DOE/CH10093-341
DE94006942
September 1994
A joint cost-sharing grant program of:
| Regional Utility: | Massachusetts Electric Company |
| Partners: | Erving Paper Mills, Inc., Flow Vision, Inc., WoodFree, Ltd., Sulzer PaperTec, Massachusetts Division of Energy Resources, Massachusetts Office of Technical Assistance |
| SIC Codes: | 2621, 5084, 2676, 5093, 5113 |
| Cost: | $2,735,371 (Industry share: $2,300,000; state share: $10,371) |
| Energy Savings: | 236 billion Btu (249 terajoules)/yr/plant |
| Environmental Benefits: | Increased post-consumer wastepaper reuse of 17,750 tons (16,103 tonnes)/yr; VOC emissions reduction of 6000 lb (2727 kg)/yr/plant; CO2 emissions reduction of 12,931 tons (11,731 tonnes)/yr/plant |
| Economic Savings: | $742,300/yr/plant |
| National Impact (2010): | Additional 710,000 tons (644,110 tonnes)/yr of post-consumer wastepaper recycled annually if 85% of U.S. de-inking plants adopt the technology |
| Applications: | De-inking mills |
| Contact: | State: Dan Sardo, (617) 727-4732; DOE-Bill Ives, (303) 275-4755 |
The U.S. paper industry is under consumer and environmental pressure to use more post-consumer wastepaper in its products. In meeting this demand, paper manufacturers use a mix of post-consumer and pre-consumer wastepaper to make de-inked paperstock for products like napkins and tissue paper.
The price paid for products made with recycled paper depends on the grade or quality of the final paper product. The amount of "dirt" or particles allowable for the paper varies with the grade. Generally, the higher grades contain less dirt. Erving Paper Mills, Inc., (EPM) of Erving, Massachusetts, is using a grant from the NICE3 program, sponsored by the U.S. Department of Energy (DOE) and the U.S. Environmental Protection Agency, to introduce a novel integration of technology in the de-inking, de-coloring, and paperstock blending processes. This technology will produce paper using higher percentages of post-consumer wastepaper while saving energy and reducing hazardous chemical usage.
Both state and federal governments require increased use of post-consumer waste in napkins and tissue paper purchased under government contract. Currently, a blend of post-consumer and pre-consumer wastepaper is pulped in a vat containing water and chemicals at 160 degrees F (71.1 degrees C) to 180 degrees F (82.2 degrees C) before being de-inked, de-colored, screened, and cleaned to remove contaminants. Chemicals used in these processes include caustic soda, sodium hypochlorite, and sodium hydrosulfite. Sulfuric acid is added in wastewater treatment to neutralize the caustic soda.
EPM will modernize its process line using chemical and mechanical technology not previously combined in paper recycling. With chemicals supplied by WoodFree, Ltd. of the United Kingdom and others, EPM is modifying its Nucell de-inking system by using FAS (formadine sulfonic acid) and Enessco-D (a proprietary chemical) to replace caustic, chlorinated bleaches used for de-inking paper.
Mechanically, a new type of moving-belt washer will replace older "side-hill" washers and allow more particle removal with less loss of fiber. Moving-belt washers have smaller screen grids, that trap more dirt particles while significantly reducing the amount of rejected waste that must be landfilled.
After the paperstock (which contains high percentages of post-consumer wastepaper) is de-inked and cleaned, it is mixed with pulp substitute, a high grade of pre-consumer wastepaper. A particle analysis system used in the plastics industry will be adapted to provide real-time information for minimizing the use of pulp substitutes. Four particle analyzers, installed in the process line, will "see" the concentration of impurities in the mix. With realtime adjustment of the process, EPM estimates that an additional 500 tons (454 tonnes) or 6.25% of post-consumer wastepaper can be processed in its plant yearly without sacrificing quality
By processing the paperstock mix at room temperature during deinking, EPM expects to cut its use of No. 6 fuel oil by 1.4 million gal (5.3 gigaliters)/yr.
EPM will increase its use of post-consumer wastepaper by 35% to 40% over current practices. About 17,750 tons (15,103 tonnes)/yr of wastepaper will be removed from the regional waste stream. EPM will eliminate all of the chlorine compound bleaches and reduce volatile organic compound (VCC) emissions. By changing the de-inking chemicals, sulfuric acid usage in the plant will be cut by 75 tons (68 tonnes)/yr by 1998. Also, carbon dioxide, nitrous oxide, and sulfur dioxide emissions will be decreased because of less fuel oil being burned.
By reducing fuel oil usage, EPM will save $406,300/yr over the current technology. The improved modified process line will reduce waste that must be landfilled, which will save an additional $336,000/yr for a total annual savings of $742,300.
Many paper companies must use more post-consumer waste while improving air quality and wastewater emissions. There are currently 84 U.S. de-inking mills that could adopt some or all aspects of EPM's new system.
Last Updated: January 25, 1996