifiedspentpulpingliquorsasachiefalternatefuelfor papermakers.Whenthesechemicalsbecometooweakafterbeingusedandrecycledseveral timesinthepulpmanufacturingprocess,theyareburnedtorecovertheirenergycontent. Otherimportantfuelsinthiscategoryincludebarkandotherunpulpablewoodwaste,with theirBTUuseinrecentyearsexpandedby176%,andvarioustypesofrefuse,fromindustrial andmunicipalwastetousedautoandtrucktires.Useofsuchrefusederivedfuels,orRDF, increasedmorethan650%atpapercompaniessincetheearly1970s,fromabout0.25trillion BTUstomorethan1.9trillionBTUs. 6.2.2TheCleanWashingtonCenter Foundedin1991,theCleanWashingtonCenter'sfocusandmissionhasbeentodevelop markets,technologies,andbeneficialendusesforrecycledmaterials.TheCleanWashington Center(CWC)managedanddocumentedoverninetyprojectsvalidatingrecyclingtechnologies orrecycledcontentproducts,andhasdevelopedBestPracticesInRecyclingforseveral recyclablecommodities.Thenowdefunctcenterprovidedresearchintopapermillwaste streamreductionprojects(www.cwc.org). 6.2.3TheNewYorkStateEnergyResearchandDevelopmentAuthority In1995,theAuthoritydevelopedareportthatevaluatedtheNewYorkpapermillindustryin termsoftheproductivemanagementandtreatmentofsolidwastes.Thereportcanbe accessedat:http://www.osti.gov/bridge/product.biblio.jsp?osti_id=119919. 6.2.4TheWisconsinDepartmentofNaturalResources TheWisconsinDNRoffersaWasteReductionandRecyclingDemonstrationGrantProgram, withagrantcategoryforindustrialwastes,includingthepaperindustry.See http://dnr.wi.gov/org/caer/cfa/EF/RECYCLE/PROJECTS/ind.htmfordetails. 6.2.5U.S.EPAGrantsandWasteWiseProgram TheU.S.EPAperiodicallyprovidesgrantsforresearchintopapermillandindustrialbeneficial use.NCASIandtheNaturalResourcesResearchInstitute(NRRI)arebothrecipientsofthisgrant program.WasteWiseallowsindustrypartnerstoenrollintheEPAprograminordertoreduce waste. 32

6.2.6BeneficialUseofIndustrialMaterialsSummit Thisisanannualconferenceheldthatspecificallyaddressestheuseofindustrialbyproducts targetingvariousproducers,includingpapermills.Informationfromthe2008summitisposted athttp://www.beneficialusesummit.com/2008/index.html. 6.3.Finalconsiderationswhenevaluatingwastereductioncostsandbenefits Inthisbriefreport,wefirstidentifiedmajorcomponentsofthepulpandpaperindustrywaste stream.Wastewatertreatmentplantresiduals,boilerash,andcausticizingresiduesmakeup thelionshareofthewastestream,however,otherimportantwastecomponentsincludewood yarddebrisandpulpandpapermillrejects.Wethenreviewedstateoftheartwastereduction andreusetechniquesemployedbyindustryleadersandemergingwastereduction technologies.MonitoringindustrysustainabilityreportsfiledonlinethroughtheGlobal ReportingInitiatives(GRIs)corporateregistryisagoodwayforDOEandmillsparticipatingin theIFPtokeepabreastofthelatestmethods.Themostprominentwaysindustryleadersare reusingtheirwastestreamsareforlandapplications,alternativeenergy,construction materials,andinputsintotheproductionprocess. Wethenprovidedanoverviewofemergingmarketsforpulpandpaperindustrywaste.Overall, weidentifiedanddiscussed46marketablecommoditiesthatcanbeextractedfromthewaste streamandputtoawiderangeofbeneficialuses.Whilethereareanumberoftechnicaland economicbarrierstomorewidespreadparticipationinthesemarkets,IFPmillsarealready implementinganumberofwastestreamreductionandreuseinitiatives.Someadditional considerationsforgreaterparticipationinclude: Resourcesavingsandresourceefficiencyreducingandreusingwastecansavemills moneyonpurchasedenergyandmaterialcostsandreducedlandfillfees. Substitutingfossilenergysourcesforwastebasedsourcesandonsitecompostingcan beapotentialsourceofcarboncreditsformillsparticipatinginemergingcarbon markets. Wasteproductscanbeusedtosupportmillsinfrastructurewithsuchitemsasroad buildingcomponents,soilamendments,fuelforelectricity,andconstructionmaterials. Futureresearchbygovernmentandnonprofitorganizationsaswellastheindustrywillreveal theextentofpotentialcostsavingsassociatedwiththeseoptionsforwastestreamreuse. 33

