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Consolidated Papers Inc. Chlorine Reduction in Kraft Bleaching Process |
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| Standard Industrial Classification (SIC) | Paper/2600 and Printing/2700 | ||
| Type of Waste | Dioxin as a byproduct of chlorine pulp-bleaching process | ||
| Strategy | Process modifications and material substitutions | ||
| Company Background | Consolidated Papers, Inc. produces coated and supercalendered printing papers, kraft pulp from virgin wood fiber and recycled pulp from post-consumer office wastepaper. They also manufacture lightweight coated specialty papers for product packaging and labeling. Other products manufactured by the company include paperboard, paperboard products and standard and custom-designed corrugated displays and containers. Consolidated is headquartered in Wisconsin Rapids, employs approximately 6,000 people and operates manufacturing facilities in central Wisconsin; Niagara, Wisconsin; and Duluth, Minnesota. | ||
| Original Process | Pulp is bleached to remove colored materials from the wood fibers and produce a pulp white enough for subsequent use. Like most kraft pulp mills, Consolidated's Kraft Division was originally designed to use chlorine in the first step of the bleaching process. That chlorine reacted with the residual lignin in the pulp and produced a variety of chlorinated organic substances. Most of these chlorinated substances were disposed of along with the bleach plant wastewater. Some of the more volatile substances were also emitted to the air. Both the wastewater and the air emissions were treated prior to release. The wastewater was treated in a company-owned and operated wastewater treatment plant. The bleach plant air emissions were treated in a scrubber with a caustic (alkaline) scrubbing media to remove chlorine and other pollutants. | ||
| Motivation | When the use of elemental chlorine in the pulp-bleaching process was linked to the creation of dioxin (2,3,7,8-TCDD), Consolidated Papers took aggressive steps to reduce the use of elemental chlorine in the kraft pulp-bleaching process. The company's goals were to virtually eliminate the generation of dioxin and significantly reduce the formation and release of chloroform and other chlorinated organic compounds by implementing a multi phase plan. | ||
| Pollution Prevention Process | Two techniques are in use to reduce chlorine;
improved processes to remove as much lignin and other colored materials
from the pulp; and material substitution for chlorine in the bleach plant.
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| Material/Energy Balance |
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| Stage of Development | Phase I was completed in 1992, Phase II was completed in 1993 and Phase III is expected to start up in late 1996. | ||
| Economics | Capital Costs
$35 million (Phases I and II) Payback Period |
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| Benefits | The significant results are: nondetectable levels of dioxin in the pulp, treated wastewater effluent, and wastewater treatment biosolids; substantial reduction in the emission of chlorinated organic compounds; and a significant decrease in the formation and emission of chloroform. | ||
| Obstacles | The cost of the project was high with little increase in productivity. Many pulp mills are completing similar projects at this time which complicated equipment delivery schedules. In Wisconsin, pollution prevention equipment is not provided the same preferential tax treatment as pollution control equipment. | ||
| Other Waste Reduction Activities |
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| Technology Transfer | This equipment is commercially available. | ||
| Company Address | Consolidated Papers, Inc. 231 First Avenue North P.O. Box 8050 Wisconsin Rapids, Wisconsin 54495-8050 |
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| Contact Person | James D. Weinbauer, Director of Environmental
Affairs 715/422-3693 |
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| Pollution Prevention Resources |
Free, On-site Technical Assistance Pollution Prevention Information Clearinghouse |
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Last Revised: Friday May 26 2006
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