Black Gold from Wood-waste Water Treatment Plant

Transcription

1 Black Gold from Wood-waste Water Treatment Plant Melissa MacIntyre, P.Eng. Environmental Manager Louisiana Pacific East River Mill March 3, 2009

2 Presentation Content Louisiana Pacific History Louisiana Pacific Process Compost Facility Process Composting Success Awards Questions

3 Louisiana Pacific - History Hardboard Mill located within East River close to Chester, NS. LP produces various profiles of exterior siding and interior door skins. LP averages a production of 211 per day of various products, of which 99% were exported outside the province and 40% out of the country.

4 Louisiana Pacific - History Construction of the Mill was started in 1966 and began production with one line in A second production line was added and was in full production in Up to 1976 there was little wastewater treatment. By 1978 there was a full secondary treatment facility in place.

5 Louisiana Pacific - History Up to 1992 treatment plant sludge was disposed of within a onsite quarry and the solids settled and the water was pumped back to the treatment plant. The solids were excavated and disposed of within an onsite landfill. After 1992, a belt press was installed and the dewatered sludge was placed in the onsite landfill.

6 Louisiana Pacific - History In the mid 1990 s, it was determined that the landfill was not going to have an extended life and either a new landfill was needed or an alternative found. In 1999, composting trials began to determine if the sludge from the wastewater treatment plant could be composted into a viable product. In 2003/04 the onsite landfill was closed and capped. Since that time 100% of the wastewater treatment plant sludge has been successfully sent to the compost facility.

7 The process begins with round wood, which gets chipped, washed, metered, and cooked. Louisiana Pacific - Process

8 Louisiana Pacific - Process Fiber is created by mechanical means. This fiber is mixed with water and chemicals to create our stock

9 Stock is then pumped onto a moving drainage table, cut into fiber mats and loaded into the press. Louisiana Pacific - Process

10 The fiber mat stays in the press from 7 to 25 minutes depending on the product being produced. Louisiana Pacific - Process

11 Louisiana Pacific - Process After pressing; the product goes through several other steps before it is ready for market: re-humidification, equalizing, cutting to size and painting. This all occurs in our Converting Department and creates very little to no water loading on our wastewater treatment plant.

12 Louisiana Pacific Wastewater Treatment Plant Process Water from the production process is pumped to a lift station and is then pumped to the wastewater treatment plant.

13 Louisiana Pacific Wastewater Treatment Plant Process Water is pumped to a dissolved air floatation (DAF) tank to remove large (un-dissolved particles), this material is sent to the belt press for dewatering. Water from the DAF is pumped to the first of two aeration basins.

14 Water then enters the first of two settling basins (clarifiers), sludge from this basin is either recycled back to the aeration basin or pumped to the belt press for dewatering. Louisiana Pacific Wastewater Treatment Plant Process

15 Louisiana Pacific Wastewater Treatment Plant Process Water is then sent to the second aeration basin and settling basin prior to discharge through a diffuser. Sludge created during this last process is also either recycled back to the aeration basin or sent to the belt press for dewatering.

16 Louisiana Pacific Wastewater Treatment Plant Process The belt press takes sludge at a solids content of 5% and dewaters to 15-20%. This dewatered sludge is then trucked to the compost facility, which is located on site.

17 Sludge from the belt press is trucked to the Compost Facility and placed inside the building for initial mixing with bulking biomass. Compost Facility Process

18 The mixture of sludge and bulking biomass are placed over air injection pipes to start the composting process, the material is placed in windrows within the building and turned throughout the time within the building. Compost Facility Process

19 Compost Facility Process Once the compost has been actively composted the material is placed outside on a covered pad to continue active composting. After this point the compost has completed its active phase and it is ready for curing.

20 Screening and then sold. Compost Facility Process

21 Compost Facility Success Material Diverted to Compost Facility 2000: : 13, : 31, : 34, : 53, : 38, : 40, : 45, : 29,311 Compost Sold 2004: 8, : 13, : 14, : 12, : 27,125

22 Compost Facility Success Nova Scotia has a capacity of 172,250 /yr of composting within the Province with 20 facilities. (As indicated on and updated Apr. 9, 2008) East River is the largest capable of 50,000 of composting per year. 30% of Nova Scotia s compost volume.

23 Compost Facility Success A community group has been established to ensure an open dialogue with community members. We meet 4-6 times per year; We have a website and community bulletin board; We will be hosting our 6 th annual Open House on June 13th. We have involved the Municipality of Chester, the Chester Basin Gardening Club, local children s organizations, the Canadian Compost Council of Canada. Odor complaints have gone from 11 in 2004 to 1 in 2006, to zero in both 2007 & What changed? We employed better reporting with the community; We reduced and avoid tasks during particular weather conditions to prevent odor migration. We improved surface water drainage, dry compost doesn t have odor.

24 Compost Facility Success According to current fees of $70/tonne to handle similar material This would have cost LP over 15 million dollars to handle as a waste. Composting is not free, this method of handling our waste has cost LP 2.4 million in the past 5 years, with sales to help off set this cost. The Kaizer Meadows Landfill was contacted to determine the actual impact this material would have. David Daniels informed us that the landfill is designed for 42,500 /year over 5 years. Louisiana Pacific is diverting approximately 39,000 /year to the Compost Facility. This volume would decrease the lifespan of the local landfill by over 85%.

25 Solid Waste Disposal Reduction Solid Waste Category Card Board / Paper / Food Compost 2,041 kg 3,375 kg 5,364 kg 26,016 kg 36,894 kg 35,532 kg 36,860 kg 36,860 kg 36,860 kg Scrap Metal Dust to Compost Dust to Boiler 9,617 13,824 12,997 15,995 13,751 12,212 14,026 11,231 11,969 Landfill (Mixed Waste) 50,755 12,215 1, Wood Waste (Landfill) 5,023 5,948 1,367 1,897 1, Wood Waste Recycled 48 1,374 7,616 10,500 5,845 5,193 9,331 8,315 4,355

26 Awards In 2005 Eco-Efficiency's Success Story Annual Award In 2006 RRFB s Business of the Year Award In 2007 Canadian Manufactures and Exporters: Canadian Innovation Award Recognition for Environmental Technology.

27 Questions?