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McCormick,Stuart(Weyerhaueser)andBryer,David(MeadWestvaco).TwoCorporate ApproachespresentedatMidwestIndustrialByProductsBeneficialUsesSummit,August19 20,2002,Chicago,IL. 34

 MetsaliittoGroup.2006.CorporateResponsibilityReport.www.metsaliitto.com. MondiBusinessPaper.2004.WellontheWaytotheFuture:Businessand SustainabilityReview.www.corporateregister.com.

NationalCouncilforAirandStreamImprovement,Inc.(NCASI).2001.ProceedingsoftheNCASI MeetingonByProductsSynergy.SpecialReportNo.0106.ResearchTrianglePark,NC: NationalCouncilforAirandStreamImprovement,Inc. NationalCouncilforAirandStreamImprovement,Inc.(NCASI).2005.Compilationofalternative landfillcoverexperienceusingwastewatertreatmentplantresiduals.TechnicalBulletinNo.900. ResearchTrianglePark,N.C.:NationalCouncilforAirandStreamImprovement,Inc. NationalCouncilforAirandStreamImprovement,Inc.(NCASI).2007.BeneficialUseofBy ProductSolidsfromtheKraftRecoveryCycle.TechnicalBulletinNo.0931.ResearchTriangle Park,NC:NationalCouncilforAirandStreamImprovement,Inc. Neenah.2006.SustainabilityReport.www.neenah.com. NipponPaperGroup.2006.SustainabilityReport.www.corporateregister.com. NorkseSkog.2006.SustainabilityReport.www.norkseskog.com. OjiPaperGroup.2006.EnvironmentalandSustainabilityReport.www.corporateregister.com. RMTInc.,preparedforNCASI,BeneficialUseofIndustrialByProducts,December2003. Scott,C.Tim,Simonsen,John,Klingenberg,DanandZauscher,Stefan,2000.BeneficialUseof PulpandPaperResiduals:ExtrusionfortheManufactureofBuildingPanels.NCASITech.Bull. 814;NCASI:ResearchTrianglePark,NC. StoraEnso.2006.SustainabilityReport.www.storaenso.com. Thacker,Bill.CompostingofByProductSolidsFromthePulpandPaperIndustry,presented atthe2005TAPPIEngineering,PulpingandEnvironmentalConference,Philadelphia,PA Thacker,Bill.PresentationManagementofByProductSolidsGeneratedinthePulpandPaper industriesgiventoEPAOSWStaffonJanuary23,2007a,WashingtonDC. http://www.epa.gov/epaoswer/nonhw/imr/ircmeet/03paper.pdf Thacker,Bill.PresentationonFebruary1,2007battheBeneficialUseSeminar:Recycled ProductsinHighwayConstruction,LittleRock,AR,PaperIndustryByProductsinHighway ConstructionandRelatedApplications. 35

 Thacker,W.E.Managementofbyproductsolidsgeneratedinthepulpandpaper industry.PresentedatWEFTEC2005,78thAnnualWaterEnvironmentFederation AnnualTechnicalExhibitionandConference.Session74,IndustrialIssues&Treatment Technology:IndustrialResidualsManagement,MinimizationandReuse.Washington, D.C.,Oct.29Nov.2,2005. Thacker,W.E.andVriesman,R.TheLandApplicationandRelatedUtilizationof PulpandPaperMillSludges;NCASITech.Bull.439;NCASI:ResearchTriangle Park,NC,1984. U.S.DepartmentofEnergyOfficeofEnergyEfficiencyandRenewableEnergy,ForestProducts IndustryoftheFuture,FiscalYear2004AnnualReport.PublishedFebruary2005. UnitedStatesEnvironmentalProtectionAgency(EPA).Webpageonstatepolicies: http://yosemite.epa.gov/gw/statepolicyactions.nsf/uniqueKeyLookup/MSTY5Q4LFS?OpenDocu ment. UnitedStatesEnvironmentalProtectionAgency(EPA).2002.ProfileofthePulpand PaperIndustry,2ndEdition. http://www.epa.gov/compliance/resources/publications/assistance/sectors/notebooks/pulp.ht ml

Votorantim.2006.SustainabilityAnnualReport.www.corporateregister.com.

