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Recycled Paper and Sludge

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Recycled Paper and Sludge Recycled paper and sludge As the use of recycled paper increases timated average yields of 90 percent across the nation, consumers are begin- for recycled paperboard and container- ning to question the environmental impli- board, 85 percent for newsprint, 75 by Judy Usherson cations of the paper manufacturing proc- percent for tissue and 70 percent for ess and its waste by-products. printing/writing papers. An API spokes- Judy Usherson is associate editor of Removing the ink, clay, coatings and person indicated that some mills are re- Recycled Paper News, a Springfield, contaminants from waste paper in order porting yields as low as 60 percent when Virginiá-based newsletter providing inde- to salvage reusable cellulose fibers to using mixed post-consumer waste pendent coverage of recycled paper is- produce recycled paper creates deinking paper. sues. She is also a recycling specialist sludge. And deinking sludge creates dis- Each deinking operation produces at CERMA, a nonprofit, nonpartisan posal problems. The sludge also creates sludge with somewhat unique charac- educational organization that offers vari- consumer concern about the potential teristics, depending on the type of waste ous programs that encourage recycling presente of heavy metals, polychlo- paper processed. Waste paper with high and recycled product procurement, in- rinated biphenyls (PCBs) and dioxin. amounts of filler, such as clay-coated cluding the Recycled Products Informa- Is recycled paper harmful to the magazine paper, produces much lower tion Clearinghouse, a national hotline. planet? What are the environmental yields of usable fiber than does waste This article originally appeared in the liabilities associated with this aspect of paper that is mostly cellulose fiber, such January 1992 issue of Recycled Paper paper recycling? And what can be done as computer printout or old newspaper. News. with all that sludge? Paper that is only lightly printed will pro- duce less sludge than paper that is Recycled paper mills and sludge heavily printed. Alkaline papers contain Deinking mills shoulder sizeable costs, high filler-to-fiber ratios and, therefore, not only from the capital investment re- produce more sludge. Post-consumer 1s recycling hurting quired to establish a deinking facility but feedstocks generally produce more the environment? also from the expense of managing and sludge than pre-consumer grades be- disposing the waste by-products. cause they tend to be more heavily con- Thirty-one tissue mills, nine newsprint taminated. mills, nine printingiwriting mills and eight market pulp mills in the United States Solid waste disposal problem have deinking facilities, with a total an- Deinking sludge is definitely a solid nual capaclty of approximately five mil- waste disposal headache. The Franklin lion short tons, according to the Ameri- report estimated that about 700,000 tons can Paper Institute. The amount and na- of sludge will be generated by deinking ture of sludge generated is directly re- and repulping operations in 1995. Dis- lated to the type of waste paper con- posal is becoming a major problem be- sumed by the mill. Along with the inks, cause siting new landfills is difficult and deinking removes other noncellulose because few commercially viable uses materials from the fiber, including coat- exist for sludge. Some paper industry ings, adhesives, dyes and fillers like cal- representatives believe that while the cium carbonate and clay, as well as ob- government mandate for paper recycling vious trash like paper clips, baling wire, may extend the lives of municipal land- staples and banana peels. All wind up in fills, it unfairly shifts responsibility and the sludge. costs for solid waste disposal to private “Yield” is the term used by paper man- landfills managed by paper mills. ufacturers for the amount of usable fiber An illustration of sludge generation rendered after the cleaning and deinking potential by recycling mills is offered by processes remove contaminants. In a Pat Hoekstra, a process consultant with recent report for the Recycling Advisory Jaakko Pöyry, Inc., in an article pub- Council, Franklin Associates, Ltd. es- lished in Ameritan Papermaker in April 95 Resource Recycling March 1992 1991. Hoekstra calculated that a large, Incinerating. A few mills burn deink- Landspreading. Severa1 rriills land- state-of-the-art deinking mill (500 metric ing sludge in their boilers as “hog” fuel. spread sludge. One example is Pope & tons per day with an 87 percent yield) This practice is not widespread, how- Talbot, a 100 percent recycled tissue generates 175 cubic yards of sludge per ever, because the high moisture of the mill in Eau Claire, Wisconsin. The day - enough to cover two acres of sludge affects its ability to burn effi- sludge, which is composed of 50 per- land in one year with a layer of sludge ciently. To enhance its heating value, cent inorganic fillers (clay and calcium 20 feet deep. the sludge is sometimes mixed with dry carbonate) is spread on farmland with waste material (such as wood chips). the farmers’ cooperation and approval. Disposal options Fluidized bed combustion is one The material adds some organic matter Traditionally, deinking sludge has been emerging technology that works par- to the soil and provides trace nutrients, handled in three different ways: landfill- ticularly well with the wet sludges pro- including nitrogen, phosphorous and ing, incinerating and landspreading. duced by deinking mills. In this proc- potassium. The calcium carbonate acts Landfilling. Landfilling is the most ess, air is bubbled through a bed of inerl as a lime substitute, which helps bal- widely used method for disposal of material (usually sand or limestone), ance overly acidic conditions. The clay deinking sludge. Before the sludge is which greatly improves the combustion increases the soil’s capacity to hold nu- landfilled, water is removed from it to process. This technology also produces trients and is particularly effective for make it about 40 percent solids. Some fewer sulphur dioxide and nitrous oxide sandy soils. The Pope & Talbot mill con- mills are permitted to use municipal emissions than do conventional hog ducts detailed evaluations of each site to landfills, but most use their own private boilers. ensure that the sludge is spread on ap- disposal facilities. Private landfills, like Burning sludge is advantageous be- propriate soil types. Important factors public ones, are becoming more difficult cause the landfill volume required for such as depth to groundwater or bed- to site because of community opposi- ash disposal is about 25 percent of that rock, and the location of homes, Wells tion, protracted and complex state en- required for sludge. In addition, boiler and surface water are all taken into ac- vironmental permitting processes, and ash from deinking sludge incineration is count. Landspreading is only done dur- rising real estate costs. Siting problems sometimes used as an aggregate in ce- ing spring and summer because it can- are particularly difficult for new recycling ment and concrete. Sludge ash concen- not be performed properly if the ground projects, which tend to be located near trates heavy metals, however, and if is frozen or too water-logged. good sources of waste paper, in urban found to contain hazardous levels, the The U.S. Environmental Protection areas where land costs are higher. ash requires special handling. Agency recently published proposed With a reputation to be proud of . 4 4JC International, Ltd. established 1976 THE WASTE PAPER EXPORTEXPERTS We Buy Municipal Waste Paper, All Low Grades, High Grades, Roll Stock Main Office New Jersey Office 9999 S.W. Wilshire 151 Passaic St. Portland, OR 97225 Rochelle Park, NJ 07662 EALL Ph: (503) 297-4895 Ph: (201) 712-941 O/l 1 Fax: (503) 297-4395 Fax: (201) 712-9524 m ID PROWCTS. INC.. 47%’ A ADAM6 Ro. CHATT- A. TN 37343 mnm El51 8755150 FAX IEX51 870-2941 Circle 431 on RR service card Circle 108 on RR service card 96 Resource Recycling March 1992 regulations for the landspreading of sludge from pulp and paper mills using m Table 1 - Heavy metal content of sludge in parts per million (1) chlorine and chlorine-derivative bleach- Deinking sludge Deinking sludge Municipal ing processes. Among other things, the lowest content highest content sludge proposed regulations would establish Cadmium 0 qo.2 15 stringent standards for organochlorine Chromium 16 118 200 (such as dioxin) levels in the sludge. Copper 31 400 1,000 The regulations do not differentiate be- Lead 3 210 600 tween virgin paper mills and recycling Manganese 31 680 300 Nickel 1 25 50 mills. (Though many recycling mills do Zinc 36 1,200 1,200 not use elemental chlorine in their bleaching processes, organochlorine (1) Heavy metal content in sludge samples from f& deinking plants compared with a sample of molecules from the recycled paper are municipal sludge. usually present in minute but detectable levels in recycling sludges.) Many paper Source: Amefican Papermaker, April 1991. industry representatives and the Ameri- can Paper Institute have challenged the scientific validity of the risk assessment While deinking sludge is routinely bonless paper. Because carbonless conducted by EPA. tested for leachable heavy metal con- manufacturers stopped using PCBs 20 tent, a recent study found that a mu- years ago, however, the sporadic inci- Toxicity nicipal sludge sample contained three dente of this material will diminish over Heavy metals and PCBs. In the past, times the amount of lead and more than time. the greatest percentage of hazardous double the amount of copper typically Dioxin and furan. Dioxin has been material in deinking sludge carne from found in deinking sludges (see Table 1). called the most toxic substance known the inks and pigments used on the Polychlorinated biphenyls (PCBs) are to man. Although the accuracy of that waste paper. In recent years, however, another potentially hazardous material charge has been challenged, definitive ink manufacturers have made enormous that can occasionally be found in, deink- answers are difficult to reach because of strides in eliminating heavy metals from ing sludge.
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