MANAGEMENT OF BYPR

SOLIDS GENERATED IN 

PULP AND PAPER INDU

Bill Thacker

NCASI

Presentation to EPA OSW Sta

Washington, DC

January 23, 2007
Presentation Coverage

• Brief introduction to the U. S. pulp and p• Review of the generation, characteristics

management of byproduct solids

• Presentation of two brief case studies • Discussion limited to

· Wastewater treatment plant (WWTP)

residuals (“sludge”)

· Boiler ash
U.S. Pulp and Paper Indu

430 Pulp & paper mills

• National annual production: 100 million t

paperboard, and market pulp

• Top 10 states (yr 2000): 

GA AL LA WA WI MI SC ME OR 

• Variety of manufacturing processes, mill c

end products 
Byproduct Generation

• Annual generation of solid wastes or bypro

15 million dry tons 

• Including

· Wastewater treatment plant (WWTP) res· Boiler ash (also flue gas desulfurization mat· Causticizing residues· Wood yard debris· Pulping and papermaking rejects
WWTP Residuals

• 5.5 million dry tons annually• Types

· Primary (including deinking residuals)· Secondary (waste activated sludge)· Combined primary and secondary· Dredged 

• Mechanical dewatering is the norm,

with solids content typically 30-40%, range 20-60%

• Small number of mills dry residuals (70-95
Characteristics of WWTP Re

• Primary WWTP residuals consist mainly of

· Wood fiber· Inorganic or mineral matter (e.g., clay, CaCO

3

• “Ash” (inorganic) content of primary WWTP 

from <10% to >70% (dry wt. basis)

• Secondary WWTP residuals consist mostly o

biomass (non-pathogenic)
Other B

U

11.

Landfill/Lagoon

51.8%

Land App

14.6

Management of WWTP Res

2002 data (AF&PA)
Management of WWTP Res

• Land application

· Utility: soil conditioner, fertilizer, liming a· Potential issue: high C:N ratio

(quite high for primary residuals)

• Burning (usually onsite)

· Utility: energy, volume reduction· Potential issues: high moisture

high “ash”
Other Uses for WWTP Res

• Papermaking fiber/filler• Industrial absorbent• Animal bedding/litter• Manufactured soil component• Compost feedstock• Landfill barrier cover• AMD* control cover• Building board/fixture• Brick or concrete additive• Glass or lightweight aggregate• Cement kiln feedstock• Fuel pellet ingredient* Acid mine drainage
WWTP Residuals Case St

• Startup company in the Northwest began m

residuals-based products for consumer, agrindustrial markets in 1986

• Technical and marketing challenges resulte

of effort before first profit realized

• Major products currently are

· Small-animal bedding· Cat litter· Oil-spill & general industrial absorbents
WWTP Residuals Case St

• Products available in 16 countries• Bedding & litter available in major U.S. pe

department store chains

• Recently built a 2nd manufacturing plant in 

to better serve Eastern U.S. and began prodin December 2004
Boiler Ash

• 4 million dry tons annually• Types (based on fuel)

· Wood· Coal· Wood and coal· Wood, coal, or both with miscellaneous 

• Wood ash

· High in unburned carbon (char)· High in Ca, source of K and P· Alkaline· Cementitious
Landfill/Lagoon

65.4%

Land Applicat

9.3%

Management of Boiler A

2002 data (AF&PA)
Management of Boiler A

• Land application

· Utility: liming agent, fertilizer· Potential issue: unburned carbon (wood 
Other Uses for Boiler A

• Compost feedstock• Manufactured soil component• Cement kiln feedstock• Concrete additive• Flowable fill (CLSM)*• Waste stabilization• Soil stabilization • Earthen construction• Asphalt aggregate• Landfill daily cover* CLSM = controlled low-strength material
Boiler Ash Case Study

• Southeastern mill had its coal fly ash used a

ingredient for highway & other application

• State DEP approved injecting wood ash int

obtain more energy and lower ash loss-on-i

• State DOT approved use of coal-wood fly a

after short-term and long-term (>3 yrs) tes

• With coal-wood fly ash added, concrete is

· Stronger and more durable· More resistant to water erosion (saltwater use)· Less expensive

• Coal-wood bottom ash employed as aggreg

mixes and in concrete blocks
Summary

• Two significant byproducts from the pap

are WWTP residuals and boiler ash

• Land application is an important benefic

both types of materials

• There are numerous examples of other u• Paper companies continue to seek benefi

opportunities and increasingly explore n
Questions & Comment

Bill Thacker

NCASI

269-276-3548

william.thacker@wmich.edu

www.ncasi.org