Wiegand,PaulS.andJayP.Unwin.Volume77,No.4TAPPIJournal,April1994.Alternative ManagementofPulpandPaperIndustrySolidWastes. WisconsinBiorefiningDevelopmentInitiative.www.wisbiorefine.org. WisconsinPaperCouncil.www.wipapercouncil.org Worrell,Ernst,N.Martin,N.Angolan,D.Einstein,M.Khrushchev,andL.Price. 2001.OpportunitiestoimproveenergyefficiencyintheU.S.pulpandpaperindustry. LawrenceBerkeleyNationalLaboratory.Berkeley,CA.LBNL8353. http://ies.lbl.gov/iespubs/48353.pdf

36

 Appendices Appendix1: PaperIndustryWastewaterTreatment ByProductStandards/Specifications/Guidelines(RMTInc.2003). STANDARD/SPECIFICATION/GUIDELINE SoilAmendment PlanningGuideandStateRegulation SummaryforLandApplicationofMill ByProductSolids.NCASITechnical Bulletin863.NationalCouncilforAir andStreamImprovement.May2003. UtilizingPaperMillByProductsas ForestSoilAmendments:Forest Responses,Recommendations,and IndustryCaseStudies.NCASITechnical Bulletin798.NationalCouncilforAir andStreamImprovement.February 2000. Compost AASHTOMP1003.Standard SpecificationforCompostfor Erosion/SedimentControl(Compost Blankets).AmericanAssociationof StateHighwayandTransportation Officials. AlternativeDailyCoverataLandfill ASTMD652300.StandardGuidefor EvaluationandSelectionofAlternative DailyCovers(ADCs)forSanitary Landfills.AmericanSocietyforTesting andMaterials.April2000. DESCRIPTION Thisguidelinedescribespracticalstepsfor establishingasuccessfullandapplicationprogram forwastewatertreatmentplantresiduals,boiler ash,andotheralkalinebyproductsolids.The guidelinediscussesregulatoryconsiderations, methodsforevaluatingfeasibility,statecontacts andpermitting,researchresults,andenvironmental managementandcomplianceissues. Thisguidelinereviewsthecharacteristicsandforest landapplicationsofwastewatertreatmentresiduals andboilerash,providesareviewofsuccessfulland applicationprogramsandregulatoryconsiderations, andprovidesrecommendationsforusingthese byproductssuccessfullyasforestsoilamendments, whileminimizingthepotentialforadverseeffects ontheenvironment. Thisspecificationcoverscompostproducedfrom variousorganicbyproducts(includingindustrial residualsandbiosolids)foruseasasurfacemulch forerosion/sedimentcontrolonslopedareas.

Thisstandardprovidesageneralsetofguidelinesto assistendusersinassessingdifferentoptionsfor ADCsatsanitarylandfills.Thestandardprovideskey performanceinformationonbroadclassificationsof ADCs,andwastewatertreatmentplantresidualsare includedasasubcategory.Thesuitabilityand acceptabilityofADCsaredependentonclimate, operatingconditions,andregulatoryrequirements; therefore,specificperformanceinformationmust beevaluatedonacasebycasebasis.

 Appendix1,continued HydraulicBarrierLayers LaboratoryHydraulicConductivity TestingProtocolsforPaperMill ResidualsUsedforHydraulicBarrier Layers.NCASITechnicalBulletin848. Nelson,M.andC.Benson.June2002.

Thisguidelineprovidesresearchdefinedprotocols forthedeterminationofhydraulicconductivityof wastewatertreatmentplantresidualsforuseas hydraulicbarriersinlandfillcovers.Theguideline includesadraftofanASTMstandardguide,whichis currentlybeingballotedbyASTMthrough SubcommitteeD18.04. EPA/600/R93/182.QualityAssurance Thistechnicalguidelineprovidesguidancefor andQualityControlforWaste developingconstructionqualityassurance ContainmentFacilities.Daniel,D.and proceduresforsolidwastelandfills.Theguideline R.Koerner.September1993. containsasectiononhydraulicbarriers,which includesdiscussionsonlinerrequirements, compactionrequirements,constructionvariables thataffecthydraulicbarriers,andpreprocessingand placementtechniques.Theguidelineisnotspecific towastewatertreatmentresiduals,butthequality assuranceproceduresapplygenerallytoalltypesof barriermaterials. AFieldStudyoftheUseofPaper Thisguidelineprovidestheresearchresultsoffield IndustrySludgesinLandfillCover scalelandfillcoversthatwereconstructedto Systems:FinalReport.NCASITechnical comparethefieldperformanceofpaperindustry Bulletin750.NationalCouncilforAir WWTPresidualsandclayhydraulicbarriers.The andStreamImprovement.November resultsshowedthatWWTPresidualshadhydraulic 1997. conductivitiescomparabletothoseofclayand underwentnodeterioration.BioMixis trademarkedbyAlliedWasteIndustriesandisa blendofsoilandShortPaperFiber.Theend productisamanufacturedsoilwithahydraulic conductivityofbetween107and109cm/s.The standardsforselectionofthewastewatertreatment plantresidualsandproductionofBioMixare confidential. IndustrialSorbents/AnimalBedding ASTMF72699.StandardTestMethod Thisstandardcoversatestmethodthatdescribes forSorbentPerformanceof theperformanceofadsorbentsinremoving Adsorbents.AmericanSocietyof nonemulsifiedoilsandotherfloatingimmiscible TestingandMaterials. liquidsfromthesurfaceofwater.Thestandard February1999. providesdefinitions,testingprocedures,and adsorbentclassifications. 38

 Appendix1,continued InternationalAbsorbents,Inc.

InternationalAbsorbents,Inc.,createstrademarked animalbeddingandindustrialabsorptionproducts frompristinewastewatertreatmentresiduals. InternationalAbsorbentsspecificationsand standardsforselectionandproductionare confidential. CompleteSpillSolutions(formerly CompleteSpillSolutionscreatestrademarked Cellutech,Inc.) industrialabsorptionproductsfromwastewater treatmentresiduals.Itsspecificationsandstandards forselectionandproductionareconfidential. Lightweight/GlassAggregate ASTMC33103.StandardSpecification Thisspecificationcoverslightweightaggregates forLightweightAggregatesfor intendedforuseinconcretemasonryunits,whena ConcreteMasonryUnits.American primeconsiderationistoreducethedensityofthe SocietyforTestingandMaterials.May unit.Thespecificationprovidesthegeneralphysical 2003. requirementsforlightweightaggregates,thetest methods,andanaggregategradingguidefor concretemasonryunits.Thespecificationisnot specifictoWWTPresiduals. ASTMC33003.StandardSpecification Thisspecificationcoverslightweightaggregates forLightweightAggregatesfor intendedforuseinstructuralconcreteinwhicha StructuralConcrete.AmericanSociety primeconsiderationistoreducethedensitywhile forTestingandMaterials.May2003. maintainingthecompressivestrengthofthe concrete.Thespecificationprovidesthegeneral physicalrequirementsandthetestmethodsfor lightweightaggregates.Thespecificationisnot specifictoWWTPresiduals. Lightweight/GlassAggregate MinergyCorporationhasapatentedtechnologyfor continues creatingglassaggregatefromWWTPresiduals. MinergyCorporationsstandardsandspecifications forselectionandproductionareconfidential.

Note:Moststatesrequirematerialspromotedorsoldaslimingagentsorfertilizertobe registeredwiththestateagriculturaldepartment.Ingeneral,thematerialsarerequiredtomeet adefinedsetofspecifications(e.g.,calciumcarbonateequivalence)tobeconsideredliming agents.

39

Appendix2: WoodAshStandards/Specifications/Guidelines(RMTInc.2003) STANDARD/SPECIFICATION/GUIDELINE SoilAmendment StandardsandGuidelinesfortheUse ofWoodAshasaLimingMaterialfor AgriculturalSoils.IBSN:0778522806. AlbertaEnvironment,Scienceand StandardsBranch.July2002. ProductfromResidue:Standard SettingforAlkalineMillResiduesin Quebec.TAPPIProceedings,1998 InternationalEnvironmental ConferenceandExhibit.pp.779783. RecommendedPracticesforUsing WoodAshasanAgriculturalSoil Amendment.Bulletin1147.The UniversityofGeorgia,Collegeof AgriculturalandEnvironmental Sciences.September2002. PlanningGuideandStateRegulation SummaryforLandApplicationofMill ByProductSolids.NCASITechnical Bulletin863.NationalCouncilforAir andStreamImprovement.May2003. DESCRIPTION These(Canadian)standardsandguidelinesapplyto woodashrecoveredfromenergygeneration systems.Thestandardsandguidelinesprovide generalinformationonwoodash,regulatory requirementsforgenerators,andrecommended practicesforlandmanagers. ThisstandardforQuebec,Canada,coversvarious alkalineresidues,includingwoodash,foruseas agriculturallimingagents.Thestandardprovides theperformancerequirementsandincludesthe qualityrequirementsformetalsandspecificorganic contaminants. Thisguidelinecoversaprocedureforapplyingwood ashasalimesubstituteonagriculturallands.The guidelineprovidesgeneralinformationonthe methodstobeusedbywoodashproducersand dealers,theteststobeperformedonthewoodash, andtheapplicationpracticesforlandowners. Thisguidelinedescribespracticalstepsfor establishingasuccessfullandapplicationprogram forwastewatertreatmentplantresiduals,boiler ash,andotheralkalinebyproductsolids.The guidelinediscussesregulatoryconsiderations, methodsforevaluatingfeasibility,statecontacts andpermitting,researchresults,andenvironmental managementandcomplianceissues. Thisguidelinereviewsthecharacteristicsandforest landapplicationsofwastewatertreatmentresiduals andboilerash,providesareviewofsuccessfulland applicationprogramsandregulatoryconsiderations, andprovidesrecommendationsforusingtheseby productssuccessfullyasforestsoilamendments, whileminimizingthepotentialforadverseeffects ontheenvironment.

UtilizingPaperMillByProductsas ForestSoilAmendments:Forest Responses,Recommendations,and IndustryCaseStudies.NCASITechnical Bulletin795.NationalCouncilforAir andStreamImprovement.February 2000.

40

 Appendix3: CausticizingByProductsStandards/Specifications/Guidelines(RMTInc.2003) STANDARD/SPECIFICATION/GUIDELINE SoilAmendment PlanningGuideandStateRegulation SummaryforLandApplicationofMill ByProductSolids.NCASITechnical Bulletin863.NationalCouncilforAir andStreamImprovement.May2003. DESCRIPTION Thisguidelinedescribespracticalstepsfor establishingasuccessfullandapplicationprogram forwastewatertreatmentplantresiduals,boiler ash,andotheralkalinebyproductsolids.The guidelinediscussesregulatoryconsiderations, methodsforevaluatingfeasibility,statecontacts andpermitting,researchresults,andenvironmental managementandcomplianceissues. ThisstandardforQuebec,Canada,coversvarious alkalineresidues,includinglimemud,greenliquor dregs,andslakergritsforuseasagriculturalliming agents.Thestandardprovidesperformance requirementsandincludesqualityrequirementsfor metalsandspecificorganiccontaminants. Thisstandardprovidesageneralsetofguidelinesto assistendusersinassessingdifferentoptionsfor ADCsatsanitarylandfills.Thestandardprovideskey performanceinformationonthebroad classificationsofADCs.Thesuitabilityand acceptabilityofADCsaredependentontheclimate, theoperatingconditions,andtheregulatory requirements;therefore,specificperformance informationmustbeevaluatedonacasebycase basis.

ProductfromResidue:Standard SettingforAlkalineMillResiduesin Quebec.TAPPIProceedings,1998 InternationalEnvironmental ConferenceandExhibit. pp.779783. AlternativeDailyCoverataLandfill ASTMD652300.StandardGuidefor EvaluationandSelectionofAlternative DailyCovers(ADCs)forSanitary Landfills.AmericanSocietyforTesting andMaterials.April2000.

41

Appendix4: WasteStreamSurveyofMillsParticipatingintheIndustrialFootprintProject (Responsessummarizedinitalics) Howmanytonsofwastesaregeneratedatyourmill? Millsreportedthisinvariousways.Boilerash:22,300tonsasis;8320yards/yr;60tonsadayat 50%moisture.Treatmentplansolids:3,300drytons/yr.;150tonsperdayat70%moistureof sludge;21,300tonsannualdrybasis;Slakergrits:1,700tonsdrybasis;OCC(recyclerejects), burned:2,800tonsdrybasis;OCC(recycle)rejects,discarded:2,200tonsasis;Hogfuelrejects: 1,500tonsasis. Howisthismaterialmanaged? Percentagegoingtolandfilland/orlagoon:100%,27% Percentagegoingtolandapplication:0%,30%,100%oftreatmentsolids Percentagegoingbackintoproductioncycle:0%,0%,positive,butnotestimated Percentagegoingtootherbeneficialuses:23%,50%,100% Hasyourfacilityundertakenanywastereductioninitiatives?Ifso,pleasesummarize. Recycling Reuse Refusederivedfuel Solidwastereductiongoals Byproductssynergygroup Boilerashtocementkiln Rechippingthenreusinghogfuelrejects Improvedrecyclingofofficewaste Hasyourfacilityworkedcooperativelywithanycompanies,landfills,agriculturallands,etc. tobeneficiallyusemillwastestreammaterials?Ifso,pleaseexplain. Initiativesreported:Orchardsusingcompost,WADOTusingcompost,agriculturalfertilizer companyusingdyes,landscaperbuyingfelts,TRACbuyskilnbricksandtalcbagsusedinRDF, cartridgesrecycled,coresrecycled,metalrecycled,solidwastetofuel,usingfiberrichportionof wastewatersludgeforabsorbents. 42

WasteWaterTreatmentPlantResiduals Pleasefilloutthetablebelowbymarking(X)theappropriateboxforeachbeneficialuseor endmarket(numbersindicatehowmanymarkswerereceivedintotal).

BeneficialUseorEnd Market Papermakingfiberand filler Industrialabsorbent Animalbedding/cat litter Manufacturedsoil component Compostfeedstock Landfillcoverorbarrier cap AcidMineDrainage (AMD)controlcover Buildingboard/fixture Brickorconcrete additive Glassorlightweight aggregate Finemineralproduct Cementkilnfeedstock Rooffelt/tarpaper Fuelpelletadditive OtherUses: Hydroseed Engineeredseedpellet Alreadyusing wastethisway(X) 1 1 1 Plantousewaste thisway(X) 1 1 1 1 1 Economically infeasible(X) 1 1 1 1 1 1 Infeasiblefor otherreasons (X) 2 1 1 1

43

BoilerAshResiduals Whattypeofboilerashresidualsaregeneratedatyourmill?Coal,woodoramixtureofthe two? Wood(allthreeresponses),butalsosomenoncombustiblematerialthatenterssewers, especiallypaperadditives. Haveyouimplementedahighefficiencyboilertoreducewasteresidualsandtoreduce amountofflyash?Twonoresponses,oneyes. Pleasefilloutthetablebelowbymarking(X)theappropriateboxforeachbeneficialuseor endmarket.

BeneficialUseorEnd Market Compostfeedstock Manufacturedsoil component Cementkilnfeedstock Concreteadditive Flowablefill ControlledLow StrengthMaterial (CLSM) Wastestabilization Soilstabilization Cattlebedding Earthenconstruction Asphaltaggregate Landfilldailycover Activatedcarbon manufacture OtherUses: Alreadyusing wastethisway(X) 1 1 1 Plantousewaste thisway(X) 1 1 Economically infeasible(X) 1 Infeasiblefor otherreasons (X) 1 1 1

1 1

1 1

2 1 1 1

2 1

44

Appendix4,continued

CausticizingResiduals
BeneficialUseorEnd Market Limingagenton agriculturalland Cementkilns Forestlandapplication Acidminereclamation Manufacturedsoil ingredient Soil stabilization/earthen construction Surfacemine reclamation ClayBrickadditive Gaseoussulfur compoundtreatment Hydraulicbarrier materialmix neutralization PHadjustmentof processwater WastewaterAOX removal Compostfeedstock Roaddustcontrol Sludgebulkingcontrol Asphaltadditive OtherUses: Alreadyusing wastethisway (X) 1 Plantousewaste thisway(X) 1 Economically infeasible(X) 1 1 Infeasiblefor otherreasons (X) 1 1

1 1 1

1 1 1 1 1

WoodYardDebrisorPulping/PaperRejects
BeneficialUseorEnd Market Boilerfuel(energy input) Secondgradepaper production Alreadyusing Plantousewaste wastethisway(X) thisway(X) 3 2 Economically infeasible(X) Infeasiblefor otherreasons (X) 1

45